TVS MOTOR COMPANY Date :

Spl process Supplier Quality System Audit Summary

Supplier Name & Address Supplier code :
M/S Chief Executive - Name : Mr
Telephone :
Fax :
Cell No:
E-mail :
Products Manufactured ISO / IATF certificate details

1 Certificate Type

2 Certified by

3 Certification Date

4 Certification Period

5 Valid up to

6 Year of Establishment Annual turnover :

AUDIT OBSERVATIONS:
Good Points
1

10

11

12

13

14

15

The Action plan should be submitted to TVSM within 6 working days from the date of audit.

Audit Rating Score - Minimum 80 %

Auditee Sign : Auditor Sign :

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 SPECIAL PROCESS AUDIT CHECK LIST - POWDER COATING ON STEEL
Supplier :
TVS MOTOR COMPANY
Date :
Auditee : Max.Possible Actual Score value
Score Scored in %
Auditor :
Overall System Rating

Score
# CHECK POINTS
0 1 2 Remarks
Document Control ( Management
1.0
Responsibility ) 0x 1x 2x
1.01 Verify for latest drawings in TVS Motor company name
Verify for incoming inspection plan for all ( PT chemicals
1.02
& Powder from approved source)
Verify for List of Approved RM supplier list and Tier 2 /
1.03
Vendor list for special process (TVSM Approval is must)
Check for availability of latest TVSM Standard /
1.04
International standard /Customer requirement
Verify Operation standards, PFD,PFMEA,Control Plan
1.05
etc., (PPAP) (availability, adequacy, adherence)
Customer approval records for changes, deviations etc., (
1.06
Process Change, Source change or any 6M change)
Check whether Tier 1 source is following audit system of
1.07
AIAG CQI 12 with records
Check whether Tier 1 source is having auditing system
1.08
for tier2 with records
Check for availability of Supplier inspection report as per
1.09 latest TVSM Standard / International standard
/Customer requirement.
External test or 3rd Party (NABL) lab test plan /
1.10 adherence & Adequacy / records, in case of lack of
facility.
1.11 Availability of child part matrix and inspection plan.

Total scored value 0x 1x 2x

2 Handling customer Complaints 0x 1x 2x

Procedure for customer complaints and recording
2.01 complaints (Ensure lead-time available for M1,M2 & M3
action)

2.02 Analysis and permanent action for customer complaints

Tracking system of customer complaints, with
standardization details, QC story/8D report reference/
2.03
Horizontal deployment & effectiveness monitoring
(Electronic/Notebook)
2.04 Verification of available kaizens/8D report/QC story.

2.05 Verification of standardisation / Horizontal deployment

Trend of customer complaints (Number of complaints

2.06 received ,Closed, Pending, Number of repeat
complaints,)
Total scored value 0x 1x 2x

3 Process Control 0x 1x 2x
3.01 Availability of qualified persons (Chemist)

3.02 Availability of control plan

Verify for availability and display of operation standards

3.03
stage wise

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 SPECIAL PROCESS AUDIT CHECK LIST - POWDER COATING ON STEEL
Verify for matching of control plan parameters in
3.04
operation standards
Verify Storage condition of PT Chemicals and Powders
3.05
and FIFO System / Self life of chemicals.
Check whether the Powder Supplier is an approved
3.06
source of TVSM
Check whether the PT Chemical Supplier is an approved
3.07
source of TVSM
Check whether incoming pre treatment chemicals/
3.08
Powders are checked and recorded batch no wise
Are parts visually examined for material defect like
3.09 rust,dent,damage,weld missing, weld blow holes etc.
prior to pre treatment operation
Pre Treatment by jigging system or by loading in
3.10
baskets? Jigging is must.
Verify the Pre treatment line available is of semi auto /
3.11
fully automatic/ manual type. Fully automatic is must.
Check whether the powder coating booth / Bake oven
3.12
are with Glass enclosure to prevent dust entry
Poka-yoke system to indicate abnormality in the
3.13
process( Conveyor speed, Bath / Oven Temps, time etc.)
Verify for existence of Hot Phosphating system.
3.14 Verify for existence of Hot Degreasing system in
Alchrome line.
The parts to be powder coated are taken for Pre
3.15 Treatment operation only after machining operation (
for aluminium parts only )
Shot blasting or Vibro polished or buffing done prior to
3.16 Powder coating .

Verify oil skimmer systems for its availability & effective

3.17
functioning
Check whether the chemical contents are checked as per
3.18
fixed frequency of control plan and recorded
Check whether the chemical additions for various baths
3.19
carried out as per analysis and recorded
Verify rinse tanks for concentration (floating oil, smut &
3.20 dust not allowed) at random & also records. Does it have
overflow system or not
Verify for availability of standards & adherence for Raw
3.21 water, DM Water quality ( Like Conductivity,pH, TDS,
etc.)

3.22 Verify for Dry off oven Baking schedule. (with poke yoke)

Verify for storage & handling of phosphated/Alchromed

parts prior to powder coating in case of semi automatic
3.23
system. Verify the phosphated/Alchromed parts are
handled only with gloves
Check at random PT process parameters & verify
3.24 whether it is as per control plan (conc.,temperature ,
etc.)
Verify for powder coating process parameters (gun
3.25 pressure, Voltage, etc.) as per fixed frequency in the
control plan
Verify for Baking schedule (oven temperature through
3.26 TTR) as per fixed frequency in the control plan
.Availability of TTR instrument
Verify for availability of control charts for bath
3.27 temperature, pH , bath concentration , etc. and checked
as per fixed frequency in the control plan
Is Process Qualification done once a year and verification
3.28
of records
Is in-house system for monitoring rejection trend and
3.29
analysis

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 SPECIAL PROCESS AUDIT CHECK LIST - POWDER COATING ON STEEL

3.30 Is action plan available for rejection

Check whether GENSET facility is available to meet

3.31
nonavailability of EB power
Is there a colour codification for the water lines ( Raw
3.32
water, DM water ) , Air line, LPG line
Thickness Mapping report
3.33 (Part to part, with in part, fixture and man to man
variation)
3.34 Corrosion Mapping report

3.35 Process Mapping

3.36 SPC control for special characteristics

Total scored value 0x 1x 2x

4 Product Test 0x 1x 2x
Check inspection plan and records as per TSES 083
4.01
(except h & j other parameters to be tested on part)
Check whether separate inspection facility with adequate
4.02
light ( 1000 lux available )

4.03 Visual standards / Limit samples Plan / review system.

a Visual 100 %

b Coating thickness

c Adhesion -Cross Hatch test

d Corrosion resistance

e Water resistance ( Hot water test )

f Humidity resistance

g Acid resistance

h Weather resistance ( UV resistance )

I Hardness - Pencil hardness

j Flexibility test -bend test

k Gloss level ( Visual or by measurement )

l Multi impact stone chip resistance

m Condensation water constant Atmosphere

n Ageing test

o Alternate climate test

p Resistance to pressure water jetting

q Accelerated weathering color stability

r Accelerated weathering crack stability

s Cyclic corrosion test

t CASS test

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 SPECIAL PROCESS AUDIT CHECK LIST - POWDER COATING ON STEEL
u Dry scratch resistance test - Crock meter

v Benzene/Petrol resistance

w Motor engine oil Resistance

x Engine cleaner/Degreaser resistance

y Motor bike cleaner resistance

z Out door exposure test

Total scored value 0x 1x 2x

5 Inspection test facilities 0x 1x 2x

Visual inspection with 1000 Lux Light intensity as per JIS
5.01
Z 8723 ( as per TSES 450 ) Availability of Lux meter
Paint thickness Gauge with Master with operating
5.02
procedure and evidence
Adjustable knife,3M or Johnson & Johnson (Permaseal)
5.03
make Cello tape etc. to carry out adhesion test
Corrosion chamber to carry out Neutral salt spray test as
5.04
per ASTM B 117 with WI ( only on part )
Hot water immersion test- 70 deg C for a period of 1
5.05
hour
Humidity resistance - 50 +/-2 Deg C at 98+/-2 % RH -240
5.06
hours
Acid resistance test- (a) For all paints 1N H2SO4 at 20+/-
5.07 1 deg C , Humidity 68-78 % RH for 24 hours (b) For single
top coat Silver metallic paint 0.1 N H2SO4
Weather resistance -Accelerated weather resistance test
5.08 (UV-weather meter with UVB313 bulb).with 4 hrs. UV
(50 deg C) and 4 hrs. condensation (40 deg C) cycle.
Availability of Mitsubishi UNI grade Pencil hardness for
5.09
checking Pencil Hardness

5.10 Flexibility and Adhesion test facility

Gloss meter with master- To measure Gloss as per JIS

5.11
K5400
PH meter with operating procedure and calibration
5.12
evidence
Conductivity meter with operating procedure and
5.13
calibration evidence

5.14 Multi impact stone chip resistance tester with procedure

5.15 Wet Humidity chamber with procedure

5.16 Ageing oven with procedure

5.17 Alternate climate test chamber with procedure

5.18 High pressure water test facility

5.19 Xenon Arc - Accelerated weathering tester

5.20 Xenon Arc - Accelerated weathering tester

5.21 Cyclic corrosion test chamber with procedure

5.22 CASS test chamber with procedure

5.23 Dry scratch resistance test - Crock meter with procedure

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 SPECIAL PROCESS AUDIT CHECK LIST - POWDER COATING ON STEEL
5.24 Availability of Benzene/Petrol

5.25 Availability of Motor engine oil

5.26 Availability of Engine cleaner/Degreaser

5.27 Availability of Motor bike cleaner

External test plan/adherence/records, in case of lack of

5.28
facility. (SL No. 5.07,5.09, 5.11)
5.29 Visual standards / Limit samples Plan / review system.

Total scored value 0x 1x 2x

6 Control of nonconforming product 0x 1x 2x

Non conforming product / parts are kept in earmarked
6.01
bin / area
6.02 Rework & re-inspection system available

6.03 Do you have deviation handling & approval system

Availability of temporary / permanent countermeasure

6.04
with target incase of deviation
Total scored value 0x 1x 2x

7 Gauges and Instruments control 0x 1x 2x

Procedure for calibration
7.01
(Ensure Contingency plan, due overlaps etc..,)
Availability of calibration plan and records - Equipment's
7.02
/ Process control indicators / instruments
Availability of report - MSA / Thermal mapping /SAT /
7.03
TUS / Baking window /TTR
Availability of calibration records for "masters"
7.04 (thermocouple, Hardness tester block,Spectro meter
etc.. )
Calibration due label available in gauge / instrument /
7.05
equipment /controller
Total scored value 0x 1x 2x

8 Maintenance 0x 1x 2x
8.01 Procedure for preventive and breakdown maintenance

8.02 Chemical maintenance schedule and adherence

8.03 Jig /Trolley/Bin maintenance schedule and adherence

8.04 Is machine breakdown monitored - Hours / occurrence

8.05 What action taken to prevent the breakdown

8.06 Verification of standardization / Horizontal deployment

Total scored value 0x 1x 2x

9 Identification and Traceability 0x 1x 2x

Check whether parts are kept in Dedicated area Like
9.01 Receipt , Accepted , Under progress samples in Rust
proof condition
Is there a identification on the part for its Production
9.02
date / batch number?
Is there a system to identify subsequent operation (from
9.03
RM Receipt to final inspection with tag system)
Total scored value 0x 1x 2x
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 SPECIAL PROCESS AUDIT CHECK LIST - POWDER COATING ON STEEL
10 EHS
0x 1x 2x
Check whether the Powder coater is having Government
10.01 approved Effluent Treatment facility and records
maintained
Verify availability of water(RO / DM) purification
10.02
system.

10.03 Verify availability of ETP system.

Total scored value 0x 1x 2x

11 Material handling system 0x 1x 2x

Check whether the casted parts are kept in trollies in all
11.01
stages
Check whether the core and parts are kept in trollies are
free from touching from one another and also not
11.02
getting damaged by contact ( Ensure provision of PVC
sleeve wherever required)
Total scored value 0x 1x 2x

12 Training 0x 1x 2x
12.01 Are operators / inspectors trained in related work

12.02 Number of critical operations - Identified

Availability of training module for identified critical

12.03
operations

12.04 Is training given to all operators prior to certification?

Verify whether certified operators available in those

12.05
critical operations
Total scored value 0x 1x 2x
Guidelines for Score Guidelines for score - Each category
No system in place 0 No written procedure available / No evidence of practice / Procedure available but adherence is poor

Procedure available but adherence not satisfactory / No procedure available but evidence of work
System in place but adherence is not satisfactory 1 practice found good which can be converted into procedure / Procedure available but not adequate

Procedure available and adherence is good. Evidence of complete activities available and improvement
System in place and adherence is good 2 action evidence through review minutes. PDCA improvement is seen

Rev No. Reason for change Sheet no. Date Name

0 New release -- 12.06.16 NG/ VMQ
1 Customer complaint check points revised -- 21.11.18 NG

Prepared by : Cell Head Approved By : Section Head

7 / 7 QSF QAD 06 01 001 Rev 1 Dated 21.10.02