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SQAM

SUPPLIER QUALITY ASSURANCE MANUAL

TVS Motor Company Ltd


POST BOX No. 4, HARITA, HOSUR, TAMILNADU, 635109
PHONE: +91 (04344) 276780
Fax: +91 (04344) 278841
Website: www.tradewithtvs.com

Manual Revised on 18.03.2015

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CONTENTS
Page no

1. INTRODUCTION & KEY INFORMATION


1.1 Objective 04
1.2 Introduction to Supplier Quality Assurance Manual 05
1.3 Designation of Customer Representatives 07

2. NEW PRODUCT DEVELOPMENT PROCESS (NPD)


2.1 Overview of Part Development and Approval Process for NPD 09
2.2 Manufacturing Feasibility 18
2.3 Agreement Of Inspection and Testing 20
2.4 Advanced Product Quality Planning (APQP) 22
2.5 Production Part Approval Process (PPAP) 24

3. Q A ACTIVITIES IN MASS PRODUCTION


3.1 Sustenance of Quality 35
3.2 Design & Calibration Guidelines for Checking Fixtures,
Gauges and Test Equipment 42
3.3 Non Conforming Product Handling 45
3.4 Customer Complaint Handling (Field / Line / Lot) 48
3.5 Change Control Management 52
3.6 Supplier Quality System / Process Audit 55
3.7 Supplier Performance 56
3.8 Tier 2 Supplier Management 58
3.9 Control of TVSM Supplied Tools 60
3.10 Guidelines for Identification, Traceability and Material
Handling 62
3.11 Supplier QMS Certifications 64
3.12 Records and Retention Periods 65

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4. ANNEXURES

5.1 Abbreviations 69
5.2 List of Formats 71

FORMATS AVAILABLE IN SAP WEBSITE 72

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1.0 INTRODUCTION & KEY INFORMATION

1.1 OBJECTIVE

The objective of providing this manual is to implement an effective QA &


communication system and to have transparency of information between Suppliers
and TVS Motor Company Limited (TVSM), from the part development planning phase
to mass production and regular supplies. Prime focus is to standardize the
methodology of part development and regular supply across the supply chain.

TVS Motor Company Ltd (TVSM) and suppliers together share their experience /
learning for mutual benefit, and as a team, commit to achieve world class quality to
satisfy the end customer’s expectations by -

 Built-in quality in the product and process design


 Zero defect approach
 Quick and effective problem resolution
 Reduction of variation and waste in supply chain
 Continual improvement

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1.2 INTRODUCTION TO SUPPLIER QUALITY ASSURANCE MANUAL

Purpose:

The purpose of this manual is


 To communicate TVSM expectations and requirements to suppliers regarding
the policies / norms to be adhered to for supply of parts to
TVSM(OEM&Spares)
 To encourage teamwork and co-operation between suppliers and TVSM to
meet the dynamic demands of end customers.
 To define and describe QA system & procedures that suppliers shall follow
and demonstrate to assure quality from development to mass production and
regular supplies through effective quality system deployment at every process.
 To communicate and encourage suppliers to follow defect prevention
approach in each stage of development and in mass production, problem
resolution towards continual improvement.

Document Control related to SQAM:

TVSM Responsibilities:

 To provide one hard copy of this manual to each supplier and also the soft
copy of formats in the TVSM website.
 To maintain the revision and distribution control system of this manual and
also obtain acknowledgement from suppliers.
 To provide drawings through SAP ‘C’ folder for both New products and current
products.
 To communicate and ensure availability of information on the changes made
as and when required and the revision status to our suppliers through the
TVSM website.
 To train the suppliers in the application of SQAM as required

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 To maintain master control revision record.

Supplier Responsibilities:

 To maintain, control, issue / use of the manual and revisions provided by


TVSM.
 To ensure adequate care while distributing the copies to appropriate persons
and maintain a document tracking method to ensure the compliance to the
latest revision, and to ensure that copies do not go to any unauthorized third
parties.
NOTE:

Distribution of copies outside the supplier’s organization is strictly prohibited


without prior approval from TVSM Central Purchase department.
In case of any clarification related to SQAM usage and application, supplier
may contact TVSM Central Purchase category head through E-mail or write to
the following address.

TVS Motor Company Limited,


Post box No. 4,
HARITA, HOSUR
TAMILNADU
Pin code: 635109
Phone: +91 (04344) 276780
Fax: +91 (04344) 278841

Supplier shall follow all the formats provided in this manual. Suppliers may use their
own format for Control Plan, provided it meets the SQAM requirements and is
approved by TVSM Quality.
In this manual,
 The word “shall” refers to mandatory requirements that each supplier has to
comply with.

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 The word “supplier” refers to suppliers who supply directly to TVSM and Tier
2 refers to suppliers to TVSM suppliers.
 The word “product” refers to assembly / sub assembly / part.

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1.3. DESIGNATION OF CUSTOMER REPRESENTATIVES

Objective:

To define roles and responsibilities of “Customer Representatives” (CRs) and other


key personnel nominated by the supplier and notified to TVSM.

Scope:

Applicable to all TVSM suppliers.

Details:

The Customer Representative nominated by the supplier shall be at manager level,


possessing, technical knowledge, good communication and co-ordination skill for
effective flow of information between TVSM and supplier and to implement required
actions at supplier end.

Supplier Responsibilities:

The supplier shall provide details of CRs, contact number, email ID and other details
to TVSM Purchase / Quality in format (QSF PUR SQAM 001)

The supplier shall nominate one person for quality related issues for regular product
and another person for all new product related issues. The nominated representative
may preferably be the Quality Manager.

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Current product representative:

The responsibilities include


 Implementing and maintaining all Quality Management Systems to
comply with the SQAM requirements.
 Providing feedback to TVSM on quality issues, problem resolution and
related matters.
 Coordinating the containment activities such as segregation & rework,
corrective action and horizontal deployment.
 Representing the supplier during meetings with TVSM.

NPD representative:

This person is responsible for coordinating NPD activities such as drawing study &
manufacturing feasibility feedback, APQP, product & process verification & validation,
AOI and PPAP.

General:

The supplier shall submit an organisation chart including the roles and responsibilities
of each function and number of persons (Manager, Executives, and Inspectors) along
with the contact information.

If supplier parts are manufactured at multiple locations / plants, supplier shall provide
a separate set of completed forms to TVSM for each location / plant.

The supplier shall notify TVSM of any changes in their contact information as and
when they are made. Revised forms shall be sent within 7 days of such changes.

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2. NEW PRODUCT DEVELOPMENT PROCESS (NPD)


2.1 OVERVIEW OF PART DEVELOPMENT AND APPROVAL PROCESS FOR NPD
Objective:
To explain the different phases involved in development of new parts.
Early involvement - Understanding TVSM requirements(Quality, Cost,
Phase1 Delivery)
Product design verification of semi / tooled up
Alpha - Phase2
samples
Process design verification of samples made out of
Beta - Phase3 production intent process set up – Tooled up
samples
Product and process validation of samples made in
QP - Phase4
production environment
Start Of Mass Production and Regular Supplies
Mass production -
phase (from approved Part and Manufacturing
Phase5
Process)

The figure given below provides the general outline of NPD activities
Early Involvement – Phase 1

NPD Phases

Note: Part development to be ready by one phase ahead of TVSM indicative mile stone

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Objectives:

 To confirm that the supplier understands TVSM requirements such as –


- RFQ (Request for quotation) & SRS (System requirement
specification for proprietary design) with indicative timing plan,
QCD targets and samples submission
- Drawings, technical specifications & standards, special
characteristics, product & process verification & validation
- APQP and PPAP
- Start of Production and Regular Supplies.
 To assess manufacturing feasibility & risk analysis, review and clarify / resolve
all the issues / constraints.
 To prepare, review and sign-off Draft Agreement Of Inspection and Testing
(AOI) along with part specific inspection requirement.
 To prepare, review and sign-off APQP timing plan for the part development.
 To release Purchase order (PO) / Letter of indent (LOI) to start the part
development.

TVSM Responsibilities:

TVSM development team shall

 Send L1 drawings, Target cost, Request for quotation (RFQ) & System
requirement specification (SRS) along with detailed TVSM requirements (
Quality, Cost, Delivery, Indicative Timing Plan )
 Upload Part / Fixture / Gauge Drawing in SAP C Folder.
 Provide clarity to the supplier team on the TVSM requirements as required.
 Review Manufacturing Feasibility, AOI, APQP timing plan, Risk Analysis
including design feedback and resolve issues / constraints.
 Conduct early supplier involvement.

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Supplier Responsibilities:

Supplier shall
 Receive L1 drawing, Target cost, RFQ & SRS along with TVSM
requirements ( Quality, Cost, Delivery, Indicative Timing Plan )
 Form APQP team and study RFQ & TVSM requirements
 Visit and interact with TVSM development team to clarify / understand the
details
 Prepare Manufacturing Feasibility and Risk Analysis format QSF PUR
SQAM 002,003 and drawing feedback & agreement form QSF PRG 02 01
018 and feedback / suggestions for QCD improvements
 Prepare draft AOI document
 Prepare APQP timing plan
 Prepare detailed cost break up of the quotation
 Review Manufacturing Feasibility, Risk Analysis, AOI and APQP timing
plan with TVSM development team.
 Supplier shall ensure intellectual property (IP) and patent requirements. for
his design (No violation shall be allowed for IP and patent requirements).

Alpha – Phase 2

Objectives:

 To release Purchase order (PO) / Letter of indent (LOI) to start the part
development
 To design and develop part and / or process
 To develop the required tools, Gauges, Fixtures.
 To verify that the product & process design meets the requirements by
producing the part with tool i.e. Tooled up condition. (Product design is
applicable for suppliers who are design responsible i.e. for the products of
proprietary nature)

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TVSM Responsibilities:

TVSM development team shall


 Incorporate supplier manufacturability feedback, drawing feedback &
agreement and release L2 drawings.
 Release PO / LOI for development of the part
 Approve supplier drawings for proprietary parts for Alpha samples
submission along with drawing approval request.
 Prepare TMIS
 Review and Signoff Manufacturing Feasibility, drawing feedback &
agreement, APQP timing plan, Target cost and Risk Analysis & Mitigation
Plans, Draft AOI.
 Review design documents submitted by the supplier and provide feedback.
 Provide gauge design to suppliers for critical parts as applicable
 Receive alpha samples along with documents, verify and provide feedback
to the supplier
 Review APQP progress, applicability of COP approval parts (Refer chapter
3.1 K Conformity of production) progressive PPAP documents and provide
guidance on a continual basis
 Ensure the following Markings in the COP parts as per AIS 037 except
metallic fuel tank
- Trade Mark / Manufacturer's Emblem
- Identification code assigned for the part by the Manufacturer
- Reference of the Type approval TAC No. / E Mark / ISI Mark /
DOT Mark
- In addition Markings as mandated by the part standard

Supplier Responsibilities:

Supplier Shall
 Receive PO / LOI for development of the part based on L2 drg.
 Obtain sign off for Manufacturing Feasibility, Draft AOI, APQP timing plan,
Target cost and Risk Analysis & Mitigation Plans
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 Prepare Product and Process Design Inputs Sheets based on the TVSM
requirements (RFQ and SRS) and sign-off documents (Mfg feasibility, Risk
analysis, AOI and APQP timing plan).
 Carryout Product design (Applicable for proprietary suppliers and shall use
design tools & techniques such as QFD, DFM, DFA, DFS, DFMEA, FEA,
Design Analysis, CP and others as appropriate. Involve TVSM in DFMEA and
Technical design reviews).
 Supplier shall verify COP applicable parts (Refer annexure...) and ensure the
availability of type approval certificate (TAC) or conformity of production (COP
certificate) – Applicable for proprietary parts
 Supplier shall ensure the following Markings in the COP parts as per AIS 037
except metallic fuel tank.
 Trade Mark / Manufacturer's Emblem
 Identification code assigned for the part by the Manufacturer
 Reference of the Type approval TAC No. / E Mark / ISI Mark / DOT Mark
 In addition Markings as mandated by the part standard
 Carryout Process design (Applicable for proprietary as well as non-proprietary
suppliers and shall use design tools & techniques such as PFD, PFMEA, CP,
Inspection standard (Product & child parts) and others as appropriate)
 Submit proprietary part drawing along with the request in the specified format
for approval. Organise review of design with TVSM development team and
obtain approval.
 Develop and manufacture checking fixtures, test facilities, in-process and final
acceptance gauges at supplier end and their suppliers (Tier2, etc) . (Ref
chapter no 3.2). Suppliers shall use TVSM gauge design for critical parts as
applicable.
 Discuss and get approval from TVSM on Process Design, Fixture Design and
Gauge Design for critical parts to get mutual benefit.
 Discuss with TVSM on investments for Fixture, Gauge etc., to avoid delay in
lead time.
 Develop mutually acceptable performance test standards and equipments
(Refer AOI).

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 Produce Alpha Samples with prototype control Plan and verify the parts as per
TVSM requirements.
 Submit Alpha Samples along with agreed documents (including progressive
PPAP documents)
 Obtain feedback on Alpha Samples from TVSM development team
 Provide APQP progress updates on a continual basis.

Beta – Phase 3

Objectives:
 To resolve problems identified during Alpha trials
 To incorporate countermeasures in part & process design
 To verify product & process design meets the requirements with dedicated
tool and process.

TVSM Responsibilities:

TVSM development team shall


 Incorporate countermeasures arrived from Alpha trials and release L2R
drawings. Approve supplier drawings for proprietary parts for submission of
Pilot Lot samples. (Based on revision in SRS)
 Verify the countermeasures arising out of alpha feed back are incorporated in
part & process at supplier end.
 Receive Beta samples along with documents, verify and provide feedback to
the supplier
 Review APQP progress, progressive PPAP documents and provide guidance
on a continual basis
 Review Q,C,D requirements / Manufacturing feasibility pending points to
finalise / revise standards (Drawing, TSES, TMIS, SRS)
 Conduct IPTR based on PPAP submission level.

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Supplier Responsibilities:

The supplier shall

 Obtain Alpha feedback, analyze and arrive at countermeasures.


 Incorporate countermeasures in part & process design
 Ensure that gauges and fixtures are capable to meet drawing and Inspection
standards.
 Produce parts with fully tooled up facility and Beta Control Plan as per L2R
Drawing.
 Verify special process qualification.
 Verify and confirm that the part meets TVSM requirements.
 Submit Beta samples along with agreed documents and update online
inspection report as per TMIS (including progressive PPAP documents)
 Conduct IPTR and send Report as per checklist (based on PPAP level).
 Obtain feedback on Beta samples from TVSM development team
 Provide APQP progress updates on a continual basis.
 Review Q,C,D requirements / Manufacturing feasibility pending points to
finalise / revise standards (drawing, TSES, TMIS, etc)

QP – Phase 4
Objectives:

 To resolve problems identified during Beta trials


 To incorporate countermeasures in the part & process design
 To verify that the part & process design meets the requirements by
producing the part in the “Production Environment”.
 To successfully complete process validation and PPAP requirements
 To resolve problems identified during QP trials

TVSM Responsibilities:

TVSM development team shall

 Release L3 Drawing for QP trials.

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 Receive QP samples along with documents, verify and provide feedback to


the supplier
 Ensure the availability of the ARAI or any approved agency reports for the
applicable parts
 Review APQP progress and provide guidance on a continual basis
 Conduct SPTR as per PPAP submission level, review PPAP documents,
Master sample identification for critical / functional parts.
 Incorporate countermeasures arrived from QP trials and release L4 drawings.
Approve supplier drawings for proprietary parts for Mass Production & Regular
Supplies.
 Signoff PSW, AAR, AOI and warranty agreement (as applicable) after L4
Drawing release.

Supplier Responsibilities:

Supplier shall
 Study, analyse and arrive at countermeasures for TVSM feedback and in-
house problems faced during Beta trials
 Ensure and submit the ARAI or approved agency reports for the applicable
parts.
 Incorporate countermeasures in the part & process design
 Achieve control over special characteristics
- Prevention and detection controls over all special characteristics.
- Required process capability levels for all variable special
characteristics (Refer 2.5 Progressive part approval process for
target Pp, Ppk levels)
 Produce parts in Production Environment and pre launch Control Plan as per
L3 Drawing.
 Verify and confirm that the part meets TVSM requirements.
 Submit QP samples along with agreed documents (including progressive
PPAP documents)
 Communication to TVSM on SPTR and ensure the part availability for trials.
(300 nos or 8 hours production.)

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 Send SPTR report incase of PPAP level A,B & C.


 Obtain feedback on QP samples from TVSM development team
- Supplier may depute a person during QP trials at TVSM to understand
quality issues related to supplier parts in TVSM manufacturing lines
 Provide APQP progress updates on a continual basis.
 Identify and complete countermeasures for QP problems.
 Provide QP trial feedback for manufacturability review and obtain customer
engineering approval if required.
 Identification of master sample along with TVSM for critical / functional parts,
to be preserved and validated periodically.
 Receive L4 drawing for start of mass production
 Obtain PSW, AAR, AOI signoff document

Start of Mass Production (SOMP) – Phase 5


Objectives:

 To start Mass Production & Regular Supplies


 To achieve customer satisfaction
 Monitor Q & D for the specified period

TVSM Responsibilities:

TVSM development team shall


 Monitor Quality, Delivery.
o Quality – Initial customer complaint (PPFR), lot rejection, Line
rejection, Process capability
o Delivery – Line stopper, schedule Vs Supply adherence
 Provide feedback to the suppliers for corrective action

Supplier Responsibilities:

Supplier shall

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 Incorporate countermeasures in the part & process design Start Mass


Production and Regular Supplies (with the agreed controls if PPAP is
conditionally approved)
 Obtain PPAP approval .
 Implement Mass Production Control Plan
 Identify opportunity for improvements such as reduced variation
 Monitor Quality, Delivery.
 Capture project learning and incorporate in the next project.
 Conduct survey and take time bound actions to improve customer (TVSM)
satisfaction.
 Check lots as per AOI and update “Online Inspection report”.

2.2 MANUFACTURING FEASIBILITY

Objectives:

 To understand TVSM requirement and carryout manufacturing feasibility


 To carryout Risk Analysis & prepare Mitigation Plans
 To review and complete Manufacturing Feasibility sign off

TVSM Responsibilities:

TVSM development team shall


 Provide all the clarifications that may be required by the supplier team
 Review Manufacturing Feasibility, drawing feedback & agreement. along
with all the supporting documents
 Complete Manufacturing Feasibility Sign-Off

Supplier Responsibilities:

Supplier shall
 Study RFQ, L1 & L2 drawings, SRS (for prop parts)
 For any ambiguities, clarify all the requirements

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 Carryout manufacturing feasibility, drawing feedback & agreement for L1


and after L2 release, review and signoff. Follow manufacturing feasibility as
per checklist QSF PUR SQAM 003
- Drawings and specifications (including Draft AOI – see 2.5)
- Part specific conditions and requirements including Identification,
traceability and material handling requirements
- Material, functional and performance requirements
- Surface treatment requirements
- Supplier capacity
 Outsourcing / subcontracting capability & capacity (Plant, facility, tools,
fixtures, gauges measuring and test equipment, parts, process etc.,)
- Supplier APQP timing plan (see 2.5)
- Supplier recommendations and feedback
 Determine risks and carryout analysis as per TVSM format
 Prepare Mitigation Plans for all those risks that have risk numbers more
than 20.
 Present the Manufacturing Feasibility to the supplier’s management and
obtain support.
 Present Manufacturing Feasibility and submit the document consisting of
following –
- Filled up Manufacturing Feasibility checklist, drawing feedback &
agreement
- Agreement of Inspection document
- APQP timing plan
- Risk Analysis and Mitigation Plans
 Carryout revisions in the manufacturing feasibility documents based on the
TVSM development team feedback.

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2.3 AGREEMENT OF INSPECTION AND TESTING

Objectives:
 To understand the part quality requirements, plan and mutually agree for the
following during design & development and regular supplies which has two
sheets, one is general requirement another is part specific requirement.
- Verification & validation system
- Inspection & testing plan
- Maintenance of the measuring devices
- Reports submission frequency

TVSM Responsibilities:

TVSM development team shall -


 Review and provide all the clarifications that may be required by the supplier
team
 Complete AOI document Sign-Off

Supplier Responsibilities:

Supplier shall
 Understand the part quality requirements such as material composition,
appearance / visual, dimensional, functional, performance – reliability &
durability, packaging and preservation, any other specific requirement.
 Prepare draft AOI document covering the following
 During Design and Development process
- Layout inspection and functional testing plan
- Design Verification Plan
- Design Validation Plan
- Reliability & Durability testing plan
- Process qualification and validation plan
- Process capability study plan
 During regular supplies

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- Layout inspection and functional testing plan for final product as well as
for child parts based on tool & die life assessment, changes in 5 Ms
(refer change management), agreed frequency.
- Incoming inspection
- In-process inspection
- Final inspection
- Pre-delivery Inspection
- Audits such as Product Audit, Manufacturing Process Audit, Dock Audit
- Process re-qualification and re-validation
- Process capability study & improvement plans
- Poka Yoke audit
 Discuss with TVSM NPD quality member, clarify and complete AOI sign-off
 Inspection plan shall consist of quality characteristics, Inspection methodology,
measuring devices (including hardware and software), by whom and samples
size during design & development process and regular supplies ( to be
included in part specific inspection agreement)
 Guidelines for designing checking fixtures, gauges and test equipments ref
chapter 3.2
 Inspection and testing reports submission frequency shall cover during design
& development process and regular supplies
 External laboratories ,when used ,shall be NABL accredited with relevant
scope
 Maintenance of Measuring Devices: Inspection, Checking Fixtures, Gauges
and Test Equipments
 Procurement / development of measuring devices such as inspection
instruments, test rigs / equipments, gauges, panel checkers etc. required for
functional, reliability and durability testing shall be included in APQP timing
plan.
 Supplier shall use TVSM format QSF QAD 10 11 05 for preparation of AOI.
 Supplier shall carry out similar exercise of AOI with the TIER 2 suppliers and
shall retain at supplier end, subject to audit by TVSM.

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2.4 ADVANCED PRODUCT QUALITY PLANNING (APQP)

Scope:

 APQP is required for all new parts development


 TVSM development team, depending upon the criticality of the part to the
project, communicates whether the part falls under A / B / C category along
with progress review methodology and frequency.
 Any major change in the scope of supply / requirement, requires revisiting of
APQP and re-sign-off of the APQP timing plan

Objectives:

 To ensure that supplier understands TVSM QCD requirements and prepares


APQP timing plan accordingly, in line with TVSM project milestones
 To review APQP timing plan for suitability & adequacy and agree by signing-
off the same.
 To review the progress periodically and ensure that APQP timing plan is
adhered and benefits achieved

TVSM Responsibilities:

TVSM development team shall


 Review and provide all the clarifications that may be required by the supplier
team
 Communicate TVSM milestones details in RFQ / LOI. Subsequent to RFQ /
LOI any major changes to be communicated to supplier.
 Review for adequacy and suitability and sign-off APQP timing plan
 Review the progress of the APQP as follows –
- “A” category part - weekly basis through C-projects
- “B” category part - during Alpha, Beta & QP samples submission

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- “C” category part - during the visit by TVSM

Supplier Responsibilities:

Supplier shall
 Understand the TVSM QCD requirements of the part being developed.
 Use project management techniques for preparing and managing APQP
timing plan ( Latest edition )
- Nominate project leader, select team members based on their
competency and promote team working environment
- Roles and responsibilities are defined for each team member
- Establish a project control room at supplier end with all the
required facilities such as soft boards, PC, LCD projector,
Internet connection, access to TVSM Collaboration folder &
projects, and communication devices.
- Establish communication & reporting system within the team and
also with supplier management
- Supplier management shall have periodic reviews of the APQP
progress and provide all the direction and support to the team
needed for the successful completion of the project.

 Use TVSM APQP template QSF PUR SQAM 004 for preparing APQP timing
plan. The details of each activity are explained in the template itself.
Additionally take help from TVSM development team as required from time to
time.
 Ensure that the phases, activities, milestones and review gates are aligned to
TVSM project requirements.
 Updating of the APQP progress shall be on a continuous basis
 Make every effort to adhere to the agreed timing plan

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2.5 PRODUCTION PART APPROVAL PROCESS (PPAP)


Objectives:
To establish that
 Supplier understands customer (TVSM) requirements
 Product and process designs have considered all factors and variables
 Supplier’s production process has the capability to produce a product meeting
all needs and expectations of the customer (TVSM).
Details
PPAP is required for all new parts for the conditions stated in chapter 3.5 Change
control management.
Levels of PPAP and submission requirements:
There are five levels of PPAP submission –
- Level A 1 – PSW and AAR.
- Level B 2 – PSW ,AAR, Limited data
- Level C 3 – PSW ,AAR, Full data, optional SPTR witness
- Level D 4 – PSW & AAR, Limited data, SPTR witness mandatory
- Level E 5 – PSW & AAR, SPTR witness mandatory
NOTE:
Irrespective of submission levels to TVSM, Supplier is required to complete all the
PPAP requirements as per AIAG manual (latest edition) & retain at supplier end .All
these documents are auditable by TVSM.
PPAP Level Vs Activity:
# Activity Level E Level D Level C Level B Level A

1 Review and assess By TVS-M By TVS-M By TVS-M By TVS-M By


the readiness for Supplier
PPAP

2 Conduct IPTR Witness by Witness by By By By


(alongwith LSR -Line TVS-M TVS-M Supplier Supplier Supplier
Side Review) and submit and submit
report to report to
TVS-M TVS-M
3 Conduct SPTR Witness by Witness by By Supplier By Supplier By Supplier
(alongwith LSR -Line TVS-M TVS-M and submit and submit and submit
report to report to report to
side Review) and
TVS-M TVS-M TVS-M
Carry out 300 piece ,witness by
trial in Production TVSM is
environment *optional
4 Approval By TVS-M By TVS-M By TVS-M By TVS-M By TVS-M

5 Monitoring of By TVS-M By TVS-M By TVS-M By TVS-M By TVS-M


incoming lots and
approval for DTL
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REVISED PPAP LEVELS :


TVSM
SI. PPAP Level
Proposed Part Categorisation
No As perAIAG
Level
All Proprietary Parts (Design
1 5 E responsibility with Supplier ).

TVSM Design Parts :


Structural Parts, Style Parts,
Engine parts Casting &
Machining, Forgings, Rubber,
2 4 D Plastics & Fabricated, Electrical
pats, Safety Parts, Sub
Assemblies.
Eg : Frame, Swingarm, Fuel tank
Style parts, Wiring harness, etc
Other Parts (TVSM Design) :
Machined parts, Other Forgings,
Fabricated Parts, Rubber Parts,
3 3 C
Non style plastic parts, other
castings.

Catalogue parts, Commodities


(like bearings Orings, grommets,
buffers, plugs, dust seal, rivet,
4 2 B
clamp, wave spring washer, key,
rivet, etc.,)

Fasteners, Clips, Clamps, Shims,


5 1 A
Circlips, Split pin etc

26
SQAM

Submission requirements:
Sl.No Document Title Level A Level B Level C Level D Level E
1 List of Documents submitted R S S S S
Design Records R R
Bill of Material R S S S S
2
Drawing R R S S S
Test Standards R S S S R
3 Engineering change Documents R R S S R
4 Customer Engineering Approval R R S S R
5 Design FMEA NA/R NA/R NA/R NA/R R
Process flow Diagram R R S R R
6 Overall Process flow (for Assembly) R R S R R
Process flow shop( for Feeder shop R R S R R
7 Process FMEA R R S R R
8 Dimensional results R S S S S
9 Material Performance Test results R S S S S
Initial Process Study PP, PPk Calculation sheet R R S R R
Summary of Initial process Studies R R S S R
10
Control chart R R S R R
PP, PPk Calculation sheet R R S R R
Measurement System Analysis Studies R R S R R
11 MSA for variable characteristics R R S R R
MSA for attribute characteristics R R S R R
12 Qualified Laboratory Documentation R R S R R
13 Control plan R R S S R
PSW S S S S S
14
Weight Calculation sheet S S S S S
15 Appearance Approval report S S S S S
16 Bulk Material requirements checklist R R S S S
17 Sample product R R S S S
18 Master Sample R R S R S
19 List of checking Aids R R S R R
Records of compliance with customer- specific R R S R R
List of Approved TIER 2 suppliers R R S S R
Agreement of Inspection S S S S S
Photographs of tool,Fixtures,Gauges
R R S R R
20 &Equipment
List of external laboratories (if the services
R R S R R
are used
Process Qualification Records R R S S R
Packaging Standard R R S R R

Supplier shall submit soft


Copies of reports in C folder

S: Submission
R: Retain at Supplier End.
For Level C, D review and approval by TVSM

27
SQAM

Progressive PPAP:
PPAP is required to be submitted progressively i.e. documents submission
during Alpha, Beta and QP samples submission will be as per table 1. In QP
phase, a four-stage approach shall be followed :
 Readiness Review – To assess whether supplier is ready for
PPAP production trials. This is done by reviewing product and
process design documents as per checklist CL QAD 10 11 001
 IPTR (Initial Production Trial Run) – To assess whether
supplier process can meet basic quality requirements by
conducting a small batch production trial run – typically 50 nos.
and reviewing the results as per checklist CL QAD 10 11 002
 SPTR (Significant Production Trial Run) – To assess whether
supplier can meet all PPAP requirements by conducting a
significant production trial run (8 hours Production or 300 nos ) at
planned run-at-rate and reviewing the results as per checklist CL
QAD 10 11 003
 TVSM may witness the SPTR based on the PPAP submission
levels.
 PSW Approval – Final assessment of the SPTR sample parts
by conducting vehicle production trial run (EJO trials) at TVSM
end and accord approval based on the results.

Supplier Responsibilities:

 IPTR & SPTR shall be completed as per APQP plan.


 TVSM representatives may witness the SPTR. The supplier shall notify TVSM
Quality and Purchase at least 10 days in advance of SPTR due date.
 Supplier shall include all processes including special and bottleneck
processes and assembly processes as applicable in the SPTR.
 SPTR shall represent the mass production conditions in all respects
1. Tooling, equipment, and checking facilities shall be available as per
Control Plan.

28
SQAM

2. Trained operator who will be deployed for mass production shall be


deployed for the SPTR. (Include operators of all the shifts if multiple
shift working is envisaged)
3. If mass production is planned in multiple line, machine, tools, etc,
SPTR shall be conducted in each of this lines, machines, tools.
4. Production condition shall be similar to mass production condition
and include
a) Availability of documented operation standard / work instruction
b) Mass production control plan
c) Tool change and set-ups work instructions
d) Mass production line speed and line balancing (TAKT time)
e) Mass production work environment
f) Lay out with manpower positioning
g) Cycle time details including loading / unloading

h) Cycle time Vs Takt time balance chart


 Mass production material shall be used for the trial.
 All Process and Product parameters as per Control Plan shall be monitored
and recorded during the trial.
 All engineering change implementation shall be completed.
 OK samples from SPTR shall be sent to TVSM with identification and
traceability after ensuring that the part meets the latest / relevant drawing
requirements.
 Trial targets of quality and quantity are as follows;
1. Quality:
Parts produced from the trial shall meet the mass production drawing (L3 /
L4), approved AOI / Inspection Standard and approved limit sample
2. Quantity:
Rate of production of OK parts (not re-worked parts) shall meet TVSM mass
production volume requirements.
 Trial production shall be as per the required takt time, without any interruption
for 8 Hours or 300 no’s, whichever is less. Process output shall be recorded
(Produced Quantity, Accepted Qty, Rejected Qty, Rework Qty etc)

29
SQAM

 The SPTR shall be repeated until the target Quality and Quantity targets are
met. The measured data from this trial can be used for process capability
studies.
 After successful completion of trial, the supplier shall send the SPTR status
report along with results and countermeasure implemented to TVSM
Purchase and Quality department.
 If the supplier is unable to achieve the target levels after taking
countermeasure, they shall communicate to TVSM Purchase and Quality
dept. The notification shall also include the supplier plan for achieving the
target and interim containment actions.

PPAP approval criteria

 Full approval – All documents OK, Parts OK, No deviation in the


manufacturing process during witness of production trial run.
 Conditional approval / Interim approval – Parts OK, No
deviation in the manufacturing process during witness of
production trial run, minor inadequacy noticed in documentation.
In case of minor deviation in manufacturing process, TVSM NPD
team may decide to approve based on action plan provided by
the supplier (for limited time period or quantity).
 Rejection – In all other cases.

Failure Mode Effect Analysis (FMEA)


 FMEA shall follow the latest edition of FMEA reference manual published by
AIAG. All rankings shall be inline with this manual.
 High risk in FMEA is defined where severity is high and / or RPN is high for a
failure mode / cause. High Severity  7 or High RPN  63 ( action plan
required to reduce severity or RPN ).
 Occurrence ranking shall be aligned to current performance of the process for
similar parts (rejection and rework at supplier end and line, lot and warranty
rejections).
30
SQAM

 Although all the risks need be addressed to reduce the RPN numbers, special
attention to be given for high severity rankings even if RPN is low. Whenever
severity is 9 or 10 and no actions are possible to reduce severity ranking,
efforts shall be taken to minimize occurrence and detection ranking.
 FMEA is a live document; it shall be revised periodically and updated to
always reflect current state of design and process including those failure
modes occurring after the start of mass production.

Measurement System Analysis (MSA)


 Supplier shall plan and conduct MSA for all new inspection, measuring; test
equipment and gauges referred in control plans and inspection standards
(especially IMTE used to measure special characteristics).

MSA shall include evaluation of all 5 types of variation present in a


measurement system in a statistical manner.
1. Bias
2. Linearity
3. Stability
4. Repeatability
5. Reproducibility

Supplier shall submit the MSA reports to TVSM as a part of PPAP file.
Supplier shall use MSA reference manual latest edition of AIAG for all attribute
and variable gauge studies.
On an on going basis, the supplier shall conduct Gauge R&R (variable and
attribute studies) on all types of measurement systems at least once in a year.
The types of measurement system shall be identified / grouped based on
instrument type, instrument range and resolution, part characteristics,
operating environment and skills / competences of personnel using the
instrument.

31
SQAM

Special characteristics – determination, deployment and control

 Determination of special characteristics is done by multidisciplinary


approach and typically involves members of Product Design, Process
Design, Purchase, Quality, Production, Service, Customer Representative,
Maintenance, TVSM development team etc.
Following table provides the guidance for determination of special characteristics and
the final decision of determining and classification of special characteristics entirely
lies with the multidisciplinary team.
 The special characteristics typically are determined first on assembly
characteristics, then deployed to sub assembly characteristics, then to parts
characteristics and finally to process characteristics.
 The guidelines for determining special controls for controlling special
characteristics are provided in the PPAP formats. It may be noted that the
best and most preferred control for controlling special characteristics is POKA-
YOKE (mistake proofing or error proofing). Supplier shall make every effort to
control special characteristics through POKA-YOKE.
 The supplier shall ensure that all special characteristics are deployed in
DFMEA, Supplier Drawings, PFMEA, Control Plan, Work Instructions,
Inspection Standards etc.
 Supplier shall adopt either TVSM symbols or equivalent supplier symbols.
Supplier shall confirm the symbols and criteria with TVSM Part Approval
Authority.
 Guideline for Control Mechanism:
Level I : Prevention control system.
Level II : Detection Control System
Level III : Detection in subsequent stages
Level IV : SPC (ex. X bar and R chart )
Level V : 100 % Inspection

32
SQAM

Minimum Process
Special Performance index / process
Symbol characteristics Explanation capability levels for variable
description characteristics
Geometric Others
Safety / Statutory Characteristic that influences the safety,
the security, the environment and that it is
/ regulatory
subject to regulatory requirements.
Determining effect on the customer
severity = 9 or 10. 1.00 1.67
Examples –
a) Brake shoe bonding failure
b) Poor lighting intensity
c) No horn sound
d) Fire hazard
Fit / Function – Characteristics that influences the
Critical operation of the vehicle (loss of primary
function) or performance. Customer is
highly dissatisfied. Determining effect on
the customer severity = 7 or 8.
Examples – 1.00 1.67
a) Vehicle starting trouble
b) Vehicle suddenly stops
c) Poor mileage
d) Engine oil leakage
e) High oil consumption.
Fit / Function – Characteristics that influences comfort or
major convenience items or noise, vibration and
harshness. Customer is somewhat
dissatisfied. Determining effect on the
customer severity = 5 or 6. OR If the team
leader thinks that the characteristic is
important for the robustness of the product.
1.00 1.33
Examples –
a) Engine Noise
b) Brake Noise
c) Shock Absorber hard
d) Rust formation.

Statistical Process Control (SPC)

 SPC shall be in line with latest edition of AIAG manual.


 Process capability studies shall be carried out over a sample size of minimum
100 nos. (25 subgroups of 4 samples each or 20 subgroups of 5 samples
each)
 If the process becomes unstable or non-capable (as per table), supplier shall
introduce 100% inspection for the parameter, till the Corrective Action is taken
and normalcy restored.
 Results shall be recorded in process study.

33
SQAM

Control plan
 Control plan shall meet TS 16949 - Appendix A requirements
 Control Plans are written description of a system to control product(s) and
processes. They provide a structured approach to selection, design and
implementation of value added control methods. They do not replace Process
or Work Instructions.
 These documents facilitate promotion of quality awareness and consciousness
at all levels of operation.

 Control Plans are prepared by CFTs as a part of New product development


process.
Supplier shall prepare Control Plan at 3 stages.
Prototype: Details of dimensional measurements, material and performance
test occurring during prototype.
Pre launch: Details of Process control and dimensional measurements,
material and performance tests that is required during pilot production.
Post Launch (Mass production): Comprehensive documentation of product /
process characteristics, process controls, tests and measurements that is
required during mass production.
 For bulk material, PPAP submission shall be as per the mutually agreed
checklist
 The supplier is required to follow the above methodology for the approval of
parts and manufacturing processes that are being outsourced (TIER2 for
TVSM).
 For any clarification, supplier shall contact TVSM Development Engineer OR
TVSM PPAP approval authority.

Appearance approval
 Appearance approval format QSF QAD 10 11 008 shall be inline with the
format provided in PPAP formats (Applicable for appearance item only).

34
SQAM

TVSM Responsibilities:
TVSM development team shall
 Depending upon the criticality of the part to TVSM product, communicate the
level of PPAP submission.
 Review PPAP documents submitted by supplier, and provide the feedback to
supplier.
 Verify samples submitted and provide feedback to suppliers at every stage of
PPAP submission.
 Witness PPAP trials based on the level of PPAP submission and as required
 Approve PPAP - Fully Approved / Conditionally Approved depending upon the
compliance to the PPAP requirements.

Supplier Responsibilities:
Supplier shall
 Prepare all the PPAP documents as per TVSM requirements. Based on the
PPAP submission level, supplier shall submit PPAP documents. Table 1
shows the 19 requirements for the PPAP submission.
 Use TVSM formats – for preparation of PPAP documents ( as a guideline )
 Review the adequacy of the PPAP documents and ensure that all the
documents are in order prior to submission.
 Submit the PPAP documents through Collaboration Folder link available on
www.tradewithtvs.com
 Receive TVSM feedback and correct PPAP documents accordingly
 Make ready for any trials that TVSM may witness – eg. Alpha, IPTR and SPTR
 Carry out similar PPAP methodology for the TIER2 suppliers. Approve TIER 2
supplier PPAPs before PPAP approval by TVSM.
 Mass production and regular supplies can start only if the part PPAP is
approved by TVSM.

35
SQAM
QP (PPAP
submissio Mass
productio
S No Document Format Alpha Beta n& n (ECN & Remarks
approval Others)
stage)
1 Design records Suppliers to submit QP1 is with L3, QP2 onwards with L4
TVSM Drg / Yes Yes Yes (L4) / release. Subsequent on-going
Yes (L4)
Supplier Drg (L2) (L3) ECR changes are with ECRs.
2 Engg. Change No specific format If applicable
No Yes Yes Yes
drawings
3 Customer Engg. No specific format If applicable
Approval Yes Yes Yes Yes

4 DFMEA QSF RND 04 51 Applicable for parts designed by


001 suppliers (Proprietary). Document
may be requested by TVSM for
No No No No verification, if the supplier is not willing
to submit, the same shall be reviewed
at supplier end.

5 Process Flow QSF PED 02 03


Diagram 001 Yes Yes Yes Yes

6 PFMEA QSF PED 02 03


Yes Yes Yes Yes
005
7 Dimensional report No specific format Layout inspection and functional
Yes Yes Yes Yes
testing report to be submitted.
8 Material, No specific format
performance and
Yes Yes Yes Yes
endurance test
results
9 Initial process studies No specific format For special characteristics
No No Yes Yes

110 MSA No specific format For instruments / gauges for


No No Yes Yes measuring special characteristics
111 Qualified Lab No specific format
No No Yes Yes
Documentation
112 Control plan Supplier’s format
or QSF PUR Yes Yes Yes Yes
SQAM 005
113 PSW QSF QAD 10 11
No No Yes Yes
002
114 Appearance approval QSF QAD 10 11 as applicable as per the checklist (ML
report 008 No No Yes Yes QAD 10 11 001)

115 Bulk requirement No specific format As applicable


No Yes Yes Yes

116 Sample Production No specific format


part Yes Yes Yes Yes

117 Master samples / No specific format (As applicable e.g. - for AAR parts,
Limit samples No No Yes Yes Carburetor, Cyl Head etc.)
118 Checking aids No specific format No No Yes Yes
119 Customer specific No specific format As per the Supplier Quality Manual
requirements and specific requirements (special
process qualification, list of TIER2
suppliers, List of special
No No Yes Yes characteristics, List of Poka Yoke,
Lay out with man power deployment,
Cycle time details including loading /
unloading, Cycle time vs takt time bar
graph)

Stage wise submission requirements (Applicable mainly for NPD supplier parts approval

36
SQAM

3. QA ACTIVITIES IN MASS PRODUCTION


3.1 SUSTENANCE OF QUALITY
Objective:

To explain the supplier’s responsibilities for consistent quality achievement.

Scope:

Applicable to all existing and new suppliers of TVSM.

Details:
Supplier shall establish a system to achieve consistency in quality. The following
records / reports are to be maintained and updated on periodical basis.
a. Supplier Inspection Report
b. Product audit records
c. Process audit records
d. Performance & endurance test reports
e. Layout inspection reports
f. Process qualification records
g. Jig / Fixture / Tool / Machine Preventive Maintenance records
h. System audit records
i. Tier 2 audit records
j. Process capability report
k. Conformity of production

The audit plan, adherence to audit, audit findings and action taken based on the
audit, shall be made available and reviewed during the monthly review with section
heads, to track the closing of NCRs and also to be reviewed during supplier top
management review.
The above may be verified by TVSM Quality during the system and process audit

37
SQAM

a. Supplier Inspection Report:


Supplier has to carry out the inspection as per the agreed Inspection standard
( AOI / TMIS ). Supplier shall retain PDI reports for every lot.

 Supplier shall submit relevant reports at a frequency as defined in AOI


 For all visual check / appearance check, supplier shall follow master / limit
samples approved by TVSM.
 Supplier shall identify inspectors, train & certify them for final & Pre delivery
inspection.
 Certified inspectors shall inspect PDI and approve the lot.

b. Product Audit:

 Supplier shall make plan for product audit covering all products at periodic
interval depending upon the volume of product and quality performance.
 Supplier shall perform product audit for ready for despatch parts, to confirm
dimensions against standard, Functionality, Packaging, Labeling, etc.
 Supplier shall record product audit findings and raise non-conformances (NCs)
if not ok against specifications. Make action plan for disposal action for the
parts available in pipeline / at customer end and corrective action to prevent
the defects and monitor the same for completion of the actions.

c. Process Audit:

 Supplier shall make process audit plan covering all processes / machines (Die
casting, forging, moulding, welding, pressing, machining, heat treatment,
plating, painting, powder coating and assembly processes).
 The supplier shall verify the process parameters are set as per the Control
Plan for the process including Poka-yoke.
 Audit shall be conducted based on TVSM approved control plan as applicable.
 Supplier shall record process audit findings and raise non-conformances
(NCs) if not ok against specifications. Make action plan for disposal action for

38
SQAM

the parts available in pipeline / at customer end and corrective action to


prevent the defects and monitor the same for completion of the actions.

d. Performance and endurance audit:

 Supplier shall make a plan for performance & endurance testing for all the
existing products in consultation with TVSM Quality / as agreed in AOI (on
frequency of testing and sample size) and submit the plan annually to TVSM
Quality / Purchase.
 The supplier shall test for all part(s) when performance or functional test
requirements are specified in TSES, drawing / inspection standard (AOI).
 Performance test results shall indicate and include
- The drawing and TSES change level of part tested
- Any authorized engineering change documents that have not yet
been incorporated in the drawing
- Date of testing, quantity tested
- Actual results and decision

e. Layout inspection:

 Supplier shall prepare a plan and carryout layout inspection of all the parts, in
consultation with TVSM Quality / as per the AOI.
 Supplier shall retain the latest Layout inspection report along with the samples
which is auditable by TVSM.
 Raise NCs for the dimensions that does not meet the specifications and make
action plans to correct the same.
 If the solution identified by the supplier requires a change in the product or
process design, the supplier shall initiate the change request.

39
SQAM

f. Process qualification:
 Supplier shall identify the special processes ie (Heat treatment, Plating,
Painting, Powder Coating, Welding, etc) and make a plan for conducting the
process qualification, including Tier 2.
 The process shall be set at minimum condition for all process parameters as
per the Control Plan and produce the product as per the normal batch size.
(E.g. Temp: 160 ~ 200 deg Time: 5minutes ~ 8 minutes in a plating process
then produce the batch by setting temp at 160 deg and time 5 minutes for
minimum condition)
 Check the product parameters as per Drawing, Inspection Standard / Control
Plan including destructive type parameters. (Like Chrome thickness by
couloscope, High Sculpture, Case depth / penetration / load etc)
 In a similar manner set the process at maximum condition for all process
parameters and produce the batch, record the result for both minimum and
maximum condition
 If the final product requirement is met for min and max condition, the process
is ok otherwise identify the causes and make action plan to achieve the
requirement.

g. Jig / Fixture / Tool / Machine (Preventive Maintenance):

 Supplier shall make a plan for all Jigs / Fixtures / Tools / Machines covering all
the processes. Frequency can be decided based on the volume of production,
frequent wear and breakdowns.
 Identify the parameters to check the condition by visual for each jig / fixture /
tool / machine.
 Monitor the parameters & replace the wear parts if required and record the
dimension before & after replacement, maintain the history card for each jig /
fixture / tool / machine and record.
 Maintain & monitor the minimum stock of spares to avoid any abnormality.

40
SQAM

h. System audit:
 Supplier shall make a plan for Quality Management System audit covering all
the QMS processes at planned intervals.
 The processes mean purchase process, new part validation process,
calibration process, nonconforming product handling, etc.
 Verify the adequacy & adherence of the processes and record the
observations. Raise NC where not meeting the requirement and make action
plans for Corrective & Preventive Action.
 The summary of audit finding and action status shall be covered in the
Supplier’s Management Review.

i. Tier 2 audits:

 Supplier shall make a plan for Tier 2 audit covering all Tier2 suppliers.
 Supplier shall verify following areas
- Availability of latest revision of drawing and inspection standard
- Adherence to Control Plan
- Condition & Calibration of Gauges / Instruments / Tool / Equipments
- Part parameter audit
- Condition of jig / fixture / tools / gauges & history maintenance.
- NC products identification and handling
- Deployment of certified operators and inspectors in critical processes
- If a special process is done by Tier 2, then the special process
qualification to be verified and approval by TVSM.
- Layout inspection, product audits.
- Supplier may cover additional areas as required

41
SQAM

j. Process capability report:

Supplier shall send the of process capability reports on monthly basis for
special characteristics, controlled through X-bar, R chart. Action plan to be
submitted to improve the process capability, if Cpk is below the norms
specified in the manual.
k. Conformity of production (COP):
Supplier shall send the COP report as per the fixed frequency from the
approved agencies. The list of applicable COP parts are enclosed.

2W & 3W Safety Parts : COP Details

# Part name 1st COP Start date 1st COP End date COP Frequency

1 LPG Regulator (3W) 31.03.2010 1 Year

2 CNG Regulator (3W)

3 Safety glass (3W)


01.04.2009 (Phase I)
4 Brake hose 31.03.2011

5 Tyre

6 Horn
2 Years
7 Bulb
01.10.2009 (Phase II) 30.09.2011
8 Rear View Mirror

9 Lamps

10 Reflex reflector 01.04.2010 (Phase III) 31.03.2012

11 Fuel tanks

42
SQAM

3.2 DESIGN & CALIBRATION GUIDELINES FOR CHECKING FIXTURES,


GAUGES AND TEST EQUIPMENT

Objective:
To explain the requirements for the test equipment planned during part development
to evaluate the production of parts with reference to drawings / quality plan / other
quality requirements.

Scope:

This is applicable to all the checking fixtures, gauges and test equipments used for
checking the finished parts, including Tier 2 process.

Supplier Responsibilities:

 The supplier is responsible for design and manufacture of necessary checking


fixtures, gauges and test equipment identified during part development.
 The supplier may discuss with TVSM Quality to establish design concept
before detailed design begins. The supplier may refer to the guidelines given
in this section.
 All checking fixtures, gauges and test equipment shall be accurate according
to recognized automotive industry standards. Refer annexure – for approved
gauge calibration agency list.
 The equipment shall include documentation to establish traceability to the
appropriate national / international standards.
 MSA to be performed by the supplier in line with the latest rev TS16949
supplementary manual.
 The supplier is responsible for maintenance and calibration of all checking
fixtures, gauges, test equipment, test rigs, process monitoring equipments like
temperature controller, Ammeter, Volt meter, Thermometer etc. All shall be
calibrated on planned basis including Gauge R&R studies.

43
SQAM

 Certification shall be traceable to a national / international / certifying body.


The records of calibration shall be made available to TVSM upon request.
 Gauges, checking fixtures and test equipment shall be identified with gauge
no, part number, engineering change level, certification date, calibration due
date, etc.
 All the checking fixtures, gauges and test equipments which are required for
inspection are to be made ready and qualified to evaluate the tooled up
sample parts.
 Supplier shall ensure that required training is given to all the Operators /
Inspectors, for proper usage of checking fixtures, gauges and test equipment.
 The supplier shall ensure handling, preservation, storage and the usage
condition of checking fixtures, gauges and test equipment to maintain the
accuracy and fitness for use.
 If calibration activities are carried out at in-house standards room, then the
standards room shall conform to ISO / IEC 17025. External labs when used
shall be NABL accredited.
 Primary / Secondary master to be traceable to National / International
standards.
 Standards room manual is to be maintained.
 Documentation shall include before and after calibration results and history.
 Employees involved in using calibration equipment shall have competency to
carry out calibration.
 Whenever there is an engineering change, the relevant measuring devices
shall be reviewed for its suitability.

44
SQAM

GUIDELINES FOR CHECKING FIXTURES


 Datum shall be in line with drawing and quality
plan
Datum position  Datum surface shall be of appropriate size
 Clamps shall be of appropriate size and shall
not distort the part with excess pressure.
 For ease of measurement, appropriate gap to
be maintained between the part and fixture.
 Nominal / upper limit / lower limit shall be
shown in the gauge / fixture wherever
Measuring position
applicable
 All parameters mentioned in inspection
standard shall be easily measurable.
(Identified gauge parameter)
 Part shall be easily loaded and removed from
device without damage
Workability
 There shall not be any interference between
part and checking fixture
 Must be rigid enough to last the product life.
 Clamps and high usage area must be strong
Durability enough to take care of the above
 Datum contact surfaces shall be wear
resistant
 The design may accommodate multiple
Interchangeability
common parts wherever applicable.
 All loose parts shall be properly tied to main
fixture or stored in a box to prevent loss.
Maintenance of gauge / fixture
 All the identification marks / color codes shall
be legible and understandable.
Spares for wear parts used in  Minimum stocks of spares to be maintained
Gauges & Fixture

45
SQAM

3.3 NON CONFORMING PRODUCT HANDLING


Objective:
To explain suppliers responsibilities for NC product control, handling & corrective
actions.
Scope:
Applicable to all parts suppliers of TVSM.

Supplier Responsibilities:

Supplier shall establish and maintain documented procedure to ensure that non-
conforming parts are prevented from proceeding to subsequent process. This
procedure shall explain the method of identification, evaluation, segregation,
disposition and notification of non-conformance to TVSM and Tier 2.

Non-conformance of Minor in nature:


If the non conformance is minor in nature and if the supplier feels that it will not affect
either the subsequent process at TVSM or the intended functional requirements at
TVSM customer’s end, then they shall request TVSM for clearance thro, Deviation
Approval Request format (QSF PUR SQAM 007) immediately and explain the non
conformance nature. The suppliers are encouraged to visit TVSM and explain the
deviation in person along with sample. TVSM Quality may either accept or reject the
request based on the judgment. If TVSM accepts the deviation, the supplier shall
identify the lot and send the material with prior intimation about the date of despatch
and arrival at TVSM.

Non-conforming parts shipped to TVSM and suppler end:


If supplier suspects that non – conforming parts have been shipped to TVSM or finds
the non-conforming parts at supplier end.
 Supplier shall send Notification of Suspected Shipment of Non-confirming
Product format (QSF PUR SQAM 006) to TVSM Purchase / Quality.

46
SQAM

Non-conforming parts detected at TVSM:


 The suppliers are notified through Quality Deviation Highlights (QDH) on
 Web www.tradewithtvs.com, the supplier shall ensure corrective actions on
receipt of QDH and communicate the causes of failure.
 QDH raised for non-conformance shall be replied within 24 hours through E-
Mail, Fax, Courier, or in person.
 As an immediate measure, supplier shall indicate the following:
- Containment activity for the parts at TVSM, at the supplier and in transit
- Short term / temporary countermeasure with time line.
- Method of segregation or sorting
- Identification after segregation or sorting.
- Supplier shall arrange for sorting / reworking of the parts for smooth
running of lines
 Subsequently the supplier shall follow the procedure described in the section
3.4 Customer complaint handling (Field / Line / Lot)
NOTE:

 The supplier shall respond to the QDH for the completion of action. In case the
committed target is not met, the supplier shall intimate the revised target date
with reasons.
 Till the permanent counter measure is implemented, suppliers shall ensure
only OK parts have been shipped to TVSM.
 If the suppliers have any disagreement with the Quality Deviation Highlights,
they shall contact TVSM Quality.
 Improved lot shall be separately identified and submitted with PPAP
modifications if required, with prior information to TVSM.
 Supplier shall have a system to communicate the TVSM assembly line
complaints and Field complaint to the respective stage operators and
inspectors. Defective sample / VCS to be displayed in the appropriate place.
 Ensure suspected and obsolete parts are identified & kept in identified
location. These parts are treated as Non-conforming parts.

47
Corrective action score (QA Matrix score)
SQAM

5 4 3 2 1
• Prevention type • Detection type • 100% dimensional • 100% visual check • Sample checks
Poka Yoke Poka Yoke check & sample for dimension
dimensional check
• Design improve- • Design improve- • Introduction of • Sample check
ment (Sev < 5) ment (Sev 5 to 7) calibration for • Use of trained for visual
Jigs & Fixtures operators features
• Process improve- • Process improve-
ment (Cpk > 1.67) ment (Cpk 1.33 to • Introduction of tool • Provision of • One point lesson
1.67) change frequency inspection standard / Quality alert
• 100% automated (SOP)
test • 100% additional • provision of variable

48
test station gauging
• Automation of tool
change frequency • Automation of tool • PM Check list
- Machine change frequency operation
shutdown - visual control

Process control focus Inspection focus


SQAM

3.4 CUSTOMER COMPLAINT HANDLING (FIELD / LINE /LOT)


Objective:
To specify the responsibilities for analysis and improvement activities in case of
complaint received from field / TVSM assembly line.
Scope:
Applicable to all parts suppliers of TVSM.
Details:

On receipt of customer complaint from TVSM, Supplier shall identify root cause and
corrective action as per the procedure explained.
In the process of complaint resolution, TVSM and supplier shall share the relevant
documents and data through “Supplier Collaboration” facility available on
www.tradewithtvs.com.

TVSM SUPPLIER

Process the customer


complaint parts (Field / line)

Do preliminary analysis of
customer complaint and - Analyse problem thro’ QC
forward information to Story approach for field and
supplier Kaizen for line complaint

- Determine the counter


measure
Organise review meeting with
supplier and get - Validate the counter measure
countermeasure and implement.

Confirm and & monitor the


effectiveness of counter
measure

49
SQAM

Line / Lot Complaint:


TVSM Quality responsibilities:

 Collect information, defective part and make preliminary analysis where


applicable.
 Test the part on the vehicle for performance, if required.
 Share the information & defective parts with concerned supplier

Supplier Responsibilities:
 Upon the receipt of complaint (Email / Fax / Quality Deviation Highlights),
supplier representative shall visit TVSM to understand the problem within 24
hours.
Supplier shall take containment action for all stocks available in TVSM, field,
transit and at supplier end. The actions that are to be taken are as follows:
M1 action - Immediate action to be taken on stocks at TVSM- Quarantining /
segregation / 100% inspection etc.
Target lead time for completion of M1 action -Within 24 hrs
M2 action -Temporary action to be taken at all stages of manufacturing, transit
and storage through out the supply chain. to prevent the defect reaching
TVSM.Example of means used --100% inspection / switch over from sampling to
100% inspection / Gauge introduction, etc
Target lead-time for completion of M2 action - Within 48 hrs
M3 action - Corrective action through problem solving approach (QC Story/Kaizen
sheet/8D- report )
Target lead-time for( i) Submission of corrective action reports –within 7 days
(ii) completion of M3 action – Within 15 days (according to the nature of problem
and resolution)
M4 action - Horizontal deployment of the corrective actions to all the applicable
areas. Example - Horizontal deployment across models processes etc.
M5 action - Standardization activities (Capturing learning’s and providing
information for future products/processes)
Example – Updation / preparation of Product Design Guidelines, Process Design
Guidelines, Part Development Guidelines, FM directory, Training Modules, Quality
System correction etc.

50
SQAM

 Supplier shall conduct detailed investigation of the part and process both at
their end as well as at Tier 2 supplier end before concluding the root cause of
the problem. It is recommended to use QC story methodology while analyzing
possible reasons.
 . The corrective action score shall be minimum 4. Refer “Corrective Action
Score” (QA Matrix score) enclosed in the manual.
 The supplier shall update the relevant standard (drawing, FMEA, control plan,
work instructions etc) to prevent the problem in future models.
 For continual improvement, the supplier shall see the web data on daily basis
and initiate action for line / lot complaint resolution, Format (QSF PUR SQAM
009)
 This updated data and actions shall be discussed in the monthly review at
TVSM

Customer Complaint: Field


TVSM Quality Responsibilities:

 Collect information, defective part and make preliminary analysis where


applicable.
 Test the part on the vehicle for performance, if required.
 Share the information & defective parts with concerned supplier
 Visit the dealer if required to understand the complaint.
Supplier Responsibilities :

 Upon the receipt of complaint (Email / Fax / Quality Deviation Highlights),


supplier shall take containment action for all stocks available in TVSM, Field,
Transit and at supplier end. The actions that are to be taken and timelines
shall be the same as those specified in resolution of line/lot complaints
.However in case of field complaints ,whenever requested by TVSM ,the
supplier will be additionally required to extend M1 actions to the vehicles/parts
available in field .

51
SQAM

 Supplier shall visit TVSM as per agreed schedule for joint analysis of warranty
parts and send analysis report to TVSM as per agreed time line.
 Analyze the failure, using warranty analysis guidelines and warranty analysis
summary format QSF PUR SQAM 010 & QSF PUR SQAM 011. It is
recommended to check 50 – 100 nos of failed parts randomly and verify the
following observations.
- Phenomena of failure, kms etc
- Location of failure
- Bench mark study to identify the improvements
- Simulation of field failure in lab
- Identify the root cause of failure
- Identify the counter measure
- Compare the improvement in lab testing (before & after)
- Implement the action with time plan format
- Monitor the results
 The updated data and actions shall be discussed in monthly review at TVSM.
The implemented corrective action score shall be minimum 4.
 For continual improvement the supplier shall see the web on for warranty
parts.
 The supplier shall update the relevant standards based on the improvements
(drawing, FMEA, control plan, etc)

Example – Updation / preparation of Product Design Guidelines, Process Design


Guidelines, Part Development Guidelines, FM directory, Training Modules, Quality
System correction etc.

52
SQAM

3.5 CHANGE CONTROL MANAGEMENT

Objective:

To specify guidelines for

 Initiating the changes,


 Assessing the impact of the changes
 Verification and validation of changes,
 Notification to TVSM and obtaining approval and
 Implementation of changes

Scope:

As given in the table below -

No Nature of change Examples

1 Product Design Material Changes / Use of alternate material for the first time
Changes (Supplier
initiated changes)
Co-ordinate / Geometric dimensions, Tolerances, Surface Finish
Surface protection / appearance attributes (plating / plating, powder coating)

Change in constituent parts (changes in child / sub assy parts)


Changes to component level drawings, Design records (No change in physical part but
changes are effected in notes / spl characteristics symbols e.g
1. Change in Reliability, Durability, Maintainability and Life targets,
2. Test Specification changes / methods
3. Change in Special characteristics – major to safety)
Changes in Bulk materials
(Process technology new to the supplier, not previously used for this product)
2 Process design / Process sequence and or parameters / layout change.
Method / work
Method / work practices ( Inspection method ) (including changes in work timings)
practice changes
(Supplier initiated Material Handling devices / storages devices
changes)
Tool change frequencies against the agreed norms (New / major repairs of non perishable
tools such as moulds, dies, press tools etc.)
Measurement methods / measurement instruments / measurement frequencies

3 Supplier changes New supplier, new supplier location / plant

Change in TIER 2 suppliers


Supplier inactive for more than 12 months
Changes at supplier end – in terms of org changes etc. (Mergers / Takeovers)

53
SQAM

No Nature of change Examples


4 Volume / Volume increase beyond 20% wrt Approved Production rate signed off in PSW
Manufacturing
location Mfg at a new location / new plant / building
Rearrangement / refurbishment of machines, tools, equipment at existing location, for
capacity increase
5 Operator / Rebalance of operator job content with / without changes in process flow.
Manpower
6 Machines / tools / Use of new machines and or new tooling
equipment
Use of modified machines and or modified tooling

Use of machines / tooling after a major breakdown

Use of machine / tooling inactive for 12 or more months

Rearrangement / refurbishment machines tools equipment at existing location

7 Logistics Changes in inbound / outbound system

Packaging method
8 Other QMS Invoking contingency plans (including labour shortages, key equipment failures, field
changes returns, strikes / bandhs, patent infringements etc.)

TVSM responsibility:

 TVSM initiated changes shall be communicated through ECR / ECO route


and approval through PPAP.
 TVSM shall provide all the necessary clarification for any changes
requested by the supplier.
 TVSM shall receive notification, study the changes in details and provide
concurrence (either through PPAP approval or written consent to enable
supplier start regular supplies).

Supplier responsibility for TVSM initiated changes

 Supplier shall study the ECR drawing and provide feedback (change
assessment and impact on QCD) through ‘C’ Folder facility available on
tradewithtvs.com website.
 Supplier shall obtain feedback / concurrence from TVSM before submitting
samples along with necessary PPAP documents for evaluation

54
SQAM

 Supplier shall follow PPAP and obtain approval prior to regular supplies.

Supplier responsibility for self initiated changes

 Supplier shall submit request for engineering changes – format no. QSF
PUR SQAM 014, process changes format no, QSF PUR SQAM 013 and
obtain necessary clearance from TVSM for going ahead with the change
implementation.
 Supplier shall submit notification and obtain further guidance from TVSM
 Supplier shall ensure that the changes are verified & validated and follow
PPAP for obtaining approval from TVSM prior to implementation of
changes and start regular supplies.

Note :

Full / Partial non compliance of change control system at supplier end


resulting into warranty failure, line stopper, deviation in product performance
parameter shall result into initiation of appropriate action by TVSM.

55
SQAM

3.6 SUPPLIER PROCESS AUDIT

Objective:

To explain the procedure for quality systems / process audit at supplier end.

Scope:
Applicable to all existing suppliers, new suppliers and Tier 2 suppliers of parts

Process audit:

The purpose of process audit is to verify the sustenance of actions, taken by


the supplier for quality, delivery improvements and new product development
issues.

 The purpose and scope of the audit may be sent in advance.


 The supplier may be asked to do self audit on a case-to-case basis.
 Action plans are to be sent as per the format (3W1H) to TVSM Quality and
also to update the status of action completion regularly.
 The audit shall be conducted with or with out prior intimation to the supplier
using TVSM process audit check sheet.

Note :
 Supplier shall do system audit on periodical basis and correct non
conformance with action plan and maintain records.

56
SQAM

3.7 SUPPLIER PERFORMANCE


Objective:
To explain the Supplier Responsibilities in terms of meeting quality targets and
give feedback for improvement.
Scope:
Applicable to all suppliers of parts to TVSM.
Details:

TVSM shall set targets for their suppliers in term of quality


TVSM Quality dept. are primarily responsible for improving ‘Q’ rating
improvement. These targets and progress shall be reviewed by TVSM regularly.
Supplier shall aim for Zero defect as primary objective. These targets may vary
based on current level.
TVSM expects total commitment from the supplier to set and meet the targets for
mutual benefits.
Following information’s are to be given to the supplier in the website by TVSM
 Quality Rating
 No of lot rejected
 Line PPM
 No of lot segregated
 No of lot rejected and reworked

NOTE:

Supplier shall be charged accordingly for the recourses spent by TVSM


1. Quality performance report for each supplier is published on the website
www.tradewithtvs.com. Quality rating is arrived based on the quality performance
covering lot, line rejections, and warranty returns including spare parts supply. If
rating is less than 90%, supplier shall forward the action plans proposed / planned
along with the time frame to meet the target, the progress of which shall be
reviewed by the supplier management on monthly basis and to be presented to
TVSM on demand.
(Please refer to Table (5) in page no 56 basis for calculating the Quality Rating).

57
SQAM

Supplier Quality Rating = Average Lot Rating x Derating For Line & Field Rejection
(NET RATING)
F1 = Lot Acceptance Crieteria Factor
(I) INDIVIDUAL LOT RATING (Li) DP = Direct pass 1.0

RG = Regularisation 1.0

Lot rating = Qty Accepted X F1 SK = Skip 1.0


Quantity Received
CA = Concessional Acceptance 0.9

RTSG = Rework & Segregation 0.0

EC = Engg. Concession 0.2

RJ = Rejected 0.0

(II) Average lot rating = L1R + L2R + …… + LnR


(ALR) n
(III) Net Rating = A.L.R X N.R.F
Where Net Rate Factior (N.R.F) = M1 X M2
M1 is for inhouse MSN (LINE REJECTION)

M1 % = MSN quantity for all shops except warranty

Total quantity accepted for the month

M2 is for warranty MSN (FIELD REJECTION)

M2 % = MSN qantity from warranty (3 months)

Total quantity accepted for the month(3 months )

If M1 % <= 0.01then M1 = 1 If M 2 % < 0.05 then M2 = 1

If M1 % >= 0.01 < 0.05 , then M1 = 0.9 If M2 % > 0.05 <0.1 then M2 = 0.8

If M1 % > = 0.05 , then M1 = 0.8 If M2 % >= 0.1 , then M2 = 0.6

Overall Rating for the supplier :- Net rating of ith Item X No.of lots in ith item)
Total No. of lots of all items

Table 5. Criteria for supplier quality rating calculation


Supplier shall study the feedback and revert back on action proposed / action
plan along with target date to meet the targets in Quality

58
SQAM

3.8 TIER 2 SUPPLIER MANAGEMENT

Objective:

To provide requirements on TVSM supplier’s responsibility in controlling the


Quality and Delivery of their suppliers and also the guidelines for managing Tier 2
suppliers.
Scope:
Applicable to all parts suppliers to TVSM.
Details:
 The role of the supplier in coordinating and guiding the Tier 2 suppliers to
 SQAM and TVSM specific requirements.
 The supplier is responsible for the part quality and delivery of the T2
supplier.
NOTE:

 Any failure of T2 supplier cannot be a reason for delay in mass production


/ part supply and quality requirements.
 For Special process supplier shall not change the source with out TVSM
intimation and approval. However for other process supplier shall validate
all the requirements ,maintain records and intimate 10 days in advance for
formal approval and implementation
Supplier Responsibilities:
The supplier shall
 Have a system for evaluating and selecting T2 supplier.
 Maintain master list of all the T2 suppliers.
 Maintain master list of all the T2 suppliers with clear details of the
operations carried out and provide a copy to TVSM along with PPAP.
 Guide Tier 2 supplier for designing, developing and establishing the
processes. TVSM may review the PFD, PFMEA & Control Plan of the Tier
2 supplier during part development if required.

59
SQAM

 Ensure and assess the production and process control capability of T2


supplier, including the inspection and testing facilities and ensure the
action taken for TVSM complaint if related to Tier 2
 Ensure that correct data of all specification, drawing and inspection
standard, TSES etc have been communicated to Tier 2 suppliers.
 Guide Tier 2 in planning and problem solving activities as required, for
quality and delivery assurance.
 Ensure the countermeasures are taken for the problems identified during
trial production by Tier 2 suppliers and also prevent the problem
reoccurrence during the mass production.
 The supplier shall notify Tier 2 supplier that TVSM may join any quality
audits of their facility jointly with the supplier if required.
 In order to change or add Tier 2 supplier, Supplier shall obtain approval by
submitting change request format (QSF PUR SQAM 015)
 After TVSM approval the supplier shall submit Re PPAP along with PPAP
lot.
 Discard the earlier T2 supplier only after the approval of Re PPAP by
TVS -M.
 Inform and obtain the approval for any change of operations at T2 like
offloading.
 Carry out special processes like heat treatment, plating, painting, powder
coating etc only at the mutually approved sources.
 Ensure Tier 2 supplier procures raw material only from sources approved
by TVSM.
 Monitor and improve QCD performance of all T2 suppliers.
 Deploy supplier best practices to T2 suppliers
 Encourage QMS certification (ISO 9001:2008 to start with and eventually
for ISO/TS16949) for TIER 2
 Supplier shall plan and carry out audits at Tier2 Suppliers at fixed
frequency
 Audit finding, NCR and Corrective and preventive action to be made
available during TVSM audit / upon request.
 TVSM may audit tier 2 suppliers as part of PPAP audit during NPD.
60
SQAM

3.9 CONTROL OF TVSM SUPPLIED TOOLS& GAUGES

Objective:

To specify the procedure for control / maintenance of TVSM supplied tools /


equipments/gauges

Scope:

Applicable to all suppliers of parts to TVSM.

TVSM Responsibilities:
 Discuss and finalise tool design concept along with the supplier and tool
designer.
 Discuss and finalise tool life target (no. of shots, production volume etc).
 Discuss and finalize tool maintenance activities that are to be carried out
by the supplier and their frequencies.
 Monitor that the supplier carries out preventive maintenance activities on
tools as per the agreed plan and checklist.
 Review the condition of tool when quantity produced reaches 75 % of the
agreed life. Thereafter, review the tool condition at incremental 10%
production of the agreed tool life quantity
 Obtain Management Sanction for new tool and inform supplier to go ahead
with new tooling.

Supplier Responsibilities:

1. Discuss and finalise tool design concept along with TVSM.


2. Discuss and finalise tool life target with TVSM (no. of shots, production
volume).
3. Discuss and finalize tool maintenance activities to be carried out by supplier
and their frequencies.

61
SQAM

4. Plan, procure and maintain stock of tool replacement parts so that the parts
are available at all times.
5. Issue Tool Ownership Certificate (QSF PUR SQAM 017) to TVSM, once the
tools are proved.
6. Maintain history card for all the dies and the press tools
7. After any major tool maintenance, check first off sample and record the
measured value. If part meets drawing / inspection standard requirement,
continue the production.
8. Carry out preventive maintenance on each tool as per agreed maintenance
plan and checklist. In case of delays in carrying out the defined preventive
maintenance beyond 3 days, inform TVSM buyer.
9. Tool shall be maintained to prevent from any damage.
10. Review the condition of tool when quantity produced reaches 75 % of the
agreed life. Thereafter, review the tool condition at incremental 10%
production of the agreed tool life quantity
11. Based on the tool condition, agreed tool life and agreed lead-time for new
tool manufacturing, tryout and corrections, prepare plans for replacement
tools.
12. Prepare new tool request sanction and submit to TVSM at-least two months
in advance of target purchase order date for replacement tool procurement.
13. Submit copy of history card / report on usage condition, upon request.
14. Obsolete tool (tool life is over / obsolete part tool) shall be returned back to
TVSM.

62
SQAM

3.10 GUIDELINES FOR IDENTIFICATION, TRACEABILITY AND


MATERIAL HANDLING

Objective:

To define and explain identification, traceability and material handling of parts.

Scope:

Applicable to those parts where identification and traceability requirements are


specified in the drawing and / or Inspection standards. .

Details:

Identification: This is a method adopted by suppliers to identify a part so that


necessary information can be obtained quickly in case of suspected problem
occurrence
This includes
Batch Number
Supplier Identification
LH / RH designation
Date of manufacture, Month, Year
Cavity no, Mould no, Die no,
The above information may help the supplier as well as TVSM, to contain the
material at their respective location, in case of any suspected problem
occurrence.

 Supplier shall take necessary steps to identify parts by suitable means to


from RM receipt, in process through delivery stage.
 Supplier shall ensure FIFO (First in First out) at all stages.
 Supplier shall ensure identification requirement specified in Drawing /
Inspection Standard.

63
SQAM

 Supplier shall determine appropriate level of identification based on their


experience in industry standard.
 If supplier is preparing the inspection standard all such identification
requirement shall be included
 In case of any change in the identification proposed, the same shall be
informed to TVSM.

Traceability:

This refers to the ability to track a part, back through all the stages of manufacture
up to raw material stage. Process parameter used in manufacture of critical
components shall also be traceable, with applicable inspection and test results.
Identification is the key parameter for any traceability system.
E.g.: Date Code / Heat Code.

Supplier Responsibilities:
 Supplier shall ensure that documented procedures and systems are in
place to control the traceability of all the critical parts right from RM stage
to the date of manufacture and date of despatch to TVSM.
 The supplier shall also ensure the same with their supplier, to control the
trace ability of all the special process parts / critical parts. (as agreed)
 Incase of Rubber or Polymer parts the supplier is required to keep master
batch sample for each lot. Duration may be discussed and decided with
TVSM Quality and the corresponding records of composition & parameter.
 Suppliers are recommended to develop traceability for part identification,
even if it is not specified in drawing or inspection standard, to investigate
the process during trouble shooting of defective / failed parts.
Material handling:

Supplier shall plan for dedicated material handling facility like crates / bins /
trolleys / pallets for material despatch to TVSM and for in - house material
handling, to prevent damage of parts, burr, and dust.

64
SQAM

3.11. SUPPLIER QMS CERTIFICATIONS


Objective:

To define the requirements with respect to Quality Management System


Scope:

Applicable to all suppliers of parts to TVSM.


Supplier Responsibilities:
Supplier shall demonstrate the ability to establish, document, and implement an
effective Quality Management System (QMS) that comprises of all the applicable
elements of ISO / TS16949: 2009 or its latest version. Supplier shall ensure that
quality policy is thoroughly distributed, understood, maintained and that adequate
levels of authority have been established to ensure continuous improvement of
Quality Management System.
Supplier shall get accredited with ISO / TS 16949 with immediate effect and keep
such accreditation valid at all times by constantly upgrading themselves, in line
with the revisions to standard, that may be made in future. Suppliers who do not
meet this requirement shall immediately forward detailed action plan to fall inline
with this requirement.
Supplier shall periodically update their TS certification validity in web. TVSM will
monitor status of certification of non certified suppliers on an yearly basis.

65
SQAM

3.12 RECORDS AND RETENTION PERIODS

Objective:

To explain supplier’s responsibilities to establish maintain and control all quality


related documents and records.

Scope:

This procedure is applicable to all parts suppliers of TVSM.

Details:

TVSM expects the suppliers to establish, maintain and control all quality
documents and records related to TVSM in accordance with international
standards like ISO - 9001 / TS16949 with the following minimum requirements
1. Issue / revision control
2. Control of distribution
3. Retention period of documents / calibration details / records / registers
etc
4. Availability of latest relevant documents
5. Master list of quality records

All TVSM related quality records shall have minimum retention period as per the
following table to ensure traceability of parts / process conditions.

Records shall be legible and stored properly to prevent deterioration.

All Quality Records and Documents shall be made available to TVSM for
verification upon request.
All documents / records related to TVSM parts / process shall be kept in strict
confidence and shall not be disclosed to any third party without approval from
TVSM. Even when it is required to share such information, such as external
66
SQAM

audits of ISO / TS, it is the responsibility of the supplier to ensure confidentiality


by the third party.

Supplier shall return the Old Drawings / Standards to TVSM in case of obsolesce
of the part .The supplier shall destroy all copies of such documents and confirm to
TVSM to prevent misuse.

Sl.No Type of record Example Minimum


retention
period
1 Quality System Inspection Standards, Inspection 2 calendar
Records Reports, Tooling Maintenance year
Reports, Control Chart, Material Test
Reports, Performance Test Reports,
Calibration Records, Machine
Capability Study Reports, Audit
Reports, QUALITY DEVIATION
HIGHLIGHTS, Action Plans,
Kaizens, QC Story
2 Drawings, APQP For the life of
Documents and the product
Master Samples

67
SQAM

.
4.0 SPARE PART REQUIREMENTS

Objective:
To ensure quality of parts supplied as spares

Scope:
Applicable to all suppliers of parts to TVSM.

Supplier Responsibilities:
1. All parts produced for spares shall go through the same system of quality
assurance as that of a regular product.

68
SQAM

ABBREVIATIONS

AAR Appearance Approval Report


AOI Agreement of Inspection
APQP Advanced Product Quality Plan
ARAI Automotive Research Association of India
CFT Cross Functional Team
COP Conformity of Production
CP Control Plan
CPK Process Capability Index
DFA Design for Assembly
DFM Design for Manufacturability
DFMEA Design Failure Mode and Effect Analysis
DFS Design for Serviceability
ECO Engineering Change Order
ECR Engineering Change Request
EHS Environment Health and Safety
FEA Finite Element Analysis
FIFO First In First Out
FMEA Failure Mode and Effect Analysis
IPTR Initial Production Trial Run
LOI Letter of Indent
MSA Measurement System Analysis
NC Non Conformance
PCR Process Change Request
PDI Pre Delivery Inspection
PFD Process Flow Diagram
PFMEA Process Failure Mode and Effect Analysis
PO Purchase Order
PPAP Production Part Approval Process
PPFR Product Performance Feedback Report
Ppk Process Performance Index
PSW Part Submission Warrant
QCD Quality, Cost and Delivery

69
SQAM

QDH Quality Deviation Highlight


QFD Quality Function Deployment
QMS Quality Management System
QP Quality Proving
R& R Repeatability and Reproducibility
RFQ Request for quotation
SIR Supplier Inspection Report
SPTR Significant Production Trial Run
SQAM Supplier Quality Assurance Manual
SRS System Requirement Specification
TAC Type Approval Certificate
TSES TVSM System of Engineering Standard
TVSM TVS Motor Company

70
SQAM

LIST OF FORMATS AVAILABLE IN WEBSITE


FORMAT FORMAT NO. SEC REF .
1. SUPPLIER CONTACT QSF PUR SQAM 001 1.3

2. RISK ANALYSIS QSF PUR SQAM 002 2.1

3. MANUFACTURING FEASIBILITY QSF PUR SQAM 003 2.1

4. DRAWING FEEDBACK & AGREEMENT QSF PRG 02 01 018 2.1

5. AGREEMENT OF INSPECTION QSF QAD 10 11 05 2.3

6. APQP QSF PUR SQAM 004 2.4

7. PPAP READINESS REVIEW CL QAD 10 11 001 2.5

8. INITIAL PRODUCTION TRIAL RUN CL QAD 10 11 002 2.5

9. SIGNIFICANT PRODUCTION TRIAL RUN CL QAD 10 11 003 2.5

10. PROCESS FLOW DIAGRAM QSF PED 02 03 001 2.5

11. PFMEA QSF PED 02 03 005 2.5

12. CONTROL PLAN QSF PUR SQAM 005 2.5

13. PART SUBMISSION WARRANT QSF QAD 10 11 002 2.5

14. APPEARANCE APPROVAL QSF QAD 10 11 008 2.5

15. NOTICE OF SUSPECTED SHIPMENT QSF PUR SQAM 006 3.3

OF NC PRODUCT

16. DEVIATION APPROVAL REQUEST QSF PUR SQAM 007 3.3

17. QUALITY IMAGE QSF PUR SQAM 008 3.4

18. LINE / LOT REJECTION PERFORMANCE QSF PUR SQAM 009 3.4

19. WARRANTY ANALYSYIS GUIDELINE QSF PUR SQAM 010 3.4

20. WARRANTY ANALYSIS SUMMARY QSF PUR SQAM 011 3.4

21. ECR IMPLEMENTATION HISTORY QSF PUR SQAM 012 3.5

22. PROCESS CHANGE REQUEST QSF PUR SQAM 013 3.5

23. ENGINEERING CHANGE REQUEST QSF PUR SQAM 014 3.5

24. TIER 2 CHANGE QSF PUR SQAM 015 3.8

25. TOOL OWNERSHIP CERTIFICATE QSF PUR SQAM 017 3.9

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SQAM

List of Formats:

Note: List of formats is available in

SAP – C Folder / Training Modules - Formats & Templates

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