Axles India Limited
SUPPLIER QUALITY MANAGEMENT SYSTEM MANUAL
Date of Issue
:
21.01.2017
This Manual is the property of Axles India limited. It has been Compiled to convey the Quality system expectations of AIL. These contents are meant for use by supplier / Vendors. ====================================================
Axles India Limited Singaperumal Koil Road Sriperumbudur – 602 105
=================================================== Distribution : As per Master List ML/COM/PUR/026
Page 1 of 76
Table Of Contents Sl No
Section
Page No
1
Foreword
3
2
Issue Amendment Procedure
3
3
Issue Amendment Record - SQMSM
4
4
Abbreviations Used
5
5
Quality Policy
6
6
Environmental Policy
6
7
Supplier Business Code Of Conduct
7
8
Supplier Quality Management System Requirements
10
9
Selection Of Vendors For Direct Materials
11
10
List Of OEM Approved Second Party Auditors
11
11
Procedure For Initial Sample Inspection Report
12
12
PAP Requirements
13
13
Supplier Performing Special Process
17
14
Self Certification Procedure
18
15
Calibration
18
16
Guidelines For On-Going Performance Monitoring
19
17
Special Characteristics
20
18
AIL Environmental Management System
21
19
Procedure For Supplier Development
22
20
Customer Specific Requirements
23
21
Process Flow Diagram
28
22
Control Plan
30
23
Work Instruction
30
24
Inspection Instruction & Visual Aids
31
25
Dimensional Inspection Report
31
26
Material Test Report
32
27
Checking Aids
32
28
Corrective Action
33
29 30
Capacity Verification SPC Related Terms
34 35
31
Failure Modes And Effect Analysis
41
32
Annexure
50
Page 2 of 76
Section – 01
: Foreword
AXLES INDIA Ltd considers their suppliers as an integral part of their Quality System. This manual explains the Quality system requirements of AIL from their suppliers for meeting the ultimate goal of Quality, Consistency, Continual Improvement & Cost reduction. To meet the never ending appetite on part of the customer and competition for survival & growth, we request our suppliers to use this manual as a tool to broaden their understanding of the Quality assurance systems of AIL. This manual is to be used as a reference for establishing Quality systems, Promoting continual improvements and cost reduction activities in your organization. This would certainly result in parts being supplied to AIL are of highest Quality, delivered at the right time and which finally leads to Customer Satisfaction. The main purpose of this manual is to give guidelines for development of suppliers and to monitor their performance in meeting the AIL requirements. To ensure that all these requirements are met and to have confidence, periodic assessments will be performed at supplier’s facility by OEM approved Second party auditors, inline with the expectations conveyed through this manual. Whenever required AIL provide their services also.
Section – 02
: Issue Amendment Procedure
The issues and revisions along with Issue Amendment Record shall be distributed to all points of controlled distribution in accordance with the “Master list of Distribution”.
This manual shall carry an issue number on the cover page starting with Number 1. When the entire manual is revised and issued, the Manual Issue no will be incremented. Only controlled copies are permitted for use.
All the suppliers are requested to acknowledge in writing for the receipt and possession of latest revision of this manual so that AXLES INDIA Ltd maintains the evidence of issue records.
Page 3 of 76
Section – 03 : Issue Amendment Record - SQMSM MANUAL ISSUE NO
PAGE NO
REV NO
1
ALL 23
0
01.08.2005 New Issues
1
20.08.2005 “ At the Minimum - PAP Requirement added
5
1
05.01.2006 Quality Policy Revised and updated
17
1
“Note on Audit Man days” - Removed
5A
0
Environment policy Added
Exhibits
-
Revised Supplier Evaluation/Re evaluation from (8sheets): and work instruction for evaluation & Reevaluation (7 Sheets
ALL
0
2
EFFECTIVE NATURE ISSUE CHANGE DATE
HOD PUR SIGN
30.06.2006 Revised Issues Part Submission Warrant-4th Edition Retention/Submission Requirements Table 4.2 added
15
1
20.07.2006 Revised Issue Minimum score Changed from 75 to 90%
3
ALL
0
11.05.2007 Revised Issue
4
ALL
0
30.04.2009 Revised &Reissued
5
ALL
0
30.01.2010 Revised &Reissued a. Supplier Evaluation/ Re- Evaluation form
6
ALL
0
10.04.2011 Customer specific requirements deployment Daimler - added
7
ALL
0
10.04.2013 Quality Policy Revised
8
ALL
0
10.04.2014 Supplier code of conduct added Capacity verification added
9
ALL
0
17.04.15
Customer specific requirements deployment VOLVO - added
10
ALL
0
04.05.16
Vendor Selection Criteria & Vendor Rating procedure Modified
11
ALL
0
06.07.16
Quality and Environmental Policy updated
ALL
0
21.01.17
Customer Specific Requirements - Updated ( Volvo)
Page 4 of 76
Section – 04
: Abbreviations used
AIL
:
Axles India Ltd
FMEA
:
Failure Mode and Effect Analysis
IATF
:
International Automotive Task Force
IMTE
:
Inspection, Measuring and Test Equipment
ISO
:
International Organisation for Standardisation
ISK
:
Indian Ink Sketches
OEM
:
Original Equipment Manufacturer
PAP
:
Part Approval Process
PPE
:
Personal Protective Equipment
PPM
:
Parts Per Million
SQAM
:
Supplier Quality Assurance Manual
SQMSM
:
Supplier Quality Management System Manual
DICV
:
Daimler India Commercial Vehicle
DIST
:
Daimler India Special Terms
Note: Whenever the term Supplier appears, it is to be noted that it includes “Vendors” also.
Page 5 of 76
Section – 05
: Quality Policy
Quality Policy of Axles India is: Maintain Domestic market leadership and strong presence in export markets for the products manufactured. Ensure customer satisfaction by meeting their expectations on product performance, on time delivery and competitive prices. Promote continual improvements by motivating employees at all levels.
Revised on 06.07.2016
V. Madhavan Managing Director
Section – 06
: Environmental Policy
We, Axles India Limited, are committed to manufacture axle housings and axle assemblies in a clean, green and safe environment by: Complying with applicable environmental regulations and other requirements.
legislations,
Continual improvement in environmental performance through: • Conservation of natural resources • Minimizing waste • Prevention of pollution Promoting awareness of environmental issues to our employees and contractors.
06.07.2016
V. Madhavan Managing Director
Page 6 of 76
Section – 07 : Supplier Business Code of Conduct Introduction:
Axles India Limited is committed to do business in an ethical manner and we do believe that this commitment will benefit our customers and other stakeholders in carrying out their business in an ethical and acceptable standard. Therefore, it is essential that our suppliers also understand and appreciate that standard of business conduct that is expected of any company that does business with Axles India.
This code identifies our expectations concerning business conduct that are essential for companies that do business with Axles India. We also believe that these standards will serve to advance the performance of our companies to our mutual benefit.
Therefore, compliance with Axles India’s Supplier Business
Code of Conduct is mandatory for all Purchase contracts.
Respect for People:
All suppliers shall abide by all applicable Employment Laws.
Our Suppliers
shall determine for his or herself whether employment is in his or her best placed in a position of making this determination. Therefore Axles India will not allow the use of child labor as defined by appropriate statutory laws. Our suppliers shall not use any forced or involuntary labor in any form, including human trafficking or physically abusive disciplinary practices.
Axles India also expects its suppliers to provide employee wage and benefit levels that satisfy basic needs in the light of local conditions.
Our suppliers
shall abide by all applicable laws related to limits on regular and overtime working hours and compensation and, we expect our suppliers to respect freedom of association of its employees in accordance with local employment laws.
Page 7 of 76
Safe Workplace: Our suppliers shall encourage a positive and diverse workplace by treating the workforce
with
dignity
and
maintain
a
work
environment
free
from
discrimination and abusive behavior, including gender, race, religion, color and caste based in any form or manner whatsoever. Axles India also expects its suppliers to provide its employees with a safe and healthy work environment and to abide by all applicable health and safety laws.
Environmental Protection: Our suppliers shall abide by all local Environmental laws and Regulations. We believe that suppliers should work to minimize waste, prevent pollution, and conserve energy.
We encourage our suppliers to seek external verification
concerning their environmental performance, such as through the ISO 14001 certification process. Axles India suppliers are expected to use materials that conform to all Legal and Regulatory requirements. Gifts and Favors: Axles India will select its suppliers on the basis of total value, including quality, price and services offered. Therefore, suppliers should not give gifts, favors or entertainment to Axles India employee that is of significant value or that is inappropriate or unbecoming to Axles India’s employees. Suppliers must not try to unfairly influence Axles India employee’s through inappropriate gratuities. If any Axles India employee solicits you for a gift or favor, it should be immediately reported to Axles India. Improper Payments: It is Axles India’s policy that bribes, kickbacks, or other improper payment should not be offered or paid directly by or on behalf of Axles India employee or employee of any customer, supplier or competitor or to a third party if you know or have reasons to suspect that any part of the payment will be given or offered as a part of an improper payment. This includes, but is not limited to, payments to government officials. If you are acting on Axles India’s behalf in any manner, you must comply with this policy. If you are performing services
Page 8 of 76
for Axles India, you may be required to certify and provide evidence of your understanding and compliance with this policy. Fair Business Deals: Information given to Axles India during the course of negotiations or otherwise must be accurate. You must not attempt to improperly influence the course of negotiations through any deceptive means.
You must abide by all laws and
regulations that may affect our business together.
Good Ethics:
Axles India believes that adherence to the above principles have a mutual benefit
for
both
Axles
India
and
its
suppliers.
In
case
of
any
questions/clarifications concerning whether particular conduct related to your supply of goods or services to Axles India is inappropriate; the same shall be brought to the attention of your business contact at Axles India.
Questions: If you have any questions or concerns related to any of the matters identified in this code of conduct, please contact Axles India Limited’s Purchasing representative or through +91-44-27162482/
[email protected].
Revision – A / 27.12.2013
Page 9 of 76
Section – 08
: Supplier Quality Management System Requirements
General: Suppliers must establish a Quality Management System as per requirements given in this manual Scope: Applicable to suppliers directly providing production materials, production of service parts and those providing heat treating and other finishing services. Compliance Requirements : The development programme has one of the following criteria to be achieved by the above suppliers. a). Development of Suppliers to confirm the Technical Specification (ISO/TS 16949 : 2009) b). Suppliers to the organization shall be third party registered to ISO9001:2008 by an accredited third party certification body. c). Compliance to AIL’s SQMSM achieved during on-site evaluation by OEM customers approved Second Party Auditors as per the list enclosed or Qualified Internal Auditor from AIL. d). For selected customer applications, suppliers those who have only ISO 9001:2008, will have to submit roadmap to obtain TS16949 In this manual, the term Vendor/Supplier is used to denote Suppliers of Raw Materials, Bought out parts, Consumables and packing materials. The term Supplier is used to denote Suppliers of Services.
Classification: Category 1: Direct Input Material Raw materials, Castings, Forgings, Fasteners, other Bought out parts, Subcontracted parts, Conversion services like Heat treatment, Acid pickling, welding wires and rods, paints.
Category 2: Indirect Materials Process consumables, Tools, Jigs & Fixtures and Packing Materials.
Page 10 of 76
Section – 09
: Selection of Vendor for Direct Material CRITERIA
New Vendor / Supplier of Direct input materials and existing Vendor/Supplier who wish to supply new parts/services are to be evaluated and selected by a combination of the following methods. i.
By on-site evaluation of the Quality System and Technical Capability of Vendor / Supplier to meet the requirement (F/COM/PUR/001)
ii.
By evaluation of product samples obtained with or without a trial order (Refer Procedure for Part Approval Process).
iii.
Based on performance of similar supplies (Evidence of vendor rating) / documented experience of other reputed users ( e.g. letter from Collaborators, Group companies, Customers).
iv.
Based on Third Party Quality System Certification for the scope of products being supplied ( ISO 9001,TS16949).
v.
Customer (OEM) approved sources.
Section – 10
: List of OEM approved Second Party for
on-site Audit & development for Direct Materials 1). Mr. BHARAT SRINIVASAN No:6, First Main Road, Seethamma Extension, CHENNAI – 600 018
2). M/s TQM UNIVERSAL Quality Management Consultant. CHENNAI – 600 092 Mr. MANASAROVAR RAJA Plot No:4, Falt No:12 11A, Arcot Road, Porur CHENNAI – 600 116 Phone : 044-24760908
Page 11 of 76
Section – 11 : Procedure for Initial Sample Inspection
Report (ISIR) ISIR & PAP approval from AIL is required for the supply of new part or changed part before volume production from all the suppliers. ISIR & PAP approval applicable to any one of the following situations: a). New Supplier. b). New Components or Product from existing Supplier. c). Engineering Changes with respect to tooling/dimensional/material /process (i.e, for every modification level of drawings) d). Resumption of Production after 2 years from previous supply. e). When previous submission is rejected. Note: This procedure is not applicable for the new part number allotted as a regularization of existing ISK Part Numbers. Requirement for ISIR: Dimensional Report & Metallurgical report if applicable Requirement for PAP: AIL expects to level 4 submission (Refer PAP requirements). Initial samples are to be minimum 5 numbers made out of production tooling and process. In the case of PAP submission, sample quantity should be high to meet PAP requirements. Samples for PAP submission are to be made out of production tooling, gauges, materials and operator. ISIR submission can be replaced by PAP submission. In this case PAP submission will be taken as an evaluation and selection criteria.
Page 12 of 76
Section – 12 : PAP Requirement The Production Part Approval Process ensures there is a documented verification that all customer engineering design requirement are met by the supplier/vendor and the process has potential to produce these requirements during an actual production run. Production parts are those manufactured at the production site using the production tooling, gauging, process, material, operators, and environment and process settings. The Supplier shall meet all specified requirements (e-g. Design record, Specifications). Inspection and testing for PAP shall be performed by Supplier’s testing facility or by an accredited laboratory approved by nationally recognized accreditation body. The supplier shall submit PAP for approval prior to the first production shipment. These records shall be maintained for the length of time that the part is active plus one calendar year. The following documents and items in the check list must be completed by the supplier for each part. For customers DAIMLER and VOLVO application, Level 3 PPAP should be submitted.
Page 13 of 76
Check list for “Part Approval Process”
PART NAME PART NO REV LEVEL
DT:
SUBMISSION LEVEL INDEX
SL No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
CONTENTS Part Submission Warrant DESIGN RECORDS (PART DRAWING) ENGINEERING CHANGE DOCUMENT CUSTOMER ENGINEERING APPROVAL DESIGN FMEA PROCESS FLOW DIAGRAM PROCESS FMEA DIMENSIONAL RESULTS MATERIAL PERFORMANCE TEST RESULTS PROCESS CAPABILITY STUDIES MEASUREMENT SYSTEM ANALYSIS STUDY QUALIFIED LAB DOCUMENTATION CONTROL PLAN APPEARANCE APPROVAL REPORT BULK MATERIAL REQUIREMENT CHECKLIST SAMPLE PRODUCT MASTER SAMPLE CHECKING AIDS RECORDS OF COMPLIANCE WITH CUSTOMER SPECIFIC REQUIREMENTS
STATUS *
Note : Please indicate as “Submitted / Not Submitted / Not applicable”.
Page 14 of 76
Retention/Submission Requirements Table 4.2 (Normative) Requirement 5 1. Design Record -for proprietary components/ details -for all other components/ details 2. Engineering Change Documents, if any 3. Customer Engineering approval, if required 4. Design FMEA 5. Process Flow Diagrams 6. Process FMEA 7. Control Plan 8. Measurement System Analysis Studies 9. Dimensional Results 10. Material, Performance Test Results 11. Initial Process Studies 12. Qualified Laboratory Documentation 13. Appearance Approval Report (AAR), If applicable 14. Sample Product 15. Master Sample 16. Checking Aids 17. Records of Compliance With Customer-Specific Requirements 18. Part Submission Warrant (PSW) Bulk Material Checklist (see 4.1 above)
Level 1
Level 2
Level 3
Level 4 Level
R R R R R R R R R R R R R R S
S R S S R R R R R R S S R S S
S R S S S S S S S S S S S S S
* * * * * * * * * * * * * * *
R R R R R R R R R R R R R R R
R R R R
S R R R
S R R S
* * * *
R R R R
S S
S S
S S
S S
R R
S= The organization shall submit to the customer and retain a copy of records or documentation items at appropriate locations. R= T h e organization shall retain at appropriate locations and make available to the customer upon request. *= The organization shall retain at appropriate locations and submit to the customer upon request. Level 1 Level 2
Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the customer. Warrant with product samples and limited supporting data submitted to the customer.
Level 3
Warrant with product samples and complete supporting data submitted to the Customer.
Level 4
Warrant and other requirements as defined by the customer.
Level 5
Warrant with product samples and complete supporting data reviewed at the organization’s manufacturing location.
Page 15 of 76
AIL expects its suppliers to level 4 submission, except for Customer Specific requirements. Customer specific requirements will be informed by AIL separately At the minimum, the following documents are to be furnished. However it is expected to submit all the appropriate documents as per the above “PAP check list” for system improvement. o o o o o o
Part Submission Warrant – PSW Design Records (Component Drawing) Dimensional Results Material test results Control Plan Process Flow Diagram
Condition for Customer Notification required for PAP submission during serial production. 1) A new product or part prior to volume production. 2) Production from new or modified tools (except perishable tools), dies, molds, patterns etc, including additional or replacement tooling. 3) Production following refurbishment or rearrangement of existing tooling or equipment. 4) Production from tooling and equipment transferred to a different plant location or from an additional plant location. 5) Change of sub supplier for parts, non-equivalent materials or services (e-g. Heat treating, Plating) that affect customer fit, form, function, durability or performance requirement. 6) Product and process changes related to components of the production manufactured that impact fit, form, function, and durability or performance requirement. 7) Change in test/inspection method, new technique (no effect on acceptance criteria). 8) Production following any change in process or method of manufacturing. 9) Product or Part Re-released after the tooling has been inactive for volume production for 24 months or more.
For reference Refer PSW format in Annexure page 63.
Page 16 of 76
Section – 13
: Supplier Performing Special Processes
Process specification will be provided through Axles India Limited’s Work Instruction / Specification, specifying process parameters, requirement of monitoring and recording. Requirement of Test Certificate will also be specified. Suppliers Performing Induction Hardening Those suppliers who carry out induction hardening service will be provided with Work Instruction and Engineering Specification. These suppliers will be audited by AIL at least once in a year to ensure compliance with Work Instruction provided. Suppliers performing Heat Treatment Process for Export Housings application to M/s DANA CORPORATION have to meet “AIAG – CQI 09 Heat treatment System Assessment” requirements. The annual assessment will be done by an experienced QMS Internal auditor.
Format for audit check list are as hereunder. For Heat treatment
:
F/COM/PUR/006 (Page 51 of Annexure)
For Induction Hardening :
F/COM/PUR/007 (Page 54 of Annexure)
Improvement actions are required with target dates for completion of gaps observed will be recorded in the above formats.
Page 17 of 76
Section – 14 : Self Certification Procedure A supplier for a particular item can be accorded the status of self certification by meeting the following conditions. Three consecutive lots satisfactory to inspection and testing. Third party certification of Quality System for the scope of product supplied (or) qualified is developed by AIL through supplier Development. A controlled copy of pertinent inspection plan / specifications will be provided by AIL. Suppliers to supply parts along with appropriate Test certificates The lot can be accepted after review of the Test Certificate against the pertinent inspection plan / specification. A cross check inspection shall be performed by AIL at least once in 6 months to continue self certification status. When deviation is more than 20% of tolerance, the self certification status will be withdrawn and de-listed from the “Master list of self certified vendors”
Section – 15
: Calibration of Gauges
Only calibrated Gauges and Instruments are to be used. All gauges and instruments are to be identified, their frequency, method and acceptance criteria are to be established and the calibration is to be traceable to National / International standards. If traceability could not be established, check method is documented and complied with. A master list of all Gauges and measuring instruments is to be maintained by the suppliers / Vendors. Instruments are to be calibrated at the defined intervals for their full operating range before use. All the Gauges are to be calibrated on or before the due dates either at AIL or at any other external calibration center. The calibration records are to be maintained and to be made available to AIL when required. Any default will result in the supplies be quarantined. Out of calibration situation – Refer the exhibit “Out of calibration Report” Whenever the results of calibrations are found to be unsatisfactory, out of calibration report is to be raised. If the IMTE is beyond calibration condition, it should be defaced, scrapped and removed from the master list. When not in use, IMTEs are to be kept in trays, stands, Hangers, Racks, cup boards, pallets or in boxes supplied by the manufacturer. Gauges that are prone to rust shall be smeared with a film of oil or white petroleum jelly or anti-corrosive chemical while in storage.
Page 18 of 76
Section – 16: Guidelines for On-going performance
monitoring On-going Performance monitoring for suppliers providing Direct input Raw materials, Castings, Forgings, Fasteners, other Bought out parts, Subcontracted parts, Conversion services like Heat treatment & Acid pickling will be based on Quality and Delivery performance as given below on a monthly basis. Overall Rating (OR) = Quality Rating (QR) + Delivery Rating (DR) + Service factor. Quality Rating (in %) = (DA x1)+((CA+SA) x 0.8) + (RAx 0.7)+(R x 0) (Part No / Item wise) Total quantity supplied
Where, DA is Directly Accepted Quantity CA is Concessionally Accepted Quantity SA is Segregated and Accepted Quantity RA is Reworked and Accepted Quantity R is Rejected Quantity. Delivery Rating (in %) = Quantity Supplied Schedule Quantity Service factor of +5% to be applied when there is no premium freight or Customer complaint on account of respective supplier else 0%. Overall rating calculation is done as per the following formula for each supplier. OR % = [(QR%) x 0.70] + [(DR%) x 0.25] +5% (or 0). •
For Overall Rating 100% : 90 to 99% : 80 to 89% : 75 to 79% : Below 75% :
•
If Overall Rating score is less than 80% for a supplier, a corrective action plan with target date must be obtained from supplier. Supplier will be advised to show improvement trend based on the corrective action and its effectiveness as part of continual improvement to achieve a higher rating. Apart from the above actions on overall rating, Corrective action must be obtained in writing where QR is less than 90%.
•
• •
the following grading will be applied: Excellent Good Satisfactory Marginal Unsatisfactory
Re-Evaluation as per F/COM/PUR/020 will be done for following Criteria:
1. 2. 3. 4.
Merger, Acquisitions which can have impact on Quality/ Delivery Incoming parts quality less than 80% for 2 consecutive months. Delivery performance less than 90% for 2 consecutive months. Any other specific reason as decided by Purchase / Quality head.
Page 19 of 76
Section – 17
: Special Characteristics
All product and process characteristics are important and need to be controlled. However, some characteristics referred to as “Special” or “Critical” need extra attention because excessive variation in them might affect product safety, compliance with Government regulations, fit functions, appearance or quality of subsequent manufacturing operations. Critical (related to Government regulations or related to safety), significant (related to fit, function, appearance and quality of subsequent operations). For Customer identified special characteristics refer to following symbol
Sl.No
Symbol
Initiated by
Explanatory note
Axles India
Special / Critical Characteristic. Process capability Value Cpk>1.33 to be achieved
1
2
Tata Motors – Pune and Jamshedpur
3
Tata Motors – Pune and Key instruction inspection through Control Plan Jamshedpur
4
Mahindra & Mahindra Pune
Dana, USA 5 Dana, USA 6
Requires inspection through Control Plan
Requires inspection through Control Plan Ppk >= 1.67, Cpk >1.33 to be achieved by ongoing process capability Ppk - 1.67 on going process capability not required
Dana, USA 7
*8
Ppk >= 1.67, Cpk >1.33
[1] / CC [2] , [3] / SC
VOLVO VOLVO
Cpk >= 1.67, Cpk >= 1.33
If the required capability Index is not achieved, 100% inspection is allowed on a short term period with full traceability. Action for inspecting the process to be jointly arrived at. * AIL will send the exclusive standard for VOLVO customer specific requirements for the respective suppliers.
Page 20 of 76
Section – 18
: Axles India Ltd’s Environment Management System
All our Suppliers of products and services shall have to adhere to relevant legal requirements while supplying materials and services. Following are the minimum requirements.
Suppliers of Hazardous Chemicals / Collection parties of Hazardous waste Any material which is hazardous in nature as per Environmental Rules, shall accompany with
Material Safety Data Sheet ( MSDS) Transport Emergency Card (TREM) Certificate of analysis “Hazardous” label on the container Training to Driver Driver’s instruction card (Do’s & Don’t’s) Pollution under Control Certificate
Suppliers of the Gas Cylinders shall ensure / Provide
Colour coding of the cylinder Proper valve protection cap No physical damage on the cylinder Last test certificate / Inspection details of the cylinder Material Safety Data Sheet ( MSDS) Transport Emergency Card (TREM) Driver’s instruction card (Do’s & Don’t’s) Pollution under Control Certificate
All other service providers / Manpower suppliers Provision of adequate PPE to all the personnel Your adherence to our system requirements Adherence to our Safety & Environmental procedures and systems Following our Waste Management systems
Adherence to our Environmental Policy requirements.
Page 21 of 76
Section – 19 : Procedure for Supplier Development by
Axles India through SQMS Manual AIL Sl.No
Audit Clause
Applicable points
1
Quality Management System
42
2
Management Responsibility
17
3
Resource Management
24
4
Product Realization
99
5
Measurement Analysis & Improvement
18
Total
Points Scored
200
Points scored Achieved audit score =
------------------- x 100 Applicable points
1). Suppliers who have scored 60% and above are considered to attain “Developed” status. These Vendors / Suppliers should have Development program to achieve 100% under continuous improvement plan. 2). A minimum 30 points to be scored in Quality Management System clause. 3). After attaining “Developed” Status, surveillance audit must take place at least once in a year.
( Please refer the evaluation format in Annexure page no.58)
Page 22 of 76
Section – 20
: Customer Specific Requirements
a) Special Characteristics for VOLVO Individual components or systems that are directly connected to legal requirements or regulations or features of a part that have the potential to impact compliance, are defined using the symbols [CC] or [SC]. These symbols appear on VOLVO drawings or are stated within the related VOLVO technical specifications controlling the part. VOLVO standard STD_105-0007 defines the guidelines for grading the characteristics. The designation of [CC] or [SC] differentiates the degree of significance of the characteristic in question. [CC]: Critical Characteristics refer to special characteristics which affects safety. [SC]: Significant Characteristics refer to special characteristics which can affect compliance with regulations, form, fit, function and performance, or subsequent manufacturing-process steps. It is mandatory for [1],[2],[3],[CC] & [SC] features to be inspected or tested and the necessary documentation (inspection results, test reports, certificates) to be kept at the supplier for a period of time consistent with the document retention policy. For all features identified as a special characteristic, the following requirement applies:
Characteristics level [CC], [1]
Characteristics level [SC], [2], [3] Cpk ≥ 1.33
Cpk ≥ 1.67
Checking frequency adequate to demonstrate • On-going Statistical Process Control • Compliance to capability requirement (Inspection results recorded maintained and stored, available upon request).
On-going Statistical Process Control • Process appropriate checking frequency • Ppk Analysis every 6 months (control charts or electronic data stored and available upon request) •
Process under statistical control Normally distributed
• Process not under statistical control or Capability not achieved
• •
Electronic or Automated Poka-Yoke Effectiveness verified once per shift Volvo approved action plan for achieving Process Control and Capability
•
•
100% Inspection till agreed period for achieving process control Plan for achieving control and capability
Page 23 of 76
b) Safety Management - VOLVO Safety requirements are determined based on the potential of a feature, product or system to create a personal hazard to any person in contact with the products or effects caused by the product. A safety Customer effect is considered when a danger can lead to injuries to vehicle operator, passengers, other travelers, passers-by or maintenance personnel. The production of safe, fully conforming products to the VOLVO group companies is the supplier’s responsibility and is part of the supplier’s contractual commitment. Suppliers are responsible to ensure that all subsuppliers and contractors are aware of and comply with the requirements related to safety requirements. Suppliers of safety critical components must have safety system requirements embedded in their quality management system. Suppliers must be able to demonstrate they have the organization, systems, processes, and competencies to manage the VOLVO requirements related safety critical features. VOLVO has developed and uses a technical audit to evaluate the safety management systems of suppliers of safety related parts. A safety management audit will be conducted during the sourcing process and potential suppliers are required to achieve a passing score prior to supply. Suppliers those achieve a passing score but do not achieve 90% are required to develop a detailed action plan with a time line for achieving 90% score. This plan must address all audit findings. A copy of the Safety Management Audit template is available for review on the VOLVO supplier portal.
c) Quality System Requirements - VOLVO VOLVO requires all suppliers and sub-tier suppliers are 3rd party certified ISO 9001 with a plan for achieving ISO/TS 16949. Suppliers have full responsibility for the quality assurance and corrective action of products delivered from subtier suppliers for use in VOLVO products. VOLVO purchasing reserves the right to have direct access to sub-tier suppliers and processes that could have significant impact on final product quality. This will generally concern technical processes like surface treatment, Heat treating, Forging, Casting etc.
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d) QMS Assessment Audit for Critical processes Purpose: The purpose of QMS assessment audit is to evaluate the supplier performance in terms of quality systems, in-process controls and adherence to agreed practices along with conformance of part to drawing requirements. The result of a process audit will indicate the performance of supplier and identifies potential areas for continual improvement. Process audit must be done for the actual process chain at the supplier’s / sub-supplier’s manufacturing end. Scope: QMS audit of critical processes applies to Casting, Metallurgy (Forging, Heat treatment) and Surface treatment part suppliers of specific customer application based on AIL’s discretion. Supplier Responsibility: The Supplier is responsible to develop and maintain their process quality in a way that audit score of 60% or above is guaranteed and no stopping parameters exists. Regardless of the score suppliers are expected to work aggressively to address any concerns or action items identified during audit. Procedure: 1. Supplier will be identified for the audit based on the following criteria prior to commencement of supplies to specific application. • Parts proposed to be used for VOLVO export application. • Any other parts intended by specific customer requirements. 2. AIL Purchase will issue a written notification along with required formats about the audit to the supplier prior to the scheduled time of audit. Audit will be done along with customer for certain customer specific requirements as per their procedure. 3. Upon completion of audit, AIL auditor and OE customer will jointly prepare a summary report and then meet with the supplier to discuss the results and countermeasure plan activities. 4. A detailed report on audit findings with actual scores will be sent to the supplier by AIL within a week. For the audit findings, the supplier has to give the countermeasure plan for all the observations within 10 days. Countermeasure plan must be signed by the supplier’s top management. 5. After the issue of countermeasure plan, the supplier is required to present the plan and actions implemented to AIL. This has to be mutually followed by supplier and AIL within 60 days from the date of audit report. 6. After the review, based on the status, a suitable date will be fixed for conducting the verification audit.
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e) Environmental Requirements – VOLVO
•
Suppliers must comply with all applicable environmental legal requirements
•
Suppliers must have knowledge of the VOLVO group Environmental Policy
•
Suppliers of Production materials and services must be third party certified to ISO 14001
•
Suppliers must be able to report on their environmental work, including organization, fulfillment of legal demands and environmental results.
•
Chemicals or materials involved in products meant for VOLVO group must fulfill the requirements stated in the VOLVO standards 100-0002, 1000003 and 100-0005.
•
When required by VOLVO Group, suppliers shall report specified chemical and material content of component parts in the International Material Data Systems (IMDS STD 100-0006)
Latest version of VOLVO Supplier Quality Manual is available in the Quality Section within the E-Library of VOLVO Supplier portal. Suppliers are advised to refer the following website for downloading the complete manual.
http://www.volvogroup.com/suppliers/global/engb/supplierselection/ourrequirements/keyelements/Pages/KeyElementPr ocedures.aspx
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Customer Specific Requirements - Daimler 1). Daimler India Special Terms – (DIST) Those who supply parts to Daimler application should comply with the requirements of Daimler India Special Terms. AIL Purchase will send the DIST before commencing the supply or parts. Supplier must clearly and permanently identify those tools which are DICVowned tools as the property of DICV. During stock taking at the end of the year, the supplier shall transfer the necessary information. Suppliers should ensure the marking as per the Exclusive standards mentioned in the drawings to maintain lot traceability. DICV is entitled to participate in inspections, appraisals, reviews or tests carried by the supplier and sub-supplier or to have these observed by third parties authorized by DICV. Suppliers can be audited by DICV with prior notice. Suppliers have to document the quality assurance methods with proof of quality assurance. Supplier shall provide AIL with information on relevant products, materials and processes for DICV’s internal life cycle assessment audit.
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Section – 21 : Process Flow Diagram Process Flow Diagram is a schematic visual representation of the current or proposed process flow. It also captures, in a standardized format, additional information associated with various steps of the process. Its benefits are •
Shows the entire process at once
•
Allows each operation to be questioned
•
Exposure source of variation
•
Highlighted non-value added steps
The standardized symbols and format is given below for reference and understanding. Symbol
Activity
Definition
Operation
When something is done to or by the subject being followed at a given work area. Something is being changed, added to or created.
Transportation
When something is moving or being moved from one work space or location to another.
Inspection
When something is checked or verified for quality or examined for information, or the act of doing so.
Delay
When something or someone waits or is delayed or when flow is interrupted.
Storage
When something is kept and protected against unauthorized removal
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Page 29 of 76
80
70
60
50
40
30
20
10
Incoming Sources of Variation
Part / Process No.
----
Product Characteristics
PREPARED
Process Characteristics
CHARACTERISTICS
Other Approval/Date (if reqd)
Other Approval/Date (if reqd)
Supplier/Plant & Supplier Code :
Process Flow Diagram
Customer quality Approval /Date (if reqd)
Supplier / Plant Approval Date:
Part Name
Operation Description
Customer Engineering Approval/ Date (if reqd)
Core Team:
Part Number / Latest Change :
Date (orig) :
Key Contact/Phone :
Process Flow Chart No:
Process Flow Chart
Remarks
Date (Revn)
APPROVED
Section – 22:
Control Plan
Control Plan is a written description of the system for controlling the parts & processes. It is a comprehensive documentation of product / process characteristics, process controls, tests and measured systems that will occur during production. It is a living document and should be updated to reflect the addition/deletion of controls based on experience gained by producing parts. Mass production will provide the producer the opportunity to evaluate output, review control plan and make appropriate changes. The benefits of a control plan are, • Communication will be improved within the organization. • Communication between Supplier & Customer will be improved. • Provides an emphasis on prevention. • Provides a focus on process control • Provides a pro-active planning • Promote Continual Improvements • Provides entire picture of control • Helps to standardize documentation Control plan should be in a standardized format (AIAG). Format of Control plan shown in Annexure page no. 64 can be used as a reference for understanding.
Section – 23 :
Work Instruction
There should be a documented process monitoring & Operator instructions for all employees having responsibilities for operation of processes. These instructions are to be accessible at work stations. A good work instruction must • be linked to the control plan • be manageable • be available at each operation • show step by step detail • be easy to understand • Reaction to non-conformance • Options • be easy to maintain • be controlled • be understood by all involved
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Section – 24 :
Inspection Instruction & Visual aids
There should be a documented inspection/testing instructions for all employees having responsibilities for inspection and testing. These instructions are to be accessible at work stations. A good inspection instruction must •
be available at each inspection stations
•
be understood by inspection personnel
•
shoe details of checking frequency
Visual aids are those which are used during judgment of product characteristics with only visual aspects. It can be in the form of well identified limit master samples (for both acceptable & non-acceptable categories) or photographs of sample showing the same. This is applicable for all stages which has been identified as “Visual inspection” in the control plan. A list of Visual aids used in production run is to be prepared and submitted.
Section – 25 :
Dimensional Inspection Report
Dimensional inspection must be performed on all parts and product materials with dimensional requirements to determine conformance with all relevant design record specification. All dimensional (except reference dimensional), characteristics and specifications as noted on the design record and control plan are to be listed in the enclosed format with actual results recorded. Blanket statements as OK or NOT OK will not be accepted. Indicate the data of design record, change level and any authorized engineering change document not yet incorporated in design record to which the part was made.
It is the supplier’s responsibility to meet all applicable specifications. Any results that are outside specifications are cause for the supplier not to submit the parts and /or documentation. Every effort has to be made to correct the process so that all design record requirements are met. If the supplier is unable to meet any of the requirements, AIL is to be contacted for further instructions.
The product which was measured has to be identified properly and sent to AIL for verification and approval.
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Section – 26 :
Material Test Report
Material tests must be performed for all parts and product material when Chemical, Physical & Metallurgical requirements are specified. If the supplier cannot perform the required tests, external services can be procured from a qualified source or upon special request from AIL facilities. When external lab services are used, the results must be submitted on their letter heads. All tests required by the design record and related specifications are to be listed in the format. Also indicate any authorized engineering change documents that have not yet been incorporated in the design record. Blanket statements as OK or NOT OK will not be accepted - Indicate the design record change level of the parts tested and the number, date and change level of the specifications to which the part was tested - Indicate testing date - Indicate material supplier’s name It is the supplier’s responsibility to meet all applicable specifications. Every effort must be made to correct the process so that all design record requirements are met. If the suppliers is unable to meet any of these requirements, AIL is to be contacted for determination of corrective action.
Section – 27 :
Checking Aids
Checking aids are nothing but gauges, inspection fixtures, master reference samples, templates etc which is being used for inspection and testing.
A list of the same is to be maintained pertaining to each product along with calibration details and submitted to AIL.
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Section – 28 :
Corrective Action
This report should be initiated by the supplier in case of repeated nonconformances is observed in the product i.e. repetitive. Concession/deviation requests and in the case of quality complaints received from AIL and also depending upon the magnitude of problem. The supplier should immediately generate the referred document describing the details about the problem, interim corrective action planned and initiated, identified root cause and implementation of permanent corrective actions in order to prevent recurrence of such defects. Implementation and effectiveness of the corrective and preventive action will be verified by AIL as appropriate through evaluation visit to the source or through evaluation of future lots after the date of corrective action. In case corrective action requires any change in process/part/material it shall be done in consultation with AIL. Countermeasures should be implemented carefully and keeping the following points in mind. -
It should not simply end with verbal instructions, guidance, education to workers etc., but should result in up gradation of control system and review/revision of standards and procedures.
-
Consider if it is possible to install error-proofing devices in the process to prevent errors.
-
Investigate if there is a danger of occurrence of a similar parts or similar processes. If such possibilities are there, then implement countermeasures against each of them. When there is a rejection in supplied components, rejection note is raised in the format “F/COM/QAD/003” ( refer annexure page no. 66) Incase of rejection which is significant in terms of quality / application requirements, an additional note will be raised requiring “Corrective Action Report” in the format “F/COM/QAD/032” attached ( refer annexure page no.67). Purchase department will send the original rejection note along with corrective action format to the supplier. Purchase department will ensure that corrective action report is completed and received with in 10 days. The completed reports will be scrutinized by QAD and subsequent three batches will be monitored for the absence of such defects. The corrective action will be considered as cleared after that. If the corrective action report is not received with in 10days, further lots from the concerned supplier will not be accepted.
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Section - 29 :
Capacity Verification
Purpose: The purpose of capacity verification is to • • •
Determine if there are capacity constraints Identify process bottlenecks Be capable to meet full production volume during PPAP
Scope: Capacity verification shall be performed on all the appropriate supplied components and must be completed as part of all new or major modification PPAP submissions. Procedure: The Supplier shall fill up the form as given in the Annexure page no. 65 for each individual part number with the following guidelines. A). Suppliers to give details about parts which follow similar production sequence occupying the same production capacity to meet the monthly demand of each part. B). Cycle time required for one component at each stage is provided and based on which output per day at each stage is calculated. Incase of multi- cavity operations, output per cycle to be considered. C). Available hours per month are to be provided for a working standard of 3shifts of 8 hours max for 25 days. D). Machine downtime to be provided considering all setting change, breakdown, planned maintenance downtimes etc., E). Hours lost due to operator effectiveness like operator change, less skilled operator are recorded. F). Out of total available hours, the hours allocated to AIL is denoted in hours. Hours utilization for other customers is also to be provided along with spare capacity. G). Supplier need to submit an action plan, if there were any capacity constraints at any of the manufacturing stage.
A minimum 20% free capacity is preferable for each process. It helps in meeting sudden increase in requirement.
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Section – 30 : SPC related Terms Definition of Quality: Totality of characteristics of an entity that bear on its ability to satisfy stated and implied needs of customers. Definition of Quality Control: Quality control is “the process through which we measure actual quality performance, compare it with a standard, and act on the difference”
SPC Statistical Process Control is a tool for controlling the manufacturing process to prevent defects rather than detect them.
STATISTICAL Taking of measurements and arrangement of those measurements in clear pattern to allow predictions to be made on performance.
PROCESS Any activity that involves a combination of Man, Machine, Material, Method, Environment working together to produce a final product.
CONTROL Comparing actual performance with target and decide when and what corrective action is necessary to achieve the target. A process is said to be in statistical control when the only source of variation are from common causes. Process capability is determined by the variation that comes from common causes.
VARIATION No two products or characteristics are exactly alike, because any process contains many source of variability. The differences among products may be large or they may be immeasurably small, but they are always present. In practice, variation is inevitable in any process or product. The variation is of two types. 1. Inherent variation due to Common causes (or) Chance causes 2. Identifiable variation due to Special causes ( or) Assignable causes
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1). Inherent Variation due to Common causes / Chance causes / Random causes Sources of variation which are built into the process and will be caused by such problems as vibration, speed, power etc., These are the sources of random variation, the extent of which can be measured and monitored. This level of variation will continue unless a fundamental change occurs in the process.
A large number are in effect at any time
Each has an individual effect that is too small to mention
Only a change in the system will reduce that part of the variability
Remain constant over time
2). Identifiable Variation due to Special causes / Assignable causes. Sources of variation which will be due to specific identifiable causes such as variation in raw material, operator, tool wear, wrong setting, state of maintenance, etc., these removal are usually the responsibility of someone who is connected directly with the operation Ideally, only inherent variation in the process is preferred. If only the inherent variation is present, the output of the process will form a pattern which is stable over time and predictable. The occurrences of special causes will produce additional variation on irregular basis which will remove the predictability of the process.
Very few in effect at any time
The effect is measurable
They can be found and eliminated
The machine operator is best able to discover and make changes
They occur infrequently in an unpredictable manner.
Process Capability: To understand the extent to which a quality characteristic of a process meets the specified requirements, “Process capability” analysis done. It is a comparison between the spread of the quality characteristic to the specification limits. Process Capability concerns with the Variation caused by all sources of variations : The Machine, The Material used, The Methods employed, The people involved and The environment as it affects the product To make a process capability study, Data must be collected over a fairly long period of time the machine.
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Process Capability & Performance: Definition of Cp: Cp is an index comparing the variation within the process to the spec limits. The higher the number, the less variation in the process.
Definition of Cpk: Cpk is an index (a simple number) which measures how close a process is running to its specification limits, relative to the target of the process. The larger the index, the less likely it is that any item will be outside the specifications. Cpk 0.5 1.0 1.33
Confirming Output (%) 93.3 99.86 99.997
PPM
67,000 ppm 1,400 ppm 30 ppm
Cp & Cpk - Calculation: C pk =
Min( USL - Xm) or (Xm-LSL) 3σ Cp = ( USL - LSL ) = Tolerance 6σ 6σ σ = Standard Deviation = √(X-X)2 or R when n = 5, d2 = 2.33 n-1 d2
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Comparison Of Cp & Cpk :
Cpk
Low Cp
High
Low
High
Reduce Process Variability
Impossible
Move process mean
Seek a target dimension
Cpk will always be less than or at the most equal to Cp.
If the process is Preferably Centered, Cpk and Cp shall be e qua l
1.33 < Cpk :
The process capability is ample, review the specification or process if excessive
Cpk = 1.33 : Ideal status. “The goal” for all processes
1 < Cpk < 1.33 :
This status is desirable, but careful control is necessary because defective units may be generated when Cp approaches 1
Cpk < 1 :
Since defective units exist, it is necessary to take action, such as change operation methods or total screening
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Examples of Cp, Cpk USL
Cp=2, Cpk =1.5 LSL USL
LSL Cp=Cpk =2 USL
Cp=.8, Cpk =.75 LSL USL
LSL Cp =1 Cpk =1
6 Sigma And Cp & Cpk 3.4 ppm
3.4 ppm +/- 1.5α
Cp=2 Cpk = 1.5
Cp=2 Cpk = 1.5 Cp=Cpk =2
-6α -5
-4
-3
-2
-1
0
1
2
3
4
5
6α
Process Capability Study Page 39 of 76
Preliminary and periodic process capability studies are to be conducted for the characteristics specifically intimated by AIL as safety/Significant/Critical characteristics.
This is represented in the drawings. An acceptable level of process capability must be determined by evaluation using variables data.
The purposes of this study if to find out whether the production process is likely to produce product that will meet AIL requirements.
Preliminary process capability study using X bar & R chart is the starting activity. These are short term and will not predict the effects of time and variation in people
materials,
methods,
equipment,
measurement
systems
and
environment whereas periodic process capability captures all the above variations.
For short term studies the sample size should be at least 25 sub-groups of data containing at least a total of 125 individual readings.
The control chart should be examined for signs of instability. If there are signs if there are signs of instability, corrective actions should be taken.
If stability cannot be achieved, contacts AIL and determine appropriate action.
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Section – 31 : Failure Modes and Effect Analysis FMEA (System, Design, Process, Service), as applicable, shall be carried out by the supplier. He shall share with AIL about the details pertaining to potential failure.
Process FMEA Process Failure Modes and Effect Analysis (Process FMEA) is a method for identifying potential or known processing failure modes and providing problem follow-up and corrective actions. 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.
Objective: The Process FMEA is a disciplined analysis of the part process with the intent to identify and correct any known or potential failure modes before the first production run occurs. Once these failure mode is systematically ranked so that the most severe failure modes receive priority attention. The completion of Process FMEA is the responsibility of individual product / process engineer. This individual process engineers is the most knowledgeable about the process structure and can best anticipate the failure modes and their effects and address corrective actions.
Timing: The Process FMEA is initiated during the early planning stages of the process before the machines; tooling, facilities, etc are purchased. The Process FMEA is continually updated as the process becomes more prior to the first production run. Requirements: Completing the Process FMEA form FMEA risk ranking Guidelines
Ranking of failure modes and causes: It will be most desirable to eliminate all Failure modes and causes. However practical considerations based on cost and time, dictate the need to tackle only those critical modes and causes based on a priority ranking system. The ranking system in FMEA is based on the probability of 1) Occurrence 2) Severity 3) Detection
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Occurrence: Estimate the probability of occurrence of the potential failure on a 1 to 10 points scale. Only controls intended to prevent the cause of failure from occurring should be considered in this estimate.
Severity Ranking: Severity is an estimate of the effect on the user. Severity is the factor that represents the seriousness of the failure to the customer after it has occurred. Estimate the severity of “Effects of failure” to the customer on a 1 to 10 points scale.
Detection: Apply a scale of 1 to 10 which will enable probability of detection to be rated. Each assignable cause must be addressed and the probability of detection rated.
Risk Priority Number (RPN) It is a measure of design risk. It is the product of the Severity (S) x Occurrence (O) x Detection (D) Higher the RPN the team must undertake efforts to reduce the risk through corrective actions. However the action plan should be planned for failure modes having higher severity and occurrence rating also, irrespective of the RPN.
PFMEA – Team Effort: During the initial process potential FMEA preparation, the responsible engineer is expected to directly and actively involve representatives from all affected areas. These areas should include. But not limited to design, assembly, manufacturing, materials, quality, service and suppliers as well as the area responsible for the subsequent assembly. The FMEA should be a catalyst to stimulate the interchange of ideas between the functions affected and thus promote a team approach. The process FMEA is a living document and should be initiated before or at the feasibility stage, prior to tooling for production, and take into account all manufacturing operations from individual components to assemblies. Early review and analysis of new or revised processes is promoted to anticipate, resolve or monitor potential process concerns during the manufacturing planning stages of a new method or component program. The process FMEA assumes the product as designed will meet the design intent. Potential failures which can occur because of a design weakness need not, but may be included in a Process FMEA. Their effect and avoidance is covered by the Design FMEA. The Process FMEA does not rely on product design changes to overcome weakness in the process, but does take into consideration a product’s design characteristic relative to the planned manufacturing or assembly process to assure that, to the extent possible, the resultant product meets customer needs and expectations.
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Process function / requirements Enter a simple description of the process or operation being analyzed (e-g., turning, drilling, tapping, welding, assembly). Indicate as concisely as possible the purpose of the process of operations with different potential failure, it may be desirable to list the operations as separate processes.
Potential Failure Mode Potential Failure Mode is defined as the manner in which the process could potentially fail to meet the process requirements and /or design intent. It is a description of the non-conformance at that specific operation. It can be a cause associated with a potential failure mode in a subsequent (down stream) operation or an effect associated with a potential failure in a previous (upstream) operation. However, in preparation of the FMEA, assumption should be made that the incoming part(s) are correct. List each potential failure mode for the particular operation in terms of a component, subsystem, system or process characteristics. The assumption is made that the failure could occur, but may not necessarily occur. The process engineer/team should be able to pose and answer the following questions: 1).How can the process / part fail to meet specifications? 2).Regardless of Engineering Specifications, what would a customer (end user, subsequent operations or service) consider objectionable? A comparison of similar processes and a review of customer (end user, subsequent operations or service) claims relating to similar components is a recommended starting point. In addition, knowledge of the design is necessary. Typical failure modes could be, but are not limited to bend, cracked, grounded, binding, deformed, open circuited, burred, dirty, short circuited, handling damage, tool worn, etc.,
Potential Effect(s) of Failure Potential effects of failure are defined as the effects of the failure mode on the function, as perceived by the customer. Describe the effects of failure in terms of what the customer notice or experience, remembering that the customer may be an internal customer as well as the ultimate end user. State clearly if the function could impact safety or noncompliance to regulations. The effects should always be stated in terms of the specific system, subsystem or component being analyzed. Remember that a hierarchical relationship exists between the component, subsystem and system levels. For example, a part could fracture, which may cause the assembly to vibrate, resulting in an intermittent system operation. The intermittent system operation could cause performance to degrade, and ultimately lead to customer dissatisfaction. This intent is to forecast the failure effects to the team’s level of knowledge. Typical failure could be noise, poor appearance, erratic operation, unpleasant odour, inoperative, etc.,
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Severity (S) Severity is an assessment of the seriousness of the effect (listed in the column “potential failure mode” to the customer). Severity applies to the effect only. If the customer affected by a failure mode in the assembly plant or the product user, assessing the severity may lie outside the immediate process engineer’s / team’s field of experience of knowledge. In these cases, the Design FMEA, Design engineer, and/or subsequent manufacturing or assembly plant process engineer should be constituted. Severity should be estimated on a “1” to “10” scale. Suggested Evaluation Criteria: (The team should agree on an evaluation criteria and ranking system, which is consistent, even if modified for individual process analysis.
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Classification: This column may be used to classify any special characteristics for components, subsystems or systems that may require additional process controls. If a classification is identified in the Process FMEA, notify the design responsible engineer since this may affect the engineering documents concerning control item identification. Note: An item identified in the Design FMEA should have the special process controls identified in the process FMEA.
Potential cause (s) / Mechanism(s) of Failure: Potential cause of failure is defined as how the failure could occur, described in terms of something that can be controlled. List to the extent possible, every conceivable failure causes assignable to each potential failure mode. If a cause is exclusive to the failure mode, then this portion of the FMEA thought process is completed. Many causes however are not mutually exclusive, for example, may be considered to determine which root cause are the major contributions and which can be most easily controlled. The causes should be described so that remedial efforts can be aimed at those causes, which are pertinent. Typical failure causes may include, but are not limited to •
Improper torque – excess / less
•
Improper weld - current, time, pressure
•
Inaccurate gauging
•
Improper heat treatment – time, temperature
•
Inadequate gating – venting
•
Inadequate / no lubrication
•
Part Missing or mis-located
Only specific errors or malfunctions (e-g, Operator fails to fit a seal) should be listed, ambiguous phrases (e-g, operator error, machine malfunction) should not be used.
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Occurrence (O): Occurrence is how frequently the specific failure cause / mechanism is projected to occur. The occurrence ranking number has a meaning rather than a value. Estimate the likelihood of the occurrence on a “1” to “10” point scale. Only occurrences resulting in the failure mode should be considered for this ranking. Failure detecting measures are not considered here. The following occurring ranking system should be used to ensure consistency. The “Possible Failure Rate” is based on the number of failures which are anticipated during the process execution. If available from a similar process, statistical data should be used to determine the occurrence ranking. In all other cases, a subjective assessment can be made by utilizing the word descriptions in the left column of the table, along with any historical data available for similar processes. Suggested Occurrence Evaluation criteria The team should agree on an evaluation criteria and ranking system, which is consistent, even if modified for individual process analysis.
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Current Process Control “Current process controls” are descriptions of the controls that either prevent to the extent possible the failure mode from occurring or detect the failure mode should occur. These controls can be process controls such as fixtures or statistical process controls (SPC), or can be post process evaluation. The evaluation may occur at the subject operation or at a subsequent operation. There are three types of process controls / features to consider those that: 1) Prevent the cause / mechanism or failure mode / effect from occurring, or reduce their rate of occurrence. 2) Detect the cause / mechanism and lead to corrective actions, and 3) Detect the failure mode. The preferred approach is to first use the type1 controls to the maximum possible extent and then other two types in the order. The initial occurrence rankings will be affected by the type 1 controls provided they are integrated as part of the design intent. The initial detection rankings will be based on the type 2 or type 3 current process controls, provided the process being used is representative of process intent.
Detection (D) Detection is an assessment of the probability that the proposed type2 current process controls, listed in column 16, will detect potential cause/mechanism (process weakness), or the probability that the proposed type3 process controls will detect the subsequent failure mode, before the part or component leaves the manufacturing operation or assembly location. Estimate the detection controls in a “1” to “10” point scale. Assume the failure has occurred and then assess the capabilities of all “current process controls” to prevent to prevent shipment of the part having this failure mode or defect. Do not automatically presume that the detection ranking is low because the occurrence is low (e-g, when the control charts are used), but do assess the ability of the process controls to detect low frequency failure modes or prevent them from going further in the process. Random quality checks are unlikely to detect the existence of an isolated defect and should not influence the detention ranking. Sampling done on a statistical basis is a valid detection control.
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Suggested PFMEA detection evaluation criteria
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Annexure
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AXLES INDIA LIMITED
ONSITE AUDIT CHECKLIST FOR HEAT TREATMENT PROCESS OF SPINDLE
COMPONENT
F/COM/PUR/006
Part No
SUPPLIER NAME
CONTACT PERSON
DATE OF VISIT
LAST VISIT DATE
VERIFICATION POINTS :
1 Review of last visit report
2 Availability of component drg/WI with latest issue level
3 Availability of relevant engg specification of latest issue
4 Availability of relevant Work Instruction of latest issue
5
Whether the above documents are preserved property and old modification levels destroyed /returned
6 Whether suppliers find them understandable and any support needed
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AXLES INDIA LIMITED
ONSITE AUDIT CHECKLIST FOR HEAT TREATMENT PROCESS OF SPINDLE
F/COM/PUR/006
7 Whether the following process parameters are being recorded for each load a) Hardening Temperature b) Soaking Time c) Quench Medium d) Quench hardness e) Tempering temperature f) Time at tempering 8
Whether Inspection carried out and recorded as per Work Instruction
Whether performing heat Treatment 9 a) Process For Export Hsg to Dana Corporation (FORD) Application
Yes/ No
If yes third party has been audit carried b) out in line heat treatment system survey report as per format
Yes/No
c) Is yes status of pending corrective action if any
Yes/No
10 Calibration Status a) Hardness Testing machine b) Crack Detection Unit (ammeter) c) Temperature Indicators 11 Test Certificates 12 Control of Inspection reports/complaint reports/corrective action reports (both AIL/Vendor) 13 Availability of fool proof system in processing 14 Whether separate areas are provided for keeping spindles after hardening & tempering
Represented by Supplier
Represented by AIL
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IMTE Code :
Accetance Criteria :
Report S No.:
Decription :
Actual Error :
Date :
Action on IMTE
Tick appropriate box
Repair the IMTE & Recalibrate
Adjust and Recalibrate
Reject & Scrap
Display the error for user compensation and permit use
Review calibration frequency
Signature of Calibration Personnel
Action of Product
Error negligible - No Action
Concession raised for potential dimensional error
Stock on hand segregated (Annex results)
Error serious, inform customer (Annex disposition)
Usage not traceable - No action
Justification for "No action" Remark :
HOD Signature
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AXLES INDIA LIMITED
ONSITE AUDIT CHECKLIST SPINDLE JOURNALS INDUCTION HARDENING
F/COM/PUR/007
PART No COMPONENT
SUPPLIER NAME
CONTACT PERSON
DATE OF VISIT
LAST VISIT DATE
VERIFICATION POINTS : 1
Review of last visit report
2
Availability of component drg/WI with latest issue level
3
Availability of relevant engg specification of latest issue
4
Availability of relevant work instruction of latest issue
5
Whether the above documents are preserved properly and old modifications levels destroyed/returned
6
Whether Suppliers find the understandable and any support needed
Page 54 of 76
AXLES INDIA LIMITED
7
ONSITE AUDIT CHECKLIST SPINDLE JOURNALS INDUCTION HARDENING
F/COM/PUR/007
Whether the following process parameters are being recorded for each load?
a) Selecion of coil configuration
b) Frequency
c) Cycle Time/ Heating Time
d) Dwell
e) Coil Speed
f) Job Rotation
Whether Inspection carried out and 8 recorded as per Work Instruction (WI/COM/MET/030)
9. Whether performing Induction Hardening (a Process For Export Hsg to Dana Corporation ) (FORD) Application
If yes Third party has carried out audit in (b line with heat treatment system survey ) report as per format
©
If yes status of pending corrective action, if any
Page 55 of 76
AXLES INDIA LIMITED
ONSITE AUDIT CHECKLIST SPINDLE JOURNALS INDUCTION HARDENING
F/COM/PUR/007
a) Hardness testing Machine
b) Crack Detection Unit (ammeter)
c) Temperature Indicators
10 Calibration Status 11 Test Certificates
12
Control of Inspection reports/ Comlaint reports/ Corrective Action reports
13
Availability of fool proof system in processing
Whether separate areas are provided for 14 keeping spindles after hardening & tempering
Page 56 of 76
IMTE Code :
Accetance Criteria :
Report S No.:
Decription :
Actual Error :
Date :
Action on IMTE
Tick appropriate box
Repair the IMTE & Recalibrate
Adjust and Recalibrate
Reject & Scrap
Display the error for user compensation and permit use
Review calibration frequency
Signature of Calibration Personnel
Action of Product
Error negligible - No Action
Concession raised for potential dimensional error
Stock on hand segregated (Annex results)
Error serious, inform customer (Annex disposition)
Usage not traceable - No action
Justification for "No action" Remark :
HOD Signature
Page 57 of 76
Sl No ELEMENTS A
1
2
Max Score Scoring
QUALITY MANAGEMENT SYSTEM (QMS) Has the supplier established, documented and implemented a Quality Management System Has the supplier identified the processes needed for the QMS Have appropriate measurables been identified as appropriate for monitering the performance of the processes for the QMS Does the supplier have at min the following procedures as a part of their QMS? # Control of Documents # Control of Records # Control of Non-Conforming Products # Internal Audits # Corrective Action # Preventive Action # Training (defined min, identification of training needs and competence qualifications including Contract Labours) # Competence qualification Does the supplier have a quality Manual that includes # Scope of the QMS # Exclusions if any with justification # QMS procedure with reference to them # Process Flow Map showing the sequence of QMS processes Are the controls needed defined in procedure?
3
Are documented statement of quality Policy & quality objectives available?
2
3 3 3
8
4
Had the supplier implemented a document control procedure and following controls in place: # Documents approved by defined authority # Re-approved when documents are revised/changed # Changes and current revision status are identified # Relevant version of applicable documents are available at points of use
7
# Documents are legible and are readily identifiable # External Documents are listed and distributions are controlled # Obsolete documents are identified suitable to prevent unintended use
3
Does the supplier maintain records of design change implementation effective dates? Are these design changes subjected to customer requirements of product approval process? Does supplier maintain records specified by customers?
3 3 3
Page 58 of 76
B
MANAGEMENT RESPONSIBILITY Has the suppliers management identified and appointed a management representative who in addition to his existing responsibilities will ensure the requirements of this SQM are established, implemented and will promote the awareness of this SQM in the suppliers company improvements and effectiveness of the QMS
1
2
3 C
1
2 3 4 5 6 7 8
Are the Quality objectives measurable? Have personnel been authorized to stop production to correct quality problems? Is there a system for prompt communication of product/process nonconformities? Is there a communication process 3established internally regarding the effectiveness of the QMS Process? Has the suppliers management communicated to its employees he importance of meeting customer, statutory requirements? Are the quality objectives provided to relevant functions and levels within the organizations? Have responsibility & authority been defined and communicated to appropriate personnel? Are shifts stagged with personnel in charge of and with responsibility of Quality? Are reviews of the QMS conducted to ensure continuing suitability, adequacy and effectiveness? Do the reviews include performance trends, quality objectives and exploration of opportunities' for improvement? Has the suppliers management determined areas of action that will enhance customer satisfaction? Are the action plans available with the appropriate personnel to implement and achieve quality objectives? Are achieve improvements and resources requirement recorded? RESOURCE MANAGEMENT a) Are the norms for competence of personnel performing work affecting product quality established? b) Is there a preventive maintenance system for process equipments and associated utilities? Are these personnel qualified against these norms? Are training needs identified to fill the gaps? Are qualified personnel developed to perform work affecting product quality? Does the supplier provide on the job trailing for any new or modified job affecting product quality? Are safety instructions & equipment provided as appropriate? Is lighting adequate in production & inspection areas? Are house keeping practices in place and are they maintained?
7
7
3
3
3 3 3 3 3 3
Page 59 of 76
D 1 2 3
PRODUCT REALIZATION Does the supplier prepare a new product development timing plan containing the activities, start and finish timings? Does the plan identify the design and/or development stages? Is there evidence of regular tracking of the status with prompt corrective actions as appropriate?
3 3 3
4
Is there system for control and management of changes (like design, process, non-perishable tooling changes, source changes, material changes,etc..) to ensure introduction as per customer requirements?
3
5
Are records of change implementation effective dates maintained?
3
6 7 8 9 10
11
12
Is there any confidential information (product/Project) for which the supplier has to maintain confidentially? If yes are the confidentiality controls adequate? Does the supplier perform a formal order/schedule review? For new product does the review address manufacturing feasibility before acceptance? If differences/feasibility problems exist, does the supplier resolve them with the customer before order acceptance? Are reviewed orders/schedule,. Co-ordinated and integrated into production planning, material planning and dispatch planning as appropriate? Does the supplier use multidisciplinary approach to prepare for product realization that includes, # Development of Timing Plan # Finalization of special characteristics # Development of PFMEA and for Follow-up actions # Development and review of Control Plans Are the Design and Development inputs identified and Listed? Doe the design and development outputs include, # Process Flow Chart # Process FMEA # Control Plan # Work Station Instructions # Product Approval Acceptance Criteria
3 3 3 3 3
4
6
# SPC & MSA requirements to meet customer product approval
Page 60 of 76
13 14 15 16 17
18
Has the supplier understood the product approval process to be followed by him as specified in this manual? Are records of product approval by customer maintained? Id supplier purchases material/parts/services are evaluation & selection criteria defined?
3
Is there a rating and evaluation covering at the minimum quality & quantity?
3
Is customer approved sources/materials are involved, does supplier records shows conformance to customer requirements? Does the supplier have a process to verify the quality of purchased product against his inspection standard by, # Receiving Inspection
3
3
3
3
# Product Evaluation/testing by customer approve/accredited lab
19
20 21 22 23 24 25 26 27 28 29 30 31
# Another me this agreed by customer Does the supplier carryout manufacturing process under controlled conditions that includes, # Availability of information that describes the characteristics of the product. # Availability of WI as necessary # Use of suitable equipments # Availability and use of monitoring and measures devices # Implementation of monitoring and measurement # Dispatch release authorizations. Does the supplier develops Control Plan? Are there records to show the job set-up verification Are special processes pre-qualified to validate control limits? Does the supplier identify # Product # Inspection Status Are customer supplied tooling identified satisfactorily? Are customer supplied products stored and identified? Does the supplier have adequate storage area and facilities? Has supplier defined # Calibration Frequency # Acceptance Criteria # Identification IMTE Is the a method of identifying calibration status? Are records av ailable to show evidence? Are Calibrations traceable to national/international standards? When IMTE is out of calibration is there a system to assess and record the impact of situation on the inspection and test results of the product and the test results of the product and the actions on the IMTE to correct the problem.
6
3 3 3 2 3 3 3 3 3 3 3 3
Page 61 of 76
E 1
2
3
4
5
MEASUREMENT, ANALYSIS & IMPROVEMENT Does the supplier have a process/procedure to measure customer perception of satisfaction? a) Does the supplier has a system for monitoring and analyzing, # Customer Satisfaction # Product Quality # Process Performance # QMS measurables b) Does the supplier have a system in place for corrective and preventive actions? Does the supplier monitor and analyze such data and maintain records for the same? Does the supplier use quality tools for problem solving Does the supplier verify the captured data for subsequent actions required, if any? Are error proofing methodologies used here appropriate? Does the supplier take corrective actions on the same, if it calls for? Does the supplier identify actions for improvements? Does the supplier extend corrective actions to similar products and processes where applicable?
3
4
2 3
3
3
Scoring Guide # 0 where elements are missing # Max score can be awarded where the system is implemented effectively
Page 62 of 76
Part Submission Warrant Part Name
Cust. Part Number
Shown on Drawing No.
Org. Part Number
Engineering Change Level
Dated
Additional Engineering Changes
Dated
Safety and/or Government Regulation
Yes
Checking Aid No.
Checking Aid Engineering Change Level
No
Purchase Order No.
Weight (kg) Dated
ORGANIZATION MANUFACTURING INFORMATION
CUSTOMER SUBMITTAL INFORMATION
Organisation Name & Supllier/ Vendor Code
Customer Name/ Division
Street Address
Buyer/ Buyer Code
City
Region
Postal Code
Country
Application
MATERIALS REPORTING Has customer-required Substances of Concern information been reported?
Yes
No
n/a
Yes
No
n/a
Submitted by IMDS or other customer format:
Are polymeric parts identified with appropriate ISO marking codes? REASONS FOR SUBMISSION (Check at least one) Initial Submission
Change to Optional Construction or Material
Engineering Change(s)
Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional
Change in Part Processing
Correction of Discrepancy
Parts Produced at Additional Location
Tooling Inactive > than 1 year
Other - please specify below
REQUESTED SUBMISSION LEVEL (Check one) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location SUBMISSION RESULTS The results for
dimensional measurements
These results meet all design record requirements:
material and functional tests Yes
No
appearance criteria
statistical process package
(If "NO" - Explanation Required)
Mold / Cavity / Production Process DECLARATION I affirm that the samples represented by this warrant are representative of our parts which were made by a process that meets all Production Part Approval process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of _____/ __hours. I also certify that documented evidence of such compliance is on file and available for review. I have noted any devitions from this declaration below. EXPLANATION/ COMMENTS:
Is each Customer Tool properly tagged and numbered?
Yes
No
n/a
Organistion Authorized Signature Print name Title
Phone No.
Fax No.
E-mail FOR CUSTOMER USE ONLY (IF APPLICABLE)
PPAP Warrant Disposition:
Approved
Rejected
Other
Customer Signature Print Name March 2006
Date Customer Tracking Number (optional)
CGG-1001
Page 63 of 76
Page 64 of 76
Reviewd by
Prepared by
Process
Signature
Product
Signature
No.
Characteristics
Name
for Mfg
Jig, Tools
Machine, Device,
Name
Operation Process Name / / Process Operation Number Description
Date (Rev.)
Other Approval/Date (If Req'd)
Approved by
Signature
Name
Control Method including Error proofing
Customer Quality Approval/Date (If Req'd)
Sheet ---- of --------Rev No Customer Engineering Approval/Date (If Req'd)
Date (Orig.)
Methods Char. Product / Process Evaluation Sample Class. Specification/Tolerance Measurement Technique Size Freq.
Special
Other Approval/Date (If Req'd)
Supplier / Plant
Supplier Code
Supplier/Plant Approval/Date
Part Name / Description
Production Key Contact/Phone
Core Team
Pre-launch
Control Plan Number Part Number / Latest Revision
Proto type
Control Plan
Reaction Plan
Page 65 of 76
:
3
Trials
8
7
6
4 5
/ Serial production.
4
5
6
8
When cloumn B lists final process enter ' Ship " in this place : Number of shift worked on this process per day : Total Hours available per shift ( Subtract breaks and scheduled down time ) : Standard number of Days / month (for this process is scheduled) ( Do not include overtime unless process is designed to operate that way : Interval between Parts coming off process ( in seconds ) : Number of pieces per cycle
7
Shift/ Hours Days/ Cycl e Time pcs / day /shif t month (seconds) Cycle
/
:
Issue Date
Similar Process
Next Process
/
Final Inspection and Ship packa ging
2
1
3
Process Name
Process Number
Plan
: : :
Contact Person Phone Num ber Email id
Instructions Fo r Comp leting Capacity Stu dy of Each Process : Individual Proces s N umber 1 : Name of Process ( e.g. Molding , Welding ,Assembly 2 : Next Process for this part 3
In put :
Part Number
Data (Cycle t ime, %Up time, %FTPR) Based on :
Part Nam e
Supplier N ame : Plant Location : Part Num ber :
Capaci ty Study Sheet for Each Process
9
Dail y P rocess Capacity
+91
10
12 13 14 15 16 17 18
9 10 11
11
13
14
15
16
Total hours / month = 525 (3shift basis) or 40 0 (2 s hift basis )
Part s
17
YES
YES NO YES NO YES NO YES NO YES NO YES NO YES NO YES NO
NO YES NO
YES
NO
: 9 X 10 X 11 : Hours per month (allocated for this process of this part) : Hours per month allocated to other parts : Hours per month process is not used ( Other than regular scheduled down tim e ) : 12 X 13 / ( 4 X 5 X 6 ) : Daily Requirm ent for this part to meet customer demand : Is this a capacity c onstraining process for this part
: ( 4 X 5 X 3600 / 7 ) X 8 : Percentage of production time vs available tim e ( 4 X 5 ) - u nplann ed downtime : Percentage of Good Pieces (First Time right only vs. production)
12
Pa rt
Completed by
Daily Daily Constraint C apacity Reqmt by on Capacity Unus ed for this part custom er
Hours alloted per m onth
Actual % Up % for this process Proce ss Tim e Good For This For O ther Capacity
(circle one)
Signature
Name Title Date
Page 66 of 76
QAD:
1
Sl.No. Nature of defect
Qty
Qty rejected:
Batch Qty Rework/Deviation/ Reject/Scrap
Authorised Sign:
Attributed to
Split up details for stock purpose
Quality Report for Bought out components
Qty accepted:
A
Axles india limited
GIN No. / Date
DC No. /Dt as per GIN
Part name
Part No
Vendor as per GIN
Date
Ref: QAD/CR/
JUNE'05
F/COM/QAD/003
Rework done by AIL/ Party
Party
Cost of rework to Remarks be debited
Qty rejected/ Scraped
Summary of rejections for debit purpose
Report based on sample inspection / on 100% inspection
PART I - RESP. - AIL QAD
AXLES INDIA LTD
VENDOR / SUPPLIER CORRECTIVE ACTION REF.No.: REPORT Date:
GIN No:
REPORTED AREA
DC No.: GIN QTY.:
AIL'S ORIGIN BASED ON MAGNITUDE AND RISK INVOLVED
BASED ON REPETITIVE IN NATURE
CUSTOMER ORIGIN
PART No : PART NAME :
SUPPLIER :
REF.CR No.: NATURE OF COMPLAINT (S ) :
QAD SIGN.
PART II - RESP. - VENDOR
TO BE FILLED BY THE SUPPLIER DISPOSITION ACTION / CONTAINMENT ACTION
RESP.
TARGET DATE
ROOT CAUSE(S) : ( ATTACH ADDITIONAL SHEET IF NECESSARY ) ( USE WHY? WHY? ANALYSIS ) FOR OCCURRENCE
FOR DETECTION
CORRECTIVE ACTION (FOR OCCURRENCE &DETECTION):
RESP.
TARGET DATE
Note: Incase of corrective action involving change in tooling, material, process or process sequence or location, PSW to be submitted with necessary
PART III - AIL PURCHASE APPROVAL
VENDOR SIGN:
Purchase Officer:
Purchase Head:
QA Incharge:
QA Head:
PART IV - AIL QAD APPROVAL
Date:
Date:
VENDOR COLUMN PART II - TO BE FILLED AND SEND BACK TO AIL WITHIN 10 DAYS FROM THE DATE OF COMPLAINT F/COM/QAD/032
Aug'15
Page 67 of 76
PAGE 1 OF 8
Supplier Evaluation Form
Axles India Ltd
F/ COM / PUR / 001 Apr-16
A.General Information 1 Name of the Company 2 Address (of referred unit) Office
Works
3 Phone No(s):
Works
Office
4 Fax No(s) 5 E-Mail ID Name
Designation
Name of the Owner/ patner/Directors/ 6 Ministery 7 Name&Address of ContactPerson. 8 Contact person in Chennai: 9 Address of branch offices: (If any) 10 Details of other Sister/Mfg units: 11 E-Mail Fax No: TIN NO/ DATE CST NO Excise Regn No Bankers Name & Branch
Evaluation (Pls in appropriate cell)
Re Evaluation (Pls in appropriate cell)
80%&Above Approved
61-70% 71-79% Restricted approval. Re evaluation give details of Restriction after Corrective action
Re evaluation due to deficiency in initial evaluation
Rejection
Re evaluation after approval and reason for Evaluation
Final Recommendation based on above Details By HOD- Purchase
Page 68 of 76
PAGE 2 OF 8
Axles India Ltd 1
2 3 4
Supplier Evaluation Form F/ COM / PUR / 001 Apr-16
B.Commercial Information Small Scale Classificatio n of industry (Pl.appro priateCell) Large Scale Registration Number Year of establishment Proprietary Type of ownership Public (Pl.appro Private
Agent/trader
Patnership Government Others Confirmation from Supplier Annual Qty requirement Proposed by AIL
5
Capacity of the unit
6
Connected to any big groupof Companies
1 2 3
C.Financial Information Total Capital invested Debit/ loans borrowed out side Operating Profit
4
Part Nos proposed
Medium Scale
Description
Installed Capacity inQty
Spare Capacity in Qty
Year Turnover in Rs Laks/ Turn Over in last 3 years Crores PAT Equity
Attach Copy of latest balance Sheets(if necessary) 5 6
1
2 3 4
Name of bankers
D. Personnel information Employee details a. Total no employees b. Tecfhnical employees c.Administrative Staff S.No Category
Organizational Structure(Enclose) Weekly holiday Shift Working I Shift hours II Shift III Shift
I Shift
II Shift
From
III Shift
To
Page 69 of 76
PAGE 3 OF8
Axles India Ltd
Supplier Evaluation Form F/ COM / PUR / 001 Apr-16
E.Technical information
1
2 3 4 5 6 7
Steell Rolling Mill Tubes/Pipes Precision Machining Nature of work Machinig activity Pl. in appropriate Cell Pressed items Items
Casting Forging Plating Heat Treatment Proprietary Others
Production facilities Special processheat treatment Special processplating treatment
Enclosed as Per theFormat in Table In-house facility available Subcontracted to M/S In-house facility available Subcontracted to M/S In-house facility available Metrology facilities Subcontracted to M/S
F.Quality System
1
2
3
Certified for Quality No Systems (pl in appropriate Cell) Valid upto
ISO
QS Certifying agency
please Specify Whether the cerficate is applicable for all manufacturing divisions
Details of Certification (Enclose Copy Of Certificates)
Any inspection plan followed (for incoming,InProcess
TS
(Attach flow Chart if necessary)
Page 70 of 76
PAGE 4 OF 8
Axles India Ltd
Supplier Evaluation Form F/ COM / PUR / 001 Apr-16
4
Calibration Procedure established(Pl.) If yes,Calibration procedure
5
6
7
System available for Corrective Preventive actions
System available for recording&responding Customer Complaints Any hazardous material used
Table-1:(List of production of facilities Extend table if Necessary)) S.No 1
Machine descripition
Make
Year of Mfg
Capacity
Quantity
Least Cont
Quantity
2 Table-2:(List of Inspection facilities Extend table if Necessary) S.No
Instument/Equipment
Make
Range
1 2
Table-3:(List of Major Supplier Extend table if Necessary) S.No 1
Supplier Name/(Sub
Items
Vol Supplied(Approx.in Rs/qty)
Ventor Rating
2 3 4 5
Table-4:(List of Major Customers Extend table if Necessary) Name of the Customer S.No 1
Vol Supplied(Approx.in Rs/qty) Items
% of your business
2 3 4 5
Page 71 of 76
PAGE 5 OF 8
Axles India Ltd
Supplier Evaluation Form F/ COM / PUR / 001 Apr-16
G . Table for Safety Related aspects S.no
Detail
1
Protection of eyes
2
Fire fighting equipments Precautions against dangerous fumes ,gases,etc
3 4 5 6 7
Comment by Vendor
Remarks
Medical facilities & Ambulance proper training forForkift and Crane Operators Recruitment of Safety Officer No involvment of young Person( Child) in any activity.
Signature PURCHASE -REP
QAD/PRD/PDE/MED/-REP
Page 72 of 76
Axles India Limited
F/COM/PUR/001 Apr-16
Supplier Evaluation Questionnaire
PAGE 6 OF 8 Max Sl.No Criteria Scored Remarks Points 1 Does the management team include technically capable 3 personnel? 2 Is the availability of technically capable supervision 3 satisfactory for the entire working hours ? 3 Do they have reputed customers at present? Furnish details 3 4 5 6 7 8
9 10
11 12 13 14 15
Are they aware of environmental requirements? Is the Quality function formerly organized with sufficient responsibility and authority ? Is the management Quality conscious? Are there regular review of Quality issues by Management?
3 3
Do they preserve drawings and specifications provided by customers properly and do they ensure that latest specifications are followed : Is the communication to workman and inspectors about latest specifications, inspection procedures satisfactory ? Do they preserve customer’s inspection reports and other Q.C. communications and are they available for reference ?
3
Are their machine tools suitable and adequate for the items under consideration? Are their above machine tools well maintained? Do they have adequate standard inspection instruments and test equipments as necessary? Have they developed adequate limit gauges and inspection fixtures or do they expect the customer to provide them? Is the calibration system of gauges, and jigs and fixtures satisfactory?
3
4 3
3 3
3 3 3 3
Page 73 of 76
F/COM/PUR/001
Axles India Limited
Apr-16
Supplier Evaluation Questionnaire 16
PAGE 7 OF 8 Max Scored Remarks Points Is the material identification and issue control satisfactory? 3
17
Is the receiving inspection carried out adequately?
3
18
Do they carry out first off sample, patrol and stage inspection? Are adequate records maintained? Do their lab facilities adequate to control the incoming and in process operation? Is the final inspection carried out adequately?
3
Do they have proper system for carrying out defect analysis and prompt actions taken to improve quality? Do they reply promptly to the customers about the corrective actions taken, whenever quality problem are referred? How are the facilities for material storage and handling?
3
How the identification of in-process material is accepted material and rework pending material? Is the rejected material identified, kept separately and disposed? Do they carry out proper identification for trace ability items as applicable? Do they submit detailed Test Certificate with each consignment? Is there a systematic training Programme for personnel carrying out work affecting Quality? Are they aware of SPC techniques & application?
3
Is SPC techniques on practice and action plan for out of control condition? Whether the unit is Third Party Certified to ISO9001-2008
3
Sl No
19 20 21 22
23 24 25 26 27 28 29 30 31
Criteria
3 3
3
3
3 3 3 3 3
10
ISO / TS 16949-2009 ADDITONAL INFORMATION A General House Keeping B
Potential for Development
C
Expansion Plans
Page 74 of 76
Axles India ltd Improvement activities
Date :
Supplier Evaluation Form follow Records Sub contractors Target for Completion
Reviewed :
F/COM/PUR/001 Apr-16 PAGE 8 OF 8
Review Status
Date
Approved :
Page 75 of 76
Supplier Re-evaluation F/COM/PUR/020
Reason for Audit
Supplier Name
Processes audited
Higher PPM
Critical Process
Repetitive Rejection
Location Change
Conventional Machining
CNC Machining
Forging
Casting
Pressings & Formed Heat Treatment
Protective finishing Welding & Assy
Not audited Date: previously Rolling Others
Current Audit coverage Part Name
Sl.No
June2005
Audit No:
Previous Audit
Application / Part Number Model
Date
Pending as on date
Total No. of Open issues raised
1 2 3 4 Fully compliance=4
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
Satisfactory compliance=3
Partial compliance=2
Less compliance=1
Closure of previous audit open issues Availability of component drawings with Latest revision Availability of Relevant Engg Specifications Calibration status of Gauges and Records maintenance Handling and Preservation of Gauges to prevent damage Replacement of wear parts in Gauge, if applicable Adherence to Process Flow as per last submitted PPAP Adherence to Control Plan as per last submitted PPAP Control of operation having special characteristics Adequate system for carrying out Final inspection Availability of Proper system for Defect analysis Evidence of corrective actions for the past complaints Material Handling practices to meet the desired quality Avoidance of Mix up between similar parts Identification of Input, WIP and FG with suitable tags Arrangement for keeping the rejected parts separately Adequate system for Final inspection Wear parts monitoring in the Jigs and Fixtures Functioning of Poka-Yoke, if applicable Response to quality issues against customer complaint Maintenance of Machines to get planned output Schedule Vs Supply performance for the last 3 months Willingness to increase the capacity in short notice Availability of spare Tools and consumables Flexibility and adequate resource to manage manpower
Total Score
0 Grading
90 to 100
80 to 89
Full compliance
60 to 79
Less than 60
Satisfactory Compliance Partial Compliance Improvement plan to be submitted in 20 days if the score is less than 80%
Represented by AIL - QA
Represented by AIL - Purchase
No Compliance
Represented by Supplier
Page 76 of 76
