Rev :05 Supplier Name & Address Key Contact Person Name & Mobile No. : Supplier code : Date of Audit : E-mail : CEO Name : Other Major Customers : Sign.: Sign.: Certification : Cert. Body & Valid upto : Tool room supported by CAD/CAM facility : In Business Since : Association with Pricol Since : Employee Details Staff : Operators : Annual Turnover : List of Machineries & Special equipments Business Share With Pricol : Technology : Products / Parts : 1 Management Responsibility 2 Internal Audit 3 Incoming Material & Sub Supplier Control 4 In-Process Control 5 IMTE control 6 Machine tool die Maintenance Future Expansion Plan : Yes / No 7 Control of Non Confirming Product If Yes, please tick appropriate 8 Analysis of Customer complaints 9 New Product Development 10 Customer Supplied products 11 Document Change Data Control New machinery procurement 12 Storage, Packing and Preservation Others (pl. specify) 13 House Keeping 14 HR & Training GYR Grade Score 15 Statutory/Regulatory requirements TOTAL = (1 to 15) Green 100 - 81 % k Up Trend Yellow 80 - 61 % n Same Red Below 60 % m Down SUPPLIER QUALITY MANAGEMENT SYSTEM AUDIT SCORE CARD Jan-10 Auditor - SQA Team Member Auditee - Supplier Rep. AUDIT ELEMENTS Previous Audit Present Audit Trend Max Actual Max Actual Expansion of present unit : New plant / unit Overall Audit Status Audit elements Improvements Trend Indicator Very Good % of Marks scored by the Supplier = ( Points scored / Applicable points ) x 100 Average Minimum Score required for Preferred status > 90% Previous Audit level Present Audit level Trend Below Average G / Y / R G / Y / R Scoring Criteria - Marks 0. Not meeting requirement / system not in practice 1.Practiceevidencedstepimprovementrequired 2.Justmeetingrequirementsscopeforfurtherimprovement 3. System is in place, meeting requirement with full effective implementation Even if you are on the right track, you will get run over if you just sit there - Will Rogers 0% 20% 40% 60% 80% 100% Management Responsibility Internal Audit Incoming Material & Sub Supplier Control In-Process Control IMTE control Machine tool die Maintenance Control of Non Confirming Product Analysis of Customer complaints Customer supplied products & NPD Document Change Data Control Storage, Packing and Preservation House Keeping HR & Training Statutory/Regulatory requirements Audit Elementwise Audit Score Distribution Supplier Name & Location: Auditee: ____________________
Sign of Auditee : Sign of Auditor: Follow up audit status for Quality Management System Auditor : ______________ Last audit score : ______ Last audited Date : ______ Follow up Audit Date: ________ Area / Function Previous Audit Observation Follow Up Audit Comments Improvement Status Revised Target Date by supplier 1.Management responsibility 2.Internal Audit 3.Incoming material & Sub supplier control 4.Inprocess control 5.Inspection Measuring & Testing Equipment 6.Machine, tool, die maintenance 13.House keeping 14.HRD & Training 15.Statutory / Regulatory requirements 7.Control of Non conforming product 8.Analysis of Customer complaints 9.New product development 10.Customer supplied products 11.Document change & Data control 12.Storage, packing and preservation SUPPLIER NAME : Audit date : Function Audit Elements Score 0 - 3 Audit findings Corrective action Resp. & Target Date 1. Does the supplier has documented Quality Policy and objectives ? 2. Are the Quality Policy and Quality objectives displayed in the shop floor ? 3. Are Management Review meetings conducted at regular frequency ? 4. Does the Management Review Meeting covers all the Internal & External key performance indicators ? (Customer end, In-house Rej. & Rew. PPM, Customer Satisfaction, Delivery Schedules, M/c break down details, Employee absentism, NPD status, NCR's - Pricol Audit, NCR's - Internal Audit, Environmental test results, Environmental/ Safety statutory/regulatory requirements, Any safety/environmental issue,NCR's - Third party audits, Purchased parts quality & delivery status) 5. Is supplier aware of Pricol's Environmental and Health and safety requirements. 1. Are the internal auditors trained and certified ? 2. Are audit schedules adhered as per plan? 3. Does the audit covers all functions and scope of Quality System ? 4. Does the audit cover the waste disposal system and restriction of hazardous substances ? 5. Are follow up audits conducted to verify the effectiveness of the corrective actions taken ? 1. Does the supplier maintain master list of approved sub - suppliers for Job work (Incl.special Processes), raw matl. and bought out parts 2. Does the supplier carry out assessment of its sub supplier for their manufacturing and inspection capabilities? (Excluding raw matl. Suppliers) 3. Are the Quality plans for incoming materials inline with IS / other relevant standards ? (For raw materials) 4. Are the quality plan covers sample size , frequency & inspection method ? (For job work & bought out parts) 5. Does the supplier has adequate Inspection facilities to ensure incoming part quality and inspection records maintained? 6. Does the supplier maintain an audit plan for all its sub-suppliers ? Are the schedules adhered to? 7. Are the raw materials / parts received from approved sub suppliers and stored in a defined location with proper identification ? 8.Do the supplier check or monitor the hazardous substances contents in the incoming parts. 1. Does the supplier has Control Plan / WSS & Work instruction for all processes and is it accessible for use at the workstation ? 2. Does the supplier has Check sheet for all Pricol parts and the check sheet parameters reflected in the control plan / WSS ? SUPPLIER QUALITY MANAGEMENT SYSTEM AUDIT CHECK SHEET M a n a g e m e n t
R e s p o n s i b i l i t y
I n t e r n a l
A u d i t I n c o m i n g
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S u b
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C o n t r o l Important note: Corrective action is to be submitted for clauses where score awarded less than 3 in Pricol corrective action format. Target date_____________ (not more than 15 days from the date of this audit ) Page 3 of 7 SUPPLIER NAME : Audit date : Function Audit Elements Score 0 - 3 Audit findings Corrective action Resp. & Target Date SUPPLIER QUALITY MANAGEMENT SYSTEM AUDIT CHECK SHEET 3. Are Initial process qualification records made available at shop floor (for special process such as Heat treatment, painting, plating, welding, brazing, soldering etc.,)? 4. Are Initial process qualification results updated in Control plan / WSS / Work instructions ? 5. Are all the process parameters (set as per control plan, WSS, Setting data sheet) verified and recorded ? 6. Are the Set up / First piece approval system in place ? 7. Are the patrol inspection / Inprocess inspection records available at all manufacturing stages? 8. Are the control plan / WSS for inprocess inspection covers sample size, frequency & inspection method ? 9. Does the supplier has adequate Inspection facilities to measure the parameters identified in the control plan and inspection records maintained? 10. Are Critical parameters identified in the control plan and are they monitored using Statistical Process Control tools ? ( such as Xbar & Rchart, n-p chart) 11. Are the final inspection control plan / WSS / Quality plan covers sample size ,frequency & inspection method ? 12. Are PDI reports covers all the parameters mentioned in Pricol checksheet ? 13. Does the supplier carry out layout inspection once in a year / for any modification in process, tool , die ? Are the relevant records available ? 14. Does the supplier have approved limit samples / master samples at shop floor / work place ? Are they re-validated at regular intervals? 15. Does the supplier conduct Measurement System Analysis (MSA) for critical parameters ? Are the results of Gauge R&R within 10% ? 16. Is there any system available to track any process change which can change the environment and those changes are communicated to customer ? 17.Does there any system exist to avoid mixing of hazardous and Non hazardous substances ? 1. Does the supplier maintain a master list of instruments including pressure gauges, temperature gauges and other process control gauges ? 2. Does the supplier adhere to the calibration plan ? 3. Does the supplier maintain an unique codification system for IMTE? 4. Are the procedure / method & acceptance criteria defined and meet IS / relevant standards? (applicable for in-house calibration only) I n p r o c e s s
C o n t r o l I n s p e c t i o n
M e a s u r i n g
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( I M T E ) Important note: Corrective action is to be submitted for clauses where score awarded less than 3 in Pricol corrective action format. Target date_____________ (not more than 15 days from the date of this audit ) Page 4 of 7 SUPPLIER NAME : Audit date : Function Audit Elements Score 0 - 3 Audit findings Corrective action Resp. & Target Date SUPPLIER QUALITY MANAGEMENT SYSTEM AUDIT CHECK SHEET 5. Are the status of calibration clearly identified on the instruments / equipments? 1. Does the supplier has a preventive maintenance plan for all machines and equipments? 2. Does the supplier maintain history cards for all the machine and equipment ? 3. Does the supplier maintain a master list of moulds / jigs / fixtures / tools etc., ? 4. Does the supplier maintain an unique Identification for mould / jig / fixtures etc.,? 5. Does the supplier maintains history cards for all the mould / jig / fixtures / tools? 6. Does the supplier have any monitoring system for tool regrinding ? 1. Are the non confirming products / parts clearly identified and stored in earmarked area / bin ? 2. Does the supplier maintain a register for recording rework and rejection ? 3.Does the supplier have any rework procedure ? 4. Does the supplier reviews the rejection + rework on a daily / monthly basis and corrective action taken appropriately ? 1. Does the supplier maintain a register for recording customer complaints ? Are the trend graphs on customer complaints displayed at shop floor for monitoring ? 2. Does the supplier use 8D approach for resolving the customer complaints? 3. Are the Process FMEA, Control Plan, Work instructions, Gauge design, Mould / Jigs / Fixture drawings updated after implementing the corrective action ? 4. Are 8D reports duly filled and sent to Pricol on time? 5. Does the supplier monitor the effectiveness of Corrective and Preventive Action for subsequent 3 months? 6. In case of any customer complaints, does the supplier display One Point lesson at workplace for operator's awareness ? 7. Are the corrective actions initiated through B2B is effective? 1. Are the PPAP documents available for recently developed products (within a year) ? I n s p e c t i o n
M e a s u r i n g
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T e s t i n g
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( I M T E )
M a c h i n e ,
T o o l ,
D i e
M a i n t e n a n c e C o n t r o l
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n o n
c o n f o r m i n g
p r o d u c t A n a l y s i s
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C u s t o m e r
C o m p l a i n t s N e w
p r o d u c t
d e v e l o p m e n t Important note: Corrective action is to be submitted for clauses where score awarded less than 3 in Pricol corrective action format. Target date_____________ (not more than 15 days from the date of this audit ) Page 5 of 7 SUPPLIER NAME : Audit date : Function Audit Elements Score 0 - 3 Audit findings Corrective action Resp. & Target Date SUPPLIER QUALITY MANAGEMENT SYSTEM AUDIT CHECK SHEET 2. Are the PPAP documents submitted before pilot batch production? Does the documents meet Level III? 3. Does the supplier maintain the records of SIR (Sample inspection report) for new products / process? 4.Does the Supplier captured all the Customer requirements (Including Environment, RoHS and Safety)? 1. Does the supplier has a list of Pricol supplied tool / products / parts ? 2. Does the supplier has a system to identify and protect Pricol supplied tool / products / parts ? Does the supplier maintain master list of documents and issue control registers for the following 1. Pricol drawings 2. Pricol check sheets 3. Process Flow chart , FMEA , Control plan / WSS / SOP , Work instruction 4. Drawings / Check sheets provided to sub supplier 5. Change in MSDS and communication to customer 1. Does the supplier has a system for material handling? Are the parts safe from metal to metal contact , dent, damages and rust ? 2. Are the production parts at each manufacturing stage identified with appropriate tags ? 3. Are the identification tags secured firmly to the container which carries material status? 4. Does the supplier have separate earmark place for finished goods? 5. Does the supplier follow FIFO ( First in - First out ) system ? 1. Are the Aisles (gang way) and work places separated using yellow lines ? 2.Are the unnecessary stock, machine, jigs, tools, board, photos etc., removed periodically ? 3. Are the jigs, fixtures, tools, dies, gauges and office files arranged based on shape, size ? 4. Does the supplier practicing 5S concepts for shop floor and office ? C u s t o m e r
s u p p l i e d
p r o d u c t s D o c u m e n t
c h a n g e
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D a t a
c o n t r o l S t o r a g e ,
p a c k i n g
a n d
p r e s e r v a t i o n H o u s e
k e e p i n g N e w
p r o d u c t
d e v e l o p m e n t Important note: Corrective action is to be submitted for clauses where score awarded less than 3 in Pricol corrective action format. Target date_____________ (not more than 15 days from the date of this audit ) Page 6 of 7 SUPPLIER NAME : Audit date : Function Audit Elements Score 0 - 3 Audit findings Corrective action Resp. & Target Date SUPPLIER QUALITY MANAGEMENT SYSTEM AUDIT CHECK SHEET 1. Does the supplier has organization structure which clearly defines the roles and responsibilities of each level ? 2. Does the supplier maintain and monitor skill matrix for all operators ? 3.Are there any system for regular training on fire fighting equipments, emergency situations, first aid etc. 4. Does the supplier has a training plan for all operators /staff ? 1. Status on compliance to Safety regulatory requirements 2. Adherence to pollution board/statutory requirements Copy of this report received by (Supplier) : H R D
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T r a i n i n g S t a t u t o r y
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R e g u l a t o r y
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Important note: Corrective action is to be submitted for clauses where score awarded less than 3 in Pricol corrective action format. Target date_____________ (not more than 15 days from the date of this audit ) Page 7 of 7