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ROOP AUTOMOTIVES LTD.
Supplier Quality Assurance
Manual
RAL-SQAM-001 Rev.00
COPYRIGHT STATEMENT
This document is the property of Roop Automotives Ltd. and no part of this may be reproduced without prior written permission.
Effective since 01.01.2016
Page 1 of 38
Revision Status of Supplier Quality Assurance Manual RAL-SQAM-001
S. No. Revision detail Rev. No. Rev. Date
1 First Edition 00 01.01.2016
Supplier Quality Assurance Manual
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Table of Contents Page
1.0 Introduction 6
2.0 General 7
2.1 Vision 7
2.2 Mission 7
2.3 Quality Policy 7
2.4 Environmental Policy 8
2.5 Health & Safety Policy 9
3.0 Scope 10
4.0 Objective of Supplier Quality Assurance manual 10
5.0 Prerequisite for Supplier Approval 11
5.1 Supplier Quality Assurance System Site Self- Assessment 11
5.2 On-Site Quality System Site Assessment 11
6.0 Requirements for existing suppliers 12
6.1 Requirements for existing & New suppliers 13
7.0 RAL’s Specific Requirements 13
7.1 Quality System 13
7.2 Right of access 13
7.3 Advanced Product Quality Planning (APQP) 13
7.4 New Product Development by Supplier 13-14
7.5 Special Processes 15
7.6 Material and Print Specifications 15
7.7 Proprietary items 15
7.8 Engineering Source Approval 15
8.0 Hazardous Material 15
9.0 ELV Compliance 16
10.0 Supply Chain Management 17
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11.0 Education & training 17
12.0 Managing Change 17
13.0 Special Characteristics 18
14.0 Samples 19
15.0 Label Identification Requirements 19
16.0 Production Part approval Process (PPAP) 20
17.0 PPAP documents required from supplier 20-21
18.0 Material / Product Deviations 22
19.0 Traceability 22
20.0 First In First Out 23
21.0 Verification of Purchased Product 23
22.0 Cleanliness Requirements 23
23.0 Non-Conforming Product/ Corrective & preventive action/ Supplier charge back 23-24
24.0 Shipment and Packaging Requirements 25
25.0 Supplier evaluation 26
26.0 Record Retention 27
27.0 Re-validation/Layout inspection 27
28.0 Pre-dispatch Inspection report 27
29.0 Supplier Audits 28
30.0 Other Requirements 28
Additional Information 28
31.0 Controlled Shipping 28
32.0 Implementation criteria for Controlled shipping 29
33.0 Exit criteria for Controlled shipping 29
34.0 Mistake – Proofing 29
35.0 Continual Improvement Process 30
36.0 Statistical Techniques 30
37.0 Cost Reduction and Continuous Improvement 31
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38.0 Government and Safety Compliances 31
39.0 Supporting Documents 31
40.0 Examples of Records for Retentions May Include but are not limited to 32
Forms/Tags 34-38
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Management Message
The release of our first “Supplier Quality Assurance Manual” is a unique opportunity to come to the
same platform unitedly with our suppliers to meet and exceed the needs of our Customers
This manual shall be the window through which we share key business requirements and
performances with our supplier partners in order to
1. Increase Suppliers Participation.
2. Implement Proven Quality & Management Practices.
3. Improve our products.
4. Create Opportunities for sustainable and mutually profitable business.
In today’s technology driven world, assurance of innovative & learning environment is a key issue in
assuring effective & nurturing/developing quality practices.
Quality develops strong partnership with people, communicate their shared purpose high standards &
values, undertake regular & ongoing evaluation & are open & honest in sharing information.
The technique of TQM with the concept of sustainable development has been the key to success of
many small & big organisation, as TQM is a management philosophy that supports the process of
continuous improvement within an organization, where total emphasis is placed on customers. In
manufacturing that too auto components, the conditions are tougher & we believes & practice two
points;
-Quality is seen: which is overall view & perception when customer enters our premises & judge how
company believes in Quality, as measurement & checking follows later.
-Quality in Mind (QIM): as everything starts on your thinking & believe in Quality.
We want to take this opportunity to reinstate that “Our focus on Training and Development to the
Team” must not be ignored. Our investment in skill up-gradation and new skills acquisition will not only
help team grow into better professionals but also yield qualitative results for your organisation. This will
directly impact your Top and Bottom line.
We as partners welcome you all to our Training programs that happen at our facilities time to time, and
shall keep you abreast with the events and appreciate your participation.
Roop Automotives acknowledge, appreciate and applaud efforts of all our business partners in terms
of quality, cost & service. Thus we want this manual to serve as a roadmap for our continued
partnership towards Global Leadership.
Mohit Oswal P. K. Salhotra Gaurav Jain
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1.0 Introduction
Presently, Roop operates out of three geographical locations in India
GUJARAT (upcoming)
UNIT IV: Plot PE 121, Sanand II, Industrial Estate, Near Village Bol,
Ahmedabad- 382110
HARYANA
UNIT I: Plot 19, 30, 31 and 210, Rozka Meo Industrial Area, Sohna, Gurgaon, 122103 UNIT II: Plot 439, 440, Sector 8, IMT Manesar, Gurgaon, 122050
TAMIL NADU
UNIT III: PLOT A 10 1 (A), Sipcot Industrial Park, Irrungattukottai,
Sriperumudur – 602 105
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2.0 General
2.1 Vision
“Aim for operational excellence and consistently enhance our technical capabilities and know how, hence becoming a supplier and employer of choice”
2.2 Mission Compete: To become No. 1 supplier with all customers Develop: To develop world class teams including strategic business partners Deliver: To exceed our customer requirements and deliver values to all stakeholders Build: To build an organisation based on fair practices
2.3 Quality Policy
To continuously upgrade systems and methods to improve quality of our Products;
To meet & exceed Customers’ requirements.
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2.4 Environmental Policy
Roop Automotives Ltd, engaged in the manufacturing of automotive components, is all set to achieve brilliance in its environmental performance through sound environmental management systems (EMS).
To attain this we obligate ourselves to:
Integrating environmental friendly practices in all our business processes and practices by elimination or minimization of environmental impacts of the same, with specific consideration to the substitution of potentially unsafe chemicals which pose a serious threat to the ecosystem or have the potential to do so in case of an accident.
The effective treatment of smoke & dust, waste water and other industrial effluents through sound effluent management.
Developing, implementing, achieving, reviewing and maintaining the environmental policies in accordance with the applicable legislations.
Keeping the consumption of renewable resources within the limits of their replenishment by conservation of resources like oil, water, electricity, paper, etc. and wise consumption of others.
Instilling awareness among employees for maintaining a pollution free environment and enhancing environmental consciousness among our business associates, suppliers and contractors.
Ceaseless product innovation to improve environmental compatibility.
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2.5 Health & Safety Policy
Roop Automotives Ltd. exhibits total commitment to the better health and full safety
of its employees and other persons who may be affected by its operations. We envision
that safe work practices results into better business performance, raised level of
motivation of workforce and higher productivity. Hence we commit ourselves to
implement the formulated polices; equally, fairly & without and exception; to create a
safe and healthy work environment a culture of our organization.
We shall attain this by:
Integrating health and safety matters in all our activities
Creating healthy mindset and developing wellness & fitness attitude among all employees by educating adequately, imparting practical training, empowering and motivating properly so that they are safety conscious and they follow safety rules in full and practices safe work habits at all the hours.
Applying proper techniques for the execution of the tasks and adhering to the injury prevention & safe practices. Will work for the continual improvement in OH & S management & OH & S performance
Follow all the applicable legal & other requirements
Promoting health & safety awareness amongst suppliers and contractors.
Control of man, machine performance and physical environment for prevention as well as correction of unsafe conditions & circumstances.
Regular identification of unsafe conditions and timely corrective actions for the same.
Planned and systematic effort in the execution of the task to minimize accident frequency rate and to achieve longer accident free period continuously.
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3.0 Scope
The requirements given in this manual are applicable to all the suppliers supplying
material to any plant of Roop Automotives Ltd.
Exclusions:
Customers who supplies Raw Material/BOP to RAL.
Tooling/Machineries/Gauges/General consumable item suppliers
Job workers who does rough machining for RAL (not a finished dim. as per
Customer drawing)
4.0 Objective of Supplier Quality Assurance Manual
The objective of this Supplier Quality Assurance Manual of Roop Automotives Ltd.
hereafter called RAL is to communicate clearly the conditions of doing business with
RAL and to develop systems that drive continual improvement, prevent defects, and
reduce variation and waste in the entire supply chain. Information presented in this
manual are RAL precedence, unless officially notified by authorized RAL personnel.
Suppliers are responsible for the quality of their products and services.
Our suppliers are expected to have;
Zero incidents for
a. Minor issue- Which does not affect production or assembly at RAL.
b. Repetitive issue- Which does not affect production or assembly but is a
recurring nonconformance.
c. Major Non-conformance- Which directly affects production and assembly.
A DAR (Defect Analysis Report) may be issued to the supplier when non-conforming
material is detected (Format attached)
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Zero disruptions
– Cases of failure in supplying the material on time which resulted into line stoppages
at RAL/Customer.
Zero defect
– Supplier is expected to deliver defect free products
Flawless delivery performance
– Supplier is expected to deliver defect free product on time.
On-time responsiveness to issues
– Supplier is expected to be responsive on the issues related to customer complaints,
new product development, RFQ’s etc. on time
The original RAL Supplier Quality Assurance Manual is a controlled document.
5.0 Pre-requisite for Supplier Approval
5.1 Supplier Quality System Site Self-Assessment
A potential supplier will complete the supplier self-assessment in order to provide RAL
with a general understanding of their quality management system.
5.2 On-Site Quality System Site Assessment
An on-site quality system assessment is required prior to issuance of any initial
purchasing agreement.
The supplier shall be evaluated based on the following criteria.
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Manufacturing feasibility.
Commercial viability.
Quality assurance Systems.
Capacity available
Fair Business Practices.
Safe working environment
Supplier to provide proof of financial stability in the form of balance sheet or auditor
certificate that there is no default of financial repayments and that funds from
operation are sufficient for normal operations.
6.0 Requirements for Existing Supplier
As part of RAL quality surveillance program.
The assessment will be conducted by a RAL representative(s) and who will verify
the existence of a quality system and the disciplines necessary to meet its
requirements in the following conditions
Prior to placement of significant new business.
As a result of not meeting required quality performance/quality issue.
When there is a significant change (refer PPAP manual table 3.1 customer
notification) in the supplier facility.
A change in ownership (transfer of stake >15%, cumulative).
Change in facility / change in use of equipment.
A significant change in the nature of the product previously supplied e.g. if a
supplier is supplying hot forgings & sets up a cold forging facility, the same
would be subject to a fresh audit.
During development of the new parts, RAL Purchase department will consider the
supplier rating & for selection, consideration will be given on the past performance.
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6.1 Requirements for Existing & New Suppliers
7.0 RAL’s SPECIFIC REQUIREMENTS
7.1 Quality System: Suppliers must have a documented quality system in
compliance with latest version of either ISO: 9001 or TS16949 and agree
to on-site assessment by RAL. It is preferred that suppliers be registered
to one of the standards listed above.
7.2 Right of Access: Supplier must offer the right of access at their premises
to RAL & its customer. In case of emergency, RAL/ RAL’s Customers can
visit supplier even without intimation to supplier.
7.3 Advanced Product Quality Planning (APQP): As requested, the
Supplier must have resources available and capable of performing APQP
and Production Part Approval Process as per latest AIAG manual.
7.4 New Product Development by Supplier
Any new product offered to the supplier has to follow the process flow
chart as follows:
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Process Flow Chart
Not OK
OK
OK
Selection of Supplier
Issue of Drgs /Applicable Std. to
Supplier
Quotation received from Supplier
with detailed break up.
Finalise the supplier/ Commercial Settlement
Issue of L.O.I./P.O.
Request for Quotation
Formation of CFT
Team Feasibility
Submit Development
plan
Submission of Samples
with Report
Insp. of
samples
Capacity, Capability, Quality Verification
Approve the PPAP.
Go ahead to
Supplier for PPAP
run
Reject the PPAP.
Not OK
Not OK
OK
RAL SUPLLIER
PPAP Run
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7.5 Special Processes
Supplier supplying the material with the below mentioned processes must qualify the
below standards. An audit for the same will be conducted by RAL on annual basis.
a) Heat Treatment------CQI 9
b) Plating------------------CQI 11
c) Any other mentioned in customer requirements & or considered as special process.
7.6 Material and Print Specifications
Suppliers must produce products for RAL to the print specifications. The same is
expected from their sub-suppliers too. IMDS for all the Raw material/BOP items is
essential wherever applicable.
7.7 Proprietary items
In case of proprietary items (whose design & testing responsibility is of suppliers),
specification once freezed can’t be changed without prior approval from RAL. IMDS for
all the material is essential wherever applicable.
7.8 Engineering Source Approval
RAL specified material or sources must be adhered to. Any changes shall require prior
approval from RAL.
8.0 Hazardous Materials
Suppliers must supply all information related to Hazardous Materials, and satisfy all
governmental and safety requirements. Suppliers will be required to submit Material
Safety Data Sheets (MSDS) for all identified items.
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9.0 ELV Compliance
Suppliers must submit the compliance report of not using the banned elements in their
parts during PPAP. Banned elements are Lead (Pb), Mercury (Hg), Hexavalent
Chromium (Cr6+), Cadmium (Cd) & Bromine (Br) of the chemical form specified
following shall not be present in the final product.
Polybrominated biphenyl (PBB) and Polybrominated diphenyl ether (PBDE).
Subsequently this report is to be submitted to RAL annually
Below is the maximum acceptable limit for these elements
Element Specified limit max.
Lead(Pb) 1000PPM
Mercury(Hg) 1000PPM
Cadmium(Cd) 100PPM
Hexavalent Chromium(Cr6+) 1000PPM
Both Polybrominated biphenyl (PBB) and Polybrominated diphenyl ether (PBDE) 1000PPM
Suppliers must supply material free from radioactivity. A compliance report/declaration
of not using the radioactive material is required to be submitted during the first supply.
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10.0 Supply Chain Management
Suppliers must identify and manage their entire supply chain. It's is the suppliers
responsibility to ensure that the products coming from its supply chain and those that
may be recommended by RAL meet the RALs' product requirement.
11.0 Education & Training
Supplier should develop education & training program for all manpower including
contracted manpower across all levels. A training plan to be made & shall be carried
out as per training plan. Effectiveness of training to be assesses by a suitable method.
12.0 Managing Change
Suppliers must notify RAL of any intended process change and obtain RAL
approval prior to implementation of same.
Suppliers must also make this a condition of their own entire supply chain. In
some cases, samples and documentation will be required as part of the approval
process.
Supplier must submit a report of 4M change to RAL on monthly basis.
There shall be no change to the Specifications, Part Drawings and
Purchase Order Requirements or to the Process without written approval
from RAL
ECN procedure is to be followed to get the approval of any change.
Complete status of the obsolescence of material/tooling/gauges etc. is to
be decided jointly with RAL.
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If the supplier has an improvement or concern that can only be resolved with a
process change, a Supplier Change Request containing a complete description of
the change with the reason accompanied by supporting documentation, should be
submitted to the RAL Purchasing Department.
13.0 Special Characteristics
Special Characteristics are shown on current drawings using symbols that
identify the importance level.
It is the supplier’s responsibility to incorporate these Characteristics into the
Control Plans, PFMEA’s, and Work Instructions of all products supplied to RAL
Other important characteristics shall be conveyed by the Quality Manager or
the Purchasing Department of RAL.
Suppliers are expected to have their processes under statistical control
consistent with the guidelines of the current ISO 9001 or TS 16949 Standard
and related reference manuals.
Features or properties (dimensional, visual, functional, mechanical, or material)
which are designated to communicate to either manufacturing operations or
suppliers the significance of these characteristics and the need to ensure the
production process has inherent capability or sufficient control for meeting the
specification / tolerance limits.
Critical is a characteristic where special due diligence is required since the
consequence of an assembly or manufacturing variation outside of specification
could cause unsafe product function.
Safety is a characteristic where the failure to maintain that feature can lead to
an accident.
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14.0 Samples
Whenever samples are submitted to RAL for approval, it should be thoroughly checked
by supplier. The sample inspection report should cover all the dimensions & tests
specified in print. The S. No. in the inspection report to be marked in the ballooned
drawing. The ballooned drawing with the inspected Samples & Sample Inspection
Report including the steel mill certificate, chemical, mechanical & metallurgical
report to be submitted to RAL. Inspected samples to be separately packed &
should be traceable to the submitted report. Supplier to ensure the S. Nos. on the
inspected samples.
If the die/ mould are having the multiple cavity, report of all the cavities to be submitted
for approval. Die/mould number to be marked on the samples.
15.0 Label Identification Requirements
The initial PPAP submission to RAL and the first production run after PPAP approval
shall be clearly identified on the packing box with the words & the tag sample given in
the last pages of this manual:
Attn: Quality Department – PPAP Submission “or” – First Production Shipment
Notification. The supplier should clearly specify whether the shipment is for PPAP or
production. Any deviations to this requirement must be approved by the RAL Quality
Department prior to shipment.
NOTE: Any shipment of first production lots shall be preceded by a PPAP submittal and
approval. Any deviation to this requirement must be approved by the RAL Quality
Department.
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16.0 Production Part Approval Process (PPAP)
Level 3 PPAP is required for all submissions unless otherwise specified by the RAL
SQA or as otherwise identified on the purchase order. PPAP is to be done at supplier
premises in presence of RAL SQA representative. PPAP’s are to be submitted directly
to the RAL SQA of the respective locations shown on the purchase order. Final PSW
sign-off will be done after achieving the run @rate. The review of PPAP submissions
from Tier 2/Tier 3 suppliers may also be required.
NOTE: PPAP shall be submitted in accordance with the AIAG manual. Additional
requirements may also be specified by RAL
17.0 PPAP Documents required from Supplier
Given on next page
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Reference AIAG Production Parts Approval Process (PPAP) 4th Edition Table 4.1
Retention/Submission Requirements Table Submission Level
# Requirements 1 2 3 4 5
1 Design Records (Drawings, Specifications) R S S * R
- for proprietary components/Details R R R * R
- for all other components/Details R S S * R
2 Authorized Engineering Change Documents, if any R S S * R
3 Customer Engineering Approval, if required R R S * R
4 Design FMEA (if applicable) R R S * R
5 Process Flow Diagram R R S * R
6 Process FMEA R R S * R
7 Control Plan R R S * R
8 Measurement Systems Analysis Studies (Gage R&R) R R S * R
9 Dimensional Results R S S * R
10 Material & Performance Test Results R S S * R
11 Initial Process Study R R S * R
12 Qualified Laboratory Documentation R S S * R
13 Appearance Approval Report (AAR), if applicable S S S * R
14 Sample Product R S S * R
15 Master Sample R R R * R
16 Checking Aids R R R * R
17 Records of Compliance with Customer-Specific Requirements R R S * R
17.1 Manufacturing Feasibility Sign-off S S S * S
17.2 Capacity Planning & Verification S S S * S
17.3 Packaging Information/Instructions w/Sample Label R R S * R
17.4 ELV Documentation S S S * S
17.5 Sub-Supplier PPAP (Warrants) S S S * R
17.6 Balloon Print R R S * R
17.7 Rework/Repairs Procedures R R S * R
17.8 Safe Launch Plan (Final Inspection Standard) R R S * R
17.9 Control Characteristic Matrix/List S S S * R
17.10 Engineering Specification (ES) Test Planning R R S * R
17.11 Product or Process Qualification Plan R R S * R
18 Part Submission Warrant (PSW) S S S S R
Bulk Materials Requirement Checklist (bulk material PPAP only) S S S S R
R - The supplier shall retain at appropriate locations, including manufacturing, and material Readily available to the customer representatives, when requested.
S - The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at appropriate location, including manufacturing.
* - The supplier shall retain at appropriate locations and submit to RAL upon request.
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18.0 Material/Product Deviation
The supplier shall not deviate from RAL engineering drawings, specifications or other
RAL requirements without written approval and/or deviation authorization. The supplier
is responsible for the quality level of all material and/or product delivered to RAL If the
supplier detects a non-conforming condition, he shall submit a Request for Deviation for
review of product. The written request shall be submitted to the RAL Purchase
department along with the following information:
Part number and latest engineering change letter
Quantity of parts affected
Specification(s) involved
Statistical analysis of the non-conforming characteristic(s), as applicable
A statement of the requested deviation
The containment plan to be implemented
Corrective/preventative action to be taken along with the time line for
implementation which shall include the date and or lot number for the
completed actions.
RAL Purchase department will internally get it approved if feasible & will communicate
accordingly to supplier. The material if approved by RAL to be clearly identified to
prevent mix up.
19.0 Traceability
When product traceability is required, suppliers must provide unique identification of
product as per print. Parts should be traceable till raw material stage.
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20.0 First in First Out
Supplier shall implement & follow First in First out (FIFO) system for all incoming, in-
process & finished product.
Shelf life of the parts mainly rubber parts like O- ring, oil seal, v belts etc. to be assessed
at regular frequency.
21.0 Verification of Purchased Product
RAL has full right to verify the purchased products at its premises.
22.0 Cleanliness Requirements
RAL requires that all material shall be clean and free of contamination including debris
adhered through residual magnetism. The supplier is responsible for ensuring that all
material/product delivered to RAL shall be clean and free of contamination from
debris/burrs, and packaged in such a manner to assure material cleanliness. Other
drawings and/or Purchase Order requirements may apply at times.
23.0 Non-Conforming Product/Corrective & preventive action/ Supplier
charge back
Suppliers must only ship product that meets specification, or obtain a written deviation
prior to shipment for any nonconforming product.
A Defect Analysis report (DAR) shall be issued to the supplier when a RAL facility
detects non-conforming product.
In the event of a quality issue related to a supplier’s products, A Corrective Action Report
must be furnished that outlines the problem using a formal problem resolution method
DAR.
The supplier’s initial response including containment plan, shall be provided to RAL
within 24 hours (one working day) from the date the supplier receives notification of the
non-conformance.
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A written preliminary corrective action must be sent to the RAL Quality Department
within ten (10) days identifying the root cause.
Final resolution of the corrective action will be made within fifteen (15) days of the
supplier’s submittal.
Any request for additional time should be directed to the Quality Department and shall
be in writing. The written request shall include the action plan and time line for
implementation.
If product is found to be non-conforming at RAL, the supplier is expected to provide the
resources necessary to contain, evaluate, sort and/or scrap the non-conforming product
It will be determined whether product is sorted on site or returned to the supplier. If time
does not allow the supplier’s personnel to arrive for sorting, RAL may elect to execute
the sort due to need. If it is determined that inspection alone cannot detect the defect,
the product will be returned to the supplier or scrapped as agreed. Segregation to sort
defective product does not relieve the supplier of their responsibility for the quality or
delivery of product.
RAL will identify any costs incurred for doing any sort and will initiate a chargeback to
the supplier.
If the supplier fails to fulfill the requirements for complaint responsiveness and
effectiveness of problem resolution they may have Controlled Shipping invoked and be
put on new business hold until resolved.
A supplier shall comply with RAL process to recover costs associated with a supplier’s
unacceptable performance.
RAL shall be entitled to recover all costs and expenses reasonably incurred in
taking corrective action/sorting from the supplier.
The cost to process a DAR is Rs.1000/- and that will be the minimum charge that
is passed on to the supplier for each occurrence
All cost & expenses occurred in case of cost recovery by customer due to
supplier fault will be charged back from supplier
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Cost recovery for machining where parts are found defective on the line on
account of supplier’s fault is also to be charged back to supplier.
24.0 Shipment and Packaging Requirements
RAL & suppliers must agree to a packing & transportation plan prior to start of supplies to
RAL. Reusable packing is recommended. Suppliers must comply with specifications for
shipping and packaging. This includes safeguarding the products by applying rust
preventive if applicable & following the labeling specifications. RAL requires that all
suppliers provide packaging that is adequate to protect material/product from damage and
contamination for a suitable period of use. RAL reserves the right to require specific
packaging practices such as, packing materials and restrictions on packaging size.
These requirements shall be communicated through drawings and/or purchase order
requirements. Products are to be packaged in such a manner to provide adequate
protection against subsequent product degradation and contamination.
Each container shall be clearly marked and identified with the following:
Supplier Name
Part Name
Part Number
P.O. No.
Invoice No & date
Quantity
Signature
Sample Tags given at the last pages.
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25.0 Supplier Evaluation
Measurement Weightage Target
Overall Rating 100% 100
Quality Rating 40% 100
Delivery Rating 40% 100
Service 20% 100
CLASS COLOUR RATING STATUS
Excellent Supplier 90-100 On Approved Supplier List
Good Supplier 80 - 89 On Approved Supplier List
Acceptable Supplier 70 - 79 On Approved Supplier List, Request Corrective Action
Suspect Supplier 60 - 69 Place On Master List, Re-evaluate
Unacceptable <60 Review for removal From Master List
Quality Rating Formula
Q.R.= Component Rating (CR) -2* Instances of Segregation-10 X Repeated QPCR -5 X New QPCR -5 X Open QPCR -15*QPCR at customer end due to supplier
CR= (Q1+0.5Q2-1.25Q3-0.75Q4)100/ Q
Where: Q1= Qty. Accepted Q2= Qty. Accepted under deviation Q3= Line Rejection Qty. Q4= Quantity accepted after rework Q= Total Qty. Received
Delivery Rating Formula
Demerit points for DAR will be limited to one (either customer or at RAL)
DR= Quantity received on time X 100 – 10 (no of instances of line stoppage) - 5 (no of instances of premium freight paid by RAL)/ Quantity as per schedule
Service Rating Criteria
1. Response in emergency = 25 points
2. RFQ response = 25 points
3. PPAP documents = 25 points
4. On time development support = 25 points
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Note: If any parameter is not applicable then rating will be calculated from balance
parameters, e.g. if there is no PPAP documentation, then the rating will be calculated
from 75 points. In case the performance of supplier does not improve in spite of support
& time given, RAL management may develop an alternate source or further business
will be on hold till supplier shows improvement in performance.
26.0 Records Retention
Suppliers must maintain quality records (hard or soft copies) for special
processes for a minimum of 15 years unless otherwise specified on the
purchase order.
All the PPAP & changed records to be kept till the life of product+5 years.
This requirement may be extended by RAL as required.
These records shall be stored in an environment that does not allow document
deterioration and are readily accessible upon request by a RAL representative.
It is also expected that the supply chains records pertaining to RAL products
shall be retained in the same manner.
27.0 Revalidation/Layout inspection
Supplier to submit the re-validation/layout inspection report of all the products
annually. Non-conforming parameters if any to be discussed with RAL.
28.0 Pre-dispatch inspection report
While dispatching the material, supplier to ensure the PDIR (pre-dispatch inspection
report) as per agreement of inspection with RAL for the products. Samples inspected
must be identified & separately packed. For Gauges, tooling (customized) & Jigs &
Fixtures critical, fitment & functional dimensions are to be checked by supplier & report
to be submitted with material. (Customer supplied products are exceptions). Failure
to do this may result in rejecting the material without inspection.
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29.0 Supplier Audit
A yearly supplier audit plan will be issued where every supplier will be covered at least
once. QA department will carry out the quality system audit at the supplier
premises as per the plan as per the audit check sheet. Supplier has to submit the time
bound action plan against the audit observations. Verification of the corrective action
shall be done either by asking evidence of countermeasures by RAL or by visiting
suppliers.
Apart from the above, RAL reserve the right to audit the supplier facility with a short
notice in case of any complaint/quality issue.
30.0 Other Requirements
Ex. Employees of RAL
Supplier cannot employ directly or indirectly RAL’s ex-employees for a min. period of
10 years after his/her leaving RAL. This would apply to any consultancy or other
methodology, directly or thru any agency or entity.
The supplier may expect other specific requirements in addition to the requirements of
this Manual. If applicable, these requirements shall be communicated to the supplier
through RAL Purchasing Department.
Additional Information
31.0 Controlled Shipping
Controlled Shipping is a demand by RAL that a supplier put in place additional inspection
process at the supplying location to 100% sort for a specific and specified nonconformance
to isolate RAL from receipt of nonconforming parts/material. The additional inspection must
be in addition to the normal process controls.
Supplier Quality Assurance Manual
Page 29 of 38
32.0 Implementation criteria for Controlled Shipping
Repetitive issue
Suppliers current controls are not sufficient to ensure conformance to requirements
Duration, quality, and/or severity of the concern
Major disruptions
Quality concern at OEM and/or in the field
33.0 Exit criteria for Controlled Shipping
One month data (from implementation of corrective action) which verifies that the normal
production controls are effective for controlling the discrepancy identified in the
Controlled Shipping activity.
Volume to be determined by RAL where suppliers use batch processes.
Documentation showing root cause was identified and verified.
Documentation indicating that corrective action was implemented and validated.
Copies of all documentation revised as required (Control Plan, PFMEA, operator
instructions, etc.)
Documentation indicating that every effort was taken to implement error proofing.
Note: RAL approval must be given prior to supplier stopping Controlled Shipping. An
audit by RAL may be required prior to approval.
34.0 Mistake – Proofing
RAL expectation is zero defects. Achieving this level of quality requires capable
processes combined with statistical process control techniques and the utilization of
mistake-proofing methodology. When causes of non-conformance are determined, the
supplier shall employ solutions in the process to prevent or detect these non-
conformances. These solutions shall be independent of operator’s actions. Solutions
shall be designed and installed integral to the process to prevent or detect defects.
Supplier Quality Assurance Manual
Page 30 of 38
35.0 Continual Improvement Process
The supplier should promote and implement a continual improvement philosophy
applying proven methodology and processes. These methods and processes shall be
used throughout the Supplier organization to continually improve the quality, delivery,
cost and service of supplier products.
Recommended tools of the continuous improvement process are:
Benchmarking
Brainstorming
Pareto Analysis
5-Way Analysis
Cause and Effect
4M change
Process Capability/Performance
Process Mapping, etc.
36.0 Statistical Techniques
It is strongly recommended that Suppliers monitor process performance using the
appropriate statistical techniques in accordance with AIAG Statistical Process Control
manual. The determination of need is based on the ability to control and verify the process
capability and product characteristics. The use of quality planning tools such as Design
Failure Mode and Effects Analysis (DFMEA) and/or Process Failure Mode and Effects
Analysis (PFMEA) are essential. The supplier shall submit capability data for RAL
characteristics identified on the drawing. Supplier is encouraged to use statistical
techniques including:
Gauge R&R Study
Predictive Maintenance
Defect Analysis
Supplier Quality Assurance Manual
Page 31 of 38
Sampling and Process Analysis
Process Analysis with Control Charting Methods
And other Graphical Methods
37.0 Cost Reduction and Continuous Improvement
Cost reductions are viewed as an essential aspect of maintaining a competitive position
for both the supplier and RAL
The supplier shall endeavor to provide cost reduction and continuous improvement
suggestions to RAL
All proposals shall be submitted to the Purchasing Department.
A supplier may be asked to provide a commercial review for a cost or continuous
improvement proposal.
38.0 Governmental and Safety Compliance
All the Government & safety compliances are necessarily to be followed by supplier for
doing the business with RAL
39.0 Supporting Documents
The supplier must have the current editions of the following documents and any other
reference documents available for review at all appropriate manufacturing locations.
Supporting documents are requirements of ISO 9001, TS16949 and information
referenced in this Manual:
Quality System Requirements (ISO 9001)
Advanced Product Quality Planning (APQP) and Control Plan Manual *
Production Part Approval Process (PPAP) Manual*
Supplier Quality Assurance Manual
Page 32 of 38
Failure Mode and Effects Analysis (FMEA) Manual*
*These documents are available from the Automotive Industry Action Group
(“AIAG”) and may be purchased from:
Automotive Industry Action Group
26200 Lahser Road, Suite 200
Southfield, Michigan 48034
Phone: (248) 358-3570
Fax: (248) 358-3253
Internet: www.aiag.org
40.0 Examples of records for retention shall include, but are not limited to
Measurement Data
Measurement System Analysis Data
Gauge Calibration and Maintenance Records
Capability and SPC Data
Heat Treatment Processing Data
Destructive and Non-Destructive Testing Data
Functional and Performance Test Data
Quality Rejections and Disposition Records
Corrective Action Requests and Responses
Major Process Change data
Production Lot / Product ID / Traceability
Initial Sample Inspection Report
Supplier Quality Assurance Manual
Page 33 of 38
Any existing supplier can’t get a new business unless he agree to follow the
requirements mentioned in this manual.
This manual covers all products supplied by the suppliers that may have been
awarded before the date of release of this manual & shall covers all parts that may be
awarded in future.
End of Supplier Quality Assurance Manual
Supplier Quality Assurance Manual
Page 34 of 38
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Supplier Quality Assurance Manual
Page 35 of 38
PR
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Supplier Quality Assurance Manual
Page 36 of 38
Co
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Supplier Quality Assurance Manual
Page 37 of 38
DOC. NO. : F-05-02
REV. NO. : 01
DATE : 19.12.2015
PAGE : 1 OF 1
Customer : Part Name :
Part No. :
Feasibility Considerations :
YES NO
Conclusion :
Feasible
Feasible
Not Feasible
Sign-Off :
Team Member /Title / Date: Team Member /Title / Date:
___________________________ ___________________________
Team Member /Title / Date: Team Member /Title / Date:
___________________________ ___________________________
Design revision required to produce product within the specified requirements.
Changes recommended (see attached).
Product can be produced as specified with no revisions.
Where statistical process control is used on similar products:
Are the processes in control and stable?
Are Cpk’s greater than 1. 33?
TEAM FEASIBILITY
COMMITMENTROOP AUTOMOTIVES LTD.
Does the design allow the use of effcient material handling techniques?
Our product quality planning team has considered the following question, 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 our concerns and / or proposed
changes to enable us to meet the specified requirements.
Can Engineering Performance Specifications be met as written?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with Cpk’s that meet requirements?
Is there adequate capacity to produce product?
CONSIDERATION
Alternative manufacturing methods?
Is statistical process control presently used on similar products?
Is product adequately defined (application requirements, etc.) to enable feasibility
evaluation?
Can the product be manufactured without incurring any unusual:
Costs for capital equipment?
Costs for tooling?
Supplier Quality Assurance Manual
Page 38 of 38
Part No……………………..………………...……
Rev. No……………………..………………...……
Part Name……………….…………….…………
P.O. No……………………………….…………..
Invoice No & Date………….……...……….
Qty………………………………..………………..
Signature……………………..…...……………
Production supplies
Supplier name……………..…..……………….
6”
4”
Part No……………………..………………...……
Rev. No……………………..………………...……
Part Name……………….…………….…………
P.O. No……………………………….…………..
Invoice No & Date………….……...……….
Qty………………………………..………………..
Signature……………………..…...……………
PPAP SAMPLES
Supplier name……………..…..……………….
6”
4”
ROOP
ROOP AUTOMOTIVES LTD. CORPORATE OFFICE
(Location -1) 19, Rozka Meo Industrial Area, Sohna
Gurgaon – 122103 (India) Phone: +91 8396969522-26, Fax: +91 124 2362568
Email: [email protected]
(Location- 2) Plot No- 439, Sector – 8, IMT
Manesar, Gurgaon – 122050 (India) Phone: +91 124 4959800
Fax: +91 124 4959639
(Location- 3) Plot No- A10 A(1), Irrungattukottai,
Sipcot Industrial Park, Chennai – 602105, (India)
Phone: +91 44 67103600-620
( Location- 4)
UNIT IV: Plot PE 121, Sanand II, Industrial Estate, Near Village Bol,
Ahmedabad- 382110 (India)
www.roopauto.com