SUPPLIER QUALITY SYSTEM SURVEY iMaRQ

AUDIT

Direct Production Material

Supplier
: M/s Metal forms (p) LTD

Location : Chennai

Commodity : Sheet metal&fabrication

Date of Audit : 31.07.2017

Auditor :D.Navamani
1st audit 30.04.2017 60.50%

2nd audit 31.07.2017 64.06%

 Acceptance Criteria

Overall Score Rating Disposition

> 90 Excellent Accepted

80 – 89 Good Accepted with action plan to reach score 90

Conditionally approved with quality

70 – 79 Satisfactory
improvement plan

< 70 Un satisfactory Rejected

Calculation Methodology

Individual Score = Weightage X Actual Score

Over All Score with Design = {Sum of individual score in (Management

Responsibilities(A) + Manufacturing Capabilities(B) + TAFE's specific Requirements (C)
+Design capabilities(D))} / Total weigtage(415)

Over All Score without Design = {Sum of Individual score in (Management

Responsibilities(A) + Manufacturing Capabilities(B)+TAFE's specific Requirements (C))} /
Total weightage without design(325)
SQA 01 004
 SUPPLIER QUALITY SYSTEM SURVEY
iMaRQ AUDIT
Supplier :Supplier : M/S Metal forms (P) LTD Audit Date :31.07.2017

Address: No :530,T.H.Road ,Redhills, Chennai-52

Supplier Code : TBDM0101

Business Value : 50lacs/annum

Number of parts : 5

Contact Person : Mr.Balaji Buyer :Mr.Nazhar

Phone No : 7418023424

E Mail ID :balaji.costing@metalforms.co.in

Supplier's Participants
Mr.Babu - VP Mr.Adhiveerakumar

Mr.Balaji

Mr.Swaminathan

Mr.Myilpillai

Mr.Nataraj

Mr.Senthil kumar

TAFE Participants
Mr.D.Navamani

Mr.Santhoshkumar

Purpose of the Audit

New Supplier Up gradation Major Discrepancy

Scope of the Audit Sheet metal & fabrications

EVALUATION SUMMARY

Score 64.06%

Rating Un satisfactory

Disposition Rejected

Scored ' 0' 0

Scored < 40 4

Scored < 60 31

Scored > 80 14
Corrective Action Plan Submission Date 14.08.2017

Re Audit Schedule -

SQA 01 004
SUPPLIER QUALITY SYSTEM SURVEY SCORING SHEET
iMaRQ AUDI

Supplier : M/S Metal forms (p) LTD Survey Date : 30.07.2017

Customer : TAFE Auditor : D.Navamani

SN Area of Evaluation Key Check points (Guidelines to be referred)

A MANAGEMENT RESPONSIBILITIES

Quality Policies

1 Quality Policy Written policy; percolated to all employees.

Quality Improvement Planning (Business

2 Existence of plans: depts. involved.
Plans)

3 Employee Involvement in Quality (TQC) Quality circles, multi-discipline teams, etc.

4 Training Training programmes tailored to quality.

Orgnanisation structure and

Systems

5 Role & Authority of the Quality Function Existence of function and of various tools for control.

6 Quality System Procedures Availability of Quality Manual.

7 Quality System Audit Existence of system; action plans; documentation.

8 Corrective Actions to the System Actions based on audit, monitoring, time-based reviews.

Management Monitoring

9 Cost of Quality System to establish and report, and used as a tool.

MIS,Trends monitoring and triggering the top ten in line

10 Analysis and Use of Data
with the business objectives.

Regular management reviews by Top Management with

11 Management reviews
respect to business objectives
 Total Score Management Responsibility

B MANUFACTURING CAPABILITIES

New Parts Development

12 Advanced Quality Planning PFD,FMEA, SPC,Control Plans,Process Sheets etc

Jigs,fixtures,gauges,toolings design and

13 Production Engineering
manufacturing,Tooled up samples preparation

Ppk Studies,Process and product qualification.Customer

14 PPAP Sign Off
approval

Sub Supplier Controls (Critical

RM,HT,ST,Finish opn).

Sub Supplier Approval System and up Procedures, quality systems rating, management
15
gradation commitment to quality

Technical Documentation with Sub Availability of dwgs., specs., quality stds. With sub supplier
16
Supplier in line with customer requirements

Sub Supplier's parts and process

17 Process control studies and audit by supplier.
qualification

Corrective Action Methods used with sub

18 Control of non-conformities, corrective action plans.
suppliers

Process Controls

Layout logical; sufficient space for material movement;flow

19 Machine & Plant Layout
chart available

20 Machine , Tooling & Process capability SPC Techniques, etc.

FMEA studies, action plans for points with high-risk

21 Process FMEA
numbers.

Identification of special and critical characteristics &

22 Parts Characteristics Classifcation
classifaction

Technical Documents

Incoming,inprocess,out going quality plans,critical process

23 Control Plans
and product parameters

24 Process Sheets Availability of process sheets at each work-station

Listing dims / features that require checking, sampling

25 Inspection Instruction Sheets
frequency,methods etc
 Error proofing,poko yoke ,fail safe
26 Poka Yoke culture driven by Top Management
approach

Product Identification

Product Identification and lot traceability Identification from raw material stage to finished product
27
method stage

Documentation

Master list of drawings,standards,toolings ,Updating of

Managing Technical Documentation &
28 quality stds, processes during production and after
product changes
modification if any

Documentation showing; lot/phase of process, sample size

29 Documentation of Controls
checked ,root causes of non conformities ,etc

Preventive Maintenance

Preventive maintenance programme based on past repair

30 Preventive Maintenance
maintenance

Monitoring of services, eg water, compressed air, heating,

31 Monitoring of Facilities
generators etc

Inspection Controls

Automatic controls of processes subject to variability and

32 Monitoring of Process Parameters
special process

Systematic first piece approval during each set up prior to

33 Set up approval
production clearance

Receipt material storage, verification approval and release

34 In coming inspection
to line

Checks in line with instruction sheets; automated checking

35 In process inspection
of significant characteristics ,corrective actions to be taken

Regular audits as per customer-oriented checklist;

36 Outgoing inspection
improvement plan for demerits found

Inspection Gauges & Instruments

Gauges, etc available to conduct all checks required by

37 Availability & Use of Gauges & fixtures
process sheets,inspection sheets,& technical spec.

Master samples,reference samples to Establishment of mutually agreed customer samples for

38
narrow down subjectivity subjective parameters

Existence of comprehensive system (frequencies, records,

39 Gauge & Test Equipment calibration
controls)

Non Conformance Handling

 Identification system, correction of non-conformities,
40 Handling of Non-Conforming products
deviation system etc

Analysis of Non-Conforming products & Systematic analysis of failures reported by customer, root
41
subsequent Corrective actions cause determination,corrective action , verification

Deviations

Formal procedure for requesting customer's approval of

42 Deviations (Internal & External)
deviations

Production Planning and control

Planning of production and interlink with customer

43 Production planning and control requirements and sub suppliers schedules. Daily /just-in-
time scheduling, automated information system

Material Handling, Transport & packaging Procedures for packaging instruction, material handling
44
(FIFO) equipment,storage,delivery

C TAFE's Specific Requirements

Tracking and monitoring customer delivery with satisfaction

45 Delivery Performance
level.

Tracking and monitoring customer end rejections with

46 Customer end rejections (PPM level)
agreed targets

47 5 S Activities Company's culture

48 ISO 14001 Consent Order Continuously maintaining orders

statutory and regularity Requirements Pan no,Company licence ,Tin no ,ESI no,PF no,Service Tax
49 compliance
Reg no

Total Score Manufacturing Capability

SCORING SUMMARY

Management Responsibilities - A

Manufacturing Capabilities - B + C

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

RQ AUDIT

Auditee : Balaji&team

Reason for Audit : Upgradation

Actual Weightage x
Weightage
Score Actual Score

5 80 400

7 80 560

6 60 360

7 60 420

7 80 560

4 80 320

5 60 300

5 60 300

3 80 240

8 60 480

8 60 480
65 760 4420 68.00

5 80 400

8 80 640

7 80 560

6 40 240

5 40 200

8 40 320

6 60 360

8 60 480

9 80 720

9 60 540

6 60 360

9 60 540

9 60 540

9 60 540
8 40 320

6 60 360

4 60 240

3 60 180

7 60 420

2 80 160

10 60 600

9 60 540

9 60 540

10 60 600

10 60 600

10 80 800

3 60 180

10 60 600
 5 60 300

9 60 540

4 60 240

3 60 180

7 60 420

8 80 640

10 80 800

5 60 300

4 60 240

2 80 160

260 2380 16400 63.08

65 760 4420 68.00

260 2380 16400 63.08

325 3140 20820 64.06

SQA02004
 Part No P10213C03301,Flange-MS gear box Mtg.Material specified in the drawing
is ERW IS : 3601 YST 310 or TSMS 012 (MAHS) ERW 2 Normalised .But tensile
1 strength was found 423 instead of 450 N/MM2 tested at microlab report no
ML/30452/1/16-17 Dt-06 Feb 2017

2 pH value meter to be introduced to check the coolant concentration level.

P10213A00802,Flange-MS gear box Mtg,First off inspection report dated

3 10/05/16.Dimensions such as ,N8,N7 are not covered in the First off report.

Oxyfuel profile cutting,Bed and torch should be cleaned periodically.Need to fix

4 frequency of cleaning.

5 Sub supplier M/s Tube designer ,No evidence of sub supplier approval system.

Rear cover after oxyfuel profile cutting bend found up to 1mm , rejected
6 components kept in shop floor no evidence for analysis report.

Rear cover after oxyfuel profile cutting bend to be conrol with in specification
7 0.3 mm max ) the same need to amended in control plan.Introduce to gauge at
profile cutting.

Calibration is not done for the gauges of P10213C05201- Assy flange gear box mtg,
8 P10113C01001- Dummy flange gauge, Rear Cover Reciver gauge.

Operation 40 : Facing & Machining In random inspection done , Under size

9 observed in rear cover thickness up to 10.84mm.
 Operation 60 : Rear cover Drilling, It is mentioned as copper in control plan but
10 physically it was parmar machine used.Need to be update in CP.

Rear cover face machining process - component not properly seating on the butting
block after clamping . Due to block worn out up to 0.77 mm and also found soft
11 condiition in butting block .HT to be done for butting block to increase the life(wear
& tear).

Part No P10213A0130260,Operation 20:welding.Process qualification and

12 validation plan not evidence.

welding parameters to be monitored on daily basis through check sheet . Like

13 current ,voltage ,gas flow , etc..

Welding parameters need to interlock with machines. (Current ,voltage ,feed rate ,
14 gas flow )

No evidence for sub supplier QMS audit report format number.but as per
15 procedure showned for Doc.No:MF/MQMSP/7.4;Revision:04/27.5.16.

Welding machine No MIG25/MF2/013.Calibration report available but no evidence

16 for accptance Criteria .Example setting spec : 50.00mm but actual:49.80mm Error
found -0.20mm.

Welding SPM Made for Mahendra machine tools, No evidence of preventive

17 Maintenance record for job holding center.

Machine maintenance & Preventive maintenance check list found be generic

18 mode.Technical points specification are not covered .For example sliding
play,spindle run out etc.,
 Customer complaint;Part Name: Assy GB box mounting dated
17.03.2017,Spec:148.0/147.8.Actual Found 148.10.Non conformity analysis
method is not effective.because occurence related action been not taken only
19 detection control introduced in final stage (gauge), monthly 10 nos rework occured
also during the process there is a possible of mixup with ok components. Need to
analysis clamping system and to be reduce the process variation.

No evidence of preventive maintenance for tool and fixtures ( Flange MS gear

20 mounting , flange -LH ) .Preventive maintenance plan to be made for all the fixtures
and adhered as per plan.

21 Cost of Quality datas are availbale.But,there is no evidence of Analysis report.

22 No evidence found for Sub supplier Drawing control system and Quality plan.

23 Process Capability study needs to be taken for all the critical dimensions.

M/s TAFE related parts,No evidence found for Poka yoke system .Need to drive
24 poka yoke system and monitoring on regular basis.

Part No P10113C00201,Bought out from M/S willpower engineers.There is no

25
evidence of PPAP signed off with sub supplier M/s willpower engg.

26 Welding wire specification need to be updated in control plan

Part No P10213A0020260,Operation 20:Welding process,After welding process 20

27 minutes cooling time given.But not evidenced in control plan & Work instruction.

28 After training to be ensure effectiveness with related projects.

 SPM WELDING - torch adjusted by operator for each and every component because
29 only one torch is available .Two torch facility to be made to avoid torch frequently
adjustment and to improve welding Quality/Productivity.

30 Welding machine gas flow meter no evidence for calibration reports

Welding Torch Pneumatic cylinder air pressure to be updated in control plan &
31 Work instructions.

32 5S Procedure to be amended in TS 16949 procedure and need to conducted

periodical aduit based on the report & make the imrovements plan.

33 Rework targets to be arrived and the same Incorporate in quality objective.

Rework/Rejection /customer complaints analysis not effective need to strength

34 analytical skill . During analysis to be use Statistical tool like 7 QC tools ,six sigma
,QUALITY CIRCLE etc..,

Sub supplier M/s willpower Engg raw material audit frequency should be
35 incorporate to control plan.

Sub supplier M/s willpower Engg rating documents not evidenced for month june
36 & july.

Mr.Tamizh & Mr.Gopinath audit was done for schedule 17-18.but no evidence of
37 internal auditors qulified certificate .

Flange-MS gear box Mtg 36 &42 tube has been done for grinding process found at
38 tacking stage.No evidence for concession & deviation note.