MARUTI SUZUKI INDIA LIMITED

Issue Deptt. QA/SC Prepared Verified

Vendor Quality System Assessment Report - Tier II
Date of Issue
Copy to Supplier name
Supplier Supplier Attendant Name Audit Date
SC 1

Audit Person
Cluster Name Hanon Systems India Pvt Ltd

(Audit Score)
Achieved Score：
Total Score：
46 Vendor (Tier 1) person
×１００ = 41
112

Total
Subject: Vendor System Assessment Part Number：
Part Name:
Observation:-

0 1 2

1 4/8 0 4 0 1.Production
preparation
2.Regulation for initial
production control
2 3/6 0 3 0

3 5/ 10 0 5 0 16. Process Audit

15. Adequate testing facility 3.Changing management
cal parts Management 50
4.Standards
4 3/4 0 1 1 ndling Management
management
12.Products management
11.Implementation 0 5.Education and training

5 4/6 0 2 1 6.Quality audit and p

7.Supplier control

6 3/6 0 3 0

7 2/2 0 0 1

8 8 / 12 0 4 2 14.Crit
i
13.Ha
9 7 / 10 0 3 2 Total

10 7 / 10 0 3 2

11 0/8 0 0 0

12 0 / 10 0 0 0

13 0/4 0 0 0
14 0/ 6 0 0 0 of standards
10.Equipment/ 9.5S management 8.Handling abnormality
15 0/6 0 Ach0ie ed 0 Inspection in quality
v equipment's
management
16 0/4 0 0 0
Total 46
/ 112 0 28 9
(MSI
L)
Pre decided negative marking Improvement Submission Date Last Audit Rating First time
(if any)
r
 Approved

Audit Date

Audit Person

Vendor (Tier 1) person

ocess
verification
First time

r
 Supplier 0
Name

Part Name 0

Category Audit Area Concerning regulation

1
Regarding implementation rule of 1
production preparation

Regarding management /
implementation by production
preparation plan / report (master
1. 2 plan) 1
Production
preparation /
New Product
Developmen t

Defect prevention on the stage of

3 process design by using 1
FMEA/Matrix diagram

Product/process evaluation at the

quality evaluation meeting in each
4 1
trial
 1 Regulation for
initial production control

Regulation for
２． Regulation
initial production control
for
initial
production
control 2

2
Implementation of initial 1
production control

1
Definition and implementation of 1
changing management

Supplier 0
Name

Part Name 0
 Category Audit Area Concerning regulation

３． Changing
management 2

2
Definition and control method for
initial part
2

Procedure to make process

1 control standards(QA process 1
charts)

４． Standards
management Procedure to control standards
・Process control standards
・Inspection specifications
2 ・Operation instructions 1
 1

1 Education/ training procedure

2
５． Education
and training

Supplier 0
Name

Part Name 0

Category Audit Area Concerning regulation

 Education for
2 managers/Inspectors/ Special 1
operators

Activity to keep/improve
production quality
1 1

６．
Quality audit 1
and process
verification
2 Content of process review

７． Supplier 1
Evaluation method for new 1
control suppliers

1
Handling when abnormal situation
occurs
 Handling when abnormal situation 2
1
occurs

1
８． Handling
abnormality in
quality

Supplier 0
Name

Part Name 0

Category Audit Area Concerning regulation

Prevention of recurrence
・Customer claims
・In process failure 2
・Suppliers failure

3
 1

1 Location of production site

９．
5S 3
management

2
Production equipment's
management

１０．
Equipment/I
nspection Maintenance of equipment's , jigs
equipment's 1 and tools
１０． 2
Equipment/I
nspection Maintenance of equipment's , jigs
equipment's 1 and tools

Supplier 0
Name

Part Name 0

Category Audit Area Concerning regulation

management 3

2
Maintenance of inspection
equipment's

2
 1

１１．
Implementati
1 Implementation of standards
on of
standards
3

1 management of parts flow

１２． Products 3
management
 Supplier 0
Name

Part Name 0

Category Audit Area Concerning regulation

2 Non-confirming parts management

13.
Handling
Management 1

1 Bins/ Trolley Management

14.
Critical parts 1 Maru A Parts Management 2
Management
14.
Critical parts 1 Maru A Parts Management
Management

15.
Adequate 1

testing
facility 2
1 Testing Facility

16. Process 1 As per PCS

Audit

2
VENDOR ATTENDEES :
0

Concerning regulation

Do you define the procedure for Product development including

the following ? -scope of parts, responsibility of each department,
control contents / items?

Do you implement follow-up to control the schedule and progress

of production preparation items? Incl top management

Do you consider following items and implement corrective and

preventive action to the processes and standards before regular
production?
-Troubles in the past; -Defect items expected;
-Defect items unable to capture at customer;
-Defect items difficult to repair;

Do you prevent defects by quality improving activities of cross-

function team to evaluate quality performance?
Do you define following items related to initial production control
by standards ?
-controlled parts; -controlled items; -inspection method;
-initial production control period;
-a person who announce start/end of initial production control; -
finish condition;

How do you define items required special control during initial

production control? Do you set stricter inspection methods than
the ordinary inspection?

Do you control process capability and defect rate during initial

production control?

Do you define unexpected change (unusual) and planned change

clearly?

VENDOR ATTENDEES :
0
Concerning regulation

Do you define procedure(rules applied from sharing information

to result confirmation) at change occurrence?

Do you record product quality check results to ensure traceability?

Incl retroactive checks

Do you define and control initial part clearly?

Do you control initial parts separately and make quality records

about them?(both internal and outsourced process are included)

Do you make and review process control standards,

Inspection specifications, Operation instructions for all products
which is shipped to SMC / MSIL / Tier 1 ?

Do you have consistency to keep process control standard,

inspection specification, operation inspection and parameter
chart?
Do you clarify the department in charge of promoting quality
education, implement education based on annual plan?
Are records of education kept?

Do you define and implement the skill evaluation of operator to

determine whether operator can work without surveillance?(e.g.
acceptable revel/evaluation frequency/evaluation method)

VENDOR ATTENDEES :
0

Concerning regulation
Do you periodically monitor the skill of certificated operators and
follow up to improve their skill?

Do you conduct quality audit to identify issues and properly

improve them?

Do you confirm consistency between actual operation and

standard?

Do you confirm if countermeasures are taken properly to prevent

reoccurring of quality failure?

Do you define criteria to certificate new suppliers and implement

them?

Do you define clearly what is abnormal situation and make

operators know the definition?
Do you clarify and standardize the handling rules/routes for
customer claims, in process failure and supplier failure?

Do you have criteria to estimate the scope of suspected lot for

abnormal situation? When abnormal situation occurs, do you
trace suspected lot based upon the criteria?

Do you prevent recurrence of issues by analyzing cause of

occurring defect based on process investigation result such as 5-
why analysis?

VENDOR ATTENDEES :
0

Concerning regulation

Do you reflect corrective action to improvement of process control

and review of standards?

After corrective action are taken, do you conduct on-site check up

and evaluate the effectiveness? And horizontal deployment.
Do you keep store material, work-in-process, finished products,
inventory and container at appropriate storage prevented from
dust, rust, scratch, deformation and rainwater?

Do you control material, work-in-process and finished product by

designated location, volume and standard using visual control?

Do you implement inspection or critical operation under the

properly controlled environment luminance
/temperature/humidity/vibration/noise/work table, etc.)?

Do you keep condition of production equipment's, jigs and tools

properly?

Do you keep condition of inspection equipment's properly to

ensure accuracy?

Do you conduct daily/regularly check of production equipment's,

dies and jigs? Are records of maintenance kept?
Do you confirm regularly the function of Pokayoke, automated
stop and alarm? Are records of maintenance kept?

VENDOR ATTENDEES :
0

Concerning regulation

Do you standardize frequency of polishing and replacement for

consumable tools(blade/electrode/rub stone, etc.)?

Do you calibrate regularly inspection equipment's and put the

expire date on them?

Do you control deterioration (expire date) of boundary samples for

objective judgments such as appearance inspection?
Do you use easy expression (visualizer, onomatopoeia
,etc.) for operation instructions? So that operator can easily
understand process and critical points.

Do you keep operation instructions on the accessible place and

post important quality points and critical operation points on the
place where operators can see it easily?

Do you regularly monitored that each operator operates according

to the operation instructions？

Is it possible to judge OK/NG specifically by each check sheet (of

daily equipment check, quality control report, etc.) you use?

Do you keep first-in first-out of finished products and work-in-

process (material, reserve parts） by using identification tag or lot
indication?

Do you control follows production history by product lot

numbers?
-production date; -production volume; -shipping date

Do you control identification of similar parts separately?

VENDOR ATTENDEES :
0

Concerning regulation

Do you control identification of non-confirming parts and parts on

hold. Do you store them separately?

Regarding repaired non-conforming parts and parts on hold to re-

use, do you define responsibility to implement? Are repair record
kept?

Do you make arrangements with customers about the packing

style & transportation system to prevent damage during handling
of finished products & perform accordingly.

Do you have system to maintain Bins /Trolleys in Good Condition.

Do you have Special checks/Inspection for Maru A parameters of

Maru A part are available .

Do you have Identification of Maru A Process/Operator on Shop

Floor.
Do you keep the repair history when repairing & using Maru A
items

Does the supplier has all inspection instruments required as per

drawing requirements

Does the supplier has all Testing Equipment's/Rigs required as per

drawing requirements

Does the Supplier has trained manpower to operate these

inspection and testing instruments

Conduct process audit as per process control standard

Closure of all the observations

Achieved Score
Maximum Score
Audit Rating
 Requirements

Procedure for regular production plan , Procedure for Product development

including scope of parts, responsibility of each department, control contents / items as
per APQP guidelines,

- Development Time plan (Master and Micro level)

- Review frequency and evidence
- Reason of delay and action
- Evidence of review by Top management.
-Production plan monitoring after SOP

- FMEA Procedure
- FMEA / QA matrix.
- Past defect history and Potential defect included in FMEA.

- List of Quality issues / defect faced In-house and Customer end during trials.
- Their complete analysis in the form of PDCA.
Initial Supply Control Procedure including
- Initial Supply Control period (3month for new parts)
- person responsible to announce start/end of initial supply control
- Control items & inspection method (check method) and criteria for selection of control
item
- Criteria for termination of initial supply control period

Stricter Control during Initial Supply Control period:

- Increase sample size or frequency
- Frequent Process Capability Study (Cpk > 1.33)
- Fast removal of problems / analysis
- Change in Inspection Method
- Verification of Standards, operation standards, facility etc. (Process audit)
- Stricter visual inspection (100% inspection/ 200% inspection)

Evidence of Process capability study / defect rate (rejection % or ppm) monitoring and
action if not meeting the target as decided for product and critical parameters as
mentioned in Spec. Meeting or Critical parameters decided by supplier

Procedure / WI for expected change (4M : Operator, machine & jig/die, material and
method change) and unexpected changes (Tool breakage, power failure, machine
breakdown, inspection equipment failure etc.).

Rules to be defined from sharing information to the concerned person / Deptt up to the
result confirmation of product produced before and after the change.

Recording of product quality check with product details like Lot no, quantity and
marking on products etc.

- Definition of initial part.

- Control method/ system in procedure.
- Identification tag
- Inspection & test record of initial parts / lots (All developments lot including pilot lot).
- Inspection / test reports of sub vendor's required in case part produced by sub vendor.

- Process control std, control Plan, Inspection standard and operation Instruction of all
parts.
- Review system and records of updated std against a change.
- Retention period of documents and records

Coherence between all documents like PCS / Control plan, inspection standard,
operation standard and MIS -P.

Training procedure / WI including person responsible for Training related to Quality

(QS, Process Audit, Inspection, Using inspection & testing instruments / Equipments
etc.), Training need identification and effectiveness check system.
- Training Calendar for all Operators, Supervisor and Managers
- Training systems and record for New Joinee (Staff / operator)
- Training Plan v/s Actual records
- Effectiveness check records

WI for Skill evaluation criteria level wise, evaluation frequency and method.
Cross checking of operator's skill periodically against a decided parameter and by
simulating defect.
Evidence of retraining plan and effectiveness check.

Plan and evidence of conducting Internal Quality system Audit. Action taken for
improvement against the Quality Issues observed during audit.

Evidence of process audit based on work instructions / PCS and actual working.
Process with poor workability

Evidence of Countermeasure effectiveness check at shop floor during process audit.

New Supplier selection procedure indicating supplier audit check sheet & min qualifying
criteria especially for quality.
Evidence of audit done and supplier list

Definition of abnormal situation and Operator's awareness about the abnormal

situations.
Procedure for customer complaint handling, in-process failures (defect/rejection/rework)
and supplier failures

Procedure for handling suspected parts at the time of abnormal situation including
criteria for estimating suspected parts (quantity produced before abnormal situation)

5 Why Analysis/Root Cause Analysis to be done for the defects Criteria for raising A-3
sheet/DAR for internal and supplier issue

Standardization (Review of standards) of countermeasures as decided in Defect Analysis

Sheet

Onsite check up of countermeasure at regular interval Evidences of horizontal

Deployment of countermeasures

Storage of RM, BOP, WIP, FG and bins/trolleys to prevent from dust, rust, scratch,
deformation and rainwater (Shop floor audit)

Storage of RM, BOP, WIP & FG parts at designated location with tag for visual control
- Unwanted Material Control at work place(Red Tag area) There is exist
possibility of mix-up of FG/WIP/Rework part
-Temporary storage
Inspection or critical operation under properly controlled environment:
- temperature
- humidity
- noise
- Proper layout/ arrangements on work and inspection table
- lux level etc.

Physical condition of production equipment's, jigs and tools Evidence of daily/ regular
check
Storage arrangements with identification

Physical condition of inspection equipment's properly to maintain accuracy

Evidence of daily/ regular check (Validation report) Proper storage arrangements

Daily and preventive maintenance of production equipment's, dies and jigs

Machine/ tool history card and PM check sheet
Spare parts list with minimum quantity required

Regular check of Pokayoke and their record List of Poka Yoke

Frequency of polishing and replacement for consumable tools and change records
Calibration record of inspection Equipment's
Calibration status on inspection Equipment's (Calibration date & due date)

Expiry date on limit samples (for objective judgments such as appearance inspection)

Visual confirmation of work done (glowing of green/yellow/red light indicating

completion or incompletion of work)

Work Instructions to be made in Local Language

Display of WI's, Quality Check points & instructions related to critical operations at
easy accessible location (so that operator can read and take out them easily for
reference)

Periodic records of operator observance audit to check operator working as per various
standard such as WI, PCS, Daily check etc.

Judgment criteria should be mentioned on each check sheet (e.g..- Upper/ Lower
tolerance, check method and criteria )

Incoming Material / WIP / Finish Goods to be maintained with Identification Tags and
storage location at each stage.
Production Date/ Lot/ Qty/ dispatch date to be recorded for traceability purpose.

Similar parts control by different color bin / tags/packing material

Separate area/ red bin for storing NC part with tag Reason marking on NC part

- Rework procedure/WI
- Responsibility for Rework and area/table for rework
- Inspection record of rework material
- Traceability (Lot detail) of Reworked Material

Packing standard and transportation mode

WI to maintain Bins/Trolleys ( WIP & FG) in good condition Cleaning and repairing
area and check points of good bin/trolleys

Special check points for Maru A parts in Inspection standards (in- process & final) as
per inspection standard/drawing

work stations, operator and machine/line

Check same system for critical items

Record of Rework/Repair history of Maru A parts

Inspection instruments list.

Testing Equipment's list and arrangements.

Lab person and inspectors training records and experience.

Plan and actual evidence of Process audit . NC list.

Closure evidence of observations.

Follow Up
Follow Up
Follow Up
Follow Up
Follow Up
Follow Up
 Date:
Auditors:

Remarks
Judgment

1
1

1
1

1
2

1
1

1
2

2
2

1
 0

112

0
73
 MARUTI VE

Supplier
0
Name

Part Name
Category Audit Area

Management information 3

1
1

Organisation Structure 1
E
 1.1

1.2

1.3

2 Quality Systems
1.4

1.5

3 Net Sales (Rs Lacs) 1

4 Net Profit ( Rs Lacs) 1

5 MSME Category
1

7 Industrial Climate
 8

9
7 Industrial Climate
Scale of Organisation
 10

11

4
Capability to
invest for 1
Investment Capability for
future Future Expansion 5

expansion
6

Types of Raw Material being

1 used.

2 Make of Machine
Adequate
Manufactu 3 Life of Machine
ring
capability
4 Machine condition
 ring
capability

Availability of Auxiliary
5 Equipments

NDOR QUALITY SYSTEM AUDIT

Vendor Attendees
0

Concerning regulation

Background & Qualification

Is there a succession plan for the owners?

Are Quality & Productivity targets available & Monitored by

mgmt?
Is there any system by which management monitors customer
rating?

Does the vendor have organisation Chart. Are following clear

in the chart:
1.Reporting levels are clear
2.Role clarity at each level
3.Adequate quality organisation structure
4.Persons are available as per chart, no shortage of staff

5. Is responsibility for check on check available at all levels

People profile 1. No of contract employee
2. No of permanent employee
What is the Qualification Criteria of Operators selection?

Does The Unit have any ISO/ TS certification?.

Certificate (ISO or TS)

If yes, name of ceritification body

Date of issue

Expiry Date

Does the unit review the effectiveness of Quality system ?.

2013-14
2014-15
2015-16

2013-14
2014-15
2015-16

Any labour issue in last 5 years

Union exists ?

Does company provide Tea/Snacks to all employees

How are general working conditions (Condition of toilet, Hot,

humid , Noise level etc)
By what date, payments to employees is done
Is any training given to employee before putting into the job?

How is Salary & PF for contract employees is managed

(Directly or Thru contractor)
How often overtime is done & what is overtime rate?

Is there a suggestion scheme in the company ?

Are there additional benefits to employees ? ( Canteen,

Transport, Medical etc)
Does company provide uniform to its employees?

Investment detail (In last 2 years)

Future growth /Investment plan

What is the D/E ratio ?

Cash Generation (PAT+Dep-Loan)? ROCE?

What are the other businesses of the promoter?

Have supplier taken any benefit from govt on MSME category?

Have Tier-1 supplier financed tooling, equipment, testing

facilities at Tier-2?

Payment terms with customers

Payment terms with Suppliers

Price updation frequency by major customer

T
 CUM FOLLOW UP REPOR
Requirements Answer

Yes

Yes

MRM, Target & objectives display Yes

Customer rating monitoring by

Top management. Yes

Yes

Yes
Yes
Yes
Yes

No

Contract : 70
Permanent : 56

Yes

Yes
R
T (Tier -2)
7/28/2016

Remarks Follow Up

01/ six months

Monthly CSR from Customer

 ITI

No registered

Tea/snacks twice in shift of 10

hrs
 Annual medical check up

Other group companies

 Vendor Performance Score Card
Vendor Name Progressi Vendor Code
1 MSIL Line Defects 14~15 ve 15~16 2. 14~15
13~14 Stamping Hanon
Monthly Avrg s Pvt. Ltd. Line
Defect
Total 13~14
Total
Target

Remarks :- Row 12 Row 13 Remarks :- Total Monthly Avrg

Quality Imp. By (%) Delivery Imp.
By (%)

4. Tier-2 Vendor - Internal Rejection (PPM) 5. No of Line Stoppages at Hanon

13~14 14~15 15~16 13~14 14~15
Monthly Avrg Nos

Monthly Avrg Nos

Monthl a b c
y Avrg Nos
Remarks :-
:-
Remarks
 Assessment Month Jul-18

Location
15~16 3. 14~15 15~16
Rejecio
n PPM
at
Hanon
Target Monthly Avrg
NA
Monthly Avrg Remarks :-
Quality Imp. By (%) Delivery Imp.
By (%)

15~16
 Activity

Press Machines
& Related
Infrastruture
 Details
Does supplier has parts with progressive tooling parts? Does supplier has press facility for same?
Which Make of the machines are used?
Does the suppliers check Press parallellsim (Bottom and Top Plate) and Press Alignment?
T Slot / cushion hole condition?
Does the Cushion pin checking (Length, height, bending check and standardisation) is done
Stroke length (chal) and shut height (slight) adjustment: Is same or available tool wise?
Does Supplier has standard clamping?
Safety: 2 button press operation is there or safety mechanism? Pls specify?
Does supplier uses standard parallel blocks
Does shut height indicator available?
Does the moving parts of Press is covered?
Does the Supplier has decoiling facility in case of coil blanking/progressive tools parts.

Does the Supplier has lifter facility for tool loading and unloading.
 Status
Yes
ISGEC, Yangli, Press master
Yes

Good
Yes

Available Tool wise

Yes

All presses with 2 Button

Yes
Most of the pressess

Yes

Yes

Fork Lift Avaiilable

 COPY TO :
MARUTI VENDOR ASSES
RECEIVING DATE
PLANNING

PLANNING
TOTAL 0

RECEIVING DATE
VERIFICATION

VERIFICATION
TOTAL 0

AUDIT POINT

ITEM NO. SUB ITEM DESIRED IMPROVEMENT POINTS DETAIL OF IMPROV

NO.
MARUTI VENDOR ASSESSMENT (TIER II) - COUNTERMEASU
PLANNED

VENDOR NAME 0

PLANNING
CLUSTER NAME Hanon Systems India Pvt Ltd

AUDIT DATE

December 30, 1899

VERIFICATION
AUDIT PART NAME 0

AUDIT PART NO.

0

DEADLINE FOR DEADLINE FOR SUBMISSION OF ACTUAL

SUBMISSION OF PLAN RESULT

DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE

ITEM NO. SUB ITEM DESIRED IMPROVEMENT POINTS
NO.
DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
RE REPORT
CHECKED APPROVED

RESULT OF VERIFICATION

RESULT OF VERIFICATION
 Good Points Weak points
Positive Management Retroactive inspecti
Good ventilation in shop floor Criteria for declarin Moulding and
secondary operation at same place Skill evaluation crite In-house Manufacturing of Facility for
moulds CAPA format does Good procedures and implemenation why-
why analysis f RM storage, FIFO in RM store
Adequate testing facility

on during 4M changes
g suspected parts produced during abnomral situations ria
not ask for identification & validation of potential defects,
or occurrence & defects, standardization & horizontal deployment
 Good Points Weak points
Positive Management Retroactive inspecti
Good ventilation in shop floor Criteria for declarin Moulding and
secondary operation at same place Skill evaluation crite In-house Manufacturing of Facility for
moulds CAPA format does Good procedures and implemenation why-
why analysis f RM storage, FIFO in RM store
Adequate testing facility

nges
produced during abnomral situations ria
cation & validation of potential defects,
efects, standardization & horizontal deployment