SUPPLIER QUALITY SYSTEM SURVEY SCORING SHEET

Survey Date : Customer :

SN A Area of Evaluation MANAGEMENT RESPONSIBILITIES 6 There is no Quality Policy Evident Quality policy is documeted. The quality policy is defined , documented but objectives are not quantified. Quality Policy is defined, evenly distributed and objective being monitored on monthly basis. Quality policy is committed to Total Quality management , deployed and integrated by each function/process and percolated to all employees & it is linked with customer satisfaction 2 Quality Improvement Planning (Business Plans) There is no Quality Improvement Plans. 0 There are only generic objectives defined for improving Quality. 40 The quality improvement planning is mostly directed towards 60 production. The plans cover at least these activities (Production,Quality,Design, 80 Materials) Existence of plans: All depts. Involved & their progresses reviewing on 100 monthly basis. Improvements evident 3 Employee Involvement No People involvement in Quality in Quality (TQC) people involvement are based on personal rapport rather than being formalized. There are organized methods to involve personnel in Quality Improvement There is a system, but it is applied only to few of the tools listed below. There is a written and effectively implemented system to involve personnel at all company levels in Quality Improvement.eg: Quality Circles, Employee Involvement teams, cross functional teams, Process Improvement teams. Training Training program and activity does not exist. Training needs are identified informally, Training calendar is made Training needs are identified for all key functions systematically in line with Quality objectives for technical traits Training needs are identified for all key functions in line with Quality Training needs are identified for all key functions in line with Quality Objectives for technical and behavioral traits. In addition to the above ,the effectiveness is monitored and improvements achieved as a result of training. Orgnanisation structure and Systems Role & Authority of the Quality Control Organisation Diagram is not evident / quality person is 5 not deputed. Quality Function Quality Control Organisation Diagram available. Quality Control Organisation Diagram available but partially adhered 0 40 60 80 6 60 0 360 There are regular review meeting to improve the quality for internal as well as customer specific. 7 80 0 560 0 40 60 80 100 The plan covers Production, Quality & Materials with maintenance. Design is not under scope. 80 0 480 Quality policy is available & displayed as are waiting for final audit of TS-16949. There is also monthly monitoring for all the defined parameters of the objective. Key Check points (Guidelines to be referred)

Supplier:

Auditor Auditee :
Weightage Self Assessment Actual of Score Suppliers Weightage x Actual Score Weightage x Actual Score ( For Self Assessment)

Reason for Audit :

Observations/ Remarks

Quality Policies 1 Quality Policy

100 0 40 60 7 80 0 560 Training need are identified & training are given to people.

80 100

0 40 60

80

560

Responsibilities & work area are defined. Though are not being regularly followed for its effectiveness.

Responsibilities & Authorities are documented but not effectively followed. Responsibilities & Authorities are documented & effectively followed as per Quality Control Organisation Diagram. 6 Quality System No formal systems available. ISO9001 certified . ISO9001, preparing for TS16949 certification. TS 16949 certified TS 16949 & ISO 14001 certified . Management Monitoring No System exist . Analysis and Use of Data, of Non Conforming Product and Subsequent Corrective Actions Quality Data available but no system of Failure/root cause analysis. Quality data is available but not systematically analysed and monitored. There is systematic method to gather, analyze quality data.

80 100 0 40 60 80 100 7 60 0 420 TS-16949 final certification audit is on Mar,11. Application for audit is already sent to the authority.

80

640

There are systematic method to gather the data & we conduct regular review meeting to improve the quality of internal & customer end casting rejection.

40 60

80 In Addition to above effectiveness monitored and horizontly deployed. 100 Total Score Management Responsibility MANUFACTURING CAPABILITIES Tooling Management Semi tooled up process carried out in some cases. Validation of Jigs (Periodical Inspection / & Fixtures by verifying the components. No Drawings for Jigs, Fixture & Toolings. Servicing of Jigs & Fixtures and Punches & Dies, Welding Fixture) Only corrective actions are taken whenever problem is encountered, no presence of planned activity.Jig/ Fixture / Tooling Drawings are available First piece and last piece reports are made, acted up on before start of production. Supplier has system to put such tooling in prod after proper inspection, have defined frequency to maintain toolings. Jig/Fixtures/ Tooling are periodically verified. System to verify the maintenance work carried out on such tool and issued to production only after inspection. There is no PPAP related activities exist. PPAP Sign Off The PPAP is initiated but not executed fully in an appropriate manner. The PPAP activities were performed in appropriate manner but not covered all critical parts. All the above activities are performed, reviewed in regular intervals and executed in appropriate manner for all critical parts. Action plan in place where ever Ppk is less than 1.67. The supplier performs and manages systematically all the PPAP activities successfully as agreed with the customer. The Ppk results are more than 1.67 for all the critical parameters agreed in AQP.No major quality issues during regular shipments after PPAP.

48

3580

New Parts Development Tool inspection checksheets are available & also the tool modification & rectification data available with Tool history card. Mould & core making tools are only issued only after inspection.

100

600

40 60 80 100 0 40 60 80 7 60 0 420 PPAP documents for the parts which are developed in recent days with customers like RICO auto, EATON, JCB & Eicher are avialble for review.

100

Sub Supplier Controls (Critical RM,HT,ST,Finish opn).

10

Sub Supplier Approval Sub-supply conformance to specifications is limited to quantity & identification checks. No Approval System.Only drawings are provided System ,Technical documentation & parts 0 and process qualification Drawings & Quality Plans are provided. Mock approval given. PDI 40 received from Sub Supplier. In addition to above, process & product qualification is carried out 60 against customer complaint only. In addition to above ,complete technical documentation is available. Process & product Qualification is carried out. Corrective actions are taken against receipt rejection. planned activity is available for supplier approval. Process & product qualification is carried out effectively.Control of non-conformities, corrective action plans are effective 80

80

480

Process & product related datas are captured from all the processes. Also corrective action are taken for the receipt rejection.

100

Process Controls 11 Machine & Plant Layout No plant layout & string diagram prepared. 0 Plant layout prepared in rough sketch 40 Plant layout not prepared area wise. 60 Plant layout prepared but string diagram not addressed. 80 Plant layout prepared and material flow effectively addressed. 100 No SPC techniques used Machine , Tooling & 0 Process capability Critical parameters/ Special charactristics are identified 40 Process capability study plan made and covers all identified 60 parameters. Trends are maintained and monitored for all identified parameters. 80 Good evidence of ongoing Process control & SPC study, Records are 100 maintained along with the improvement plan. No awareness of FMEA/FMEA not available. Process FMEA 0 Aware about FMEA & some FMEA's are made. FMEA made for all the process but not reveiwed. FMEA made for all the process but also reveiwed periodically. Evidences available for updated/ modified FMEA based on inhouse/customer feedback. Technical Documents 14 Control Plans No awareness of CP/CP not available. Aware about CP & Available but not updated. Control plans available. But no process qualification is carried out. Control plans available. But process qualification is carried out with not calibrated instrument, Parts characteristics are identified & inspecion method adequate. CP available .Process followed,records available,process qualified with callibrated instrument & with adequate operator skill. 15 Process Sheets No process standards available Process standards available but inadequate Process standards made but not displayed on work station. Process parameters & part Characteristics not addressed in process stds. Process standards are effectively followed and recorded. No vendor identification over Product. 0 Inadequate system is available for identification. A potentially effective method is availablebut lot traceability not available. The supplier has method for identification & lot traceability 40 60 80 0 40 60 80 100 0 40 60 80 100 6 80 0 480 We have adequate system for the part & tooling identification & traceability. 8 80 0 640 Process parameters are addressed in process standards. 8 80 0 640 Control plans available. All parts inspection are cariied out with the help of calibrated equipment. 40 60 80 100 7 80 0 560 Plant layout available but string diagram not addressed.

12

80

720

Trend analysis are done for all major parameters for analysis & continious improvement.

13

80

640

FMEA made for all process parameters but not reviewed periodically.

Product Identification 16 Product Identification and lot traceability method

The supplier has secured quarantine areas and has a formal method for timely resolution of quarantined product.Identification & lot Traceability is Effective Documentation 17 Document Control No written document control procedure exists. System exist, but is incomplete and inadequate. System ensures revision levels on all documents, forms,tags & Obsolete documents are segregated. As per rating 3, plus sysem ensures that latest revision of documents are provided to all areas requiring them. As per rating 4, plus system ensures review of document by authorised personnel prior to distribution of initial or changed documents. Preventive Maintenance 18 Preventive Maintenance No system for Preventive maintenance PM plan available for all machines. PM Checklist made for all machines/ equipments PM is carried out as per the plan and records are maintained. Status for PM of each machine is identified and effectively followed. Critical spare stock maintained. Inspection Controls No system for First off / Last off inspection and approval is not given. 19 Set up approval Such approval is given occasionally Set up approval /Sample size/Frequency / Process Parameters defined Approval is given for few out of identified critical dimensions / processes & for process characteristic set ups (pressure, temp, viscosity etc) First off/Last off approval given for all set ups, process parameter changes, tool changes followed as per define frequency and records are maintained. No receiving standards are available Dimensional Receiving Inspection standards are established but RM/metallurgical inspection standards are not established. Dimensional/RM/Metallurgical Receiving standards are established and distributed to concern suppliers Dimensional standards are followed but metallurgical not followed System is effective . No inprocess inspection followed Work instruction/SOP/Checksheet not avaibale. Work instruction/SOP/Checksheet avaibale but inadequate. Process parameters not addressed. Process parameters verified and recorded as per the frequency. Inprocess inspection effectively followed as per the work instruction / SOP. No PDI Inspection Evident PDI Inspection Check Sheet Available but not following PDI Inspection following as per Check Sheet Critical Parametrs addressed in PDI Check Sheet and PDI Inspection Report review periodically Effective System of PDI Inspection and PDI Check sheet updating based on Customer Complaint. Inspection Gauges & Instruments

100

0 40 60 80 100

60

360

System ensures revision levels in all the documents.

0 40 60 80 100

80

560

PM are carried out as per plan & data are maintained for all the major equipments.

0 40 60 80

60

420

Set up approval not there except machine shop. Mould & cores are visually inspected for good quality before going for mass production. Process parameters are given for all the processes.

100 0 40 60 80 100 0 40 60 80 100 0 40 60 80 100 10 60 0 600 PDI inspection done & followed for all the critical parts. 10 80 0 800 Process parameters are verified & recorded for all the processes as per frequency. 7 60 0 420 Dimensional, RM & metallurgical standards are available for the acceptance quality & are distributed to the suppliers.

20

In coming inspection

21

In process inspection

22

Outgoing inspection (PDI)

23

Master samples, reference samples to narrow down subjectivity

Subjectivity parameters are not identified. 0 Subjectivity parameters are identified but not defined. 40 Subjectivity parameters are defined but measured by experience. 60 All subjectivity parameters are measured as per the customer requirement by referring mutually agreed (with the customer) master / 80 reference sample. There is continuous improvement in the above parameters and master/reference samples are replaced periodically as the increased 100 demand by the customer. 4 40 0 160 Master samples are available for all the regular parts.

24

Gauge & Test Equipment calibration

No calibration schedules exist. Calibration schedules include all measuring inst/gauges.

10

40

400

Calibration schedule available & it includes all the measuring instruments & gauges.

40 Calibration frequency defined for all instruments / gauges and plan for 60 its implementation. Calibration schedules include all measuring inst/gauges. GR&R 80 studies done for inst for critical dimensions for PPAP lot only. Carries out all MSA activities for all critical instruments of . Actions are 100 evident on improving GR&R results. Non Conformance Handling 25 Handling of NonConforming products There are no procedures, written or otherwise, to handle nonconforming products. Handling of non-conforming products is done only through the identification of these products and execution of rework and /or scrap. Handling of non-conforming products is done only through the identification of these products, properly quarantined and execution of rework and /or scrap. Handling of non-conforming products is done only through the identification of these products, properly quarantined and timely execution of rework and /or scrap.Partial documented. proper Identification system, correction of non-conformities, deviation system, timely disposition, proper documentation Deviations 26 Deviations (Internal & External) No system for requesting Deviation 0 Some activities are covered in non-formalized way. There is a structured system to follow to request a deviation due to product/process variance and/ or changes but no Verifications of compliance to deviation timing and/or quantities and return to original specifications. In addition to above,verification to compliances is also done. 40 60 5 60 0 300 There are proper deviation request note & material under deviation are only processed after completion of getting deviation from the concerned authority. 0 40 60 7 80 0 560 Handling of NC parts are done through a proper system & are recorded.

80 100

80 All Formal procedure for requesting customer's approval of deviations 100 followed. Production Planning and control 27 No storage systems are available for Raw material / WIP items/ Finish Material Handling, Transport & packaging products/Tools / Dies. (FIFO) Few pallets & Trolleys are available for raw material / WIP items / Finish products/Tools / Dies. Still material is lying on shop floor. Care is taken to avoid metal to metal contact or other media generating the dents & damages . Material is stored in Bins/ Pallets / trolleys/Stillages and handled in pallets / Trolleys / Bins etc. Racks are provided for storing Jig/Fixtures/Dies/Tools etc with identification. Procedures for packaging instruction, material handling equipment, storage,delivery 0 40 60 80 100 7 80 0 560 Racks are provided for storage of Jig. Fixture & pattern & core box tooling. For casting , sand & cores there are bins & trollies available.

C 28

Total Score Manufacturing Capability TMTL's Specific Requirements Quality Performance, Customer complaints are not attended within 10 days Customer end 0 rejections (PPM level) Action taken within a week and partially effective. 40 Action taken within 10 days and no recurrence. 60 Action taken within week and no recurrence. Action taken within 48 hours and no recurrence 80 100 0 40 60 80

145

1420

10320 Customer complaints are replied with following the standard format supplied by customer. Action taken are reviewed for non-occurrence in future.

80

640

29

5 S Activities

5 S activities are not evident and no awareness. 5 S awareness among workers are evident thro training classes. 5 S activities are evident partially. Score board displayed. 5 S activities are implemented systematically in all areas. Audit are conducted and scored above 70. But audit findings not implemented effectively. 5 S activities are implemented effectively and systematically. Audits are conducted regularly and scored above 85 consistently. Audit findings are well implemented No activities towards environment conservation.

40

200

5S training are given & are practised in floor.

100 We are having proper system for the air pollution control. For this we already have installed the Sand plant dust extraction system , Shot blasting area dust extraction system & fume extraction system in melting. We also have the rain water harvesting system in the plant.

30

ISO 14001 Consent Order No Valid consent order available. Immediate correction done for the nonconformance like oil spillage, coolant leakage, air leakage. Basic AwarenessTraining provided to employees regarding Environment Conservation Valid PCB consent order available for Water, Air, Haz. pollution. Data Capturing & Corrective actions for the Non-Conformance like Oil spillage,coolant leakge,Gas leakage,air leakage,Fumes,Noise, inadequate exhaust,inadequate lighting,Chemical spillage are available. Valid PCB consent order available for Water, Air, Haz. pollution. Characterestics creating impact on environment are identified and being monitored. Action plan available for significant characterestics. Procedure for waste disposal (solid, liquid and gas) available and verified through audits. Corrective action available for the Non-conformance. Training provided to employees regarding Waste disposal, Impact created to the environment by the activities performed by the organisation. ISO 14001 Certificate available. Environment policy available and deployed at all levels. EMS Objectives present in organisation business plan. Environment Management Program Availability of EMS procedure and legal equirements.organization defined the roles, responsibilities, and authorities of its employees with respect to the environmental management system .Objectives monitoring against set target. Reviewed in MRM. Total Score Manufacturing Capability SCORING SUMMARY Management Responsibilities - A Manufacturing Capabilities + TMTL Sp. Requirements - B + C

60

240

40

60

80

100

17

180

1080

48 162 1420 0

0 0

0.00 0.00

Over All Score with out design (A+B+C) For Self Assessment

210

1420

0.00

Management Responsibilities - A Manufacturing Capabilities - B + C

48 162 1420

3580 10320

Over All Score with out design (A+B+C)

210

1420

13900.00

Percentage

66.19%