2. First Edition, May 2012
The information contained herein is an exclusive property of Mahindra & Mahindra Ltd. and shall not be distributed, reproduced, or disclosed in whole or in part without prior written permission of
Mahindra & Mahindra Ltd., failing which legal action can be initiated as per Jurisdiction of Mumbai. The content of this information is subjected to change without notice.
Rise by daring to disturb
the universe
ACCEPTING
NO LIMITS
Rise with your
ingenuity
CORE VALUES
• PROFESSIONALISM • GOOD CORPORATE CITIZENSHIP • CUSTOMER FIRST • QUALITY FOCUS • DIGNITY OF THE INDIVIDUAL
ALTERNATIVE
THINKING
Rise by shaping
destinies
DRIVING POSITIVE
CHANGE
Rise Culture - The House of Mahindra
3. Rajan Wadhera
Chief Executive
(Technology Product Development & Sourcing
Member of Group Executive Board)
Mahindra & Mahindra
Group has a vision to be recognized globally for Quality, Durability & Reliability of our products. Quality focus is an integral part of our
Core Purpose and Core Values.
In Promise 2013, we laid out an aggressive road map for growth and organizational transformation. The product portfolio has been strategized
and designed in a way to develop and introduce new products as well as variants in coming three years, under various platforms.
Quality, profitability and growth plans set out in our Aspiration 2016 and Long term plans must be implemented and applied companywide,
through precise action plans. But we will not meet these targets, without your active participation and support.
The best organizations of the world focus on Supplier Development and Supplier Strategy, as the key driver for quantum growth and profitability.
Keeping this in mind, we have introduced Mahindra Supplier Evaluation Standard (MSES) as an additional milestone in our supplier selection
and development process. The purpose of this manual is to elaborate the Process and Systems requirements that need to be adopted by the supplier,
to achieve Global Quality Levels.
I look forward to your continued support and whole hearted participation to ensure the effective implementation of the MSES.
4. Hemant Sikka
Head Sourcing (AFS)
Mahindra & Mahindra
We live and work in a hyper competitive world. Competing and winning in today’s global marketplace requires that our products and services
must be of high quality, developed with short lead times, delivered in right quantities and on time and at competitive cost.
This requires very robust processes and a strong commitment, led from the top, to quality delivery and continuous improvement.
We at M&M, have a firm belief that to achieve this goal, we must work closely with our suppliers as partners. We must have a process in place
that selects, supports and ensures our suppliers meet high quality requirements.
This has made it necessary for us to define the Quality expectation of Mahindra to our supplier partners, which have been formulated in the form
of Mahindra Supplier Evaluation Standard and Rank up manual.
The objective of this manual is to define the basic quality systems and process requirements that we expect our suppliers to follow to ensure that
our mutual responsibilites for product and service quality are understood and implemented.
We look forward to your complete understanding and support and believe that by working together we can develop a robust supply chain to achieve
world class quality and satisfy our customers needs.
5. 1. Introduction........................................................................................................................ 02
a. Definition...................................................................................................................... 03
b. Objective....................................................................................................................... 03
c. Applicability.
.................................................................................................................. 03
2. Approach.
............................................................................................................................ 04
3. Evaluation Structure............................................................................................................ 05
a. Rating System.
............................................................................................................... 05
b. Final Rank and Total Score............................................................................................. 06
4. Chapter 1 Quality Policy & Quality Assurance System.......................................................... 07
5. Chapter 2 Analysis of the Quality Concerns for the Current Products.................................. 14
6. Chapter 3 Quality Assurance at the Process Development Stage......................................... 41
7. Chapter 4 Quality Assurance at the Pre-Production Stage................................................... 53
8. Chapter 5 Quality Assurance at the Production Stage......................................................... 61
9. Chapter 6 Control of Sub Suppliers..................................................................................... 148
Index
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MSES
02
As a part of this strategy we have already introduced Global Benchmark
practice of Mass Manufacturing Approval during Start Of Production. This
has yielded highly successful Ramp Up in many of our key projects.
To further support our Endeavour to be Best in class for Quality Practices
there is a need to Next Mark the way we work.
In line with this we have introduced a Preventive approach which is Mahindra
Supplier Evaluation Standard termed MSES that outlines the detailed
requirements of Mahindra & Mahindra to establish a robust methodology in
Quality Assurance Management.
MSES is a structured Quality tool, that helps in establishing a robust quality
system which will guarantee Quality Systems, Development Planning, Concern
Management, Daily Work Management and Sub Supplier Management.
This ensures readiness of supplier in terms of quality & delivery requirements
of the customer during supplier selection, in case of new business and for
Ranking Up quality level of existing supplier.
The supplier is expected to Rank Up their existing Quality Systems in line with
this methodology.
This Manual is only for Reference.
The Automotive Industry in India is one of the largest in the world and one
of the fastest growing globally. India’s vehicle manufacturing industry is the
sixth largest in the world.
This has given rise to the challenges of creating World Class manufacturing
systems and World Class Supplier Base.
At Mahindra to meet these Challenges of the Industry we have adopted the
Philosophy of Rise which is Strong Foundation of Following Three Pillars.
These are strongly supported with quality as the main ingredient.
• Accepting No Limits
• Alternative Thinking
• Driving Positive Change.
We have established our own Quality way which is the MQW (Mahindra
Quality Way)
With this increasing demand it is imperative that we are able to achieve
World Class Quality levels in all areas of our operations including our supplier
development and management
We also strongly believe that the contribution of suppliers is key to the
growth of our business as we follow the philosophy of suppliers as partners
who need to have World Class quality Practices to meet this challenge.
Introduction
7. 03
A. Definition
Mahindra Supplier Evaluation Standard is a Structured approach for evaluating
Quality Management of new supplier and for Ranking up of existing supplier
to required Mahindra & Mahindra Quality Level.
This is a guideline based approach where each and every requirement is
evaluated from World Top Level to Not Satisfactory Level.
B. Objective
The main objective of MSES activity is to clarify
1. The quality level of supplier (s) and ask to improve this level and
2. Identify supplier (s) with whom Mahindra & Mahindra should have
Commercial Relationship.
C. Applicability
MSES activity is to be carried out under following cases:
• New supplier selection.
• New plant location.
• Existing Supplier Quality level Rank-up.
MSES Flowchart
9. 05
Evaluation Structure
MSES Evaluation is based on 6 chapters which covers different aspects of
production systems which directly or indirectly affects product quality.
Different chapters of MSES Evaluation are:
Chapter 1. Quality Policy and Quality Assurance System
Chapter 2. Analysis of the Quality Concerns for Current Products
Chapter 3. Quality Assurance at the Process Development Stage
Chapter 4. Quality Assurance at Pre-Production Stage
Chapter 5. Quality Assurance at Production Stage
Chapter 6. Control of Sub-Suppliers
A. Rating System
The Rating system for MSES is broadly classified into three Categories
(1) Merit Ratings 5, 4, 3, 2, 0 are given to each checkpoint Chapterwise which have
different Weightages.
(2) Certain check points are considered to be Critical points which have Demerit
rating. These 17 Critical Points have been decided by considering their direct
effect on performance & quality of the product and are as below.
• Scoring of Critical items for demerit is as follows :
- Each item with low score (2 pts/5) => -5 points for process indicator total score
- Each item with very low score (0 or 1 pt/5) => -10 points for process indicator
total score
3 In addition to this each Chapter has different weightages in Evaluation as shown
below:
5 World top level
4 Some competitiveness
3 Implement somehow
2 Many insufficient items
0 Almost not able
1 Warranty Information Analysis 10 NC Management
2 Cause Analysis 11 Rework Management
3 Recurrence Prevention 12 Mix Up Management
4 Process FMEA 13 Abnormal Situation Management
5 Control Plan 14 Safety Characteristic Management
6 Process Change Control 15 Internal PPM reduction activity
7 Design Change Control 16 Continual Improvement
8
Control of Equipment
Condition
17 Sub Supplier Change Management
9 Operator Training
Chapter Evaluation Criteria Weightage %
1 Quality policy and quality assurance system 5
2 Analysis of the quality concerns for current products 30
3 Quality assurance at the process development stage
25
4 Quality assurance at pre-production stage
5 Quality assurance at production stage 30
6 Control of sub-suppliers 10
11. 07
Chapter 1
Quality Policy & Quality Assurance System
PURPOSE
• To assure existence of Basic Quality System like ISO/TS.
• To assure methodology of Internal audit system is followed for Sustenance.
• To demonstrate ability in Maintaining Quality Systems.
REQUIREMENTS
• Availability of ISO/TS certification for the existing
plant.
• Availability of standard procedure for the Internal
system, process, & product Audit.
• Defined Plan & Frequency of internal system,
process, & product audit.
• Availability of specific Audit checklist for system,
process, & product.
• Audits should be conducted by Qualified & skilled auditors.
• Availability of reporting mechanism for Non Conformity.
• Methodology defined for deciding gravity of NC
(Major or Minor).
• Use of standard QC tools such as Why Why analysis
deployed to arrive at root cause.
• Availability of Non Conformity monitoring system
with open/close status.
• Conduct follow-up audit methodology to close the
NC.
• Quality award from Car Maker.
REFERENCES
• Internal audit procedure.
• Master list of business process (Apex manual).
• Audit Plan.
• Audit check sheet (Ex. 1).
• Audit report.
• NC Analysis Report (Ex 2).
• NC summary.
• List of internal auditors.
1.1 QA System
Objective: To ensure existence of Standard Working Processes and Methodologies for Sustenance of Day to Day activities.
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1 of 10
Doc No.
Rev No.
Process Name : Date :
Part No : Shift :
Part Description : Area : Incharge :
Customer : Machine No./ Name :
Operator :
ACCEPTANCE CRITERIA :
I – SYSTEM CHECKS
Weightage Points Score
(a) (b) (a x b)
1.1 I 0.5
1.2 I 0.5
1.3 I 0.5
1.4 I 0.5
1.5 I 0.5
1.6 I 0.5
2.1 I 0.5
2.2 I 0.5
2.3 I 0.5
2.4 I 0.5
2.5 M 1
Process & Product Audit Check Sheet
Is checklist for material receipt available & being followed?
CATEGORY :
M - Must
Strong Area
Weak Area Not meeting above requirement
Must score 50% in all sections
I - Important
Wrapping (To be completely covered with gunny bags)
Is there any wrong identification?
Sl
No
Is the prctice being followed as per control plan/ receiving inspection
standard ?
2 ) Raw Material/Storage (If Applicable)
Is the Raw material properly identified.
Is the area marked for keeping raw material.
Date
Are all products/ packages identified?
RATING CRITERIA :
If zero in M,score will be -5
If zero in VI,score will be -2
If zero in I,score will be -1
VI - Very Important
1 ) Incoming Packing Condition (If Applicable)
Any mix up?
Any dust or dirt?
Strapping (Three strap radially and one on the circumference).
Check Item Remarks
Result
Category
Any damage in package?
Example 1 - Audit Check sheet
Refer Annexure for Ex 1
13. 09
Example 2 - N C Analysis Report
NON CONFORMITY REPORT
Doc No:
Rev No: 00
Rev date:
AUDIT SCHEDULE NO: REPORT NO: DATE:
AUDIT SDEPT/ AREA/ PROCESS: TIME : From ……………….
AUDITEE(s): AUDITOR(s):
Sl. No of Audit findings for which NC was sighted: Sign of AUDITEE
Sign of AUDITOR
Attribution to ISO-TS 16949 / ISO 140001 / OHSAS 18001:
NON CONFORMANCE / NEGATIVE OBSERVATION
ROOT CAUSE - (USE WHY - WHY ANALYSIS)
PROPOSED CORRECTIVE ACTION Target Date Responsibilit
y
DISPOSITION ACTION
FOLLOW UP AUDIT / VERIFICATION FOR IMPLEMENTATION (Write Observation)
VERIFICATION OF EFFECTIVENESS OF IMPLEMENTATION (Write Evidence )
VERIFIED BY MANAGEMENT REPRESENTATIVE
PROPOSED PREVENTIVE ACTION Target Date Responsibilit
y
DATE Auditor Sign
(use space overleaf if required)
Auditee Sign
Auditor Sign
NCR Status
Date
Sign. MR
Date
Contd...
A
A
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PURPOSE
• To assure mechanism of Quality Policy and Quality Objectives are defined in line with Company Indicators.
• To assure activity for deployment of these Objectives to Process, Product and Individual level is done.
REQUIREMENTS
• Availability of Specific Quality Policy signed by Top Management.
• Each element converted into Measurable & Quantifiable Objectives with clear
linkages to Quality Policy.
• Deployment of Quality targets based on past performance of the company and
plants.
• Company Objectives higher than all customer targets (LOI /CSR /CIR /SOR).
• Deployment of Objectives to process as well as product level on the shop floor.
• Relevant employees have been trained & understand the deployment of Objectives.
• Regular monitoring of target v/s actual.
• Should have Achieved objectives consistently for 3 years.
REFERENCES
• Quality Policy.
• Quality Objective / Business Plan / Balance Score Card / Simple Objective List.
• Customer Target Information.
• Target breakdown into product & process level (Ex 3).
• Data for target v/s actual.
1.2 Quality Objectives
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PURPOSE
• To assure existence of QA organisation within the company, with clear Roles and Responsibilities defined for Quality Management.
• To assure mechanism of conducting Regular Quality Meeting.
REQUIREMENTS
• Availability of QA Organization including
functions such as development, in-process,
final inspection, customer, incoming, change
management, continuous improvement, and
safety characteristic.
• Defined Roles and Responsibilities of each
employee.
• Guideline to conduct Quality meeting
(Agenda, Frequency & Minutes).
• Attendance of Top management in Quality
meeting once per month.
• Recommendations from top management in case of delay or no achievement of
target.
• Take CSI from all plants of customer (SCM, MM, & SQA) and improve upon the
gaps.
REFERENCES
• QA organization chart (Ex 4).
• Roles & Responsibility document for QA.
• KRA/MOP Sheet.
• Quality Meeting Guideline.
• Quality Meeting Agenda, Minutes.
• CSI format.
1.3 QA System & Organization
17. 13
Example 4 - QA Organisation Chart
HEAD Q A
Engineer - A
Operator
R M Inspection
Lab
Assistant
J E STD. ROOM
ORGANISATION LAYOUT CHART FOR QUALITY ASSURANCE DEPARTMENT
Engineer
………..
Inspectors 9
Inspectors
9
Helper
Helper
Engineer -B
Engineer -
Systems
J E Lab
1. P D I
2. Paint Shop Testing
3. Final Inspection
4. New Prod Quality
1. IMS Docs.
2. System Audit
3.Management
Review
4. Training
5. FMEA
6. Safety Audit
7. Liasoning
8. SPC
9. PPAP Approval
10. Change Control
1. Product
Audit, Dock
audit, layut
Inspection
2. Q I S
3. PokeYoke
1. Sample
collection &
Preparation.
2. Master &
representativ
e Sample
preparation
1. Process Audit
2. Product Audit
3. Supplier PPAP
4. Dock Audit
5. Layout inspn
6. Cust. Compl.
7. Rej handling
8. Problem solving
9. Safety
Charecteristics
10. Quality Meeting
1. Collection
of IMTEs
2. Servicing
of IMTEs
1. CFT, RFT,
Weld Tetsings,
BW testings, Salt
Spray, Wheel
Unbalance
Overall responsible for QA
& QS
1. Process Audit
2. Product Audit
3. Supplier PPAP
4. Dock Audit
5. Layout inspn
6. Cust. Compl.
7. Rej handling
8. Problem solving
9. Safety
Charecteristics
10. Quality Meeting
1. Calibration
of all IMT
2. External
Calibration
3. Standards
updation & MSA
1. Raw Material
Receiving
Inspection
1. CMM
Inspection of
:-
i. Product
ii. IMTE`s
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Chapter 2
Analysis of the Quality Concerns for the Current Products
REQUIREMENTS
• Availability of Warranty, Customer & In-house concern logbook / register / tracking
sheet.
• Availability of Monthly Monitoring trends for Warranty, Customer & In-house defects.
• Use of Pareto charts (By customer, by plant, by part, by defects etc ) to identify
Major contributors in case of Warranty , Delivery and In house defects.
• Mechanism for sharing these defects throughout the organization.
e.g. display of graphs at central location for tracking customerwise, monthwise,
partwise, defects / PPM.
• Defined the targets for Warranty, Customer PPM & In house PPM based on Past
1 year data.
• Defined 4M level Macro Action plan linked with organization Objective and
customer quality targets at the beginning of the Year based on this last year Quality
Performance data.
• Mechanism for monitoring the Progress of defined actions through Quality Review
Meeting.
• Defined Frequency of Quality Review Meeting (General – Monthly) and Plan as per
that frequency.
• Availability of All actions as a part of Progress Monitoring Sheet.
• Mechanism of Reviews for all earlier pending actions during Quality & Management
review MOM.
• Defined and Implemented recovery / revised action plan in case of any delay or non
achievement of target.
PURPOSE
• To assure that the targets are defined at the start of the year based on past performance.
• To assure that the targets are achieved by defining the action plan on prioritized problems and by monitoring the progress through structured
Quality concern reviews for warranty, Delivery and Internal defects.
2.1 Target Control
Objective: To ensure the Methodology of Defining and Monitoring the Progress of the actions to achieve the defined Targets
and Identifying the Real Root Causes by using Problem Solving Technique to avoid Recurrence of the problems.
REFERENCES
• Warranty Register, Customer PPM & In house PPM Register / Log book (Ex 5).
• Monthly monitoring trends, Pareto charts (Ex 6).
• Annual reduction Plan – 4M Level Macro Action plan and Monitoring(Ex 7).
• Quality Review Meeting Plan Vs Actual Status.
• Progress Control Sheet (Tracking Sheet) for Warranty, Delivery & Internal defects
(Ex 8).
19. 15
Example 5 - Warranty Register
V1 Refer BMS for current revision level Page 1 of 1
Date: Reviewed By: Approved By:
WARRANTY/FIELD COMPLAINT REGISTER
Part
Name
Prod
Line
Dealer City Zone
Chasis
Mfg.
month
Month of
prodn./ unit
no.
Qty
S No. Customer
Date of
warr.
Recd.
Car
Model
Part
No.
New/Repeat/Rare
Concern
NTF/
DNR
Claim #
Dt
Before
break
point
After
break
point
Kms
Usage
Months
Defect
Des. by
customer
Claim
Accepted /
Rejected
Phenomena
found after
analysis
21. 17
Flange bWeld unde weld shift porosity 2008 0.48
0 0 0.14 0.003 Jan 09 0.24
Feb 09
Mar 09
Apr 09
May 09
Jun 09
Jul 09
Aug 09
Sep 09
Oct 09
Nov 09
Dec 09
2010
2011
1 2 3 4 5 6 7 8 9 10 11 12
0.1
0.1 Feb
0.1 Mar
0.1 Apr
0.1 May
0.1 Jun
0.1 Jul
0.1 Aug
0.1 Sep
0.1 0
0.1 0
0.1 0
0
0
0
0
0
0
0 0
0 0
0 0
0
0
0
0 0
0 0
0 0
0 0
0 0
0 0
0
0
0
0
0
0
1, Nozzle cleaning frequency to be defined in OS to
ensure gas flow.
Over all
2, Poka yoke for less gas flow to be introduced.
ACTION
0
0.039
0.475 0.33
0.05
0
0.008
0
FEB
0.24
0
JAN
0.003
0.14
0
0.005
0.05
0.04
0.04
0.01
0.02
0.02
0.005
REMARKS
0.03
0.02
0.02
0.02
0
0
BREAK DOWN OF TARGET
DEC
OCT NOV
AUG SEP
Flange bend
conveyor is shifted before conveyor i.e. immediately
after unloading.
2, An extra packing machine is installed to avoid
wheels waiting for packing
0
Weld undercut
Flange bend
Pin hole
Runout problem
Flange width variation
0.06
0.02
ASSEMBLY
Porosity
Weld shift
2009
2008
0.08
0.08
JUN
MAR APR JUL
MAY
Batch code damage
Weld short length 0.01
Material pitting 0.01
0.01
Grinding mark
0.115
0.005
0
0
0.115
0.01
0.01
Others
Weld undercut
Weld miss
time of setting
Weld shift
Effectiveness
Monitoring (month)
Responsibil
ity
PROBLEM
Porosity
round bar
1, Final wheel inspection table located after the
1, Setting parameters to be monitored & frozen
2. To have a master setting disc to set ESO at the
1. To replace sliding rail of AW - II with round bars
2. To device fastening arrangement according to
REJECTION TARGET - ASSEMBLY
107
100
75
40
35 32
28
21
16 15 12 12 12 10 10 9 8 8 7 7 6 6 6
34
0
20
40
60
80
100
120
0
20
40
60
80
100
120
Porosity
weld
shift
weld
undercut
Flange
bend
Weld
problem
Pin
hole
Runout
problem
Dimension
problem
Batch
code
…
Weld
short
length
Grinding
mark
Material
pitting
Weld
miss
Thin
down
Trim
line
Power
cut
rej.
Due
rework
Scuffing
mark
Hub
Crack
Over
bead
Trial
(MIG
weld)
Dent
Disc
problem
Others
REJECTION ASSEMBLY - YTD
REJECTION = 0.47%
0.475
0.24
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
2008
Jan
09
Feb
09
Mar
09
Apr
09
May
09
Jun
09
Jul
09
Aug
09
Sep
09
Oct
09
Nov
09
Dec
09
2010
2011
%
Rejection
TARGET - ASSEMBLY (REJECTION)
0.33%
0.27%
0.21%
0.003
0
0.01
0.02
0.03
0.04
0.05
0.06
Jan 09 Feb 09 Mar 09 Apr 09 May
09
Jun 09 Jul 09 Aug 09Sep 09 Oct 09 Nov 09Dec 09
Porosity
0.14
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
Jan 09 Feb 09 Mar 09 Apr 09 May
09
Jun 09 Jul 09 Aug 09Sep 09 Oct 09 Nov 09Dec 09
Weld shift
0
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
0.045
Jan 09 Feb 09 Mar 09 Apr 09 May
09
Jun 09 Jul 09 Aug 09Sep 09 Oct 09 Nov 09Dec 09
Weld undercut
0
0
0.005
0.01
0.015
0.02
0.025
Jan 09 Feb 09 Mar 09 Apr 09 May
09
Jun 09 Jul 09 Aug 09Sep 09 Oct 09 Nov 09Dec 09
Flange bend
OWN TARGET
Doc No :
Rev No :
Date :
Target
Actual
Example 7 - 4M Reduction Plan Global Targets - Rejection
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Example 8 - Progress Control Sheet for Warranty. Delivery & Internal Defects
Doc No.
Rev No.
DATE
Plan Actual Plan Actual Plan Actual Plan Actual Plan Actual Plan Actual PFC
Control
plan
FMEA WI OS SIR
Set up
verificati
Start up
checklis
Alarm
level
PTD
Technic
al know
1 QD/11/01 Flange width variation 03.01.11 11.01.11 New P 03.01.11 03.01.11 03.01.11 03.01.11 10.01.11 06.01.11 17.01.11 11.01.11 17.01.11 11.01.11 17.04.11 P P 03.01.11
2 QD/11/02 Vent hole pierced at wrong location 05.01.11 10.01.11 New - NA NA NA NA 12.01.11 06.01.11 19.01.11 06.01.11 NA NA NA NA P 05.01.11
3 QD/11/03 Weld crack 05.01.11 New - NA NA NA NA P 05.01.11
4 QD/11/04 Band overlap 05.01.11 24.01.11 New - NA NA NA NA 12.01.11 07.01.11 19.01.11 24.01.11 19.01.11 24.01.11 19.04.11 P P 05.01.11
5 QD/11/05 Flange bend 05.01.11 19.01.11 New P NA NA NA NA 12.01.11 08.01.11 19.01.11 17.01.11 NA NA NA NA P 05.01.11
6 QD/11/06 Band bulged 05.01.11 12.01.11 New - NA NA NA NA 12.01.11 08.01.11 19.01.11 10.01.11 19.01.11 10.01.11 19.04.11 P P 05.01.11
7 QD/11/07 Weld shift 05.01.11 15.01.11 New - NA NA NA NA 12.01.11 05.01.11 19.01.11 17.01.11 19.01.11 17.01.11 19.04.11 P 05.01.11 30.01.11
8 QD/11/08 Air pocket 05.01.11 31.01.11 New P NA NA NA NA 12.01.11 12.01.11 19.01.11 23.01.11 NA NA NA NA 001 P P 05.01.11 30.01.11
Interim action
QUALITY CONCERNS PROGRESS CONTROL SHEET
Under progress
Closed
on
Documents Updation (Please put date when activity completed)
Root cause
analysis
Horizontal
deployment
Responsibi
lity
Target
Date
Problem
New or
Repeat
Quality
Alert
Preventive action
S.No
.
QPCR /
8D No.
Concern Description
Raised
on
Emergency
Response
Change
control
no.
Corrective action
23. 19
PURPOSE
• To assure the System of Proactive collection and recording of Warranty Information with defined details.
• To establish the mechanism of Monitoring the Alarm indicators and take actions in case of Alarm level is reached.
• To assure the Information Analysis on defined elements ( like Production month , Kms etc ) and also in case of rare claims detailed analysis is available.
REQUIREMENTS
• Defined Frequency and Responsibility to collect
Warranty Information (Proactively).
• Defined mechanism to collect Warranty raw data
with required details (Mfg. date, Sale date , vehicle
no, area, dealer, region, KM, Mfg. traceability, chassis,
model, problem description, whether parts replaced,
etc.).
• Mechanism of defining alarm controls and taking
actions in case of alarm is reached.
• Defined specific alarm control for Safety parts.
• Availability of a standard procedure for information
analysis which describes analysis steps and parameters
like Production Month, reported month, dealer, Kms etc.
• Use of Information Analysis is done for each defined item.
• Mechanism of tracking the Progress of actions for rare claims through a Progress
Control Sheet (Tracking sheet).
• Availability of Cause Analysis for Occurrence and non-detection for all the defects.
2.2 Information Analysis
REFERENCES
• Warranty Information Analysis procedure with defined Responsibility and Frequency
to collect the information (Ex 9A, Ex 9B).
• Warranty Information Register (Refer Ex 5).
• Warranty Information Analysis monthly (Ex 10).
• Detailed cause analysis for rare claims.
• Monitoring of Alarm controls which is predefined for elements (like Kms, Dealer,
region, Model etc.) with recovery action plan.
• Progress Control Sheet for rare claims to track the progress on actions.
24. M
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Example 9A - Warranty Information Analysis Procedure
Refer Annexure for Ex 9A
Procedure No
Page No
Page issue No
Issue date
Signature
Input Where Output When Who
Joint analysis report Plant Warranty log After initial analysis QA
PROCEDURE FOR WARRANTY HANDLING
TITLE :- WARRANTY HANDLING
What How
QA email / phonecall
Customer given samples
Conduct the data analysis and the preliminary joint analysis (
Visual inspection & feel) with the customer at warranty cell and
decide
a) Accept claim - Confirmed by visual inspection
b) Accept claim - needs further investigation at plant
c) Reject claim
Warranty cell
Joint analysis report &
Parts accepted /
rejected
As per customer's
requirement/monthly
QA/ Marketing Joint analysis format.
d) New claim
---
Receipt of the warranty complaint from the customer through
Telephone call / Warranty analysis meeting
Attend the Warranty
meeting at customer
end.
(1)TKML :- Once/month.
Other customer email
monthly to get data or nil
rejection from customer.
Warranty formats
As per customer's
requirement/monthly
e) Rare claim
Claim accept -a) The part in which defect is confirmed is sent to
scrap yard
b) Carryout Testing like Axial play & torque ,Push out & pullout
,Dimesional in plant standard room for the parts in which defect
is not evident.
Warranty log
Customer given samples Claim Reject : Reject claim and handover parts to customer Warranty cell NTF records After Initial analysis QA
Joint analysis report with
customer.
Analysis report
Customer given samples
Claim for Old cases (Whose actions are completed).Verify the
failure mode by visual / dimensional / metallurgical inspection Plant
Observations after
After initial analysis QA
START
25. 21
Example 9B - Warranty Assessment Flow Chart
SCOPE: Applicable for all Warranty.
Responsibility : Customer Representative/Marketing/PD
Immediately after occurred
Onces in a month
Yes
Two working day
Pareto analysis graphs updated
Data to be captured - Modelwise trend
- Vehicle model Project Manager /Engg.. - Kilometerwise trend
- Vehicel chassis(Sl.no) - Dealerwise trend
- Vehicle manufacturing / sale date - Phenomenon trend
- Vehicle defect report date(Claim Date) - Defect Wise trend
- Defect / Problem reported Yes - Aditya Production batch wise
- Dealer details (name, location) Start of year. - Location/ Zone wise trend( N,E,W,S)
- Production code of Aditya - Defect compared to sale date trend
-Aditya label / pad print details( If Applicable) - Warranty cost trend
QA/Engg/NPD
Receive the data( market Claim) for compilation
Compiled data
Data for trend analysis captured in Format
No.AAP/WGF/00/00 . & AAP/WF/01/00
QA/PD/Aditya Reps..
If no warranty information is received from customer
end, Aditya respresentative at Customer End will visit
the Customer place & collect the Information on
monthly basis or as per the customer practice.
- Conform the Warranty Information through Email &
update the the Warranty data for the month.
Receive warranty information (
market Claim)from customer
through our representative by
website, mail, fax, phone or
letter (or) returned part.
Process Output
WARRANTY ASSESSMENT PROCEDURE
Doc No. :
Org Date :
PURPOSE: To establish a documented procedure to ensure that the Product that does not conform to specified requirements are prevented from
unintended use/Before Warranty period From end user .
Input
Page No: 1 Of 3
Title: Warranty Assessment (Information collection, trend analysis & feedback to
customer)
Rev/date :
Forward this to QA / Production / Engg. /
Maintenance / Purchase.
QA /Project Manager /Engg..
Update the data production monthly wise in the format
(AAP/WF/01/00 ) .
Fix Targets for the current year with
Reduction percentage and Decide the
Focuse areas for Problem Solving Viz,
Compiled date and
make Trend/ parato
analysis
-Aditya label / pad print details( If Applicable) - Warranty cost trend
- Kilometers covered - claim monthwise
- Location/ Zone wise trend( N,E,W,S)
- Cost of warranty onces in year & ever month
- Customer PPM
Yes
Forward to QA, Operation, Production, ME &
Purchase & give the feed back as per
procedure 14 P 01 00 C
Alarm Conditions are
- New Defect
- Defect after the action Taken
- Zone Wise Defect in %
- Delear Wise Defect in % Project Manager /Engg..
Focuse areas for Problem Solving Viz,
Production Month wise Defects, Claim
Month Wise Defects, customer Zone Wise
Defects, Product Wise Defects etc.
A
26. M
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Two working day
Pareto analysis graphs updated
Data to be captured - Modelwise trend
- Vehicle model Project Manager /Engg.. - Kilometerwise trend
- Vehicel chassis(Sl.no) - Dealerwise trend
- Vehicle manufacturing / sale date - Phenomenon trend
- Vehicle defect report date(Claim Date) - Defect Wise trend
- Defect / Problem reported Yes - Aditya Production batch wise
- Dealer details (name, location) Start of year. - Location/ Zone wise trend( N,E,W,S)
- Production code of Aditya - Defect compared to sale date trend
-Aditya label / pad print details( If Applicable) - Warranty cost trend
QA /Project Manager /Engg..
Update the data production monthly wise in the format
(AAP/WF/01/00 ) .
Fix Targets for the current year with
Reduction percentage and Decide the
Focuse areas for Problem Solving Viz,
Compiled date and
make Trend/ parato
analysis
-Aditya label / pad print details( If Applicable) - Warranty cost trend
- Kilometers covered - claim monthwise
- Location/ Zone wise trend( N,E,W,S)
- Cost of warranty onces in year & ever month
- Customer PPM
Yes
Every month
NO
Yes
Prepared by : Approved by :
Ammendment details:
PG PT
A/F
1 ------ 00/06.06.09 nil 00/06.06.09 ---- -----
2
Sl
No.
ISSUE NO & DT REV NO & DT
A/F
B/F B/F NO NO
New Release New Release
Reason for change Changed By
Details of change
Forward to QA, Operation, Production, ME &
Purchase & give the feed back as per
procedure 14 P 01 00 C
Alarm Conditions are
- New Defect
- Defect after the action Taken
- Zone Wise Defect in %
- Delear Wise Defect in %
- 0- 1000 Km range
Project Manager /Engg..
Check for the Alarm Conditions / update the trend
graph.
Beyond
Alarm
Conditions
Project Manager /Engg..
.
Analysis wide Customer input and Warranty analysis
Procedure (14 P 01 00 C)
Focuse areas for Problem Solving Viz,
Production Month wise Defects, Claim
Month Wise Defects, customer Zone Wise
Defects, Product Wise Defects etc.
Below the Alarm control Action to be
taken based on the CFT review ( Focused &
Priority area action will be taken for CAPA .
Contd... A
27. 23
Example 10 - Warranty Information Analysis Monthy
Trend graphs : MODLE FORMAT
Prodn month
produced
quantity
Claims Defect PPM
Mar'10 9
Defect Qty
Center locking defective 5
FRE ECU 0 Not Open From Inside 5
FRM 6 not working 22
Back Manual 1 outside not releasing 4
170N back 0
FLE 2
RLE 0
Back ele w/o irc 3
Back ele 3
RLE 2 TOTAL 36
RLM 1
RRM 1
FRE nippon 11
FRE 1500N 0 Phenomenon trend
20N back 0 Actuator signal not passing 2
10N back 0 Actuator noise 4
RRE 3 ouside release free play 3
FLM 3 Found ok 22
950N back 0 Latch damage can,t able to analyse 5
210N back 0
141N back 0
200N back 0 TOTAL 36
FRE 0
FRE 950N 0
RRE 0
RLM 0
FRM 0
TOTAL 36
25 K to 50 K 7
10 K to 25 K 12 North 20
5 K to 10 K 4 West 6
NO TAG 2 South 4
0 to 1K 7 East 2
1 K to 5 K 4 Central 4
50 K to 75 K 0 north east
75K to 100 K 0
FRM 1520.04 0 to 3 7
Total 36 Back Manual 242.27 4 to 6 10
FLE 709.41 7 to 9 2
Back ele w/o irc 1828.08 10 to 12 4
Back ele 1977.81 13 to 15 4
Defects Qty % Cum. % RLE 1268.88 16 to 18 1
Not Working 19 52.8 52.8 RLM 271.95 19 to 21 1
Not Open From Inside 4 11.1 63.9 RRM 271.95 22 to 24 2
nor open from outside 8 22.2 86.1 FRE nippon 13879.58 After 2Yrs 5
not lock by remote 5 13.9 100.0 RRE 1903.32 Total 36
0.0 100.0 FLM 760.02
0.0 100.0
0.0 100.0
0.0 100.0
0.0 100.0 Total 24633
Total 36
Cai Industries 1
Dehradun Premier 1
DPC Motors 1
Garapati Autoventures 1
Global Gallarie 4
India Garage 1
JS Fourwheel 1
Koncept Automobiles 1
KS motors 3
MPL Automobiles 1
Conclusion: 11% of rejections has been claimed by the Dealer dehradum premier Visit Dealer Appropriately. If any Dealer causing Warranty Claim more than
10% is considered as Alarm Condition.
Zone wise trend
Conclusion: Considering the Top 3 Dealer's from a
particular Zone contributing Warranty claims more
than 10% of the total is considered as Alarm Cond
& necessary action will be taken.
Warranty Trend Analysis of March'11
Doc No. : Org Date :
Page No: 1 Off 3 Rev/date :
Warranty Cost
Defect to Production batch - trend
Conclusion: From the Graph FRM has highest
Warranty Claim & is considered for Analysis
Note: Warranty Target cannot be fixed because:
1. Based on production batch: There are 25 models
& production Qty will vary for every model in every
month. Data/ claims available from Sep'09 whereas
production batch varies from Year 2008-10.
2. Based on Warranty PPM Target fixed: Target fixed
in PPM but the data available in Qty & PPM cannot
be calculated.
Defect wise trend
Conclusion: Prioritise the Defects for which
Actions to be taken by plotting the Pareto Graph.
Take Corrective & Preventive Action for Horizantol
deployment of all the Defects.
Note:
1. For each & every defect/ phenomena we are
plotting the Pareto & taking Corrective actions for
all the problems.
2. If the warranty is claimed after CAPA
Implementation date then it is considered as Alarm
condition & necessary action will be taken.
Model trend
Kilometerwise trend
Conclusion: 50% of rejections have failed in b/w
25K-50K Kms Range.
27% of rejections have failed in b/w 25k to 50k Kms
Note:
1. Warranty Claims less than 1000Kms is considered
as Alarm Condition & actions will be taken for the
same.
2. Warranty target could be fixed based on
percentage but it is not the appropriate method.
MIS Trend
Monthly Defect wise Pareto Graph
Dealerwise trend
5 5
22
4
0
5
10
15
20
25
20
6
4
2
4
0
5
10
15
20
25
North West South East Central north
east
2
4
3
22
5
0
5
10
15
20
25
1 2 3 4 5 6 7
4
3
2 2 2 2
3
2.5
3
3.5
4
4.5
0
2
4
6
8
10
12
14
1 2 3 4 5 6 7 8 9 10 11 12 13
Alarm
Condition
0
6
1
0
2
0
3 3
2
1 1
11
0 0 0
3 3
0 0 0 0 0 0 0 0 0
0
2
4
6
8
10
12
19
4
8
5
0.0
20.0
40.0
60.0
80.0
100.0
120.0
0
2
4
6
8
10
12
14
16
18
20
Pareto for Supplier Rejections
%
Cumulative
Qty
0
0
0
0
0
0
0
0
0
0
0
2000
4000
6000
8000
10000
12000
14000
16000
7
10
2
4 4
1 1
2
5
0
2
4
6
8
10
12
0 to
3
4 to
6
7 to
9
10
to
12
13
to
15
16
to
18
19
to
21
22
to
24
After
2Yrs
A
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Back ele 1977.81 13 to 15 4
Defects Qty % Cum. % RLE 1268.88 16 to 18 1
Not Working 19 52.8 52.8 RLM 271.95 19 to 21 1
Not Open From Inside 4 11.1 63.9 RRM 271.95 22 to 24 2
nor open from outside 8 22.2 86.1 FRE nippon 13879.58 After 2Yrs 5
not lock by remote 5 13.9 100.0 RRE 1903.32 Total 36
0.0 100.0 FLM 760.02
0.0 100.0
0.0 100.0
0.0 100.0
0.0 100.0 Total 24633
Total 36
Cai Industries 1
Dehradun Premier 1
DPC Motors 1
Garapati Autoventures 1
Global Gallarie 4
India Garage 1
JS Fourwheel 1
Koncept Automobiles 1
KS motors 3
MPL Automobiles 1
Narain Automobiles 2
Nataraj Mobiles 1 0.111111111
NO tag 2
Patwa Automobiles 2
Pratik Automobiles 2
Provincial Automobiles 1
Royal Automobiles 1
Sablok cars 1
Silver Jublee 1
Sri durga 1
Sterling Motor 3
Tirupati Automobiles 1
Trendy Wheels 1
Tvs Sundram 1
United Automobiles 1
Total 36
Problem Description
Mar-08 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 Jan-10 Year'07/Blanks/Year'00/Year'04 Total
Found ok 1 1 1 1 1 1 2 14 22
Actuator Failure 1 1 1 3
Actuator soldering missing 1 1 2
Actuator working noise 0
Clow singal unlock From both side 2 3
Inside release lever stuck 1 1
Outside not open 1 1
Not opening by key 2 2
Blanks 1 1
Lock lever broken 0 0
TOTAL 0 1 0 0 0 0 0 0 0 1 0 0 1 2 1 1 0 2 0 2 1 4 0 18 34
Ammendment details:
DT PG PT
Conclusion: 11% of rejections has been claimed by the Dealer dehradum premier Visit Dealer Appropriately. If any Dealer causing Warranty Claim more than
10% is considered as Alarm Condition.
MANUFACTURED MONTH
Sl No.
ISSUE NO & DT
Monthly Defect wise Pareto Graph
Dealerwise trend
Details of change Reason for change Changed By
A/F
B/F B/F A/F NO NO
1 1 1 1
4
1 1 1
3
1
2
1
2 2 2
1 1 1 1 1
3
1 1 1 1
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
19
4
8
5
0.0
20.0
40.0
60.0
80.0
100.0
120.0
0
2
4
6
8
10
12
14
16
18
20
Pareto for Supplier Rejections
%
Cumulative
Qty
0
0
0
0
0
0
0
0
0
0
0
2000
4000
6000
8000
10000
7
2
4 4
1 1
2
5
0
2
4
6
8
0 to
3
4 to
6
7 to
9
10
to
12
13
to
15
16
to
18
19
to
21
22
to
24
After
2Yrs
0
5
10
15
20
25
30
35
40
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Lock lever broken
Blanks
Not opening by key
Outside not open
Inside release lever stuck
Clow singal unlock From both side
Actuator working noise
Actuator soldering missing
Actuator Failure
Found ok
Contd... A
29. 25
2.3 Cause Analysis of Returned Parts (Sequence should be Warranty, Delivery and In-House Defects)
PURPOSE
• To assure the System of Proactive collection and analyzing of Warranty & Delivery returned parts.
• To ensure the use of Detailed Cause Analysis / problem solving technique to identify the real Root Cause for Customer & In House complaints.
• To assure the Analysis of NTF concerns.
REQUIREMENTS
• Defined frequency to collect Warranty
& Customer returned parts.
• Mechanism to make analysis with
defined frequency for Warranty
& Delivery (Warranty - monthly /
customer PPM - monthly).
• Defined Standard procedure for Root
Cause Analysis. (Non detection &
occurrence, cause validations)
• Use of such defined guideline for
analysis of warranty PPM (all defects),
Customer PPM (all defects & Internal
Concerns major contributors.
• Availability of Targets Set for NTF or DNR reduction and Monthly Monitoring with
action plan in case of non achievement.
• Availability of part wise or commodity wise Dos & Don’ts signed off with customer.
• Defined agenda for Line Visit.
• Availability of Customer line verification plan and actual status.
• Defined and applied analysis method by Phenomenon (for assembly / system
related defects) / Master Ishikawa for Part level, and its application.
REFERENCES
• Cause Analysis procedure (Ex 11A).
• Cause Analysis Flowchart (Ex 11B).
• Detail Root Cause Analysis report (eg. 8D) for Warranty, Customer & Internal
concerns (Ex 12).
• Phenomenon wise analysis Flow Chart (Ex 13).
• Approved recommendation sheet (by Customer SCM / STA & buyer) with Dos &
Don’ts (Ex 14).
• Customer Line Verification Plan (Ex 15).
• Customer line verification Check Sheet and Agenda for visit (Ex 16).
• NTF & DNR Target , Monitoring sheet with action plan to reduce the same (Ex 17).
• Master Ishikawa for Part level Repetitive concerns (Ex 18).
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Example 11A - Cause Anaysis Procedure
Refer Annexure for Ex 11A
SOP
CAUSE ANAYSIS PROCEDURE SOP
Date
Page
Rev No 04
CAUSE ANAYSIS PROCEDURE
PROCESS APPROACH FOR ANALYSIS OF PROD/PROCESS PROBLEMS & INITIATION OF CORRECTIVE & PREVENTIVE ACTIONS
TS CLAUSE NO. 8.4, 8.5.2, 8.5.2.1, 8.5.2.2 , 8.5.2.3, 8.5.2.4 & 8.5.3 ISO 14001 CLAUSE NO. 4.5.3
Rev. No. 04
1 PURPOSE
To establish and maintain a system for taking corrective and preventive actions
2 SCOPE
To establish and maintain a system for taking corrective and preventive actions.
Applicable to Customer return , warranty return , as well as inhouse rejections ( Monthly Basis) .
3
3.1 Head quality assurance is overall responsible for implementation of this process approach.
3 2 R i i i h ibl f i l i f h i di d d id d b CFT/
PROCESS OWNER
3.2 Respective section incharges are responsible for implementing of the immediate and permanent countermeasures decided by CFT/ team.
3.3 Respective section incharges are responsible for analyzing the potential non-conformances with concerned CFT and submit the countermeasure report to head quality assurance.
3.4 Other specific responsibilities are as given in the procedure by means of flow chart.
4
Doc.No. Location
Description Retention Period Responsibility Method Of Disposal
Quality Records
F07-8204 Defined place
F02-7103 Defined place
5
Action plan Current financial year+1 year back Relavent sec.head Sale to scrapper
DEFINITION
Defect information cum countermeasure report Current financial year+1 year back Relavent sec.head Sale to scrapper
5
CFT Cross functional team IN HO In House
QC Quality control CL Customer Line
Activity responsible department WR Warranty Return.
DEFINITION
FMEA Failure mode effect analysis
OCI Operation control instruction
CFT Cross functional team IN-HO In-House.
QA Quality assurance
6
R ibilit F
P f i di t R l t T Q/E D t il f P f I di t R f D u t
CP Control plan
Effectiveness & Efficiency Indicators /Performance Indicators
p
Responsibility Frequency
Monthly
Monthly
Performance indicators Relavent To Q/E Detail of Performance Indicators Reference Documents
Effectiveness Q
No.of fool proofing done in the process Respective
incharge
Summary of poka-yoke
No.of preventive actions taken DICR reports
y
7
Q-Quality Management System Requirement , E-EMS Requirement
REFERENCES
8 AMENDMENT RECORD
----------
------------
8
Amd By Approved By
AMENDMENT RECORD
Amendment Date Amd No Amd Details Reason For Amd
04.01.10 03 Nill Periodical Review Bhupendar MR
31. 27
Example 11B - Cause Analysis Flow Chart
SOP
Date
Page
Rev. No.
QA Pur Engg Prod PPC Sales CFT All
1 CFT .
customer line complaints/ in-
house mothly top 2 issues
based on pareto / Warranty
Complaints.
Using QC tools through
DICAR
Customer end & In
house at relavent
stages.
As & when complaint
received from customer &
For inhouse , take a major
rejections monthly once.
To resolve the
issue
F07-8204 ----------
2 CFT Defect details.
1.Implement the 100 %
inspection/ Prepare one point
lesson / Work instructions
for prevent the output flow
2.Implement Error Proofing
(or) kaizen for prevent the
occurrence.
At relavent stage
Within 12 hrs of defect
noticed
To resolve the
issue
F07-8204 ----------
3 CFT
Interim Corrective action
details
Simulation test /
effectiveness varification
At relavent stage
Effectiveness varification
continue one shift of
after action taken
To confirm the
countermeasure
F07-8204
No repeatation
of non
conformance
4 CFT. Non-Conformity detials Identify the Probable causes At relavent stage
As & when complaint
received
To identify the
probable causes.
…………. ……………..
5 CFT Probable causes of the defect 4M Method At relavent stage
Immidiate and after the
identification of probable
causes.
To identify the
potential causes.
F07-8204
6 CFT
Potential causes for each
subclauses
Verify the status , by
specification of the potential
causes VS observations.
Each and every
potential cause
Immidiate and after the
identification of potential
causes.
To validate the
potential cuase
and find out the
root cause.
F07-8204
7 CFT
Potential cause specification"s
observation status
5 Why-Why.
Observation
potential causes
Immidiate and after the
validation of potential
causes.
To find out the
root cause.
F07-8204
Format Rev.
INTEGRATED MANAGEMENT SYSTEM
PROCESS APPROACH FOR ANALYSIS OF PROD/PROCESS PROBLEMS & INITIATION OF CORRECTIVE & PREVENTIVE ACTIONS
TS CLAUSE NO.
8.4, 8.5.2, 8.5.2.1, 8.5.2.2 ,
8.5.2.3, 8.5.2.4 & 8.5.3
ISO 14001 CLAUSE NO. 4.5.3
Sl.
no
Responsibility
(WHO)
INPUT
Activity/ WHAT
HOW WHERE WHEN WHY
Output/Format
& Reference
Instruction
CONTROL
/CRITERIA
Prepared By Checked By Approved By
Analyse the complaint
considering environmental
aspects if applicable.
1 4
3
2 5 7 19 20
19
Do the brain storming for why
defect occured ? & Why defect
not detected ?
Draw the Cause and effect
diagram for why defect occured
? & Why defect not detected ?
Carried out the validation for
cause of occurrence ,non
detection and findout the status
If status significant ,Conduct
WHY WHY analysis for the
potential causes for why defect
occurred ? And why defect not
detected?
If status non
significant,
validate the
next causes
Identify and implement the
interim countermeasure for
output flow & occurrence.
Is Interim
corrective action
effective ?
If NO
19
If Yes
19
19
19
19
19
A
C
A
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MSES
MSES
28
SOP
Date
Page
Rev. No.
QA Pur Engg Prod PPC Sales CFT All
8
CFT /
sec.incharge -
relavent area
Root cause of defects
Appropriate action to
eliminate the reoccurence of
non conformance
At relavent stage With in 14 working days
To avoid re-
occurance of
defect
F07-8204 ---------
9
CFT /
sec.incharge -
relavent area
F01-8501
Through mail
correspondence / Visit the
customer , if customer is in
local place.
Customer end.
Immidiate after
established the corrective
action.
Proper
communication
given to customer.
F07-8204
10
Sec.incharge-
Q.A./CFT
Corrective action details
Simulation test /
effectiveness varification
At relavent stage
Effectiveness varification
continue three month of
action taken
To confirm the
countermeasure
F07-8204
No repeatation
of non
conformance
11
Sec.incharge-
Q.A./CFT
Simillar process
,product,defect,systems.
Identify in all area by
considering environmental
aspects
Similar area
After 3 months of
effectiveness verification
To avoid re-
occurance of same
defect
F02-7103 ---------
12 CFT Action plan Plan vs actual status At relavent stage Decided time frequency
For timely
execution of
activities
F02-7103 -------
13 CFT Activity status Plan vs actual status At relavent stage Decided time frequency ---Do--- --------- --------
14 CFT Countermeasure details
Incorporate all actions in
documents
Related documents
As per decided time
frame-F01-8501
To update the
documents
PFMEA , CP
,Work
instructions ,
process sheet
---------
Format Rev.
INTEGRATED MANAGEMENT SYSTEM
PROCESS APPROACH FOR ANALYSIS OF PROD/PROCESS PROBLEMS & INITIATION OF CORRECTIVE & PREVENTIVE ACTIONS
TS CLAUSE NO.
8.4, 8.5.2, 8.5.2.1, 8.5.2.2 ,
8.5.2.3, 8.5.2.4 & 8.5.3
ISO 14001 CLAUSE NO. 4.5.3
Sl.
no
Responsibility
(WHO)
INPUT
Activity/ WHAT
HOW WHERE WHEN WHY
Output/Format
& Reference
Instruction
CONTROL
/CRITERIA
Prepared By Checked By Approved By
Identify and implement the
permanent corrective
action for occurrence and
non detection.
Is corrective
action effective ?
Identify the similar application in
the product/ process/systems &
make action plan .
Review the status of actions
Implement as
per plan
Review and update process FMEA,
control plan, Work instructions ,
process sheets ,PFD,Inspection
reports,maintenance check sheets,
tool drawing, fixture drawing as
applicable.
YES
19
19
19
19
19
19
If No
NO
YES
Communicate the results
to customer if it is a
customer complaint (or)
Warranty Complaint.
B
B
END
19
1 4
3
2 5 7 19 20
C
A
Contd... A
33. 29
Example 12 - Detail Root Cause Analysis Report (8D Report)
OK NG
Store (SONA)
Godown(Vendor)
Factory(Vendor)
M12
DEFECT INFORMATION CUM COUNTERMEASURE REPORT (8D Report)
DICR NO. : Phenomenon
Defect
Phenomenon Repeat Informed By
Occurance Date
Model & Customer
Defectective Qty.
Part No. & Name
e
d
o
C
h
c
t
a
B
e
c
a
l
P
e
c
n
a
r
u
c
c
O
Supplier/Sub-Supplier Name:
OK PART PHOTO
Remark
(Name & Signature) (Name & Signature)
Reviewed By
Customer End
Id mark
on OK
part
Date
Batch
Code
Parts checked
(Location)
Approved By
STEP-1 ( PROBLEM DESCRIPTION ) STEP-2 PROCESS FLOW DIAGRAM : STEP-3 IMMEDIATE ACTION Prepared By
NG PART PHOTO
CFT Members Name & Department :
1.
2.
3.
4.
(Name & Signature)
Detail :
Phenomenon Occur 1st time Phenomenon Occur 2nd time
On line at Sona
Sub Cause Specification Observation Status (Yes/No) Why Why Why Why Why
STEP-4 ( CAUSE ANALYSIS PROCESS/ OCCURANCE ) STEP-5 ( Cause Validation Of Occurance) Why-Why Analysis
Cause
Man
Machine
Material
Method
Measure-
ment
Why
Status (Yes/No) Why
Material
Observation
STEP-6 ( CAUSE ANALYSIS(INSPECTION OVER LOOK /DEFECT OUTFLOW ) ) STEP-7 ( Cause Validation Of Ouflow) Why-Why Analysis
Cause Sub Cause Specification
Machine
Man
Why Why Why
Method
t
n
e
m
y
o
l
p
e
D
l
a
t
n
o
z
i
r
o
H
1
1
-
P
E
T
S
n
o
i
t
a
s
i
d
r
a
d
n
a
t
S
0
1
-
P
E
T
S
Step-8 Countermeasure taken (Against Occurance) Step-9 Countermeasure taken (Against Outflow)
Measure-
ment
S.No. T.Date
Temporary Action Resp. T.Date Status S.No. Temporary Action Resp. Status
Resp. T.Date Status Part No. & Name
Machine
/Area
Resp. T.Date
Status S.No. Document
Applicable (
Yes/No)
1 Process Flow Diagram
2 PFMEA
Quality Check Sheet
3 Control Plan
4
Status
RQA Inspection std.
S.No. Permanent Action Resp.
S.No. s
u
t
a
t
S
e
t
a
D
.
T
.
p
s
e
R
n
o
i
t
c
A
t
n
e
n
a
m
r
e
P 5
6
7
T.Date
STEP-12 Check Effectiveness
8 Final Inspection Standard
Machine check sheet
One point lesson M9
M1 M2 M3 M4 M6
MAN
MACHINE MATERIAL
METHOD MEASUREMENT
MAN
MACHINE MATERIAL
METHOD MEASUREMENT
A
34. M
A
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SUPPLIER EVALUATIO
N
S
T
A
N
D
A
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D
MSES
MSES
MSES
30
M12
9
10
11
12
13
Method
Measure-
ment
Why
Status (Yes/No) Why
Material
Observation
STEP-6 ( CAUSE ANALYSIS(INSPECTION OVER LOOK /DEFECT OUTFLOW ) ) STEP-7 ( Cause Validation Of Ouflow) Why-Why Analysis
Cause Sub Cause Specification
Machine
Man
Why Why Why
Method
t
n
e
m
y
o
l
p
e
D
l
a
t
n
o
z
i
r
o
H
1
1
-
P
E
T
S
n
o
i
t
a
s
i
d
r
a
d
n
a
t
S
0
1
-
P
E
T
S
Step-8 Countermeasure taken (Against Occurance) Step-9 Countermeasure taken (Against Outflow)
Measure-
ment
S.No. T.Date
Temporary Action Resp. T.Date Status S.No. Temporary Action Resp. Status
Resp. T.Date Status Part No. & Name
Machine
/Area
Resp. T.Date
Status S.No. Document
Applicable (
Yes/No)
1 Process Flow Diagram
2 PFMEA
Quality Check Sheet
3 Control Plan
4
Status
RQA Inspection std.
S.No. Permanent Action Resp.
S.No. s
u
t
a
t
S
e
t
a
D
.
T
.
p
s
e
R
n
o
i
t
c
A
t
n
e
n
a
m
r
e
P 5
6
7
T.Date
STEP-12 Check Effectiveness
8 Final Inspection Standard
Machine check sheet
One point lesson
STEP-13 Pl. Circle Appropriate Root Cause
Work Instrucions
MEASUREMENT
MAN MATERIAL
SOP-QMS .
Cutting Tool Dwgs
Product Drawings
MACHINE METHOD
Non-Cutting Tool Dwgs
M9
M1 M2 M3 M4 M6
MAN
MACHINE MATERIAL
METHOD MEASUREMENT
METHOD MEASUREMENT
14
15
Gauges Dwgs
Past Trouble data Updation
Rev No : 01
Contd... A
35. 31
Example 13 - Phenomenon Wise Analysis Flow Chart
Analysis flow of CRACK
Prepared By Approved By
PHENOMENON WISE ANALYSIS
Department Name :- MOULDING
Reported Problem :- Broken Phenomenon :- CRACK
Problem :- Broken
Problem Found at
Customer End
Defective Components
received from customer
Visual inspection of the
components / Part
All Usual Parameters.
1) Check for the location of defect on
component.
2) Check for performance..
Compare defective Sample
against defect library
CRACK observed
Collect the data for analysis
at various stages.
1) Check for the compound.
2) Check for the process parameter
(Temp, Cure time)
3) Check for operating process of operator.
4) Check for the tool.
Verify the Compound used.
If it is ok….?
NO
Modify the compound &
Revalidate
Verify the tool used.
If it is ok….?
NO
Yes
Rectify the tool & Take necessary
action and revalidate the tool
Call CFT & Technical
Person for further
analysis
If Flat Mark not observed, Inform to
Customer & arrange a joint meeting to
resolve the problem with evidence
Verify the compound
Manufacturing process
Yes Yes
If it is ok….?
NO
Set the same parameters
, verify & Revalidate
Check for : Process setting parameters
1.Check for processing parameter
2.Temperature 3. Cycle time.
Check for :
1. Different chemical lab approval
2.Check for physical properties.
Verify the Moulding Process &
Operating method
Yes
If it is ok….?
NO
Give refresh training
/Retraining to operators &
revalidate
Check for :1.Curing Time, 2.Loading
weight, 3.pressure, 4. Temperature, 5.
Operating method
Check for :
1.Burr
2.Shrap edges
3. Damage mark
36. M
A
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SUPPLIER EVALUATIO
N
S
T
A
N
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A
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D
MSES
MSES
MSES
32
Sr. no. DO'S DON’T
Always ensure the Crorugated cap on the Plastic Socket Do not take without cap part for assembly
hmaoSaa Qyaana do kI plaasTIk saa^koT pr kaorugaoToD k^p lagaa huAa hO. kop ko ibanaa paT- AsaoMbaila ko ilayoa na lao.
Ensure perfect guide when lock set is placed in the fixture.
Do not clamp the assembly if the lock set is not located in the stearing
column
laa^k saoT kao iFkscar mao rKnao sao phlao ]saka gaa[D saih hO yaa naih yao
jaaca lao.
yaid laa^k saoT sToirnga ka^lama mao laaokoT naih hao rha tao Asaomabaila na kro.
Recommendation Sheet for Lock Set
This will Damage /bend the terminals of the plastic socket causing electrical assembly failure.
1
RISK
2
yah plaasTIk saa^koT ko Trimanala kao baoMD yaa D^maoja krgaa ijasasao [laokT/Ikla AsaoMblaI nahI haogaI .
Locking Screws
Location for
Stearing lock
assly
During Handling always keep the lock set in this position
Do not place the parts at any other position ( the terminals may touch
the floor)
laa^k saoT kao [stmaala krto samaya inacao idKayao tirkosao hI rKo. paT- kao ikisaBaI AaoOr paoJaISana maoo na rKo Trimanala jaimana kao laga sakta hoO.
M&M - Stores ( Name,Sign & Date ) M&M -TCF ( Name,Sign & Date )
Approval
3
RISK
[sao la^ca laa^k Aoaor sToirnga ka^lama ko ibaca kaif jyaada [MTrfosa banaogaa ijasasao sToArIMga laa^k Aa^proT nahI haogaa .
RISK
yah plaasTIk saa^koT ko Trimanala kao baoMD yaa D^maoja krgaa ijasasao [laokT/Ikla AsaoMblaI nahI haogaI .
This will creat high interference between Latch lock & stearing column due to which stearing lock will not operate.
This will Damage /bend the terminals of the plastic socket causing electrical assembly failure.
Example 14 - Approved Recommendation Sheet with DO’s & DONT’s
37. 33
Example 15 - Car Maker Line Verification Plan
Doc. No:
Rev. No:
Rev. Date:
Customer Place Frequency April May June July August September October November December January February March
ABC Pune M
XYZ Pune M
DEF Pune M
EFG Pune M
HIJ Baramati M
ABAB Kandiwali AM
GAP Nasik Q
MNO Nasik Q
PQR Zahirabad Q
TUV Pithampur Q
SRK Aurangabad Q
NOTE:
Indicates visited.
Indicates not visited.
Agenda for discussion during visit to customer :
1) Discussion on earlier open points with customer if any.
2) Interaction with receiving inspection , line people of customer.
3) Understand the Quality concern if any and initiate action for resolution of the same.
4)Verification of Do's & Don'ts in customer premises from receipt of material up to assembly.
CAR MAKER LINE CONFIRMATION VISIT PLAN & AGENDA
Date: Reviewed By: Approved By:
CUSTOMER VISIT PLAN FOR YEAR 2010-11
M= Monthly, Q=Quarterly
38. M
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SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
34
Example 16 - Customer Line Verification Checksheet & Agenda
S.
NO
Quality Communication Log
No
TARGET
DATE
8 .
a
b
c
d
d
e
f
g
h
i Part assemled as per defined instructions
CHECK POINTS
Are the Boxes properly unloading at Store
7
5 EFFECTIVENSS OF IMPLEMENTED ACTIONS
CUSTOMER AUDIT STATUS
6
4
2 LINE REJECTION
PACKAGING ISSUES
3
USAGE OF PARTS
Are the boxes properly stacked at store with pallets
Are the boxes properly transferred from store to line
Is the Conditions of line container proper
Operarator handling the part properly without any
damages before assembly
Are parts stored with facing upwards
CORRECTIVE ACTION
1 WARRANTY ISSUE
OBSERVATION
CHECKPOINT RESPONSIBILITY
Is the Low point being matched with high point on
tyre while assembling
SUGGESTION FOR IMPROVEMENT
Is torque set as per specification
Is the torquing sequence being followed by line
operator while fitting part
Doc No : F/QA/268
Rev No: 00
Rev Date:
CUSTOMER VISIT CHECKLIST
39. 35
Example 17 - NTF & DNR Monitoring Sheet with Action Plan
NTF Warranty Trend - Monthwise Qty
34
22
7
5
2
0
7 4
0 0 0 0
0
5
10
15
20
25
30
35
40
A 10 S 10 O 10 N 10 D 10 J 11 F b 11 M 11 A 11 M 11 J 11 J l 11
Qty
NTF QTY. Vs MONTHWISE FROM AUG'10 TO JULY'11
QTY
Target
NTF TARGET 4 NOS PER MONTH
S.No.
1
2
3
ACTION PLAN
Owner
Action
For tempered cases discuss with Customer warranty & team that
training to be given to dealer how to dismentale the part from vehicle
15-Aug-10
ABC
Status
Target
Inprocess
For found ok pieces check on vehicle with Customer warranty team &
Team for confirming no defect
XYZ 16-Dec-10 Started and rejecting claim at Customer
Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11
40. M
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SUPPLIER EVALUATIO
N
S
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A
N
D
A
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D
MSES
MSES
MSES
36
Example 18 - Master Ishikawa for Part Level Repetitive Concerns
Doc No:
Rev.No :
Rev. Date:
PROCEDURENOTUPDATED
MOULDHEATUP PROCEDURENOTAVAILABLEATWORKSTATION
HIGHOILTEMPERATURE CYCLEDELAY
INSERT HIGHSIDEMTCSET NOREFRESHTRAINING UNTRAINEDPERSON
NOTCLEANEDPROPERLY LONGLEAVE WORKINSTRUCTIONNOTAVAILABLE
POORQUALITY OILYSURFACEONTHEMOULD NOTFOLLOWED WRONGMATERIALFEED
PUNCTUREDHOSE SILICONSPRAYUSED PROCEDUREVIOLATION UNTRAINEDPERSON
WARNOUT NEGLIGENCE UNTRAINEDEMPLOYEE
EXCESS OILSCATTEREDAROUNDTHEM/C LACKOFAWARENESS NEWMANHANDLING
GREASINGONEJECTORASSY INSTRUCTIONNOTFOLLOWED SHORTAGEOFMANPOWER
GREASECOMINGOUT UNTRAINEDRELEAVER ATTENDAFTERLONGLEAVE
LOOSEFITTING EJECTORPIN LACKOFHELPER LACKOFAWARENESS
MOULDHOSEPROBLEM SKIPOUTOPERATION NEWMANINVOLVED
SEALBROKEN NOTFEELINGWEEL
LACKOFAWARENESS
HANDGLOVESNOTBEENUSED
NOTAVAILABLE
HIGHPRESSURESETTING WRONGGRADE
UNCLEANEDBINSUSED
PROCEDURENOTUPDATED
FALLENPART FIRSTTIMEOBSERVED
SETUUPPARTSMIX-UP
WRONG PROCEDUREADOPTED
SAMEPARTOFOTHERMODEL
MAN
METHOD MATERIAL
MASTERISHIKAWA
Date: ReviewedBy: ApprovedBy :
CAUSE&EFFECTDIAGRAM/ISHIKAWAforOILMARK
MACHINE
OIL MARK
41. 37
PURPOSE
• To assure the mechanism to identify the Occurrence and Non Detection level Causes during Analysis.
• To assure the system to avoid the repetition of concerns by monitoring effectiveness and systemic actions through relevant document Updations.
• To assure the mechanism of Utilization of Past Concerns for New product development.
REQUIREMENTS
• Mechanism of identifying the Root Causes for Occurrence & Non Detection.
• Defined Criteria to monitor effectiveness (where to check, what to check, how long
to check and condition to restore).
• Availability of effectiveness monitoring evidence for Corrective & Preventive actions.
• Defined and applied actions for Horizontal Deployment to similar parts, processes
or plants.
• Mechanism to update relevant documents (Eg. CP , PFMEA, PFC, PTDB etc) based
on the actions taken on the quality concerns during analysis.
• Defined responsibility for PTDB updation.
• Technical Know How based on the design (Process + Product) level actions on the
defects.
• Availability of Check list for New Product development to ensure the usage of all
such past Lessons Learned.
2.4 Prevention of Recurrence
REFERENCES
• Horizontal Deployment in CAR.
• Monitoring system for warranty, Customer & Internal concerns.
• Updated documents based on Corrective & Preventive actions.
• Updated PTDB (Ex 19).
• Lessons Learned (Things gone Right & Wrong).
• Technical Know-How Document (Ex 20).
42. M
A
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I
N
D
R
A
SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
38
Example 19 - Past Trouble Database
Name of the
new project
Implementati
on status -
Put Yes / No
Remarks
Name of the
new project
Implementation
status -Put Yes /
No
Remarks
1 10.1.2011 In-house 7 DICR NO:-1 YES NA NA YES Yes
It is addressed in
the FMEA & line
Yes
It is addressed
in the FMEA &
line
2 10.1.2011 In-house 12 DICR NO:02 YES NA YES NA Yes
It is addressed in
the FMEA & line
Yes
It is addressed
in the FMEA &
line
3 08.02.2011 Customer complaint 1 1 YES YES NA YES Yes
It is addressed in
the FMEA & line
Yes
It is addressed
in the FMEA &
line
4 12.2.2011 In-house 17 DICR NO:03 YES NA NA YES Yes
It is addressed in
the FMEA & line
Yes
It is addressed
in the FMEA &
line
5 12.2.2011 Warranty 18 DICR NO:04 YES NA NA YES Yes
It is addressed in
the FMEA & line
Yes
It is addressed
in the FMEA &
line
6
7
8
47
45
2
45
100%
REV No 00
Feed Back Ratio ( in %) :
Format No.:
No.Of Past TGW Considered (YES) :
No.Of Past TGW Not Considered (NO) :
Applicable TGW nos :
No.Of Past TGW : CFT Members & Sign
APPLICABILITY REVIEW FOR NEW PROJECT
4M
Work
Instruction
Part No
Part
Name
Control
Plan
PFMEA
Corrective
Action
of Non
Detection
Corrective Action
of Occurrence
Root Cause Of
Occurrence
Root Cause Of
Non
Detection
Model
Name
Category ( Warrnty
/Customer
complaint / In-
House Rejections )
Lessons
Learnt
Technical
Know-How
PAST TROUBLE DATABASE
Updated On
S.No
ABC PROJECT XYZ PROJECT
DICR No. / QPCR
Qty
Nature of defect
Custome
r
43. 39
Example 20 - Technical Know-How Document
TECHNICAL KNOW HOW DOCUMENT
Deployment to New Project :-
1. For new machines / manufacturing line. 2. New Development Design Input Checklist.
Lessons Learned / Technical Knowhow :-
Friction factor has to be considered wherever relative motion between component and machine part is involved, in order to arrest the change in orientation of the
component. This has been added as design input.
Countermeasure Taken:-
1. To replace the rectangular slide rail of assembly welder I with round bars
2 To modify the fasteners to accommodate the round section
Doc No:
Rev No:
Rev Date:
REF NO: TKH/QA/002 DATE:
BEFORE AFTER
Approved By
Reviewed By
Prepared By
CUSTOMER: INTERNAL PROBLEM
MODEL: ALL MODELS
PART NAME: STEEL WHEEL
PART NO: ALL PRODUCTS
Problem Faced:-
Weld Shift observed in assembly welding. The problem was observed coming intermittently
Rectangular slide
More Contact Area
Round slide
Less Contact Area
44. M
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SUPPLIER EVALUATIO
N
S
T
A
N
D
A
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D
MSES
MSES
MSES
40
PURPOSE
• To assure the Mechanism of tracking all the steps during the analysis and ensure the closure of the actions as per defined timelines for each step.
REQUIREMENTS
• Availability of progress control list inclusive of all Quality concerns (Warranty,
Customer & Internal).
• Defined target time for each step of analysis Eg. Target timeline for steps from
immediate containment, cause analysis till PTDB updation and closure with
customer in case of warranty & delivery concerns.
• Availability of Permanent countermeasures as per defined target timelines.
• Mechanism of review of such compiled Progress Control Sheet is existing and
status is known to all related persons.
• Mechanism of Confirming the effectiveness of counter measure (eg. criteria is
defined – where to check , what to check , how long to check and condition of
acceptance etc).
2.5 Progress Control of Target Defects
REFERENCES
• Updated Progress control sheet (Refer Ex 8).
• Effectiveness monitoring mechanism for each defect.
• Time line defined for each step in the Cause Analysis Procedure.
45. 41
Chapter 3
Quality Assurance at the Process Development Stage
PURPOSE
• To assure that PFMEA has been made with a true intent of identifying all possible Failure Modes and the Preventive and Detection controls are available to overcome the
possible causes of failure mode.
• To assure that all previous failure modes on similar products have been considered while preparing PFMEA and the applicable controls are in place.
REQUIREMENTS
• Availability of Process FMEA Standard (5W1H).
• Availability of Core team is identified and defined Selection standard based on
knowledge.
• Defined RPN Rule meeting customer specific requirement.
• Availability of defined rating tables for Severity, Occurrence and Detection based
on latest AIAG Guidelines.
• Availability of PFMEA Review check sheet.
• Defined review frequency and conditions for PFMEA Review and it is followed.
• Availability of Countermeasure setup according to the defined RPN threshold, All
RPN is under target score.
• Recommended actions are implemented as per timeline & RPN is updated with
monitoring mechanism established.
• Availability of backup data for Occurrence based on causes and defects.
• All past trouble database are feedback to FMEA (all the failure modes of actual
product are included in FMEA sheet) with feedback ratio of 100%.
3.1 Process FMEA
Objective: To ensure that all Failure Modes are Identified and Controls including Prevention are established during process
development.
REFERENCES
• FMEA Procedure (Ex 21).
• FMEA checksheet (Ex 22).
• Review plan.
• PTDB (Refer Ex 19).
• Occurrence matrix (Ex 23).
46. M
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SUPPLIER EVALUATIO
N
S
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A
N
D
A
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MSES
MSES
MSES
42
Example 21 - PFMEA - Procedure
Refer Annexure for Ex 21
SOP
Date
Page
Rev. No.
Q Pur Engg Prod PPC MR CFT All
1
Head
Engineering
New Products built, Existing
product(or) process
modification stage.
Based on Skill Requirement such as
Hard skill , soft skill and Technical
skills in cause & Effect analysis,
Ranking stages.
Project Room
Whenever formulate newly
(or) added/deleted the
members list.
To form the CFT
GuideLine for skill
requirement.
F1-7101B
F10-7101B
F09-7101B
……………….
2 CFT
Master schedule ,PFMEA
input check sheet , CFT
members list, simillar process
PFMEA, List of poke yoke ,
lesson learnt and past trouble
data base
1.Past Trouble Data base with guide
line of update & Diploy the horizantal
diployment ,2. Drawing, 3.Similar part
comparision,(Detection & prevention
mechanisim,
Project Room
At the time of making fresh
PFMEA.
To make PFMEA
F01-7101B
F06-7101B
F06A-7101B
F03-7101C
F02A-WI/SOP-
7101B/01
F07-7101B
WI/SOP-7101B/02
……………….
A
E
M
F
P
-
t
c
e
j
o
r
p
w
e
N
.
t
r
a
h
c
w
o
l
f
s
s
e
c
o
r
p
g
n
i
s
U
.
m
a
r
g
a
i
d
w
o
l
f
s
s
e
c
o
r
P
T
F
C
3
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
To make PFMEA F20-7101 ……………….
4 CFT
Customer (or) internal
drawings / Simillar part
PMEA
Customer (or) internal drawings /
Simillar part PMEA
New project -PFMEA
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
Every product
characteristics fialure
modes to be analysed.
………………. ……………….
5 CFT
past trouble datas , simillar
part pfmea,List of poke yoke,
lesson learnt
CFT inputs / Past trouble datas
simillar part pfmea,List of poke yoke,
lesson learnt
New project -PFMEA
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
To prevent the
re-occurrence,warranty
failures,customer
complaints.
F01-7101B
F06-7101B
F06A-7101B
F03-7101C
F02A-WI/SOP-
7101B/01
……………….
6 CFT
Simillar part PMEA ,Customer
feedback,Field informations
Based on product knowledge New project -PFMEA
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
To identify the potential
risk.
F06-7101B
F06A-7101B
……………….
7 CFT
Simillar part PMEA ,Customer
feedback,Field informations
Based on product functions failure with
respect to next process , assembly line
,Customer line and enduser .Ranking
should be given for all effects of
failures and highest ranking should be
taken as severity ranking
AIAG -latest manual.
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
To identify the severity
effects
F03-7101B ……………….
8 CFT
Customer (or) internal
drawing
Customer (or) internal drawing New project -PFMEA
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
To identify the safety &
regulatory and to decide
on Sev rating
……………….
9 CFT
past trouble datas , simillar
part pfmea, list of poke yoke
and lesson learnt.
past trouble datas , simillar part pfmea,
list of poke yoke and lesson learnt.
New project -PFMEA
At the time of making fresh
PFMEA./ Revised the
existing PMEA.
To prenvent the re-
occurrence .To identify
the process control
methos using 4M
F01-7101B
F06-7101B
F03-7101C
F02A-WI/SOP-
7101B/01
F07-7101B
……………….
Collect and summarize the last 6
PFMEA PROCEDURE
PROCESS APPROACH FOR PFMEA MAKING
.
O
N
E
S
U
A
L
C
1
0
0
4
1
O
S
I
2
.
3
.
3
.
7
/
1
.
1
.
3
.
7
.
O
N
E
S
U
A
L
C
S
T
Output/Format &
Reference
Instruction
Sl.n
o
Responsibility
(WHO)
INPUT
CONTROL
/CRITERIA
Y
H
W
N
E
H
W
E
R
E
H
W
W
O
H
Activity/ WHAT
1 4
3
2 5 18 19 20
Start to prepare
Identify the
Operation Name /
Number.
Identify the
Process/Function
requirement.
Identify the Potential
Identify the
Potential effects
of failure
Identify the Sev
Rating (S).
Identify and mentioned
the Class.
Identify the potential
Cause(s)/Mechanism(s)
of Failure and implement
the same in new project
19
19
19
19
19
19
19
19
Formulate the CFT
members.
47. 43
Project name:
II quarter III quarter IV quarter
1
2
3
4
5
6
6
6
INPUT
Have the engineering drawings/engineering
standards been considered while making PFMEA ?
Drg No, Rev No & Dt
Mention the PTD latest
updation date.
Have DFMEA been considered?
Mention DFMEA No.,
Rev no., Rev dt.
Have similar part PFMEA been considered?
Mention PFMEA No.,
Rev no., Rev dt.
Have list of new equipment , Tooling and Facilities
Requirements been identfied ?
as per procedure
A
B
B
A
:
r
e
m
o
t
s
u
C
All processes defined in
PFC should reflect in
PFMEA.
I quarter
OBSERVATION
CFT team as per
procedure
Have list of special process characteristics have been
identifed ?
as per procedure
Is CFT team being formed for making the PFMEA ?
d
r
a
d
n
a
t
S
T
N
I
O
P
K
C
E
H
C
O
N
.
S COMMENTS
XYZ
ABC
Have process flow chart been considered while
making PFMEA ? ( Mention the Rev no. and rev dt
of the PFC )
Have all PTD information considered ?
PFMEA REVIEW CHECKSHEET
Part size :
Doc No:
Rev No: 01
Rev Date:
6
6
6
7
8
9
10
11
12
13
14
15
16
REVIEW
Has the preliminary listing of product and process
parameters been considered?
as per procedure
Have Customer Complaints / internal rejections been
considered?
as per procedure
ranking for severity ,
occurance and
detection as per
procedure
identification of special
characteristics as per
procedure
Have updated occurance backup sheet been
considered?
Mention the latest
updation date
Has key date been replaced by the earliest date
mentioned in counteractions ?
as per procedure
Have RPN reduction plan been made for failure mode
which exceed the allowable RPN ?
criteria as per standard
Are target date , responsibility been defined for
counteraction ?
as per procedure
Are all special characteristics identified by the
symbol ?
as per procedure
Have special characteristics been identifed in the
PFMEA ?
Have potential failure mode been identifed for all
process defined in PFC ?
Have ranking for PFMEA done correctly ?
have control method applied as per the criticality of
the characteristics ?
Have occurance rate being estimated correctly ? as per procedure
as per procedure
y
B
d
e
w
e
i
v
e
R
:
y
B
d
e
r
a
p
e
r
P Approved By
as per procedure
Have next review date being defined for reviewing
the FMEA?
as per procedure
Example 22 - PFMEA Review Checksheet
48. M
A
H
I
N
D
R
A
SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
44
Example 23 - Occurrence Matrix
Improper Filling 4 5
Dia offset / Ovality 0 2
Dia oversize 0 2
Dia undersize 0 2
Heavy flash 0 2
Annealing High hardness 0 2
Microstructure not ok 0 2
Decarb not ok 3 5
Low hardness 0 2
Quenching crack in bar 0 2
Bend in torsion bar 0 2
Roller Mark on the bar 0 2
Low Core Hardness 2 4
Variation in hardness 0 2
Low Hardness 0 2
High Hardness 0 2
Microstructure not ok 0 2
Bend Inspection Bend on torsion bar more than
specification 2 4
Bend Correction Deep mark on torsion bar 1 4
Stress Releaving Stresses not releaved totally 0 2
Coverage not as per specification 0 2
Big particle indentation on rod. 0
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
10,172
0.39
0.00
0.00
0.00
0.00
0.00
0.00
0.29
0.00
0.00
0.00
0.00
0.20
0.00
0.00
0.00
0.00
0.20
0.10
0.00
0.00
0.00 2
Operation Defect Codes
Rejected parts in
past 6 months
Total Quantity
Produced in past
6 months
Rejected
pcs per 1000 pcs OCC No.
Heating & Upsetting
Heating & Quenching
Pit Tempering
Shot Peening
49. 45
PURPOSE
• To assure identification of Product-Process Characteristics and its control during the manufacturing process and necessary reaction plans for deviant conditions.
REQUIREMENTS
• Availability of procedure for preparing control plan including - Input, review
frequency, format, check sheet.
• Mechanism for identifying process parameters required for product parameters by
Process validation or product-process characteristic relationship matrix etc.
• Availability of Control plan from the beginning of process development phase
(APQP phase 2- Prototype, Prelaunch and Production control plan).
• Availability of system for identifying control methods of product and process
parameters according to gravity (safety, functional, regulatory).
3.2 Control Plan
REFERENCES
• Control Plan procedure (Ex 24).
• Control Plan review Checklist (Ex 25).
• Product-Process relationship matrix (Ex 26).
• Prototype-prelaunch-production Control Plan.
• Guideline for assigning control method based on gravity (Ex 27).
50. M
A
H
I
N
D
R
A
SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
46
Example 24 - Control Plan Procedure
Refer Annexure for Ex 24
Doc. No.
ISSUE
REV No
DATE
PRODUCTION CONTROL PLAN
:
:
:
5. ACTIVITY DETAILS:
Sl.
No
1 Triggers
2 Inputs
3 Team
Process Flow
Item
START
1. New Product
2. Engineering Changes
1. Results of Corrective Actions
2. Results of Continuous Improvement
3. Customer Audits and Feedback
4. Customer Complaints
5. Warranty Issues
6. Inputs from Internal Audits
7. VA / VE 8. FMEA Revision
For New
Control Plan
For Revision of
existing Control
Plan
1. DFMEA
2. PFMEA
3. Engineering Drawing
4. Engineering Specification
5. Material Specification
6. Drawings an Spec. changes
7. Eqpts, Tooling & Facilities
8. Special Prod./Process Charecteristics
9. Guages and Testing Equipments
10. Packaging standards & Specifications
11. Process Flow Chart
12. Floor Plan Layout
13. Charecteristics matrix
14. Lessons Learned from Similar parts
Form Cross Functional Team with
representations from Manufacturing, QA, PE,
R&D, Maintenance, Tool Room, Purchase,
R&D
Change in Location
Change in Machine / Tooling
Change in Process Parameters
Change in Process Sequence / methods
CHANGES
1
1
51. 47
Example 25 - Control Plan Review Checklist
S.NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
REVIEW
REVIEW
Have the lessons learned from similar parts been considered?
Have the guages and testing equipments been considered?
Have list of new equipment , Tooling and Facilities Requirements been identfied
?
Havethe latest Engg Drawing been considered?
Have observation observed during trial / ramp up been adressed in the control
plan ?
Have correct evaluation measurement technique been defined ?
Specify Updation date yes
Have the packaging standards been considered? Specify Doc No, Rev No & dt no Packaging Standard to be prepared.
As per procedure yes
Have list of special process characteristics have been considered ? As per procedure yes
As per procedure yes
Have the latest Engg Spec been considered? Specify Doc No, Rev No & dt yes
Specify Doc No, Rev No & dt yes
Have latest DFMEA Considered? Specify Doc No, Rev No & dt yes
Specify Doc No, Rev No & dt yes
Project name:
Have latest process flow chart been considered while making control plan ?
Is customer specifed format used for control plan ?
Part size : XYZ
INPUT
Have latest PFMEA considered ?
Prepared by Reviewed By Approved By
Production control plan
YES
Have controls been extended as per the result of process capability study ? As per procedure
Have observation observed during ramp up been addressed in the control plan
?
As per procedure YES
Have result of MSA been considred while adopoting the evaluation system ? As per procedure
YES
As per procedure no
Have correct control method been identifed ? As per procedure yes
Have reaction plan been defined for out of control conditon ? As per procedure yes
As per procedure yes
XXXX
Customer Specified format to be used.
Specify Doc No, Rev No & dt yes
As per procedure no
For each of the evaluation measurement technique where sampling technique
has been adopted, Have sample size and frequency correctly defined ?
As per procedure yes
As per procedure yes
Have specification for control parameter been defined ? As per procedure yes
Have all process and product control parameter been defined ? As per procedure yes
Have special process and product control parameter been identified with the
symbols ?
CONTROL PLAN REVIEW CHECKLIST
ABC
Evaluation points
Check point YES / NO COMMENTS
Customer :
Format No.:
Rev No:
Rev Date:
53. 49
Example 27 - Guideline for Assigning Control Method based on Gravity
Page 1 of 1
Sl No
1. P Y Checksheet
2. Prev. maint ch.sheet
1. P Y Checksheet
2. Prev. maint ch.sheet
1. P Y Checksheet
2. Prev. maint ch.sheet
1. P Y Checksheet
2. Prev. maint ch.sheet
Set Up Verification and S I
Automatic / Visual
Measurement Equipment/
Technique
Control Methods
X- R chart
Run chart
Run chart
Automatic / Visual
1. P Y Checksheet
2. Prev. maint ch.sheet
X- R chart
4. Run Charts
5. 100% Checking
6. Set Up Verification and
X- R chart
Run chart
Automatic / Visual
1. P Y Checksheet
2. Prev. maint ch.sheet
1. Prevention Poka Yoke
2. Detection Poka Yoke
5. 100% Checking
1. Prevention Poka Yoke
2. Detection Poka Yoke
3. SPC
2
1
3
3. SPC
4. Run Charts
5. 100% Checking
Charecteristics Symbol
Safety
Regulatory
Critical
1. Prevention Poka Yoke
2. Detection Poka Yoke
3. SPC
4. Run Charts
Control Methods by Gravity
ANNEXURE -I
1. SPC
6. Set Up Verification and
Stage Inspection
Set Up Verification and S I
Format
5. 100% Checking
Set Up Verification and S I
Format
6. Set Up Verification and
Stage Inspection
2. Set up verification Set up verification Checklist
1. P Y Checksheet
2. Prev. maint ch.sheet
X- R chart
Run chart
Automatic / Visual
5
4
X- R chart
Stage Inspection sheet
1. Prevention Poka Yoke
2. Detection Poka Yoke
3. SPC
4. Run Charts
1. P Y Checksheet
2. Prev. maint ch.sheet
Others
Major
3. Periodical Inspection
Page 1 of 1
100% Visual
No complaint for continuous 3
months, Poka yoke introduction
No complaint for continuous 3
months, improvement in
Fixture/gauge usage
No complaint for continuous 3
months, improvement in Fixture
usage
- 100% Visual & marking
Check & implement Product
or process pokayoke
No complaint for continuous 3
months, Poka yoke introduction
Check & improve over
fixture usage
Use of fixture/gauge
(Detection)
Fixture/gauge
validation
100% check & marking,
Do fixture/gauge
validation
Check & improve over
fixture / gauge usage
Check & implement Product
or process pokayoke
Additional 100% Visual
& marking (Detection)
100% Visual & marking -
No complaint for continuous 3
months, improvement in Poka
yoke sustainance
SPC Study - 100% check & marking -
No complaint for continuous 3
months
100% testing with
machine
Daily poka yoke check
& machine validation
100% check & marking,
Do poka yoke &
machine validation
Check & improve over poka
yoke sustainance
Fixture control
(Prevention)
Fixture validation
100% check & marking,
Do fixture validation
NEW CONTROL METHOD
CONTROL METHOD CHANGE STANDARD
ANNEXURE - II
Immediate Permanent
Control Methods
EXIT CRITERIA
CURRENT PROCESS CONTROL METHOD
Issued By Prepared By Reviewed and approved By
No complaint for continuous 3
months, improvement in Poka
yoke sustainance
Process pokayoke
(prevention)
Daily poka yoke check
100% check & marking,
Do poka yoke validation
Check & improve over poka
yoke sustainance
No complaint for continuous 3
months, improvement in Poka
yoke sustainance
Process pokayoke
(detection)
Daily poka yoke check
100% check & marking,
Do poka yoke validation
Check & improve over poka
yoke sustainance
Check & improve over poka
yoke sustainance
No complaint for continuous 3
months, improvement in Poka
yoke sustainance
Product pokayoke
(detection)
- 100% check & marking
Check & improve over poka
yoke sustainance
100% check & marking
No complaint for continuous 3
months, improvement in Poka
yoke sustainance
Product pokayoke
(prevention)
-
54. M
A
H
I
N
D
R
A
SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
50
PURPOSE
• To assure that required Mistake Proofing as per PFMEA & Control Plan is installed on the Shop Floor & Daily Verification Mechanism is in place.
REQUIREMENTS
• Availability of Risk Analysis on identified locations.
• Availability Poka Yoke at all risk location. (3 Proactive approach)
• Availability risk analysis approach during line installation from past trouble
experience.
• Have Potential Risk identified (requested by P-FMEA, QA matrix, QFD table etc.)
3.3 Poka Yoke
REFERENCES
• Poka Yoke Procedure(Ex 28)
• Master list of Poka Yoke
• Poka Yoke Installation standard.(Ex 29)
55. 51
Example 28 - Poke Yoke Procedure
Refer Annexure for Ex 28
Page 2 of 4
POKA YOKE
1 Triggers
2 Initiation
3 Inputs
START
1. New Product
2. Engineering Changes
3. Process Changes
1. Results of Corrective Actions
2. Results of Continuous Improvement
3. Customer Audits and Feedback
4. Customer Complaints
5. Warranty Issues
6. Inputs from Internal Audits
7. Results of Internal Rejections
1. PFC
2. Similar part FMEA
3. PTD
4. DFMEA
5. Engineering Spec.
6. Tooling
7. System Diagram
8. Bill of Materials
9. Similar part Control Plan
10. Product reliability & Quality goals
11. Material Specification
12. Product Design requirements
13. Process Design Requirements
14. Drawing & Specification changes
15. Customer Complaint/ Internal rejections
16. Preliminary listing of product / process
charecteristics
1. Before or at feasibility stage
2. To be initiated prior to tooling for production
Conditions Triggering Poka Yoke
1. Adjustments
2. Constant equipment changes
3. Dimensionality, specifications,
critical condition
4. Safety charecteristics
5. Many parts / Mixed parts
6. Multiple steps
7. Lack of or ineffective standards
8. Rapid repetition
9. High volume
10. Environmental conditions:
a. Material/ process handling
b. Housekeeping
c. Foreign matter
d. Poor lighting
e. Other
56. M
A
H
I
N
D
R
A
SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
52
Example 29 - Poka Yoke Installation Standard
DOC.NO:
REV.NO:
DATE:
TYPE OF
POKA-
YOKE
RAW
MATERIAL
INSP
COILER
BUTT
WELDER
TRIMMER
EDGE
NIPPING
EDGE
ROLING
FLARING RF-1 RF-2 RF-3 EXPANDER AIR LEAKAGE
VALVE
HOLE
ASSLY.
PRESS
ASSLY.
WELDER
LPM BC
A X X X X X X X X X X X X X X X X
B X X X X X X X X X X X X X X X X
C X X X X X X X X X X X X X X X
D X X X X X X X X X X X X X X X X
E X X X X X X X X X X X X X X X
F X X X X X X X X X X X X X X X X
G X X X X X X X X X X X X X X X X
H X X X X X X X X X X X X X X X X X
I X X X X X X X X X X X X X X X X
J X X X X X X X X X X X X X X X X
K X X X X X X X X X X X X X X X X X
L X X X X X X X X X X X X X X X X X
M X X X X X X X X X X X X X X X X X
N X X X X X X X X X X X X X X X X X
O X X X X X X X X X X X X X X X X X
P X X X X X X X X X X X X X X X X X
Q X X X X X X X X X X X X X X X X X
R X X X X X X X X X X X X X X X X X
S X X X X X X X X X X X X X X X X X
T X X X X X X X X X X X X X X X X X
U X X X X X X X X X X X X X X X X X
V X X X X X X X X X X X X X X X X
W X X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X
Y X X X X X X X X X X X X X X X X X
Z X X X X X X X X X X X X X X X X
AA X X X X X X X X X X X X X X X X
AB X X X X X X X X X X X X X X X X X
AC X X X X X X X X X X X X X X X X X
AD X X X X X X X X X X X X X X X X X
AE X X X X X X X X X X X X X X X X X
AF X X X X X X X X X X X X X X X X X
AG X X X X X X X X X X X X X X X X
X
Various types of POKA-YOKE-RL-1
AC)Edge deep cut AD)Trim line AE) Flange width variation
P) Bad fusion
J) Welding on disc only
O) Over lap
B) Reverse component loading
POKAYOKE NOT REQUIRED
C) Wrong component loading ( Different product )
M) Opposite stamping / stamping problem N) Dim stamp
Q) Under cut, thin down R) B/w crack
Y) Porosity, Pin hole Z) Batch code damage / Deep stamp
POKAYOKE REQUIRED
POKAYOKE AVAILABLE
AA) LVH wrong side AB) Exp block mark
AF) Short weld
AG) Run out Out of Spec
A) Two component feeding at a time G) Weld shift
H) More / less weld penetration
I) Welding on rim only
K)Major scratch, line mark, deep dent,
heavy pitting, heavy burr
L) Twisted coil/ strips
POKAYOKE PLAN SHEET
S) Flaring bulge
U) Expander bulge V) B/w air leak W) LVH damage
T) Bad rolling
X) Zig zag weld
D) Wrong fitment
E) Wrong assembly dimension
F) Weld Miss
57. 53
REFERENCES
• APQP master plan (Ex 30).
• Phase wise APQP review report (Internal/Customer) (Ex 31).
• Action plan/tracker/MOM in case of non-achievement of targets.
• Guideline to identify SC/CC (Ex 32).
• List of SC/CC characteristic.
Chapter 4
REQUIREMENTS
• Availability of Timing plan as per phases of APQP and updated regularly in case of
any changes with actual status.
• Availability of all elements in APQP timing plan with Customer Build dates.
• Availability of Internal and customer APQP Review mechanism with planned frequency.
• Availability of APQP Status report for each review & detailed action plan in case of
non achievement of target.
• Rule defined & followed for gateway/phase clearance.
• Mechanism to select Special Characteristics (e.g. SC/CC).
• Availability of customer approved Special Characteristics (e.g. SC/CC) list.
• Availability of Quality Targets at SOP stage (initial process capability, internal
rejection).
• Achievement of defined targets at SOP stage and Action Plan for non achievement.
• Availability of mechanism to manage Safety Characteristics separately from General
Characteristics (targets, frequency of monitoring).
PURPOSE
• To assure tracking & completion of items during the Product Development Phase.
• To assure phase wise review mechanism.
• To monitor & control important Quality items & their implementation as per timeline.
Objective : To ensure structured method for defining and executing the 4M actions necessary for New Product Development to
satisfy all Customer Requirements.
Quality Assurance at Pre-Production Stage
Pre-production QA
58. M
A
H
I
N
D
R
A
SUPPLIER EVALUATIO
N
S
T
A
N
D
A
R
D
MSES
MSES
MSES
54
Example 30 - Apqp Master Plan
MAHINDRA APQP - SUPPLIER PART DEVELOPMENT MONITORING
Issue Date:
SOP Date :
Annual Volume : 45,000 P.A
CP VPO VP1 PP1 PP2 SOP
Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct
FEU
Team Members
1-Jan-09
Design Reviews
NA
Time line / Project Management
Initial Design Concept
Detailed Design
Design FMEA
NA
Supplier Code
Reason for Re-Issue
Time Scale
Supplier Plant
Supplier Name
Part No
Project ECN No
Part Name
SOR/Drawing Level
Build Level
Dept. / Function Contact No. / E-mail
No Project Item (Detail)
Responsible Person
(supplier)
Process FMEA
Plan
Actual
5-Aug-09 50
2009
P
R
O
C
E
S
S
D
E
S
I
G
N
2008
10
VP1 14-Sep-09 50
VP0
MRD Quantity No. of SCs
CP
PIPC%
2010
No. of CCs PIST%
APQP Team Build Details
SOP
2PP
1PP
Design Verification Plan
CAD Packaging
Plan
Actual
Plan
Actual
Actual
Plan
Actual
Plan
Plan
Actual
Plan
Actual
Plan
Control Plans
CP0 Build Parts
Sub-supplier Product Approval
Actual
Plan
Measurement Systems Evaluation
Operation Sheets
Actual
VP0 Build Parts
Floor Plan Lay-out
Production Facilities (inc.Test)
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Plan
Actual
Design Sign-Off (Drgs & Specs frozen)
DV Testing
Tooling & Gauges Manufacturing
Manufacturing & Assly Process Flow Chart
Recruitment and Training
Sub-supplier PPAPs
21
20
19
18
22
6
13
12
11
10
17
16
15
14
1
P
R
O
D
U
C
T
D
E
S
I
G
N
P
H
A
S
E
D
E
V
E
L
O
P
M
E
N
T
P
H
A
S
E
5
4
3
2
9
8
7
A
59. 55
Note: Approval by Mahindra & Mahindra shall not relieve the supplier in any way from its responsibilities.
Name
Project Team
Supplier sign-off
Comments -
Signature
Production
QA Engineering
Signature
Project Leader Purch / Sales Date
Name
Process FMEA
Plan
Actual
Mahindra & Mahindra Sign off
24
PPAP Approval
Appearance Approval
Production Trial Run
Actual
Plan
Preliminary Process Capability Study
Production Validation Testing
P
R
O
C
E
S
S
P
R
O
V
E
O
U
T
P
H
A
S
P
R
O
C
E
S
S
D
E
S
I
G
N
P
H
A
S
E
Date
Prod'n Control
CAD Packaging
Plan
Actual
Plan
Actual
Actual
Plan
Actual
Plan
Plan
Actual
Plan
Actual
Plan
Control Plans
CP0 Build Parts
Sub-supplier Product Approval
Actual
Plan
Measurement Systems Evaluation
Operation Sheets
Actual
VP0 Build Parts
Floor Plan Lay-out
Production Facilities (inc.Test)
Actual
Plan
Actual
Plan
Actual
Plan
Plan
Actual
Plan
Actual
Plan
Plan
Actual
Plan
Actual
Plan
Actual
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Plan
Actual
Actual
Plan
Actual
32
31
30
29
Ramp up activity
SOP at M&M
Design Sign-Off (Drgs & Specs frozen)
DV Testing
Tooling & Gauges Manufacturing
Manufacturing & Assly Process Flow Chart
Supplier Pre-Production Audit (incl.
Run@Rate)
SOP at Supplier
Recruitment and Training
Sub-supplier PPAPs
Packaging Specifications
21
20
19
18
28
27
26
25
23
22
13
12
11
10
17
16
15
14
N
P
H
A
S
E
D
E
V
E
L
O
P
M
E
N
T
P
H
A
S
E
9
8
7
Contd... A
