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MARUTI SUZUKI INDIA LIMITED

Issue Deptt. Prepared Verified Approved


 Vendor Qualitry System Audit Report
Date of Issue
Copy to Supplier name
Audit Date
Supplier Attendant Name

Supplier code Audit Person


(Audit Score)

Achieved Score: 129


×100 = 57
Total Score: 228
Total
Part Number:
Subject: Vendor System Audit
Part Name:
Observation:-

○ △ ×

1 3 / 24 3 3 2

2 12 / 15 4 1 0

3 6 / 18 3 2 1

4 6 / 18 2 4 0

5 9 / 18 3 3 0

6 6 / 15 3 1 1

7 18 / 21 6 1 0

8 15 / 21 5 2 0

9 15 / 18 5 1 0

10 12 / 15 4 1 0

11 3 / 15 3 0 2

F003-3 QA/MT Ver. 5


12 12 / 18 4 2 0

13 12 / 12 4 0 0

14 N/A / N/A 0 0 0
Total
(MSI 129 / 228 49 21 6
L)
Pre decided negative Improvement Submission
Last Audit Rating
marking (if any) Date 

F003-3 QA/MT Ver. 5


pproved

on

F003-3 QA/MT Ver. 5


F003-3 QA/MT Ver. 5
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Vendor Attendees
Date : 17 /18/19.03.14
Sigma
Supplier
Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd

Part Name Damper


Category Audit Area Concerning regulation Judgment Remarks Follow Up
1.  Regarding
Production 1 Do you define in reguration following items for
implementation rule of Timing chart for new development parts are from RFQ to SOP
preparation production ① production preperation?-scope of parts,-responsibility of ○ at customer end.
preparation each department -control contents/items?

Do you define importance level during production


② preparation for each product and clarify control items ×
based on it ?
Regarding
2
management
/implementation by Do you implement follow-up to control the schedule and Production Prepration meeting reviews are being done at
① ○
production progress of production preparation items? defined frequency. (FM/EDD/45)
preparation
plan/report(master
plan) Are production preparation plan and report controlled by
② a person in charge of progress(top management) △ The Meetinj reviews are being done by Department heads.
periodically?

Defect prevention on
3
the stage of prosses Do you consider following items and reflect them to the
design by using processes and stadards beforehand? Lesson learned are being transferred and taken care for new
FMEA/Matrix diagram ① -Troubles in the past; -Defect items expected; △ projectes in initial RFQ Feasibility meetings.
-Defect items unable to capture at customer; Potential Defects are being captured in FMEA initial review.
-Defect items difficult to repair;

Do you review and improve FMEA or Matrix diagrams FMEA are being updated during any critical issue at customer
② ○
when any critical issue occurs after SOP? or Inhouse.

Product/process
4
evaluation at the Do you prevent defects by quality improving activities of Actions for Inhouse Quality issues are being taken to improve
quality evaluation ① △
cross-function team to evaluate quality performance? the Product quality.
meeting in each trial

Do you define condition to start mass production and


② ×
then check on the product line prior to SOP?

2. Regulation for
Regulation 1
initial production
for control Do you define following items related to initial production Initial Production parts are identified by Special Stickers.
initial control by standards ? Quality team involve in development activities and problem
observed during development stage is shared with Quality
production -controlled parts; -controlled items; -inspection method;
① ○ team.
control -initial production control period; Responsible person defined for start / End of Initial production.
-a person who annonce start/end of initial production Guidelines for verification of material at early production stage
control; -finish condition; is also there, verified WI/QAD/223

Items are defined which required special controls during initial


How do you define items required special control during production controls.
Special Identification stickers are being put on initial
② initial production control? Do you set stricter inspection ○ controlled items.
methods than the ordinal inspection? Verified WI/QAD/223, Guidelines for verification of material at
early production stage

Do you share the information of initial production control Information are being shared among the team for actions /
③ ○ Improvement. Also Shared with T-II Supplier.
among the related department?

2
Implementation of Do you pick up issues and improve them during initial Issues during initial are being take up with the team for
initial production ① △ impovement.
production control?
control

Defect rate for initial production control parts are being


Do you control process capability and defect rate during
② ○ monitired.
initial production control?

3. Definition and
Changing 1
implementation of Yes, changes are defined and are being processed through
management Do you define unexpected change (unusual) and planned
changing ① ○ ECN. (PR/EDD/06, Rev E, ECN Doc no. - FM/EDD/24). 4 M
change clearly? change management being followed.
management

Do you define procedure(rules applied from sharing


② information to result confirmation) at change △ 4 M change procedure WI/QAD/221 defined and are being monitored.
occurrence?

Do you record product quality check results to ensure


③ ○ Records are being maintained with Retention peroid.
traceability?

Do you retroactively check about product quality when Before and after results are being monitored and recorded with ECN.
④ ○
unexpected change occurs? (EC/2013/0023)

Definition and control


2
method for initial part ① Do you define initial part clearly? × To be define

F0003-1 QA/MT Ver. 5


3.
Changing
management

MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT


Vendor Attendees
Date : 17 /18/19.03.14
Sigma
Supplier
Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd

Definition and control


Part Name2 Damper
method for initial part
Category Audit Area Concerning regulation Judgment Remarks Follow Up

Do you control initial parts separetely and make quality


Initial parts are identified with unique identification numbers on
② records about them?(both internal and outsourced △ each part.
process are included)

4. Procedure to make
Standards 1
process control Do you make process control standards for all products
management standards(QA process ① ○ Control plan for each Part is available
which is shipped to SMC / MSIL?
charts)

Do you mention defined both characteristics of quality Process flow for all the product is available.
② △ Quality and production char. Are defined in Control plan.
and production control on the process control standars?

Do you mention followings on process control standards


required to each process?
-quality comfirmation method; -regulations; Controal plan / Operation standard / WI contains Inspection Methos,
③ △ Ref. standard, Inspection Frequency, Sampling plan, Poka - yoke etc.
-standards (operation instruction/items to be focused Procedure for prepairing control plan WI/QAD/222 is there
on);
-boundary samples; -parmeter chart; -Pokayoke
4. Procedure to control
Standards 2
standards Do you define following concerned abou standards?
management -department in charge of making;
Operation standard prepration and maintaining the document is
・Process control -a person in charge of making;
① △ defined with authority.
standards -a person in charge of authorizing; Retention period also defined for MSIL parts.
・Inspection -making period; -timing to submit to customer;
specifications -revision rule; -retention period;
・Operatoin
instructions Do you have consistency to keep process control There is Coherence among Control plan, inspection standard,
② standard, inspection specification, operation inspection ○ operation standard and MIS -P.
and parameter chart?

Do you make use of lists to control preparation and List of history is updated on the control plan and operation
③ △ standard. Documents are issued with receiving information.
revision of standards and share the updated information?

5. Education/ training Do you clarify the department in charge of promoting


Education 1
procedure quality education,implement education based on annual
① ○
and traning plan? Training related to technical department wise (Functional
Are records of education kept? Training), HSE, 5S are being planned and records are being
maintained.
Do you define and implement the skill evaluation of
operator to determine whether operator can work without Skill Matrix is being evaluated six monthly as per procedure to
② ○
surveillance?(e.g. acceptable revel/evaluation evaluate skill level WI/?
freequency/evaluation method)

Prior to SOP, do you instruct each operator based on


③ △
actual operation instructions?
The training is being provided prior to SOP.
Education for
2 Do you implement planned education to supervisers for
managers/Inspectors/ ① △
skill improvement ? Trainings are being given to all levels in the organization.
Special operators
Internal and external trainings are being organized.
Do you implement special education or technical training
② to inspectors and operators of particular process ○ Special education and Technical Training like customer
(required specialized skills)? Are training records kept? requirements etc are provided to Inspectors and Operators.

Certificated Operators are being monitored.


Do you periodically monitor the skill of certificated
③ △
operators and follow up to improve their skill?
6. Do you conduct internal quality auditor periodically?
Quality audit 1
Activity to following are standardized:, -suditor team; -audit Internal Audits are being planned as per schedules. The audit
and process keep/improve ① ○ is planned as per standardized checksheet.
frequency; -audit timing; -audit method; -audit
verification production quality checksheet;

Do you conduct quality audit to identify issues and Process Audits are being done to identify issues and action
② ○ plan is made to improve them.
properly improve them?

Content of process
2
review Do you focus on useful know-how of operation,
Methods are prepared during development stage and shared
① operations with poor workabillty and operation which △ during initial Trials for improvements.
need a lot of repair and standardize them?

Do you confirm consistancy between actual operation


② ×
and standard?

Do you confirm if countermeasures are taken properly to The problem / Failure are linked with the preventive measures
③ ○
prevent reoccuring of quality fail? by implement action on the checksheets , control plan, WI etc

7. 1 Evaluation method for


Supplier new suppliers New Suppliers are certified after audit by SQA Team as per
Do you define criteria to certificate new suppliers and
control ① ○ defined procedure of supplier selection, evaluation & approval
implement them? PR/PUR/01

Management, quality
2
evaluation and Do you collect supplier failure information, determine
Monthly supplier rating is being prepared and circulated to each
① supplier grade according to quality level and conduct ○
instruction for supplier.
suppliers audit and instruction periodically?

For outsourcing any production, do you instruct them


Important control items are being instruct to supplier. Agrement of
② clearly about function and improtant control items of ○ insoection is signed off with supplier.
products at the meeting ?

For outsourced process,do you control the progress of


③ ○ Process audit of supplier is done at defined frequency.
production preparation and confirme issues ?

F0003-1 QA/MT Ver. 5


7.
Supplier
control MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Management, quality Vendor Attendees
2
evaluation and Date : 17 /18/19.03.14
Sigma
instruction for
Supplier suppliers
Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd

Part Name Damper


Category Audit Area Concerning regulation Judgment Remarks Follow Up

Do you make suppliers to conduct initial production Initial production parts are installed at supplier end and monitored
④ ○ by SQA Engineer.
control and decide department in charge of conduct?

Regarding the parts which are shipped directly to the


⑤ custmers from outsourced suppliers, do you have ○ No product is being shipped directly to customer from supplier.
method to assure product quality performance?

Do you make outsourced suppliers to conduct initial Record of initial parts (pilot lot) Inspection at sub supplier prepared
⑥ parts and 4M changing management and is it possible to △ and verified by QA Engineer.
trace? Confirmation taken from supplier for 4 m change.

8. Handling when
Handling 1
abnormal situation Do you define clearly what is abnormal situation and Abnormal situation is denfined. Opearators are know about the
abnormality occures ① △ abnormal situation.
make operators know the definition?
in quality

Do you clarify and standardize the handling rules/routes Standardized rules to handle customer cmplaint, Internal Failures
② for customer claims, in process failure and supplier ○ and supplier failures are defined. WI for handling Customer
failure? complaints is also there WI/QAD/94A

Do you have criteria to estimate the scope of suspected


lot for abnormal situation? When abnormal situation The Suspected lots can be traceback based upon the Box no., Route
③ △ cards. Work instruction for handling abnormal situation WI/QAD/219
occurs,do you trace suspected lot based upon the is there
criteria?

Prevention of
2 Do you prevent recurrence of issues by analyzing cause
recurrence
① of occuring defect based on process investigation result ○ Preventive actions are being taken to prevent recurrence of issue.
・Customer claims such as 5-why analysis?
・In process failure
・Suppliers failure
Do you reflect corrective action to improvement of Corrective actions are reflect by adding in the check sheets and
② ○ poka- yoke verification where ever required.
process control and review of standards?

After corrective action are taken, do you conduct on-site


③ ○ Effectiveness is being checked and recorded.
checkup and evaluate the effectiveness?

Do you cascade information of corrective action to Actions are being horizontally deployed for the similar parts and
④ ○ process.
similar parts and processes?

9. Location of
5S 1 Do you keep store material, work-in-process, finished
production site The store material, work-in-process, finished products,
management products, inventory and container at appropriate storage
① ○ inventory and container are plced at appropriate location to
prevented from dust, lust, scratch, deformation and avoid dust, Deformation Rain water.
rainwater?

Do you control material, work-in-process and finished Storage of RM, BOP,WIP&FG parts at designated location as per
storage standard defined.
② product by designated location, volume and standard ○ Location no is provided for FG and Raw material.
using visual control?

Do and don't are displayed on the shop floor.

Do you forbid operators to put temporary storage on Work Instructions ( Do's & Do not's) for not having temporary
③ △ storage(storage on shop floor, over racks, on work tables, on
work place?
machines, in non standards bins / trolleys.

Do you implement inspection or critical operation under Inspection of critical operation inspection / testing at lab under
④ the properly controlled enviroment luminance ○ properly controlled environment:- temperature, humidity .
/temperture/humidity/vibration/noise/work table, etc.)? Lux level is maintained on Inspection table.

Production
2
equipments Do you keep condition of production equipments, jigs
management ① ○ Location for Tools and Jigs are defined.
and tools properly?

Do you keep condition of inspection equipments properly


② ○ Inspection Equipments are keep properly with verification.
to ensure accuracy?

10. Maintenance of Do you conduct daily/regulary check of production


Equipment/I 1
equipments , jigs and ① equipments, dies and jigs? Are records of maintenance ○
Production equipment, Dies, Jigs etc are being checked
nspection tools regularly and records are being maintined.
kept?
equipments
management Do you confirm regulary the function of Pokayoke,
Poka-yoke defined In a list and being verified at a defined frequency
② automated stop and alarm? Are records of maintenance ○ and records are maintained.
kept?

Do you standardize frequency of polishing and


③ replacement for consumable △
tools(blade/electrode/rubstone, etc.)?
Maintenance of
2 Do you caliburate regulary inspection equipments and Inspection equipement are calibrate as per defined frequency. Due
inspection ① ○
put the expire date on them? date is mentioned on each equipment.
equipments

F0003-1 QA/MT Ver. 5


10. MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Equipment/I
nspection Vendor Attendees
equipments Date : 17 /18/19.03.14
management Sigma
Supplier
Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd

Part Name
2
Damper
Maintenance of
inspection
Category Audit Area
equipments Concerning regulation Judgment Remarks Follow Up
Do you control deterioration (expire date) of boundary
Boundary sampels are being reviewed at defined frequency with
② samples for objective judgments such as appearance ○ objective is also mentioned.
inspection?
11. Implementation of
Implementati 1
standards Do you use easy expression (visualizer, onomatopoeia
on of ① ,etc.) for operation instractions? So that operator can ○ Work instructions are availble for the operator for inspection.
standards easily understand process and critical points.

Do you keep operation instractions on the accessible


place and post important quality points and critical WI are displayed on the inspection table, Near to operation & are
② ○ easily assessable to operators.
operation points on the place where operators can see it
easily?

Do operators and supervisers operate according to the


③ × Standard Operation defined
operation standards?

Do you regularly monitore that each operator operates


④ × Verification
according to the operation instructions?

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


Specification for parameters are provided and Defective
⑤ sheet (of daily equipment check, quality control report, ○ photographs are provided in WI.
etc.) you use?
12. management of parts
Products 1
flow Do you keep first-in first-out of finished products and
Material WIP / FG are being identified with Identification tags
management ① work-in-process (matelial, reserve parts) by using ○ and FIFO is being maintained
identification tag or lot indication?

Do you control follows production history by rproduct lot


② numbers? ○ Traceability of Production Date/ Lot/ Qty/ dispatch date maintained.
-production date; -production volume; -shipping date

③ Do you control identification of similar parts separetely? ○ Similar parts are identified by colour dot marking.

Non-confirming parts
2 Do you control identification of non-confirming parts and
management ① ○ Non- confirming parts are identified and stored separately in locked
parts on hold. Do you store them separetely? room.

Do you define procedure to handling (following items) Procedure for control of non-conforming product PR/QAD/04
non-confirming parts and parts on hold? available defining handling of non-confirming parts & WI/QAD/94 for
control of Non-conforming products
② -root cause analysis; -person responsible for final △ Authority is defined to take final decision.
judgment Root cause analysis,
-ttiming; -feedback procedure

Regarding repaire non-confirming parts and parts on


Procedure to define Hold part & reporcess is define WI/QAD/ 220
③ hold to re-use, do you define responsibility to implemet? △ and records are being mainatined.
Are repair record kept? 

13. 1 Bins/ Trolley


Do you make arrangements with customers about the
Handling Management packing style & transportation system to prevent damage
Management ① ○ Packing Aggrements are made with customer
during handling of finished products & perform
accordingly.

Are the packaging style & storage environment controlled Packing and storage conditions are defined to prevent material from
② ○
with consideration to contamination contamination and damage.

Do you have system to maintain Bins /Trolleys in Good Returnable bins are being cleaned as per defined procedure WI/PRD-
③ ○ 02/26
Condition.
Packing Aggrements are made with customer & Packing and storage
Does the Packaging method prevent Transportation
④ ○ conditions are defined to prevent material from contamination and
damage damage.
14. 1 Maru A Parts
Do you have Special checks/Inspection for Maru A
Critical parts Management ① NA
parameters of Maru A part are available .
Management
Do you have Identification of Maru A Process/Operator on
② NA
Shop Floor.

Do you keep the repair history when repairing & using


③ NA
Maru A items

F0003-1 QA/MT Ver. 5


COPY TO : MARUTI VENDOR AUDIT- COUNTERMEASURE REPORT
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AUDIT DATE
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VERIFICATION

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AUDIT PART NO.


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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
NO.

F003-4 QA/MT Ver. 4


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

F003-4 QA/MT Ver. 4


MARUTI VENDOR AUDIT- COUNTERMEASURE REPORT
CHECKED APPROVED

RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4


RESULT OF VERIFICATION

F003-4 QA/MT Ver. 4