QCM 2020 Abridged Version

Synopsis
of
QUALITY COMMUNICATION MEET
2020
This is strictly for reference only & not for circulation

© 2020 Maruti Suzuki India Limited
1
Strictly for reference only and not for circulation Quality Excellence across value chain in New Normal © 2020 Maruti Suzuki India Limited
Topics Covered Page No.
• Sustaining Quality in Challenging Times 3-12
• New Model Parts Development 13-26
• Mass Production Quality Status & Way Forward 27-46

• Moving towards Zero Defect
- Zero Defect Approach – Learning & Way forward 47-54
- Training & Skill Development – DOJO Training Center 55-57
- Operator observance System through 10 Cycle 58
- Abnormality Handling 59
• Global Environment Regulations : Restrictions on

60-67
Substance of Concern (SOC)
2
Sustaining Quality in Challenging Times
Vipin Garg
Executive Vice President
Quality Assurance
Maruti Suzuki India Ltd.
3
Quality Communication Meet (QCM) Journey
 Recap - ZD Methodology
 Mold maintenance guidance manual
 10 Cycle check
 TISP preparation
 Revalidation of Parts “QCM-3
 Plant Maintenance
“QCM-2
 Zero Defect Concept
 Mini DOJO concept
 Zero Defect methodology  Best Practice Sharing
 DOJO concept  Tier-2 assessment - Red/Yellow/Green
ACHIEVE & SUSTAIN
 Focus on New Model “QCM-1 ZERO DEFECT
 Tier 2 Control
 Revalidation of Parts 2018 2019 2020
 4M Change Mgt
Traceability
4
Key Activities initiated Post lockdown
Advisory to Vendors- Part & RM Storage Mass Communication session
Training session
Process Wise Check sheets
 Process Readiness & Dry Run  Tool ,Die &Plant Maintenance
 Abnormality Handling
 Things To Do- Before & After Production Re-start  Operator Observance -10 cycle check
Advisory for Tier-2 Control & Operator
Training (Dojo Centre) Joint Review with Tier-1 & Critical Tier-2
 Resume Normal Operations:

 Focus on improvement Journey
 Post Lockdown – Main Focus was on  Drive Tier-2 Audits & Guidance
Re-starting the operations & Volume  Bring back focus on Tool, Die & Plant Maintenance
Ramp-up  Strengthen Quality Systems & Processes
Apr’20 May’20 Jun’20 Jul’20 Aug’20 Sep’20 Oct’20 Nov’20 Dec’20
Extensive virtual engagement and 3G audit- Vendor Plant & Warehouse 5

Quality Performance & Analysis
Sudden Increase In FY'20 ~21 (Post Lockdown)

Man Related Defects
System Non
Adherence
Operator Skill
Q4 FY19-20 Q1 FY20-21 H1 FY20-21 Q3 FY20-21
6
Reasons for Increase in Man Related Defects
 Manpower shortage
 Frequent changes in manpower
 Lack of training and supervision
Manpower Training – [Dojo Concept]
Objective : All Manpower - Trained at Dojo Training Centre before deployment at Shop floor
 Majority Vendors utilized Dojo Training

Centres for Training of New Manpower-
Post Lockdown
 Request Vendor Partners to implement
and utilize Dojo facility.
Ensure Training Of Manpower Before Shop floor Deployment 7

‘10 Cycle Check’ system of Operator Observance
Objective : Evaluation of System adherence at Gemba for Operators & Inspectors
Check
Check Check Cross
WI Availability
5 General Points WI Adherence Inspection
& Awareness
Dedicated Team to Conduct this ‘10 Cycle Check’
8
Quality Challenges: New Model Parts
Key Concerns in New Model parts Other Challenges - New

Development Features / New Technologies
• Inadequate PFMEA: Capturing All Advanced Technologies:

Failure Modes • Electronics, Connected Cars
• Defects in Common Parts : - Less Know how & Skill
[Revalidation Before Usage in New Model ]
• New Regulations (CAFÉ
• Pre ECN/Trial Parts Mix up Norms & Whole Vehicle
• PPVT & IFM at Tier – 2 Safety)
9
Substance of Concerns (SOCs) Compliance
“Lead” “Hex chromium” “Asbestos”
SOC causes health hazards
To Safeguard Humans & Environment:
Strengthen System to ensure Create Awareness at Sub

Compliance to Environment Suppliers for SOC Control
Regulations
Ensure SOC Compliance & Monitoring for MSIL Parts 10

Key Quality Initiatives
Revision In Defect Punching Criteria : Defect Punching
Criteria Revised
FY’19-20 Dec’19 FY’20-21
Apr’20
Communication sent to vendors
regarding “Other Quality Concerns”
Other Quality Concern :

• All Appearance Defects
• Wrong Part & Mix up issues
• GCA : Appearance defects
• Bar Code Wrong/NG
A step towards our goal of achieving “ZERO DEFECT” -Started treating “Other Quality Concerns” as “DEFECTS”
11
Summarization of Quality Challenges & Way Forward
Resume Normal Operations & Drive Improvement Activities
Manpower Skill in New Normal & Adherence to Rules
Focus on Preventive Maintenance of Tools,Dies&Equipments
Increase Tier-2 Engagement, Audit & Guidance
Compliance to Regulations, SOC & Traceability requirements
Development Team to work towards YNC ZD Lines
Ensure Quality System Sustenance to achieve “Zero Defect” 12

New Model Parts Development
By:
AVN Rao
AVP (QA-Parts Quality)
13
Recap – Previous “Quality Communication Meetings”
 Implement Past Defect Learnings  Off -Tool (OT) Parts in PP Trial
 Tier-2 Quality Planning
 Off Tool – Off Process (OTOP) Parts in MPT
 Quality Milestones in Development Schedule
Spec Quality
Meeting Planning
New Model
Parts :
Focus Areas
PPVT IFM
 Plan Facilities –Ensure OTOP before MPT  IFM for 3 months after SOP
 PPVT at MPT- Actions before Pilot  Monitor Break-downs, Rejection & Re-work
Thanks for implementing these activities at your end . 14
New Model Quality Performance & Learning
Line Defects at MSIL Learning
Overall defects are
improving but Single
defect are still a concern. Inadequate PFMEA
Defects in Common Parts
Handling & part Mix-up
Defects from Tier 2
Single defect cased also to be Reduced. Need to achieve Zero Defect.

15
PFMEA: Methodology & Concerns
Past Defect Failure mode Actions for defect Standardization of

identification prevention Control plan/WI
Drawing
Requirements All Past defects not considered
Process flow PFMEA Submitted Joint PFMEA review Less Involvement of Production & QA
To MSIL ( YCA , Y1K )
Base PFMEA not Elaborative
Recommended Actions
• Poka Yoke must be Implemented for all Past Failures
• Change points & Possible Human Errors are additional inputs for PFMEA
• Involve expert members from Production, QA & Engineering for Review
• PFMEA must be a live document – timely update learnings
16
Common Parts Evaluation in New Model
Requires Periodic health check for Common Parts
Assess Tool condition of common Parts thoroughly
Revalidation Guidelines
① Inspect Parts as per drawing ④ Capacity & Quality

② Verify Process as as per PCS confirm through PPVT
(if volume ≥ 20%)
③ Check Tool Condition -
If required
Refurbishment / Re-tooling
Complete Evaluation of Common parts of YNC by End Dec’20

17
Trial & Pre ECN Parts mix-up
Request to Vendors:
① Train manpower for Abnormality Handling Procedure
② Identify trial parts with Tag at separate location
③ Ensure Physical Disposal against scrap note
18
Extension of activities to Tier2 – Request to Vendors
Tier-2 Tier-1 MSIL
PPVT PPVT
IFM IFM
IFM by few vendors at Critical Tier-2 in Y1K

Decided IFM Check Training to IFM IFM station Setup Increased Audits
Points (CTQ) inspectors at Tier-1 & Monitoring during IFM
Request : Extend PPVT and IFM to all your Tier-2 Vendors.

19
Way Forward
1 Root Cause Analysis – Trial Problems
2 Learning implementation - SOR
3 Planning for New Technology Parts
20
Adequate Closure of Development Stage Issues
Feedback
Sources Part Inspection
Bench Testing Root Cause Analysis &
Trial at MSIL / Vendor Countermeasures
Vehicle Trial
Process Rejection
Mass Defect at Trial Stage

Production
PP MPP Pilot SOP Root cause not analyzed
Repeat Issue at SOP
• Hold Up
• Delay in SOP/ Launch
21
Adequate Closure of Development Stage Issues
PP Trial MPT Trial Pilot SOP
QPCR - Development
Record all defects during Trial
Proposed Method :
Record all issues
during Trials
Deep Analysis by CFT
(QA, Engg ,Prod)
Review Actions by
Plant head
Actions must be taken
before next Trial
Countermeasures must be verified and approved by Plant Head

Actions must be implemented before next Trial 22
Need For Standardization – Quality SOR
Concern Best practices are not horizontally deployed.

Learning Need for Standard Quality Requirements.
SOR : Statement of Quality Requirements
Raw Material Requirements
•
•
Storage
Testing
Methodology:
Part Specific Requirements
• Part handling
• Process Equipment
Discussion of Implementation verification in
Sharing of Quality Implementation Plan process
Process Requirements Requirements ( During spec meeting ) ( During Process Audit )
• Poka yoke
Inspection requirements
• Frequency
• EOL
Plan the process as per SOR from next Model

23
Advance Planning for New Technology Parts
New Technologies - Increased Electronics & Features
□ Lack of Past database Need for
□ No Previous Experience Advance Planning
□ Inadequate Skill
Quality Benchmark with Collaborator & Collect Past failures and actions
Data Study Local Usage Conditions and Revise Test Standards
Process Involve Collaborator for PFMEA

Know-How
Early Process set up – Target by PP Trial
Fix Operators and Train for New Tech Processes

Skill
Impart Training at Collaborator Plant (Wherever possible)
Need to Advance Development Activities 24

Challenge in Pandemic Situation – Request to Vendors
YNC is the 1st Model under development in this Challenging situation

Priority : Bring Focus on YNC - Realign resources & actual 3G Visits
Challenges Immediate Actions
 Delay in Facility Setup  Actual Tool Trials & Evaluate Parts

 Focus on Line Trials – Prod & QA
 Tools & Process Audits on
Virtual Mode  Train manpower in DOJO center
 OJT on actual Production line
 Manpower Concerns
 Review Tier 2 readiness
 Tier 2 : Limited engagement
 Evaluate Child Parts & Process
25
Summary
Extend PPVT & IFM to Tier-2 Vendors
Thoroughly Evaluate Common Parts
Strengthen PFMEA – Must Include all Past Defects
Let’s work to Deeper Root Cause Analysis of Trial Stage Problems

achieve
“Zero Defect”
in YNC Plan the process as per Quality SOR
Advance Development activities for New Technology Parts
26
Mass Production Quality
Status & Way Forward
Sushant Bose Kanchan Kishor Srivastava

GM (Parts Quality -Gurgaon) DGM (Parts Quality-Manesar)
Maruti Suzuki India Limited Maruti Suzuki India Limited
27
Post SOP –Challenges for Quality Sustenance
Major gaps observed
1.System non Adherence
2.Operator skill
3.Tools & Die maintenance
4.Others
Majority of defects are Man related defects 28

Non Adherence to System
Last Year – we requested to implement 10 cycle check
• Guidelines launched
• Please Adopt 10 cycle check system
Operator Skill improvement and Assessment - DOJO
Make best use of DOJO
Ensuring 100% Operator training and assessment in DOJO centers before deploying on line
29
Tool &Die Maintenance Concern
Increase in Tool & Jig
Defects Post Lockdown
Inadequate Tool Preventive Maintenance
Delayed Correction of Tools
Inadequacy of Weld Equipment
Q1' 20 Q2'20 Q3'20 Non-adherence to Spares Management

Tool / Jig Defect Trend (2020-21)
Tool Maintenance System collapsed post lockdown and subsequent increase in volumes
Implement & ensure compliance to Die & Tool Maintenance Systems as given in our guidance manuals
30
Plant Maintenance Improvement Activity
CONCERN AREAS IMPLEMENTATION APPROACH

- Relying on Breakdown Maintenance Implementation of Model Machine
- Poor Basic condition of machine concept through CLIT activity
- Poor workmanship (Cleaning, Lubrication, Inspection and
- Lack in Spare part planning Tightening
MODEL MACHINE ACTIVITY FLOW :
Model Machine On job Pre-assessment & Correction & Post- assessment &
selection Training abnormality capturing improvement Re-validation
31
Importance of Compliance to Regulation
Dispatch Suspension
Financial loss & Heavy Penalties

Impact of Non
Compliance
Legal Issue / Recalls
Loss of Sales, Brand Image
Compliance to Regulation is not a Choice 32

Homologatory Requirements
PP Stage MPP Stage Pilot / SOP Stage After SOP
Suppliers
Part Level Type Approval/Homologation
OEM
Suppliers + OEM
Vehicle Level Type Approval / Homologation
Conformity of Production Cycle Starts
Examples of Homologation parts:

Windscreen Tyres Safety Belts IRVM Headlamp Fuel Tanks Brake Assembly
33
Suppliers need to ensure the Valid COP is established through Testing Agency before expiry
Key Learnings in Regulation compliance
Create awareness of Regulations in your organization
Dedicated team for Periodic Verification of R-Marking
Approval from authorized agency for Manufacturing location change
Ensure Regulatory marking in Child Part Drawing, MISP & on Parts
Timely renewal of Type approval certificate from authorized agency
34
TRACEABILITY
MSIL VEHICLES HOLD UP DATA INDICATES NEED OF STRONG TRACEABILITY
• Even one critical

process/ child part
can result in
incomplete linkage
• Ensure TISP to
include Traceability
for Process / Critical
Child parts
35
Frontend Traceability Method
MSIL Policy for Front end Traceability to be implemented from YNC Onwards
Method 1: Method 2:
100% Frontend Traceability Batch Level Traceability
Scanning Part before Scanning trolley/bin at

fitment in Vehicle receipt or at line feeding
36
Safety Defect (Maru A) Concerns
Some Reduction
observed Recommendations After thorough Analysis
• Process fool proofing to avoid human error
• Special drive for Contamination controls
• PFMEA review to address potential failures
• EOLs test cycle review / Vehicle level
replication
FY 19~20 FY20~21
• CCTV installations to capture
• Some Reduction observed
abnormalities
• But Nos. Still Very High
37
Un-Approved Changes
4M
Man
Machine
Material
Method
18~19 19~20 20~21

Projected
Unapproved changes- A Major concern area

Changes should be transparently communicated and validated 38
Vehicle Dispatch Hold – Parts Defect
Hold up results in repair and inspection at MSIL in difficult situation
 High Man-hours
lost in clearing
holdup
Checking using endoscope (underbody and engine room)
 Hold up results in
tedious repair at
MSIL
Brake check by Multiple time pedal Repair inside cabin
Request to Focus on Defects leading to Vehicle Hold 39

Horizontal Deployment of Learnings
Defect Reported - MSIL
Implement Actions at All Plants
Line 1 Line 2 Line 3

Ensure Parallel Actions at All Lines of Same Plant Ensure Actions Across All Plants
 Maru A , Regulatory , Functional Defect- Ensure HD across your Lines and Plant
 MSIL to announce a structured IT mechanism for this soon 40
Adherence of MISP Parameters
Inspection MISP
Std.
Gaps Identified in MIS-P
MSIL Management
Communication Review Process
Periodic Review
Request to Align Internal Standards & Periodically Review the same 41

Focus on Trolley / Bin Maintenance
Line Rejection Analysis at MSIL
1. Packaging
Approval
5. Supply as per 2. Packaging

Major Line approved OK Maintenance
Packaging Plan
Rejections Qty is
due to Transit
Damages
4. Maintenance 3. Packaging
as per Plan Check sheet
Ensure Periodic Maintenance of Trolleys / Bins and maintain in Good condition 42

Request to Vendor Partners
Steps for Ensuring Sustenance – 3C
Involve Operators in defining

Collaborate Rules easy to implement
Communicate Communicate Frequently

≥80 70~80 60~70
Importance of
Strong Internal Audit management
Check & Improve with qualified auditors Strong Systems
43
Vendor System Audit in the new Normal
Pre-Covid
Audit Audit at
VSA report
Schedule and Vendor
released
Intimation Location
The NEW VSA Process
Online Audit
Shop Floor
Audit • Online Provisional Final VSA
Audit at
Schedule and applications VSA report report
Vendor
Intimation like WebEx/ released Released
MS Teams etc Location
44
Revalidation : Sustaining Part & Process Quality
2019~20 2020~21
• Selected Parts Revalidation • Regulatory marking verification
MSIL • Process Verification • Regulatory process audit
• Revalidation System Audit
Vendor • Part Revalidation (As per Drawing) • Report submission on MSIL Portal
Partners • Report Submission by mail
Strengthen Revalidation System at Tier2
Become Self Sufficient in Revalidation in 2 Years…. 45
Let’s Summarize – Request to vendors
Implement 10 cycle check to improve adherence of process.
Ensure each Operator goes through DOJO Training before deployment
Timely Preventive Maintenance of Tools, Dies and Plant
Ensure adherence & awareness to Regulations
Prepare TISP and ensure adherence to improve Traceability
Ensure all MISP Parameters covered in Vendor Inspection Standards
Become Self Sufficient in Revalidation & Sustain robust Quality systems

46
“Moving towards
Zero Defect”
Sanjay Thakar
Senior Vice President
Quality Assurance
Maruti Suzuki India Ltd. 47
Recap - Zero Defect Approach
Zero Defect Structure

 Process Strengthening  Organization Structure  Material handling  Maintain as New
• PFMEA Review • Adequate, Empowered Quality • Review of material flow and mix up • Implementation of PM
• Change point / CTQ control • Role Clarity : DWM • Handling method of sensitive child guidelines
parts
 Poka Yoke control  Manpower Planning  Tool Health monitoring
• Timely recruitment  Traceability & FIFO • Timely corrective action
 Strong Outflow Control • Manpower Mapping : Skill Matrix
• Manpower continuity on Critical  Capable Equipment for Zero
 System & Process stations  Receipt inspection & pass thru Defect
Adherence improvement characteristics of Tier 2 parts • Evaluation of machines tool jigs
 Trained Manpower at Tier 1 being used on line
 Process Audit/Review of • Dojo Centre • Machine capability study
Action on Past defect • Multi-skilling  Tier2 up gradation activity by
• Training on New Technology Tier1
METHOD MAN MATERIAL MACHINE

Robust Quality Systems
Robust Product Development
People Motivation & Involvement
Top Management - Zero Defect Commitment

48
Key Concern Areas
Inadequate PFMEA Non Adherence to Inadequate Material Weak Tier II Controls Inadequate
shop floor rules Handling Maintenance
49
B. Non Adherence to Rules - Gaps & Recommendations
Setup Part Handling Inadequate
Recommendations
What Went wrong?
Set-up Part Handling rule not followed Frequent Awareness on Set up Part handling rule
Check on Check System to be strengthened
Ensure Set-up Part Handling Rule Awareness & Adherence by Operators
50
B. Non Adherence to Rules - Gaps & Recommendations
Non-adherence to 4M Change Management
Defect : Fitment
problem due to Hole
Blockage
Hole blockage in Plastic part Extra Material on Lock
What Went wrong? Recommendations

Retroactive inspection not done after M/c Break down
(Change not validated) Validation of 4M change to be ensured as per 4M change
matrix
4M change rule not adhered
Ensure strict adherence to 4M change rules

51
C.Material Handling - Gaps & Recommendations
Child part mix-up during Changeover
Non-coated
child part used
Defect : Part Fitment NG in place of
coated
1 Hole missing Coated Child Part : 3 Holes Non-Coated part : 2 Holes
observed
Coated-Non-Coated Mix-up

Line Drainage System not followed during variant
change Check on Check System to be ensured during line change over
52
C.Material Handling - Gaps & Recommendations
Material storage condition inadequate
Defect : Crack observed in

Rubber Part
Joint Crack due to

contamination Parts Kept in open condition

Packing Std. for WIP parts to be made & approved
Packing Standard for WIP parts not available internally
53
Self Sustenance – Zero Defect Line
• Inadequate Top Management Review
Non sustenance of Zero defect lines
Gaps • Non adherence to Quality Systems
deteriorated over a period after SOP
Recommendations
• Make Sustenance check-sheet for monitoring the Zero defect line periodically
• Analyze defects from Zero defect lines & take countermeasures
Way Forward
Top Management Horizontal Tier II Upgradation People
Detailed PFMEA
Review Deployment
ZD
Line
54
“Training & Skill Development” - DOJO Training Center
55
DOJO Journey & Concerns
Concern Areas
• Non Utilization
• Inadequate Training Facility
• Non Adherence to Training System
Areas of Improvement
• Management Review
• Trainer
• Training Duration
• Production Rule & Process Dojo
Available on MSIL extranet
All Vendors are requested to implement DOJO centers at their Plants by Mar’2021
“No manpower should be deployed on shop floor without DOJO training”

56
Mini Dojo for Tier-2’s
Concept: Less space and limited budget Mini Dojo Layout Glimpses of Mini Dojo
Approx. Area Required 15 m2
Investment (Approx.) Rs.50,000/-
8 Steps:
Mini Dojo Methodology - 03 Steps on LED Display
- 05 Steps practical
Guidance
Manual
57
Operator Observance System through 10 Cycle
Guidelines for Operator Observance - Handbook
This system checks & Background and Need for

Operator Observance
Improve
Operator Observance for 10
- Availability & Adequacy Cycles Methodology
- Awareness
Planning, Role and
- Adherence of work Responsibility
Instruction
Analysis, actions &
Effectiveness Monitoring
58
Abnormality Handling : List Of Abnormalities
S.No. Abnormalities covered under Module
1 Fallen Part
2 Handling of NG part in inspection
3 Set up NG Part Handling
4 Unidentified Part
5 Part Handling at Inspection Table
6 Power Failure Part
7 Incomplete Processed Part
8 Incomplete Inspection
9 Handling of FG Part
10 Handling Of Child Part
11 Similar Looking / Child part Mix
12 Traceability Abnormality
13 Handling of Similar Looking Parts
14 Handling of Trial / Pre ECN Part
15 Model / Variant Changeover Control
16 Handling of Rework Part
17 Abnormal Situation Handling- STOP-CALL-WAIT Rule
59
Global Environment Regulations :
Restrictions on Substance of Concern (SOC)
Amit Sharma
General Manager
Quality Assurance – Material Analysis
60
Presentation Contents
 SOC based Regulations & Related Health Effects
 Supplier SOC Adherence & Sustenance
 SOC Monitoring & Control
 Labelling & Packaging of Hazardous Chemicals
61
SOC based Environment Regulations
Substances of Concern pose potential risk to Humans & Environment
End-of-Life Vehicle Classification, Asbestos POPs & Phthalates

Directive Labelling & Packaging Restriction Restriction
Restriction of Heavy metals (Europe) (Japan) (Global)
2009
2002 2009 2012 2018 onwards
2008 2011 2012 2018 

Restriction of POPs and
First MSIL model ELV Labelling of applicable Asbestos Verification
other SOCs (22 substances)
compliant Export parts Activity
Restriction of Phthalates
(4 substances)
India to adopt similar substance registration, authorization, restriction & labelling rules (2021 expected)
62
SOC – Substances of Concern
Types, Applications & Effects in Automotive
Types of SOC’s SOC suspected parts Health Effects of SOCs
Heavy metals: Pb,Cd,Hg,Cr6+ Passivation on Zinc Mercury

(Plating, Coatings, Plastic Parts)
Coatings (MFZn etc) Brain & Liver Lead
damage Brain & Nerve
damage
Asbestos
Clutch Disc
(Brake pad)
Chromium6+ Cadmium
Eye Injury Asbestos
Phthalates DNA damage Lung cancer
PVC Coated Parts
(Plasticizers in PVC) Kidney failure
POPs Grease
(Grease, Coatings, adhesives)
VOCs Phthalates & POPs

Eye Irritation Hormonal Disorders
Volatile Organic Compounds Interior Plastic Parts Skin cancer
(Interior Parts of vehicle)
63
Supplier SOC Adherence & Sustenance
MSIL has established Green Procurement Guidelines with all its suppliers
Compliance with Environmental Regulations
IMDS Data Input for all models
Compliance to Standards
Restriction of Prohibited Substances
Control of Tier-down suppliers
Supplier must strictly comply with Green Procurement Guidelines

64
Supplier SOC Evaluation
MSIL SOC Audit
A-Rank
OK
All Suppliers B-Rank Take

Self Audit MSIL Audit
Countermeasures
C-Rank
No further business
Key Improvement Areas
Green Procurement Supplier Awareness Control Procedures

Strengthen awareness on latest
Establish Green Procurement Establish SOC Compliance Procedures
regulations through Standards and
Contracts with Tier-down suppliers in Quality Systems
GADSL List
Suppliers must identify gaps and take countermeasures to sustain SOC Compliance 65
SOC Monitoring: IMDS & Declarations / Reports Submission
International Material Data System:
SOCs Verification (Asbestos, POPs etc.)
Tool to collect, validate, manage supplier substance level data for SOC and RRR
• Activity Timeline : ~ 6 – 8 Weeks*

IMDS Request to Vendors IMDS SUBMISSION WITHIN 90 DAYS*
Including sub suppliers

• Through Declaration & Test Reports
Concern: IMDS submission is not being done within 90 days Concern: Delay in submission of documents
Reasons for Delay Impacts

 High IMDS Rejection  Increase in lead time during product development
 Attrition of IMDS trained members at vendors  It may affect compliance to environment regulations
 System for IMDS control not adequate
*These deadlines may be reduced based on model development requirements, request your timely support
Develop system to ensure timely and correct SOC related submission 66

GHS Label With Hazardous Products
GHS is Globally Harmonized System of Classification & Labelling of Chemicals
GHS Regulation Applicability : Suppliers submitting spare parts to MSIL for EU, Japan & Australia Exports
GHS Applicable Products Actions to be taken by Vendors

Applicable Products EU Japan Others*
Desiccant o 1. Provide SDS for GHS products (e.g. grease)
Volatile Corossion Inhibitor o
Oil, Paint, Grease, Adhesive, etc. o o o
Tire Repair Kit o o 2. Provide GHS Label when product is given as a
Airbag Inflator & Pretensioner o separate item with spare part (e.g. grease packet)
Wind Washer Fluid (Spare Part) o o o
* Exact information may differ country-to-country. This is a generalised form.
1 2
MSIL Standard Formats

1. MSIL Standard GHS Label
2. Ensure proper leak-proof packaging
Strengthen your dispatch systems to ensure compliance at all times.

67
68
This is strictly for reference only & not for circulation
© 2020 Maruti Suzuki India Limited
69

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Synopsis

This is strictly for reference only & not for circulation

• New Model Parts Development 13-26

• Mass Production Quality Status & Way Forward 27-46

• Global Environment Regulations : Restrictions on

 Resume Normal Operations:

Apr’20 May’20 Jun’20 Jul’20 Aug’20 Sep’20 Oct’20 Nov’20 Dec’20

Extensive virtual engagement and 3G audit- Vendor Plant & Warehouse 5

Sudden Increase In FY'20 ~21 (Post Lockdown)

Q4 FY19-20 Q1 FY20-21 H1 FY20-21 Q3 FY20-21

 Majority Vendors utilized Dojo Training

Ensure Training Of Manpower Before Shop floor Deployment 7

Objective : Evaluation of System adherence at Gemba for Operators & Inspectors

Dedicated Team to Conduct this ‘10 Cycle Check’

Key Concerns in New Model parts Other Challenges - New

• Inadequate PFMEA: Capturing All Advanced Technologies:

“Lead” “Hex chromium” “Asbestos”

SOC causes health hazards

To Safeguard Humans & Environment:

Strengthen System to ensure Create Awareness at Sub

Ensure SOC Compliance & Monitoring for MSIL Parts 10

Other Quality Concern :

Resume Normal Operations & Drive Improvement Activities

Manpower Skill in New Normal & Adherence to Rules

Focus on Preventive Maintenance of Tools,Dies&Equipments

Increase Tier-2 Engagement, Audit & Guidance

Compliance to Regulations, SOC & Traceability requirements

Development Team to work towards YNC ZD Lines

Ensure Quality System Sustenance to achieve “Zero Defect” 12

Defects in Common Parts

Handling & part Mix-up

Defects from Tier 2

Single defect cased also to be Reduced. Need to achieve Zero Defect.

Past Defect Failure mode Actions for defect Standardization of

① Inspect Parts as per drawing ④ Capacity & Quality

Complete Evaluation of Common parts of YNC by End Dec’20

① Train manpower for Abnormality Handling Procedure

② Identify trial parts with Tag at separate location

③ Ensure Physical Disposal against scrap note

IFM by few vendors at Critical Tier-2 in Y1K

Request : Extend PPVT and IFM to all your Tier-2 Vendors.

1 Root Cause Analysis – Trial Problems

2 Learning implementation - SOR

3 Planning for New Technology Parts

Mass Defect at Trial Stage

Repeat Issue at SOP

Record all defects during Trial

Countermeasures must be verified and approved by Plant Head

Concern Best practices are not horizontally deployed.

Plan the process as per SOR from next Model

Process Involve Collaborator for PFMEA

Fix Operators and Train for New Tech Processes

Need to Advance Development Activities 24

YNC is the 1st Model under development in this Challenging situation

 Delay in Facility Setup  Actual Tool Trials & Evaluate Parts

Extend PPVT & IFM to Tier-2 Vendors

Thoroughly Evaluate Common Parts

Strengthen PFMEA – Must Include all Past Defects

Let’s work to Deeper Root Cause Analysis of Trial Stage Problems

Advance Development activities for New Technology Parts

Sushant Bose Kanchan Kishor Srivastava

Major gaps observed

1.System non Adherence

3.Tools & Die maintenance