MARUTI SUZUKI INDIA LIMITED

Issue Deptt. Prepared Verified Approved

　Vendor Qualitry System Audit Report Date of Issue
Copy to Supplier name
Audit Date
Supplier Attendant Name
Supplier code Audit Person
(Audit Score)
Achieved Score： 129
×１００ = 57
Total Score： 228
Total
Part Number：
Subject: Vendor System Audit
Part Name:
Observation:-

Total
Achieved
○ △ ×
1 3 / 24 3 3 2
1.Production
2 12 / 15 4 1 0 preparation
N/A
100 2.Regulation for initial
production control
3 6 / 18 3 2 1
80
4 6 / 18 2 4 0 13.Handling Management 3.Changing management
60
5 9 / 18 3 3 0
40
6 6 / 15 3 1 1 12.Products 4.Standards
management 20 management
7 18 / 21 6 1 0
0
8 15 / 21 5 2 0
11.Implementation
5.Education and training
of standards
9 15 / 18 5 1 0
10 12 / 15 4 1 0 10.Equipment/
6.Quality audit and process
Inspection
11 3 / 15 3 0 2 equipment's…
verification

12 12 / 18 4 2 0
9.5S management 7.Supplier control
13 12 / 12 4 0 0 8.Handling abnormality
in quality
14 N/A / N/A 0 0 0
Total
(MSI
129 / 228 49 21 6
Pre decided negative Improvement Submission
Last Audit Rating
marking (if any) Date

F003-3 QA/MT Ver. 5

 MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Vendor Attendees Date : 17 /18/19.03.14
Sigma
Supplier
Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd

Part Name Damper

Category Audit Area Concerning regulation Judgment Remarks Follow Up
１．　 Regarding Do you define in reguration following items for
1
Production implementation rule Timing chart for new development parts are from RFQ to SOP
① production preperation?-scope of parts,-responsibility of ○
preparation of production at customer end.
each department　-control contents/items?
preparation
Do you define importance level during production
② preparation for each product and clarify control items ×
based on it ?
Regarding
2
management Do you implement follow-up to control the schedule and Production Prepration meeting reviews are being done at
① ○
/implementation by progress of production preparation items? defined frequency. (FM/EDD/45)
production
preparation
plan/report(master Are production preparation plan and report controlled by
plan) ② a person in charge of progress(top management) △ The Meetinj reviews are being done by Department heads.
periodically?
Defect prevention on Do you consider following items and reflect them to the
3
the stage of prosses processes and stadards beforehand? Lesson learned are being transferred and taken care for new
design by using ① -Troubles in the past; -Defect items expected; △ projectes in initial RFQ Feasibility meetings.
FMEA/Matrix diagram -Defect items unable to capture at customer; Potential Defects are being captured in FMEA initial review.
-Defect items difficult to repair;

Do you review and improve FMEA or Matrix diagrams FMEA are being updated during any critical issue at customer
② ○
when any critical issue occurs after SOP? or Inhouse.

Product/process
4
evaluation at the Do you prevent defects by quality improving activities of Actions for Inhouse Quality issues are being taken to improve
① △
quality evaluation cross-function team to evaluate quality performance? the Product quality.
meeting in each trial

Do you define condition to start mass production and

② ×
then check on the product line prior to SOP?

２． Regulation for
1 Initial Production parts are identified by Special Stickers.
Regulation initial production Do you define following items related to initial production Quality team involve in development activities and problem
for control control by standards ? observed during development stage is shared with Quality
initial -controlled parts; -controlled items; -inspection method; team.
① ○
production -initial production control period; Responsible person defined for start / End of Initial
control -a person who annonce start/end of initial production production.
control; -finish condition; Guidelines for verification of material at early production stage
is also there, verified WI/QAD/223

Items are defined which required special controls during initial

How do you define items required special control during production controls.
Special Identification stickers are being put on initial
② initial production control? Do you set stricter inspection ○
controlled items.
methods than the ordinal inspection? Verified WI/QAD/223, Guidelines for verification of material at
early production stage

Do you share the information of initial production control Information are being shared among the team for actions /
③ ○
among the related department? Improvement. Also Shared with T-II Supplier.

2
Implementation of Do you pick up issues and improve them during initial Issues during initial are being take up with the team for
① △
initial production production control? impovement.
control
Do you control process capability and defect rate during Defect rate for initial production control parts are being
② ○ monitired.
initial production control?

３． Definition and
1 Do you define unexpected change (unusual) and planned Yes, changes are defined and are being processed through
Changing implementation of
① ○ ECN. (PR/EDD/06, Rev E, ECN Doc no. - FM/EDD/24). 4 M
managemen changing change clearly? change management being followed.
t management
Do you define procedure(rules applied from sharing
② information to result confirmation) at change △ 4 M change procedure WI/QAD/221 defined and are being monitored.
occurrence?

Do you record product quality check results to ensure

③ ○ Records are being maintained with Retention peroid.
traceability?

Do you retroactively check about product quality when Before and after results are being monitored and recorded with
④ ○
unexpected change occurs? ECN. (EC/2013/0023)

Definition and control

2
method for initial part ① Do you define initial part clearly? × To be define

F0003-1 QA/MT Ver. 5

３．
Changing
managemen
t

MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT

Vendor Attendees Date : 17 /18/19.03.14
Sigma
Supplier
Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd
Definition and control
Part Name2 Damper
method for initial part
Category Audit Area Concerning regulation Judgment Remarks Follow Up

Do you control initial parts separetely and make quality

Initial parts are identified with unique identification numbers on each
② records about them?(both internal and outsourced △ part.
process are included)

４． Procedure to make
1 Do you make process control standards for all products
Standards process control ① ○ Control plan for each Part is available
managemen standards(QA which is shipped to SMC / MSIL?
t process charts)
Do you mention defined both characteristics of quality Process flow for all the product is available.
② △
and production control on the process control standars? Quality and production char. Are defined in Control plan.

Do you mention followings on process control standards

required to each process?
-quality comfirmation method; -regulations; Controal plan / Operation standard / WI contains Inspection Methos,
③ △ Ref. standard, Inspection Frequency, Sampling plan, Poka - yoke
-standards (operation instruction/items to be focused etc. Procedure for prepairing control plan WI/QAD/222 is there
on);
-boundary samples; -parmeter chart; -Pokayoke
４． Procedure to control Do you define following concerned abou standards?
2 -department in charge of making;
Standards standards
-a person in charge of making; Operation standard prepration and maintaining the document is
managemen ① △ defined with authority.
t ・Process control -a person in charge of authorizing; Retention period also defined for MSIL parts.
standards -making period; -timing to submit to customer;
・Inspection -revision rule; -retention period;
specifications Do you have consistency to keep process control There is Coherence among Control plan, inspection standard,
・Operatoin ② standard, inspection specification, operation inspection ○ operation standard and MIS -P.
instructions and parameter chart?

Do you make use of lists to control preparation and List of history is updated on the control plan and operation standard.
③ △
revision of standards and share the updated information? Documents are issued with receiving information.

５． Education/ training Do you clarify the department in charge of promoting Training related to technical department wise (Functional
1 Training), HSE, 5S are being planned and records are being
Education procedure ① quality education,implement education based on annual ○
maintained.
and traning plan?
Do you define and implement the skill evaluation of Skill Matrix is being evaluated six monthly as per procedure to
operator to determine whether operator can work without evaluate skill level WI/?
② ○
surveillance?(e.g. acceptable revel/evaluation
freequency/evaluation method)
Prior to SOP, do you instruct each operator based on
③ △
actual operation instructions?
The training is being provided prior to SOP.
Education for Do you implement planned education to supervisers for
2
managers/Inspectors/ ① △
skill improvement ?
Special operators Trainings are being given to all levels in the organization.
Do you implement special education or technical training Internal and external trainings are being organized.
② to inspectors and operators of particular process ○
(required specialized skills)? Are training records kept?
Special education and Technical Training like customer
Do you periodically monitor the skill of certificated requirements etc are provided to Inspectors and Operators.
③ △
operators and follow up to improve their skill?
Certificated Operators are being monitored.
６． Do you conduct internal quality auditor periodically?
1 following are standardized:, -suditor team; -audit
Quality Activity to Internal Audits are being planned as per schedules. The audit
① ○
audit and keep/improve frequency; -audit timing; -audit method; -audit is planned as per standardized checksheet.
process production quality checksheet;
verification Do you conduct quality audit to identify issues and Process Audits are being done to identify issues and action
② ○
properly improve them? plan is made to improve them.

Content of process Do you focus on useful know-how of operation,

2 Methods are prepared during development stage and shared
review ① operations with poor workabillty and operation which △
during initial Trials for improvements.
need a lot of repair and standardize them?
Do you confirm consistancy between actual operation
② ×
and standard?
Do you confirm if countermeasures are taken properly to The problem / Failure are linked with the preventive measures
③ ○
prevent reoccuring of quality fail? by implement action on the checksheets , control plan, WI etc

７． 1 Evaluation method for New Suppliers are certified after audit by SQA Team as per
Supplier new suppliers Do you define criteria to certificate new suppliers and
① ○ defined procedure of supplier selection, evaluation & approval
control implement them? PR/PUR/01

Management, quality Do you collect supplier failure information, determine

2 Monthly supplier rating is being prepared and circulated to each
evaluation and ① supplier grade according to quality level and conduct ○ supplier.
instruction for audit and instruction periodically?
suppliers
For outsourcing any production, do you instruct them
Important control items are being instruct to supplier. Agrement of
② clearly about function and improtant control items of ○ insoection is signed off with supplier.
products at the meeting ?

For outsourced process,do you control the progress of

③ ○ Process audit of supplier is done at defined frequency.
production preparation and confirme issues ?

F0003-1 QA/MT Ver. 5

７．
Supplier
control
MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Management, quality Vendor Attendees Date : 17 /18/19.03.14
2
Sigma
evaluation and
instruction for
Supplier
Name Vibracoustic
suppliers Auditors: Mr. Manil Gogia
India Pvt. Ltd

Part Name Damper

Category Audit Area Concerning regulation Judgment Remarks Follow Up

Do you make suppliers to conduct initial production Initial production parts are installed at supplier end and monitored
④ ○
control and decide department in charge of conduct? by SQA Engineer.

Regarding the parts which are shipped directly to the

⑤ custmers from outsourced suppliers, do you have
method to assure product quality performance?
Do you make outsourced suppliers to conduct initial
⑥ parts and 4M changing management and is it possible to
trace?
○ No product is being shipped directly to customer from supplier.
Record of initial parts (pilot lot) Inspection at sub supplier prepared
△ and verified by QA Engineer.
Confirmation taken from supplier for 4 m change.

８． Handling when
1 Do you define clearly what is abnormal situation and Abnormal situation is denfined. Opearators are know about the
Handling abnormal situation ① △
abnormality occures make operators know the definition? abnormal situation.
in quality
Do you clarify and standardize the handling rules/routes Standardized rules to handle customer cmplaint, Internal Failures
② for customer claims, in process failure and supplier ○ and supplier failures are defined. WI for handling Customer
failure? complaints is also there WI/QAD/94A

Do you have criteria to estimate the scope of suspected

lot for abnormal situation?　When abnormal situation The Suspected lots can be traceback based upon the Box no., Route
③ △ cards. Work instruction for handling abnormal situation WI/QAD/219
occurs,do you trace suspected　lot based upon the is there
criteria?
Prevention of
2 Do you prevent recurrence of issues by analyzing cause
recurrence ① of occuring defect based on process investigation result ○ Preventive actions are being taken to prevent recurrence of issue.
such as 5-why analysis?
・Customer claims
・In process failure
Do you reflect corrective action to improvement of Corrective actions are reflect by adding in the check sheets and
・Suppliers failure ② ○
process control and review of standards? poka- yoke verification where ever required.

After corrective action are taken, do you conduct on-site

③ ○ Effectiveness is being checked and recorded.
checkup and evaluate the effectiveness?

Do you cascade information of corrective action to Actions are being horizontally deployed for the similar parts and
④ ○
similar parts and processes? process.

９． Location of Do you keep store material, work-in-process, finished

5S 1
production site products, inventory and container at appropriate storage The store material, work-in-process, finished products,
① ○ inventory and container are plced at appropriate location to
managemen prevented from dust, lust, scratch, deformation and avoid dust, Deformation Rain water.
t rainwater?

Do you control material, work-in-process and finished Storage of RM, BOP,WIP&FG parts at designated location as per
storage standard defined.
② product by designated location, volume and standard ○ Location no is provided for FG and Raw material.
using visual control?

Do and don't are displayed on the shop floor.

Do you forbid operators to put temporary storage on Work Instructions ( Do's & Do not's) for not having temporary
③ △
work place? storage(storage on shop floor, over racks, on work tables, on
machines, in non standards bins / trolleys.

Do you implement inspection or critical operation under Inspection of critical operation inspection / testing at lab under
④ the properly controlled enviroment luminance ○ properly controlled environment:- temperature, humidity .
/temperture/humidity/vibration/noise/work table, etc.)? Lux level is maintained on Inspection table.

Production
2
equipments Do you keep condition of production equipments, jigs
① ○ Location for Tools and Jigs are defined.
management and tools properly?

Do you keep condition of inspection equipments properly

② ○ Inspection Equipments are keep properly with verification.
to ensure accuracy?

１０． Maintenance of Do you conduct daily/regulary check of production

1 Production equipment, Dies, Jigs etc are being checked
Equipment/I equipments , jigs and ① equipments, dies and jigs? Are records of maintenance ○
regularly and records are being maintined.
nspection tools kept?
equipments Do you confirm regulary the function of Pokayoke,
managemen Poka-yoke defined In a list and being verified at a defined frequency
② automated stop and alarm? Are records of maintenance ○ and records are maintained.
t kept?
Do you standardize frequency of polishing and
③ replacement for consumable △
tools(blade/electrode/rubstone, etc.)?
Maintenance of Do you caliburate regulary inspection equipments and Inspection equipement are calibrate as per defined frequency. Due
2
inspection ① ○
put the expire date on them? date is mentioned on each equipment.
equipments

F0003-1 QA/MT Ver. 5

１０． MARUTI VENDOR QUALITY SYSTEM AUDIT CUM FOLLOW UP REPORT
Equipment/I
nspection Vendor Attendees Date : 17 /18/19.03.14
equipments Sigma
Supplier
managemen
t Name Vibracoustic Auditors: Mr. Manil Gogia
India Pvt. Ltd

Part Name Damper

Maintenance of
2
Category inspection
Audit Area Concerning regulation Judgment Remarks Follow Up
equipments
Do you control deterioration (expire date) of boundary
Boundary sampels are being reviewed at defined frequency with
② samples for objective judgments such as appearance ○ objective is also mentioned.
inspection?
１１． Implementation of Do you use easy expression (visualizer, onomatopoeia
1
Implementat standards ① ,etc.) for operation instractions? So that operator can ○ Work instructions are availble for the operator for inspection.
ion of easily understand process and critical points.
standards Do you keep operation instractions on the accessible
place and post important quality points and critical WI are displayed on the inspection table, Near to operation & are
② ○
operation points on the place where operators can see it easily assessable to operators.
easily?

Do operators and supervisers operate according to the

③ × Standard Operation defined
operation standards?

Do you regularly monitore that each operator operates

④ × Verification
according to the operation instructions？

Is it possible to judge OK/NG specificlly by each check

Specification for parameters are provided and Defective
⑤ sheet (of daily equipment check, quality control report, ○ photographs are provided in WI.
etc.) you use?
１２． management of parts Do you keep first-in first-out of finished products and
1 Material WIP / FG are being identified with Identification tags
Products flow ① work-in-process (matelial, reserve parts） by using ○
managemen and FIFO is being maintained
identification tag or lot indication?
t
Do you control follows production history by rproduct lot
② numbers? ○ Traceability of Production Date/ Lot/ Qty/ dispatch date maintained.
-production date; -production volume; -shipping date

③ Do you control identification of similar parts separetely? ○ Similar parts are identified by colour dot marking.

Non-confirming parts
2 Do you control identification of non-confirming parts and Non- confirming parts are identified and stored separately in locked
management ① ○
parts on hold. Do you store them separetely? room.

Do you define procedure to handling (following items)
non-confirming parts and parts on hold?
② -root cause analysis; -person responsible for final
judgment
-ttiming; -feedback procedure
Procedure for control of non-conforming product PR/QAD/04
available defining handling of non-confirming parts & WI/QAD/94 for
control of Non-conforming products
△ Authority is defined to take final decision.
Root cause analysis,

Regarding repaire non-confirming parts and parts on

Procedure to define Hold part & reporcess is define WI/QAD/ 220
③ hold to re-use, do you define responsibility to implemet? △ and records are being mainatined.
Are repair record kept?
13. 1 Bins/ Trolley Do you make arrangements with customers about the
Handling Management packing style & transportation system to prevent damage
① ○ Packing Aggrements are made with customer
Managemen during handling of finished products & perform
t accordingly.
Are the packaging style & storage environment controlled Packing and storage conditions are defined to prevent material from
② ○
with consideration to contamination contamination and damage.

Do you have system to maintain Bins /Trolleys in Good Returnable bins are being cleaned as per defined procedure WI/PRD-
③ ○
Condition. 02/26

Does the Packaging method prevent Transportation Packing Aggrements are made with customer & Packing and
④ ○ storage conditions are defined to prevent material from
damage contamination and damage.
14. 1 Maru A Parts Do you have Special checks/Inspection for Maru A
① NA
Critical Management parameters of Maru A part are available .
parts
Do you have Identification of Maru A Process/Operator on
Managemen ② NA
Shop Floor.
t
Do you keep the repair history when repairing & using
③ NA
Maru A items

F0003-1 QA/MT Ver. 5

 COPY TO : MARUTI VENDOR AUDIT- COUNTERMEASURE REPORT
RECEIVING DATE PLANNED CHECKED APPROVED

VENDOR NAME
PLANNING

PLANNING

PLANNING
VENDOR CODE

TOTAL 0
AUDIT DATE
RECEIVING DATE
VERIFICATION

VERIFICATION

VERIFICATION
AUDIT PART NAME

AUDIT PART NO.

TOTAL 0

DEADLINE FOR DEADLINE FOR SUBMISSION OF

AUDIT POINT
SUBMISSION OF PLAN ACTUAL RESULT

SUB ITEM RESULT OF

ITEM NO. DESIRED IMPROVEMENT POINTS DETAIL OF IMPROVEMENT PLAN IN-CHARGE DATE
NO. VERIFICATION

F003-4 QA/MT Ver. 4