PUR-PM-06 Initial Flow Control For PCS Supplier

POLYRUB COOPER STANDARD FTS PVT. LTD.
,
CHAKAN - PUNE
Procedure for Initial Flow Control for PCS Supplier.
Document No.: Rev. No: Rev. Date Issue No: Issue Date Page
PUR/PM/06 00 -- 01 10.11.2023 1 of 3
1. Purpose
This procedure defines the steps required for the initial production controls establishment to ensure
customer is protected from defects during new program launch.
Also define the method of initial supply control after start of production or in case of Ramp up or product /
process changes implemented through engineering change note.
2. Scope
This procedure applies to all Supplier, which supplies parts to all PCS plant.
The scope of procedure covers the following situations during the initial supply period:
- New product 3 month or 5000 parts whichever is later.

- Mass production running parts/ ECN parts 1 month or 1500 parts whichever is later.
- Process changed parts -15 days or 1000 parts.
3. Responsibility
QA Head • Review and approve sample delivery after review IFC check sheet.
Quality Head • Through his/her staff, has the responsibility for defining the IFC requirements and support IFC area and
resource deployment.
Quality Engineer • Deploy IFC as defined in this procedure,
4. Process:
1. Setup IFC area and identify markings and process flow to ensure control of non-conforming material.
2. IFC should be conducted offline, separate, and independent inspections performed from the normal manufacturing
process. The IFC area should represent the customer location, and not be established as a general containment area.
In special cases, end of line IFC activities may be performed (due to part size/complexity).
3. Establish boundary samples and secure customer approval for visual characteristics (if applicable).
4.Train all personnel relative to the standardized work instructions to be performed at each IFC containment location.
Training records must be retained.
5. Parts must be serialized along with the person’s identifier that conducted the inspection (on non-show surface) as
per inspection instructions. The serial number must be recorded on the inspection report for correlation and traceability
purposes should a nonconformance be detected at the customer.
6. Inspect all parts according to the IFC inspection Standard.
7.IFC parts must be gauged 100% when specifically requested by the customer, otherwise and enhanced sampling
plan must be implemented.
8.Document safe launch findings and corrective actions on tracking sheet / open issues list (regional format is fine).
9. Identify and disposition non-conforming parts in appropriate reject containers/racks available at point of inspection.
Document No.: Rev. No: Rev. Date Issue No: Issue Date Page
PUR/PM/06 ‘00 -- 01 10.11.2023 2 of 3
Prepared By: Manager STA Approved & Reviewed By: HOD PE

POLYRUB COOPER STANDARD FTS PVT. LTD.,
CHAKAN - PUNE
10.Should a nonconformance be detected during the IFC process, immediate notification to be provided to the area
production supervisor and upstream processes for problem resolution
11. Report all findings in a format visible to the production area.
12.Add a certification sticker next to the shipping label indicating parts have undergone the IFC inspection. Sticker to
include operator number and date. If customer have special requirements for the sticker, comply with customer
requirements.
17. Verify part number label and packaging meets customer requirements.
18.Responsibility must be assigned in the regional RASIC by reviewing dimensional data, visual appearance, labelling,
and packaging. IFC check sheet must be signed by function team members post part review as an indication that all
parts meet customer requirements. If parts contain visual or dimensional non-conformances, the nonconforming
product process must be initiated and reviewed by function team. If have any critical issues, customer must be notified,
and written authorization requested if parts are to be used. If the customer’s specific requirements state that written
authorization to ship is required in these circumstances, parts will be quarantined until authorization is received. In
addition, customer receiving plants must also be informed. Records of approval must be retained locally.
Duration:
New product, ECN /PCN:
The safe launch process should be in place for 3 months or 10000nos whichever is later until the exit criteria are met.
(Duration and quantity may be reduced or increased based on customer specific requirements and production
volumes).
In case above criteria not met in low volume program then IFC will be closed after monitoring 5 production lots.
Exit Criteria:
Review the initial production control declaration sheet (Ref Format no. ENGG/FM/74). with APQP team and take a
decision on
termination of initial supply control (ISC), which is done in following condition:
1st 2nd 3rd
Criteria Specification Month Month Month Result
Actual
Customer Rej. PPM 0 PPM
Customer Quality Complaints 0 Nos
Supplier/Incoming Rejection _______PPM
Inhouse Rejection PPM ______ PPM
Readiness of Standards & Documentations Completed
Process Capability Analysis (Every Cpk ≥ 1.67
Process Audit Results (Two Times) Completed
NC of Product & Process Audit should be Closed
Any Issue (Customer, Inhouse,Supplier) Closed
s

CHAKAN - PUNE
In case If IFC target not achieved then IFC will reinitiate from beginning as per procedure. In case positive trend not
achieved then IFC will be extended till positive trend will achieved. The IFC must remain in effect until corrective action
has been implemented & deemed effective.
5. Records/ Logs:
Initial supply control tag

IFC Inspection report
Initial production control declaration
Quality assurance check Sheet-Resizing
Problem analysis sheet
Engineering change note
MASTER COPY
Document No. : Rev. No: Rev. Date Issue No: Issue Date Page
PUR/PM/06 ‘00 -- 01 10.11.2023 3 of 3
6. References:
Global Read Across System

Management Review Procedure
Global Safe Launch Procedure
Management operating procedure for control of non-conforming product
Management operating procedure for corrective and preventive action
Customer Specific Requirement
7. Revision Information: -
Rev No-- Rev. Date Reason for change

CHAKAN - PUNE

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POLYRUB COOPER STANDARD FTS PVT. LTD.

- New product 3 month or 5000 parts whichever is later.

Quality Engineer • Deploy IFC as defined in this procedure,

6. Inspect all parts according to the IFC inspection Standard.

Prepared By: Manager STA Approved & Reviewed By: HOD PE

11. Report all findings in a format visible to the production area.

New product, ECN /PCN:

Prepared By: Manager STA Approved & Reviewed By: HOD PE

Initial supply control tag

Global Read Across System

Rev No-- Rev. Date Reason for change

Prepared By: Manager STA Approved & Reviewed By: HOD PE

Prepared By: Manager STA Approved & Reviewed By: HOD PE

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