MARUTI SUZUKI INDIA LIMITED

Issue Deptt. QA/SC Prepared Verified Approved

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

Audit Person
Cluster Name Hanon Systems India Pvt Ltd

(Audit Score)
Vendor (Tier 1) person
Achieved Score： 46
×１００ = 41
Total Score： 112
Total
Part Number：
Subject: Vendor System Assessment
Part Name:
Observation:-

Total
Achieved
0 1 2

1 4/ 8 0 4 0
1.Production
preparation 2.Regulation for initial
2 3/ 6 0 3 0 16. Process Audit production control

3 5 / 10 0 5 0 100
15. Adequate testing facility 3.Changing management
4 3/ 4 0 1 1

5 4/ 6 0 2 1
14.Critical parts Management 50 4.Standards
6 3/ 6 0 3 0 management

7 2/ 2 0 0 1

8 8 / 12 0 4 2
13.Handling Management 0 5.Education and training
9 7 / 10 0 3 2

10 7 / 10 0 3 2
12.Products
11 0/ 8 0 0 0 management
6.Quality audit and process verification

12 0 / 10 0 0 0

13 0/ 4 0 0 0
11.Implementation 7.Supplier control
of standards
14 0/ 6 0 0 0

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

F003-3 QA/MT Ver. 5

 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
VENDOR ATTENDEES : Date:
Supplier 0
0
Auditors:
Name

Part Name 0

Category Audit Area Concerning regulation Requirements Judgment Remarks Follow Up

Do you define the procedure for Product development Procedure for regular production plan , Procedure for Product
Regarding implementation 1 including the following ? -scope of parts, responsibility development including scope of parts, responsibility of each 1
1 rule of production preparation
of each department, control contents / items? department, control contents / items as per APQP guidelines,

- Development Time plan (Master and Micro level)

Regarding management /
1. Do you implement follow-up to control the schedule and - Review frequency and evidence
implementation by production
Production 1 progress of production preparation items? Incl top - Reason of delay and action 1
2 preparation plan / report
preparation / management - Evidence of review by Top management.
(master plan)
New Product -Production plan monitoring after SOP
Developmen
t
Do you consider following items and implement
corrective and preventive action to the processes and
Defect prevention on the - FMEA Procedure
standards before regular production?
stage of process design by 1 - FMEA / QA matrix. 1
3 -Troubles in the past; -Defect items expected;
using FMEA/Matrix diagram - Past defect history and Potential defect included in FMEA.
-Defect items unable to capture at customer;
-Defect items difficult to repair;

Product/process evaluation at - List of Quality issues / defect faced In-house and Customer end
Do you prevent defects by quality improving activities of
4 the quality evaluation meeting 1 during trials. 1
cross-function team to evaluate quality performance?
in each trial - Their complete analysis in the form of PDCA.

Regulation for
initial production control
Do you define following items related to initial production Initial Supply Control Procedure including
control by standards ? - Initial Supply Control period (3month for new parts)
-controlled parts; -controlled items; -inspection method; - person responsible to announce start/end of initial supply control
1 1
1 -initial production control period; - Control items & inspection method (check method) and criteria for
-a person who announce start/end of initial production selection of control item
control; -finish condition; - Criteria for termination of initial supply control period

２． Regulation for
Regulation initial production control Stricter Control during Initial Supply Control period:
for - Increase sample size or frequency
initial - Frequent Process Capability Study (Cpk > 1.33)
How do you define items required special control during
production - Fast removal of problems / analysis
2 initial production control? Do you set stricter inspection 1
control - Change in Inspection Method
methods than the ordinary inspection?
- Verification of Standards, operation standards, facility etc.
(Process audit)
- Stricter visual inspection (100% inspection/ 200% inspection)

Evidence of Process capability study / defect rate (rejection % or

Do you control process capability and defect rate during ppm) monitoring and action if not meeting the target as decided for
2 Implementation of initial 1 1
initial production control? product and critical parameters as mentioned in Spec. Meeting or
production control
Critical parameters decided by supplier

Procedure / WI for expected change (4M : Operator, machine &

jig/die, material and method change) and unexpected changes (Tool
Definition and implementation Do you define unexpected change (unusual) and planned
1
1 breakage, power failure, machine breakdown, inspection equipment 1
of changing management change clearly?
failure etc.).

Do you define procedure(rules applied from sharing Rules to be defined from sharing information to the concerned
2 information to result confirmation) at change person / Deptt up to the result confirmation of product produced 1
occurrence? before and after the change.
３．
Changing Do you record product quality check results to ensure Recording of product quality check with product details like Lot no,
3 1
management traceability? Incl retroactive checks quantity and marking on products etc.
- Definition of initial part.
1 Do you define and control initial part clearly? - Control method/ system in procedure. 1
- Identification tag
Definition and control method
2 for initial part - Inspection & test record of initial parts / lots (All developments lot
Do you control initial parts separately and make quality
including pilot lot).
2 records about them?(both internal and outsourced 1
- Inspection / test reports of sub vendor's required in case part
process are included)
produced by sub vendor.

- Process control std, control Plan, Inspection standard and

Procedure to make process Do you make and review process control standards,
operation Instruction of all parts.
control standards(QA 1 Inspection specifications, Operation instructions for all 1
1 - Review system and records of updated std against a change.
process charts) products which is shipped to SMC / MSIL / Tier 1 ?
- Retention period of documents and records
４．
Standards
management Procedure to control
standards
Do you have consistency to keep process control
Coherence between all documents like PCS / Control plan,
2
1 standard, inspection specification, operation inspection 2
・Process control standards inspection standard, operation standard and MIS -P.
and parameter chart?
・Inspection specifications
・Operation instructions

Training procedure / WI including person responsible for Training

related to Quality (QS, Process Audit, Inspection, Using inspection &
testing instruments / Equipments etc.), Training need identification
Do you clarify the department in charge of promoting and effectiveness check system.
quality education, implement education based on annual - Training Calendar for all Operators, Supervisor and Managers
1 1
plan? - Training systems and record for New Joinee (Staff / operator)
Are records of education kept? - Training Plan v/s Actual records
Education/ training procedure - Effectiveness check records
1

５．
Education
and training Do you define and implement the skill evaluation of
operator to determine whether operator can work without WI for Skill evaluation criteria level wise, evaluation frequency and
2 1
surveillance?(e.g. acceptable revel/evaluation method.
frequency/evaluation method)

Education for Cross checking of operator's skill periodically against a decided

Do you periodically monitor the skill of certificated
2 managers/Inspectors/ 1 parameter and by simulating defect. 2
operators and follow up to improve their skill?
Special operators Evidence of retraining plan and effectiveness check.

Plan and evidence of conducting Internal Quality system Audit.

Do you conduct quality audit to identify issues and
1 Activity to keep/improve 1 Action taken for improvement against the Quality Issues observed 1
properly improve them?
production quality during audit.

６． Evidence of process audit based on work instructions / PCS and

Quality audit Do you confirm consistency between actual operation
1 actual working. 1
and process and standard?
Process with poor workability
verification
2 Content of process review
 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
VENDOR ATTENDEES : Date:
Supplier 0
0
Auditors:
Name

Part Name 0
６．
Quality audit
and process
verification
Category Audit Area Concerning regulation Requirements Judgment Remarks Follow Up
2 Content of process review

Do you confirm if countermeasures are taken properly to Evidence of Countermeasure effectiveness check at shop floor
2 1
prevent reoccurring of quality failure? during process audit.

７． New Supplier selection procedure indicating supplier audit check

Supplier Evaluation method for new Do you define criteria to certificate new suppliers and
1 1 sheet & min qualifying criteria especially for quality. 2
control suppliers implement them?
Evidence of audit done and supplier list

Do you define clearly what is abnormal situation and Definition of abnormal situation and Operator's awareness about the
1 1
make operators know the definition? abnormal situations.

Do you clarify and standardize the handling rules/routes

Procedure for customer complaint handling, in-process failures
Handling when abnormal 2 for customer claims, in process failure and supplier 1
(defect/rejection/rework) and supplier failures
1 situation occurs failure?

Do you have criteria to estimate the scope of suspected

Procedure for handling suspected parts at the time of abnormal
lot for abnormal situation?　When abnormal situation
８． 3 situation including criteria for estimating suspected parts (quantity 1
occurs, do you trace suspected　lot based upon the
Handling produced before abnormal situation)
criteria?
abnormality
in quality
Do you prevent recurrence of issues by analyzing cause
5 Why Analysis/Root Cause Analysis to be done for the defects
1 of occurring defect based on process investigation result 2
Criteria for raising A-3 sheet/DAR for internal and supplier issue
such as 5-why analysis?

Prevention of recurrence
Do you reflect corrective action to improvement of Standardization (Review of standards) of countermeasures as
2 1
・Customer claims process control and review of standards? decided in Defect Analysis Sheet
2
・In process failure
・Suppliers failure
After corrective action are taken, do you conduct on-site Onsite check up of countermeasure at regular interval
3 check up and evaluate the effectiveness? And horizontal 2
deployment. Evidences of horizontal Deployment of countermeasures

Do you keep store material, work-in-process, finished

products, inventory and container at appropriate storage Storage of RM, BOP, WIP, FG and bins/trolleys to prevent from dust,
1 1
prevented from dust, rust, scratch, deformation and rust, scratch, deformation and rainwater (Shop floor audit)
rainwater?
Storage of RM, BOP, WIP & FG parts at designated location with tag
Do you control material, work-in-process and finished for visual control
2 product by designated location, volume and standard - Unwanted Material Control at work place(Red Tag area) 1
using visual control? There is exist possibility of mix-up of FG/WIP/Rework part
1 Location of production site -Temporary storage
Inspection or critical operation under properly controlled
environment:
- temperature
９． Do you implement inspection or critical operation under
- humidity
5S 3 the properly controlled environment luminance 2
- noise
management /temperature/humidity/vibration/noise/work table, etc.)?
- Proper layout/ arrangements on work and inspection table
- lux level etc.

Physical condition of production equipment's, jigs and tools

Do you keep condition of production equipment's, jigs
1 Evidence of daily/ regular check 1
and tools properly?
Storage arrangements with identification
Production equipment's
2 management
Physical condition of inspection equipment's properly to maintain
Do you keep condition of inspection equipment's accuracy
2 2
properly to ensure accuracy? Evidence of daily/ regular check (Validation report)
Proper storage arrangements

Daily and preventive maintenance of production equipment's, dies

Do you conduct daily/regularly check of production
and jigs
1 equipment's, dies and jigs? Are records of maintenance 1
Machine/ tool history card and PM check sheet
kept?
Spare parts list with minimum quantity required

Maintenance of equipment's ,
1 jigs and tools

Do you confirm regularly the function of Pokayoke,

Regular check of Pokayoke and their record
2 automated stop and alarm? Are records of maintenance 1
１０． List of Poka Yoke
kept?
Equipment/I
nspection
equipment's
management Do you standardize frequency of polishing and
Frequency of polishing and replacement for consumable tools and
3 replacement for consumable tools(blade/electrode/rub 2
change records
stone, etc.)?

Calibration record of inspection Equipment's

Do you calibrate regularly inspection equipment's and
1 Calibration status on inspection Equipment's (Calibration date & due 2
put the expire date on them?
date)
Maintenance of inspection
2 equipment's

Do you control deterioration (expire date) of boundary

Expiry date on limit samples (for objective judgments such as
2 samples for objective judgments such as appearance 1
appearance inspection)
inspection?

Do you use easy expression (visualizer, onomatopoeia Visual confirmation of work done (glowing of green/yellow/red light
1 ,etc.) for operation instructions? So that operator can indicating completion or incompletion of work)
easily understand process and critical points.

Work Instructions to be made in Local Language

Do you keep operation instructions on the accessible
place and post important quality points and critical
2 Display of WI's, Quality Check points & instructions related to critical
operation points on the place where operators can see it
operations at easy accessible location (so that operator can read
１１． easily?
and take out them easily for reference)
Implementati
Implementation of standards
on of 1
standards Do you regularly monitored that each operator operates Periodic records of operator observance audit to check operator
3
according to the operation instructions？ working as per various standard such as WI, PCS, Daily check etc.

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

Judgment criteria should be mentioned on each check sheet (e.g..-
4 sheet (of daily equipment check, quality control report,
Upper/ Lower tolerance, check method and criteria )
etc.) you use?
 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
VENDOR ATTENDEES : Date:
Supplier 0
0
Auditors:
Name

Part Name 0

Category Audit Area Concerning regulation Requirements Judgment Remarks Follow Up

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

Incoming Material / WIP / Finish Goods to be maintained with
1 work-in-process (material, reserve parts） by using
Identification Tags and storage location at each stage.
identification tag or lot indication?

1 management of parts flow

Do you control follows production history by product lot
Production Date/ Lot/ Qty/ dispatch date to be recorded for
2 numbers?
traceability purpose.
-production date; -production volume; -shipping date
１２．
Products
management 3 Do you control identification of similar parts separately? Similar parts control by different color bin / tags/packing material

1
Do you control identification of non-confirming parts and Separate area/ red bin for storing NC part with tag
parts on hold. Do you store them separately? Reason marking on NC part

Non-confirming parts
2 management
Regarding repaired non-conforming parts and parts on - Rework procedure/WI
2 hold to re-use, do you define responsibility to - Responsibility for Rework and area/table for rework
implement? Are repair record kept?　 - Inspection record of rework material
- Traceability (Lot detail) of Reworked Material

Do you make arrangements with customers about the

packing style & transportation system to prevent damage
1 Packing standard and transportation mode
during handling of finished products & perform
13. accordingly.
Handling 1 Bins/ Trolley Management
Management
2
Do you have system to maintain Bins /Trolleys in Good WI to maintain Bins/Trolleys ( WIP & FG) in good condition
Condition. Cleaning and repairing area and check points of good bin/trolleys

1
Do you have Special checks/Inspection for Maru A Special check points for Maru A parts in Inspection standards (in-
parameters of Maru A part are available . process & final) as per inspection standard/drawing
14. Identification of Maru A processes by displaying Maru A symbol on
Critical parts 1 Maru A Parts Management 2
Do you have Identification of Maru A Process/Operator work stations, operator and machine/line
Management on Shop Floor. Check same system for critical items

Do you keep the repair history when repairing & using

3 Record of Rework/Repair history of Maru A parts
Maru A items

Does the supplier has all inspection instruments required

1 Inspection instruments list.
as per drawing requirements
15. Does the supplier has all Testing Equipment's/Rigs
Adequate 2 Testing Equipment's list and arrangements.
1 Testing Facility required as per drawing requirements
testing
facility
Does the Supplier has trained manpower to operate
3 Lab person and inspectors training records and experience.
these inspection and testing instruments

1 Conduct process audit as per process control standard Plan and actual evidence of Process audit . NC list.

16. Process 1 As per PCS

Audit

2 Closure of all the observations Closure evidence of observations.

Achieved Score 0

Maximum Score 112

Audit Rating 0 73
 MARUTI VENDOR QUALITY SY

Supplier
0
Name

Part Name

Category Audit Area

Management information
3

Organisation Structure 1
 1.1

1.2

1.3
2 Quality Systems
1.4

Scale of 1.5
Organisation
2

3 Net Sales (Rs Lacs) 1

4 Net Profit ( Rs Lacs) 1

5 MSME Category

7 Industrial Climate 6

9
 10

11

Capability 4

to invest
Investment Capability for
for future 1
Future Expansion 5
expansion
6

Types of Raw Material

1
being used.

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

Availability of Auxiliary
5
Equipments
TI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW
Vendor Attendees

Concerning regulation

Background & Qualification

Is there a succession plan for the owners?

Are Quality & Productivity targets available &

Monitored by mgmt?

Is there any system by which management monitors

customer rating?

Does the vendor have organisation Chart. Are

following clear in the chart:
1.Reporting levels are clear
2.Role clarity at each level
3.Adequate quality organisation structure
4.Persons are available as per chart, no shortage of
staff
5. Is responsibility for check on check available at all
levels
People profile 1. No of contract employee
2. No of permanent employee
What is the Qualification Criteria of Operators
selection?
Does The Unit have any ISO/ TS certification?.

Certificate (ISO or TS)

If yes, name of ceritification body

Date of issue

Expiry Date

Does the unit review the effectiveness of Quality

system ?.

2013-14
2014-15
2015-16

2013-14
2014-15
2015-16

Any labour issue in last 5 years

Union exists ?

Does company provide Tea/Snacks to all employees

How are general working conditions (Condition of

toilet, Hot, humid , Noise level etc)

By what date, payments to employees is done

Is any training given to employee before putting into

the job?
How is Salary & PF for contract employees is
managed (Directly or Thru contractor)

How often overtime is done & what is overtime rate?

Is there a suggestion scheme in the company ?

Are there additional benefits to employees ?
( Canteen, Transport, Medical etc)

Does company provide uniform to its employees?

Investment detail (In last 2 years)

Future growth /Investment plan

What is the D/E ratio ?

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

What are the other businesses of the promoter?

Have supplier taken any benefit from govt on MSME

category?

Have Tier-1 supplier financed tooling, equipment,

testing facilities at Tier-2?

Payment terms with customers

Payment terms with Suppliers

Price updation frequency by major customer

UDIT CUM FOLLOW UP REPORT (Tier -2)

Requirements Answer

Yes

Yes

MRM, Target & objectives

Yes
display

Customer rating monitoring

Yes
by Top management.

Yes

Yes
Yes
Yes

Yes

No
Contract : 70
Permanent : 56

Yes
Yes
PORT (Tier -2)
7/28/2016

Remarks Follow Up

01/ six months

Monthly CSR from Customer

ITI
 No registered

Tea/snacks twice in shift of

10 hrs
 Annual medical check up

Other group companies

 Vendor Performance Score Card
Assessment Month Mar-20

Vendor Name Progressive Stampings Pvt. Ltd. Vendor Code Location

1 MSIL Line Defects 2. Hanon Line Defect 3. Rejecion PPM at Hanon

13~14 14~15 15~16 13~14 14~15 15~16 13~14 14~15 15~16
Monthly Avrg -0.01 Monthly Avrg -6% Monthly Avrg 0.333

Total Total

Monthly Avrg
Target

NA

13~14

14~15

15~16
1

13~14

14~15

15~16
Row 12 Row 13 Total Monthly Avrg

Remarks :- Remarks :- Quality Imp. By (%) Remarks :-

Delivery Imp. By (%)

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

13~14 14~15 15~16 13~14 14~15 15~16
Monthly Avrg 0.287 Nos 80% 0.547

Monthly Avrg Nos

13~14

14~15

15~16

13~14

14~15

15~16

a b c
Monthly Avrg Nos

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

Does the Supplier has lifter facility for tool loading and unloading. Fork Lift Avaiilable
 COPY TO : MARUTI VENDOR ASSESSMENT (TIER II) - COUNTERMEASURE REPORT
RECEIVING DATE PLANNED CHECKED APPROVED

PLANNING VENDOR NAME 0

PLANNING

PLANNING
CLUSTER NAME Hanon Systems India Pvt Ltd

TOTAL 0
AUDIT DATE December 30, 1899
RECEIVING DATE
VERIFICATION

VERIFICATION

VERIFICATION
AUDIT PART NAME 0

AUDIT PART NO. 0

TOTAL 0

DEADLINE FOR DEADLINE FOR SUBMISSION OF

AUDIT POINT
SUBMISSION OF PLAN ACTUAL RESULT

SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE RESULT OF VERIFICATION
NO.

F003-4 QA/MT Ver. 4

 SUB ITEM
ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE RESULT OF VERIFICATION
NO.

F003-4 QA/MT Ver. 4

Good Points Weak points

Positive Management Retroactive inspection during 4M chan

Good ventilation in shop floor Criteria for declaring suspected parts p
Moulding and secondary operation at same place Skill evaluation criteria
In-house Manufacturing of Facility for moulds CAPA format does not ask for identific
Good procedures and implemenation why- why analysis for occurrence & de
RM storage, FIFO in RM store
Adequate testing facility
ve inspection during 4M changes
or declaring suspected parts produced during abnomral situations
uation criteria
mat does not ask for identification & validation of potential defects,
analysis for occurrence & defects, standardization & horizontal deployment