Supplier Development Manual

REVISION 00
"GROW TOGETHER" DATE 10/07/2012

SUPPLIER DEVELOPMENT MANUAL
1
REVISION 00
1. FOREWORD
Pricol considers its suppliers as an integral part of Pricol Quality System. This Manual
explains the Quality System requirements of Pricol from its suppliers.
The main purpose of this Manual is to develop and monitor Supplier's performance in
meeting the Pricol requirements.
One of the key o!ective of an organi"ation is to provide products # services $hich
meet the requirements % expectations of the O&M # &nd customer. To ensure the
successful implementation of the company's o!ective( periodic assessments $ill e
performed at supplier's facility y Pricol )*T to develop the suppliers to meet the key
o!ective in a structured % cost effective manner.
+y $orking along $ith supply chain ,tier - ./ suppliers the products # services supplied
to Pricol are expected to e of consistent Quality. The same shall in turn help Pricol to
meet o!ectives of )0STOM&1 S2T3S*2)T3O4( of Original &quipment Manufacturers
,O&Ms/
Pricol also expect its suppliers to e a$are aout their responsiilities to$ards
maintaining clean and safe environment. This is required not only for us ut for our
future generation also.
2t Pricol( this is extremely important activity in our usiness operation. 5e think it is
the social responsiility of each individual to protect the environment % natural
resources.
M.Chanda!"#aan G.A. V"n#a$"!h N.S%a&a'(h)
S*A H"ad + SMS CMO
2
REVISION 00
TA,LE OF CONTENTS
S-. N. T./01 Pa2" N.
1
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67
8.a Quality Policy
67
8. &nvironmental Policy 67
8.c Quality system requirement % expectation 67
8.d &nvironmental system requirement % guideline 69
8.e :uideline for supplier on environmental caring 69
2
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6;
8 N"% P.d)1$ / 1.'/.n"n$ d"4"-./'"n$. 6<
=.a 3nitial sample sumission 6<
=. Production Part approval process 86
=.c Situation $here customer notification not required 86
=.d PP2P 1un 88
9
S&!$"' $. (" 0'/-"'"n$"d ("7." !$a$0n2 Ma!!
P.d)1$0.n
8=
>.a &stalishment of Process )ontrol Plan # Standard 8=
>. &stalishment of operations standards % 5SS. 8>
>.c )ontent 8>
: S&!$"' $. (" 0'/-"'"n$"d a7$" !$a$0n2 'a!! /.d)1$0.n 87
7.a Quality 1equirement for regular suppliers 87
3
REVISION 00
7. )ompliance to statutory # regulatory requirements 8;
7.c System for development of su supplier. 8;
7.d System for maintaining quality history of parts and its analysis. 8;
7.e :uideline for regular production deliveries. 8;
7.f 1evalidation # layout inspection? 8<
7.g Ongoing process capaility studies 8<
7.h Tool Management 8@
7.i *irst 3n *irst Out Practice? 8@
7.! )aliration of 3MT& ,3nspection measuring % test equipment/? 8@
7.k Maintenance of production equipment 8@
; P01.-+.n2.0n2*)a-0$&I'/.4"'"n$ 8@
9.a :uideline ? 1eporting on quality prolems. .6
9. Supplier Performance 1ating .8A.@
9.c Supplier 2uditsAQMS % Process audits =6A==
9.d Supplier Performance management ==
7 Chan2" Mana2"'"n$ =>
;.a &ngineering )hange management =>
;. >M )hange management. =>
< Ta0n0n2 3 C.n$0n).)! I'/.4"'"n$ =7
= S"-7+C"$0701a$0.n 10$"0a >DTS+DIRECT TO STORES? =;
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11 L0!$ .7 F.'a$ >6
4
REVISION 00
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1.a? *UALIT@ POLIC@
Pricol $ill provide value and satisfaction to customers on products and services.
This $ill e achieved through
a/ Systematic training and motivation of employees.
/ )omplying $ith customer requirements and applicale statutory # 1egulatory
requirements.
c/ )ontinually improving the efficiency and effectiveness of the Quality
Management Systems.
1.(? ENVIRONMENTAL POLIC@ A
Pricol is committed in carrying out environmental friendly manufacturing and
management practices. This $ill e achieved through
&ncourage innovation to prevent environment pollution
)omply $ith environmental legislation( regulations( other requirements agreed
upon
Minimi"e $astes to preserve natural resources
)reate environment preservation a$areness amongst employees(suppliers and
the community.
)ontinually improve the efficiency and effectiveness of the environmental
Management System and OBS2S.
1ecycle and reuse to the extent possile
1.1? *UALIT@ S@STEM RE*UIREMENTS / EBPECTATIONSA
P01POS&?
This manual explains the quality requirements of Pricol's suppliers and various
activities employed y Pricol for the selection of Suppliers( Procurement of items( and
Performance 1ating for suppliers and the Cevelopment of Suppliers. The $ord
DSupplierE is all inclusive and includes SuAcontractors as $ell as Fo 5orkers
5
REVISION 00
S)OP&?
This procedure is applicale to activities related to procurement of 1a$ Materials(
)omponents( 2ssemlies( Su 2ssemlies( Packing Materials( )onsumales and
)hemicals required for regular products and products under development( ut does not
apply to materials # items $hich do not affect the quality of the pricol products.
Pricol has adopted The TSA89@>@ Quality Management System in compliance $ith our
O&M customer requirements. Suppliers to pricol shall estalish a Quality System as per
3SO @668?.66< requirements $ith expectation to upgrade to level of TS 89@>@?.66@
as part of the continual improvement.
Pricol $ill carryout periodical assessments of Supplier Quality System to verify
conformance as per the Manual # customer specific requirements. The Supplier shall
take a timely corrective % preventive action on the discrepancies reported for
susequent verification y pricol.
1.d? ENVIRONMENTAL S@STEM RE*UIREMENTS / EBPECTATIONS
Though 3SO 8>668 certification is not a mandatory requirement ut pricol certainly
expect them to fulfill all legal ( environmental and safety regulations. This is applicale
to all products ( services % on site ha"ardous processes # operations . This requirement
shall e verified during periodical supplier audits y Pricol team.
Suppliers $ho are certified to TS89@>@( 3SO @668#3SO @66.( or 3SO8>668 are
expected to sumit a copy of the current and appropriate registration certificate to
Pricol. 2ny change in status ,loss( updated( ne$ standard( name change( location
change( scope change etc./ must e reported to Pricol immediately.
1."? GUIDELINES FOR SUPPLIER ON ENVIRONMENT CARINGC
PRACTICES
8. 0se environment friendly ra$ material?
&ncourage the use of environment friendly materials in your organi"ation to the
extent possile.
.. 2void Gand )ontaminations?
2void land contamination y leakage and improper disposal of oil( $ater and
chemicals.
6
REVISION 00
=. Safe $aste disposal?
&nsure environmentally safe disposal of $aste generated in process of any !o in
your organi"ation.
>. Optimum utili"ation of resources?
*ull effort required at every stage for optimum utili"ation of resources.
&ncourage reuse( reAcycling of material $henever#$hereever possile.
7. Gegal compliance?
&nsure compliance $ith the statutory environment requirement applicale to
your industry.
9. &nsure safety?
Safety procedure to e follo$ed every$here.
MSCS ,Material safety data sheet/ guidelines strictly e follo$ed for proper
storage % transportation of ha"ardous materials and others as applicale.
;. Cisplay of +oards?
0se display oards and highlights good practices and precautions to educate
employees on etter environmental management practices.
<. :ood $ork culture ,7S/?
Maintain neatness % cleanliness in $orking area and around.
+uild $ork culture on them of preserving nature#earth for the next generation.
Periodical 7S audit of your site as per checklist.
@. Training?
Provide training for the employees on the a$areness aout environment friendly
practices .
2. EVALUATION 3 SELECTION PROCESS FOR SUPPLIERS OF
MATERIALS / COMPONENTS
Supplier sourcing decisions require approval of BOSA SMS ased on evaluation of
Preliminary supplier assessment ,PS2688/ % susequent Supplier On Site 2ssessment
,SC#O2*#68/ y the Supplier Quality 2ssurance Team of Pricol.
7
REVISION 00
SMS uyers $ill send the preliminary supplier assessment form ,PS2688/ to the
prospective supplier and the supplier shall duly fill and for$ard the same to Pricol for
evaluation $ithin ; $orking days.
The follo$ing $ill e used ut not limited to in the approval process.
SQ2 Memer $ill evaluate the potential supplier as per onsite assessment form
,SC#O2*#68/ $ith a minimum score of 97H and $ith each of the mandatory
questions satisfied.
&valuation of Supplier data related customer PPM( in house re!ection PPM(
re!ection handling system % corrective action.
:eneral details? financial staility( top management involvement % competent
facility.
Suppliers experience $ith customers of 2utomotive 3ndustry.
Technical capaility of facilities and processes to meet Pricol's requirement.
3SO @668?.66< # TS 89@>@?.66@ certifications for Manufacturers % 2uthori"ation
letter or certificate for distriutors( dealers % traders.
*or nonA3SO suppliers( a road map for System )ertification $ithin 8 year of
approval.
)ommercial Tax 1egistration.
2fter Supplier selection is done y Pricol( 1*Q( component specifications # dra$ing
have to e released( and if required Purchase contract to e released accordingly.
Purchase contract has to e agreed and signed y supplier.
R"+E4a-)a$0.n .7 !)//-0" A
The supplier shall inform Pricol $henever( there has een any change in location #
Management # scope of supply ( for reAevaluation and approval.
Pricol $ill reA evaluate the supplier once in every = years.
BOS-SMS and SQ2 Memer $ill evaluate # reAevaluate the oservations # details and
recommend for approval.
8. NEW PRODUCT / COMPONENT DEVEOPMENT PROCESS .
8.a INITIAL SAMPLE SU,MISSION
O!ectives of this phase are to revie$ and approved supplier deliverales to ensure
that product and process quality expectation are reached and to prepare product
launch.
8
REVISION 00
The documents listed elo$ are to e prepared y the supplier and !ointly examined
and get approval $ith the )*T#4PC Team.
8. PreACelivery 3nspection 1eport.
.. Process *lo$ Ciagram.
=. 5ork instruction.
Once these documents have een examined and approved y Pricol( the supplier
undertakes to comply $ith them. 2ny proposal for modifying or improving the product
or process( including proposal related to transfer of production or move or relocation of
the production equipment( shall have to e approved y Pricol on the asis of the
documents modified y the Supplier.
Samples must e sumitted $ith required documentation as specified in the Pricol
requirements.
Minimum 86 no initial samples or as agreed must e sumitted to pricol for
verification.
3n the case of several processes at the supplier ,e.g.? several cavities inside a plastic
in!ection tool/ - the supplier is requested to sumit cavity $ise sample $ith report.
Supplier to preserve 7 4os initial samples per processes and have them properly
identified for the entire life of the component plus t$o years and must e accessile y
the supplier and Pricol at any time.
Supplier shall identify samples using an identification tag.
Supplier shall commence Pilot supply only after otaining the sample approval y Q&
pricol. Supplier to sumit( follo$ing documents along $ith Samples ?
8/ Supplier S31?
866 H Cimensional report is required for supplier tooling # Ceveloped components.
*or pricol supplied tooling( $here the S31 has een done % approved y pricol(
Supplier to sumit all critical dimensions as identified in Cra$ing( check sheet( control
plan.
./ 1a$ Material Test )ertificate ,2s 2pplicale/? Supplier to sumit ra$ material test
report( along $ith specimen.The test certificate to e mentioned $ith the atch#lot no
for easy traceaility.

=/ Cra$ing details availale at supplier? Supplier shall maintain the latest controlled
copy dra$ing( check sheet % S31 $ith revision status of component.
>/ 2ny Specific test or test given in the dra$ing?

4ote? *or Multiple )avity tool( cavity details are mandatory.
9
REVISION 00
8.(? P.d)1$0.n Pa$ A//.4a- P.1"!!
P01POS&?
This guideline explains the various activities involved in the approval of production part
approval process ,PP2P/ for suppliers. The production part approval is required to
determine if all P13)OG's engineering design record and specification requirements are
properly understood and the process at supplier end has the potential to meet the
product requirements consistently during actual production run at the quoted
production rate.
S)OP&?
8. This procedure is applicale for all components supplier supplying $ith their o$n
Material # Pricol supplied material.
.. This procedure is not applicale to 1a$ Materials( )onsumales( Proprietary parts(
Packing materials( as they are not supplying components# part specific to P13)OG
design. *or standard parts# components Pricol has prepared its dra$ing ased on the
standard on the supplier specification # dra$ings.
Part 2pproval Process sumission is required for all suppliers making parts as per pricol
specification % to e used for incorporation into finished products prior to first supply of
parts to pricol efore the regular production.
Part 2pproval shall e otained from pricol $hen any of the follo$ing conditions occur(
prior to dispatch of ulk production.
8. *or a ne$ part
.. *or a product design change # &)4
=. *or a process # 1a$ material # Machine# Production location changes
at supplier end.
>. &xisting part $ith ne$ mould # tool.
7. Ma!or mould # tool # die correction affecting significant %
critical characteristic.
9. 2ny other O&M customer specific requirements
;. )hange of sucontractor for parts( processes ,e.g. heat treating( plating/
8.1? SITUATIONS WHERE CUSTOMER NOTIFICATION IS NOT
RE*UIREDA
10
REVISION 00
4OT&? )ustomer notification is not required $here the changes do not affect
customer fit( form( function( duraility and performance.
8. )hanges to component level dra$ings( manufactured at supplier end internally or y
their sucontractors that do not impact the part supplied to Pricol.
.. Tool movement $ith in the same plane ,used in equivalent equipment $ith no
changes in Process flo$( no disassemly of the tool/ or equipment movement $ithin
the same plant ,same equipment( no change in process flo$/.
&g A +ased on the lean manufacturing initiatives( some equipment is designed for
Moility(i.e. on $heels $ith quick disconnects. )ell configurations or location $ithin a
department may e changed $ithout affecting process flo$.
4o change made to Process flo$ or )ontrol Plan.
=. )hange in equipment ,same process flo$ $ith same asic technology or
methodology/
&g A 4e$ equipment( additional equipment( replacement( or change in
&quipment si"e.
>. 3dentical gage replacement.
&g A :ages replaced as a part of gage maintenance or caliration system.
7. 1ealance of operator in !o content $ith no change in process flo$.
&g A Gean manufacturing allo$s for realancing( !o content to eliminate ottleneck
3ssues.
9. )hanges resulting in reducing 1P4 on P*M&2 ,$ith no change to process flo$/
&g A &xamples include added controls( increased sample si"e and error Aproofing
3nstallation.
8.d? PPAP R)n
Product # Process )hange 4otification *ormat to e used in case of product # process
change than the previous agreed specs.
Minimum =66 nos # =66 shots or one set of shift production or as agreed shall e taken
for PP2P run
The purpose of this stage is to ensure that the process developed y supplier is
capale to produce the defined components in compliance $ith Pricol requirements(
and targets defined for the one shift and consequently to demonstrate?
1un at rate and Pricol reserved capacity
)apaility of the process.
11
REVISION 00
+uild correct product in accordance $ith Pricol approved $ork instructions and
control plan.
The duration of run must e sufficient to assess the staility of the process
,minimum = hours of production and =66 components # shots/ - Bo$ever
depending on the nature of the component pricol reserve the right to require the
supplier to run longer and more components than here referred.
Supplier to identify training needs of all concern production % quality
engineering personnel( training record to e maintained % shall e made
availale for verification on demand.
*ollo$ing the production run( the follo$ing reports must e issued to Pricol
*ull run production report? conditions( quantities produced and re!ected(
analysis of defects( speed of the production line( Total Gine 1e!ect to e
calculated $ith decision accepted or refused.
Process audit report including capailities )p( )pk study for )ritical#key
characteristics as per drg#identified. Minimum )pk required is not less than
8.== or as agreed. )apaility study to e performed on at least 76
components.
R"5)0"d S)('0!!0.n .7 d.1)'"n$!A
0nless other $ise specified( the follo$ing documents and parts to e sumitted for
Production Part 2pproval Process?
8. Cesign records.
.. &ngineering )hange Cocuments ,3f any/.
=. Pricol &ngineering 2pproval ,5here required/.
>. Cesign *M&2.
7. Process *lo$ Ciagrams.
9. Process *M&2.
;. Cimensional 1esults.
<. Material( Performance Test 1esults.
@. 3nitial Process Study.
86.
Measurement System 2nalysis.
88.
Qualified Gaoratory Cocuments.
8..
)ontrol Plan.
8=.
2ppearance 2pproval 1eport.
8>.
+ulk Material 1equirements )heck Gist.
12
REVISION 00
87.
Sample Product.
89.
Master Sample.
8;.
)hecking 2ids.
8<.
Part Sumission 5arrant.
8@.
1ecords of )ompliance $ith pricol specific requirements ,if any/.
The supplier shall sumit to the uyer and retain a copy of the 1ecords #
Cocumentation at appropriate location of manufacturing( along $ith approved master
sample from Pricol % make it readily availale to the Pricol representative upon
request.
9.S&!$"'! $. (" 0'/-"'"n$"d ("7." !$a$0n2 'a!! /.d)1$0.n
9.a? E!$a(-0!h'"n$ .7 P.1"!! C.n$.- P-an / S$andad
5hy is Process control standard necessaryI
Quality can never e achieved only through inspection of finished parts. 3t has to e
uilt into the process. *or uilding quality in the processes ( it must e carefully
planned % controlled. This could e done y estalishing a standard for controlling the
process in all the manufacturing stages starting from the receipt of ra$ materials to
shipment of part. 2 properly planned % effectively implemented process control
standard $ill help to?
a. 2chieve stale quality y controlling variations.
. Jno$ if stale quality is eing maintained or not.
c. Jno$ if defects are eing detected quickly or not
d. Jno$ if further processing # dispatch of defective product is to e stopped or not
after detection.
Keral instructions to $orkers( making !udgement y intuition % $orking $ith only
common sense are some of the asic reasons for generation of defects. The method to
avoid defects is to make a process control plan #standard % implement it thoroughly.
Preparation of Process control plan # standard shall e started efore sample # pilot
production. Since it is difficult to meet all conditions during sample production( the
13
REVISION 00
process capaility shall e studied % carefully examined. The process control plan
standard must e modified suitaly on the asis of sample # pilot production results.
)heck sheets should e carefully designed to record data of various checks on the
asis of the process control plan # standard. The check sheets should contain check
items( specification( measuring instrument # equipment used etc. so that they provide
handy data $hich can e used for investigation in case of defects % also for up
gradation of process. Supplier to use pricol defined )B&)J SB&&T % S2MPG34: PG24
for PC3 verification( supplier to ensure availaility of latest dra$ing # check sheet as
per specification.
9.(? E!$a(-0!h'"n$ .7 O/"a$0.n S$d! / WSS
The primary purpose of making operation stds. is to provide correct $ork instruction to
operators( thus preventing generation of defects due to ignorance of $orkers. 2lso an
operation std(. helps in maintaining the same level of quality even if operator of a
process station is changed. The ne$ operator can e easily trained using the operation
std. Thus avoiding personAtoAperson variation reducing the chance of human error.
Operation stds. are also necessary for control purpose ,i.e check if $orkers are doing
the !o as per the instructions/.
S1./"A 3n principle( operation standards must e made for all the process stations %
fundamentally speaking shall e made for such operations $here their asence $ould
adversely affect product quality.
Bo$ever( please ,indicate safety # critical char. in the title column as per the dra$ing #
flo$ chart provided y pricol if the operation has a earing on item of a part/. 2n
operation standard format shall have( among other things( the columns for enactment
date( revision records( and control no.( place of usage % copy distriution. 2 control
register should e made for operation standards % original operation standards should
e kept in safe custody.
91. C.n$"n$!A
Operation Method?
5rite the operation condition( operation procedures % descrie the correct $ay of
performing an operation in a simple manner preferaly through sketches # visual aids .
)aution Points?
&xplain in an easily understandale $ay using pictures( sketches etc. the caution
points % don'ts regarding the operation.
14
REVISION 00
Process # Machine parameters?
5rite the control parameters of the process # machine % their control specifications for
that station. The control parameters given in your std. shall conform to process control
standard.
Quality )heck Points?
5rite the quality check points ( !udgment criteria( % check frequency etc. for that
station
2normality Bandling?
5rite instructions for the operator( as to $hat he should do in case of anormalities
, e.g inform the supervisor ( 866H inspection etc. /
Cefect Bistory?
5rite details % causes of occurrence of critical quality prolems( $hich have occurred
at the station or at similar stations( so as to prevent recurrence of these prolems.
3mplementation of operation standards?
The supervisors of your company should continually check if the operators follo$ the
standards or not. 3n case $orkers don't follo$ the operation standards( the supervisors
must educate them. They must also revie$ the standards % revise them to eliminate
any shortcomings. Operators should e encouraged to give their suggestions for
upgrading the standards. 3t is the responsiility of Production supervisor # 3ncharge to
ensure that 5SS ,5ork Standard Sheet/ are follo$ed at all stations.
1evie$ of Operation standards?
5henever there is a quality anormality or a feed ack aout quality prolem( it shall
e thoroughly investigated % during this time all related operation standards must e
critically revie$ed. +ased on investigation results( not only the directly relevant
operation stds( ut also the ones related to similar operations must e revised %
upgraded . 1ememer the dictum Dif a std. is not upgraded periodically( it gradually
ecomes uselessL. 3n case of any anormality reported in the process output the same
is deployed hori"ontally at all the similar stations.
Fo set up instructions?
15
REVISION 00
The instructions ,set up % verification of set up/ for all ma!or !o changes ,die change(
ma!or tool change( and model change/( affecting critical quality characteristics etc.
shall e recorded.
:.S@STEMS TO ,E IMPLEMENTED AFTER STARTING MASS PRODUCTION.
:.a? *)a-0$& R"5)0"'"n$ 7. "2)-a !)//-0"!
Pricol $ill accept only purchased material( components( or processes $hich meet
the Pricol's dra$ings # specifications. The supplier shall estalish and 1eA
maintain a system to assure that only the latest applicale
dra$ings#specifications are used.
The supplier is expected to perform the inspections # tests required to
sustantiate conformance to the applicale dra$ing specifications. &ach lot
supplied to Pricol should e attached $ith the PC31( 5here ever defined(
supplier to use Pricol defined check sheet for PC31
0nless other$ise specified( supplier to maintain the ra$ material verification
report#Mill test report for each atch of ra$ material procured. % shall e
sumitted to Pricol upon request.
The supplier shall send the test specimen for the la check purpose
a. Test pad % utton for ruer parts during ne$ atch production.
. &nd its of rod % sheet during fresh procurement of ra$ material
+atch declaration letter to e enclosed $ith the PC31 until the next atch of ra$
material is produced # procured.
Supplier to ensure every lot to e identified $ith T2: $ith detail as defined.
Supplier to follo$( defined standard packing method( quantity for each lot( any
change in method of packing should get prior approval from SQ2.
The supplier is expected to respond $ith )orrective 2ctions 1eport for all nonA
conforming product or material received y Pricol and for high re!ection
materials the process needs to e revie$ed and relevant PP2P documents need
to e modified.
The supplier is expected to maintain @6H on time delivery performance( $hich
$ill e communicated periodically.
3n order to minimi"e the amount of inventory at Pricol( suppliers are expected to
meet delivery requirements( reduce lead times and react effectively to schedule
changes.
The supplier is expected to analy"e and take appropriate corrective actions for
delayed supplies.
4OT&?3f the supplier is unale to meet Pricol's Celivery requirements and the
production Schedules indicate that the product must e expedited using
alternate transportation
16
REVISION 00
*ollo$ing rules#instructions to e strictly adhered during process as part of
system?
8. Gast shot samples shall accompany the tool#mould#die( $henever( there is a reak
do$n or tool#mould#die is offAloaded.
.. 3mmediate information to Pricol( $henever a suspect shipment has een made
ased on the later on findings in your process#records.
=. Cie#Mould#Tool preventive maintenance schedule must include the )heck of 3nserts(
pins( segments health#any crack#$ear out etc.
>. &xtra -precaution in 4ight Shift $orking i.e. added supervisor#Quality 3nspector can
e one of the $ays. ,5ith a Proper Gog +OOJ#communication System for day shift/.
7. 2ny correction # modification in the Cie#Mould#Tool shall e carried out at the
supplier end after the concurrence from pricol.
:.(? C.'/-0an1" $. !$a$)$.& / "2)-a$.& "5)0"'"n$!
2ll suppliers of materials( components( processes shall have a process to assure
that governmental and safety constraints on restricted( toxic and ha"ardous
sustances are complied $ith relative to purchased products and the manufacturing
process. 3n order for Pricol to develop products $hich are compliant to current
1egulated # 1estricted Sustances policies of oth governmental agencies and our
)ustomers( the supplier shall sumit at the time of supply of initial lots( the relevant
MSCS# Pollution )ontrol oard certificate and confirm that they comply $ith the
regulatory requirements.
:.1? S@STEM FOR DEV. OF SU,+SUPPLIERSA
Supplier shall prioriti"e % estalish a documented system for ensuring quality
management system at their critical su Asuppliers on similar grounds. The supplier
has the responsiility of ensuring that its suAcontractors have een approved and are
under a controlled system of evaluation and revie$.
:.d? S@STEM FOR MAINTAINING *UALIT@ HISTOR@ OF PARTS 3 ITS
ANAL@SISA
17
REVISION 00
The supplier shall estalish a documented system for maintaining quality history
of each part. *or each part( trends shall e maintained month $ise for each type
of re!ection. On a monthly asis analysis of all these re!ections shall e carried
out to see the effectiveness of corrective actions initiated % )ontinuous
improvement $ith reference to Pricol set o!ectives. 3t is recommended to
maintain the quality records sheet of prolems reported ,Q*1 # $arranty in
Pricol/ along $ith the corrective # preventive action initiated.
:."? GUIDELINESA REGULAR PRODUCTION DELIVERIES
MO43TO134: C&G3K&1M P&1*O1M24)& :03C&G34&S?
O4 G34& S)B&C0G34: SMST&M ,+.+/
O!ective? 2ll the approved suppliers shall operate through O4 G34& S)B&C0G34:
SMST&M( there y reducing the follo$ up and communication cost.
8. 2 unique supplier code shall e allocated to each supplier( $hose schedules are
displayed on his respective +.+ $e site.
The suppliers can access their +.+ $e site y logging on to our materials site
$hich is as follo$s
h$$/A//%%%./01.-.1..0n/'a$"0a-!/
.. The initial 0ser login % Pass$ord $ill e their respective code( $hich can e
changed as and $hen required to maintain the privacy.
=. The supplier shall al$ays have a valid &AM23G 3C( $hich shall e used y pricol
and the respective supplier for communication $ith their uyers.
>. The supplier shall ensure the frequent visiting to their respective +.+ sites(
$hich automatically get updated $ith the revision of our production plan ,at
least t$ice in day/ to have updated kno$ledge of their schedules and status of
previous deliveries.
Supplier shall monitor the performance of the supply vs schedule % shall initiate
immediate corrective % preventive actions against shortfall of 866H ontime delivery.
:.7? REVALIDATION / LA@OUT INSPECTIONA
1evalidation is a detailed verification of appearance( performance( endurance items
including the PC31 items $hich comprises items for regular check. Supplier shall carry
out revalidation of parts ,for all functional parts % for those frequency to e decided
ased on the usage( general parts asked y Pricol % revalidation of ra$ material at
least once a year. 2ction plan for layout on yearly asis can e taken.
Minimum five parts shall e checked for revalidation. 3ncase of multiple line # moulds(
minimum one sample per line#mould shall e taken for revalidation. &ach year
revalidation plan shall e made % if asked y pricol ( reports shall e sumitted for
18
REVISION 00
verification. The similar activity can e extended to critical su suppliers to ensure the
consistency in pricol quality requirement.
:.2?.ONGOING PROCESS CAPA,ILIT@ STUDIES
Curing the mass production for items of part % for those characteristics as decided
along $ith pricol or as per control plan . On going process capaility studies shall e
carried out $hich includes the control charts to e maintained for special
characteristics. *or these characteristics control limits shall e calculated % e used for
their control charts. 3n case of any nonAcontrol of the process is oserved immediate
corrective action shall e taken.
*or calculating the control limits( data should e taken for the enough period so that all
possile variations are included ,e.g. variation of man # machine # method #
measurement # environment( material etc./
The control limit calculated shall e verified on monthly asis % shall e changed in
case of any process change.
)apaility index ,)p % )pk/ for all the fit characteristics shall e calculated every
month. )apaility index for all these characteristics shall e 8.== % aove. 3n case it is
less than 8.== improvements in the process shall e taken up $ith parallel 866H
inspection till )pk 8.== is achieved. 3f reports of the capaility study is asked y pricol
same shall e sumitted to pricol.
:.h? T..- Mana2"'"n$
)ompany shall have the proper facilities for maintenance( repair of tools % their
storage. 2 recording#monitoring system shall e implemented.
A To record the details of tool ( change of tool ( repair of tools % tool life .
A To change the tools as per the specified frequency.
A 4e$ tool # mould monitoring $ith respect to timely completion shall e as per
Tool Progress 1eport % sumitted to Pricol.
:.0? F0!$ In F0!$ O)$ Pa1$01"A
*3*O shall e practiced as part of the system in component % *inished parts stores.
2ny simple( user friendly % effective D*3*OE methodology shall e adapted as per your
company processes # layout .
:.D? Ca-0(a$0.n .7 IMTE >In!/"1$0.n '"a!)0n2 3 T"!$0n2 E 5)0/'"n$?A
Suppliers shall implement an effective caliration control system for all types of 3MT&.
,3nspection measuring % testing equipment/ used in inspection % processes.
19
REVISION 00
:.#? Ma0n$"nan1" .7 /.d)1$0.n "5)0/'"n$
2 documented system shall e implemented for proper control % maintenance of
production equipments.
System shall include follo$ing?
5ork start up checks? ,2utonomous maintenance/
Periodic checks? ,Preventive maintenance/.
These are the checks of important dimensions of machine tools( dies( mould etc. to
kno$ the extent of $ear % also for caliration of measuring devices fixed on machines.
; .PRICOL + CONTINUOUS *UALIT@ IMPROVEMENT

2 )ontinuous Quality 3mprovement plan is required from suppliers to achieve the level
of PPM ,Parts per Million/ that the automotive industry requires. This plan $ill focus
on?
Preventive quality
&radication of prolem root causes.
Gearning from mistakes $ith lessons learned cards
This is to e initiated y the supplier during start of serial production % Pricol revie$s it
periodically.
Pricol intiates in terms of Quality )ost Celiveries % performance measurale. This Q)C
enefits is designed in such a $ay to help Pricol Pricol and the suppliers to
continuously improve product quality (competitiveness and the logistics chain
The development of ne$ usiness et$een Pricol and its suppliers depends on the
achievement of the " E". D"7"1$ " performance level.
This $ill e monitored through
1eporting on quality issues.
Supplier performance 1eports.
Supplier audits.
>M change management.
Supplier development % follo$ up.
;.a? GUDIELINESA REPORTING ON *UALIT@ PRO,LEMS
3n case of Quality prolem oserved at line or end of line (customer complaints(
,during line usage # $arranty failures/ $hich requires corrective action from supplier(
Pricol $ill intimate the Quality *ailure to the supplier. 2 corrective action shall e taken
y the supplier in order to prevent the reoccurrence of the same % any other similar
processes.
20
REVISION 00
Supplier can adopt <C or Jai"en methodology for reporting corrective action.
2s soon as( the intimation received either through mail or veral communication(
supplier to update customer concern log sheet and quality responsile person to note
the defect( and initiate correction as elo$.
Supplier to estalish )*T $ith all concern area( along $ith team leader( define
the prolem as reported and actual concern # discrepancy oserved >D1 3 D2?.
3nterim action to e initiated to contain defective shipment to pricol. 2ll pipe line
stock#quantity to e identified and arrange for segregation of parts( all in house(
transit % stock availale at pricol to e reverified 866H efore dispatching to
pricol >D8?.
>D9? 3dentify the root cause? supplier to define all the event( that produce the
defect part( use fish one chart( related to >M condition#5hy $hy analysis as
defined in 2pex report to e sumitted to pricol $ithin ; days
>D:? Permanent )orrective 2ction? 3dentify and implement permanent
corrective actions that $ill eliminate the prolem. 1ememer that permanent
means forever. The prolem should never e ale to occur again.
>D;? Kerifies &ffectiveness of 2ction? Kerification takes place in these four
areas? 1oot )ause( 3nterim 2ctions( Permanent 2ctions( Prevention. Kerify the
implemented action does eliminate the prolem ,short term( long term and
other similar processes/ and does not cause any other prolems.
>D7? Prevent 1ecurrence? Preventing recurrence means preventing changes to
the part( process or system that allo$ a prolem to occur. Prevention covers all
similar and related processes( designs( systems( etc update all concern
documents as defined in 2pex.
>D<? )ongratulate Mour Team 1ecogni"e the contriutions of all the team
memers as a group and individually.
Supplier to close the all aove <C $ithin 87 days( supplier to monitor( next three
lots( for corrective action effectiveness.
N.n+C.n7.'0n2 S)//-0"! >D"40a$0.n A//.4a-?
5hen a supplier identifies a deviation from specification( Q& Cepartment at Pricol must
e informed of the details. The nonconforming products must not e dispatched to
Pricol till clearance from Q& Cepartment.
;.(? SUPPLIER PERFORMANCE RATINGA
21
REVISION 00
Kendor 1ating - Overvie$
Kendor rating for Pricol $ill have four parameters( covering the quality and
transactional aspects of supply. These parameters are?
a. Celivery A Transactional 2spect
. Quality A Transactional 2spect
c. )ooperativeness ,1ush Orders/ A Transactional 2spect
The aove factors A Celivery( Quality and )ooperativeness shall e considered for
phase 8 of implementation.
)orrective 2ctions in +.+ shall e considered for phase . of implementation
8. Schedule lines - 1ating )alculation
The matrix elo$ indicates the distriution of $eightage for each scenario mentioned
Tale 8? 5eightage Matrix for each schedule line
S.4.
Scenario Celivery Quality )ooperativeness
8
1ush
Schedules
4ot
2pplicale
6.7 6.7
.
Standard
Schedules
6.7 6.7 4ot 2pplicale
.. Schedule lines - Celivery 1ating )alculation
)orrect master records are preArequisite for effective rating. Celivery 1ating $ill e
computed as follo$s?
Tale .? Celivery 1ating Matrix
Cay Schedule
Sl. 4o Celivery Kariation against Schedule
date
CK *actor
8 up to N8 Cay , Gate y one day/ 8
. +et$een N. Cays to N9 days 6.@
= +et$een N; day and N87 Cays 6.7
> Others 6
5eek Schedule
22
REVISION 00
date
CK *actor
8 upto N; Cay , Gate y seven days/ 8
. +et$een N< Cays to 8. days 6.<6
= Others 6
Month Schedule
date
CK *actor
8 upto N=8 Cay 8
. Others 6
The overall rating for a standard schedule line is illustrated elo$
3n case of the delivery rating for the supply date $ill come from the 86= entry( $hile
the Quantity details $ill come from the 867 entry at the respective stores. *or a P.O
$ith . schedule lines( Material accounting is to e carried out on *irstAin asis for each
schedule line
Tale = ?Sample )alculation
Tale =.8 1eceipt Cetails
1eceipt Got 3tem
1eceived
QTM
)umulative
1eceived QTM
1eceived Cate
Sch
Gine
3t
e
m
Typ
e of
Sch
Schedul
e
1elease
date
Sch
Gine
Qty
2
1equire
d
Celivery
Cate
1eceive
d Qty
+
1eceiv
ed
Cate
Qty
1atio
)
CK
*actor
C
Overall
1atingOQty
1atoP CK
*actor
Schedule
Gine
3tem Standard
Gead Time
1equired
Gead Time
Type of
Schedule
Schedule
1elease date
Schedule
Gine Qty
1equired
Celivery Cate
8 Q 86 days 7 Cays 1ush .< *e .686 766 67 Mar .686
. Q 86 days 86 Cays Standard .< *e .686 .66 86 Mar .686
23
REVISION 00
8 Q 876 876 67 Mar .686
. Q .76 >66 6< Mar .686
= Q 8;7 7;7 6@ Mar .686
> Q 8.7 ;66 86 Mar .686
24
REVISION 00
Tale =.. ?
Material
1eceipt
accounting
against
schedule
lines and
calculation
of Kendor
delivery#
service
level rating
Sch
Gine
3t
e
m
Typ
e
of
Sch
Sche
dule1
eleas
e
date
Sch
Gine
Qty
1equi
red
Celiv
ery
Cate
1ecei
ved
Qty
1ecei
ved
Cate
Qty
1ati
o
CK
*act
or
)oA
operati
veness
*actor
)oper
ativen
ess
Score
Overall
)oopera
tiveness
Score
,on
scale of
866/
8 Q 1u
sh
.<
*e
.686
766 67
Mar
.686
876 67
Mar
86
O,8
76#
766
/
O6.
=6
4ot
2ppli
cale
8
,Suppli
ed
$ithin
reqd.
date/
O8P6.
=
O6.=
O2vg
,6.=(6(6
/P866
O6.86P8
66
O86
8 Q 1u
sh
.<
*e
.686
.76 6<
Mar
86
.76
#76
6
O6.
7
6 O6.7P
6
O6
8 Q 1u
sh
.<
*e
.686
866 6@
Mar
86
866
#76
6 O
6..
6 O6..P
6
O6
25
REVISION 00
Sch
Gine
3tem Type
of
Sch
Schedul
e
1elease
Cate
Sch
Gin
e
Qty
1equire
d
Celivery
Cate
1eceiv
ed Qty
1eceiv
ed
Cate
Qty
1atio
CK
*act
or
1atin
g
,On
scale
of
866/
Servic
e
1atin
g
Over
all
Celiv
ery
1atin
g
, on
Scale
of
866/
. Q
Stan
dard
.< *e
.686
.6
6
86 Mar
.686
;7
86
Mar
.686
O;7#.
66
O6.=;
7
8 O6.=;
7P8P8
66
O=;.7
4ot
2pplic
ale
for
Stand
ard
Sched
ules
Osu
m,.=
;.7(=
=.;7/
O98.
.7
. Q
Stan
dard
.< *e
.686
8.7
.6
Mar
.686
O8.7#
.66
O6.9;
7
6.7
O6.9;
7P6.7
P866
O==.;
7
8. S1h"d)-" -0n"! F *)a-0$& Ra$0n2 Ca-1)-a$0.n
Quality 1ating $ill e computed taking into consideration re!ection and re$ork of
components. The computation logic $ill e as follo$s?

R"D"1$0.n PPM Quantity re!ected# Total Quantity Supplied P 8666666
R"%.# PPM Quantity re$orked#Total Quantity Supplied P 8666666
Sa-4a2" PPM Quantity Salvaged# Total Quantity Supplied P8666666
*//' 1e!ection PPM N 1e$ork PPM
Therefore

5here QT O The target in ppm that Pricol has set for a commodity class
QppmO 2ctual ppm level for the vendor for a particular component in that
commodity class
1e!ection and re$ork ppm $ill e considered for computing Qppm and $ill form part of
the vendor rating $hile salvage ppm $ill e computed separately and $ill e only for
reference for Pricol.
*)a-0$& Ra$0n2A *R G *//'/*T
26
REVISION 00
The logic of keeping salvage ppm separate is that one of the reasons for salvage is also
our design specification issues and other for manufacturaility issues( for $hich the
vendor should not e penali"ed.
The rating and for vendors shall e as per the tale elo$?
Tale >? Quality 1ating Matrix
Parameter 1ating
Q1RO8 866
Q1S8 24C RO8.7 <6
Q1S8.7 24C RO. 96
Q1S. 24C RO..7 >6
Q1S..7 .6
The Quality Target ,QT/ shall e as per the elo$ matrix ?
Tale >.8
Material :roup 4o. Material :roup 4ame Quality Target ppm ,QT/
866 1a$ Material 3mports 876
868 1a$ Material Comestics 876
888 Packing Materials =66
88. )onsumales A Production =66
88= )onsumales - Tools =66
88@ &lectronics .66
8.6 3mport .66
8.. )onsumales - Others =66
.66 Pressed 8766
.68 Machined >666
.6. Moulded .666
.6= Proprietary 8766
.6> Su 2ssemly A 3nhouse ;76
.67 Moulded )omp,3/ 1uer 8766
.69 Su A 2ssemly APlastic .666
.6; Su A 2ssemly APressed 8766
.6<
Su A 2ssemly
AMachined
>666
.6@
Su A 2ssemly A5ire
2ssy
8766
=68 Cie )asting >666
=6. *errous >666
)B&M3)2GS )hemicals =66
M2134& M2134& 8766
others Others 8766
27
REVISION 00
*or the given example
1ec
eipt Got
3tem
1eceived
QTM
)umulative
1eceived
QTM
1eceive
d Cate
2ccept
ed Qty
1e!ected Qty
8 Q 876 876
67 Mar
.686
8>@ 8
. Q .76 >66
6< Mar
.686
.76 6
= Q 8;7 7;7
6@ Mar
.686
8;> 8
> Q 8.7 ;66
86 Mar
.686
8.7 6
PPM
OT,8N6N8N6/#,;66/UP8666666
O.<7<
2ssuming component as the Molded component
Target PPM for Molded component , from Tale >.8/ .666
Q1
O.<7<#.666
O8.>.@
Quality 1ating ,*1OM T2+G& >/ O<6
9. S1h"d)-" -0n"! F C../"a$04"n"!! Ra$0n2 Ca-1)-a$0.n
)ooperativeness and compliance to +.+ for corrective action are the t$o areas s
measured for service. )ompliance to +.+ is planned for inclusion in Phase of vendor
rating ,planned to e released y Sep .686/
System $ill check the Gead Time given to vendors for supply of components and the
Gead time that has een entered in master dataase in the system. 3n case the lead
time given to vendors is greater than lead time entered in the master dataase( then
such a supply $ill e considered as regular schedule. Only regular schedules are
considered for Celivery 1ating
Bo$ever( in case the lead time given to vendors for supply is less than the lead time
entered in the master dataase( then such schedules are considered as rush schedules
and the same $ill e highlighted in +.+ $ith a flag reading as V10SB'. Only rush
schedules are considered for Service 1ating.
*or rating this part of the service rating( )ooperativeness $ill e measured as follo$s?
28
REVISION 00
Tale 7..? Sample )ooperativeness Score
)ooperativeness parameter O ,Qty supplied against Schedule# Total 1ush Schedule
QTM/P866
*or delivery quantities against rush schedules( actual delivery date extending up to
7H and or 8 day $hichever is higher eyond required delivery date is a$arded
866H delivery rating.
3f the vendor has got no rush Schedules for the month( then cooperativeness rating
$ill not e applicale.
:.S1h"d)-" L0n" + O4"a-- Ra$0n2
Tale 9..? )orrective 2ctions in +.+A 1ating Matrix
S.4.
Scenario
Celivery
,1d/
Quality
,1q/
)ooperative
ness ,1c/
)orrective
2ctions in
+.+ ,1/
Overall 1ating
8
1ush
Schedules
4ot
2pplica
le
6.7 6.7
4ot
2pplicale
O
,1qP6.7N1cP6.7/#866
.
Standard
Schedules
6.7 6.7
4ot
2pplicale
4ot
2pplicale
O,1qP6.7N1qP6.78/#
866
*or the aove example ? , KendorAMaterialAPOASchedule $ise/
S.4.
)omp
onent
Schedule Type
Celivery
Score ,1d/
Quality
Score
)ooperativeness
Score
Overall 1ating
8 Q
1ush
Schedules
42 <6 =6
O
,<6P6.7N=6P6.7
/
O77
. Q
Standard
Schedules
98..7 <6 42
O,98..7P6.7N<6
P6.7/#866
O;6.9.7
Sch
Gine
3tem Type of
Sch
P.O
1elease
date
Sch
Gine
Qty
1equir
ed
Celiver
y Cate
1ece
ived
Qty
1eceiv
ed
Cate
Qty
1atio
CK
*acto
r
)oA
operativ
eness
*actor
)oA
opera
tiven
ess
Score
8 Q 1ush
.< *e
.686
766
67 Mar
.686
876
67 Mar
86
O,876#
766/
O6.=6 4ot
2ppli
cale
8
,Supplie
d $ithin
reqd
date/
Osum
,=6H
N6H
N6H/
O=6
H
8 Q 1ush
.< *e
.686
.76
6< Mar
86
.76#76
6 O6.7
6
8 Q 1ush .< *e
.686
866 6@ Mar
86
866#76
6 O 6..
6
29
REVISION 00
;.C.'/.n"n$ L"4"- F Ra$0n2 Ca-1)-a$0.n
9.=?)omponent Gevel 1ating Tale
Month
)om
p
Standard Schedules 1ush Schedules Overall 1ating for
)omponent
, H/
O,2N+/#,MN4/ H
Total
1ating
Scored
,2/
Total
Possile
score
,M/
Total 1ating
Scored
,+/
Total
Possile
score
,4/
2pr
.686
Q 42 42 77 866
OT,77N;6.9.7/#.6
6UP866
OT8.7.9.7#.66UP8
66
O9..<8H
2pr
.686
Q ;6.9.7 866 42 42
7. C.n!.-0da$"d V"nd. Ra$0n2
Kendor )omp
Overall 1ating for )omponent
,average of rating of all components/
86 Q 9..<8H
86 M =6H
2pr .686 Overall O 2verage ,9..<8H(=6H/ O>9.>8H
P2ssumption that rating for component M is =6H ,calculated on the same methodology
as that illustrated for component Q/
<. P"7.'an1" D"+a$0n2A

D"-a&! 1a)!0n2 D"+a$0n2
8. Premium freight 8H
.. Pricol line stoppage .H
=. )ustomer line stoppage <H
<.1 P"'0)' F"02h$A
30
REVISION 00
The supplier ahsll maintain records of premium freight paid y them ,$hether payale
y themselves or payale y pricol/ along $ith date( amount involved % reasons
thereof. They shall send monthly statements of such premium freight to pricol
Materials Management.
Pha!" 2 R"5)0"'"n$!
:. C-.!)" .7 1."1$04" a1$0.n! >$h.)2h ,2,? Ra$0n2 Ca-1)-a$0.n
2ny nonAconformity raised in +.+ is evaluated for closure and rated as per the
matrix elo$
Tale 9.8? )orrective 2ctions in +.+A 1ating Matrix
Parameter 1ating
)orrective
action $ithin
; days 866
)orrective
action $ithin
87 days 76
)orrective
action given
after 87 days 86
2t default the )losure of corrective action should e at 866. This $ill e the case if the
vendor has no re!ection at all.
PS ? )losure of corrective actions ,through +.+/ is planned for inclusion in the overall
rating y Sep .686 after necessary system readiness and training of vendors.
;.1? S)//-0" A)d0$! .
5e shall explain in this chapter regarding the audit of quality system( $hich is
conducted y Pricol on its suppliers. The o!ective of audits is to maintain % improve
quality of product through effective implementation % improvement of quality system.
Preparation for the audit ?
3t is useful to prepare the checklist to carry out the audit. )hecklist should include all
the areas to e audited.
2udit records?
31
REVISION 00
2udit results % improvement action plans identified during supplier audits are
circulated through mail#minute( after the audit. *ollo$ up audit may e planned ased
on the criticality( score % susequent supply status.
Quality Management System 2udit ,QMS 2udit/?
5e shall explain in this chapter regarding the quality management system audit
,SQM686/( $hich is conducted y pricol on your company. These audits are
undertaken as a preventive measure to get the confidence that the quality
management system eing follo$ed y your company on the follo$ing requirements(
8. Management 1esponsiility
.. 3nternal 2udit
=. 3ncoming material % su supplier control
>. 3nAprocess control
7. 3nspection Measuring % Testing &quipment ,3MT&/ control
9. Machine tool die maintenance
;. )ontrol of non confirming products
<. 2nalysis of customer complaints
@. 4e$ product development
86. )ustomer supplied products
88. Cocument change data control
8.. Storage( packing % preservation
8=. Bouse keeping
8>. B1 % Training
87. Statutory # 1egulatory requirements
QMS 1ating criteria?
Supplier overall performance $ill e monitored as per the elo$ criteria(
Ra$0n2 C0$"0a
G""n
>V"& G..d?
@"--.%
>A4"a2"?
R"d
>,"-.% A4"a2"?
QMS 2udit Score <8H A 866H 98H A <6H +elo$ 96H
2ctions 1equired
&nsure sustenance
% focus on
continuous
improvements
)ounter measure
report to e
sumitted to
achieve :reen
ststus
)ounter measure
report to e
sumitted to
achieve :reen
status
Process 2udits?
32
REVISION 00
5e shall explain in this chapter regarding the process audit ,SMP2)A68/( $hich is
conducted y pricol on your company % $hich can e conducted y you $ithin your
company. These audits are undertaken as a preventive measure to get the confidence
that the processes eing follo$ed y your company shall continue to produce defect
free parts .
These are the detailed audit of your processes. These audits are conducted as per the
documented control plan % other standards referred in the drg. The purpose of the
audit is
to identify areas $here improvements are required for correcting specific quality
prolem faced
to highlight areas $here improvements can e made in the process for effecting
general improvement in the quality % productivity of parts produced.
2ction plan?
2fter an audit y pricol( supplier $ill e asked to sumit an improvement action plan
giving specific dates for implementation of improvement actions against each point
mentioned during audit.
Preparation for process audit?
&stalish the purpose of the audit i.e. preventive measure or to solve the specific
quality prolem .
)ollect all relevant std. # documents
3nvestigate the previous quality performance of the part % collect the relevant data
, re!. PPM Or complaint from the customer ( line prolems previously reported./
)ollect the previous audit % countermeasure report.
Prepare a checklist of the critical areas you $ould like to check to ensure that the allA
critical areas are covered.
)hecklist may include the follo$ing areas?
8. Cocumented $ork instructions # process control parameters
.. )heck for !o# machine set up efore regular production
=. Machine !igs # fixture control
>. Cie # mould # tool control
7. Process control
9. 3ncoming # in process # final inspection
;. Storage # Bandling
<. Traceaility
@. )aliration of inspection # measuring instruments
86. )orrective % preventive actions
88. )ontrol % monitoring of special processes
8.. Plant Gayout for smooth material flo$ % 7S
33
REVISION 00
8=. Statistical process control
;.d? S)//-0" P"7.'an1" Mana2"'"n$
+ased on the last = months Quality performance Pricol $ill identify the Poor Performing
Suppliers( $hich $ill e follo$ed on a monthly asis(
Pricol $ill launch a Supplier performance improvement Program,SP3P/y notifying the
poor performing supplier mainly focused on follo$ing methodology?
Top Management meeting ,division # ranch # group level/? Pricol $ill notify Top
Supplier Management ,:roup senior management( )hief Operating Officer( or
Plant :eneral Manager/ y sending an official letter.
Supplier top management to present( detail analysis % provide action plan to
improve quality performance
:&4+2 2ctivity ,shop floor activity/? Pricol $ill check the implementation and
the efficiency of corrective actions presented during the monthly meeting y
visiting the supplier's facility $ithin the month. 2t the same time( Pricol $ill
propose to support the supplier y deploying the Pricol supplier performance
improvement program.
The exit of the supplier from Supplier Performance 3mprovement Program
,SP3P/$ill e decided y the Pricol SQ2#SMS BOS upon satisfactory achievement
of the targets agreed in the SP3P charter ut $ill take along at least =
consecutive months in order to measure accurate improvement.
3n case of no improvement during = consecutive months follo$ing action $ill e
decided y Pricol $ith the follo$ing consequences?
4o 1*Q process for any ne$ usiness
4o ne$ +usiness a$ard from any Pricol plant for the duration of the 4e$
+usiness on Bold status
2 monthly follo$Aup y the BOS SMS in order to evaluate the relevance of the
Supplier action plans.
5hen the supplier achieves the target given y pricol( quality performance status for a
period of three months to confirm the results.
Phase O0T?
34
REVISION 00
3f the supplier is not improved after applying the quality activities through Supplier
Performance 3mprovement Program,SP3P/( Pricol $ill decide to phase out the
reluctant supplier $ith a clear deadline and identified resources to manage the
transfers.
7. CHANGE MANAGEMENTA
7. a? En20n""0n2 Chan2" Mana2"'"n$A
Supplier $ill receive notification for engineering change $ith relevant ne$
specifications # Cra$ings from memer material( supplier $ill study the requirements
and revie$ the changes required in tooling # material # process and implement the
same $ithin the expected date and get sample inspection approval efore pilot lot
production.
The suppliers have to communicate and get decision from the SMS uyer on the
disposal of materials availale at their unit.
The osolete dra$ing shall e scrapped or sent to Pricol or marked as Vosolete' and
can e used for later reference.
The supplier shall follo$ the production part approval process as in the chapter =(
efore taking production lot.
7. (? 9M 1han2" 'ana2"'"n$A
The supplier has the oligation to communicate any product or process changes to
Pricol in $riting and to otain approval prior implementing the expected changes.
Supplier to inform in $ritten( respective uyer( % shall get approval from Pricol Q&(
efore starting mass production.
Pl refer elo$ tale( to understand >M )hange conditions(
35
REVISION 00
>M Cefinition &xamples of >M changes
Material
)hanges to e made to $hat
is used in the components or
ra$ materials or to the
component or ra$ material
source
Material change from Polyamide to
polypropylene or equivalent(
Packaging material from = ply cardoard to .
plies
)hange in packing # quantity method.
)hange ra$ material supplier or suAsupplier
Method
)hanges to e made in ho$
$e produce or test or control
components
Packaging # 3nspection # 1e$ork operation
addition or deletion# location shift.
2utomatic process to manual process(
Single component processing to atch
processing
Temperature in heat treatment furnace(
)ontrol frequency change from 866H to 7 at
start of production( or vice versa
Machine
)hanges to e made in the
machines( gauges or tools
used to produce or test or
control components
)hange layout of production line( ut no change
in equipment.
)hange in supply site( one unit to another or
sister unit.
2ddition of ne$ machine in order to increase
capacity.
1enovation of old mould #tool(
Ma!or re$ork #1epair of tool.
Purchase ne$ test equipment(
Man
)hanges to e made in the
organi"ational of the
$orkforce involved in the
manufacturing of the goods
Boshin activity of Gine realance from >
operators to = operators
Go$er skill set of the operators to reduce direct
laor costs
4e$ shift has to e constituted at the supplier to
extend capacity
4on respect of the >M y the supplier( $hich $ill lead to pricol line stoppage( customer
line quality failure in field # usage( customer dissatisfaction( Pricol management $ill
decide appropriate action.

<. TRAINING 3 CONTINUOUS IMPROVEMENTA
Ha0I"n
To provide value for money to the customer to remain competitive % to maintain
gro$th of the organi"ation( path of kai"en or continuous improvement shall e
follo$ed. Jai"en signifies small improvements as a result of continuous efforts
involving employees at all levels from all areas.
36
REVISION 00
*or implementing kai"en in your company( employees should e motivated to give
suggestions ,e.g. y giving re$ards( recognition etc./ % an environment in your
company should e created $hich gives confidence to the employees that their
suggestions $ill e listened % if appropriate $ill e implemented.
2ll the improvements done may e converted into the $orth of money Saved e.g
- Man hour saved
- Space saved
- Material saved
This $ill help your company in analy"ing the quality # effectiveness of suggestions and
the enefits your company is getting from this activity.
Quality # productivity # cost # customer satisfaction performance measurement %
improvement
Mour company shall $ork to improve the quality % productivity continuously.
Performance indicators shall e identified y you to improve quality % productivity .The
progress in these areas shall e monitored y the management at regular intervals.
*ollo$ing are the examples of performance indicators
Performance indicators
- machine do$n time
- machine set up ( tool die change % machine change over time
- cycle time for each product
Some of the suggested techniques used for improving the productivity
- machine reakdo$n analysis
- time % motion study of each process
3mproving the quality of the product Performance indicators
- 3n house re!ection# re$ork trend.
- )apaility indices , )p % )pk / H of processes having )pk 8.== % aove
- Measurement System 2nalysis , H 1 % 1 /
- S1K re!ection # line re!ection at pricol
- H $arranty
S.'" .7 $h" $"1hn05)"! $ha$ 1an (" )!"d 7. 5)a-0$& 0'/.4"'"n$! a"
SP)
*M&2
)ause % &ffect diagram
Bistogram
MS2
Pareto analysis
Cesign of experiments
*ault tree analysis
37
REVISION 00
TPM
Six Sigma
Quality )ircle
5hy 5hy analysis
C.!$ "d)1$0.nA
Some of the performance indicators are
- Kalue added per employee
- )ost of quality
- Product produced per employee,Per Man# Cay production monitoring system/
- 1eduction in material movement inside the company
- Man hour saved
- Saving of shop floor space
- )ost of carrying inventory
S.'" .7 $h" $"1hn05)"! )!"d 7. 1.!$ "d)1$0.n
- ench marking
- standardi"ation
- measure of cost of quality
- value analysis
2ny changes done in the process( material( method( design( susupplier location shall
e done in consultation $ith pricol( if necessary $ith prior approval of pricol.
I'/.4"'"n$ 0n 1)!$.'" !a$0!7a1$0.n
The supplier shall $ork continuously to improve the customer satisfaction i.e. pricol ..
Performance indicators
- Quality system audit # process audit rating # Supplier Performance rating
- 4o. Of complaints ,veral complaints( other feedack/
- 4o. 5arranty claims # Hage of PPM
- Celivery performance , H on time delivery /
- )ost control # K2 # K&
- Quick response to Pricol needs # )ycle time.
- H Of components supplied in reusale packing
The performance level on the customer satisfaction shall e a part of your
Management revie$.
=. SELF+CERTIFICATION CRITERIA >D TS A DIRECT TO STORES ?A
Self )ertification of suppliers $ill e ased on successful implementation of quality
assurance requirement as per the SQ2 % the CTS agreement et$een supplier and
pricol.
38
REVISION 00
O!ective % scope?
To eliminate non value adding activity in supply chain and shall e applicale for all the
in$ard components from suppliers.
)omponent identification ased on ?
4o re!ection#1e$ork PPM for the past one year
Gots supplied is 7 % aove.
QMS Score more than 96H
Supplier $illingness
CTS 1equirements
CTS Tag $ith details
CTS seal stamped invoice
Pre delivery inspection report
Gay out inspection report
*or any deviation on CTS supply( the supplier should immediately arrange for the
segregation and support pricol line assemly $ithout affecting the production
schedules.
2nalyse the exact root cause and sumit the corrective action to SQ2 $ith proper
evidences. SQ2 $ill monitor the consistency of the corrective action and once the
corrective action found to e ineffective( lot $ill e in$arded through normal
inspection.
39
REVISION 00
SUPPLIER ACHNOWLEDGEMENT/ACCEPTANCE FORM
5e have received the Pricol Supplier development manual and agree to aide $ith the
expectation(terms and conditions as stated in the manual. 5e promise to make ourself
a$are of the related activities that are considered to pose a significant impact on the
activities of pricol in its !ourney to$ard quality.
5e extent our support to the o!ectives and efforts taken y pricol for an occupational
health( safety and environmental friendly manufacturing and management practices.
Supplier details?
Supplier name ?
Supplier )ode ?
2ddress ?
,$ith email id/
)ontact 4umer ?
)&O# Plant head ?
Signature ?
Cate?
*Please return a copy of the acknowledgement form duly accepted and signed by
the CEO/Plant head of the organization within 15 days of receipt
Supplier Quality 2ssurance Team
Pricol Gimited( Plant 3
Periyanaickenpalayam(
Ooty Main 1oad(
)oimatore 9>8 6.6
Tamil4adu(3ndia.
40
REVISION 00
Sa'/-" F.'a$! 7. R"7""n1"
Supplier Assessment
Form1.doc
PPAP Formats - IV
Edition.xls
8 D Report.xls
dts tag size.xls !S Audit "#ec$
s#eet.xls
PR%"ESS A&DI'
"(E") S(EE'.xls
41
PSA form
DTS -Tag
QMS Checksheet
Process audit Check sheet
PPAP Format IV edition
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REVISION 00

"GROW TOGETHER" DATE 10/07/2012

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