VENDOR UPGRADATION MEET

WELCOME FOR QUALITY

UPGRADATION MEET

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 VENDOR UPGRADATION MEET

Purpose of Vendor Up gradation

 Better understanding Customer specific requirements.

 Positive approach towards enhancing Quality management

system.

 Surviving in Competitive market for better quality &

Competitive Cost.

LOYAL SUPPLIER- CUSTOMER RELATIONSHIP.

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 VENDOR UPGRADATION MEET

Impacts of Vendor audit system rating

 Assessment audit score impact over all Vendor rating calculated
by Supply chain

 Good vendors got more opportunities in Increasing in share &

new business.

 Vendors can be given recognition for Best Vendor performance

award.

 Reduction in Vendor rating may impact the Current share & new
Business. Even may lead to exclusion based on performance.

 Re- audit will be done on chargable bases by MACE

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 VENDOR UPGRADATION MEET

Customer Voice

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 VENDOR UPGRADATION MEET

Voice of Customer
 MSIL Vendors to achieve minimum 70% of the score in
system audit rating.

 Vendors to meet QCDD requirements as per the Customer

requirement.

 Focus on processes, NPD & component revalidation..

 More Emphases on (Quality is produced not inspected)

Vendor should comply the requirement of Customer complaints,

Defects (QPCR), PPMS , On time delivery & Warranty returns as
per the Customer needs & requirement
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 VENDOR UPGRADATION MEET

Salient features of Vendor system audit.

 The new vendor audit system is Benchmarked with Suzuki &

our Auditors are trained by Suzuki Audit Experts.

 Suzuki started the new system in 2003 MARUTI started the

same audit through MACE in 2004.

 System audit check sheet contains Total 22 main items &

115 Sub items.

 Total Marks – 209 & There is no partial marking allowed.

(Marks can be given either full or zero)

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 VENDOR UPGRADATION MEET

Continued.

 Each item has either got 1 marks or 3 marks

( 3 for more important)

 Total 4 man days are involved in System Audit.

 Requirement check sheet sent in advance Two weeks before

for Self assessment

 MSIL Target to score minimum 70% for each supplier as most

of our suppliers are certified to ISO/TS 16949.

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 VENDOR UPGRADATION MEET

DETAILED DESCRIPTION OF CLAUSES.

Clause :- 01 Production Preparation (New parts, design change
parts, new technology parts, factory transfer etc.)
 Procedure: Production preparation addressing new part, change part
development from receipt inspection to mass production stage.
APQP activities matrix to used to prepare development plan. Review
& main activity to be identified and monitored through Micro level
Timing chart
List of problems with countermeasures in PDCA format. Effectiveness
of C/M to be checked.
Guide line for FMEA. Cut off for RPN, occurrence and detection.
Review frequency and event.
Specs. meeting requirements to be added in development plan.

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 Prod. Preparation VENDOR UPGRADATION MEET

SOP of customer
from customer

Mass Prodn
Design Trial
Order receipt

Prodn Trial

Process Change
ECN Receipt
Trial

SOP of ECN

SOP of Process
Initiation

Change
APQP (1) (1)
Prodn. Preparation Phase (1)
Change Points

1) Process Parameter Change ( e.g feed/ angle/ press./ temp etc)

2) Tool/ Die/ Machine/ Equipment change 4)Relocated Plant

Process Change 3) Layout change 5) Supplier Change

6) Operator Change

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Clause No.02- Initial Supply control. (Special control until the quality
is stabilized after the start of mass prod's)
 Initial supplies after sample approval ( up to 03 Month’s for
New Parts / lots /quantities)

 Additional (control) checking and preventive actions. (Follow up of Pre

launch Control plan/PCS during Initial supply Control)

 Objective : To overcome teething problems (to stream line supplies in

terms of quality and quantity)

 Display of process and sub vendors Initial supply control Tags

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 Initial Supply Control VENDOR UPGRADATION MEET

Design Trial

ECN Receipt
Prodn Trial

SOP of Process
SOP of ECN
Mass Prodn
receipt from

customer
SOP of

Initiation
Change
Process

Change
customer

Trial
Order

(1) (1)

APQP I/C (2) I/C (2) I/C (2)

Prodn. Preparation Phase (1)

Few e.g. of extra controls during I/C -

SOP Increased inspection items
Period of I/C Increased frequency
(Usually 3 months) A combination of above two
No. of Defects

Frequent Process capability (Cpk)

Ist Extra Controls evaluations
Supplier Audits
2nd Reaffirmation of operator skills
3rd Added roles & responsibilities of
managers & supervisors
Reduced cycles times for problem solving
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 Initial Supply Control VENDOR UPGRADATION MEET

TERMINATION CONDITIONS

1) Cpk > 1.67

2) All problems occurring before SOP are resolved

& a recheck done to confirm that they remain solved

3) Any new problem arising in I/C is also resolved

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Clause No.03- Initial product control. Control of new parts, design

change parts, Process change parts, trial parts.
 Definition of Initial product.

Identification of I/P

 Inspection of I/P and retention

 Tolerance standard for non given tol.

 NC dealing procedure for I/P.

 Check sheet to ensure availability of inspection report, FPP card

etc.
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 Initial Product Control VENDOR UPGRADATION MEET

SOP of customer

Process Change
ECN Receipt
from customer

SOP of ECN

SOP of Process
Mass Prodn
Design Trial
Order receipt

Prodn Trial

Initiation

Change
Trial
(3) (3) (3)

(3) (3) (1) (1)

I/C (2) I/C (2) I/C (2)

APQP

Prodn. Preparation Phase (1)

Initial Products

Defn of Initial Product (I/P):- The first piece/ part or lot or samples
from the first lot produced during prodn trial, mass prodn trial,
after SOP of a new part or a change point.
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Clause No.04- Corrective & Preventive measure of defects.

 Organization shall establish , the procedure of Handling of Customer

complaints &In-house rejects addresses the communication of same to the
operator immediately.
 How the Serious problems & Customer complaints informed to the Top
Management.
 Organization shall establish, maintain & Implement procedure for
handling of the problem analysis & countermeasure reported during
Customer Claims, In-house defects & Supplier defects.
 Effectiveness of counter measure is being monitored & relevant docs
revise as per the counter action raised.

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Clause No.04- Corrective & Preventive measure of defects.

 Horizontal deployment of the same action on similar process & is

documented into the Countermeasure reports.
 Organization shall establish & display of actual quality results & how
they are reducing the Defects.
 The Organization has maintained control register of Customer
complaints , In-house Defect & supplier defects & effectiveness of the
counter measure monitored
 Organization shall calculate Cost of poor quality ( Company wise as well
as Department wise).

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 VENDOR UPGRADATION MEET

Clause No.05- Training & Education

 Consider all level of people in organization (including the contractual

workers,etc.) in training plan and monitor.

 Training Plan vs. Actual ( Staff & Manager Level)

 Link in Skill Matrix & training plan

 Orientation / on the job training

 Maintain training history ( Individual)

 Training records (attendance, F/back)

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Clause No.06- Quality Audit

 Top management carry out the audit according to the procedure

 Perform the Internal audit based on the annual audit plan

 Quality policy and deploy it company wide

 Decide the yearly quality target of company and each department and
follow up the actual results numerically (money loss for defect ,number of
cases and defect rate etc.)

 Documented evidence of Internal quality audit ( NCR Report, Audit

Audit Report, Audit Schedule )

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 VENDOR UPGRADATION MEET

Clause No.07- Supplier Control

 Documented Procedures to instruct and educate the sub vendors
 Record the number of defect cases and contents etc. for every sub vendor.
 Compile the defect information Sub vendor-wise and perform the audit &
training for the worst ranking sub vendors
 Supplier audit check sheet decided for Supplier audit
 when A parts, and functional parts/ processes are out source/ sub-vendor
changed, do you inform Maruti
 Supplier Evaluation based on the selection standard?
 Prepare and exchange the inspection standard with your sub-vendor ?.
 Incase of the sub vendors with chronic defects and where no
improvement has been observed despite repeated instructions, do you take
action to reduce the supplies to achieve desired quality of parts

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 VENDOR UPGRADATION MEET

Clause No.08- Control of Drawing & Stds.

 Controlling section for control of drawings/ engineering changes clearly
defined in the procedure

 Are the new, revised and old drawings clarified through a control register
and do you control the latest one

 Control the revision of related standards based on the changes to

drawings

 Collection of the old drawing copies or ensure that the old drawing copies
is destroyed

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 VENDOR UPGRADATION MEET

Clause No.09 &10 -Control of Inspection standard & Process control standard & Operation Std.

Documented procedure for the the creations of Inspection std & authority of approval
defined
check the records of any change in the process resulting in change of relevant procedure
(Evidence related to customer complaints, ECN Change & Process change).
Are their any boundary samples / Limit samples displayed on station for visual
identification
Supplier has approved MIS-P (For MARU'A' Parts)

Control register for (Inspection standard & PCS) with revision number & date along with
reason of change.
Establish Linkages between the PCS, Inspection standards with the relevants documents.

Retention period of the old documents as per Maruti Guidence Manual.

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 VENDOR UPGRADATION MEET
Observance (Implementation) of Operation Standards

ROUTE MAP OF QUALITY :

Maintenance ???

Machine Man/ Operator

Health of Operator
Jig Morale of Operator
Fixtures Skill of Operator
Tool

Quality of the Prod.

Incoming /
Receipt Insp.
Insp. Stds,
Material Method/ Process Control Plans

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 VENDOR UPGRADATION MEET

Clause No.11- Observance ( Implementation) of operation standard

 Is the operation carried out as per the standard Audit of operator by

supervisor as per plan using check sheet

 Is there any check on the operations/ activities carried out by the

operator/ way of working etc. by the supervisor .

 Is the quality check for the observance of operation standard carried

out as decided and recorded.

( Similar activities has been carried out by MSIL named as MOS-K)

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Clause No.12- Role of manager, supervisor

 Roles & responsibilities of each manager & supervisor defined in

normal & abnormal situation.

 Responsibilities & Authority of each Supervisor & manager

to be defined for production preparation, Initial supply
control & Initial product control.

 DWM shall be carried out for each individual

( Level from Supervisor & Manager)

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 Role of manager, supervisor VENDOR UPGRADATION MEET

A few of the daily responsibilities of the supervisor :

Holding morning meetings
 Red Bin Analysis.
Operator Change/ New Operator- Training
Carrying out quality inspections of the product / process on a
sampling basis
Ensuring Operator is checking all the parameters
While starting the work, check if the operator is checking
machines, tools, poka yoke etc.
Are there unwanted / suspect products lying on the ground
 Daily Plan vs. Actual Roles during New Dev.
/ I/C

* Participation in new comp. Briefings & making Plans

* Participation in evaluation meetings/ trials/ chekkai
* Making plans for Mass Prodn.
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 VENDOR UPGRADATION MEET

Clause No.13- Quality improvement of process

 System to develop the Projects for Process Improvement & Defect
free parts e.g. Vendor CFT conduct the audit & check the imperfect
setting, wrong parts, inverse assembly & missing parts can be
discovered.

 Documented evidence of Projects initiated by CFT with Roadmap

of improvement of Process imprecision.

 Is there any scope of pokayoke / lay out change / material handling

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Clause No.14- Control of manufacturing machine, jig & die

Supplier has a system in place to ensure that the Inspection item, frequency & criteria of
each equipment defined & do the supplier perform daily & periodical inspection of
Machine, Jig & Die.
Is the life of the cutting /regrinding tools , redressing tools & electrode dressing tools
defined, check the record of the same.
Documented procedure to check & correct the jig/tools/equipments in case of any
defective part is produced during production stage.
Preventive & prediction maintenance checksheet of machine & equipment, check the
records of repair history of the same.
Is the results & history of the machine & equipment recorded in the history sheet.

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 VENDOR UPGRADATION MEET

Clause No.15- Control of inspection equipment, jig, gauge

Recording of daily & periodical inspection of instruments with frequency , method &
criteria of inspection.

Daily Instrument & equipment results are recorded in the checksheet.

Documented procedure to check & correct the jig/tools/equipments in case of any
defective part is produced during production stage.
Measuring equipment history sheet & records of repair in the same sheet if applicable.

Check all the equipment used during intial development are used at the time of Mass
production ( Check the Intial inspection standards,Operation std & verify as per the
current situation)
Documented procedure mentioning the responsible person of handling & control of
measuring equipment.
Calibartion stickers are displayed on each instruments mentioning due date of calibartion

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 VENDOR UPGRADATION MEET

FOCUS AREA
 These are the AFI’S (Area for Improvements) to improve in the
weak areas to achieve minimum requirement of 70% of Customer.

 We have not received the Countermeasure action plan re-audit from

most of the supplier’s, where a audit has been carried out.
( Only 05/ 21 Nos. of Suppliers submitted their Counter measure
action plan which are present here)

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Clause no.16- Statistical method

 Organization shall establish SPC manual and application of SPC.

 Use SPC at the time of problem solving

 Decide inspection plan based on the Cp / Cpk (Review all the

sampling plan

 Review control limit as per SPC study

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Clause No.17- Prevention of missing process, wrong assembly.

 Mix up possibilities (RM/WIP/FG) identification

Temporary storage (Identification, Work instruction)

 Fool proofing installation as per FMEA

 Functional checking of Fool proofing

 Horizontal deployment of Fool proofing

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 VENDOR UPGRADATION MEET

Clause No. 18- Control of non conforming product

Check whether the Non conforming & ok product are identified with tags.

Check whether the reason of Non conformance defined on the Non conforming parts.
Is their documenetd procedure for the disposal of non conforming parts with the resposnibility
of approving & disposal of Non conforming products.
Check any evidence of non conforming product found during production are traced back to
WIP Product, Finished goods & at customer end. Is there is any documented history made
avaialble

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Clause No. 19-Storage of product

Check whether handling of finished goods, WIP & BOP Parts protected from rain & prevents
from Rust, dust & moisture.
Any pacakaging standards defined along with customer & performed accordingly ( Check any
packaging standards with pacakaging conditon & transportation).
Checck the condition of packaging, should be free from any contamination

Check is there is any chances of damage of packaging material during transportation.

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Clause No. 20- FIFO

 FIFO to be practice for Raw material storage, WIP & Finished
parts.

 Identification tags comprising of Part Name, Number, qty,

Manufacturing date etc. specified on Material.

 Old stocks (Expired) at location

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Clause No. 21- History Management (MARU “A” parts)

 Establish & maintain a batch codification system for product

traceability & display of daily Batch code near the process station

 Establish a system to trace & search the manufacturing date,

manufactured parts quantity during field failures.

 Maintain Repair history records of reworked items for future

Reference.

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Clause No. 22- Implementation of inspection

Check the records of inprocess inspection & Final inspection as per the Standards available.

Check the acceptance criteria of BOP Parts & recording of the same as per the Inspection
criteria.
Check whether the Inspection items, frequency , method of inspection aligned as per the MIS-P
& relevant stanadards.

Check all the Mis-p requirement are covered in the PCS.

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 VENDOR UPGRADATION MEET

THANKS

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