HOT WHEELS

MANAGEMENT MISSION
The purpose of this document is to ensure that all members of the Group
are aware and understand our governing Management Procedures and
their application in the work place.
We have a mission to design, develop and provide services and products
for a broad range of customers which includes other business units of
HOT WHEELS. We want these services and products to be consistently
of high quality, and we expect them to meet the full needs and
expectations of our customers.
To meet our mission, we must all ensure that documentation, material,
product and services delivered to satisfy our clients are in accordance with
our mission and the supporting management policies.

Application of Management Policy

Our Management Policies are the basis for the Quality Management
System (QMS). This QMS is described in our Management Policy
Manual, and is supported by Standard Procedures (SPs), Work
Instructions (WIs) and other instructions and directions. Collectively,
these procedural instructions are given to enable all of us to plan, perform,
verify and improve our daily work.
Please ensure that you understand your responsibility for the quality of the
work that you must carry out safely without any adverse effect on the
environment, and how this is recorded and demonstrated to the
satisfaction of our customers.

Quality Manager
Technology Group
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OPERATING CENTRES:
Headquarters and Projects
HOT WHEELS (*)

Projects\Operations\Programmes

Test & Calibration Centres

Overseas
HOT WHEELS (Deutschland)
GmbH

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TECHNOLOGY GROUP

QUALITY POLICY
HOT WHEELS’s mission is to design, develop and provide
services and products for our customers, including other business
units of HOT WHEELS. Services and products of consistent
high quality are provided to meet the expectations and needs of
our customers. These services and products will be provided
safely without any undesirable impact on the environment.

In the promotion of HOT WHEELS’s mission, our people use a

Quality Management System that complies with International
Standard AS/NZS ISO 9001:1994. Use of this system provides a
supportive Total Quality Management environment that enable
our people to better serve their customers.

By using documented procedures and willingly taking part in our

continuous improvement efforts, our people are responsible
collectively for the quality of our products and services. In
support, managers exercise the authority delegated to them to
resolve quality issues affecting their operations.

HOT WHEELS places great emphasis on developing and

upholding good customer relations. Our people are
empowered to ensure customer expectations of the products
and services provided are consistent with our mission and
the supporting Quality Management System.
Group General Manager
29 February 1996

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QUALITY MANAGEMENT SYSTEM DOCUMENTATION

RELATED POLICY, PROCEDURE MANUALS AND PLANS
Note: These are separate documents
AT.01 Technology Group Management Policy Manual
NN HOT WHEELS Administration and Authorities Manual
QMA 17.01 The Quality Management Audit

STANDARD PROCEDURES
01. 01 Management Review...................................................................................................4
02 Organisation for Managing Quality ...........................................................................2
03 Delegation of Authority...............................................................................................6
02.. 01 Quality Management System......................................................................................6
03. 01 Contract Review..........................................................................................................6
02 Tendering.....................................................................................................................12
04. 01 Service Design Control................................................................................................8
05. 01 Control and Issue of Documents.................................................................................12
02 Preparation & Improvement of SPs and WIs..............................................................13
03 Control of Forms..........................................................................................................4
06. 01 Control of Purchases....................................................................................................5
02 Control of Subcontractors and Suppliers.....................................................................6
07. 01 Control of Customer Furnished Material and Equipment..........................................2
08. 01 Control of Correspondence and Files..........................................................................5
09. 01 Process Work Flow Diagram ......................................................................................3
10. 01 Final Audits-Deliverables............................................................................................4
11. 01 Calibration of Measuring and Test Equipment...........................................................3
12. 01 Status Identification.....................................................................................................5
13. 01 Control of Nonconforming Products...........................................................................6
14. 01 Corrective and Preventive Action...............................................................................8
15. 01 Handling, Storage, Packaging, Preservation and Delivery.........................................5
16. 01 Control/Retention of Quality Records.........................................................................4
17. 01 Internal Quality Audits................................................................................................8
18. 01 Training........................................................................................................................9
01 Induction Training.......................................................................................................8
19. 01 Customer Surveys........................................................................................................7
20. 01 Statistical Quality Management..................................................................................3

FORMS REGISTER

Form No. Title

CL A001 Payroll Checklist.
CL A002 Counselling and Disciplinary Process Check List
CL A003 Employee Induction Checklist
CL A004 Employee Separation Checklist
F A001 Employee Application Form
F A002 EEO
F A003 Telephone. Reference Check Form
F A004 Bank Account Details
F A005 Increment/Probation Report
F A006 Application for Overtime
F A007 Application for Emergency Leave
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Form No. Title

F A008 Employee Change of Details
F A009 Payroll Adjustment
F A010 RDO Substitution
F A011 Employee Pay Query
F A012 Cessation of Employment
F A013 Application for Leave
F A014 Network Access Authorisation
F N0001A Attendance Record
F N0001B Attendance Record
F N0002 Travel Authorisation
F N0003A Expense Reimbursement
F N0003B Expense Reimbursement
F N0004 Chain of Custody
F N0005A Mastercard Authorisation & Coding Summary
F N0005B Mastercard Authorisation & Coding Summary
F N0006 Employee Commencement Details
F N0007 Application For Leave
F N0008 Invoice Header Sheet
F N0009 Record of Counselling/Disciplinary Interview
F N0010 Record of Counselling/Disciplinary Review
F N0014 Cheque Requisition/Cash Advance
F N0015 Petty Cash Summary
F N0016 Petty Cash Voucher
F N0017 Job Costing Structure
F N0018 Job Closure Form
F N0019 Faulty Computer Report
F-N0020 Record of Conversation
F S0301 Tender/Contract Review for Major Projects
F S0401 Service Design Review or Validation
F S0501A Document Improvement Proposal (DIP)
F S0501B Document Change Notice - (DCN) Issue & Amendment
F S0801 Correspondence Registration Form
F S1201A Stamp Issue Register
F S1201B Authorisation Signatures
F S1401 Corrective/Preventive Action Request
f s1501 Safety Manual Handling Checklist
F S1701 Internal Audit Report Form
F S1801A Record of Training
F S1801C Application For Training
F S1801D Training Attendance List
F S1801E Evaluation of Training
F S1802A Employee Induction Checklist
F S1802B Safety Induction Checklist
CL S1901A Customer Survey Checklist
CL S1901B Performance Checklist

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1. MANAGEMENT RESPONSIBILITY - SP 01.01, SP 01.02, SP 01.03

Management responsibility calls for:

(a) A quality policy statement from the Top Executive.

(b) An organisation structure to manage and verify quality.

. (c) At regular intervals, those with an interest in the quality system should have a
formal review of the adequacy of the system.

Objective evidence is:

· The Quality Policy Statement.

· The appointment of a “Management Representative” (Quality Manager).
· Job descriptions.
· That personnel have been assigned to cross-check, verification, or inspection
duties. These people may have many other responsibilities as well.
· That management review is formal and recorded and covers both past activities
and future requirements.

2. QUALITY MANAGEMENT SYSTEM - SP 02.01

The intent of the quality management system is to ensure the needs and expectations
of the customer are satisfied. This is effectively achieved by developing and
implementing a company wide documented system for management.

Actions required to satisfy the intent are:

 Maintain a documented quality system.

 Prepare Quality Plans in accordance with specified requirements.
 Ensure effective implementation of the above documented system.

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3. CONTRACT REVIEW - SP 03.01, SP 03.02

The spirit of intent behind Contract Review is that before we:

(a) submit a tender or quotation, or,

(b) accept a contract or order,

we assess the tender or contract requirements so we know we can supply

our customer's needs and expectations (requirements) in full, on time.

Objective evidence is:

· Procedures and plans that show how review is achieved. SP 03.01 and SP 03.02
 Documented communications with the customer showing that the customer's
requirements are adequately understood. (Bid File(s))
· Completed checklists showing that the supply of requirements has been assessed
and has the appropriate authority. (Form FS0301)
· Documents in the form of minutes of meetings, order placement forms, registers
of tenders & quotations submitted and of contracts received that show signatures
of authorised personnel and/or dates as appropriate.
· Documents which show that the contract or order received has been compared
with any quotations supplied and which also show that differences noted have
been documented and action taken to resolve them.

4. DESIGN CONTROL - SP 04.01

A suitable Design Control system ensures that planning, design, review, verification and
validation activities for each design are focused to satisfy the customer and organisational
requirements. Actions needed to satisfy this intent are:
 Maintain procedures for the control, verification and validation of the design.
 Plan and identify the responsibility for each design activity. Update the plan as the design
evolves.
 Assign qualified personnel, adequately resourced, to design verification activities.
 Identify technical and support interfaces.
 Identify, review and document the design process.
 Express the design in terms of requirements with analysis.
 Assign competent personnel to document the verification that the design meets the design
input.
 Maintain procedures for the review and approval of design changes and modifications.

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Objective evidence is:

 Design procedures and plans that show for the design the input, output, review,
verification and validation processes. (SP 04.01 and FS 0401)
 Documents that show assumptions made during design development, review,
approval of changes and modifications. (Design File(s))

5. DOCUMENT CONTROL - SP 05.01, SP 05.02, SP 05.03

A suitable Document Control system ensures that documents that are critical to final
product (service) quality are:

(a) Reviewed and approved by appropriate personnel.

(b) Distributed so their ongoing whereabouts are known.

It also ensures that modifications to these documents are also reviewed and approved
and superseded documents are withdrawn or appropriately marked for purpose.

Objective evidence is:

· Documents requiring control have been stipulated

eg quality manual, procedures, work instructions and associated forms, audit

reports, training records, inspection and test records, nonconformances,
purchasing data, delivery paperwork, customer's purchase orders, drawings,
formulae, specifications, inspection and test criteria etc.

· That the distribution of quality system documentation is strictly controlled.

Distribution lists and Document Registers at the nominated distribution points.

· That there are no obsolete copies of controlled documentation (including forms) in

circulation.

· That there are no unauthorised copies of procedures and work instructions in use.
A common habit is to photocopy a page and stick it on a wall. These documents
are not in control. The method of approval or authorisation is stipulated in SP
05.01.

· That no unauthorised changes to documents have been performed.

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6. PURCHASING - SP 06.01, SP 06.02, JAS-ANZ/Approved Supplier Registers

By controlling our purchasing (or buying from suppliers- sometimes known as a

Vendor) we know that our purchase order clearly describes what we want and that we
have placed the order on a supplier who we have evaluated and approved as
somebody from who we wish to buy.

Objective evidence is:

· That an approved suppliers register is maintained. Approval of a supplier is by:
(a) Inspection of goods on receipt
(b) Acceptable past performance
(c) An audit by us on our supplier
(d) An audit by someone else on our supplier
· That a method of approval for each supplier has been nominated and that the
approval status of each supplier has been reviewed at the nominated intervals.
· Purchase orders for supplies that put risk to or form part of a “deliverable” are
only placed on approved suppliers.
· Purchase orders contain sufficiently clear and unambiguous information to ensure
that the supplier delivers exactly what was required.
· That information on the purchase order contains quantity, type, style, grade,
colour, part no., or other precise identification. (Purchase Orders)
· The specification of applicable drawing numbers, testing requirements,
specifications, approval requirements, quality and approved supplier requirements,
etc are entered on purchase orders.
· That Purchase Orders are approved by authorised personnel before their release.

7. PURCHASER SUPPLIED PRODUCT - SP 07.01

If a customer gives us documented data, a part, raw material, or sub assembly which
he/she wants incorporated into his/her final product, we must have systems to ensure
our customer's property is not damaged or lost (this is extended to include customer
furnished information or data (intellectual property).

Objective evidence is:

· That the procedure (SP 07.01) identifying the customer property (including
information) is applied.
· That there are records of inspection of customer supplied product on receipt to
establish that the article has been received in good condition at our premises.
· Where applicable, written correspondence that the customer has been notified of
damaged or lost articles. Project/Product Files/Asset Register

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8. PRODUCT IDENTIFICATION AND TRACEABILITY - SP 08.01

This service component is satisfied by identifying and tracking incoming and outgoing
data. eg. As applicable, the registration and filing of incoming and outgoing
correspondence (includes facsimiles).

Objective Evidence is:

· Evidence of compliance to SP 08.01. (Correspondence and File Registers)
· Determine what traceability requirements are specified (either customer, statutory,
or internal) of incoming and outgoing correspondence, facsimiles and files.
(Files)

9. PROCESS CONTROL - SP 09.01

The intent behind Process Control is that we should supply enough information and
supervision to our employees, not only to deliver a service (or manufacture a product)
correctly, but to ensure they know they have done it correctly and that this is
recorded.

Objective evidence is:

· Adequate information in the form of standard procedures, work instructions,

drawings, manufacturer's instructions and manuals, standards and statutory
regulations etc., has been provided to those performing the work. (This
information should give instruction on the use of resources, skills, forms, and
information on acceptance criteria).

· Some processes cannot be adequately or economically inspected by us or the

customer. These are called special processes. Special processes require a tighter
level of control. Evidence is:

- Work Instructions exist for the special processes and appropriate records
are maintained.
- Personnel are trained and prequalified (if necessary).
- Inspection, measuring, and test equipment used in-process is calibrated.
- Service delivery notices and their validation.

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10. INSPECTION AND TESTING - SP 10.01

We must have confidence that:

(a) the materials we receive from our suppliers are as ordered and conform to any
specification supplied.

(b) appropriate inspection and testing takes place for in-process and through the
service delivery cycle.

(c) the service or product is right before it gets to the customer.

Inspection and Testing is divided into three parts - Receiving, In-Process and Final.

Objective is:

· Records to indicate that goods received from suppliers have been inspected on
receipt to ensure that they are as ordered or are as per supplied specification.
ie. Signed delivery docket.

· That In-process inspection requirements comprising inspection points, procedures,

standards of workmanship and test and inspection equipment, and some form of
documentation of the results have been specified and are maintained or exist.
Records of satisfactory completion of in-process inspection

· Release or authorisation of the final product (includes a Service being delivered)

should be by authorised personnel who have the authority to do so. ie. SP 10.01,
job description, or some kind of "authority to sign" register.

11. INSPECTION MEASURING AND TEST EQUIPMENT - SP 11.01

We need to have confidence that the equipments used to measure and test has the
capability of measuring and testing what they are supposed to, and that they are
accurate enough for the purpose.

Equipment which does not conform must be isolated from use and calibrated before
being used again.

We must assure ourselves that the standards we use to calibrate the equipment are in
fact standards.

Objective evidence is:

· Control of inspection, measuring and test equipment documentation.
· Evidence of calibration. Applicable calibration intervals should be documented
on the equipment record card and calibration schedule.
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· Procedures developed for calibration of the equipment. These procedures

should be controlled documents.
· Records that show the calibration carried out, ie. the actual results obtained.
· The measuring and test equipment records need to be traceable to the equipment.
This may be in the form of in-house equipment identification numbers or
“manufacturers'' serial numbers.
Note: Measuring and test equipment includes test hardware, jigs, fixtures, templates,
go/no go gauges etc and test software.

12. INSPECTION AND TEST STATUS - SP 12.01, FS 1201

The ongoing status of inspection/testing/verification of a product/service should be

identified in some way.

Objective evidence is:

· Work procedures nominate the method of indicating the inspection, test or verification
status through physical marking of the product eg tags, label, marking, physical
segregation, or stamps etc..

· That personnel responsible for final releases of satisfactory product (including service) are
identified in either job descriptions, authority to sign registers, or in the
procedures/work instructions.

13. CONTROL OF NONCONFORMING PRODUCT - SP 13.01

We need to segregate faulty product so it cannot be used in other products, sold, or

delivered to the customer.

We also need to document a problem so we have a history and can fix the recurring
ones.

Possible objective evidence is:

· That the problem has been documented and that the system cause is being determined
(CAR). ie. Evidence that corrective action has been taken to fix the problem.

· That the person with the delegated authority to decide how to dispose of the faulty
product has taken appropriate action as defined in SP 13.01.

· That where contractually required, problem resolution has been discussed with the
customer. (Applicable Records)

14. CORRECTIVE AND PREVENTIVE ACTION - SP 14.01, FS 1401

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As problems are uncovered or foreseen, either in the product or system, some action
has to be taken to prevent the problem from happening again or occurring at all.

Problems in the product or system will be uncovered by a number of methods. For example,
faulty product/service problems, warranty returns, customer complaints, results of internal
and external audits, analysis of work processes and operations, and other forms of quality
records.

Problems may be one-offs or recurring. Only you can determine if the problem was serious
enough to warrant action to stop it happening again. There is a balance between cost of
taking corrective action and cost of producing and delivering a faulty product or service.

Objective evidence that corrective action has been taken is:

· That once the real cause (root cause) has been found, corrective or preventive action
to prevent a recurrence of the problem has been determined and documented. (FS
1401)

· That the person responsible for quality has followed up to determine that the action
taken was satisfactory, was effective, and taken in a timely manner. (FS 1401)

 That an action register is established to record the corrective or preventive action, and
that it has been completed properly. CAR Register (ARIS)

15. HANDLING, STORAGE, PACKAGING, PRESERVATION AND DELIVERY

SP 15.01

We need to have systems, procedures, areas and equipment suitable to ensure that
raw materials, work in progress and finished goods are handled, stored, packaged,
preserved and delivered in such a manner to prevent damage and deterioration.

Delivery systems should include "on-time" requirements.

Objective evidence is:

· That in accordance with SP 15.01, staff ensure that damage and deterioration are
minimised and that safety is maximised. (PQP, QPs etc)

· That Quality Plans take into account possible damage, deterioration, safety and
statutory requirements (eg flammable liquids storage requirements).

· That safe and secure storage areas, stock rooms, or storage areas are established.

· That where necessary, appropriate paperwork accompanies movement to and from

the storage areas.

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· That the condition of stock in storage has been assessed at appropriate intervals.

· That Packaging and Preservation procedures take into account identification

requirements, damage (both storage and transport), deterioration, environmental
factors, safety and statutory requirements.

· That “Product and Service Delivery” is designed to deliver the product on time
and ensure that quality has not deteriorated (been preserved) since the final
inspection, test or verification. Validate that actual delivery times are as per
customer requirements as given at the time of taking the order.

16. QUALITY RECORDS - SP 16.01

Throughout the quality system, records are generated to show that quality conforms
to planned requirements.

What records have to be kept, where to keep them, how long to keep them for, and
who is responsible for disposal.

Objective evidence is:

· That retention times for all records are established on a record-by-record basis.
That the retention times nominate which record should be retained for how long
and who is responsible for its disposal. That where necessary, the method of
archiving or disposal has been specified.
· Determine whether specific contract requirements exceed internal retention
requirements and that these requirements have been included in the retention times
nominated.

· That Quality records have been identified to the product or service involved.
Note: Loose unidentified pieces of paper do not fulfil this category.

17. INTERNAL (QUALITY) AUDITS - SP 17.01, FS 17.01, FS 1401

There is no use in having a system which is impractical or not followed.

The assurance in quality assurance comes from regular auditing of the procedures to
determine “practicality” and “compliance”.

Objective evidence is:

· Audits have been:

(a) Planned and scheduled. AUDIT SCHEDULE
(b) Carried out by trained personnel independent of the process or activity
being audited.

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· Areas of noncompliance have been determined and corrective action taken on

deficiencies found during the audit. FS 14.01
· The results of the audit have been documented in some form of report and shown
to the auditee and agreed to by the responsible manager. FS 1701
· The documented results of the audit are analysed for trends and subjected to
management review. MRM Minutes
.
18.01 TRAINING - SP 18.01, FS 1801A, FS 1801B, FS 1801C, FS 1801E, SP 18.02,
FS 1802A, FS 1802B

We need to provide confidence to ourselves and our customers that personnel doing
the job are:

(a) Capable of doing the job.

(b) Trained to do the job.

Objective evidence is:

· Records of education and training for all employees in personnel records.

· Training requirements are included in the training procedure. SP 18.01.

· That the level of education and experience of a potential employee is established

during the initial “Application for Employment”. This application should form
part of the training records. SP 18.02, FS 1802A, FS 1802B

19. SERVICING - SP 19.01

The intent of the Servicing element is to ensure that after delivery (post-contract)
support is supplied to assure the needs and expectations of the customer.

This includes use of trained personnel, providing post delivery support, provision of
applicable spares, provision or supply of documented instructions and appropriate
after sales service.

The actions and documentation that are needed to satisfy the intent are:

 Identify the scope of servicing to be provided ie. as contracted and / or as agreed.

 Identify and document the means of receiving or determining a request for
servicing.
 Define the servicing that includes the technical and backup support to be provided.
 Provide for support by suitably qualified and experienced personnel.

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 Maintain records of customer surveys, complaints and other post delivery

information and the means of recording any servicing work provided.

20. STATISTICAL TECHNIQUES - SP 20.01

Where statistics are used (ie the analysis of data from a small sample taken from a
batch) to enhance process control and/or decide final product quality, the way this is
to be done needs to be written down. ie. Decide if statistical techniques are applicable
or an acceptable option and select what methods are to be used.

Note: Statistical techniques can be applied to market analysis, design reviews, reliability
results etc. and other areas of application

Objective evidence is:

· That appropriate records of the statistical methods used (eg charts, test results) are
taken and that these are reviewed by authorised personnel and decisions are
recorded.

Training Hint! - To respond to an auditor

The initial answer to every question an auditor might ask about ISO 9001 is that:

“It is in the manual”.

Then respond by using the following steps.

1. Locate a copy of the Standard Procedures;

2. Look up the subject of the audit question asked in the applicable procedure
(use the index);
3. Locate the Applicabilities and Responsibilities and determine if or how it
applies to you;
4. Locate the Record listing at the end of the procedure and determine where the
record the auditor needs to see might be located;
5. Locate the Record, and
6. Show the applicable record to the auditor.

“Remember to listen carefully to the question being asked and having thought through
what record you can show (as seen at step 5) then only answer the question asked.”

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