SQ Rev 18 03 2015
SQ Rev 18 03 2015
SQ Rev 18 03 2015
1
SQAM
CONTENTS
Page no
2
SQAM
4. ANNEXURES
5.1 Abbreviations 69
5.2 List of Formats 71
3
SQAM
1.1 OBJECTIVE
TVS Motor Company Ltd (TVSM) and suppliers together share their experience /
learning for mutual benefit, and as a team, commit to achieve world class quality to
satisfy the end customer’s expectations by -
4
SQAM
Purpose:
TVSM Responsibilities:
To provide one hard copy of this manual to each supplier and also the soft
copy of formats in the TVSM website.
To maintain the revision and distribution control system of this manual and
also obtain acknowledgement from suppliers.
To provide drawings through SAP ‘C’ folder for both New products and current
products.
To communicate and ensure availability of information on the changes made
as and when required and the revision status to our suppliers through the
TVSM website.
To train the suppliers in the application of SQAM as required
5
SQAM
Supplier Responsibilities:
Supplier shall follow all the formats provided in this manual. Suppliers may use their
own format for Control Plan, provided it meets the SQAM requirements and is
approved by TVSM Quality.
In this manual,
The word “shall” refers to mandatory requirements that each supplier has to
comply with.
6
SQAM
The word “supplier” refers to suppliers who supply directly to TVSM and Tier
2 refers to suppliers to TVSM suppliers.
The word “product” refers to assembly / sub assembly / part.
7
SQAM
Objective:
Scope:
Details:
Supplier Responsibilities:
The supplier shall provide details of CRs, contact number, email ID and other details
to TVSM Purchase / Quality in format (QSF PUR SQAM 001)
The supplier shall nominate one person for quality related issues for regular product
and another person for all new product related issues. The nominated representative
may preferably be the Quality Manager.
8
SQAM
NPD representative:
This person is responsible for coordinating NPD activities such as drawing study &
manufacturing feasibility feedback, APQP, product & process verification & validation,
AOI and PPAP.
General:
The supplier shall submit an organisation chart including the roles and responsibilities
of each function and number of persons (Manager, Executives, and Inspectors) along
with the contact information.
If supplier parts are manufactured at multiple locations / plants, supplier shall provide
a separate set of completed forms to TVSM for each location / plant.
The supplier shall notify TVSM of any changes in their contact information as and
when they are made. Revised forms shall be sent within 7 days of such changes.
9
SQAM
The figure given below provides the general outline of NPD activities
Early Involvement – Phase 1
NPD Phases
Note: Part development to be ready by one phase ahead of TVSM indicative mile stone
10
SQAM
Objectives:
TVSM Responsibilities:
Send L1 drawings, Target cost, Request for quotation (RFQ) & System
requirement specification (SRS) along with detailed TVSM requirements (
Quality, Cost, Delivery, Indicative Timing Plan )
Upload Part / Fixture / Gauge Drawing in SAP C Folder.
Provide clarity to the supplier team on the TVSM requirements as required.
Review Manufacturing Feasibility, AOI, APQP timing plan, Risk Analysis
including design feedback and resolve issues / constraints.
Conduct early supplier involvement.
11
SQAM
Supplier Responsibilities:
Supplier shall
Receive L1 drawing, Target cost, RFQ & SRS along with TVSM
requirements ( Quality, Cost, Delivery, Indicative Timing Plan )
Form APQP team and study RFQ & TVSM requirements
Visit and interact with TVSM development team to clarify / understand the
details
Prepare Manufacturing Feasibility and Risk Analysis format QSF PUR
SQAM 002,003 and drawing feedback & agreement form QSF PRG 02 01
018 and feedback / suggestions for QCD improvements
Prepare draft AOI document
Prepare APQP timing plan
Prepare detailed cost break up of the quotation
Review Manufacturing Feasibility, Risk Analysis, AOI and APQP timing
plan with TVSM development team.
Supplier shall ensure intellectual property (IP) and patent requirements. for
his design (No violation shall be allowed for IP and patent requirements).
Alpha – Phase 2
Objectives:
To release Purchase order (PO) / Letter of indent (LOI) to start the part
development
To design and develop part and / or process
To develop the required tools, Gauges, Fixtures.
To verify that the product & process design meets the requirements by
producing the part with tool i.e. Tooled up condition. (Product design is
applicable for suppliers who are design responsible i.e. for the products of
proprietary nature)
12
SQAM
TVSM Responsibilities:
Supplier Responsibilities:
Supplier Shall
Receive PO / LOI for development of the part based on L2 drg.
Obtain sign off for Manufacturing Feasibility, Draft AOI, APQP timing plan,
Target cost and Risk Analysis & Mitigation Plans
13
SQAM
Prepare Product and Process Design Inputs Sheets based on the TVSM
requirements (RFQ and SRS) and sign-off documents (Mfg feasibility, Risk
analysis, AOI and APQP timing plan).
Carryout Product design (Applicable for proprietary suppliers and shall use
design tools & techniques such as QFD, DFM, DFA, DFS, DFMEA, FEA,
Design Analysis, CP and others as appropriate. Involve TVSM in DFMEA and
Technical design reviews).
Supplier shall verify COP applicable parts (Refer annexure...) and ensure the
availability of type approval certificate (TAC) or conformity of production (COP
certificate) – Applicable for proprietary parts
Supplier shall ensure the following Markings in the COP parts as per AIS 037
except metallic fuel tank.
Trade Mark / Manufacturer's Emblem
Identification code assigned for the part by the Manufacturer
Reference of the Type approval TAC No. / E Mark / ISI Mark / DOT Mark
In addition Markings as mandated by the part standard
Carryout Process design (Applicable for proprietary as well as non-proprietary
suppliers and shall use design tools & techniques such as PFD, PFMEA, CP,
Inspection standard (Product & child parts) and others as appropriate)
Submit proprietary part drawing along with the request in the specified format
for approval. Organise review of design with TVSM development team and
obtain approval.
Develop and manufacture checking fixtures, test facilities, in-process and final
acceptance gauges at supplier end and their suppliers (Tier2, etc) . (Ref
chapter no 3.2). Suppliers shall use TVSM gauge design for critical parts as
applicable.
Discuss and get approval from TVSM on Process Design, Fixture Design and
Gauge Design for critical parts to get mutual benefit.
Discuss with TVSM on investments for Fixture, Gauge etc., to avoid delay in
lead time.
Develop mutually acceptable performance test standards and equipments
(Refer AOI).
14
SQAM
Produce Alpha Samples with prototype control Plan and verify the parts as per
TVSM requirements.
Submit Alpha Samples along with agreed documents (including progressive
PPAP documents)
Obtain feedback on Alpha Samples from TVSM development team
Provide APQP progress updates on a continual basis.
Beta – Phase 3
Objectives:
To resolve problems identified during Alpha trials
To incorporate countermeasures in part & process design
To verify product & process design meets the requirements with dedicated
tool and process.
TVSM Responsibilities:
15
SQAM
Supplier Responsibilities:
QP – Phase 4
Objectives:
TVSM Responsibilities:
16
SQAM
Supplier Responsibilities:
Supplier shall
Study, analyse and arrive at countermeasures for TVSM feedback and in-
house problems faced during Beta trials
Ensure and submit the ARAI or approved agency reports for the applicable
parts.
Incorporate countermeasures in the part & process design
Achieve control over special characteristics
- Prevention and detection controls over all special characteristics.
- Required process capability levels for all variable special
characteristics (Refer 2.5 Progressive part approval process for
target Pp, Ppk levels)
Produce parts in Production Environment and pre launch Control Plan as per
L3 Drawing.
Verify and confirm that the part meets TVSM requirements.
Submit QP samples along with agreed documents (including progressive
PPAP documents)
Communication to TVSM on SPTR and ensure the part availability for trials.
(300 nos or 8 hours production.)
17
SQAM
TVSM Responsibilities:
Supplier Responsibilities:
Supplier shall
18
SQAM
Objectives:
TVSM Responsibilities:
Supplier Responsibilities:
Supplier shall
Study RFQ, L1 & L2 drawings, SRS (for prop parts)
For any ambiguities, clarify all the requirements
19
SQAM
20
SQAM
Objectives:
To understand the part quality requirements, plan and mutually agree for the
following during design & development and regular supplies which has two
sheets, one is general requirement another is part specific requirement.
- Verification & validation system
- Inspection & testing plan
- Maintenance of the measuring devices
- Reports submission frequency
TVSM Responsibilities:
Supplier Responsibilities:
Supplier shall
Understand the part quality requirements such as material composition,
appearance / visual, dimensional, functional, performance – reliability &
durability, packaging and preservation, any other specific requirement.
Prepare draft AOI document covering the following
During Design and Development process
- Layout inspection and functional testing plan
- Design Verification Plan
- Design Validation Plan
- Reliability & Durability testing plan
- Process qualification and validation plan
- Process capability study plan
During regular supplies
21
SQAM
- Layout inspection and functional testing plan for final product as well as
for child parts based on tool & die life assessment, changes in 5 Ms
(refer change management), agreed frequency.
- Incoming inspection
- In-process inspection
- Final inspection
- Pre-delivery Inspection
- Audits such as Product Audit, Manufacturing Process Audit, Dock Audit
- Process re-qualification and re-validation
- Process capability study & improvement plans
- Poka Yoke audit
Discuss with TVSM NPD quality member, clarify and complete AOI sign-off
Inspection plan shall consist of quality characteristics, Inspection methodology,
measuring devices (including hardware and software), by whom and samples
size during design & development process and regular supplies ( to be
included in part specific inspection agreement)
Guidelines for designing checking fixtures, gauges and test equipments ref
chapter 3.2
Inspection and testing reports submission frequency shall cover during design
& development process and regular supplies
External laboratories ,when used ,shall be NABL accredited with relevant
scope
Maintenance of Measuring Devices: Inspection, Checking Fixtures, Gauges
and Test Equipments
Procurement / development of measuring devices such as inspection
instruments, test rigs / equipments, gauges, panel checkers etc. required for
functional, reliability and durability testing shall be included in APQP timing
plan.
Supplier shall use TVSM format QSF QAD 10 11 05 for preparation of AOI.
Supplier shall carry out similar exercise of AOI with the TIER 2 suppliers and
shall retain at supplier end, subject to audit by TVSM.
22
SQAM
Scope:
Objectives:
TVSM Responsibilities:
23
SQAM
Supplier Responsibilities:
Supplier shall
Understand the TVSM QCD requirements of the part being developed.
Use project management techniques for preparing and managing APQP
timing plan ( Latest edition )
- Nominate project leader, select team members based on their
competency and promote team working environment
- Roles and responsibilities are defined for each team member
- Establish a project control room at supplier end with all the
required facilities such as soft boards, PC, LCD projector,
Internet connection, access to TVSM Collaboration folder &
projects, and communication devices.
- Establish communication & reporting system within the team and
also with supplier management
- Supplier management shall have periodic reviews of the APQP
progress and provide all the direction and support to the team
needed for the successful completion of the project.
Use TVSM APQP template QSF PUR SQAM 004 for preparing APQP timing
plan. The details of each activity are explained in the template itself.
Additionally take help from TVSM development team as required from time to
time.
Ensure that the phases, activities, milestones and review gates are aligned to
TVSM project requirements.
Updating of the APQP progress shall be on a continuous basis
Make every effort to adhere to the agreed timing plan
24
SQAM
26
SQAM
Submission requirements:
Sl.No Document Title Level A Level B Level C Level D Level E
1 List of Documents submitted R S S S S
Design Records R R
Bill of Material R S S S S
2
Drawing R R S S S
Test Standards R S S S R
3 Engineering change Documents R R S S R
4 Customer Engineering Approval R R S S R
5 Design FMEA NA/R NA/R NA/R NA/R R
Process flow Diagram R R S R R
6 Overall Process flow (for Assembly) R R S R R
Process flow shop( for Feeder shop R R S R R
7 Process FMEA R R S R R
8 Dimensional results R S S S S
9 Material Performance Test results R S S S S
Initial Process Study PP, PPk Calculation sheet R R S R R
Summary of Initial process Studies R R S S R
10
Control chart R R S R R
PP, PPk Calculation sheet R R S R R
Measurement System Analysis Studies R R S R R
11 MSA for variable characteristics R R S R R
MSA for attribute characteristics R R S R R
12 Qualified Laboratory Documentation R R S R R
13 Control plan R R S S R
PSW S S S S S
14
Weight Calculation sheet S S S S S
15 Appearance Approval report S S S S S
16 Bulk Material requirements checklist R R S S S
17 Sample product R R S S S
18 Master Sample R R S R S
19 List of checking Aids R R S R R
Records of compliance with customer- specific R R S R R
List of Approved TIER 2 suppliers R R S S R
Agreement of Inspection S S S S S
Photographs of tool,Fixtures,Gauges
R R S R R
20 &Equipment
List of external laboratories (if the services
R R S R R
are used
Process Qualification Records R R S S R
Packaging Standard R R S R R
S: Submission
R: Retain at Supplier End.
For Level C, D review and approval by TVSM
27
SQAM
Progressive PPAP:
PPAP is required to be submitted progressively i.e. documents submission
during Alpha, Beta and QP samples submission will be as per table 1. In QP
phase, a four-stage approach shall be followed :
Readiness Review – To assess whether supplier is ready for
PPAP production trials. This is done by reviewing product and
process design documents as per checklist CL QAD 10 11 001
IPTR (Initial Production Trial Run) – To assess whether
supplier process can meet basic quality requirements by
conducting a small batch production trial run – typically 50 nos.
and reviewing the results as per checklist CL QAD 10 11 002
SPTR (Significant Production Trial Run) – To assess whether
supplier can meet all PPAP requirements by conducting a
significant production trial run (8 hours Production or 300 nos ) at
planned run-at-rate and reviewing the results as per checklist CL
QAD 10 11 003
TVSM may witness the SPTR based on the PPAP submission
levels.
PSW Approval – Final assessment of the SPTR sample parts
by conducting vehicle production trial run (EJO trials) at TVSM
end and accord approval based on the results.
Supplier Responsibilities:
28
SQAM
29
SQAM
The SPTR shall be repeated until the target Quality and Quantity targets are
met. The measured data from this trial can be used for process capability
studies.
After successful completion of trial, the supplier shall send the SPTR status
report along with results and countermeasure implemented to TVSM
Purchase and Quality department.
If the supplier is unable to achieve the target levels after taking
countermeasure, they shall communicate to TVSM Purchase and Quality
dept. The notification shall also include the supplier plan for achieving the
target and interim containment actions.
Although all the risks need be addressed to reduce the RPN numbers, special
attention to be given for high severity rankings even if RPN is low. Whenever
severity is 9 or 10 and no actions are possible to reduce severity ranking,
efforts shall be taken to minimize occurrence and detection ranking.
FMEA is a live document; it shall be revised periodically and updated to
always reflect current state of design and process including those failure
modes occurring after the start of mass production.
Supplier shall submit the MSA reports to TVSM as a part of PPAP file.
Supplier shall use MSA reference manual latest edition of AIAG for all attribute
and variable gauge studies.
On an on going basis, the supplier shall conduct Gauge R&R (variable and
attribute studies) on all types of measurement systems at least once in a year.
The types of measurement system shall be identified / grouped based on
instrument type, instrument range and resolution, part characteristics,
operating environment and skills / competences of personnel using the
instrument.
31
SQAM
32
SQAM
Minimum Process
Special Performance index / process
Symbol characteristics Explanation capability levels for variable
description characteristics
Geometric Others
Safety / Statutory Characteristic that influences the safety,
the security, the environment and that it is
/ regulatory
subject to regulatory requirements.
Determining effect on the customer
severity = 9 or 10. 1.00 1.67
Examples –
a) Brake shoe bonding failure
b) Poor lighting intensity
c) No horn sound
d) Fire hazard
Fit / Function – Characteristics that influences the
Critical operation of the vehicle (loss of primary
function) or performance. Customer is
highly dissatisfied. Determining effect on
the customer severity = 7 or 8.
Examples – 1.00 1.67
a) Vehicle starting trouble
b) Vehicle suddenly stops
c) Poor mileage
d) Engine oil leakage
e) High oil consumption.
Fit / Function – Characteristics that influences comfort or
major convenience items or noise, vibration and
harshness. Customer is somewhat
dissatisfied. Determining effect on the
customer severity = 5 or 6. OR If the team
leader thinks that the characteristic is
important for the robustness of the product.
1.00 1.33
Examples –
a) Engine Noise
b) Brake Noise
c) Shock Absorber hard
d) Rust formation.
33
SQAM
Control plan
Control plan shall meet TS 16949 - Appendix A requirements
Control Plans are written description of a system to control product(s) and
processes. They provide a structured approach to selection, design and
implementation of value added control methods. They do not replace Process
or Work Instructions.
These documents facilitate promotion of quality awareness and consciousness
at all levels of operation.
Appearance approval
Appearance approval format QSF QAD 10 11 008 shall be inline with the
format provided in PPAP formats (Applicable for appearance item only).
34
SQAM
TVSM Responsibilities:
TVSM development team shall
Depending upon the criticality of the part to TVSM product, communicate the
level of PPAP submission.
Review PPAP documents submitted by supplier, and provide the feedback to
supplier.
Verify samples submitted and provide feedback to suppliers at every stage of
PPAP submission.
Witness PPAP trials based on the level of PPAP submission and as required
Approve PPAP - Fully Approved / Conditionally Approved depending upon the
compliance to the PPAP requirements.
Supplier Responsibilities:
Supplier shall
Prepare all the PPAP documents as per TVSM requirements. Based on the
PPAP submission level, supplier shall submit PPAP documents. Table 1
shows the 19 requirements for the PPAP submission.
Use TVSM formats – for preparation of PPAP documents ( as a guideline )
Review the adequacy of the PPAP documents and ensure that all the
documents are in order prior to submission.
Submit the PPAP documents through Collaboration Folder link available on
www.tradewithtvs.com
Receive TVSM feedback and correct PPAP documents accordingly
Make ready for any trials that TVSM may witness – eg. Alpha, IPTR and SPTR
Carry out similar PPAP methodology for the TIER2 suppliers. Approve TIER 2
supplier PPAPs before PPAP approval by TVSM.
Mass production and regular supplies can start only if the part PPAP is
approved by TVSM.
35
SQAM
QP (PPAP
submissio Mass
productio
S No Document Format Alpha Beta n& n (ECN & Remarks
approval Others)
stage)
1 Design records Suppliers to submit QP1 is with L3, QP2 onwards with L4
TVSM Drg / Yes Yes Yes (L4) / release. Subsequent on-going
Yes (L4)
Supplier Drg (L2) (L3) ECR changes are with ECRs.
2 Engg. Change No specific format If applicable
No Yes Yes Yes
drawings
3 Customer Engg. No specific format If applicable
Approval Yes Yes Yes Yes
117 Master samples / No specific format (As applicable e.g. - for AAR parts,
Limit samples No No Yes Yes Carburetor, Cyl Head etc.)
118 Checking aids No specific format No No Yes Yes
119 Customer specific No specific format As per the Supplier Quality Manual
requirements and specific requirements (special
process qualification, list of TIER2
suppliers, List of special
No No Yes Yes characteristics, List of Poka Yoke,
Lay out with man power deployment,
Cycle time details including loading /
unloading, Cycle time vs takt time bar
graph)
Stage wise submission requirements (Applicable mainly for NPD supplier parts approval
36
SQAM
Scope:
Details:
Supplier shall establish a system to achieve consistency in quality. The following
records / reports are to be maintained and updated on periodical basis.
a. Supplier Inspection Report
b. Product audit records
c. Process audit records
d. Performance & endurance test reports
e. Layout inspection reports
f. Process qualification records
g. Jig / Fixture / Tool / Machine Preventive Maintenance records
h. System audit records
i. Tier 2 audit records
j. Process capability report
k. Conformity of production
The audit plan, adherence to audit, audit findings and action taken based on the
audit, shall be made available and reviewed during the monthly review with section
heads, to track the closing of NCRs and also to be reviewed during supplier top
management review.
The above may be verified by TVSM Quality during the system and process audit
37
SQAM
b. Product Audit:
Supplier shall make plan for product audit covering all products at periodic
interval depending upon the volume of product and quality performance.
Supplier shall perform product audit for ready for despatch parts, to confirm
dimensions against standard, Functionality, Packaging, Labeling, etc.
Supplier shall record product audit findings and raise non-conformances (NCs)
if not ok against specifications. Make action plan for disposal action for the
parts available in pipeline / at customer end and corrective action to prevent
the defects and monitor the same for completion of the actions.
c. Process Audit:
Supplier shall make process audit plan covering all processes / machines (Die
casting, forging, moulding, welding, pressing, machining, heat treatment,
plating, painting, powder coating and assembly processes).
The supplier shall verify the process parameters are set as per the Control
Plan for the process including Poka-yoke.
Audit shall be conducted based on TVSM approved control plan as applicable.
Supplier shall record process audit findings and raise non-conformances
(NCs) if not ok against specifications. Make action plan for disposal action for
38
SQAM
Supplier shall make a plan for performance & endurance testing for all the
existing products in consultation with TVSM Quality / as agreed in AOI (on
frequency of testing and sample size) and submit the plan annually to TVSM
Quality / Purchase.
The supplier shall test for all part(s) when performance or functional test
requirements are specified in TSES, drawing / inspection standard (AOI).
Performance test results shall indicate and include
- The drawing and TSES change level of part tested
- Any authorized engineering change documents that have not yet
been incorporated in the drawing
- Date of testing, quantity tested
- Actual results and decision
e. Layout inspection:
Supplier shall prepare a plan and carryout layout inspection of all the parts, in
consultation with TVSM Quality / as per the AOI.
Supplier shall retain the latest Layout inspection report along with the samples
which is auditable by TVSM.
Raise NCs for the dimensions that does not meet the specifications and make
action plans to correct the same.
If the solution identified by the supplier requires a change in the product or
process design, the supplier shall initiate the change request.
39
SQAM
f. Process qualification:
Supplier shall identify the special processes ie (Heat treatment, Plating,
Painting, Powder Coating, Welding, etc) and make a plan for conducting the
process qualification, including Tier 2.
The process shall be set at minimum condition for all process parameters as
per the Control Plan and produce the product as per the normal batch size.
(E.g. Temp: 160 ~ 200 deg Time: 5minutes ~ 8 minutes in a plating process
then produce the batch by setting temp at 160 deg and time 5 minutes for
minimum condition)
Check the product parameters as per Drawing, Inspection Standard / Control
Plan including destructive type parameters. (Like Chrome thickness by
couloscope, High Sculpture, Case depth / penetration / load etc)
In a similar manner set the process at maximum condition for all process
parameters and produce the batch, record the result for both minimum and
maximum condition
If the final product requirement is met for min and max condition, the process
is ok otherwise identify the causes and make action plan to achieve the
requirement.
Supplier shall make a plan for all Jigs / Fixtures / Tools / Machines covering all
the processes. Frequency can be decided based on the volume of production,
frequent wear and breakdowns.
Identify the parameters to check the condition by visual for each jig / fixture /
tool / machine.
Monitor the parameters & replace the wear parts if required and record the
dimension before & after replacement, maintain the history card for each jig /
fixture / tool / machine and record.
Maintain & monitor the minimum stock of spares to avoid any abnormality.
40
SQAM
h. System audit:
Supplier shall make a plan for Quality Management System audit covering all
the QMS processes at planned intervals.
The processes mean purchase process, new part validation process,
calibration process, nonconforming product handling, etc.
Verify the adequacy & adherence of the processes and record the
observations. Raise NC where not meeting the requirement and make action
plans for Corrective & Preventive Action.
The summary of audit finding and action status shall be covered in the
Supplier’s Management Review.
i. Tier 2 audits:
Supplier shall make a plan for Tier 2 audit covering all Tier2 suppliers.
Supplier shall verify following areas
- Availability of latest revision of drawing and inspection standard
- Adherence to Control Plan
- Condition & Calibration of Gauges / Instruments / Tool / Equipments
- Part parameter audit
- Condition of jig / fixture / tools / gauges & history maintenance.
- NC products identification and handling
- Deployment of certified operators and inspectors in critical processes
- If a special process is done by Tier 2, then the special process
qualification to be verified and approval by TVSM.
- Layout inspection, product audits.
- Supplier may cover additional areas as required
41
SQAM
Supplier shall send the of process capability reports on monthly basis for
special characteristics, controlled through X-bar, R chart. Action plan to be
submitted to improve the process capability, if Cpk is below the norms
specified in the manual.
k. Conformity of production (COP):
Supplier shall send the COP report as per the fixed frequency from the
approved agencies. The list of applicable COP parts are enclosed.
# Part name 1st COP Start date 1st COP End date COP Frequency
5 Tyre
6 Horn
2 Years
7 Bulb
01.10.2009 (Phase II) 30.09.2011
8 Rear View Mirror
9 Lamps
11 Fuel tanks
42
SQAM
Objective:
To explain the requirements for the test equipment planned during part development
to evaluate the production of parts with reference to drawings / quality plan / other
quality requirements.
Scope:
This is applicable to all the checking fixtures, gauges and test equipments used for
checking the finished parts, including Tier 2 process.
Supplier Responsibilities:
43
SQAM
44
SQAM
45
SQAM
Supplier Responsibilities:
Supplier shall establish and maintain documented procedure to ensure that non-
conforming parts are prevented from proceeding to subsequent process. This
procedure shall explain the method of identification, evaluation, segregation,
disposition and notification of non-conformance to TVSM and Tier 2.
46
SQAM
The supplier shall respond to the QDH for the completion of action. In case the
committed target is not met, the supplier shall intimate the revised target date
with reasons.
Till the permanent counter measure is implemented, suppliers shall ensure
only OK parts have been shipped to TVSM.
If the suppliers have any disagreement with the Quality Deviation Highlights,
they shall contact TVSM Quality.
Improved lot shall be separately identified and submitted with PPAP
modifications if required, with prior information to TVSM.
Supplier shall have a system to communicate the TVSM assembly line
complaints and Field complaint to the respective stage operators and
inspectors. Defective sample / VCS to be displayed in the appropriate place.
Ensure suspected and obsolete parts are identified & kept in identified
location. These parts are treated as Non-conforming parts.
47
Corrective action score (QA Matrix score)
SQAM
5 4 3 2 1
• Prevention type • Detection type • 100% dimensional • 100% visual check • Sample checks
Poka Yoke Poka Yoke check & sample for dimension
dimensional check
• Design improve- • Design improve- • Introduction of • Sample check
ment (Sev < 5) ment (Sev 5 to 7) calibration for • Use of trained for visual
Jigs & Fixtures operators features
• Process improve- • Process improve-
ment (Cpk > 1.67) ment (Cpk 1.33 to • Introduction of tool • Provision of • One point lesson
1.67) change frequency inspection standard / Quality alert
• 100% automated (SOP)
test • 100% additional • provision of variable
48
test station gauging
• Automation of tool
change frequency • Automation of tool • PM Check list
- Machine change frequency operation
shutdown - visual control
On receipt of customer complaint from TVSM, Supplier shall identify root cause and
corrective action as per the procedure explained.
In the process of complaint resolution, TVSM and supplier shall share the relevant
documents and data through “Supplier Collaboration” facility available on
www.tradewithtvs.com.
TVSM SUPPLIER
Do preliminary analysis of
customer complaint and - Analyse problem thro’ QC
forward information to Story approach for field and
supplier Kaizen for line complaint
49
SQAM
Supplier Responsibilities:
Upon the receipt of complaint (Email / Fax / Quality Deviation Highlights),
supplier representative shall visit TVSM to understand the problem within 24
hours.
Supplier shall take containment action for all stocks available in TVSM, field,
transit and at supplier end. The actions that are to be taken are as follows:
M1 action - Immediate action to be taken on stocks at TVSM- Quarantining /
segregation / 100% inspection etc.
Target lead time for completion of M1 action -Within 24 hrs
M2 action -Temporary action to be taken at all stages of manufacturing, transit
and storage through out the supply chain. to prevent the defect reaching
TVSM.Example of means used --100% inspection / switch over from sampling to
100% inspection / Gauge introduction, etc
Target lead-time for completion of M2 action - Within 48 hrs
M3 action - Corrective action through problem solving approach (QC Story/Kaizen
sheet/8D- report )
Target lead-time for( i) Submission of corrective action reports –within 7 days
(ii) completion of M3 action – Within 15 days (according to the nature of problem
and resolution)
M4 action - Horizontal deployment of the corrective actions to all the applicable
areas. Example - Horizontal deployment across models processes etc.
M5 action - Standardization activities (Capturing learning’s and providing
information for future products/processes)
Example – Updation / preparation of Product Design Guidelines, Process Design
Guidelines, Part Development Guidelines, FM directory, Training Modules, Quality
System correction etc.
50
SQAM
Supplier shall conduct detailed investigation of the part and process both at
their end as well as at Tier 2 supplier end before concluding the root cause of
the problem. It is recommended to use QC story methodology while analyzing
possible reasons.
. The corrective action score shall be minimum 4. Refer “Corrective Action
Score” (QA Matrix score) enclosed in the manual.
The supplier shall update the relevant standard (drawing, FMEA, control plan,
work instructions etc) to prevent the problem in future models.
For continual improvement, the supplier shall see the web data on daily basis
and initiate action for line / lot complaint resolution, Format (QSF PUR SQAM
009)
This updated data and actions shall be discussed in the monthly review at
TVSM
51
SQAM
Supplier shall visit TVSM as per agreed schedule for joint analysis of warranty
parts and send analysis report to TVSM as per agreed time line.
Analyze the failure, using warranty analysis guidelines and warranty analysis
summary format QSF PUR SQAM 010 & QSF PUR SQAM 011. It is
recommended to check 50 – 100 nos of failed parts randomly and verify the
following observations.
- Phenomena of failure, kms etc
- Location of failure
- Bench mark study to identify the improvements
- Simulation of field failure in lab
- Identify the root cause of failure
- Identify the counter measure
- Compare the improvement in lab testing (before & after)
- Implement the action with time plan format
- Monitor the results
The updated data and actions shall be discussed in monthly review at TVSM.
The implemented corrective action score shall be minimum 4.
For continual improvement the supplier shall see the web on for warranty
parts.
The supplier shall update the relevant standards based on the improvements
(drawing, FMEA, control plan, etc)
52
SQAM
Objective:
Scope:
1 Product Design Material Changes / Use of alternate material for the first time
Changes (Supplier
initiated changes)
Co-ordinate / Geometric dimensions, Tolerances, Surface Finish
Surface protection / appearance attributes (plating / plating, powder coating)
53
SQAM
Packaging method
8 Other QMS Invoking contingency plans (including labour shortages, key equipment failures, field
changes returns, strikes / bandhs, patent infringements etc.)
TVSM responsibility:
Supplier shall study the ECR drawing and provide feedback (change
assessment and impact on QCD) through ‘C’ Folder facility available on
tradewithtvs.com website.
Supplier shall obtain feedback / concurrence from TVSM before submitting
samples along with necessary PPAP documents for evaluation
54
SQAM
Supplier shall follow PPAP and obtain approval prior to regular supplies.
Supplier shall submit request for engineering changes – format no. QSF
PUR SQAM 014, process changes format no, QSF PUR SQAM 013 and
obtain necessary clearance from TVSM for going ahead with the change
implementation.
Supplier shall submit notification and obtain further guidance from TVSM
Supplier shall ensure that the changes are verified & validated and follow
PPAP for obtaining approval from TVSM prior to implementation of
changes and start regular supplies.
Note :
55
SQAM
Objective:
To explain the procedure for quality systems / process audit at supplier end.
Scope:
Applicable to all existing suppliers, new suppliers and Tier 2 suppliers of parts
Process audit:
Note :
Supplier shall do system audit on periodical basis and correct non
conformance with action plan and maintain records.
56
SQAM
NOTE:
57
SQAM
Supplier Quality Rating = Average Lot Rating x Derating For Line & Field Rejection
(NET RATING)
F1 = Lot Acceptance Crieteria Factor
(I) INDIVIDUAL LOT RATING (Li) DP = Direct pass 1.0
RG = Regularisation 1.0
RJ = Rejected 0.0
If M1 % >= 0.01 < 0.05 , then M1 = 0.9 If M2 % > 0.05 <0.1 then M2 = 0.8
Overall Rating for the supplier :- Net rating of ith Item X No.of lots in ith item)
Total No. of lots of all items
58
SQAM
Objective:
59
SQAM
Objective:
Scope:
TVSM Responsibilities:
Discuss and finalise tool design concept along with the supplier and tool
designer.
Discuss and finalise tool life target (no. of shots, production volume etc).
Discuss and finalize tool maintenance activities that are to be carried out
by the supplier and their frequencies.
Monitor that the supplier carries out preventive maintenance activities on
tools as per the agreed plan and checklist.
Review the condition of tool when quantity produced reaches 75 % of the
agreed life. Thereafter, review the tool condition at incremental 10%
production of the agreed tool life quantity
Obtain Management Sanction for new tool and inform supplier to go ahead
with new tooling.
Supplier Responsibilities:
61
SQAM
4. Plan, procure and maintain stock of tool replacement parts so that the parts
are available at all times.
5. Issue Tool Ownership Certificate (QSF PUR SQAM 017) to TVSM, once the
tools are proved.
6. Maintain history card for all the dies and the press tools
7. After any major tool maintenance, check first off sample and record the
measured value. If part meets drawing / inspection standard requirement,
continue the production.
8. Carry out preventive maintenance on each tool as per agreed maintenance
plan and checklist. In case of delays in carrying out the defined preventive
maintenance beyond 3 days, inform TVSM buyer.
9. Tool shall be maintained to prevent from any damage.
10. Review the condition of tool when quantity produced reaches 75 % of the
agreed life. Thereafter, review the tool condition at incremental 10%
production of the agreed tool life quantity
11. Based on the tool condition, agreed tool life and agreed lead-time for new
tool manufacturing, tryout and corrections, prepare plans for replacement
tools.
12. Prepare new tool request sanction and submit to TVSM at-least two months
in advance of target purchase order date for replacement tool procurement.
13. Submit copy of history card / report on usage condition, upon request.
14. Obsolete tool (tool life is over / obsolete part tool) shall be returned back to
TVSM.
62
SQAM
Objective:
Scope:
Details:
63
SQAM
Traceability:
This refers to the ability to track a part, back through all the stages of manufacture
up to raw material stage. Process parameter used in manufacture of critical
components shall also be traceable, with applicable inspection and test results.
Identification is the key parameter for any traceability system.
E.g.: Date Code / Heat Code.
Supplier Responsibilities:
Supplier shall ensure that documented procedures and systems are in
place to control the traceability of all the critical parts right from RM stage
to the date of manufacture and date of despatch to TVSM.
The supplier shall also ensure the same with their supplier, to control the
trace ability of all the special process parts / critical parts. (as agreed)
Incase of Rubber or Polymer parts the supplier is required to keep master
batch sample for each lot. Duration may be discussed and decided with
TVSM Quality and the corresponding records of composition & parameter.
Suppliers are recommended to develop traceability for part identification,
even if it is not specified in drawing or inspection standard, to investigate
the process during trouble shooting of defective / failed parts.
Material handling:
Supplier shall plan for dedicated material handling facility like crates / bins /
trolleys / pallets for material despatch to TVSM and for in - house material
handling, to prevent damage of parts, burr, and dust.
64
SQAM
65
SQAM
Objective:
Scope:
Details:
TVSM expects the suppliers to establish, maintain and control all quality
documents and records related to TVSM in accordance with international
standards like ISO - 9001 / TS16949 with the following minimum requirements
1. Issue / revision control
2. Control of distribution
3. Retention period of documents / calibration details / records / registers
etc
4. Availability of latest relevant documents
5. Master list of quality records
All TVSM related quality records shall have minimum retention period as per the
following table to ensure traceability of parts / process conditions.
All Quality Records and Documents shall be made available to TVSM for
verification upon request.
All documents / records related to TVSM parts / process shall be kept in strict
confidence and shall not be disclosed to any third party without approval from
TVSM. Even when it is required to share such information, such as external
66
SQAM
Supplier shall return the Old Drawings / Standards to TVSM in case of obsolesce
of the part .The supplier shall destroy all copies of such documents and confirm to
TVSM to prevent misuse.
67
SQAM
.
4.0 SPARE PART REQUIREMENTS
Objective:
To ensure quality of parts supplied as spares
Scope:
Applicable to all suppliers of parts to TVSM.
Supplier Responsibilities:
1. All parts produced for spares shall go through the same system of quality
assurance as that of a regular product.
68
SQAM
ABBREVIATIONS
69
SQAM
70
SQAM
OF NC PRODUCT
18. LINE / LOT REJECTION PERFORMANCE QSF PUR SQAM 009 3.4
71
SQAM
List of Formats:
72