PAK SUZUKI MOTOR CO. LTD. CHAPTER 14 SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION Establish a system for sub vendor in line with PSMCL requirement Establish a documented system for maintaining Quality history of each part Monitor delivery performance and analyze the cause for delays if any Conduct revalidation atleast twice a year for the following: All Maru A parts, Functional parts, those General parts as asked by PSMCL and for raw material of Maru A parts Conduct ongoing process capability studies on selected characteristics of parts Conduct periodic check on Observance of Operation standards Define daily roles & responsibilities of Managers & Supervisors on the shop floor & have a self monitoring mechanism by means of checklists Establish a system of periodic coherence check of various related standards Establish a system for Tool management, lot control, maintenance of inspection instrument, Audits training, skill development, continuous improvement, Quality abnormality measures, change approval, sub vendor control & risk assessment NOTE:- This flow chart is only a brief ‘Activity Flow’ description of the chapter. Please go through the complete chapter for detailed requirements of PSMCL Doc. # QAD-MAN-01 Rev: 00, Feb - 2011 SUPPLIER QUALITY ASSURANCE MANUAL 96 SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION 14. PAK SUZUKI MOTOR CO. LTD. SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION Vendor shall ensure the implementation of the following systems: 14.1 SYSTEM FOR DEVELOPMENT OF SUB VENDORS 14.1.1 A documented system should be established for ensuring proper Quality management system at sub-vendor's (Tier-2 Vendor's end). · Requirements: Vendor shall clearly define its requirements and establish mechanism to ensure their compliance. · List of vendors: A list of sub-vendors should be established, whose selection shall be based on the clear guidelines laid out by the vendor. · Evaluation of sub vendors: An evaluation mechanism should also be established for sub-vendors to ensure their eligibility for supplying parts. · Sub Vendor Audit: Whenever required by PSMCL, arrangement shall be done by the vendor for audit to be conducted by PSMCL at sub-vendor's end to verify that sub vendor is in conformance to the specified requirements provided by PSMCL. 14.2 ROLE OF MANAGERS AND SUPERVISORS AND JOB MAPPING 14.2.1 Daily roles & responsibilities of Managers and Supervisors on the shop floor shall be clearly defined by means of a check list. 14.2.2 These roles & responsibilities check list shall given consideration to the activities to be performed & supervised on the shop floor during the time of new model trial production, initial flow control, change management, normal production, crisis situations like customer complaints, discovery of Quality abnormalities, accidents etc. 14.2.3 These job responsibility check sheets shall be regularly filled up by the Supervisors & Managers. 14.2.4 The check sheets serve the purpose of keeping a self check, that none of the important activeties on the shop floor are missed. Also they can be used for re-allocation & distribution of workload among Supervisors & Managers in the case of special events like new model launch etc., when additional responsibilities have to be taken up. Doc. # QAD-MAN-01 Rev: 00, Feb - 2011 SUPPLIER QUALITY ASSURANCE MANUAL 97 SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION 14.3 SYSTEM FOR MAINTAINING QUALITY HISTORY OF PARTS AND ITS ANALYSIS 14.3.1 There shall be an established documented system for maintaining Quality history of each part which should be controlled. Quality history of each part shall have the following information: · Part Name & Part No. · Description of defect / abnormality Batch code. · Stage of part (i.e Development / Sample / Mass Production). · Date of Occurrence. · Acceptance / Rejection trend. · Type of rejection {in-house / PSMCL / market (Line/SRV)}. · No. of parts returned/rejected. · Cause of failure / Root Cause Analysis (e.g. Why-Why- Fish Bone etc). · Detail of the immediate countermeasures taken. · Details of permanent countermeasures taken. · Date of countermeasure Implementation. · Effectiveness status of the problem. 14.4 MONITORING OF QUALITY OF PARTS 14.4.1 REJECTION ANALYSIS 14.5.1 For each part, trends shall be maintained month wise for each type of rejection. On a monthly basis analysis of the all the rejections shall be carried out, to see whether there is any increasing trend, abrupt increase, also understanding improvement status after countermeasure and taking suitable countermeasure based on the analysis. Records of monthly analysis and the countermeasure taken shall be maintained. Whenever asked by PSMCL same shall be submitted. 14.5 RE VALIDATION Re validation is a detailed verification of dimension, metallurgy, appearance, performance, endurance items including the PSIS-P items which comprise items for regular check. Vendor shall carry out revalidation of parts (for all , Functional parts and for those General parts asked by PSMCL) and revalidation of raw material (in case of parts affecting item) at least twice a year. Minimum 5 parts shall be checked for revalidation. In case of multiple line/moulds,minimum 1 sample per line/mould shall be taken for re-validation. Each year Doc. # QAD-MAN-01 Rev: 00, Feb - 2011 SUPPLIER QUALITY ASSURANCE MANUAL 98 SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION PAK SUZUKI MOTOR CO. LTD. re-validation plan shall be made and if asked by PSMCL, reports shall be submitted as per schedule. In case of proprietary items, re-validation of inner parts shall be carried out. Vendors shall carry out re-validation of sub vendor's parts also. 14.6 MONITORING DELIVERY PERFORMANCE Vendor delivery schedule will be communicated electronically on a daily basis by PSMCL Vendor shall monitor the delivery performance of their company against the schedule of supply lots given by PSMCL. 14.7 OBSERVANCE OF OPERATION STANDARDS 14.7.1 There should be a periodic (preferably monthly) check carried out to ascertain if the operations on the shop floor are being performed by the operator exactly as per various set standards of Quality & Safety. This is to ensure that products are manufactured with consistent Quality and Adequate Safety. 14.7.2 The “Observance of Operation Standard” check is quite different from a process audit in the sense that it specially focuses on observing carefully how an operator is working on line & whether he is adhering to all the set standards. 14.7.3 This check shall be used not only for determining the compliance level of the operation standards but also as a tool to continually & proactively identify Kaizens & Poka Yoke on the shop floor & amend the standards accordingly. 14.7.4 Each vendor shall develop their own checklist for the items to be checked during this process. 14.8 TOOL MANAGEMENT Vendor shall have proper facilities for maintenance, repair of tools & their storage. A system shall be implemented: · To record the details of change of tool, repair of tools and tool life. · To change the tools as per the specified frequency. Doc. # QAD-MAN-01 Rev: 00, Feb - 2011 SUPPLIER QUALITY ASSURANCE MANUAL 99 SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION Manufacturing & Quality Control - Work Details and Authorities (Example) Daily Work Control during abnormalities & changes Production Preparation Item S. No. Check Items 1 Participate in New Product introduction Meeting. 2 Participate in a Production preparation plan sheet creation meeting. 3 Create a Production preparation sheet. 4 Participate in Primary prototype. 5 Participate in Design review. 6 Install / Maintain Equipments. 7 Ceate a Quality Check sheet. 8 Create Operation Standard / Work Instruction Sheet. 9 Participate in Quality audit. 10 Initial Flow Control. 1 Section / Department / Departmental Plant Manager Manager Line Incharge / Supervisor Control First pieces during Initial Flow Control. 2 Deploy Information for Engg. Changes / Process Changes. 3 Take actions when abnormalities occur in process (and report to Top management) 4 Identify the abnormal pieces with tag / red paint. 5 Investigate causes and take corrective actions. 6 Check Countermeasures and their effectiveness. 7 Inform to PSMCL. 8 Revise the Standards to prevent recurrences of problems. 9 Formulate plans for installing poka yoke devices. 1 Morning Meetings. 2 Prepare to Start Work (check machines, equipments etc.). 3 Attendance and absence control. 4 Provide Inspection instruments and tools. 5 Control Maintenance of inspection instruments and tools. 6 Create and check Control charts / Inspection records. 7 Check and record the proper functioning of Poka yokes. 8 Maintain 5S. 9 Evaluate Productivity. Created / Checked / Attended / Entered Legends Examined / Checked Approved Doc. # QAD-MAN-01 Rev: 00, Feb - 2011 SUPPLIER QUALITY ASSURANCE MANUAL 100 SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION PAK SUZUKI MOTOR CO. LTD. SYSTEMS TO BE IMPLEMENTED AFTER STARTING MASS PRODUCTION O : OK X : Guidance reqiured Standard Operation Inspection Sheet (Example) Operator Name: Checked by Operation/ Process : New Employee / Regular / Helper / Casual Category: Supervisor / Line In-charge : Check Items Item Approved by Plan Week 1 Week 2 Week 3 Week 4 Remarks Actual 1 The set values are matching with that of Instruction sheet / Operation standard. 2 The condition indication values eg. Temp etc., have been checked and recorded on check sheet. 3 The operation is being performed in line with the Process Operation Flow. 4 Operations are using all PPE (Personal Protective Equipment) items provided to them. 5 Quality Checks are being performed as per control plan / Work Instruction sheet and are being recorded on Check Sheet. 6 First piece identification is being done by putting tag on the piece. 7 Inspections are being done for operation and equipments during operation and are being recorded. 8 Poka yoke verification is being done periodically (in shifts) and being recorded on Check sheet. (e. g. At start of shift and after lunch). 9 Jigs and fixture inspection is being done and recorded. Operation Conditions Operation Sequence Safety Quality Check Equipment Inspection Operation inspection on inspection equipment, measuring 10 instrument and gauges are being done. Tools are being replaced in accordance with their procedures Cutting tool Replacement 11 and sequences. (Tool Life Monitoring) Abnormality Handling 12 Occurrence of defects is reported to supervisors. 13 Location Abnormal pieces are identified properly (eg. With ‘Red’ tag or point) and are kept at the designated place. The parts, measuring instruments, gauges, tools and check sheets 14 etc. are placed at their defined place. 15 Unidentified objects are not placed haphazardly. Parts Handling Parts are being stored in container as per the Work 16 instruction / Control Plan. Doc. # QAD-MAN-01 Rev: 00, Feb - 2011 SUPPLIER QUALITY ASSURANCE MANUAL 101