The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Advanced Product Quality Planning (APQP) in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.
1.0 Process Approach for Production Part approval Process (PPAP)



2.0 Turtle Diagram of Production Part approval Process (PPAP)

Example of Production Part Approval Process of SHAFT COMP., GEAR SHIFT

List of documents submitted
Part Name : SHAFT COMP, GEAR SHIFT Part No. & Rev: N8080530 Rev No : L4/d Customer : Plant Location: PPAP Submission Level : Initial | ||||
Sr No. | Document Title | Applicable Y/N | Submitted / Retained | Remarks |
1 | List of documents submitted | Y | ||
2 | Design Records Bill Of Material Drawing Test Standards | Y Y N | ||
3 | Engineering Change Documents | N | ||
4 | Customer Engineering Approval | N | ||
5 | Design FMEA | N | ||
6 | Process Flow Diagram Overall Process Flow (for Assembly) | Y | ||
Process Flow Chart (for Feeder shop & Assembly) | ||||
7 | Process FMEA | Y | ||
8 | Dimensional Results | Y | ||
9 | Material Performance Test Results | Y | ||
10 | Initial Process Study Control Chart Pp, Ppk Calculation Sheet | Y Y | ||
11 | Measurement System Analysis Studies MSA for variable characteristics MSA for attribute characteristics | Y Y | ||
12 | Qualified Laboratory Documentation | N | ||
13 | Control Plan | Y | ||
14 | PSW Weight Calculation Sheet | Y | ||
Y | ||||
15 | Appearance Approval Report | N | ||
16 | Bulk Material Requirements Checklist | N | ||
17 | Sample Product | Y | ||
18 | Master Sample | Y | ||
19 | Checking Aids | Y | ||
20 | Records of Compliance With Customer-Specific Requirements List of approved TIER 2 suppliers Process Qualification Records | |||
Y | ||||
N |
Prepared by:xxxx Date:xx.xx.xxxx
Checked by:xxxx Date:xx.xx.xxxx
Approved by:xxxx Date:xx.xx.xxxx







CONTROL PLAN | ||||||||||||||
Prototype Pre-launch Production | Key contact/phone : xxxx | Date (Orig.) : xx.xx.xxxx | Rev No.02/.Date : xx.xx.xxxx | |||||||||||
Control plan Number :CP/SGS/28 | ||||||||||||||
Part Number/Latest change level : N8080530 Rev No : L4 / f | Core Team :A,B,C,D,E,F,G,H,I,J | Customer Engineering approval: | ||||||||||||
Part Name : Shaft Comp, Gear Shift ( Star ) | Plant approval/ date : | Customer Quality approval: | ||||||||||||
Customer: TVS MOTOR COMPANY LTD | Other approval / date (if reqd) : | Other approval: | ||||||||||||
OPN No. | Process Name/ Operation Description | Machine, device, Jigs & Fixtures for Mfg. | Characteristics | Spec ial Char . Clas s | Methods | Reaction Plan | ||||||||
No . | Product | Process | Product/ Process Specification / Tolerance | Evaluation / Measurement Technique | Error proofing | Sample | Control Method | |||||||
Size n | Freq. | |||||||||||||
0 | Incoming Inspection (Bought out Materials) | 1) Inspection of Shaft, Gear Shift (N8080549) | 1 | Distance | 8.7 -0.15 | Height gauge | As per Receiving Inspection Sampling Plan | Receiving Inspection Report (QA/FM/01) | Reject / Segregation / Rework / Send back to supplier | |||||
2 | Chamfer | 1 x 30° | Visual | |||||||||||
3 | Surface roughness | 6.3 Ra | Roughness tester | |||||||||||
4 | Outer dia | Ø10.1 -0.02 | Micrometer | |||||||||||
5 | Radius | R0.2/0.4 | Visual | |||||||||||
6 | Outer dia | 11.5 -0.05 | Micrometer | |||||||||||
7 | Outer dia | 12e8 (-0.032/-0.059) | Micrometer | |||||||||||
8 | Surface roughness | 6.3 | Roughness tester | |||||||||||
9 | Surface roughness | 1.6 Ra | Roughness tester | |||||||||||
10 | Groove Width | 4.2 +0.5 | Digital vernier caliper | |||||||||||
11 | Distance | 192 | VHG | |||||||||||
12 | Distance | 183 | VHG | |||||||||||
13 | Distance | 17.5 | VHG | |||||||||||
14 | Groove dia | 9.7 -0.25 | Digital vernier caliper | |||||||||||
15 | Distance | 157.5 +0.15 | VHG | |||||||||||
16 | Groove width | 1.15 +0.15 | Digital vernier caliper |
OPN No. | Process Name/ Operation Description | Machine, device, Jigs & Fixtures for Mfg. | Characteristics | Spec ial Char . Clas s | Methods | Reaction Plan | |||||||
No . | Product | Process | Product/ Process Specification / Tolerance | Evaluation / Measurement Technique | Error proofing | Sample | Control Method | ||||||
Size n | Freq. | ||||||||||||
17 | Radius | R0.2Max | Visual | ||||||||||
18 | Groove dia | 11.3 -0.2 | Blade micrometer | ||||||||||
19 | Appreance | free from burr | Visual | ||||||||||
20 | Surface treatment | ZnFe Alloy plating | Verify Supplier Report | ||||||||||
21 | Appreance | Free from rust | |||||||||||
22 | Hardness | 24±4 | Hardness tester | ||||||||||
23 | Distance | 2 | Digital vernier caliper | ||||||||||
24 | Angle | 45° | Bevel protactor | ||||||||||
0 Cont. | Incoming Inspection (Bought out Parts) | 2) Inspection of ARM (N5080959) | 1 | Thickness | 3.2 +0.1/-0.2 | Micrometer | As per Receiving Inspection Sampling Plan | Receiving Inspection Report (QA/FM/01) | Reject / Segregation / Rework / Send back to supplier | ||||
2 | Hole dia | 7 H9 (+0.036) | Plug gauge | ||||||||||
3 | Height | 3.5 ±0.1 | VHG | ||||||||||
4 | Hole dia | 10.2 ±0.1 | Plug gauge | ||||||||||
5 | Distance | 95 | VHG | ||||||||||
6 | Flatness | 0.15 max | VHG / Dial gauge | ||||||||||
7 | CD | 107±0.15 | Digital vernier caliper | ||||||||||
8 | Position | 0.15 WRTB | CMM | ||||||||||
9 | Symmetry | 0.15 WRT B | CMM | ||||||||||
10 | Height | 12 -0.5 | VHG | ||||||||||
11 | Appreance | Free from crack, Dent, burr | Visual | ||||||||||
12 | Case Depth | 0.1/0.3 | Verify supplier report | ||||||||||
13 | Hardness | 80-91 HR15N | Verify supplier report | ||||||||||
14 | Appreance | No buldeg ouward allowed | Visual |
OPN No. | Process Name/ Operation Description | Machine, device, Jigs & Fixtures for Mfg. | Characteristics | Spec ial Char . Clas s | Methods | Reaction Plan | |||||||
No . | Product | Process | Product/ Process Specification / Tolerance | Evaluation / Measurement Technique | Error proofing | Sample | Control Method | ||||||
Size n | Freq. | ||||||||||||
15 | Chamfer | 0.5×45° | Visual | ||||||||||
3) Inspection of Pawl. ( N8080969 ) | 1 | Distance | 4.84 -0.05 | CMM | |||||||||
2 | Angle | 35.34 +0.50°/ | CMM | ||||||||||
3 | Distance | 5 -0.5 | CMM | ||||||||||
4 | Distance | 61.55 +0.15 | CMM | ||||||||||
5 | Distance | 37.87 -0.15 | CMM | ||||||||||
6 | Hole dia | 5 +0.1 | Plug gauge | ||||||||||
7 | Flatness | 0.2 | Dial | ||||||||||
8 | Appreance | Free from crack, Dent, burr | Lever Dial | ||||||||||
9 | HArdness | 45 ±3 | Hardness tester | ||||||||||
4) Inspection of Rivet (N2080499) | 1 | Outer dia | Ø8.5 -0.1 | Micrometer | |||||||||
2 | Radius | R0.3 Max | Visual | ||||||||||
3 | Outer dia | Ø7 e9 (-0.025/-0.061) | Micrometer | ||||||||||
4 | Outer dia | Ø5 -0.02/-0.07 | Micrometer | ||||||||||
5 | Inner Dia | 2.5 | Digital vernier caliper | ||||||||||
6 | Surface roughness | N9 | Visual | ||||||||||
7 | Depth | 2.5 | Dial | ||||||||||
8 | Distance | 8 | VHG | ||||||||||
9 | Distance | 3.35 ±0.05 | VHG | ||||||||||
10 | Depth | 1.5 | Digital vernier caliper | ||||||||||
11 | Hardness | 78±4 | Hardness tester | ||||||||||
12 | Case Depth | 0.5/1.0 | Supplier Report |
OPN No. | Process Name/ Operation Description | Machine, device, Jigs & Fixtures for Mfg. | Characteristics | Spec ial Char . Clas s | Methods | Reaction Plan | |||||||
No . | Product | Process | Product/ Process Specification / Tolerance | Evaluation / Measurement Technique | Error proofing | Sample | Control Method | ||||||
Size n | Freq. | ||||||||||||
13 | Hardness | 247 BHN Max | Supplier Report | ||||||||||
5) Insp.of Spacer (N2080970 ) | 1 | Inner Dia | Ø11.58 / Ø11.53 | Plug gauge | |||||||||
2 | Chamfer | 0.5 x 45° | Visual | ||||||||||
3 | Outer dia | 20.0 -0.15 | Micrometer | ||||||||||
4 | Run out | 0.05 WRT B | Dial | ||||||||||
5 | Thickness | 24.5 -0.15 | Micrometer | ||||||||||
6 | Surface roughness | N9 | Visual | ||||||||||
7 | Surface roughness | N9 | Visual | ||||||||||
8 | ID chamfer | 0.3 x 45° | Visual | ||||||||||
9 | Surface roughness | N9 | Visual | ||||||||||
Welding | Shaft & Arm Welding | Machine Code: | M/c 1 : W003 | Check Sheet | |||||||||
1 | Current | 150 – 170 Amps | Ammeter | 1 | Daily | a,b,c | |||||||
2 | Voltage | 22 – 26 Volts | Voltmeter | 1 | Daily | a,b,c | |||||||
3 | Gas Flow | 15 – 20 LPM | Flow meter | 1 | Daily | a,b,c | |||||||
4 | Rotary Welding Speed | H – Full Speed | Stop Watch | 1 | Daily | a,b,c | |||||||
5 | Welding Wire Diameter | 0.8 mm | Micrometer | 1 | Daily | a,b,c | |||||||
6 | Nozzle Cleaning | No Weld Spatters on Nozzle | Visual | Once | Every 5 Piece | a,b,c | |||||||
7 | Openning the Nozzle & Cleaning | No Weld Spatters on Nozzle | Visual | Once | Every 30 Piece | a,b,c | |||||||
8 | Liner Cleaning | No Weld Spatters on Nozzle | Visual | Once | Every 1 Week | a,b,c | |||||||
9 | Weld Blow Holes, Incomplete Weld | No Weld Spatters & Incomplete Weld | Visual | 100% | Daily | Setup cum In process Inspection Report(QA/FM/0 | a,b,c | ||||||
10 | Rust | Not allowed | Visual | 100% | Daily | a,b,c | |||||||
11 | Knurling Damages | Not allowed | Visual | 100% | Daily | a,b,c |
OPN No. | Process Name/ Operation Description | Machine, device, Jigs & Fixtures for Mfg. | Characteristics | Spec ial Char . Clas s | Methods | Reaction Plan | |||||||
No . | Product | Process | Product/ Process Specification / Tolerance | Evaluation / Measurement Technique | Error proofing | Sample | Control Method | ||||||
Size n | Freq. | ||||||||||||
10 | Shaft & ARM | Machine : W003 | 12 | Groove Pressence | Not allowed | Visual | 100% | Daily | 2) & Gauge Frequency check sheet(QA/FM/14) . | a,b,c | |||
13 | Bush Float | Not allowed | Visual | 100% | Daily | a,b,c | |||||||
14 | Arm Flatness | Not allowed | Visual | 100% | Daily | a,b,c | |||||||
15 | Arm Height | 18.2 + 0.2 | Position Gauge / VHG | Setup approval first 5 nos Inprocess 1 no / every 2 hrs by QA (Inspector), Gauge frequency check 5 nos/ every one hour by Operator & also by Final Inspector. | Setup cum In process Inspection Report(QA/FM/0 2) & Gauge Frequency check sheet(QA/FM/14) . | a,b,c,d | |||||||
16 | Perpendicularity | 0.25 WRT F | CMM | a,b,c,d | |||||||||
17 | Arm to Shaft Height | 5.5 ± 0.2 | Position Gauge / VHG | ||||||||||
18 | Welding fillet | 3mm | Digital vernier caliper | a,b,c,d | |||||||||
19 | Serration angle | 5° ± 1° | CMM/ Position gauge | a,b,c,d | |||||||||
20 | Welding strength | >150 NM | UTM / once in a month | a,b,c,d | |||||||||
21 | Spacer rotation | Free Movement | Manual | ||||||||||
20 | Riveting | Riveting Machine : RM002 | 1 | Air Pressure | 5 – 6 Bar | Pressure Gauge | 1 | Daily | Check Sheet | a,b,c | |||
2 | Pawl Bend & Twist | Pawl to be Freely Entry to Acc. Gauge | Acceptance Gauge | 100% | Daily | Setup cum In process Inspection Report(QA/FM/0 2) & Gauge Frequency check sheet(QA/FM/14) . | a,b,c | ||||||
3 | Pawl Free Rotation | Pawl to Freely Rotate on Axis | Visual | 100% | Daily | a,b,c | |||||||
4 | Pawl Float | Not allowed | Visual | 100% | Daily | a,b,c | |||||||
I | Appearance Inspection | Visual | |||||||||||
1 | Damages, Rust, Burr | Not allowed | Visual | a,b,d,e | |||||||||
2 | Wrong parts,Child Parts & Operations Missed | Not allowed | Visual | a,b,d,e | |||||||||
3 | Dent | Not allowed | Visual | a,b,d,e |
OPN No. | Process Name/ Operation Description | Machine, device, Jigs & Fixtures for Mfg. | Characteristics | Spec ial Char . Clas s | Methods | Reaction Plan | ||||||||
No . | Product | Process | Product/ Process Specification / Tolerance | Evaluation / Measurement Technique | Error proofing | Sample | Control Method | |||||||
Size n | Freq. | |||||||||||||
30 | Final Inspection | Inspection Area with Measuring Instruments and Gauges | 4 | Weld spatters | Not allowed | Visual | As per sampling plan (QA/FM/03) | Final Inspection report (QA/FM/05) | a,b,d,e | |||||
5 | Rotation of Pawl | Free Rotation | Manual | |||||||||||
6 | Sharp corners | Not allowed | Visual | a,b,d,e | ||||||||||
II | DIMENSIONAL INSPECTION | |||||||||||||
1 | Perpendicularity | 0.25 WRT F | CMM | a,b,d,e | ||||||||||
2 | Symmetry | 0.15 WRT | CMM | a,b,d,e | ||||||||||
3 | Rivet Height | 1.3 (ref) | Digital vernier caliper | a,b,d,e | ||||||||||
4 | Serration angle | 5°±1° | CMM | a,b,d,e | ||||||||||
40 | Layout Inspection | Inspection Area with Measuring Instruments and Gauges | As per drawing Dimensions to be checked, as per layout inspection plan – Layout Inspection report.(QA/FM/12 / QA/FM/13) | a,b,d,e | ||||||||||
50 | Dispatch | Dedicated crates – 16 Nos / Crate ( Photo attached ) | ||||||||||||
a – Stop Production, b – Notify Supervisor, c – Re-adjustment, d – Segregate previous batch, e – Quarantine non-conforming parts, f – Tool Rectification | ||||||||||||||
Prepared By :Mohan raj | Approved By : Ashokkumar | |||||||||||||
Revision History | ||||||||||||||
Sl.no | Rev.No | Date | Details of Revision | Revised by | ||||||||||
1 | 01 | xx.xx.xxxx | Inspection Details with Qty | xxxx | ||||||||||
2 | 02 | xx.xx.xxxx | Dimension 5.5 ± 0.2 Parameter Added and also Gauge Inspection Added in Final Inspection Stage | xxxx |

FINAL INSPECTION REPORT
VENDOR CODE : 20686 | VENDOR NAME : | ||||||||||||||||
CUSTOMER : | Part No : N8080530 Rev No : L4 / d | Part Name : Shaft comp Gear shift | |||||||||||||||
Invoice No : | Date : | Lot Size : | Sample Size: | ||||||||||||||
SL. # | PARAMETERS | Special Char. Class | Specification | Method of Inspection | OBSERVATION BY TAL | Cp | CpK | OBSERVATION AT TVS M | |||||||||
1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | ||||||||
I | APPEARANCE INSPECTION | ||||||||||||||||
1 | Damages, Rust, Burr | Not allowed | Visual | ||||||||||||||
2 | Wrong parts,Child Parts & Operations Missed | Not allowed | Visual | ||||||||||||||
3 | Dent | Not allowed | Visual | ||||||||||||||
4 | No Weld spatters | Shall present | Visual | ||||||||||||||
5 | Sharp corners | Not allowed | Visual | ||||||||||||||
II | DIMENSIONAL INSPECTION | ||||||||||||||||
1 | Perpendicularity | yes | 0.25 WRT F | CMM | |||||||||||||
2 | Symmetry | yes | 0.15 WRT F | CMM | |||||||||||||
3 | Rivet Height | 1.3 Ref | VHG | ||||||||||||||
4 | Serration angle | 5°±1° | CMM/Position Gauge | ||||||||||||||
INSPECTED BY: Sign. / xxxx | Verified at TVS Sign. / Dt. | If RW/SG Job Order No: | LAB / ETR NO: | Acceptance Status DP / RW / SG / RJ | GRN NO: DATE: | ||||||||||||
For previous lot Rejection / RT/Segregation & Field failure parameters check double the Sampling Quantity. | Sampling Plan | Lot Size | 0 – 50 51 – 100 101 – 500 501 – 2000 > 2000 | ||||||||||||||
Sample size | Appearance/Dimensional | 3 5 10 20 40 | |||||||||||||||
Performance | 1 1 1 2 3 |
Product Weight Details
Part Name: Shaft comp gear shift Part No. & Rev : N8080530 Rev No :L4 /d Customer : Plant Location : xxxx | ||
Sr No. | Weight in Kgs (upto 3 decimels) | Remarks |
1 | 0.32 | |
2 | 0.300 | |
3 | 0.33 | |
4 | 0.310 | |
5 | 0.3 | |
6 | 0.320 | |
7 | 0.32 | |
8 | 0.3 | |
9 | 0.32 | |
10 | 0.310 | |
Average | 0.313 | kg |
Prepared by:xxxx Date.xx.xx.xxxx
Checked by.:xxxx Date.xx.xx.xxxx
Approved by.:xxxx Date.xx.xx.xxxx

List of Checking Aid
Part Name : SHAFT COMP. GEAR SHIFT | Part No. & Rev: | N800530& L4 / d | ||||||
Customer Name : | Plant Location: | |||||||
Sr No. | Characteristics / Specification / Requirement | Checking Aid used (Attr/Var) | Checking Aid Name | Checking Aid Number | Calibration Due Date | R&R details | Remarks | |
1 | Perpendicularity | 0.25 WRT F | V | CMM | CMM-01 | xx.xx.xxxx | ||
2 | Symmetry | 0.15 WRT F | V | CMM | CMM-01 | xx.xx.xxxx | ||
3 | Rivet Height | 1.3 Ref | V | VHG – Dial ind.counter type with Hy.Mandrel | QA/VHG/01 | xx.xx.xxxx | ||
4 | Serration angle | 5°±1° | A | CMM | CMM-01 | xx.xx.xxxx |
Prepared by: xxxx Date :xx.xx.xxxx
Checked by: xxxx Date : xx.xx.xxxx
Approved by: xxxx Date: xx.xx.xxxx

Customer Specific Requirements | Annexure-07 Rev 01 dated -01.12.2020 | |||||||
Customer Spectific Requirement Matrix | ||||||||
IATF Requirements | Customer specific additional Requirements for TVS Motor ( ref. SQAM Supplier Quality Assurance Manual ) | Customer specific additional Requirements for Multimatic | Customer specific additional Requirements for Jay Industries | Customer specific additional Requirements for Lander Automotives | Customer specific additional Requirements for Jost | Customer specific additional Requirements for Rockman Industries | Customer specific additional Requirements for Diado India | Process Name (Where this requirement is applicable) |
4.1 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
4.2 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
4.3 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
4.4 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
5.1 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
5.2 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
5.3 Organizational roles, responsibilities and authorities | The supplier shall submit an organisation chart including the roles and responsibilities of each function and number of persons (Manager, Executives, and Inspectors) along with the contact information. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | HR |
The supplier shall notify TVSM of any changes in their contact information as and when they are made. Revised forms shall be sent within 7 days of such changes. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
6.1 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
6.2 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
6.3 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
7.1.5.1.1 Measurement systems analysis | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies. | Quality |
On an on going basis, the supplier shall conduct Gauge R&R (variable and attribute studies) on all types of measurement systems at least once in a year | ||||||||
The types of measurement system shall be identified / grouped based on instrument type, instrument range and resolution, part characteristics, operating environment and skills / competences of personnel using the instrument. | ||||||||
7.2 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
7.3 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
7.4 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
7.5 Documented information | Retention period- 2 Years Inspection Standards, Inspection Reports, Tooling Maintenance Reports, Control Chart, Material Test Reports, Performance Test Reports, Calibration Records, Machine Capability Study Reports, Audit Reports, QUALITY DEVIATION HIGHLIGHTS, Action Plans, Kaizens, QC Story | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Control of documented information |
Retention period- Life of the product Drawings, APQP Documents and Master Samples | Retention period- Life of the product Drawings, APQP Documents and Master Samples | Retention period- Life of the product Drawings, APQP Documents and Master Samples | Retention period- Life of the product Drawings, APQP Documents and Master Samples | Retention period- Life of the product Drawings, APQP Documents and Master Samples | Retention period- Life of the product Drawings, APQP Documents and Master Samples | Retention period- Life of the product Drawings, APQP Documents and Master Samples | ||
8.1 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | |
8.2.3.1.3 Organization manufacturing feasibility | Prepare Manufacturing Feasibility and Risk Analysis format QSF PUR SQAM 002,003 and drawing feedback & agreement form QSF PRG 02 01 018 and feedback / suggestions for QCD improvements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Marketing & Sale and New Product Development |
manufacturing feasibility as per checklist QSF PUR SQAM 003 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
Supplier shall use TVSM format QSF QAD 10 11 05 for preparation of AOI | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.3.2 Design and development planning | Readiness Review– This is done by reviewing product and process design documents as per checklist CL QAD 10 11 001 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | New Product Development |
IPTR (Initial Production Trial Run)– typically 50 nos. and reviewing the results as per checklist CL QAD 10 11 002 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
SPTR (Significant Production Trial Run)– (8 hours Production or 300 nos ) at planned run-at-rate and reviewing the results as per checklist CL QAD 10 11 003 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.3.3.3 Special characteristics | Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.67 others | Follow as per Drawing | Follow as per Drawing | Follow as per Drawing | Follow as per Drawing | Follow as per Drawing | Follow as per Drawing | New Product Development |
Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.67 others | ||||||||
Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.33 others | ||||||||
Supplier shall send the of process capability reports on monthly basis for special characteristics, controlled through X-bar, R chart. Action plan to be submitted to improve the process capability, if Cpk is below the norms specified in the manual. | Quality & Production | |||||||
8.3.4.4 Product approval process | Submit the PPAP documents through Collaboration Folder link available on http://www.tradewithtvs.com and Table 1 shows the 19 requirements for the PPAP submission | Pilot Lot of 300 nos along with PPAP Documents Material reports to be uploaded on IMDS If required | Intial 10 nos nos along with PPAP Documents | Intial 5 nos nos along with PPAP Documents Material reports to be uploaded on IMDS if required | Intial 05 nos nos along with PPAP Documents | Intial 10 nos nos along with PPAP Documents | Intial 10 nos nos along with PPAP Documents | New Product Development |
8.3.5.2 Manufacturing process design output | FMEA shall follow the latest edition of FMEA reference manual published by AIAG | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | New Product Development |
High risk in FMEA is defined where severity is high and / or RPN is high for a failure mode / cause. High Severity ³ 7 or High RPN ³ 63 ( action plan required to reduce severity or RPN ). | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
special attention to be given for high severity rankings even if RPN is low. Whenever severity is 9 or 10 and no actions are possible to reduce severity ranking, efforts shall be taken to minimize occurrence and detection ranking. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.4 Control of externally provided processes, products and services | Maintain master list of all the T2 suppliers with clear details of the operations carried out and provide a copy to TVSM along with PPAP. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Purchase & Quality |
Carry out special processes like heat treatment, plating, painting, powder coating etc only at the mutually approved sources. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
TVSM may review the PFD, PFMEA & Control Plan of the Tier 2 supplier during part development if required. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.4.2.4.1 Second Party Audit | Supplier shall make a plan for Tier 2 audit covering all Tier2 suppliers. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Purchase, G.M Systems & Quality |
Supplier shall verify following areas – Availability of latest revision of drawing and inspection standard – Adherence to Control Plan – Condition & Calibration of Gauges / Instruments / Tool / Equipments – Part parameter audit – Condition of jig / fixture / tools / gauges & history maintenance. – NC products identification and handling – Deployment of certified operators and inspectors in critical processes – If a special process is done by Tier 2, then the special process qualification to be verified and approval by TVSM. – Layout inspection, product audits. – Supplier may cover additional areas as required | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.5.1 Control of production and service provision | Process Qualification Supplier shall identify the special processes ie (Heat treatment, Plating, Painting, Powder Coating, Welding, etc) and make a plan for conducting the process qualification, including Tier 2. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality, Production & Purchase |
The process shall be set at minimum condition for all process parameters as per the Control Plan and produce the product as per the normal batch size. (E.g. Temp: 160 ~ 200 deg Time: 5minutes ~ 8 minutes in a plating process then produce the batch by setting temp at 160 deg and time 5 minutes for minimum condition) | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.5.2.1 Identification & Traceability | Batch Number Supplier Identification LH / RH designation Date of manufacture, Month, Year Cavity no, Mould no, Die no, Date Code / Heat Code | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Production, New Product Development & Tool Management |
8.5.1.6 Management of production tooling and manufacturing, test, inspection tooling and equipment | Issue Tool Ownership Certificate (QSF PUR SQAM 017) to TVSM, once the tools are proved. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Tool Management |
Review the condition of tool when quantity produced reaches 75 % of the agreed life. Thereafter, review the tool condition at incremental 10% production of the agreed tool life quantity | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.5.6.1 Control of changes | Supplier shall submit request for engineering changes – format no. QSF PUR SQAM 014, process changes format no, QSF PUR SQAM 013 and obtain necessary clearance from TVSM for going ahead with the change implementation. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NPD |
8.6 | No additional requirements | Material TC and Inspection report with each every dispatch | Material TC and Inspection report with each every dispatch | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
8.7.1.1 Customer authorization for concession | Non-conformance of Minor in nature If the non conformance is minor in nature and if the supplier feels that it will not affect either the subsequent process at TVSM or the intended functional requirements at TVSM customer’s end, then they shall request TVSM for clearance thro, Deviation Approval Request format (QSF PUR SQAM 007) immediately and explain the non conformance nature. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality |
The suppliers are notified through Quality Deviation Highlights (QDH) on Web http://www.tradewithtvs.com, the supplier shall ensure corrective actions on receipt of QDH and communicate the causes of failure. QDH raised for non-conformance shall be replied within 24 hours through E-Mail, Fax, Courier, or in person. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
8.7.1.6 Customer notification | Non-conforming parts shipped to TVSM and suppler end Supplier shall send Notification of Suspected Shipment of Non-confirming Product format (QSF PUR SQAM 006) to TVSM Purchase / Quality | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality |
9.1.1.1 Monitoring and measurement of manufacturing processes | SPC shall be in line with latest edition of AIAG manual | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality & Production |
Process capability studies shall be carried out over a sample size of minimum 100 nos. (25 subgroups of 4 samples each or 20 subgroups of 5 samples each) | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
If the process becomes unstable or non-capable (as per table), supplier shall introduce 100% inspection for the parameter, till the Corrective Action is taken and normalcy restored. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
Supplier shall send the of process capability reports on monthly basis for special characteristics, controlled through X-bar, R chart. Action plan to be submitted to improve the process capability, if Cpk is below the norms specified in the manual. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | ||
9.1.2.1 Customer satisfaction | Quality performance report for each supplier is published on the website http://www.tradewithtvs.com. Quality rating is arrived based on the quality performance covering lot, line rejections, and warranty returns including spare parts supply. If rating is less than 90%, supplier shall forward the action plans proposed / planned along with the time frame to meet the target, the progress of which shall be reviewed by the supplier management on monthly basis and to be presented to TVSM on demand. | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality, Marketing & Sale |
9.2.2.4 Product Audit | Supplier shall perform product audit for ready for despatch parts, to confirm dimensions against standard, Functionality, Packaging, Labeling, etc | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Purchase & Quality |
9.3 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
10.1 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |
10.2.5 Warranty management systems | Analyze the failure, using warranty analysis guidelines and warranty analysis summary format QSF PUR SQAM 010 & QSF PUR SQAM 011. It is recommended to check 50 – 100 nos of failed parts randomly and verify the following observations. – Phenomena of failure, kms etc – Location of failure – Bench mark study to identify the improvements – Simulation of field failure in lab – Identify the root cause of failure – Identify the counter measure – Compare the improvement in lab testing (before & after) – Implement the action with time plan format – Monitor the results | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality, Marketing & Sale |
The implemented corrective action score shall be minimum 4 Detection type Poka Yoke • Design improvement (Sev 5 to 7) • Process improvement (Cpk 1.33 to1.67) • 100% additional test station • Automation of tool change frequency – visual control | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality | |
10.2.6 Customer complaints and field failure test analysis | Upon the receipt of complaint (Email / Fax / Quality Deviation Highlights), supplier representative shall visit TVSM to understand the problem within 24 hours. | Corrective action required to submit on DMN Portal | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | Quality |
M1 action – Immediate action to be taken on stocks at TVSM- Quarantining / segregation / 100% inspection etc. Target lead time for completion of M1 action -Within 24 hrs | ||||||||
M2 action -Temporary action to be taken at all stages of manufacturing, transit and storage through out the supply chain. to prevent the defect reaching TVSM.Example of means used –100% inspection / switch over from sampling to 100% inspection / Gauge introduction, etc Target lead-time for completion of M2 action – Within 48 hrs | ||||||||
M3 action – Corrective action through problem solving approach (QC Story/Kaizen sheet/8D- report ) Target lead-time for( i) Submission of corrective action reports –within 7 days (ii) completion of M3 action – Within 15 days (according to the nature of problem and resolution) | ||||||||
10.3 | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | No additional requirements | NA |