The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Product Safety 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.

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Process of Identification of special characteristics 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 process of Identification of special characteristics

2) Turtle Diagram for process of Identification of special characteristics

3) LISTING OF SPECIAL CHARACTERISTICS

Part Name:                                                                                Part Number:

Customer:                                                 

Preliminary

Final

Sr. No.	Description of Special Characteristics		Specification & Tolerances	Reason for Spl Characteristics	Control Mechanism	Remarks
	Process	Product		(Refer Notes below)

Note: Reason for Special Characteristics are Given below:

F/F =Fit / Function;                              

R =Regulatory Requirement                   

E=Environmental 

S=Safety Requirements;                     

CP=Customer Prescribed

These special characteristics must be taken care while formulating PFMEA & Control Plans.

                                                                                                                                                         (Signature)

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	Safety / Statutory / regulatory- severity = 9 or 10.  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
	Fit / Function – Critical- severity = 7 or 8. Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.67 others
	Fit / Function – major- severity = 5 or 6. 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

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Control of drawing including Engineering change note (ECN) and Engineering change Request(ECR) 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 Drawing Control , ECN and ECR

2) Turtle Diagram For Drawing Control , ECN and ECR

3) Engineering Change Request

Engineering Change Request
Part Name :		Date:
Part Number/Drg Number :		Deptt: Name ;-
Request to Dept.Name
S.No.	Existing Dimensions/Part	Changes Required	Reasons of changes	Remark If any
REQUESTED BY				APPROVED BY

4) Engineering change Note

5.0 Drawing Tracker sheet

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 Advanced Product Quality Planning (APQP)

2.0 Turtle Diagram for Advanced Product Quality Planning (APQP)

3.0 AQP Timing Plan Macro Level

Project Name :                 Project No : Project Leader :
	Description		Planned	Actual	Remarks
1	CFT Sign Off	Team Leader & CFT
2	Availibility  of Ref sample /3d model
3	Feasibility review	Team Leader & CFT
4	Drawings finalize on TAL Format	Team Leader & Engg. HOD
5	Lsit of Discrepenceies observed in drgs.	Team Leader & Engg. HOD
6	Share Observations with Customer & Ask for Clarifications				5- samples along with Insp. Report to be submit to customer 25th Dec.2015
	Submiited for Clearance	Process owner
	Signed for clearance of Gate -1	Engg HOD
	Signed for clearance of Gate -1	DGM-
1	BOM /List of Raw material – In – ERP
2	Verification of Material TC from NABL Approved Lab	Quality
3	Fit & Finish Requirements & Agreement on Specimen / level with customer	Team Leader / Engg. Head & Customer			5- samples to be submit to customer 25th Dec.2015
4	Completion of Preliminary PFD /FMEA/CP	Team Leader  & CFT
5	List OF Tools , Gauges & Jig fixtures	Team Leader  & CFT
6	Closer of all Clarifications & Sign off	Customer SQA  / Team Leader			Will be close after getting feed back of Customer
7	Tools, Fixture & Jig Designing (Tooling concepts to be Review & finalize in CFT )	Team leader /CFT
8	Gauges Designing (Concepts to be Review & finalize in CFT) (Final check fixture & in process gauges)	Team leader /CFT
9	Validation of Tools, Jig & Fixture Design ( w.r.t. FMEA )	Engg HOD / CFT
10	Validation of Gauge Designs (Final check fixture & in process gauges)	Engg HOD / CFT
	Submiited for Clearance	Process owner
	Signed for clearance of Gate -2	Engg HOD
	Signed for clearance of Gate -2	DGM-
1	Tools, Jig & Fixture Manufacturing	Tool Room
2	Tools, Jig & Fixture Inspection ( Assy. & Stage inspection)	Tool Room
3	Tools, Jig & Fixture Issue to Production	Tool Room / Process Owner
4	Gauges Manufacturing	Tool Room
5	Gauges Inspection -Tool room ( Assy. & Stage inspection)	Tool Room
6	Gauges Calibration -Standard Room	Quality
7	Floor plan Layout approved by Directors	Team leader
8	New / Existing Machines/Equipment Requirement	Team leader /CFT
9	Tool Trial report with 10 no’s of samples	Tool Room
10	10 no’s child parts hand over to Std Room for layout with inspection report	Process Owner / Quality
11	Approved Samples along with Signed ISIR Document -Send to Customer	Quality /Team Leader
12	Fitment Trials at Customer End

4.0 TEAM FEASIBILITY COMMITMENT

 Date:

Part Name:                                                                                            Part Number :

 Customer :                                                                                           Vehicle / Model:

  Feasibility Consideration:

 CFT has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. The drawings and / or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All “NO” answers are supported with attached comments  identifying comments and / or proposed changes to enable us to meet the specified requirements.      

YES	NO	CONSIDERAION
		Is product adequately defined (application requirements etc.) to enable feasibility review?
		Can Engineering Specification be met as written?
		Can product be manufactured to tolerances specified on drawing?
		Can Product be manufactured with Cpks’ that meet requirements?
		Is there adequate capacity to make the product?
		Does the design allow the use of efficient materials handling techniques?
		Can the product be manufactured without incurring any unusual :
		Cost for Capital Equipment?
		Cost for Tooling?
		Alternative Manufacturing Methods?
		Is Statistical Process Control required on product?
		Is Statistical Process Control presently used on similar products?
		Where Statistical Process Control is used on similar products :
		Are the processes in control and stable?
		Are Cpk’s greater than 1.33?

     CONCLUSION :

	Feasible	Product can be produced as specified with no revisions
	Feasible	Changes Recommended (See Attached Comments)
	Not Feasible	Design Revision required to produce product with in specified requirements

     Comments:  _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _  _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _    _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _

    SIGN-OFF

  Team Member/Title/Date  Team Member/Title/Date                  Team Member/Title/Date

   Team Member/Title/Date            Team Member/Title/Date            Team Member/Title/Date

SUPPLIER SIGN-OFF

Supplier Name/Date                       Supplier Name/Date                         Supplier Name/Date

5.0 APQP Cross Functional Team

Date:  

Product:                                                                         Part No.:                                        

Customer:

Scope of Team:

Team Leader:                                                               Position:

Team Members:

Sr. No.	Name	Deptt.	Designation	Major Responsibility	Signature
01
02
03
04
05
06
07
08
09

Meeting Frequency:

Team Leader:                                                                         Date:

6.0 Customer Specific Requirements

S. No.

Name of Customer

Part #

PPAP Level

APQP Timing Plan

Special Characteristics of Products

Delivery Instructions

Pre Dispatch Inspection Report

Packaging standard

Record Retention Period

MSA Plan

SPC (Cpk)

Callibration Lab Approval

Customer Approved Supplier (If any)

Inspection Standards (If any)

Ref. Standard

Proto type Samples size

Line Rejection at Customer end from other supplier

Remarks

7.0 Listing of Special Characteristics

LISTING OF SPECIAL CHARACTERISTICS

Part Name:                                                                                                        Part Number:

Customer:                                                 

Preliminary
Final

Sr. No.	Description of Special Characteristics		Specification & Tolerances	Reason for Spl Characteristics	Control Mechanism	Remarks
	Process	Product		(Refer Notes below)

Note: Reason for Special Characteristics are Given below:

F/F =Fit / Function;                              

R =Regulatory Requirement                   

E=Environmental

S=Safety Requirements;                     

CP=Customer Prescribed

  These special characteristics must be taken care while formulating PFMEA & Control Plans.

                                                                                                                                                         (Signature)

8.0 Identification of New Machine

IDENTIFICATION OF NEW MACHINES/  EQUIPMENTS
1. Identify significant characteristics (a) Product b)Process (Machining / Heat treatment /Welding / Surface protection) c) EEC parameters etc.
S.No.	Characteristics	Operation (Stage)		Control  Mechanism
2. Fit & Finish Requirements & Agreement on Specimen /Level
Aesthetics: Agreement on Surface finish, Appearance ,Abnormalities and Assy related like Gap,Mismatch,Eveness and eccentric etc
Reference Sample Sign Off
Revalidation  Frequency
3. Tooling  – Cutting tools &  jigs and fixtures
S.No.	Tooling  Requirement	Make	Quantity	Completion date
4. New / Existing Machines / Equipment requirement
S.No.	Machine / Equipment	Make / Type		Availability Status
5. Material Handling Equipment Requirement
S.No.	Equipment	Make	Quantity	Completion date
6. Supplier selection for Bought-out Parts
S.No.	Parts	Supplier Name		TVS to approve (Yes / NO)
7. Sub-contracting requirements
S.No.	Operation Name	Supplier Name		TVS to approve (Yes / NO)
8.Gauges/Instruments / Test Equipment requirements
S.No.	Gauges / Instruments / Test Equipment Description	Make	Quantity	Completion date
9. Identification & Traceability
Method		Stamp
Supplier  identification		TAL & IR No.
Location		Hing, Rear Brake
Traceability		TAL & IR No.
10.Packing Method agreement-Explain the method briefly
Part preparation (Cleaning and oil application etc.):
Method of Primary packing:
Method of Secondary packing:.
Type of strapping:

9.0 PROCESS FAILURE MODE AND EFFECT ANALYSIS (PROCESS FMEA)

Item :

Process Responsibility :

FMEA Number :

Core Team :

Key Date :

Prepared By :

Part No./Latest Change Level:

FMEA Date(ORG) :

Rev :

ModelYear  (S)/Program(S)

Customer:-

OPN No.

Process Function/ Requirement

Potential Failure Mode

Potential Effect(s) of Failure

Sev.

Class

Potential Cause(s) Mechanism(s) of Failure

Current Process Controls

RPN

Recommended Action(s)

Resp. & Target, Completion Date

Action Results

Controls Prevention

Occ.

Controls Detection

Det.

Actions Taken Completion Date

Sev

Occ

Det

RPN

Prepared By:                                                                                                                                                                                                                                                                                                                                                                    Approved By:

10) Control Plan

Customer:-

Customer code:-

Other Approval  /Date (if Reqd.)

Other Approval / Date:-

Characteristics

Methods

Process Name/

Machine,Device,

No.

Product

Process

Special

Product/Process

Evaluation

Samples

Control Method

Reaction Plan

Part/Process

Operation

Jig,Tools

Char.

Specification/

Measurement

Size n

Freq.

Number

Description

For  Mfg.

Class

Tolerances

Technique

a – Stop Production,   b – Notify Supervisor,   c – Re-adjustment,   d – Seggregate previous batch,   e – Quarantine non-conforming parts,   f – Tool Rectification

Prepared by :-

Approved by :

Revision History

11) Process flow diagram

Part Name  :					Customer:-				Revision :
Part No./Latest Change Level:									PPD BY :
OPN No.	Fabricate	Move	Store	Inspect	Operation Description	Item No.	Key product / process characteristics		Key Control Characteristics
							product	Process

12) Floor Plan Check list

CUSTOMER OR INTERNAL PART NO. :-

QUESTION		YES	NO	COMMENT/ ACTION REQUIRED	PERSON RESPONSIBLE	DUE DATE
1	Does the floor plan identify all required process and inspection points?	Yes
2	Have clearly marked areas for all material, tools, and equipment at each operation been considered?	Yes
3	Has sufficient space been allocated for all equipment?	Yes
Are process and inspection areas:
4	Of adequate size?	Yes
5	Properly lighted?	Yes
6	Do inspection areas contain necessary equipment and files?	Yes
Are there adequate:
7	Staging areas?	Yes
8	Impound areas?	Yes
9	Are inspection points logically located to prevent shipment of nonconforming products?	Yes
10	Have controls been established to eliminate the potential for an operation, including outside processing, to contaminate or mix similar products?	Yes
11	Is material protected from overhead or air handling systems contamination?	Yes
12	Have final audit facilities been provided?	Yes
13	Are controls adequate to prevent movement of nonconforming incoming material to storage or point of use?	Yes

13.0 Measurement System Analysis(MSA) Plan / Study Results

Part Name:                                                                        

Part Number:

Customer:                                                                                                                                                       

S.No.	Instrument & ID No.	Range	Resolution (Least Count)	Characteristics	Spec of Part	Reason for MSA*	Type of analysis		Observed Results		Action, if any
							R&R	Bias/ Linearity	R&R	Bias/ Linearity

14.0 PpK and CpK PLAN / STUDY RESULTS

        Part Name:                                                                                              Part Number:

        Customer:   

Sr. No	Product Characteristics	Reason for Identifying	Stage & M/C (Operation)	Results of Cpk / Ppk Study	Action, if any

 NOTE: Refer FMEA/Control Plan and ensure that for all Special Characteristics, Ppk must be identified.

1)  Ppk / Cpk are applicable only for such operations which are stable.

2)  For unstable processes, 100 % inspection is carried out.

                                                                                                                                                                                                                                                                                          Signature                                                                                                                              

14.0 PRODUCT / PROCESS QUALITY SYSTEM REVIEW

 Part Name:                                                                                                Part Number:

 Customer:                                                                                     

SR No	Expected Modifications	Required Yes / No	If Yes, Action Reqd	Responsibility	Remarks
1	Any Change in Documentation :   – Manual – Procedures – Work Instruction – Control Plan – Inspection Std. – Process Control  Sheet
2.	Changes in the Materials Storage Systems
3.	Change in the Inventory Norms
4.	Change in the Material Handling Systems
5.	Any Training required for new instruments being taken
6.	Any Modification in the existing processes
7.	Additional SPC tools to be used
8.	Mistake Proofing required, if any
9.	Change in Plant Layout
10.	Any Change in the Purchasing System
11.	New Vendors to be developed
12.	Modifications in the  Internal Audit Schedule
13.	Any other not referred above:

                                                                                                 (Signature)

15 Process Sign Off Sheet

SUPPLIER:		PROGRAM:
MFG LOCATION:		CHANGE LEVEL (S):
PART NUMBER (S):		PRE-PSO MEETING DATE
PART NAME (S):		ISO CERT. #         TS CERTIFICTE #   ISO 14001CERT. #   EXPIRATION DATE:
EARLY CONTAINMENT REVIEWED      YES                 NO
PSO PROCESS ELEMENTS VERIFIED			DOCUMENTATION						PROCESS
			ACCEPT			UNACCEPT			ACCEPT		UNACCEPT
1	PART NUMBER, DESCRIPTION AND CHANGE LEVEL
2	PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN
3	PROCES FMEA
4	ERROR AND MISTAKE PROOFING COMPLETE
5	PROBLEM SOLVING METHODS 8-D & 5-WHY
6	INCOMING AND OUTGOING MATERIAL QUALIF/CERT
7	TEST SAMPLE SIZES AND FREQUENCIES
8	PARTS PACKAGING AND SHIPPING SPECIFICATION
9	PARTS HANDLING PLAN
10	ENGINEERING STANDARDS IDENTIFIED
11	PREVENTIVE MAINTENANCE PLANS
12	GAUGE AND TEST EQUIPMENT EVALUATION
13	TOOLING, EQUIPMENT AND GAUGES IDENTIFIED
14	SPECIAL PRODUCT AND PROCESS CHARACTERISTICS IDENTIFIED
15	CONTROL PLAN
16	EVIDENCE OF PRODUCT SPECIFICATIONS
17	PROCESS MONITORING AND OPERATOR INSTRUCTION
18	LINE SPEED DEMONSTRATION
19	INTERNAL AUDIT
20	CUSTOMER SPECIFIC
CORRECTIVE ACTION REQUIRED						YES		PROMISE DATE:
				NO
ALL PROCESS SIGN – OFF ELEMENTS APPROVED ?                 YES   NO
PROCESS SIGN OFF TEAM     TITLE                                        PRINT NAME & SIGN                                                          TITLE                                         PRINT NAME & SIGN TITLE                                         PRINT NAME & SIGN
ALL CORRECTIVE ACTIONS ARISING FROM THIS PSO SHALL BE SUBMITTED TO THE CUSTOMER WITHIN THE PROMISE DATE SHOWN ON THIS FORM.

16) Bill of Materials

					Doc No :
Part No :                                                Drg.Rev.No : Part Name : Customer Name :					Rev No :               Date:
					Page No : 1 of 1
					Control status :
BILL OF MATERIALS
Sl.No	PART NO	DESCRIPTION	LEVEL	Drg.Rev. Status	Supplier	No.Off	units
Prepared By :                                                                                                                      Approved By :

17) Part Submission Warrent

18) BENCH MARK DATA / PRODUCT – PROCESS ASSUMPTION

Part Name:                                                    Part Number:    

Customer:                                                     Person Contacted/ Interviewed, if any                                                                                                                        

Date of Visit:

A. Bench Marking Data

S. No.	Bench Marking Criteria	Bench Marking Data			Company’s Data (Similar Product)
		Supplier (Competitor)	Product	Data	Current Status	Assumed Target
1.1	Specific Applicable Features Requiring Attention :
a)	Productivity
b)	Cost / Unit
c)	Cost of Consumption of Consumables Per Unit
d)	Delivery Performance %
e)	Customer Satisfaction Index
f)	Plant Rejections %
g)	Re-works %
h)	Customer Returns
i)	Warranty Claims (ppm)
j)	Others (Specify)

B. Product / Process Assumptions

2.1	Specific Assumptions Related to Product Under Development: TechnologyMaterialsOperational Control / Features
2.2	The process of Bench Marking Partner (other supplier) and if the company needs the technological modification / acquisition.
2.3	Special Features of the process, (if Company does not have it).
2.4	Source of Acquisition if the Technology is new.

Note : For Company’s Assumed Targets, make Action Plan (after feasibility is over) for achieving     or exceeding the Bench Marking Data.

                                                  (SIGNATURES)

19) CHECK LIST FOR RELIABILITY & QUALITY GOALS

   Part Name         :                                                                                   Part Number      :

   Customer          :                                                                                   Vehicle / Model:

A. Reliability Goals

S.No	Reliability & Safety	Requirements
		Normal Conditions	Abnormal Conditions
a.	Expected Life of development Product under different operating conditions
b.	Safety Features (If any)

 ote: Use Bench Marking Data if any.

B ) QUALITY  GOALS

(Make Action Plans for Achieving Targets)

Rejection at:                           Current Data               Bench Marking            Assumed Target

(Ppm / %)                                 Similar (Product)            (If any)                      

Customer End:                           ——————         ——————     ——————

End User           :                       ——————          ——————      —————-

Car Mfr End       :                       ——————         ——————         ——————

(OEM)

Different Stages of Production at Co. End

a)                     :                       ——————              ——————              ——————

b)                     :                       ——————              ——————              ——————

c)                     :                       ——————              ——————              ——————

d)                     :                       ——————              ——————              ——————

e)                     :                       ——————              ——————              ——————

                                                                                                                              (Signature)

20 ) CHECK LIST FOR MATERIAL SPECIFICATION

 Part Name     :                                                                  Part Number :

 Customer      :                                                                  Vehicle / Model:

S.No.	Check Point	Required		Comments / Action Required	Responsibility	Due Date
		Yes	No
1.	Are Special Characteristics for materials been identified?
2.	Are specified materials, heat treat and surface treatments compatible with the product durability requirements? (For Design Companies only)
3	Are the intended materials suppliers on the customer approved list?
4	Will materials suppliers be required to provide Test Certificate / Report with each shipment?
5.	Have the materials characteristics requiring inspection been identified? If so:
a)	Will Characteristics be checked in-house?
b)	Is Test Equipment available?
c)	Will training be required to assure accurate result?
6	Will Out-side Laboratories be used for the purpose?
7	Are all Laboratories used accredited (if required)?
8.	Have the following materials requirements been considered?
a)	Handling
b)	Storage
c)	Environment during storage
d)	Identification during storage

                                                                                                                        (SIGNATURE)

21) WORK INSTRUCTION FOR SPECIFIC PPAP REQUIREMENT

PURPOSE: To generate instruction for Customer Specific Requirements to perform PPAP Documents.

SCOPE: Applicable to all New Produced Parts, Correction of Discrepancy on previously submitted Parts & In case to change in part through Engineering change in design/specification/ material.                         

PPAP REQUIREMENTS:

Sr. No.	PPAP Documents	To Customers					From Suppliers
		Level-1	Level-2	Level- 3	Level-4	Level-5	Non ISO/TS	ISO/TS
								16949
1	Product Drawing	R	S	S	*	R	S	S
2	Product Specification	R	S	S	*	R	S	S
3	Engineering change documents, if any	R	S	S	*	R	S	S
4	Customer Engg. approval, if required	R	R	S	*	R	–	–
5	Process Flow Chart	R	R	S	*	R	–	–
6	Process flow diagrams	R	R	S	*	R	S	S
7	Process FMEA	R	R	S	*	R	–	S
8	Dimensional results	R	S	S	*	R	S	S
9	Customer Inspection Report (If Available)	R	S	S	*	R	S	S
10	Material performance Test results	R	S	S	*	R	S	S
11	Initial process study	R	R	S	*	R	–	S
12	Measurement system analysis studies	R	R	S	*	R	–	S
13	Qualified laboratory documentation	R	S	S	*	–	–	S
14	Control plan	R	R	S	*	R	S	S
15	Part submission warrant (PSW)	S	S	S	S	R	–	S
16	Appearance approval report,(AAR) If applicable	S	S	S	*	–	–	–
17	Sample product	R	S	S	*	R	S	S
18	Master sample If available	R	R	R	*	R	–	–
19	Packaging and Labelling  Std & Logistics
20	List of checking aids for all drawing dimns	R	R	R	*	R	–	–
21	Records of compliance with customer- specific requirements	R	R	S	*	R	–	–
22	Sub Supplier PPAP (s)

• If customer demands PPAP and does not specify level or requirements, Level 3 shall be considered as default level.
• Level 4 shall be followed if customer does not specify the level but gives only specific requirements.
• If customer does not demand PPAP, level 5 shall be followed.

*  If required by customer.

R: Retain      S: Submit

Perform only specific PPAP – if any of the following situations take place:

• When an Optional construction or material than the previously submitted part in used.
• When production is carried out using new or modified tooling (not the perishable tools).
• When there is any rearrangement/ refurbishment of equipment / tooling.
• When there is any change in process or method of manufacture that affects quality of end product.
• When production is carried out from equipment /tooling transferred to different plant / location on from an additional plant / location.
• When there is any change in source of subcontractor of non standard Part or material that affects end product quality.
• When a production is carried out with a tooling inactive for last 12 month or more.
• When there is any change in component or its process that affects end product quality.
• When there is any change in Test / inspection methodology / technique