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SQ-Mark Evaluation (Compounded Rubber)

Supplier
Controlling Co.
HKMC Mgmt. Team
Assessor
Supporter
Eval. Date

Rubber Mixing Plant

ed Rubber)

Ver 1.0

(Compounded Rubber) Evaluation Report


1. General Status
Supplier Name

Eval. Date : 2012.


Trelleborg Vibracoustic
(Rubber Mixing)

Controlling Co.

Supplier Code

Company Registration No.

Ctrl. Co. Code

Transaction Dependency Rate (%)

HMC :

%, KMC :

%, Other :

Mgmt. Representative

Mr. Guriya/Mr. Basak

Tel. No.

Address

D-126, Industrial Area Phase-7, Sec-73, Mohali

Key Production Items

Rubber Compound

No. of Employees

Total : 87 , Office : 13 ( %), Quality : 10 ( %)

Debt Rate (%)

(Amt. of Debt / Net Worth)*100

Detailed Bus. Category

Rubber (Compounded Rubber)

ISO/TS16949 Certification

Major Customers

TBVC Mohali & TBVC Noida

Operation Rate (%)

Annual Sales ('11)

Automotive Ind. Supply Rate (%)

Equipment Status
Test Equipment
(Measuring Instruments)

RPA, MDR-2000, MV-2000, Disper tester 3000, Densimeter, Satra Ozone chamber, Zwick UTM, Ageing Oven

2. Evaluation Result
.Common Requirements
Initial Certification Date and Score

29.0

pts

.Industry Requirements

Ctrl. Co. Pre-Evaluation Score

pts (

3. Opinion Summary & Key Issues


Opinion Summary
Key Issues
Traceability & FIFO system not effective
Automatic control & reaction plan in case of abnormal situations is missing
Assessor
Assessee

1st Tier Supplier :


2nd Tier Supplier :

(Sign)
(Sign)

37.0

pts

Total

pts

Final Score (Vaatz)

66.0

pts
pts

Supporter

HKMC :

(Sign)

12.

00

(Compounded Rubber) Evaluation Sheet


Classification

No

Evaluation Category

2
3

1.0
2.0

1-3 Control, etc.)

1.5

2-1 Standards (Control Plan, Inspection Standard, Work Standard) Preparation and Revision History Implementation Status

4-1 1st Tier Supplier Inspection Agreement and Periodic Inspection/Test Status

3
3
6
2
4
3
3
4

2.0
1.5
3.0
1.0
2.0
1.0
1.5
3.5

4-2 Measuring Equipment Preparation/Control Status, Verification/Calibration Status (Including Gauge R&R)

3.5

5-1 Organizational Status for Establishing / Maintaining Quality Management System and Job Assignment Control Status

1.0

5-2 New/Transferred Team Member and Management Training (Including Special Characteristics Process and Foreign Operator

1.0

5-3 Control Status of Vulnerable Time Period for Quality Control (Late Night, Before and After Shift Changes, etc.)

1.5

5-4 Process / Customer Defect Correction and Countermeasure, Effectiveness Evaluation (Including Quality Target/Result)

2.0

50

29.0

6-1 Are stock inspection of raw materials and stock procedures being complied after standard?

2.0

6-2 Are FIFO procedure for raw materials and validity period established and being complied after standard?

2.0

7-1 Are standardization mixings conforming to standards?

3.5

7-2 Is a standard for weighting management established and being complied?

4.5

7-3 Is the distinguishing management for mix prevention after weighting/mixing performed after standard?

4.0

8-1 Situation of condition management for mixed equipment (temperature, water, chamber temperature, gas etc.)

4.0

8-2 Standardization of mixing order and situation of compliance (insert order, time)

4.0

8-3 Are CMB/FMB inspections being complied after standards?

4.5

9-1 Are aged facilities and management for rubber (CMB,FMB) appropriate?

4.5

9-2 Are setting of maturation period by material classes and management standards being complied?

4.0

50
100

37
66

1-1 Status of Outsourced Part / Raw Material Inspection Agreement and Suitability Control of Inspection Standard

.Common Requirements

Outsourcing
Part Control

1-2 Receiving & Periodic Inspection Implementation Status for Outsourced Part / Raw Material
Outsourced Part / Raw Material Storage Condition (Contamination of Foreign Objects, Damage Prevention, FIFO, Inventory

2-2 Container Load Standard per Part and Handling Status, Part Container Control Status, Process 3C5S
Process
Control

2-3 Lot Traceability Control (Raw Material~Completed Part, Completed Part Shipping, etc.)
2-4 Key Process Quality Status Display Preparation/Display and Control Status
2-5 Design and 4M change history management

Equipment
Control
Testing

Quality
Management

3-1 Equipment Operation Status (Gauge/Status Light) and Daily Inspection


3-2 Periodic Inspection for Equipment Preventive Maintenance Activities and Spare Part Control Status

Sub Total

.Industry Requirements

Raw Materia

Mix weighting

Kneading

Ripening

Pt.
Result
Alloted

Sub Total

Grand Total

Supplier :
Evaluation Opinion
Item 1-1
Item 1-2
Item 1-3
Item 2-1
Item 2-2
Evaluation Disqualification for score under 4.5 pts
Item 2-4
Item 2-5
Item 3-1
Item 3-2
Item 4-1
Item 4-2
Item 5-1
Item 5-2
Item 5-3
Item 5-4
Item 6-1
Item 6-2
Item 7-1
Evaluation Disqualification for score under 4.5 pts
Item 7-3
Item 8-1
Item 8-2
Evaluation Disqualification for score under 4.5 pts
Evaluation Disqualification for score under 4.5 pts
Item 9-2

. Evaluation Check Sheet


. Common Requirements (Outsourced Part Control)
NO

Questions

1-1

Requirements

Item

Status of Outsourced Part / Raw Material Inspection Agreement and Suitability Control of Inspection Standard
Status of Outsourced Part / Raw Material Inspection Agreement
- Receive / Maintain a copy of 1st tier supplier inspection agreement for the customer supplied parts.
- Substitute inspection agreement with inspection standard when difficult to implement inspection agreement (Example: Raw material supplied by
large corporations, plating industry, etc.)
Suitability of Inspection Standard of Outsourced Part / Raw Material (Inspection Item, Inspection and Measurement Period, Mesurement Method,
etc.)
- Establishemt and implementation of inspection standard for the customer supplied parts
- Mill Sheet receiving status and periodic material property inspection status
Control plan implementation status for inspection items within the inspection agreement (including customer supplied items)
1) Outsourced Part / Raw Material Inspection Agreement and Inspection Standard not established

Criteria

2) Outsource Part / Raw Material Inspection Agreement / Standard implemented, but some key items omitted causing quality issues

Requirements

Item

Criteria

1-2

3) Outsourced Part / Raw Material Inspection Agreement / Standard implemented, but some items do not correspond with control plans and other
standards.

Requirements

0
0.5
1
1.5

5) Inspection Agreement has been implemented, and all details of Inspection standards and other related standards are satisfactory. Excellent
revision control implemented.

Receiving & Periodic Inspection Implementation Status for Outsourced Part / Raw Material
Receiving Inspection Log List Control Status
Daily Inspection, Periodic Inspection Standard / Procedure Preparation and Compliance Status
Pre / Post Inspection Identification and FIFO Control
Inspection Master (Master Sample) Control Status, Packaging Condition of Packaged Parts
Measuring Instrument / Inspection Equipment Retention and Utilization Status
Outsourced Part Inspection Result Control (Daily, Periodic, Reliability Inspection) and Assurance of Inspection Capability
Non-conforming Part Handling Procedure and the Countermeasure Preparation Status (Non-conforming Part Containment Control)
Raw Material receiving inspection and periodic inspection management(Millsheet receiving/check, self-verification, 3rd party test)

1) Outsourced Part / Raw Material receiving inspection standard and procedure not implemented, and any inspection is not being carried out for all
parts

2) Outsourced Part / Raw Material receiving inspection and periodic inspection requirements are insufficient, and inspection is not being carried out for
some of the parts

3) Outsourced Part / Raw Material receiving inspection and periodic inspection requirements are satisfactory, but some of the inspection have been
omitted

5) Receiving Inspection and Periodic Inspection requirements are satisfactory. Excellent countermeasure preparation and its effectiveness verification

1-3

4) Outsourced Part / Raw Material Inspection Agreement has been implemented. Inspection Standard and other related standards have been
prepared and the details are satisfactory

4) Outsourced Part / Raw Material receiving inspection and periodic inspection requirements are satisfactory

Item

Pts

2.5
3

Outsourced Part / Raw Material Storage Condition (Contamination of Foreign Objects, Damage Prevention, FIFO,
Inventory Control, etc.)
Warehouse Layout Status Map, FIFO Structure (Structural System, Receiving / Issuing Process Display)
Outsourced Part / Raw Material Management Condition (Damage, Corrosion, etc.)
Outsourced Part / Raw Material Identification Control (Inspection Status, Material Grade, Material of Long-term disuse, etc.)
Outsourced Part / Raw Material Storage Condition (Contamination of Foreign Object, packae damage, Use of packaging material from the raw
material manufacturer)
Residual quantity control status after a process input (Storage condition / Identification Indication / expiration date, etc.)

. Common Requirements (Outsourced Part Control)


NO

Questions

Criteria

1-3

Pts

1) Outsourced Part / Raw Material Control / Identification / Storage Standard, etc. procedure not established

2) Outsourced Part / Raw Material Control / Identification / Storage Standard have been established, but not properly controlled due to incompliance of
standards

3) Outsourced Part / Raw Material Control / Identification / Storage Standard have been established, but some modifications to requirements are
necessary

1.5

4) Outsourced Part / Raw Material Control / Identification / Storage Standard satisfy requirements

2.5

5) Outsourced Part / Raw Material Control / Identification / Storage Standard satisfy requirements, and controlled in conjunction with computer system

Issues / Observation
Item 1-1

Inspection standards exist (Raw material specification), Internal testing


procedure is also there, Raw material specification verified for material
Dioctyl Adipate (DOA) & Carbon black N-765), Confirmation against RMS will
be taken from new suppliers.
Supplier inspection report (hitech carbon renukoot) verified for Carbon black N765 as per RMS , ship date - 29.01.16, ash content not there in supplier
report (continental carbon - orient polyfilm)- spec of Volatile matter different in
RMS & supplier test reports. Supplier test reports need to be verified as per
RMS

Item 1-2

Verified arbon black - N765, MRN No - 8416; supplier Hi tech - lot qty 2000kg,
Lot no - RK80013294-002, lot no traceability not available in system, FIFO
not ensured, Supplier inspection report verified as per inspection standard ash content not specified in supplier report & found ok, Calibration status of
OZONE test cabinet verified, DOC - 26.04.16, certificate no - VITH/VIPL/F16F17/1

Item 1-3

Physical identification of left over carbon black N765 - 150 kg not available &
in system no traceability is there for left over batch, bin qty is being shown in

Issues / Observation

Physical identification of left over carbon black N765 - 150 kg not available &
in system no traceability is there for left over batch, bin qty is being shown in
system; linage with lot no in system required

. Evaluation Check Sheet


. Common Requirements (Process Control)
NO

Questions

Criteria

2-1

Requirements

Item

Standards (Control Plan, Inspection Standard, Work Standard) Preparation and Revision History Implementation Status

Document Control Condition such as Control Plan / Work Standard Preparation and Revision Control
- Condition Control / Self Inspection Item, Specification, Period, Control Assignment, Record Control, Non-Conformance Handling
(Including Verification of Key Requirement/Necessity Item Omission Status)
Conformity and Connection Status between Work Standards, Control Plans and Inspection Standards
Process FMEA Preparation and Verify in connection with Quality Document Details (Recommandation)

1) Standards such as Control Plan, Work Standard, Inspection Standard, etc. not prepared

2) Control Plan, Work Standard, Inspection Standard have been prepared, but key inspection items / standards haven been ommitted

3) Control Plan, Work Standard, Inspection Standard have been prepared / displayed, but not corresponding with the actual control conditions

4) Control Plan, Work Standard, Inspection Standard, Process FMEA, etc. satisfy requirements
5) Control Plan, Work Standard, Inspection Standard, Process FMES, etc. satisfy requirements. Excellent document revision history control

2.5
3

Container Load Standard per Part and Handling Status, Part Container Control Status, Process 3C5S

Suitability of Display and Identification of Part Identification Tag / Process Transfer Tag for Prevention of Part Mixing
- Lot Control Status such as the Identification of Inspection Status of Completed Part, etc.
Standardization of Completed Part Container per Part and Customer Approval Control (Load Quantity / Weight)
- Industries that are, realistically, hard to standardize and approve container shall establish own control standard (Verify control status)
(Verify Container Control and Handling Condition, ex: Surface Treatment, Heat Treatment, Same Container for Receiving / Shipping from
Suppliers)
- Container Selection considering the characteristics of Part (Prevention of Inflow of Foreign Object, Contamination Prevention Cover, etc.)
- Multi-Level Loading and Plant Floor Storage Condition (Paper Box, Plastic Box, Designated Container, etc.)
Periodic Inspection of Illumination Level in the work areas / inspection areas
- Illumination Level Control Standard Preparation / Implementation Status (Measuring area: Illuminatino Level of each Key Processes)
Periodic 3C5S checks to Improve Plant Floor
- Objective Evaluation through Utilization of Check Sheet and Point System (Recommendation)

1) Standardization of Part Handling, Part Identification and Customer Approval Control not implemented
2) Standardization of Part Handling, Part Identification and Customer Approval control implemented but not complied appropriately

Criteria

2-2

Requirements

Item

Pts

0
1

Questions
Criteria

NO

3) Some of the requirements for standardization of part handling, part identification, customer approval control, illumination level control, etc. are not
satisfactory

1.5

4) The requirements for standardization of part handling, part identification, customer approval control, illumination level control, etc. are satisfactory

2.5

5) All above requirements are satisfactory, and implemented excellent periodic checks and improvement activities for 3C5S

Requirements

Item

Pts

Lot Traceability Control (Raw Material~Completed Part, Completed Part Shipping, etc.)

Preparation, Control and Record Condition for Lot Traceability of Outsourced Part / Raw Material, Subsidiary Part and Completed Part
- Suitability of Process Transfer Tag Utilization / Control and Record Condition
- Part / Press Die Lot No. Control Status, Part Container Identification Status, Long-Term In-Process Part, etc.
- Prevention of Residual Part Inflow and FIFO
- FIFO plan preparation and compliance status when Bar-Code system is Implemented
For Security / Safety Part, Security / Safety Process shall be indicated to be identified on the Part (Lot Mark, Identification Mark, etc.)

2-3
1) Lot Traceability Control Standard not prepared, and Record Control not implemented

Criteria

2) Lot Traceability Control Standard prepared, but Record Control not implemented
3) Lot Traceability Control prepared and implemented, but traceability not verified due to partially omitted record control
4) Requirements for Lot Traceability Control Standard and Security / Safety Part are satisfactory
5) Requirements for Lot Traceability Control Standard and Security / Safety Part are satisfactory, and controlled in conjunction with computer system
such as the barcode system

Requirements

Item

2-4

1.5
3
4.5
6

Key Process Quality Status Display Preparation/Display and Control Status

Key Process Quality Status Board Preparation Details and Display Locations
- Details : IQS Improvement, Field Claims, Advance Verification Part, Non-conforming Part found at Customer/HKMC location
- Location : Display in Relevant Process
(Example: Receiving Inspection Process, Relevant Process of Quality Issue Occurrence, Completed Part Inspection Process)
Prepare / Update the most updated quality status board with most recent quality issues
(Verify update status: minimum 1 / month)
Display Key Process Quality Status Board. Verify the information understanding level of team members and managers for the relevant process
Identification of Critical Process and Key Control Process in Work standard, Inspection Standard

1) Critical Process and Key Control Process not identified, nor displayed, in Work Standard or Inspection Standard
2) Critical Process and Key Control Process identified, but Quality Status Board not prepared / displayed

Criteria

3) Requirements for quality status preparation / display satisfactory, but not complied by the team members / managers due to lack of understanding
for the requirements
4) Requirements for quality status preparation / display and the understanding of details by the team members are satisfactory

0
0.5
1
1.5

Criteria

NO

Questions
5) Requirements for qualtity status preparation / display and the understanding of details by the team members are satisfactory. The information is
updated periodically and well controlled.

Pts
2

Issues / Observation
Item 2-1

Control plan CP/MIX/01 updation required for dumping criteria as per


CP/MIX/01A, Hooter for air pressure drop to be implemented in
Compound mixing. Small intermixer is not working in Auto condition manual droping of batch by operator

Item 2-2

Identification need to be improved, carbon black identification barcode


stickers not visible on all bags

Issues / Observation

Evaluation Disqualification for score under 4.5 pts

Traceability of WIP material not available in system as well as physical,


verified for Carbon black - N765, MRN no - 8416, lot no - RK80013294002 also rubber lot no 2116 - rubber 3cv60 is being shown in rubber
reports but physically rubber lot no 69215 is in use.

Item 2-4

Moulding return batches data displayed on shop floor, verified for the
month of May-16, most recent issues being discussed in daily production
meeting, board of daily production meeting not displayed, Q-triangle to be
implemented with information of most recent issues daywise.

Issues / Observation

. Evaluation Check Sheet


.Common Requirements (Equipment Control)
NO

Questions

Requirements

Item

Pts

Equipment Operation Status (Gauge/Status Light) and Daily Inspection

Visualized Control of Daily Equipment Inspection Areas and Inspection Method


Inspection Status of Equipment installed gauges and operation switches
Measurement Gauge Inspection / Calibration Status (Internal and Comparison Inspection / Calibration Capability)
Equipment Oil and Coolant Leak Control Status
Prevent any random change of equipment settings by operators

Criteria

3-1
1) Equipment daily inspection control standard not established and the daily inspection not performed

2) Equipment daily inspection control standard established and the inspection being performed, but some inspection items omitted

3) Equipment daily inspection and gauge verification / calibration being performed, but some of the requirements are not satisfactory

1.5

4) Equipment daily inspection and gauge verification / calibration requirements are satisfactory

2.5

5) Equipment daily inspection and gauge verification / calibration requirements are satisfactory. Excellent improvement activities

Criteria

3-2

Requirements

Item

Periodic Inspection for Equipment Preventive Maintenance Activities and Spare Part Control Status

Equipment Periodic Inspection Plan Establishment and Implementation Status


Key Equipment Periodic Inspection Standard Establishement and Utilization Status
Consumable and Spare Part Control Status (Safety Stock Control)
Improvement Activity Implementation Status according to the Equipment Maintenance Activity

1) Equipment Periodic Inspection Plan Not Established

2) Equipment Periodic Inspection Plan established, but for some equipment, the plan not yet established for some equipment

3) Equipment Periodic Inspection being implemented as planned,m but maintenance / repair required for some equipment

1.5

4) Equipment Periodic Inspection and Spare Part Control requirements are satisfactory

2.5

5) Equipment Periodic Inspection and Spare Part Control requirements are satisfactory. Improvement activities to prevent reoccurrence
are continually performed

Issues / Observation
Item 3-1

Equipment daily inspection to be started for testing lab - checklist to be made;


gauge verification is being done, verified for Rheometer with calibration compound

Item 3-2

Preventive maintenance plan available - verified for intermixer, in night


maintenance supervisor is not available, brakdown analysis is being done for A-30,
verified for the month of May-16
Critical spares list is there but stock status in system is not being maintained
showing 0 for Rotary joint & physically verified there is no stock whereas min req is
one pcs & max 2 pcs

. Evaluation Check Sheet


. Common Requirements (Inspection / Testing)
NO

Questions

Requirements

Item

Criteria

4-1

Requirements

Item

Pts

1st Tier Supplier Inspection Agreement and Periodic Inspection/Test Status

Inspection Agreement and Approved Copy Retention Status per Part


Inspection Criteria / Period Implementation Status (Control Plan, Work Standard, Inspection Standard)
Annual Periodic Inspection / Reliability Testing Performance and the Result Maintenance Status
Environmental Restriction (Heavy Metal) Related Periodic Testing Performance Status: Request made to 1st tier supplier or Authorized /
Approved Testing Institution

1) Inspection standard not prepared and implemented because the Inspection Agreement, per part, has not been concluded

2) Insufficient inspection standard preparation and implementation because the inspection agreement has not been concluded for some parts

3) Inspection agreement has been concluded, but some of the requirements for the completed part inspection standard and the periodic
inspection are omitted

4) Inspection agreement has been concluded and the requirements for the completed part inspection standard and the periodic inspection
are satisfactory

3.5

5) Inspection agreement has been concluded and the requirements for the completed part inspection standard and the periodic inspection
are satisfactory. Excellent revision history control

Measuring Equipment Preparation/Control Status, Verification/Calibration Status (Including Gauge R&R)

Mesuring Equipment and Inspection Fixture Reliability Assurance Status (Verification/Calibration Period Set, Calibration Condition)
Mesuring Equipment Verification/Calibration Schedule vs. Result Control Status (Measuring Equipment Verification/Calibration Report, Tag
Attachement Status, etc.)
Periodic Gauge R&R Performance Status
For High-Priced Measuring Equipment, Certification from the 1st Tier Supplier or Approved Testing Institution Required (Example: CMM,
Chemical Component Analyzer, etc.)

Criteria

4-2
1) Necessary measuring equipment not prepared and verification/calibration not performed (including externally performed
verification/calibration)

2) Some necessary measuring equipments available, but verification/calibration not performed for the equipments

3) Necessary measuring equipments available and verification/calibration performed for the equipment, but the gauge R&R not performed.

4) Necessary measuring equipments available, and the verification/calibration performance condition is satisfactory. Gauge R&R performed
5) Necessary measuring equipments available. Excellent verification/calibration and gauge R&R performance status (Good PostCountermeasure and Countermeasure Implementation History)

3.5
4

Issues / Observation
Item 4-1

Inspection standards available for verification - verified CP/LAB/02 (testing of raw


materials) Incoming inspection standard to be updated for product characteristics
like pour density; AOI - RMS has been made need to be send to all suppliers for
their confirmation

Item 4-2

Calibration plan v/s actual verified for the month of May-16; calibration of zwick
testing m/c - Z020 verified - DOC - 10.04.15 - as per date it is expired but
machine is installed in Sep-15, masters not available for testing equipments
R & R plan available verified for thickness gauge - LAB/INS/28

. Evaluation Check Sheet


. Common Requirements (Quality Management)
NO

Questions

5-1

Requirements

Item

Organizational Status for Establishing / Maintaining Quality Management System and Job Assignment Control
Status
Internal Quality Management System Establishement and Implementation Status
- Quality Manual/Procedure/Instruction Availability and Implementation Status
- Team Organization Status for Set-Up / Stablization
- Detailed Job Assignment Preparation Status
Basis for Quality Management System Implementation Target and Improvement Activities to Achieve the Target (Post-measure)

1) Team / Department for setting-up / implement QMS not organized

Criteria

2) Team / Department for setting-up / implement QMS organized, but the job assignment not prepared

Requirements

5-2

4) Team organized for maintaining QMS and job assignment prepared. The target / result control is satisfactory

1.5

Realization / Control of Processes with Special Characteristics


- Qualification Certification Standard Establishment and Qualification Granting and Renewing Status for Operators / Inspectors / Testers in Key
Processes
Qualification Certification Standard: Training, Experience, Relevant Evaluation (Written/Skill Test) and Refresher Training
Documentation of Training Procedure
- for New/Transferred/Key and Special Characteristic Process Operator and Foreign Operator, etc.
When Quality Issue Occurs, Field Training, Reoccurrence Prevention Training performed for Operators

2) Annual internal/external training plan established, but not implemented as planned

Criteria

New/Transferred Team Member and Management Training (Including Special Characteristics Process and Foreign
Operator

1) No training performed because of no documentation of training procedure nor training plan establishment

3) Annual internal/external training plan established, but the training plan is insufficient and some trainings are not performed
4) Annual internal/external training performed as planned, and the qualification certification control status is satisfactory
5) Excellent annual training performance, and the qualification certification control for the key process operators and inspectors is satisfactory

Item

0.5

3) Team organized for maintaining QMS and job assignment prepared, but the QMS target set only in formality

5) Works are processed in accordance with the organization set-up / job assignment. Excellent improvement activities for achieving targets

Item

Pts

0
0.5
1
1.5
2

Control Status of Vulnerable Time Period for Quality Control (Late Night, Before and After Shift Changes, etc.)

5-3

. Common Requirements (Quality Management)


Questions
Requirements

NO

5-3

Key Verification Item


- Verify Cleanliness of Plant Floor, Outsourced Part / Raw Material Control, Equipment / Process Control, Quality Control System

Criteria

2) Control Standard established, but the standards are insufficient and not well controlled
3) Control Standard is satisfactory, but countermeasures not implemented and insufficiently controlled when non-conformance occurs
4) Control Standard and Control Status satisfactory
5) Control Standard and Control Status satisfactory. Excellnet analysis / improvement measure performed when problems occur

Requirements
Criteria

5-4

Control Standard Establishment and Control Status


- Establishment and Control Status of Control Standard for Pre-Operation Daily Check Up (Day / Night Shift), Self Inspection and Rounding
Inspection.
- Non-Conformance Control Standard Establishment and Control Standard

1) Control Standard not established for Quality Control during vulnerable time period

Item

Pts

0
0.5
1
1.5
2

Process / Customer Defect Correction and Countermeasure, Effectiveness Evaluation (Including Quality
Target/Result)
Establishment of Quality Targets and Detailed Implementation Plan. Notification of Daily Quality Result and Monthly Comprehensive Result
to 1st Tier Supplier
- Result Control in comparison with the Targets from Previous Year (Input into VAATZ system lead by 1st Tier Supplier)
Process Defect (Production Quantity, Defect Quantity, PPM), Customer Defect (Delivery Quantity, Defect Quantity, PPM), Outsourcing
Defect (Receiving Quantity, Defect Quantity, PPM)
- Establish Improvement Measure and Continual Result Control for Target Shortfalls

Periodic Process/Customer Defect Cause Analysis/Corrective Action/Effectiveness Verification/Horizontal Deployment Implementation Status

1) Process/Customer/Outsourcing Defect Status Summary Control not performed

2) Process/Customer/Outsourcing Defect Status is controlled, but the basis for target setting is insufficient. Some result control have been
omitted.

3) Process/Customer/Outsourcing defect Status is being summarized, but the quality issue improvement activity is insufficient
4) Process/Customer/Outsourcing Defect Status summarization and Improvement activity satisfy requirements
5) Process/Customer/Outsourcing Defect summarization and Improvement activity satisfy requirements, and horizontal deployment activity to
other car models is excellent

2
3.5
4

Issues / Observation
Item 5-1

Rubber compound manual - LP_35_7.6_0036 is available, need to be reviewed for risk


assessment in case of equipment rejected in calibration, QMS effectiveness being
checked, last system audit action plan verified

Item 5-2

Training procedure is there; Operators classroom training calendar available, verified


training on 1. MSDS/chemical safety & applicable PPE by Mr. Parminder Singh. 2. Training
on new compound process & testing in the month of May-16.
Training effectiveness records also verified.
Training plan v/s actual for white collars need imropvement, trainings plan from HSE
prospective only

Item 5-3

Issues / Observation

Ispection standards available, same are being verified during night shift, log book also
available for communication during shift change, verified testing records of 20.06.16 NR3055, batch no - 622-625, For maintenance activities supervisor is not available in C
shift need to be call from home in case of urgencies.

Item 5-4

Nc batch target is less than 0.2%, Moulding returned batch 0.25% - target v/s actual verified
- under target
NC management procedure is there.
2 complaints raised to supplier in the month of June-16: 16.06.16
1. Foreign material in raw rubber - PVR 1220 - supplier - Reliance industries - report is
awaited from supplier
2. ISNR-5 raw rubber - used in rubber compound & Ts2 observed out of spec - date 13.06.16, lot no - 12B38, MRN no - 8186 - response still awaited from supplier no actions
taken by supplier - KL rading company (Travancore rubber & Tea comapny)

. Evaluation
Industry Requirements (Raw Material)
NO

Questions

Criteria

6-1

Requirements

Item

Are stock inspection of raw materials and stock procedures being complied after standard?

Setting standards for inspection of raw material and storage


Setting standards for experation date of raw material(criteria of manufacture date), temperature, humidity and the rate of containing
water(recommandation standard on the rate of containing water of CMB, FMB supplier curing agent/accelerator/antioxidant : 0.3% and below,
carbon black : 1.0% and below)
- rubber manufacturer does not apply
[F/P] Automatic contorl of temperature and humidity at raw material warehouse and alarm system
- Temperature : 205, Humidity : less than 70%
(If there is internal control limit, check evidence)
[Computerization] Raw material mooney viscosity inspection (1/lot), data computerization
- Raw rubber : Mooney viscosity, humidity
- Compounding chemicals : Humidity
The establishment state of handling process on defective goods of inspection
Eligibility on person and qualitification of inspection
Reliability verification of the result of inspection for evaluator who is doing inspecton sample in person

Requirements
Criteria

6-2

1) There is no supervision standard for setting standard of procedure, inspection and storage for material

0.0

2) The standard of procedure, inspection and storage for material has been established but is not observed.

1.0

3) The standard of procedure, inspection and storage for material has been established but some observation is missed

2.0

4) The standard of procedure, inspection and storage for material has been established and it is good but it needs to compensate the present
condition

3.5

5) The standard of procedure, inspection and storage for material has been established and it is good and the present condition is excellent

Item

Pts

4.0

Are FIFO procedure for raw materials and validity period established and being complied after standard?
State of FIFO procedure and observation
Management of distinguishment and putting other substance before and after inspection
Management state of posting status board of raw material and setting expiration date for each material
[Computerization] Computerization of raw material FIFO and aging (Bar code system)
- Prevention of raw material mixing, First In First Out, Raw material aging
- Raw rubber sheet : 6 Months from production
- Aditives : no longer than 1 year with not opened condition

1) It does not manage setting FIFO and expiration date

0.0

2) It is unsufficient observation of FIFO procedure and posting status board

1.0

3) It does not manage posting status board and expiration date but FIFO procedure is observated

2.0

4) It needs to compensate to manage expiration date but FIFO procedure and posting status board is managed

3.5

5) Quality management which is FIFO, posting status board, management of expiraton date and so on of stocked parts is excellent

4.0

Issues / Observation
Item 6-1
Operation standards for raw material are defined - verified for zinc oxide; Raw
material identified in case of storage requirements in controlled tempreature; list
available - OS/Lab/09 - chemicals verified as per list lying in AC room; Vulkalent
EC, tempreature & humidity monitoring is there alarm system to be
implemented.
Moisture content & mooney is being verified in raw rubber & for compounding
chemicals are being verified for moisture content - verified for SVR CV 60 raw
rubber lot no- 1871-1897 & for IPPD (Antioxidant) lot no - 20160121

Item 6-2
FIFO is defined, Verified for carbon black N765 lot no 8416, shelf dife defined
for all raw materials in raw material operation standard, verified fro IPPD - shelf
life 2 years, same is displayed on barcode
Pick me first stickers also displayed to maintain FIFO
Raw rubber shelf life defined is min 1 year & max 3 yrs against requirement of 6
months
Additives - min 6 months & max - 3 yrs against requirement of 1 year

. Evaluation
Industry Requirements (Mix weighting)
NO

Questions

Criteria

7-1

Requirements

Item

Criteria

7-2

Requirements

Item

Item

Pts

Are standardization mixings conforming to standards?


Publication status of work standard and conformity of the work standard content
- Possibility to distinguish workers (foreigners included), standard/record for frequent inspections
- Verification of methods for major working conditions and establishment of standard
Matching of standard and management plans, state of association
Management of standardized formulation (computerized management)
Magement situation of formulation process for work orders
Situation of record management for formulation process of daily work

1) Formulation standard for material classes is not established

0.0

2) Establishment of formulation standard for material classes is lacking

1.0

3) Formulation standard for material classes is established, but compliance is lacking

2.0

4) Formulation standard for material classes is established and being complied, but the record management is lacking

3.5

5) Formulation standard for material classes is established and being complied, and the record management is clear

4.0

Is a standard for weighting management established and being complied?


Exclusive weighting containers and cleaning management
[F/P] Automatic contorl of temperature and humidity at weighing room and alarm system
- Temperature : 205, Humidity : less than 70%(If there is internal control limit, check evidence)
[F/P] Automatic weighing for compounding and data computerization
- Minimization of weighing tolerance and distribution control
- Minimization of Anti-aging agent and processing agent(Prevention of whitening)
weighting process layout structure
Verifying if weighting automation equipment by container classes and actual stock are matching
Situtation of establishment of containers in consideration of product characteristics (prevention of pollution
of cover etc. through foreign material)
Compatibility of lot management for process parts (utilization of transfer documents and barcode system)

1) weighting standard is not established

0.0

2) weighting standard is established, but standard is not being complied

1.5

3) weighting standard is established and being complied, but result values are not being recorded

3.0

4) Computional system of weighting standard and record management is established, but prevention of lacking weighting F/Proof is not possible

4.5

5) weighting results and transfer documents are utilized and F/Proof is excellent due to establishment of computional system

6.0

Is the distinguishing management for mix prevention after weighting/mixing performed after standard?

7-3

Questions
Require
ments

NO

Criteria

7-3

Management status of identification and separation before and after weighting


Identification before and after weighting and management of FIFO
Consistency of process transfer document/ Condition of eligibility and recording

Pts
5

1) No identification management for mix-prevention after weighting/mixing

0.0

2) No compliance of existing standard for identification management of mix-prevention after weighting/mixing

2.0

3) Missing identification management of process transfer document/label etc. for mix-prevention after weighting/mixing

2.5

4) Satisfying identification management of process transfer document/label etc. for mix-prevention after weighting/mixing

4.0

5) Computerization of production planning for manufacturing processes,management for performance and lot record are being complied and
are matching with the products

5.0

Issues / Observation
Item 7-1
Automatic weighing system implemented by rice lake is implemented,
Weighing formulae fixed operator is doing loading as per standard formulaeverified for current chemical weighing for NR4550, traceability is from final
rubber compound report, WIP identification & traceability is missing

Evaluation Disqualification for score under 4.5 pts


Cleaning frequency for weigheing containers is 1 month, verified from log
book, cleaning procedure for bin cleaning in chemical weighing to be defined;
alrams for tempreature & humidity control not there
Automatic weighing is there -ricelake system
tolerance defined in formulae
No plan for minimization of anti ageing agent for prevention of whitening

Item 7-3

Issues / Observation
Automatic system of weighing is there, only that bin will open which is required
as per ongoing formulae, barcodes are being generated for every process
transfer & same are being scanned, final rubber compound traceability & FIFO
is good but being managed manual

. Evaluation
Industry Requirements (Kneading)
NO

Questions

8-1

Requirements

Item

Situation of condition management for mixed equipment (temperature, water, chamber temperature, gas etc.)
State of verifying routine inspection of equipment and establishment of standard for equipment conditions
Verifying establishment of plans for regular equipment inspections and state of conduction
Situation of equipment condition management and standard for record management
- Standard setting and routine inspection of coolant temperature, chamber temperature, roll temperature
[F/P] Automatic control of process parameter, temperature, time and wattage at mixing process
- Mixing rubber temperature real time monitoring device
- Automatic coolant control device

3) Lacking management condition of mixing equipment and hand regulation management of cooling water

2.5

4) Satisfying management of mixing equipment and management for temperature adjustment of cooling water, but no F/Proof

5) Excellent management of mixing equipment and temperature adjustment of cooling water due to F/Proof

Verifying establishment of management standard for standardization of mixing order


Verifying compliance of conditions, input order of mixing process
- Verification if operation progress of input order, the number of times, time, working method etc. are according to the working standard

Criteria

Standardization of mixing order and situation of compliance (insert order, time)

Requirements

1) No standardization and no compliance of mixing order

0.0

2) Standardization of mixing order is done, but corresponding process was not published and lacks in compliance

2.0

3) Mixing order is standardized and corresponding process is published but lacking in compliance

2.5

4) Mixing order is standardized and published, compliance is satisfying, but of mixing condition records are partly missing

4.0

5) Mixing order is standardized and published, excellent compliance of mixing condition and record management

5.0

Are CMB/FMB inspections being complied after standards?


State of acquisition and conduction of inspection equipment based on the inspection standard for raw materials
- Viscosity pattern, specific gravity, weight, carbon dispersion, curing curve
Establishment situation of handling procedure and improvement measures for defictive units during import inspection
Eligibility of inspectors and inspection qualification
Verifying authenticity of direct examination of some samples by evaulator and inspection conduction
[Computerization] Distribution control of mechanical property inspection by batch
- Specific gravity, hardness, mooney viscosity, scorch time inspection and distribution control by computerization
- Record expiration date on shipping tag ex) dd-mm-yyyy
1) No establishment of inspection standard and no conduction of inspection

teria

8-3

0
1.5

Item

Item

2) Lacking management condition of mixing equipment, cooling water cannot be adjusted

Requirement
s

Criteria

1) Mixing equipment is old, maintainence is not possible and cooling water is not circulating

8-2

Pts

0.0

8-3

Questions
Criteria

NO

Pts

2) Inspection standard is established, but inspection are not being conducted

1.5

3) Inspection standard is established and is being conducted after standard, but customer-requested content is missing

3.0

3) Inspection standard is established, is being conducted after standard and record is satisfying, but supplement of analysis management is
required

4.5

5) Conduction after inspection standard, record keeping of inspection result data and history management are excellent

6.0

Issues / Observation
Item 8-1
Routine equipment inspection is being done, verified daily check sheet - for
K2A intermixer
Dumping criteria defined - based upon Temp, time & energy
Mixing rubber tempreature specification defined in OPI - for automatic mixing &
thermocouple is there in mixer for monitoring, display is there on machine
Chiller is there for maintaining tempreature- alarm is there for tempreature out
of spec for controlling chiller temp
Testing defined in case of premature dumping

Item 8-2
Mixing order is defined - OPI to be corrected for chemical addition - validation
of programme to be done (programme to be corrected as per defined
commands)

Evaluation Disqualification for score under 4.5 pts


Inspection standards available - CP for final rubber compound testing is there
Skill matrix defined - verified for Mr. Dalshinghar - 76.7%
Testing of final compound verified - NR3065 - rheo properties verified; records
are available in soft & hard for distribution & verification
Identification sticker is there - lab tested ok & batch expiry date is also
mentioned
Analysis of hold batch is there improvement required, verified for rubber batch
no 648, compound code - NR4548 dated 06.05.16, incoming testing reports for
raw material used in rubber compound also verified

Identification sticker is there - lab tested ok & batch expiry date is also
mentioned
Analysis of hold batch is there improvement required, verified for rubber batch
no 648, compound code - NR4548
06.05.16, incoming testing reports for
Issuesdated
/ Observation
raw material used in rubber compound also verified

. Evaluation
Industry Requirements (Ripening)
NO

Questions

Criteria

9-1

Requirements

Item

Are aged facilities and management for rubber (CMB,FMB) appropriate?


State of possession of storage room and installation of a thermo-hygrostat
Setting management standard and daliy management / confirmation on action of abnormal occurance and record
Verifying possession of measuring instrument and calibration
[F/P] Automatic contorl of temperature and humidity at aging room and alarm system
- Temperature : 205, Humidity : less than 70% (If there is internal control limit, check evidence)

0.0

2) Holding of storage room, but room narrowness and thermostat,hygrostat are not established

1.5

3) Holding of storage room, but physical property of rubber CMB, FMB is changed due to missing installation of thermostat, hygrostat

3.0

4) Holding of storage room, satisfying management of thermostat and hygrostat installed, but no alarm system in case of abnormal occurrence

4.5

Requirements

6.0

Are setting of maturation period by material classes and management standards being complied?

Status of setting storage time of each material (posting standard of storage)


Management of current state and record which is FIFO, current state of coming into and out
Management state of putting expiration date and distinguish Tag to check storage time
[Computerization] Aging time, FIFO, prevention of mixing - Bar code and recording management
- Aging time, prevention of mixing, expiration period, FIFO electric control(Bar code system)
Management state of expiration date of residual FMB and putting substance such as dust
(Recommandation of FMB supplier) measurement and management of the rate of contaning water of FMB
(recommandation 0.5% and below)
- Rubber manufacturer is observate expiration date from manufacturer date/ the rate contaning water is managed from report
1) Storage time of each material is not set and observated

Criteria

9-2

1) Keeping without storage room, no existing concept for rubber storage/management

5) Holding of storage room, management is excellent for thermostat and hygrostat, and F/Proof is managed by installing an external alarm
system in case of abnormal occurrence

Item

Pts

2) Storage time of each material is set but it does not managed posting current state and record

1.5

3) Setting storage time for each material is observated but record of expiration date on some material is missed

2.5

4) Posting standard of storage time for each material, management of coming into and out are excellent but expiration date and management of
other substance need to compensate

5) Posting standard of storage time for each material, management of coming into and out, expiration date and management of other substance
are excellent

Issues / Observation
Evaluation Disqualification for score under 4.5 pts
Batches stored in controlled temp conditions, temp & humidity monitoring is
there; Alarm system for final rubber compound store in case of temp & humidity
control is not there, reaction plan for abnormal situation (like temp out of spec,
humidity out of control to be made); variation in temp & humidity records
observed.
Calibration report of tempreature & humidity indicator verified - certificate no
AACPL/TH/TIHI/160105.3.2 - doc - 05.01.16 , cdd - 05.01.17
Master calibration certificate not matching - certificate no mismatch

Item 9-2
FIFO of final rubber compound is being controlled manually - shelf life defined
- 21 days, barcode stickers for each rubber compound are being generated but one barcode for one batch & there are 4 spools in one batch identification
on each spool is by mentioning rubber compound no on individual spool where
expiry/shelf life is not mentioned - verified for rubber batch no 602 - rubber
compound 60NR98
Frequency of measuring moisture content of final rubber compound in case of
hyundai will be done, spec will be reviewed - 0.5% & below current spec is 1.0
%

) SQ-Mark Certification Evaluation Improvement Recommendation

2nd Tier Supplier :


No.

1st Tier Supplier :


Findings

1 Small intermixer not working in auto.


Identification of WIP material is missing verified for carbon

2 black

Traceability is not effective lotwise identification not available

3 in ricelake system

Physicaly rubber is being used of different lot but in system

4 generated report lot no is different.

Improvement Measure

Evaluation Date: 2
Due
25.06.16
25.06.16
25.06.16
25.06.16

No alarming system for air pressure control, temperature

5 control & humidity control in raw material, weighing & final

25.06.16

6 Pick me first to be implemented to maintain FIFO

25.06.16

rubber compound store.

FIFO for final rubber compound is manual - computerization is

7 required

Technical data sheet for all rubber & compound chemicals to

8 be verified for moisture requirement

AOI not there RMS (raw material specifications to be mailed

9 to all suppiers for their confirmation)

25.06.16
25.06.16
25.06.16

Inspection inspection reports to be verified as per standard

10 Ash content missing in supplier reports verified for carbon

black.
Cleaning procedure for bin cleaning of chemical weighing is
11 required .

12 WI to be updated for temperature spec of chemical weighing

25.06.16
25.06.16
25.06.16

Operation standard of automatic mixing to be corrected for

13 mixing order currently chemical addition is not defined in

25.06.16

14 Hold batch analysis is not satisfactory

25.06.16

OPI.

Reaction plan in case of temp & humidity abnormal conditions

15 is required.

MASTER CALIBRATION CERTIFICATE IS NOT MATCHING

16 WITH CALIBRATION REPORT.

25.06.16
25.06.16

Moisture content /water content for final rubber compound is

17 being checked in case of Hyundai only but spec to be


reviewed.
Checklist to be made for daily inspection of
18 instruments/equipments being used in lab.

25.06.16
25.06.16

19 POKA YOKE list & verification.

25.06.16

20 Lux level not being recorded.

25.06.16

Incoming inspection standard need to be updated for product

21 characteristics like pour density.

25.06.16

Zwick calibration certificate is of dated 10.04.15 as per time

22 eriod of one year it has expired but machine installed in Sep-

25.06.16

23 Master test equipments calibration certificates not available.

25.06.16

24 Risk assessment not there.

25.06.16

25 Critical spares not being maintained.

25.06.16

15.

Variation in data recording of temperature, air pressure &

26 humidity in lab.

25.06.16

27 Supplier response to complaints is not satisfactory.

25.06.16

28 4M change management system to be implemented

25.06.16

Automatic valve for controlling mill tempreature is required for

29 automation of coolant control

Assessor & Assessee : 1st Tier


Supporter : HKMC

(Sign).
(Sign).

2nd Tier

25.06.16

(Sign).

tion Date: 20-21.06.16


Resp.
Mr. Guriya
Mr.
Guriya/Mr.
Manjit
Mr. Guriya
Mr. Guriya
Mr.
Guriya/Mr.
Mukesh
Mr.
Guriya/Mr.
Manjit
Mr. Guriya
Mr. Basak
Mr. Guriya/Mr. Nalin
Mr. Basak
Mr. Guriya
Mr. Basak

Mr. Guriya
Mr. Guriya
Mr. Guriya
Mr. Basak
Mr. Basak
Mr. Basak
Mr. Tomar
Mr. Parminder
Mr. Basak

Mr. Basak
Mr. Basak
Mr. Manjit
Mr. Mukesh
Mr. Nalin

Mr. Guriya
Mr. Guriya

2nd Tier Co.

( ) 2nd Tier Supplier Findings

1st Tier Co.

Name
Name of
of Process
Process

Name
Name of
of Process
Process
Classif.

Classif.

Item

Item

Detailed Item

Detailed Item

Photo of Process and Diagram

Findings

Findings

Photo of Process and Diagram