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MARUTI SUZUKI INDIA LIMITED

Issue Deptt. MACE Prepared Verified Approved


Vendor Quality System Assessment Report - Tier II
Date of Issue Avneet
Copy to Supplier Name 24/10/2017 Singh Kalsi

Vendor 1 Audit Date


Supplier Attendant Name
SC 1 M/s Swaran Enterprises
New Jail Road Vill. Dhumaspur, Mr.Hemant Kumar (Managing Partner)
24th October 2017
Tier 1 1 Gurgaon-122101
Mr. Kuldeep- QA
MACE 1 Mr. Inderjeet- Production Audit Person
Mr. Sultan Sharma- Purchase
Cluster Name Jay ushin Ltd Mr. Rajesh Kaushik- HR
(Audit Score) Avneet Singh Kalsi

Achieved Score: 71
Vendor (Tier 1) Person
×100 = 68
Total Score: 104 Mr Tinku Jaaglan
Total 4
Part Number:
Subject: Vendor System Audit- Tier II
Part Name: Terminal Base (YE-3)
Observation:-
1. M/s Swaran Enterprises is an ISO 9001 certified company.

2. Company Is Home Grown


3. Company is manufacturing Injection Molding Parts
4 Customers: JNS, Jay Ushin, Snadan Vikas
5 Fianacial Condition is good

6. No Major Observation
Following area needs to be focus for improvement :-
1. Regulation for initial production control
2. Education and Training
3. Handling Abnormality In Quality

Detail report is enclosed for your kind consideration & improvement actions -
Total
Achieved
0 1 2

1 6/ 8 0 2 2
1.Production
2 3/ 6 0 3 0 preparation 2.Regulation for initial
16. Process Audit production control
3 8 / 10 0 2 3
100
4 3/ 4 0 1 1 15. Adequate testing facility 3.Changing management

5 / 6 0 3 0

6 4/ 6 0 2 1 14.Critical parts Management 50 4.Standards


management

7 2/ 2 0 0 1

8 7 / 12 0 5 1
13.Handling Management 0 5.Education and training
9 7 / 10 0 3 2

10 6 / 10 0 4 1
12.Products
6.Quality audit and process verification
11 5/ 8 0 3 1 management

12 6 / 10 0 4 1

13 4/ 4 0 0 2 11.Implementation 7.Supplier control


of standards
14 NA / NA 0 0 0
10.Equipment/ 8.Handling abnormality
15 4/ 4 0 0 2 Inspection
equipment's
9.5S management in quality

management
16 3/ 4 0 1 1
Total
(MSI 68 / 104 0 33 19
L)
Pre decided negative Improvement Submission
0 10/7/2016 Last Audit Rating Nil
marking (if any) Date 

F003-3 QA/MT Ver. 5


MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Do you define the procedure for Product development


Regarding implementation rule 1 including the following ? -scope of parts, responsibility of each 2
1 of production preparation
department, control contents / items?

Regarding management /
Do you implement follow-up to control the schedule and
implementation by production 1 progress of production preparation items? Incl top 1
2 preparation plan / report (master
management
plan)

1. Production
preparation /
New Product
Development
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment


1. Production
preparation /
New Product
Development Do you consider following items and implement corrective
and preventive action to the processes and standards before
Defect prevention on the stage
regular production?
of process design by using 1 1
3 -Troubles in the past; -Defect items expected;
FMEA/Matrix diagram
-Defect items unable to capture at customer;
-Defect items difficult to repair;

Product/process evaluation at
Do you prevent defects by quality improving activities of
the quality evaluation meeting in 1 2
4 cross-function team to evaluate quality performance?
each trial
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Do you define following items related to initial production


control by standards ?
-controlled parts; -controlled items; -inspection method;
1 1
-initial production control period;
Regulation for -a person who announce start/end of initial production control;
1 initial production control -finish condition;
2.
Regulation
for How do you define items required special control during initial
initial 2 production control? Do you set stricter inspection methods 1
production than the ordinal inspection?
control

Do you control process capability and defect rate during initial


Implementation of initial 1 1
2 production control?
production control
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Do you define unexpected change (unusual) and planned


1 1
change clearly?

Definition and implementation of


1 changing management
Do you define procedure(rules applied from sharing
2 2
information to result confirmation) at change occurrence?
3.
Changing
management Do you record product quality check results to ensure
3 1
traceability? Incl retroactive checks
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR
3.
Part Name
Changing Terminals
management
Category Audit Area Concerning regulation Judgment

1 Do you define and control initial part clearly? 2

Definition and control method


2 for initial part
Do you control initial parts separately and make quality
2 records about them?(both internal and outsourced process 2
are included)

Procedure to make process Do you make and review process control standards,
1 control standards(QA process 1 Inspection specifications, Operation instructions for all 1
charts) products which is shipped to SMC / MSIL / Tier 1 ?
4.
Standards
management
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals


4.
Standards
Category Audit Area Concerning regulation Judgment
management

Procedure to control standards


Do you have consistency to keep process control standard,
2 ・Process control standards 1 inspection specification, operation inspection and parameter 2
・Inspection specifications chart?
・Operation instructions

Do you clarify the department in charge of promoting quality


1 education, implement education based on annual plan? 1
Are records of education kept?

1 Education/ training procedure


5.
Education
and training
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

1 Education/ training procedure


5.Category Audit Area Concerning regulation Judgment
Education
and training
Do you define and implement the skill evaluation of operator
to determine whether operator can work without surveillance?
2 1
(e.g. acceptable revel/evaluation frequency/evaluation
method)

Education for
Do you periodically monitor the skill of certificated operators
managers/Inspectors/ 1 1
2 and follow up to improve their skill?
Special operators

Do you conduct quality audit to identify issues and properly


Activity to keep/improve 1 1
1 improve them?
production quality
6.
Quality audit
and process
verification
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment


6.
Quality audit
and process Do you confirm consistency between actual operation and
verification 1 1
standard?
2 Content of process review

Do you confirm if countermeasures are taken properly to


2 2
prevent reoccurring of quality fail?

7.
Evaluation method for new Do you define criteria to certificate new suppliers and
Supplier 1 1 2
suppliers implement them?
control

Do you define clearly what is abnormal situation and make


1 1
operators know the definition?

Handling when abnormal


1
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Handling when abnormal Do you clarify and standardize the handling rules/routes for
2 1
1 situation occurs customer claims, in process failure and supplier failure?

Do you have criteria to estimate the scope of suspected lot


3 for abnormal situation? When abnormal situation occurs, do 2
you trace suspected lot based upon the criteria?
8.
Handling
abnormality
in quality Do you prevent recurrence of issues by analysing cause of
1 occurring defect based on process investigation result such 1
as 5-why analysis?

Prevention of recurrence

2 ・Customer claims
・In process failure
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR
8.
Handling
Part Name
abnormality Terminals
in quality
Category Audit Area Concerning regulation Judgment

Prevention of recurrence Do you reflect corrective action to improvement of process


2 1
control and review of standards?
2 ・Customer claims
・In process failure
・Suppliers failure

After corrective action are taken, do you conduct on-site


3 check up and evaluate the effectiveness? And horizontal 1
deployment.

Do you keep store material, work-in-process, finished


products, inventory and container at appropriate storage
1 1
prevented from dust, lust, scratch, deformation and
rainwater?
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Do you control material, work-in-process and finished product


1 Location of production site 2 by designated location, volume and standard using visual 1
control?

9.
5S
management
Do you implement inspection or critical operation under the
3 properly controlled environment luminance 1
/temperature/humidity/vibration/noise/work table, etc.)?

Do you keep condition of production equipment's, jigs and


1 2
tools properly?
Production equipment's
2 management
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
9. Mr.Hemant Kumar (Managing Partner)
5S M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
management Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment


Production equipment's
2 management
Do you keep condition of inspection equipment's properly to
2 2
ensure accuracy?

Do you conduct daily/regularly check of production


1 1
equipment's, dies and jigs? Are records of maintenance kept?

Maintenance of equipment's ,
1 jigs and tools

10. Do you confirm regularly the function of Pokayoke, automated


2 1
Equipment/In stop and alarm? Are records of maintenance kept?
spection
equipment's
management
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR
Maintenance of equipment's ,
1 jigs and tools
Part Name Terminals

10.
Category
Equipment/In Audit Area Concerning regulation Judgment
spection
equipment's
management Do you standardize frequency of polishing and replacement
3 1
for consumable tools(blade/electrode/rub stone, etc.)?

Do you calibrate regularly inspection equipment's and put the


1 2
expire date on them?
Maintenance of inspection
2 equipment's
Do you control deterioration (expire date) of boundary
2 samples for objective judgments such as appearance 1
inspection?

Do you use easy expression (visualizer, onomatopoeia ,etc.)


1 for operation instructions? So that operator can easily 1
understand process and critical points.
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Do you keep operation instructions on the accessible place


2 and post important quality points and critical operation points 1
on the place where operators can see it easily?
11.
Implementati
Implementation of standards
on of 1
standards

Do you regularly monitored that each operator operates


3 1
according to the operation instructions?

Is it possible to judge OK/NG specifically by each check sheet


4 (of daily equipment check, quality control report, etc.) you 2
use?
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment

Do you keep first-in first-out of finished products and work-in-


1 process (material, reserve parts) by using identification tag or 1
lot indication?

management of parts flow Do you control follows production history by product lot
1
2 numbers? 1
-production date; -production volume; -shipping date

12.
Products 3 Do you control identification of similar parts separately? 1
management

Do you control identification of non-confirming parts and parts


1 1
on hold. Do you store them separately?
Non-confirming parts
2 management
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
12. Name 122101 Mr. Sultan Sharma- Purchase
Products Mr. Rajesh Kaushik- HR
management

Part Name Terminals

Category Audit Area Concerning regulation Judgment


Non-confirming parts
2 management
Regarding repaired non-confirming parts and parts on hold to
2 re-use, do you define responsibility to implement? Are repair 2
record kept? 

Do you make arrangements with customers about the


1 packing style & transportation system to prevent damage 2
13. during handling of finished products & perform accordingly.
Handling 1 Bins/ Trolley Management
Management
Do you have system to maintain Bins /Trolleys in Good
2 2
Condition.

Do you have Special checks/Inspection for Maru A


1 NA
parameters of Maru A part are available .
14.
Critical parts 1 Maru A Parts Management
Management
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

Category Audit Area Concerning regulation Judgment


14.
Critical parts 1 Maru A Parts Management Do you have Identification of Maru A Process/Operator on
2 NA
Management Shop Floor.

Do you keep the repair history when repairing & using Maru A
3 NA
items

Does the supplier has all inspection instruments required as


1 2
per drawing requirements
15.
Adequate 1 Testing Facility Does the supplier has all Testing Equipments/Rigs required
testing 2
as per drawing requirements
NA
facility
Does the Supplier has trained manpower to operate these
3 2
inspection and testing instruments

1 Conduct process audit as per process control standard 2


16. Process 1 As per PCS
Audit
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FO
Vendor Attendees:
Mr.Hemant Kumar (Managing Partner)
M/s Swaran EnterprisesNew Jail Mr. Kuldeep- QA
Supplier
Road Vill. Dhumaspur,Gurgaon- Mr. Inderjeet- Production
Name 122101 Mr. Sultan Sharma- Purchase
Mr. Rajesh Kaushik- HR

Part Name Terminals

16.Category
Process Audit Area
1 As per PCS
Concerning regulation Judgment
Audit
2 Closure of all the observations 1

Achieved Score 71

Maximum Score 104

Audit Rating 68
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Found OK

A) Development timing plan has not covered reason of


delay/advancement and some activity like production
readiness and last review meeting was not planned.
B) There is some mismatching between planned and actual
date as mentioned on the time plan e.g. FMEA review was
planned and done in Feb'16 but actual it was finalized in
Apr'16.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

No evidence found that past trouble history and defect items


expected list are considered as a input to planning of new
part

Process FMEA - SOD ratings are not assigned as per AIAG


guidelines like detection rating for attribute and visual
inspection are given 3~4 which is not correct.
FMEA of Base terminal Bkt is not revised after the customer
complaint for flash problem.
Found OK
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

MR/Quality person is not aware about the initial supply


control activity however procedure is available as provided
by customer.

Procedure of Initial supply control is not followed effectively


as this activity should be started after SOP but it was
completed during APQP phase as per the APQP plan of
Base I3S.
No evidence found of Initial supply control termination by
monitoring all parameter / condition including defect rate,
capability study and effectiveness of countermeasure.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Kindly define some more abnormal (unusual) situation with


role and responsibility of each operator / supervisor such as
sudden oil/ air leakage from machine, sudden lux level drop
during inspection, tool worn out, Sudden operator
injury/fever and leaving the work area by operator during
break for tea, lunch and Dinner etc.

Found OK

No evidence found for quality check result to ensure


traceability and retroactive check in case of sudden
breakdown in mold.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Found OK

Found OK

A) Review and issue record of Control plan and Work


Instructions does not exist, documents has not revised after
the modification in switch base assay (U30)
B) Retention period of documents is not defined as per MSIL
requirements.
- Document retention time to be defined as per MSIL
requirements i.e. Product life (model obsolete at customer
end) + 11 years.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Found OK

A) Training plan is not prepared on the basis of TNI of


employee due to which many training topics like FMEA, SPC
, MSA are not reflected in the plan.
B) Trainings are not being imparted according to the plan
incase of training on 7 QC Tools which was planned in
Mar'16 but not done yet.
C) No system and evidence found of effectiveness check
after imparting the training e.g. 7QC Tools and 5'S'
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

As system is defined for skill up gradation and evaluation of


operators level wise but the same is not followed effectively
in case for skill matrix of operator and supervisor e.g.
Mr.Lalmani is working at skill level 4 but he is not able to
explain the requirements as decided for this level.

No system and evidence found for cross checking of


operator's skill periodically against a decided parameter and
by simulating defect.

Auditor Mr. Inderjeet has not been certified and trained by a


third party for the audit of ISO/TS.
All activity like NPD, Tool Maintenance etc. are not audited
during an internal audit.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

No evidence found of process audit conducting and


confirming of consistency between actual operation and
standard during process audit.

Found OK

Found OK

Abnormal situation to be displayed at shop floor and make it


in a local language also provide training to the supervisor
and operators about their role and responsibility when
abnormal situations happen.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Supplier complaint register to be made and QPCR to be


raised as per criteria defined in the procedure.

Found OK

Why-Why analysis is not being done effectively incase of


problem for soldering open as root was operator negligence
according to the report but actual cause was not considered
to prevent recurrence of issue.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Countermeasure action to be standardized to avoid future


reoccurrence of defect e.g. customer complaint for soldering
Joint open in part RH01000 but inspection standard is not
reviewed for increased inspection frequency as decided in
the CAPA sheet.
Onsite check up of countermeasure has started for
customer complaints but last customer complaint as reported
in June'16 is not included in the effectiveness monitoring
sheet.
Horizontal deployment of CAPA to be done for similar
process and product.

WIP Parts are overfilled in bins/trolley which may lead to


dent and scratch on parts e.g. wire harness
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

There is a need to focus on implementation of 2S' activity,


some examples are,
A) Inspected material is not identified by a tag also it is kept
at unidentified location e.g. 2L50M
B) FG item i.e. CL-0-300A placed at wrong location.
C) WIP Parts are kept at unidentified location at shop floor

Lux level was found less in the shop floor so kindly define a
minimum lux level for each area including inspection area.

Found OK
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Found OK

A) All check points are not available in Preventive/daily


maintenance check sheet based on breakdown analysis.
B) Preventive machine check sheet should include check
method, check criteria and check condition for all the items
so that every person can follow the same system.
C) Spare parts list with a minimum inventory level to be
defined for all mold/Tools.
D) Daily check sheet of machine is not implemented
effectively

No evidence found of functional check of fool-proofing at


designated frequency.
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Tool (cutter/drill) change and resharp frequency to be


defined for each tool and followed.

Found OK

Limit sample is not matching with actual part incase of


terminal Base RHD its visual items like colour and flash are
not matched with the limit sample.

Easy expression like visualizer/beeps/ signals/light should


provide at station for operator so that he can easily
understand process and critical points
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

A)Some important check points are not mentioned in the WI


eg. Soaking time of after Paint application.
B) Final inspection standard is not displayed at inspection
point however inspection activity is going on.
C)Operator and supervisor are not aware about the content
of daily check sheet and machine and process parameters.

Operator observance audit activity is not being carried out


for all the operators so kindly make a plan to cover all
operators and do audit at defined frequency.

Found OK
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

FIFO system needs to be reviewed for BOP items e.g. Plate


key- Its 5 lots received in June month and FIFO Sticker i.e.
white is pasted on all the lots, so it not clear which one lot
will issue first
Some BOP items are stored without tag including inspection
status, Qty, receiving date etc.

No provision of identification of similar parts with different


colour bins/tags etc.

Identification marks or tag is not available on NG parts


available at Shop floor and inspection area e.g. Terminal
CD100
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Found OK

Found OK

Found OK
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

Found OK

Found OK

Found OK
M FOLLOW UP REPORT
24th October 2017
Auditors:

Avneet Singh Kalsi

Remarks Follow Up

As per control plan that product parameter to be be checked


in twice in a shift but the same is not evident.
MANAGEMENT & FINANCIAL INFORMATION ( TIER-2 SUPPLIER)

M/s Swaran Enterprises VENDOR ATTENDEES : CEO/MD Name: Mr.Hemat Kumar


New Jail Roaad
0
Vill-Dhumaspur,
Supplier Name PO-
Mob No: 9811137231
Badshahpur,Gurgaon-
122101
Email Id: Swaran.info@gmail.com

Plant Head Name:


Mr. Inderjeet Singh
Jay-Ushin Ltd. Mobile No:
8860712347
mail id:

Company PAN No: AALFS2199D

Part Name 0 Company status : Home-grown

S
Category Topic Details Information Remarks
No.

Background & Qualification B.TECH In Mechanical Engineering

Is there a succession plan for the owners? yes

Management information Ownership (Prop/Partnership/Pvt Ltd/Public ) Patnership

Are Quality & Productivity targets available &


yes
Monitored by mgmt.?
Is there any system by which management
yes
monitors customer rating?
Does the vendor have organization Chart. Are
Organization Chart Available
following clear in the chart:
1.Reporting levels are clear yes
2.Role clarity at each level yes

1 3.Adequate quality organization structure. Does


Qualification level meets the
company has department as HR, Production,
profile requirement .
QA, Engg (development) and Maintenance

4.Persons are available as per chart, no


NO Shortage
shortage of staff
Organization Structure
5. Is responsibility for check on check available Responsibility Defined For Check
at all levels on Check Activity

People profile :
1) 55
1. No of contract employee (Worker)
2) 05
2. No of permanent employee (Worker)
3) 13
3. No of staff

Recruitment of workers (hiring system at Tier-2) Refrencess & placement servics

What is the Qualification Criteria of Operators


Operator's minumum 10th class
selection?

Does The Unit have any ISO/ TS certification?. ISO 9001:2008

Does the unit review the effectiveness of


yes
Quality system ?.

Certificate (ISO or TS) ISO 9001:2008


2 Quality Systems
Name of certification body Qualityaustria Central asia
Scale of
Organization Date of issue 2/23/2017

Expiry Date 9/14/2017


1190 lacs
2013-14 1373 lacs
2014-15 1283 lacs
3 Net Sales (Rs Lacs)
2015-16 1313 lacs
2016-17

2013-14 31 lacs
2014-15 49 lacs
4 Net Profit ( Rs Lacs)
2015-16 42 lacs
2016-17 34 lacs

List of approved Tier-3


5
suppliers list attached
6 MSME Category

Any labour issue in last 5 years No


Does Union exists ? No

Does company provide Tea/Snacks to all


Provide Tea to all employees
employees

How are general working conditions (Condition


Good
of toilet, Hot, humid , Noise level etc.)

Does worker safety norms followed Yes

By what date, payments to employees is done 7th of every month


7 Industrial Climate
Minimum wages & above as per
How is Salary & PF for contract employees is
Govt of Haryana Labour
managed (Directly or Thru contractor)
Department
How often overtime is done & what is overtime
As per basic salary
rate?

Is there a suggestion scheme in the company ? yes

Are there additional benefits to employees ?


No
( Canteen, Transport, Medical etc.)

Does company provide uniform to its


No
employees?

Investment detail (In last 2 years) 15 lacs Details of investment

Future growth /Investment plan 30 lacs Details of investment

What is the D/E ratio ?


Cash Generation (PAT+Dep-Loan)? No Loan
ROCE?

Capability What are the other businesses of the promoter? No


to invest for
Investment Capability for Have supplier taken any benefit from govt on
future 8
Future Expansion No
expansion MSME category?

Have Tier-1 supplier financed tooling,


yes
equipment, testing facilities at Tier-2?

Payment terms with customers 45 days

Payment terms with Suppliers 45 days

Price updation frequency by major customer

Types of Raw Material being used. Phenollic Powder

Capacity utilisation (% age) 100% Utilised

Working hours for workers 8hrs

Adequate Layout of company (optimum and displayed) yes (Displayed)


Manufacturi 9
ng capability Make of Machine Taiwan

Life of Machine Available Years already finished -

Machine condition Well and Running

Availability of Auxiliary Equipments yes

Summary: Based on data provided by supplier as above and shop floor visit following is the overall summary
S No Topic Judgement Remarks

Productivity and quality targets are


monitored by management (trend monthly/
1 Management Outlook Good half yearly/ yearly) -Monthly
Customer rating - Y
Organisational structure: available

Investment done in last 2 years - 15Lacs


2 Financial Capability Good Future investment plan - 30Lacs
Debt condition -No Loan

Working conditions - Good


3 Industrial Relations Good Safety: Yes
Union exists - N
Layout of plant: Optimum
Process - Injection Molding
4 Manufacturing Capability Good
Product range - Bakelite Parts
Any major testing facility available - No
Vendor Performance Score Card : Jay Ushin Data
Assessment Date 24/10/2017

Vendor Name Swaran enterprises Vendor Code Location Badhshapur

1 MSIL Line Defects 2. T1 Line Defect 3. Rejection PPM at T1


14~15 15~16 16~17 13~14 14~15 15~16 14~15 15~16 16~17
Monthly Avrg 0 0 0 -0.01 Monthly Avrg 0.00 0.00 0.00 -6% Monthly Avrg 2148 3628 0 0.333

Total 0 Total 0

Monthly Avrg
Target

NA

2148

3628
14~150.00

15~160.00
13~140.00

16~170
0

15~16
14~15
10

20

30

Row 12 Row 13 Total Monthly Avrg

Remarks :- Remarks :- Quality Imp. By (%) Remarks :-

Delivery Imp. By (%)

4. Tier-2 Vendor - Internal Rejection (PPM) 5. No of Line Stoppages at T1


14~15 15~16 16~17 14~15 15~16 16~17
Monthly Avrg 13396 10307 8858 0.287 Nos 0 0 0 80% 0.547
M/s

Monthly Avrg Nos


13396

10307

8858

14~150

15~160

16~170
15~16

16~17
14~15

a b c
Monthly Avrg Nos

Remarks :- Remarks :-
COPY TO : MARUTI VENDOR ASSESSMENT (TIER II) - COUNTERMEASURE REP
RECEIVING DATE PLANNED

M/s Swaran EnterprisesNew Jail Road Vill.


VENDOR NAME Dhumaspur,Gurgaon-122101
PLANNING

PLANNING

PLANNING
CLUSTER NAME Jay ushin Ltd

TOTAL 0

AUDIT DATE 24th October 2017


RECEIVING DATE
VERIFICATION

VERIFICATION

VERIFICATION
AUDIT PART NAME Terminal Base (YE-3)

AUDIT PART NO. 0


TOTAL 0

DEADLINE FOR DEADLINE FOR SUBMISSION OF


AUDIT POINT #VALUE!
SUBMISSION OF PLAN ACTUAL RESULT

SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
NO.

F003-4 QA/MT Ver. 4


SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
NO.

F003-4 QA/MT Ver. 4


SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
NO.

F003-4 QA/MT Ver. 4


SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
NO.

F003-4 QA/MT Ver. 4


SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
NO.

F003-4 QA/MT Ver. 4


TI VENDOR ASSESSMENT (TIER II) - COUNTERMEASURE REPORT
CHECKED APPROVED

RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4


RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4


RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4


RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4


RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4