QUALITY MANAGEMENT SYSTEM PROCESS

INITIAL SUPPLY CONTROL

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1. PURPOSE: - Supply after development / sample approval considered as initial supply. This is confident
built process. It involves of monitoring and additional controls in the process by taking precautionary
and preventive action during the initial period of mass production of a new or changed parts for a
defined duration.

2. SCOPE: - This procedure is applicable for as mention below (a,b,c) & it starts from after SOP at Customer
End)
A. An Absolutely new component. No experience so far and Similar to existing part.
B. ECN (Design & Material) change in Existing Parts & PCN Change (Layout, New Equipment & Machine).
C. New Supplier/ Location Change of Existing Supplier, Manufacturing Location Change & Start of
manufacturing after a long layoff (12 months).

3. PROCESS OWNER: -
S.No Activity Responsibility

1 Start of ISC NPD, Head

2 Implementation of ISC QA & PRODUCTION Head

3 End of ISC QA & NPD Head

4. DESCRIPTION: -

Sl. Activity Responsibility Reference

No.
4.1 NPD Head shall be announcement of ISC with part name & number and NPD Head Announcement
period of ISC as given Para (4.2) and QA Head shall be communicating the QA Head Sheet
ISC target as defined in announcement & termination sheet to all SPI/PD/F/25
concerned department & CFT Team. SPI/PD/F/27
4.2 The Duration of initial Supply Control of Mass Production Is Decided. QA Head /
 3 Months or 3 Lots or 5000 Pcs whichever is Later for Category A. Prod. Head
(After Start of Production at Customer End).
 1 month or 3 Lots or 1000 Pcs for Category B.
 15 Days or 2 Lots or 500 Pcs for Category C.
.4.3 Special Control: -

Parameters/ Normal Period ISC Period

Controls
INCOMING INSPECTION As per Sampling plan 2 x Sampling plan QTY
FIRST PIECE & SETUP 01 No. 02 Nos.
NPD & QA Announcement
APPROVAL Head Sheet
INPROCESS INSPECTION 1Pcs/2Hrs 1Pcs/1Hrs SPI/PD/F/25
FINAL INSPECTION(DIM) 5 Pcs/Lot 10 Pcs/Lot

FINAL 100% 200%

INSPECTION(VISUAL)
PROCESS AUDIT AS PER ANNUAL PLAN BY EACH MONTH BY
PROD. CP PRELAUNCH CP
CUSTOMER PPM As per customer Target Zero PPM

DEFECT RATE CURRENT PERCENTAGE Reducing Trend

Cpk MONITORING AS PER ANNUAL PLAN EACH MONTH(Cpk>1.33)

Prepared By: - Approved By: - Issued By: - Issue Date: -

 QUALITY MANAGEMENT SYSTEM PROCESS
INITIAL SUPPLY CONTROL

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INHOUSE REJECTION PPM CURRENT PPM 30% REDUCTION OF

CURRENT PPM Target

4.4 Visual Display Control: -

 Communication to other departments through Announcement NPD & QA
sheet/Training / Initial Supply Board / ISC Table. Head
 The Record of defect and Rejection Data if any during the initial
supply control should be maintained properly.
4.5  Initial parts storage & Handling of parts should be kept at QA & PROD
Designated place as decided & White color route card shall follow in Supervisor
process & Initial Supply Control Tag of White color for customer.
4.6 Termination Condition: -
 No of Customer Complaints
 Customer Rejection PPM: Zero
 In process Rejection PPM: (30% less than the Current Target).
 Incoming Rejection PPM: (20% less than the Current Target)
 Defect rate: (Reducing Trend)
 Cpk > 1.33
 Delivery Rating: 100% NPD Head/ Termination
 Effectiveness of Countermeasure Taken against problems during QA Head Sheet
NPD should be effective & closed. SPI/PD/F/27
 Effectiveness of Countermeasure Taken against problems during
Initial supply Control should be effective & closed
 All NC during process audit shall be closed.
Note: In Case of non-achievement of above-mentioned termination
condition ISC will be extended as per below mention criteria
 3 consecutive months for Category A
 1 month for Category B
 15 Days for Category C
4.7 QA /Production Head further provide training to concerned person QA Head / Training Record
regarding the ISC part Prod. Head SPI/HR/F/12
4.8 Change in inspection method shall also be done from attribute to variable QA Head
gauge if possible or required by customer.
4.9 Pre-launch control plan shall be used during the ISC period for inspection, QA Head /
Process audit & other purpose. Prod. Head
4.10 Process audit & SPC (As per List of SC/CC Parameter) shall be conducted QA Head List of SC/CC
each first lot of the month for three months. Parameter
SPI/PD/F/03
4.11 Detail of each lot during the ISC period shall be monitored in ISC Monitoring QA Head ISC Monitoring
sheet with detail for rejection. Sheet
Rework of reject part shall be done as per the Rework WI SPI/PD/F/36
Rejection Detail to be further entered into ISC Rework sheet with
traceability till invoice and kept with ISC Monitoring Sheet.
4.12 Quick removal of problem shall be done during ISC period with PDCA QA Head PDCA
analysis as per the In-house rejection handling procedure & Update In- SPI/PD/F/09
house complaint register. Complaint Reg.
SPI/QA/F/22A
4.13 NPD & QA Head shall be terminate ISC as per given target in termination NPD Head/
sheet. Which is sustain & improving trends. If any targets are not meeting QA Head
then it will be extend as per Para (4.6).

5 INPUTS: -

Sl. No. Description From Reference

Prepared By: - Approved By: - Issued By: - Issue Date: -

 QUALITY MANAGEMENT SYSTEM PROCESS
INITIAL SUPPLY CONTROL

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1 Customer Schedule CUSTOMER

2 Stocks details of materials / parts available STORE

3 Work instructions/Operation std. PROD

4 Raw materials STORE

5 Process flow diagram PROD SPI/PD/F/07

6 White Route card STORE SPI/PROD/05

7 Announcement sheet NPD SPI/PD/F/25

8 Attendance Record QA SPI/HR/F/12

9 Prelaunch Control Plan QA SPI/PD/F/10

6. OUTPUTS: -

Sl. No. Description To Reference

1 Daily production plan PROD

2 Daily prod. Report PROD SPI/PROD/04

3 First Part Approval / In Process inspection report QA SPI/QA/F/03

4 Pre-Dispatch Inspection Report QA SPI/QA/F/06

5 White Route card PROD SPI/PROD/05

6 ISC Monitoring Sheet QA SPI/PD/F/36

7 Initial supply Control Termination Sheet NPD SPI/PD/F/27

8 Initial Supply Control Tag PROD SPI/PD/F/29

9 SPC Results QA SPI/QA/F/09

10 Audit Results QA

7. MONITORING AND MEASUREMENTS: -

Sl. Description Frequency Performance Responsibility Acceptance

No. Measurable / Criteria
Indicators
1 Termination condition Every new project All termination NPD Head 100%
parameters meet

8. RECORDS & REFERENCES: -

S. Doc. name Doc No. Retention Manner of Disposal Remark

No. period disposal authority

Prepared By: - Approved By: - Issued By: - Issue Date: -

 QUALITY MANAGEMENT SYSTEM PROCESS
INITIAL SUPPLY CONTROL

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1 Initial supply Control SPI/PD/F/27 5 Years Scrap NPD Head

Termination Sheet
2 Announcement sheet SPI/PD/F/25 5 Years Scrap NPD Head

9. REVISION HISTORY: -

Sl. Rev. Rev. Date Details of Rev. Approved By

No. No.
01 00 15.06.2019 Initial release as per new standard IATF16949:2016

02 01 16.03.2020 Special Control & Responsibility has been reviewed

Prepared By: - Approved By: - Issued By: - Issue Date: -