New Supplier Quality Manual Training Module

Honda Cars India Ltd.
Supplier Quality Manual

Training Program
Rev 10, Date 21.06.23

SQM and SQM history in HCIL 2
SQM - Supplier Quality Manual
• SQM Purpose is to establish Quality assurance requirements for

providing high quality of product , that satisfies HCIL product users.
• It includes all Quality assurance activities performed by suppliers .
• Suppliers are required to comply with each of the requirements

specified in SQM.
• Global SQM issued in Apr’23 based upon each Location SQM

• requirements, So all Suppliers training required on SQM
Development Journey
Global SQM Issued by Honda considering all Genpo requirements

Summary of revised SQM 3
◆ Honda revised SQM as below to facilitate communication with

global suppliers.
Reflected chapters
No. Major revision in revised SQM
1 Reviewing Honda’s SQM based on IATF16949 Chapter 1 to 6

Honda specific
1-1 Clarified CSRs by Honda requirements
for IATF16949
1-2 Revised the structure Chapter 1 to 6
1-3 Review requirements of SQM Chapter 1 to 6

Refer to Annex
1-4 【New additions】 Development requirements (Development
Requirements)
2 【New additions】 Compiled requests from Honda sites Chapter 1 to 6
【New additions】 Perspective picked up from
3 manufacturing-Critical Quality Problem (SEIZO-JUHIN) Chapter 2 to 6
recurrence prevention
1. Reviewing Honda’s SQM based on IATF16949 4
◆Requirements by current SQM (Excerpt from preface.)
【 Current SQM structure 】【Revised SQM structure】

Honda own requirements SQM based on IATF16949
Public Standard as
separate requirements
IATF16949,
ISO9001, etc
Specific
No requirements on Combined with requirements
the development
Global standard
IATF16949
SQM own system ISO9001
The current SQM is configured to add The revised SQM organizes the requirements
IATF16949 in addition to Honda own system. considering the idea of global standards.
1-1. Clarified CSRs (*1) by Honda 5
SQM structurer based
on IATF16949
* 1. Customer Specific Requirements defined by
IATF16949. That is new term in Honda’s SQM.
Specific
requirement
s
IATF16949
ISO9001
Revised SQM
Clarified Honda’s own requirement as CSR with refer to each requirements in IATF16949.
1-2. Revised the structure 6
Current SQM:4 chapters ◆Revised SQM:6 chapters

Pre-production stage Chapter 1:Supplier selection Investigation
Chapter 2: Product Design and Development

Mass production stage
Chapter 3:Process Design and Development
Chapter 4: Product and Process validation

General
Chapter 5: Production – Feedback, Assessment and Corrective
Tool as reference Chapter 6: General Requirements
◆Image Current vs revised

3.7 Process Quality
revised
6.4 Quality Record

4.3 Measurement
5.5 Change point

Control Table (II)
6.3 Supply Parts

Capability Study
System analysis
Production Run
SQM
3.9 Traceability
4.2 Significant
4.4 Process
Current
Control
control
SQM
3-2-1 Process
Quality Control
Table
4-3 Identification
And Traceability
4-4 Change point

control
Revised SQM restructured 6 chapters.

（Detail between current vs revised can be accessed with attached comparison table.）
1-3. Review requirements of SQM 7
Revised SQM
Turtle diagram:
IATF16949 Process approach
*
4) Material 3) Output
resources 5) Skills
2) Input 3) Output
Require Satisfied
1) Process Require
ments
ments
1) Process 4) Materials resources／5) Skills

6) How Evaluation
Indicators
One of requirements from

6) How
*
IATF16949 describes as “The
systematic definition and
2) Input
management of processes, and
their interactions, so as to achieve the
intended results in accordance with
the quality policy and strategic
direction of the organization.”
Restructured SQM requirements reviewed with 6 processes of “Process Approach (*2)”.

1-4.【New additions】 Development requirements 8
Current SQM
No
requirements
 Added ” Development
on the
development
requirement” as appendix of new
SQM to cover IATF16949
requirements.
SQM own system
Revised SQM
Added “Development
requirements” as annex
Added existing development work as apart of requirements in SQM.

2. 【New additions】 Compiled requests from Honda sites 9
◆Description in new SQM
Revised SQM
Additional requirements
refer to necessities of local site
Compiled essence of requirements from each site.

3. 【 New additions 】 Perspective picked up from manufacturing-
Critical Quality Problem (SEIZO-JUHIN) recurrence prevention
◆ Numbers of SEIZO-JUHIN ◆ Analysis of reasons the defect occurred and was not caught
【Cases/Y】 1. Insufficient rules
Total 171 JUHIN occurred

Number of manufacturing - Critical Quality
20 2. Insufficient risk analysis
18
last 18 years were analyzed.
3. Insufficient assessing validity
16 4.Non-compliance to rules
Problems occurred by Suppliers
14
5. Insufficient analysis for change points
12
6. Insufficient manpower management
10
8 7. Insufficient involvement of peer groups
6 8. Insufficient maintenance
4 9. Insufficient stock control of consumables

2
10.Insufficient training
0
04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 Sorted out 10 categories with 248 items to
Years seek recurrence prevention
◆ Analysis example ◆ Reflection example to SQM

Lack of list up for manufacturing control items caused by (Chapter 5.5 Change management Process 1)
spec-change.
Cause Approach Countermeasures Excerpt
The suppliers shall have a documented process for change point control
State in Quality
Defect Change points
Enhance omission system document (including unplanned change points) that includes the following
verification done
occurred checking against to verify change
by design dept
verification results. points in multiple a)A multi-disciplinary approach (including sub-suppliers if necessary)
only.
departments. to each change point that includes the following
-Sharing and agreement on the content and purpose of
the change points
Defect Quality Control State in Quality
was not Enhance omission
Items were system document
caught checking against
decided only by to verify control
control items.
Design Dept. items.
Examined the recurrence prevention measures from the causes of

Reflected to main text and the guidelines.
defect occurred / was not caught.
Recurrence prevention views referred what Honda learned from past critical quality
problems. Suppliers to utilize the learnings to reflect your Quality Standard / Forms
New SQM Structure
The revised New SQM contains 【Global Common Requirements】【Site-Specific Requirements】
Global Common Requirements
Designate Form
and Site-Specific Requirements. Ex: 5.5 Change point Control (Advance approval requests for changes)
表格编号：PTQ QR S0903 01 03 发行年月日
送至自主管理初物联络书公司/部门名
品质保证责任者确认担当
【Structure of New SQM】

零件号计划
零件名突发
零件特性有无对象有无影响变更项目变更内容变更理由受影响的品质特性

新材加工设夹模检运其
重要品质特性供料工序备具具查输他
应变条系变 / 变方 /
零件检查基准商更件列更工更法包
方变具变装
法更变更变
零件认可
的
变
更更
Notificação de Auto Controle de Produção de Peça Inicial Emitido em: / /
G. Qualidade
产品化学物质更 G. Geral G. CPR G. Produção G. Engenharia G. Logística Emitente
Nº da Peça Planejada Para:
Site-Specific 其他
评价项目评价内容
预
定
完
成量产预定日
Nome da peça
Característica da peça
交货预定日
Características importantes da
Aplica
Sim/Não
Afeta Sim/Nã
o 弊公司回答栏
Alteração de Item
Imprevista Nome da Área/Empresa:
供应商评价结果
Detalhe das mudanças Motivo das mudanças Característica da Qualidade afetada
Alteração de condição de processo/método

日日
Requirements
qualidade
Alteração de sequência de processo
Alteração de transporte/embalagem
Alteração do método de inspeção
工序能力 Critério de Inspeção de peças
或者工序保证能力
Alteração de jig/ferramenta
Alteração de ferramental
Alteração de máquina
Alteração de material
Aprovação de peça
Novo Fornecedor
量产过渡后的
可靠性确认试验重点监控项目年月日
Composição Química
Outros
（原则上一个月）
品质保证责任者确认担当
工序FMEA Outros
（防止未然）
ds
（防止流出）
programada
Fase Data Resposta da Honda Resultado da avaliação do fornecedor
Data real
（检证过去故障）
Data
Itens de Avaliação Detalhe da avaliação
Apresentação E-
/ /
管理No. 弊公司
1 确认
NA Site-Specific
初物测定
・工序品质管理表
LOGÍSTICA
Fluxo de processo , capacidade produtiva,
ENGENHARIA
部门名动力总成品质科部品品质系
estoque peças, fluxo movimentação de material
Alteração do processo
部门名动力总成品质科
Apresentação
E-2
/ /
部品品质系
/ /
Início da Produção / /
作业标准类的修改・制定 Teste e ensaios
年月日 Itens importante de monitoramento
年月 após transição
日
・对作业者的教育培训 Data Resp. Qual. Verif. Emit.
Requirements
para MP
PRODUÇÃO 确认担当受理确认(Regra Geral - 1 mês)
担当 / /
Revisão FMEA de processo, Padrão de Serviço,
其他 treinamento de operadores, FCQP
Confirmação da Honda
QUALIDADE
Medição das peças de produção inicial prevenção
de saída, reflexão de problemas passados,
cronograma, dimensional (Cpk n=30 cotas críticas
/ completo n=5)
CPR
N° CPI:
Global Common
Parecer para redução de custos
Nº Ctrl: Nível de alteração:
CN
OUTROS Área: Verif. Coord. Receb. Área: Verif. Coord. Receb.
/ / / /
Requirements
New SQM Procedure
SA (Change Point Control)
AO
JP
Site-Specific
Requirements
Please follow the SQM structure for detailed requirements

New SQM Structure
① SQM Text ④ SQM Annexure
① ② ③ ④
② SQM Procedure ③ Designated Form
Refer HCIL Format

for HCIL Specific
requirements
SQM Contains Main SQM Text, procedures, Designated Form & Annexure
Structure of SQM 13
Investigation 4.1 Delivery Quality at Pre-production Stage
1 Supplier
Selection
1.1 Supplier Selection Investigation
4 Product and Process

4.2 Significant Production Run (HVT/Run @ Rate)
Ref. Annexure (Development requirements)
Validation
4.3 Measurement System Analysis (MSA)
2.1 Special Characteristics
4.4 Process Capability Study
2 Product Design and
2.2 Statutory and regulatory requirements

4.5 Production Validation Testing
Development
2.3 Verification of Past Problems

2.4 Drawing and Specification Change and 4.6 Production Part Approval Process (PPAP)
Application
5 Production･Feedback, Assessment
5.1 Initial quality control in Mass production
2.5 Requirements for the Production Facility,
Mold, Jig and Tool, etc.
5.2 Control Chart
and Corrective Action

2.6 Installation and control of measurement
systems
5.3 Delivery and Storage of Production
3.1 Product Assurance Plan for Manufacturing
3 Process Design and Development
5.4 Non-conforming Product Containment and

3.2 Delivery Packing Corrective Action
3.3 Process Quality Control Table (I)/Process
5.5 Change Point Control
Flow Chart
3.4 Floor Plan Layout 5.6 Supplier Quality Audit (QAV)
3.5 Process Failure Mode and Effects Analysis
(PFMEA) 5.7 Supplier Quality Evaluation
3.6 Limit Sample and Master Sample 6.1 Designation of Quality Representative
requirements
6 General
3.7 Process Quality Control Table (II)/Control Plan 6.2 Sub-supplier Management
3.8 Operation standard 6.3 Supply Parts Control
3.9 Traceability 6.4 Quality Record
Structure of SQM 14
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Supplier Selection Investigation
Selection & Contract with Supplier
• Investigation of New Supplier M/
Do not trouble to Honda
Purchasing investigates the supplier, before initiating transactions with a new user with quality area &
P
supplier, then determines its acceptance based on evaluation results. supply area
Honda conducts a supplier investigation if any of the following apply prior to
initiating a new business relationship
 The supplier may produce important safety parts
 Honda may determine quality audit is necessary before entering into new C/M proceed for actual
Purchasing agreement weak points by
Preparation as a pre-Mass
Investigation items include the following, but are not limited to the following: investigation till M/P
 Technical competency
production stage
 Quality management system
 Supply capability (volume) Is there a system not to
 Change point survey existing products flow or generate defect in
HCIL-QD will check Supplier Quality Management System based on
M/p after Honda contract
the QAV-1 Confirmation items & View points with supplier, clear the
weak point of supplier by
investigation before
Based on above points, HCIL take judgment for New Supplier
selection contract , want to do
smooth start up and stable
In addition, Honda may request that suppliers who have done business with
Honda in the past conduct supplier selection investigations that consider the
production
followings, but are not limited to the following:
 New manufacturing locations (If there is no production record with Honda or if it is changed to a new manufacturing locations)
 New business parts (If there is no actual production or if there is no delivery record to Honda)
 New technology development (When developing new technology that neither the supplier nor Honda has ever experienced.)
New supplier performance is not available with Honda till now , So It is require to
evaluate Supplier’s Current Quality Management System Status.
Structure of SQM 16
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Definition:
Statutory Requirements - Laws passed by a state and/or central government. E.g CMVR, Minimum Wages
Regulatory Requirements - A rule issued by a regulatory body appointed by a state and/or central government
Standard - Documented procedure whose intention is to harmonize actions or processes within an specific
discipline or activity. E.g. AIS 037, Hazmat
The suppliers shall have a documented process for identifying statutory and regulatory requirements and
maintaining them after certification.
The suppliers shall identify the applicable statutory and regulatory requirements considering the following, but
are not limited to the following:
 Drawing (including the specifications, etc.)
 Information provided by Honda (information on the launching countries, etc.)
 Latest Statutory and regulatory requirements about the safety and environment of the product, collected from
government agencies, affiliated companies overseas and external organizations.
What Supplier’s Need to Do: Identification Method:

• Supplier Quality Representative or Facility Parts which require Compliance to Regulatory &
Representative should ensure that in all the supply chain HCSMS are identified in the drawing in the title
activities, chemicals identified as per Regulatory block by following symbols “NH” / “NF”
Requirements or HCSMS is adhered.
• Supplier should verify the actual usage in all its

processes and its sub supplier process for the
requirements in HCSMS and maintain a record of the
same. Verification frequency to be decided and adhered “NH” – Non Hazardous
“NF” – Non Fleon (Non Flon)
• Upon HCIL request, provide the records of verification
and compliance as per Regulatory requirements and
HCSMS 17
Input by Honda
Interface
IMDS IMDS Data Reflects in MoCS
MoCS J-Hazmat HCSMS
Standard
International Material Data System Honda System Honda
Global System Management of Chemical Substance Chemical Substance
Supplier Input Data Auto Check w.r.t HCSMS Management Standard
Error  No Error (Auto

(Waiting for Judgement) Check & Approve
•Part no Pattern
Measure
•Supplier Code Error
1. HCIL Reject & Supplier •Data Submit at Preliminary Stage. Administrative Error
Re-submit Data in IMDS •Wrong IMDS ID
•Data not Internally Release
Judgement from Dashboard

1. Take Manual Judgement
Need Chemical Subst. Chemical Substance
Manual Judgement by Judgement
by HCSMS Criteria Checking with HCSMS. (NH Mark Chemicals)
International Material Data

IMDS
System
Management of Chemical
MoCS
Substance
Honda Chemical Substance
HCSMS
Management Standard
In above example, There is no items above threshold value & approved in MoCs
Submission of compliance results with statutory and regulatory requirements:
The suppliers shall submit the following items as a result of compliance with statutory and regulatory
requirements if request by Honda:
a) Evidence that the latest Statutory and regulatory requirements in the country specified by Honda are
satisfied (compliance report, copy of the certificate, etc.)
b) Data collected according to the “Honda Chemical Substances/Recycle Data Collection Operation Manual”
c) Data regarding the chemical substance content rate (including the IMDS data)
d) Data regarding the chemical substance content rate of the auxiliary-material
e) Relevant documents, if applicable
Management of compliance with statutory and regulatory requirements

The suppliers shall perform the following to maintain compliance with the statutory and regulatory requirements
but are not limited to the following:
a) Verification of the compliance management status for the statutory and regulatory requirements and
recording of the results
b) Improvement of the production methods, inspection methods, and quality control system
c) Identification of the latest statutory and regulatory requirements, include
• Trends in statutory and regulatory requirements adopted by the launching (applying) countries for the
product
• New and revised statutory and regulatory requirements
d) Inform Honda of the latest statutory and regulatory requirements identified (Regardless of the impact on
compliance reports or certificates)
Response based on Honda's determination of conformity to statutory and regulatory requirements (acquisition
of additional certification, recertification, revision of the drawing, specification change, etc.)
20
Structure of SQM 21
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Process Quality Control Table 22
1) What is a process quality control table?
A process quality control table (PQCT) shows diagrammatically all processes for each product from
supply of materials/parts until dispatch as a finished product, to confirm whether production quality
meets the design specifications, and specifies control methods for manufacturing conditions to assure
quality in each production process.
Honda’s PQCT is made up of two parts and the contents are shown below.
PQCT - I PQCT - II
Defines Defines (Product & Process)

• Part name & number • Process description
• part category, model, qty/ vehicle • Machine details
• Process flow • Control points & limits
• Child parts details and sourcing • Inspection freq., Method, resp.
• Revision details • Checking method
• Records
• Failure mode
• Sketches for illustration
Scope
1) All parts manufactured / supplied locally.
2) All process from incoming insp. To pre-dispatch inspection particularly
• Critical processes Quality key factors
• Equipment’s and machine’s control Die, jig, tool details
PQCT Flow 23
ACTIVITIES RESP.
PQCT FORMAT ISSUE TO SUPPLIER HCIL -PQ
REFER GUIDELINES
& DISCUSS TO HCIL –
FILL PQCT AND SUBMIT TO HCIL - PQ SUPPLIER
PQ IN CASE OF ANY
DOUBT
IF NOT OK
APPROVE PQCT AFTER VERIFICATION OF
HCIL -PQ
CRITICAL QUALITY CHARACTERSTICS
BEFORE
START OF
M/PRODUCTION RETAIN COPY & SEND ORIGINAL TO
HCIL -PQ
SUPPLIER
RETAIN ORIGINAL SUPPLIER
IN CASE OF ANY SEND PROPOSAL IN FORM OF ADVANCE SUPPLIER

CHANGE NOTICE & GET APPROVAL
INCORPORATE CHANGES IN PQCT &

SUPPLIER
UPDATE REVISION NUMBER
Model 1
Designation
of parts
Others 2
Issuing Company [Supplier]
5
Confirmation Department
7 Honda Cars India Limited (GNU/TKR)
24
Approved By Checked Issued
By By Approved By Checked By Received By
Part Numer 3 8
6
Part Name 4
9. Process diagram (Attach the A3-sized sheet for more space, if necessary.)
Component Parts Sourcing List
Source
S.No. Part Number Part Name Supplier Name
Purchase Inhouse
10 11 12 12 13
SELECT AS PER GUIDELINES
PART DETAILS
APPROVALS – SUPPLIER & HCIL -PQ
CHILD PART DETAILS

R/M & CHILD PARTS SOURCES
SAME AS APPROVED BY HCIL
REVISION DETAILS
PROCESS FLOW CHART SYMBOLS
ALL PROCESS SHOULD BE SAME AS FIXED & Flow chart symbols [ Combination of symbols can be used to show multiple operation process]
APPROVED BY HCIL DURING TRIALS/EVENTS

Processing
Transfer
Quantity Inspection
Quality Inspection
Crossing line with no intersection Operation Zone
Multiple Operation-Mainly processing plus quality check

16 17
14
18
15 Initial Issue
19 20
Issued By Checked By Approved By Check By Appr. By

Storage Process Flow Multiple Operation- Mainly quality check plus counting Issue Date Content of Revision
Issuing Department [Supplier] Confirmation Dept.
FORMAT NO: HCGQF QD 0029/APR'17 PAGE 1/2
21 Original Document retentionperiod YY/MM 22
23
Guidelines for selecting part design rank 25
Structure of SQM 26
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Purpose and Definition of FMEA
◆Purpose of FMEA
Improve product quality, reliability, safety and reduce market defect
Recurrence prevention
Adequate FMEA implementation No market defects
・Revise FMEA
・D/C, manufacturing process change
FMEA is not adequate Market defects occurrence
◆FMEA (Failure Mode Effects Analysis)

・The analytical method to prevent or detect/reduce the possibility of failure before failure occur (risk analysis method) by assuming the potential failure
that may occur in the products or manufacturing process during the designing phase of the product or manufacturing process.
・One of the most important core tools among IATF16949 core tools.
・It can be divided into DFMEA(product design) and PFMEA(manufacturing process).
Risk analysis method Core tool

Product/process Improve quality, reliability, and safety.
1 5
What happens？ Why happen？ Current Risk reduction FMEA
Failure prevention, 4 measure Failure
Effect Cause
2 mode 2 detection Effectiveness prevention
management. evaluation
Failure mode
Product: ○○ does not function PPAP APQP
Process: parts set miss 3
① Assume potential product/process failure.
② Analyze effect and cause when the failure occur.
③ Evaluate current prevention and detection control against assumed failure. MSA SPC
④ Confirm risk mitigation measure/effectiveness evaluation according to the severity of the risk.
⑤ Improve quality, reliability, and safety and link to failure prevention.
FMEA Relationship with Design/Development and Implementation Process
◆Positioning with product design/development
Start product concept Program approval Prototype Pilot SOP

examination/approval
D-FMEA
Plan Plan Clarify where in the product the significant risk reside, and
Product design/development
execute product design to avoid/mitigate risk.
P-FMEA
Product/process validation
Implement risk analysis for manufacturing process design.
MP
Feedback evaluation/corrective actions

It is important to start from product/process design/development
phase to reflect preventative measures.
Utilization/effect of FMEA
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
• It helps engineers to prioritize and place countermeasures to
APQP phase Program planning/definition Product design/development Process design/development Product/process validation MP/improvement
prevent products and/or process problem occurrence.
Start Completion Optimization Revision • Reduction of design/development rework, “prerequisites” for SPEC,
FMEA timing
test plan, control plan creation.
◆FMEA implementation procedure
・IATF16949 standards recommends the “AIAG&VDA FMEA handbook 1 st Ed.” that is issued in Jun 2019 as a reference book.
・FMEA will be implemented with 7 steps (based on AIAG&VDA FMEA handbook)
Risk
System analysis Failure analysis and risk reduction
communication
Step1 Step2 Step3 Step4 Step5 Step6 Step7
Planning and Documentation of
Structure analysis Function analysis Failure analysis Risk analysis Optimization
preparation the results
Clarification of Documentation and
Clarification of Clarification of risk
Clarification of Clarification of current management communication of
Project definition function/requireme method and risk
reduction measures
analysis results and
analysis target failure chain and implementation
nts assessment conclusion
※Detailed description will be explained later.
Select analysis target with the 7 steps～clarification of failure～complete until risk mitigation measures
Background of AIAG&VDA FMEA Establishment and Overview of the Edition
◆Background of FMEA establishment
1949 1977 1980’s 1993 1996 2008 2019
FORD AIAG AIAG

Developed by US Army
utilization Utilization among US 1st 4th
auto industry AIAG-
VDA unification
Developed for reliability evaluation, VDA
Germany
revealing system and equipment failure. 1st Creating a common
foundation for automotive
Methods, evaluation standards are
◆Overview of handbook edition(change points from conventional FMEA) industry.
standardized independently.
Items Contents
Clarification of FMEA The FMEA implementation process consists of 7 steps; Step 1(planning and definition), Step 2(structure
implementation process analysis), Step 3 (function analysis), Step 4 (failure analysis), Step 5(risk analysis), Step 6(optimization), Step
7(documentation of the results) are defined.
Revision of evaluation items ・Comprehensive revision of the evaluation items (requirements, failure mode, failure effect, failure cause,
failure measures) were implemented.
・Not only focus element (target)* but also its upper and lower level became consideration target.
・Improvement measure (optimization) item column was divided into preventive measure column and detection
measure column.
・A status column was added to make it easier to understand the improvement status.
Revision of S,O,D evaluation ・Evaluation criteria for S (impact), O (frequency of occurrence), D (detection) were revised.
standard ・“organization or product line example” column was added to S, O, D evaluation table.
RPN is abolished and started ・RPN (risk priority value), which is simply multiplied by S, O, D as a risk evaluation standard, has been
AP application abolished, and instead AP (action priority index) has been introduced. In other words, method of prioritizing risk
reduction action became easier to evaluate in the order of S＞O＞D, which is the original requirement.
New FMEA ・Introduction of a new supplemental FMEA (FMEA-MSR) for monitoring and system response in addition to
design FMEA and process FMEA.
・This provides customer with a method for diagnostic detection and hurdle reduction analysis to maintain the
state of safe or compliant to laws and regulations while driving. In other words, it incorporates response to
ISO26262 (HARA analysis required by ISO26262).
＊: Component or individual process that are target for FMEA analysis are called the focus element.
PFMEA preparation process

※Based on AIAG&VDA FMEA study guide 7Step approach
Step1 Plan and Preparation
Plan and preparation Structure analysis Function analysis Failure analysis Risk analysis Optimization Documentation of
results
◆Purpose Clarify target products and team members for P-FMEA
◆Things to consider in Step1

◆Selection and role of team member
Facilitator (coordinator) Manufacturing process/manufacturing engineer Ergonomics engineer

Core team member
Manufacturing process verification engineer PIC of manufacturing process development Quality/reliability engineer
• Possess knowledge based on the experience with relevant product and process and provide information
• Contribution from past FMEA experience
• Incorporate past problems
Project manager PUR PIC Customer representative Design engineer

Expanded team memberー
(Join as necessary)
Maintenance staff Supplier Manufacturing line operator Technical expert
• Provide additional information related to special topics

• Provide advice to lead successful products and process development.
◆ The “5Ts” to consider in project planning ◆ Things to consider in order to define D-FMEA scope
① inTent: Team member shall clarify and understand the purpose and intent of FMEA • Consider entire manufacturing process line.
② Timing: Implement on project plan and evaluate status (receiving~packing/shipping, inspection, rework/repair process etc.
③ Team: It shall be composed of cross-division members with the necessary knowledge • Required SPEC, DWG, 3D model, parts list.
④ Task: Promote with 7 step approach • PFMEA for similar parts.
⑤ Tool: Determine which FMEA tool (forms and software) to use
Step2 Structure Analysis
results
◆Purpose Identify the scope of FMEA by visualizing process elements such as process, process steps, and process work elements.
Process Process steps/analysis target Work elements

Process elements (production line) (each process) (4M※:man/machine/material, environment)
Which production line is the target? What happens if you break down the elements of the process?
※The 4M that is described in handbook is different from those
◆Tool to visualize process elements commonly known, but it is OK to add methods and measurements for analysis.
①Block diagram Example: printed circuit board ASSY line ②Structure tree: express process elements hierarchically example: car navigation
High-level Analysis target Low-level

process process step work elements(4M)
Electronic Electronic
Machine parts Connector
components (E1) components (E2) [1] parts receiving
Soldering
Soldering Soldering Clamping
Man: operator
[2]Mounting electronic components
Printed circuit board Machine: mounter
Printed circuit board ASSY line on printed circuit board
Soldering reflow (Auto) Material: soldering matl.
Envir.: soldering temp.
Scope of this
document [3]Mounting mechanical parts
Man: operator
on printed circuit board
Clamping(manual) Machine: soldering iron
◆Reflection to worksheet [4]Mounting connector
Material: solder material
・Determine the analysis scope with the structure tree and enter analysis target, on printed circuit board Envir.:cleanliness
high-level, and low-level elements. Soldering (manual)
[5]Appearance inspection, Man: appearance inspector
Structure analysis (Step2)
characteristics test Machine: tester
1.Process 2.Process step/analysis 3.Work elements Matl:inspection room brightness
target [6]Packing/labeling/shipping Envir.:test room temp.
Printed circuit board [2] printed circuit board Man: operator
ASSY line soldering reflow Machine: mounter ・For each process, identify work elements that may have adverse effect
Material: soldering matl. in each process from 4M perspective.
Envir.: soldering temp. ・The tree is a base for the next step (function analysis)
results
◆Purpose Identify the scope of FMEA by visualizing process elements such as process, process steps, and process work elements.

Process elements (production line) (each process) (4M※:man/machine/material, environment)
Which production line is the target? What happens if you break down the elements of the process?
※The 4M that is described in handbook is different from those
◆Tool to visualize process elements commonly known, but it is OK to add methods and measurements for analysis.
①Block diagram Example: printed circuit board ASSY line ②Structure tree: express process elements hierarchically example: car navigation

process process step work elements(4M)
Electronic Electronic
Machine parts Connector
components (E1) components (E2) [1] parts receiving
Soldering
Soldering Soldering Clamping
Man: operator
[2]Mounting electronic components
Printed circuit board Machine: mounter
Printed circuit board ASSY line on printed circuit board
Soldering reflow (Auto) Material: soldering matl.
Scope of this
document [3]Mounting mechanical parts
Man: operator
on printed circuit board
Clamping(manual) Machine: soldering iron
◆Reflection to worksheet [4]Mounting connector
Material: solder material
・Determine the analysis scope with the structure tree and enter analysis target, on printed circuit board Envir.:cleanliness
high-level, and low-level elements. Soldering (manual)
[5]Appearance inspection, Man: appearance inspector
Structure analysis (Step2)
characteristics test Machine: tester
1.Process 2.Process step/analysis 3.Work elements Matl:inspection room brightness
target [6]Packing/labeling/shipping Envir.:test room temp.
ASSY line soldering reflow Machine: mounter ・For each process, identify work elements that may have adverse effect
Material: soldering matl. in each process from 4M perspective.
Envir.: soldering temp. ・The tree is a base for the next step (function analysis)
Same as design FMEA, the implementation stage of the process FMEA is an initial stage of process
concept stage. Therefore, formulation of “process flow chart” is introduced as a means of defining
structure/function of the process (line) subject to FMEA analysis in both reference manual/handbook. In
addition, the process flow chart is one of the manufacturing process design outputs required in
IATF16949:2016 8.3.5.2 e).
Please note that the results of structure definition of the target process (process flow chart) shall be
attached to the P-FMEA. This has been mentioned from the stage of the conventional reference manual.
Incoming material receiving/inspection
Delivery (warehouse → sub ASSY line)
【OP010】 bearing shaft grease injection
【OP020】 application of gear grease Note:

Process flow chart does not have to be
Delivery (sub ASSY line→main ASSY line) drawn with process symbols as in the
example.
【OP030】 sintering Brg. Housing press-fit However, it must capture entire process
including transportation (from receiving
【OP040】 gear cover assembly Incoming material ～products shipping).
※The chart is an example from the
【OP050】 ... handbook. (pp.84)
An example of defining structure/function in process design (process flow chart)

Step3 Function Analysis
Plan and preparation Structure analysis Function analysis Failure analysis Risk analysis Optimization Documentation of results
◆Purpose Clarify process step and work elements’ function
(production line) (each process) (4M※:man/machine/material, environment)
Process elements
Overview of the
Function of each process Function of each element
production line
※Consider how delivery destination and end users are handled. What’s the role of the process? What’s the role of each element?
◆Function analysis method

・Structure tree: Clarify what is done in each level. ※Similar to DFMEA, parameter diagram can be utilized.
process function Process stem function/products’ characteristics Work elements (4M) function/process characteristics
[2] Mounting electronic components on Operator Solder material
Printed circuit board ASSY line printed circuit board Function: set printed circuit boards and each Function: solder that is set at specified
Soldering reflow(Auto) parts on the specific location on the mounter temperature will joint printed circuit boar
Function: mount electronic components and each parts.
and connectors on printed circuit boards Function: mount electronic components Mounter
and assemble. (E1,E2) on printed circuit boards and Function: perform mounting of electronic
Solder layer temperature
components on printed circuit boards and
automatically solder by solder reflow. Function: set/maintain at specified temp.
solder reflow.
＜Examples of products characteristics/process characteristics＞
・Products characteristics(measurable products characteristics, function requirements etc.)/process characteristics(manufacturing condition etc.)/laws
and regulation, industry standards, customer requirements, internal requirements.
◆Reflection to worksheet
・Enter function/requirements of each element
Function analysis (Step3)

1. Process function 2. Function/products characteristics of 3. Function/process characteristics of
process steps work elements
Consideration of
function at the delivery Organization: mount electronic components and Mount electronic components (E1, E2) on printed Man: qualified (certified) operator
destination and connectors on printed circuit boards and assemble. circuit boards and automatically solder by solder Machine: mount components on board
customers are also Plant to be delivered: assemble to navigation main unit. reflow. Material: use specified solder
required. End user: operate car navigation system Environment: solder layer temperature setting
Step4 Failure Analysis
◆Purpose
Examine what are the potential failure modes for the analysis target, what kind of effect may be on the high-level when failure occur, and
what is the cause of the failure at the low-level (clarify failure chain).
Process Process step/analysis target Work elements
(production line) (each process) (4M: man/machine/material, environment)
Failure What happens? Failure Why happen? Failure

Failure chain effect mode cause
◆Failure analysis method

Structure tree: clarify failure of each work element
process process step work elements (4M)
Operator
[2] Mounting electronic components on Solder material
Printed circuit boar ASSY line Function: set printed circuit boards and each
printed circuit board Function: solder set to the specified temp.
Function: mount electronic components parts on the specific location on the mounter.
Soldering reflow(Auto) Failure: operator set error. Joins printed circuit board and each part.
and connectors on printed circuit boards
Function: mount electronic components Failure: joint failure due to the use of non-
and assemble. Mounter
(E1,E2) on printed circuit boards and specified solder.
Failure: electronic components (E1,E2) Function: perform mounting of electronic
automatically solder by solder reflow. components on printed circuit boards and
are not mounted, and cannot process
Failure: electronic components (E1,E2) solder reflow. Solder layer temperature
signal.
are not soldered. Failure: electronic components (E1,E2) Function:set/maintained at specified temp.
are not adsorbed. Failure: solder layer temp not adequate.
・Enter each failure effect/failure mode/failure cause.
Failure analysis (Step4)
1. Process function failure effect S 2. Process step failure mode 3. Work elements failure cause
1-1 Organization: electronic components 6 Man: operator set error
(E1,E2) are not mounted, and cannot
1-2 process signal. Machine: electronic components (E1,E2)
Electronic components (E1,E2) are are not adsorbed.
Delivery destination: input signal is not
not soldered.
1-3 transmitted and cannot process control. Material: non-specified solder use.
End user: car navigation system does not
1-4 operate. Environment: solder layer temp. failure.
Step5 Risk Analysis
◆Purpose Based on the results of failure analysis and current prevention/detection control, assess severity S, occurrence frequency O, and
detection D to estimate risk, and determine priority of the necessity of treatment.
Process Process step/analysis target Work elements Consider impact not only on own factory, but also
(production line) (each process) (4M:man/machine/material, environment) shipping destinations and end users.
Occurrence frequency S
Current O
Failure Failure Failure Determine action
prevention and priority
effect mode cause detection control Detection
O D
Severity
Cannot process S ○○ is not set at the correct D
signal due to poor Soldering not done
location Three combination assessment
conduction
◆Prevention/detection control with PFMEA ◆Criteria for risk assessment

Prevention control Detection control ・Severity of the effects(S,Severity): severity of the failure effect.
・Frequency of occurrence(O,Occurrence): frequency of failure
occurrence.
～Process design to prevent failure～～Detect failure by inspection～
Equipment comprehensive management In process inspection
・Detection rate(D,Detection): failure cause, failure mode detection rate.
SPC management Final inspection ※S/O/D is assessed on a scale of 10 using each evaluation table.
MSA etc. Product audit etc.
Action priority(AP)
An index to assess in order of S/O/D and express priority of actions to
◆Reflection to worksheet reduce risk.
・Implement S assessment for failure effect and O, D assessment for ※Use evaluation table to express priority as High,Midium,Low.
current prevention/detection, then assess action priority (AP) and Please refer to attachment for detailed assessment criteria.
Risk analysis(Step5)
enter (results). Special
Current prevention control for O 2. Current detection control for failure D AP
. Failure analysis(Step4) charact
failure cause cause/failure mode eristics
1. Process S 2. Process step failure 3. Work elements
1-1 Implement according 6 Implement appearance inspection 6 M ●
function failure mode failure cause according to circuit board appearance
to work procedure
effect 1-3 inspection equipment XX1 and
WI001
appearance inspection procedure manual
・・・ 6 ・・・・・・ 1-4 IP1.
Step5 Risk Analysis
Reference: Example of documents that constitutes “control plan” in Japanese company
All information related to “good parts conditions” for individual processes such as equipment
processing conditions, jigs and tooling used, inspection method (including frequency/equipment
used), and type of sub-material (coolant undiluted solution type including dilution ratio/replacement
frequency etc.) are required to be defined in the “control plan” and actually “controlled”.
Machining
Press Machining Press Washing Heat treatment Welding Assembly
(lathing)
(lathing) fitting
PQCT OP5 One point

OP5 OP5
Equipment (reporting flow)
Inspection (part of) work
condition table
standard sheet procedures
（contents）
※Understanding of “control plan”: all process control forms that define “good parts conditions” in individual
processes.
※It is desirable to include information to enable “reproduction” of the applicable process.
An example of documents that constitutes a “control plan” for a line.
Step6 Optimization
◆Purpose
Determine actions to reduce risk, and re-evaluate effectiveness of those actions and optimize design.
Process Process step/analysis target Work elements

(production line) (each process) (4M: man/machine/material, environment)
S Optimization
Risk assessment S
O D Risk re-evaluation
High risk Risk reduction O D
What happens? Why happen? Current items
Failure Failure Failure measure
prevention/dete effectiveness
effect mode cause
ction control evaluation
Consider additional prevention/detection action
◆ Things to consider for optimization ◆ Continuous improvement

Review results of risk analysis with team. ・Improve quality by review FMEA according to change points.
・Can be utilized as a base for similar model’s FMEA base.
Effective to implement in below order.
◆Collaboration of organization, customer, and supplier
①Process change to remove/reduce failure effect.
・ By communicating between FMEA Team, management, customers,
②Process change to reduce occurrence of failure cause. and suppliers, it is possible to deepen the understanding of process
③Enhancement of detection of failure modes or causes. function and defects.
→ By doing this, it is possible to share knowledge for risk reduction and
※ Process changes require to re-evaluate all affected process. lead to optimization.
・Conduct S evaluation for failure effect, O, D evaluation for current prevention/detection control, then evaluate and enter action priority (AP).
Optimization (Step6)
Prevention control Detection PIC Target Sta Action details Completi S O D AP Special
completion tus on date characteristics
control
date
Double check when Introduce Test PIC: ○/○ Co Introduce abc company’s mounter ●/● 6 4 3 L ●
mounter with mpl
feeding material and Honda- ete MT777
detection
selecting programs. function. san d
Step7 Documentation of Results

◆Purpose
Summarize FMEA activity and share them with the organization or customer/suppliers as necessary.
DP-FMEA report
Analysis details/results Results sharing

DP-FMEA Organization Supplier Customer
High risk failure details and action priority
Action details to reduce risk
As necessary
◆FMEA report
・Mainly used for reviewing plan vs. actual and analysis results of each task by FMEA team and other relevant members.
Items Action items

① Final situation compared to initial target set in the project plan.
(5T: intention, timing, team, task, tool)
② Clarification of analysis scope and new items.
③ Summary of function development process.
④ Summary of high-risk failures determined by the team, and summary of the S/O/D
DP-FMEA report contents evaluation table and action priority criteria (action priority table etc.) determined by the
organization.
⑤ Summary of actions taken or planned for high-risk failure.
⑥ Plan for ongoing actions.
・Commitment and timing to complete open action items (incomplete).
・PFMEA revision during MP.
Example of P-FMEA (printed circuit board ASSY line: solder reflow process)
Plan and preparation (Step1) Honda Cars India Ltd.
Company name Title S：Severity criteria（10～1） O：Occurrence criteria（10～1）
D：Detection criteria（10～1）
Location Start date DFMEA number AP：Action priority (H/M/L is determined by S/O/D table)
The expected action is defined by H (high), M (medium), L (low)
Customer name Revision date Preparer
Model(year)/program Cross-function team Confidentiality level Function analysis (Step3)

2. Function/products 3. Function/process
Structure analysis (Step2) characteristics of characteristics of
process steps work elements
1. Process 2.Process step/analysis 3.Work elements
target Organization: mount electronic Mount electronic Man: qualified (certified)
components and connectors on components (E1, E2) on operator
printed circuit boards and printed circuit boards and Machine: mount components
ASSY line soldering reflow Machine: mounter
assemble. Plant to be delivered: automatically solder by on board
Material: soldering matl.
assemble to navigation main unit. solder reflow. Material: use specified solder
End user: operate car navigation Environment: solder layer
system temperature setting
Failure analysis (Step4)
1. Process function failure effect S 2. Process step failure mode 3. Work elements failure cause
1-1 Organization: electronic components (E1,E2) are not mounted, 6 Man: operator set error
and cannot process signal.
1-2 Electronic components (E1,E2) are Machine: electronic components (E1,E2) are not adsorbed.
Delivery destination: input signal is not transmitted and cannot not soldered.
1-3 Material: non-specified solder use.
process control.
1-4 End user: car navigation system does not operate. Environment: solder layer temp. failure.
Risk analysis (Step5)
D AP Special characteristics
Current prevention control for failure cause O 2. Current detection control for failure cause/failure mode
1-1 Implement according to work procedure WI001 6 Implement appearance inspection according to circuit board appearance 6 M ●
inspection equipment XX1 and appearance inspection procedure manual IP1.
1-3
1-4
Optimization (Step6)
Prevention control Detection PIC Target Stat Action details Completion S O D AP Special
completion date us date characteristics
control
Double check when Introduce Test PIC: ○/○ Co Introduce abc company’s mounter ●/● 6 4 3 L ●
mounter with mpl
feeding material and Honda- eted MT777
detection
selecting programs. function. san
This is the example of conventional paper format, but the use of FMEA software is also recommended from the viewpoint
of ease of use/management.
P-FMEA Evaluation Criteria 1/3
Criteria for process FMEA severity
S
Effect on own factory Effect on delivery destination factory Effect on end users
Affect the vehicle/other vehicles’ safe operation.
Affect the health of the vehicle driver or the
10 Failure pose serious health/safety risk to manufacturing/assembly operators.
passengers. Affect the health of road
users/pedestrians.
9 Violation of factory regulations.
Line stop and shipping cancellation beyond

100% of the affected production full production shift. On-site
processes are scrapped. Failure repair/replacement is required (assembly
8 pose violations of factory regulations, at the end user). Vehicle’s primary loss
and/or health/safety risk to Failure pose violations of factory function (required
manufacturing/assembly operators. regulations, and/or health/safety risk to for normal
manufacturing/assembly operators. operation over the
Products are sorted, and partially Line stop and shipping cancellation for 1 life of the vehicle)
scrapped. Results in deviations from hour to a full production. On-site
7 decrease
the main process, reduced line speed, repair/replacement is required (assembly
and manpower increase. at the end user).
100% of production
6 Line stop within 1 hour. loss
process is Needs to be
Vehicle’s
reworked Some products are affected. High secondary
Part of production online and possibility of additional defective products
5 function decrease
process is accepted. and sorting is necessary. No line shut
down.
Defective parts
100% of production Very (high
4 Needs to be needs serious
process is No other sorting of presence of)
reworked/pro action plan.
defective parts is
cessed within Defective parts
Part of production required. unpleasant appearance, noise,
3 station. needs minor Somewhat
process is vibration, roughness, or touch.
action plan.
Defective parts
A little inconvenient for processes, Feedback to supplier
2 does not require A little
operations, and operators. is required.
action plan.
1 No recognizable effect
Criteria for process FMEA Occurrence
O
Type of control Preventive control
10 None No preventive control.
9
Behavioral
almost no effect.
8
6 somewhat effective.
To prevent failure cause, the preventive
Behavioral or technical
controls are
5
4 effective.
3
Best practice, behavioral, or technical
very effective.
2
Preventive control is very effective to prevent failure cause that is driven by design
1 Technical
(e.g. parts shape) or process (e.g. fastener or tooling).
Criteria for process FMEA detection Process FMEA Action Priority (AP)
Ｄ Maturity of detection Possibility of detection S O D AP
method (maturity) (opportunity) 10-6 10-1 H
Test/inspection method is not 10-2 H
10 Failure mode does not/cannot be detected.
established. 5-4
1 M
Test/inspection method almost
9 Failure mode cannot be detected easily with random or sporadic audits. 10-9 10-7 H
never detect failure mode.
Inspection using human (visual, touch, hearing), or manual measurements 3-2 6-5 M
8
(attributes or variables) to detect failure mode or failure cause. 4-1 L
Test/inspection method is not
proven to be effective and reliable. Machine based detection (automatic or semi-automatic light notification, 1 10-1 L
7 buzzer etc.), or use of inspection equipment to detect failure mode or failure
cause such as 3D measurement machine etc. 10-8 10-1 H
Inspection using human (visual, touch, hearing), or manual measurements 10-2 H
6 (attributes or variables) to detect failure mode or failure cause (including 7-6
1 M
Test/inspection method is proven products’ sample check).
to be effective and reliable. 10-7 H
Machine base detection (semi-automatic accompanied by notification with 8-7 5-4
5 light, buzzer etc.), or use of inspection equipment such as 3D measurement 6-1 M
machine etc. to detect failure mode or failure cause.
10-5 M
Detect downstream failure Machine based automatic detection 3-2
4 4-1 L
mode and method or system that prevents further
action/process identifies a product as 1 10-1 L
System is proven to be effective
non-conforming and allows it to be
and reliable, and results of gauge
Detect failure mode within automatically move to rejected parts 10-5 H
3 R&R is acceptable. 10-8
station and storage. Non-conforming parts are
4-1 M
controlled by robust system to prevent
outflow from the plant. 6-4 10-2 M
7-6
Detection method is proven to be 1 L
effective and reliable. For
Machine based detection method to detect cause and prevent failure mode 5-1 10-1 L
2 example, there are
occurrence (non-conforming products).
performance/record of method, 10-5 M
error proof verification. 10-8
3-2 4-1 L
Failure mode does not physically occur by design or manufacturing process, or detection method is proven to
1 7-1 10-1 L
always detect failure mode or failure cause.
1 10-1 10-1 L
How to Read AP Evaluation
◆Example How to read AP evaluation with current risk analysis results
Process FMEA action priority (AP)
1 S O D AP
10-6 10-1 H
10-2 H
5-4
1 M
4
10-9 10-7 H
2 3
3-2 6-5 M
4-1 L
1 10-1 L
10-8 10-1 H
◆Confirm scores in order of S→O→D and evaluate AP. 10-2 H
7-6
1 M
① Confirm Severity score →6
② Confirm Occurrence score →6 8-7 5-4
10-7 H
③ Confirm Detection score →6 6-1 M
④ AP evaluation ranks is determined. 10-5 M

3-2
4-1 L
1 10-1 L
10-5 H
10-8
4-1 M
6-4 10-2 M
7-6
1 L
5-1 10-1 L
10-5 M
10-8
3-2 4-1 L
7-1 10-1 L
1 10-1 10-1 L
Confirm scores in order of S→O→D and evaluate AP.

Structure of SQM 46
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Process Quality Control Table-II 47
2) What are monitoring items?

Factor (process)-oriented monitoring items (Process
Result-oriented monitoring items (Process Quality Control
Quality Control Table Part II: manufacturing
Table Part I: quality characteristics)
conditions)
Quality characteristics of products Manufacturing conditions that satisfy quality
e.g. outside diameter/inner diameter/surface roughness in characteristics of products
case of machining of parts e.g. hydraulic/air pressure of equipment, etc.
3) What are control levels?

The definition in JIS is, "Control levels are values that indicate the condition of a stable process". In general, they
refer to the control limit lines in control charts.
4) Preparation procedure of PQCT

① Comprehend the flow of the previous and next processes and whole process and make clear the process
(station) to be controlled.
② Divide the whole process into a number of unit processes (stations) and determine the unit processes to be controlled.
Points to consider: Impact on quality, ease of control, ease of checking, ease of taking measures, etc.
③ Clarify the operations for each unit processes to be controlled, and prepare operation standards.
④ Determine the monitoring items in the unit processes to be controlled.

Points to consider: Understanding of the relationship between the quality characteristics of the finished product and the
quality characteristics at each process, as well as the manufacturing conditions and quality characteristics to be built in at
each process.
⑤ Examine sampling and measurement methods, and define the sampling methods, measuring equipment, and methods for monitoring
items. Also, immeasurable items must be discarded as monitoring items.
⑥ Examine control methods and define when, by whom, what measuring equipment to be used, as well as confirmation frequency, and recording method
and format, in order to control. On this occasion, clarify who is responsible for.
/ 48
Processs No. 1 Failure Mode Critical Item Production Condition Control
Process Name Critical Item Quality Characteristics Data [ Equipment, die, fail safe equipment, oil pressure, voltage, temperature, and others ]
Equipment Name Filing Control Control
(Supplier Name) No. Control Item Specification Chkd By Check Method Frequency Data Type Freq. Item Value Chk By Check Method Frequency Data Type Illustartion
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
TO BE IDENTIFIED
TO BE IDENTIFIED
AS PER PROCESS FLOW DIAGRAM
ENTER THE
FREQUENCY OF
DATA RECORDING IS SUBMITTING DATA
MAINTAINED AT TO HCIL
SUPPLIER END TO
BE WRITTEN.
CONTROL ITEMS AND CONTROL STDS.

SHOULD BE SAME AS MENTIONED IN OPS/ WI
FAILURE MODE CLASSIFICATION
PRODUCT RELATED PROCESS RELATED

CONTROL POINTS CONTROL POINTS
< Complete vehicle's Failure Mode Classification > 1. Driving function failure, 2. Turning function failure, 3. Stopping function failure, 4. Guarding function failure, 5. Insulation function failure,6. Protection function failure, 7. Exhaust gas control function failure, 8. Identification function failure
FORMAT NO: HCGQF QD 0029/APR'17 PAGE 2/2
Relationship between ISO 9001 and Legality assurance 49
System of Honda's legality assurance based on ISO 9001
Certification Legal information Approval information

Division
Development Drawings
Division
Quality Control
Division QS
Division (Control Plan)

or
Ｇ-ＨＱＳ
Inspection Division
Genpo QS
Inspection Standard (GIS)

Division
Supplier Process QC table

QS
(PQCT)
Operation Standard
Division
QS
Supplier Operation
Standard
COP is assured by correctly reflecting the legal information and approval information on the
tools, with the fundamental quality assurance organization in ISO 9001 as the basis
What is required for receiving inspection (GISInsp record)
■ control plan (E.g.: Receiving inspection (Effective filtration area of air cleaner element)
■ Inspection standard * in accordance with HCIL Inspection Standard
■ Inspection Result Sheet

Part 部番
Number 17224-XXX-XXX
2012年度 Regular
FY2012 定期検査成績表 Inspection Result Sheet
AIR CLEANER ELEMENT
部品名
Part Name
検査項目
Inspection 検査方法
Item Inspection 規格
method Standard No. 1月
Jan 2月
Feb 3月
Mar 4月
Apr 5月
May 6月
Jun 7月
Jul 8月
Aug 9月
Sept 10月
Oct 11月
Nov 12月
Dec
1 4002 4007 4003 4006 4003 4002 4001 4002 4003
Effective Dedicated ≧4000cm
有効濾過面積専用測定機 4000cm 2 2 2 4002 4002 4007 4001 4007 No
生産なし 4006 4005 Receiving
生産なし生産なし 4008 criteria
4011
以上 production
filtration area measuring 3 4006 4003 4006 4002 4002 4002 4005 (standard 4001 values)
4003
machine 4 4009 4008 4003 4002 4003 4002 4002 4002 4003
must be met
In audits, inspection data and PQCT, etc. (including for the parts supplied from other
Genpos) must be presented as an evidence for mass-production control described in the
control plan.
Inspection Standard 51
PURPOSE : The purpose of inspection report is to ensure that final inspection of lot/batch is
conducted as per PQCT and self assurance for quality of parts by supplier.
PART INSPECTION AND ASSURANCE BY SUPPLIER
• HCIL QD shall provide inspection result list (standard) of each part to supplier before DANKAKU event &
can be revised before mass production where ever required.
• Supplier shall perform inspection of all parts before delivering to HCIL to ensure that parts meet all
requirement as prescribed in the drawing and on inspection result list (standard).
• The supplier shall submit the inspection results to HCIL at the frequency specified. The inspection results
provided by sub-suppliers shall be included in the Inspection Check Sheet, etc. to be submitted to HCIL.
• It is required to submit inspection report for each supply during Development.
• It is required to submit inspection report for each part on Monthly basis in regular Mass Production for
both DOL & NON DOL parts.
• Inspection Items of Inspection Result list are kept in same sequence while entering actual Observations in
Monthly reports for both DOL & NON DOL parts.
• Each inspection report format bears drawing / part No. and Part name.(Before using the format it is required
to match both the items ).
• Minimum 5 No. or 1 No./cavity inspection report is required or as specified in PQCT.
• Inspection report shall be accompanied with identified parts ( inspected parts )for the first supply of every
manufacturing lot / batch. Inspection report shall bear the Lot / Batch No.
• If subsequent supplies are made of same previous Lot/Batch, then suppliers are required to submit only
photocopy of the inspection report already submitted to HCIL along with the first supply, identifying Lot /
batch No.
• These inspection standard may be revised or updated as & when required by HCIL – MPQ.
Inspection Result List 52
㉓
SUPPLIER……………………………………………. ㉔
DATE………………………………………
DESTINA TION 1 Part number
⑧ Inspection result list (Standard)
Purpose ⑤ Approval seal ⑥ 2 Part name
Part No ①
Parts name ②
Periodic inspection Special inspection(analysis of defects) 3 Manufacturing lot number
Lot size Inspection of initial product Request of measurement
Lot No ③ ④ 4 Lot size
Reasons ⑦
5 Encircle the applicable purpose of inspection.
( Illustration and special mention ) ㉖
6 Approval from supplier
7 Write latest D.C. No if not given in the revision table
8 Deleted not to be filled
9 Encircle the applicable unit of measurement
10 Serial number
11 Inspection parameter including regulation items
12 Inspection method/instrument name
13 Standard value/sample
14 Special remark of inspection about the part
⑨ Unit m mm 15 Encircle applicable judgement
Inspection Sample
No Method JUDG.
items Standard 1 2 3 4 5
16 Revision number
⑩ ⑪ ⑫ ⑬ ㉒
17 Revision date
18 Revision article
19 Revision prepared by
20 Revision checked by
21 Revision approved by
22 Observed value against standard value
Investigation ⑭ ⑮ Judgement
Acceptable 23 Supplier name
Rejectable
24 Date of inspection by supplier

-⑯ ⑰ ⑱ ⑲ ⑳ ㉑㉕
No Date Articles Prep by Chk by App by D/C No.
25 Design change no.
HCGQF QD 0017/APR'17 26 Mention Drawings/Sketch of part including special mention
Inspection Result List –DOL Parts 53
SUPPLIER NAME:
(CHARACTERISTICS AS PER LATEST INSPECTION RESULT LIST (STANDARD)
INSPECTION RESULT LIST - DOL PARTS
PART NAME PART NO. MODEL COLOUR ISSUE DATE MONTH
➀ ➁ ➂ ➃ ➄ ➅
Date
S.N. Inspection items Method 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Standard
1 ➆ ➇ ➈ ➉
2
3
4
5
6
7
8
9
10
11
12
13
14
15
LOT NO. ⑪
QTY. ⑫
F IN A L
S T A T US ⑬
INSP. BY ⑭
REMARKS (SUPPLIER) CHECKED : REMARKS (HCIL) CHECKED :
SUPPLIER HCIL
APPROVED : APPROVED :
MIN
MAX
1 Part name: Mention HCIL Part Name 7 Inspection Items: Mention inspection Items 10 Input Min & Max value in Each date column
as mention in Inspection result List
2 Part number: Mention Latest HCIL Part No. 11 Lot No: Mention Lot date
8 Inspection Method: Mention inspection
3 Model: Mention Model code as mention in PQCT Method as mention in Inspection result List 12 Qty: mention Dispatch Qty
4 Colour: Mention HCIL Colour Code if applicable 9 Inspection Standard: Mention inspection 13 Final Status: Mention Lot Judgement ON/NG
5 Issue Date: Mention Issue date of this Report Standard as mention in Inspection result 14 Insp By: Mention Name & Sign
List
6 Month: Mention report Month
Send Approved report by 5th of every month

Monthly Inspection Result List 54
MONTHLY INSPECTION RESULT LIST

SUPPLIER NAME:
(CHARACTERISTICS AS PER LATEST INSPECTION RESULT LIST (STANDARD)
PART NAME PART NO. MODEL COLOUR ISSUE DATE MONTH
➀ ➁ ➂ ➃ ➄ ➅
Date
S.N. Inspection items Method 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Standard
1 ➆ ➇ ➈ ➉
2
3
10
11
12
13
14
15
QTY. ⑪
F IN A L
S T A T US
⑫
INSP. BY ⑬
REMARKS (SUPPLIER) CHECKED : REMARKS (HCIL) CHECKED :
SUPPLIER HCIL
APPROVED : APPROVED :
MIN
MAX
1 Part name: Mention HCIL Part Name 7 Inspection Items: Mention inspection Items 10 Input Min & Max value in Each date column
2 Part number: Mention Latest HCIL Part No.
as mention in Inspection result List
11 Qty: mention Dispatch Qty
3 Model: Mention Model code as mention in PQCT 8 Inspection Method: Mention inspection
Method as mention in Inspection result List 12 Final Status: Mention Lot Judgement ON/NG
4 Colour: Mention HCIL Colour Code if applicable
9 Inspection Standard: Mention inspection 13 Insp By: Mention Name & Sign
5 Issue Date: Mention Issue date of this Report Standard as mention in Inspection result
6 Month: Mention report Month List
Send Approved report by 5th of every month

Structure of SQM 55
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Operation Standard 56
1) What is an operation standard?
Managing work done by human beings. In other words, drawing up an appropriate operation standard and conducting
education /training for work based on this standard to make it unlikely that operation errors made by people will occur.
Operation standard
The operation standard documents the procedure for operation that will achieve the required
quality efficiently and safely. It is a means for obtaining the same understanding and results
regarding operation even when people are replaced.
2) Creating an operation standard
Contents of operation standard

1) Part name and process name
2) Component parts to use
3) Work sequence instruction
4) Control items, control methods, quality characteristics, criteria (limit sample, master sample included)
5) Name of machine and/or tool used and direction for use.
6) All key points other than above (key points include possible failure modes, such as potential non -
conformity problems or effects on the product, which may occur if the OPS are not being followed).
7) Points relating to lot control, FIFO, etc.
8) Reaction plan for abnormal condition.(Descriptions of reporting rules and routes, etc.)
9) Directives for changeover of materials, lines or machines.
10)If applicable, check and maintenance of equipment.
11)Precaution statement for thorough compliance with operation standard. (Statement to prohibit operations
other than in the operation standards.)
Points for creating an operation standard
① Do the contents enable the objective of the operation to be accurately accomplished?
② Are the focus (point) of the operation and criteria/past problems, etc. made clear?
③ Are the reasons for the importance of the focus and criteria/past problems, etc. explained?
④ Is the operation standard easy to understand, easy to read using photographs, etc., and easy to
comply with for everybody?
⑤ Does the operation standard allow regular reviews and improvement/maintenance to be carried
out continually?
Operation Standard
Inputs Details Reqd. Critical items Issue & Revision

• Drawings,
• To be confirmed with
• Process
• Part Name, Component Parts & Work actual Gemba Condition
quality Mark Critical
Sequence Instructions. & Approval to be done by
control table quality
• Control items & control method appropriate personnel
• Past history characteristics
• Points relating to lot control, FIFO, etc. designated by the
• Measuring with a symbol
• Clarify inspection methods and operation supplier
Equipment's specified by HCIL
key points. • When revising operation
& Tooling (Q) or supplier’s
• Provide detailed and easy-to-understand standards, record history
details equivalent
instructions with photographs. and reasons of revisions,
• Safety symbol.
• Describe control points for past problem. and identify the current
Gadgets to
revision status.
be used
What Supplier’s Need to Do:

• Prepare operation control standards for all the work areas in accordance with the requirements
from HCIL.
• Confirmation with Actual Work & Training to Operator’s.
How to Do:
• Include HCIL guideline when preparing for operation control standards:-
1) Past trouble, Critical Items
2) Work sequence
3) Quality & Process parameters as per Process Quality Control Table
57
• Prepare in local language for easy understanding.
Content of OPS 58
Identifies the part processed at that work

Part no. & Part name station
Broadly defines the process carried out at that

Operation stage/ process
work station
Sequence of activities Guides operator how to perform the job
Control items Defines imp. Parameters to be checked
Control limits Defines tolerances on control items
Define guidelines for inspection of control

Inspn method, freq, resp.
items
Tells - how to proceed in case of control item

Reaction plan
not found within limits (Reporting Rule & Route)
Familiarize with possible defects to be taken

Potential defects
care off
References Documents to be seen for details

59
• ACTIVITIES NOT CLEAR WITHOUT PHOTOS/ SKETCHES

• CONTROL ITEMS, LIMITS NOT DEFINED
• INSPECTION METHOD, FREQ., RESP. NOT DEFINED
• REACTION PLAN NOT DEFINED
• POTENTIAL DEFECTS NOT SHOWN
60
60
REACTION PLAN
PART NAME , No., MODEL
OPERATION STAGE/ PROCESS
• ACTIVITIES DEFINED WITH POTENTIAL DEFECTS

PHOTOS/ SKETCHES
• CHECK POINTS, CONTROL
LIMITS, INSPECTION - FREQ.,
METHOD & RESPONSIBILITY
• RECORDS GENERATED
• REFERENCES
• REVISION POINTS
61
61
AT START : CALL
SUPERVISOR FOR M/C
ADJUSTMENT
CHECK POINTS WITH DETAILED PROCESS AT END : HOLD THE

LOT
STDS; FREQUENCY; WITH ILLUSTRATIONS
REACTION PLAN &
DEFECT PHOTOS
Structure of SQM 62
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Identification and Traceability 63
PURPOSE : To ensure traceability so that, just in case of a non-conformity in the product, the
cause and quantity of products which may be affected by the said cause are traced down for a
prompt corrective action.
Lot Control Specified Parts :Lot Control specified parts shall be those specified in HES A 3050
as critical safety parts, (Identified in drawing also ).
Lot No. Formation:
•The supplier shall identify critical processes and select processes for which Lot Control is required
to be done, (Only for Lot control specified parts).
•The supplier shall fix the Lot Control Method in such a way that the manufacturing history and
releasing records are possible to be retrieved by identifying method particular to the lot control in
the select process. The Lot formation standards are as follow:
No. Classification Criteria for Manufacturing Lot Formation
1 Material Form a manufacturing lot for each material charge No. or batch.
Form a manufacturing lot when tooling in a process (including inspection
2 Mean
process) is set up.
Form a manufacturing lot for each manufacturing assignment which is
3 Equipment
made to two or more machines, equipment, molds, production lines, etc.
4 Work shift Form a lot for each production date or work shift.
Identification and Traceability 64
•Control of Manufacturing Lot

•The supplier shall determine the following matters in consultation with HCIL.
•Manufacturing lot forming unit, manufacturing lot forming process and key process.
•FIFO control method
•Display method of manufacturing lot identification (manufacturing lot number structure,
identification display method on each delivery container, display languages, barcode labels, etc.)
•The supplier shall establish a system for recording manufacturing lot, which enables
manufacturing lot and delivery lot to be retrieved from the manufacturing history of parts.
•Method of manufacturing lot control, manufacturing lot number display, etc. shall be defined in “Lot
control (Lot Number Display Details)”. The “Lot Control (Lot Number Display Details)” shall be
reviewed and approved by HCIL prior to start mass production.
•The designated format of “Lot Control (Lot Number Display Details)” is recommended for use.
However, in case that HCIL confirms that the format submitted by the supplier is equivalent to “Lot
Control (Lot No. Display Details)” format, it may be substituted for Lot control (Lot No. Display
Details)”.
•If any changes to the process that may affect quality are found in a lot other than the
manufacturing lot forming unit set forth in section above, record such changes as a manufacturing
history and separate the lot.
•If a need arises to change matters at the production stage or to add lot-control-specified parts, it
shall be determined after consultation with HCIL (receiving quality section) and take appropriate
actions.
Lot No Display Details 65
LOT NO DISPLAY DETAILS 1 PART NO AS PER HCIL DRAWING
PART NO ① SUPPLIER NAME
2 PART NAME AS PER HCIL DRAWING
PART NAME ② ③ 3 NAME OF SUPPLIER
④
IMPORTANT PROCESS
4 IN PARTS MANUFACTURING IMPORTANT PROCESS
SELECT PROCESS
STRUCTURE OF LOT NO ⑤ SHALL BE INDICATED.

⑥
LOCATION OF LOT NO.IDENTIFICATION
5 STRUCTURE OF LOT NO TO BE SHOWN (I.E. HOW
⑦
LOT NO. IDENTIFICATION METHOD THE LOT NO WILL BE DISPLAYED, FOR EXAMPLE
⑧
ILLUSTRATION OF PARTS LOT CONTROL
DATE, MONTH & YEAR OF MANUFACTURING ETC.).
6 LOCATION I.E. AT WHICH PLACE ON THE PART THE
LOT NO SHALL BE DISPLAYED.
7 METHOD OF IDENTIFYING THE LOT I.E. BRIEF
MEANING OF LOT NO STRUCTURE.
8 ILLUSTRATION OF PART SHOWING SPECIFIC
LOCATION OF LOT NO.
9A DATE ON WHICH LOT CONTROL METHOD IS ISSUED
FROM SUPPLIER.
9B DETAILS OF CHANGES MADE
9C IN-CHARGE - SUPPLIER, FINALIZING LOT NO
IDENTIFICATION METHOD.
PART NO. CHANGE APPROVAL [SAME LOT NO DETAILS REMAIN APPLICABLE]
10 APPROVAL OF GROUP OFFICER, INCHARGE & HOD -
PQ
⑪ ⑫ ⑬ ⑭ 11 DATE OF REVISION FOR LOT CONTROL DISPLAY
Date of Issue D/C No. New Part No. Prep By Check By App By
Honda Cars India Limited
⑨ ⑨ C ⑩
12 UPDATED DESIGN CHANGE NUMBER OF PART
⑨ a ⑨ b
13 PART NO. AS PER LATEST HCIL DRAWING
Rev.No Date of Issue Change Contents Prep By Check By App By Prep By Check By App By
Lot No. Details Approval Supplier Honda Cars India Ltd 14 IN-CHARGE - SUPPLIER, FINALIZING LOT NO
HCQF CM 0021/ APR'17
Lot No Display Details 66
LOT NO DISPLAY DETAILS
1 PART NO AS PER HCIL DRAWING
PART NO ９００１８－Ｓ００－００００
SUPPLIER NAME 2 PART NAME AS PER HCIL DRAWING
PART NAME ＢＯＬＴ, ＦＬＧ
XYZ Ltd.
Enter Lot form ing process and circle key process 3 NAME OF SUPPLIER
IMPORTANT PROCESS Material - Cold Working - Heat Traeatm ent - Galvanizing - inspection
SELECT PROCESS
STRUCTURE OF LOT NO 70404 4 IN PARTS MANUFACTURING IMPORTANT PROCESS

On the side of the container.
SHALL BE INDICATED.
LOCATION OF LOT NO.IDENTIFICATION
LOT NO. IDENTIFICATION METHOD

Labeling 5 STRUCTURE OF LOT NO TO BE SHOWN (I.E. HOW
ILLUSTRATION OF PARTS LOT CONTROL
THE LOT NO WILL BE DISPLAYED, FOR EXAMPLE
● Material DATE, MONTH & YEAR OF MANUFACTURING ETC.).
① Lot structure : numbering per coil.
② Lot number : 070402A ( reads April 2, '07, steel type: A)
③ Lot control record: record material records in conjunction
6 LOCATION I.E. AT WHICH PLACE ON THE PART THE
with the material lot number.
LOT NO SHALL BE DISPLAYED.
● Cold working
① Lot structure : total no. of parts processed per day. 7 METHOD OF IDENTIFYING THE LOT I.E. BRIEF
② Lot number : 070403A ( reads April 3, 2007)
③ Lot control record: record material lot number in conjunction with total MEANING OF LOT NO STRUCTURE.
number of cold-working processes.
● Heat Treatment 8 ILLUSTRATION OF PART SHOWING SPECIFIC

① Lot structure : total no. of parts processed per cold working lot.
② Lot number : 070404A ( reads April 4, 2007)
LOCATION OF LOT NO.
③ Lot control record: record in conjunction with cold-working lot, heat
treatment lot and total of heat treated parts. 9A DATE ON WHICH LOT CONTROL METHOD IS ISSUED
● Plating FROM SUPPLIER.
① Lot structure : total no. of parts plated per heat treatment lot.
② Lot number : 07/04/05 ( reads April 5, 2007)
③ Lot control record: record in conjunction with heat treatment lot, plating lot Lot No.
07/04/05
9B DETAILS OF CHANGES MADE
and total of plated parts.
● Inspection
9C IN-CHARGE - SUPPLIER, FINALIZING LOT NO
① Lot structure : inspection lot per plating lot.
② Lot number : 07/04/05 (reads April 5, 2007)
③ Lot control record: record in conjunction with plating lot, inspection lot,
release lot, no. of inspected parts and no. of released parts. 10 APPROVAL OF GROUP OFFICER, INCHARGE & HOD -
PART NO. CHANGE APPROVAL [SAME LOT NO DETAILS REMAIN APPLICABLE]
PQ
11 DATE OF REVISION FOR LOT CONTROL DISPLAY
Date of Issue D/C No. New Part No. Prep By Check By App By
Honda Cars India Limited 12 UPDATED DESIGN CHANGE NUMBER OF PART
13 PART NO. AS PER LATEST HCIL DRAWING
Rev.No Date of Issue Change Contents Prep By Check By App By Prep By Check By App By
Lot No. Details Approval Supplier Honda Cars India Ltd 14 IN-CHARGE - SUPPLIER, FINALIZING LOT NO
Structure of SQM 67
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
What is MSA? 2/7

What is MSA?
Measurement System Analysis
1.APQP & Control Plan
Contributors for variability in
2.PPAP measurements
Core tool Quantify
Variation in the measurer
⇒A manual describing techniques Investigate and determine
for quality control 3.MSA Variation in the product where the variation lies
Variation in the measuring device
4.SPC
5.FMEA
Background behind MSA’s inception
Process controls are critical during manufacturing

(e.g., control Dwg, destruct test, etc.) Demands the validity of measurements
Include the
on required part(s)
following
Variation in the material/parts OEM Supplier

Variation in the equipment/machines
Variation in the measurement by associate
Variation in the process method (e.g., build/assembly) Solution
Presents the part measurements Utilize MSA as the basis
Variation in the inspection/measurement for the correct value(s)
for the measurement system (*)
(*) Measurement system refers to the total concept related to
Unsure as to whether we are using the correct value for control… measurement, including not only the measurement instrument but the
user(s), the use method as well as all of their variation.
MSA is a tool used for quantitative assessment of measurement variation and determining
contributors of variation
3/7
Factors of Measurement Variation: ① Accuracy
Reflection Measurement process
target (theoretical) True value Inability to calculate accurately
Spec (e.g., JIS, etc.)
Variation (variability) occurs in the process of measurement Apply the reference value
Factors of variability in the process of measurement
①Accuracy (bias): difference between the means of the measurement system and the reference value
①-1 Stability: change in bias over a long period of time ①-2 Linearity: difference in bias over the entire range of measurement
e.g., any variability between immediately following calibration at t0 e.g., the difference between bias at the time of measuring A and bias at
and the next calibration at t1 the time of measuring B
Reference t0 Reference t1
Ａ
Pre-calibration Post-calibration Linearity
Reference
9.2 9.4 9.6 9.8 10 10.2 10.4 10.6 10.8 9.4 9.5 9.6 9.7 9.8 9.9 10 10.1 10.2 10.3 10.4 10.5 10.6
Stability
Clarify the variation in the measurement instrument based on the reference value and the
measurements
Factors of Measurement Variation: ② Precision 4/7
Factors of variability in the process of measurement
② Precision (variation): variability in repeated measurements. Assess “σ” (standard deviation) in the
measurement system
②-1 Repeatability: variability in the instrument (EV) ②-2 Reproducibility: variability among different measurers (AV)
e.g., variability in multiple measurements taken by a single e.g., variability in measurements taken by multiple measurers with
individual with the same instrument/product the same instrument/product
Repeatability Reproducibility
Technician A Technician B
9.2 9.4 9.6 9.8 10 10.2 10.4 10.6 10.8 9.2 9.4 9.6 9.8 10 10.2 10.4 10.6 10.8
Clearly quantify the variation in the measurement instrument/measurer(s)

②Gage R&R: Method of Assessing Precision 5/7
Assumptions (industry standard)

GR&R (Gage Repeatability and Reproducibility) is a process used to assess 3 technicians to measure
the measurement system’s ②-1 repeatability and ②-2 reproducibility MIN 1 measurement instrument
MIN 10 parts worth of data
Measurement variation (TV) consists of 3 components: Calculation method:

TV = EV (equipment) + AV (appraiser) + PV (part variability)
GR&R: standard deviation of measurement system
TV
GR&R=√σEV2+σAV2
%GR&R: percentage of GR&R out of TV
PV EV AV %GR&R=(GR&R/TV)x100
%GR&R < 10%: pass
GR&R is a quantified representation of variation 10% ≦ %GR&R < 30%: provisional pass (subject to customer approval)
30% ≦ %GR&R: fail
Analysis Method Required Data Pros Cons Remarks

2 technicians to measure Easy to capture GR&R Unable to break variability
Range Method 5 statistically stable parts down to repeatability vs. Method defined in MSA
Measure each part once and analyze a total of 10 parts worth of data reproducibility Reference Manual
Interaction between Use d2* table in Appendix C
Average and Range 3 technicians to measure Able to estimate both for calculation
repeatability and
Method repeatability and reproducibility
10 statistically stable parts reproducibility is unknown
Measure each part 3 times and analyze a total of 90
Analysis of parts worth of data
Complex calculation is Able to assess variance Standard statistical techniques using
variance (ANOVA) required more accurately analysis of variance
GR&R is intended to guarantee the device and individual(s) involved in measurement

Structure of SQM 72
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Process capability
Process capability
⇒ It is the degree that the manufacturing processes satisfy the products standards.
LSL USL
LSL USL W
Standard range; W
The process capability index against the
Wl Wu
standards Cpl Cpu
The deviation on the center The deviation on the center
value of products value of products
characteristics is not characteristics is
considered. considered.
Process capability T/2 T/2

index
X
It is the capability Cp Cpk 3σ 3σ
Data distribution range; T (6σ) X
considering the variation
within the group. Cp Cpk (Deviation is considered)
Process performance
Products standard range (W)
index Process capability =
It is the capability Pp Ppk The product characteristics data distribution range (T)
considering the variation
between the groups.
What is the difference between Cpk 1.33 and

Cpk 1.67? LSL USL LSL USL
X X
• Another document named PPAP requests Cpk 1.67 and more. Wl Wu Wl Wu
Cpl Cpu Cpl Cpu
• The allowance for the variation and control range on ordinary
industrial goods request 3σ+1σ and more, while the one for
automobile goods where weigh heavily on safety and quality
request 3σ+2σ and more.
• Because IATF16949 assumes that the manufacturer having T/2 T/2 T/2 T/2
sufficient process capability, if it is insufficient, conducting 100% 3σ 3σ σ 3σ 3σ 2σ
inspection is requested.
Cpk=1.33 Cpk=1.67
It is the degree that the manufacturing processes in which requirements vary among OEM
satisfy the products standards.
Structure of SQM 74
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
What is PPAP?
What is PPAP?
Production Part Approval Process 1.APQP ＆ Control Plan The mass production parts judgment
sheet that can commonly be
2.PPAP recognized and shared.
Core tool It is the judgment sheet giving

manufacturing permission as
※It is similar to HM’s Quality Safety Declaration.
⇒ It is the manual the mass production parts.

Sharing
describes the methods 3.MSA Supply parts
for controlling qualities. Supplier
Customer
(OEM)
4.SPC Approving
process
5.FMEA Recognizing
The reason why PPAP was born

Each OEM in US and EU The quality Supplier Obtain the approval for mass production
control on
(= the parts are approved)
ISO9001 2000 ver. ～ parts
Manufacture the
OEM products that
Company-A Company-C satisfies OEM.
Own standards Own standards
Problem
Request
The approval for mass production
⇒ The judgment criteria for the parts approval are varied among each OEM.
Company-B
Own standards
Suppliers are confused ・・・
Solution
Request
Commonize the requirements that can commonly be recognized
⇒ PPAP
Sharing information
It is the parts approval judgment sheet that can commonly be recognized by suppliers and
OEMs.
The purpose of PPAP
PPAP :
It judges if followings are existed at customers
(OEMs).
① The satisfaction to the requirements
described on Drawings/Specifications. The production efficiency required
② The assurance of the production It is the parts production volume within a certain planned
efficiency required. time agreed.
＝ Initially required number of units and the parts assurance
after the terms past are not included.
It is necessary to cover two views.
The timing chart described on APQP

Concept
Started/Approved Program is Produce Produce Mass-
approved Launch Mass-Pro.
prototypes Pro. prototypes
Planned activities are required
Plan Plan
Design/Develop the product
It is judged by
Design/Develop the process
PPAP.
Check the validity on products and processes
Mass-Pro.
Feeding back, Evaluating and Correcting
Check the
Clearly plan the Verify design Verify design validity on Feeding back, Evaluating
program /development /development products and and Correcting
of products of processes processes
PPAP does not function as itself but can realize it by coping with other core tools.
Conduct the checks for ensuring products quality plan (APQP).

Which case require the PPAP submission?
The targets that for obtaining the parts approval judgment
① The approval of new parts or products

② The correction of defectives on parts
③ The products modified along with the design changes
④ The change points required to be notified to customers (OEM)
1. The use of different structures/materials from the one before it got approved for mass production.
2. The production after jigs/tools are added/replaced, or that is with new/modified jigs/tools, dies/molds, casts or
patterns.
3. The production after jigs, tools and equipment are upgraded or relocated (with the flow different from the process
flow).
4. The production with the jigs, tools and equipment transferred from other plant or relocated.
5. The supplier change on the parts, materials and services (heat treatment, plating).
6. The production that is the first time for a while after it is operated last (more than 12 months)
7. The changes on the products or processes that related to the components of internal/supplier’s manufacturing parts.
8. The changes on the test/inspection methods.
9. The changes on the suppliers or characteristics of bulk materials.
＊Note：
The requirements that for obtaining the parts approval judgment The 19th item mentioned on left is defined
on AIAG PPAP reference manual and is
The performance the requirements specialized to “bulk
The requirements materials”. And when it is applicable, it
on the 300 pieces will be submitted to customers as the
that consists of 19 attachment of PSW. Therefore, generally
produced in 1 to 8 speaking, total 18 items up to PSW are
items*. well understood as “PPAP documents”.
hours.
The target is when the products that affects customers are ①new, ②defective, ③corrected
or ④having change points.
The items required by PPAP
APQP related item Documents or Items Content
Step1 1 Design records Software : CAD, Hardware : Drawing, Geometric tolerance sheet
Approved engineering change The change documents relating to the change points required to be notified to
Step1 2 documents customers (OEM/where the products delivered to)
Approval by the engineering The evidence showing that is approved by the engineering department in customers
Step1 3 department in customers (the signature on the drawings or on the specifications)
2.1 4 DFMEA FMEA
3.3 5 Process flow chart Process flow
3.6 6 PFMEA FMEA
4.7 7 Control plan Control plan

Measurement system analysis
3.9,4.2 8 inspection
The verification results of the measurement system
4.1,４.3,4.5 9 Dimensions measurement results The products dimensions measurement results, All dimensions measurement results
2.7,2.8,4.5 10 Materials・Performance test results Durability test results
3.10,4.3 11 Initial process inspection Process capability verification results

The documents for the certified test
2.12 12 place
It proves that is evaluation results provided from the certified test place.
2.6 13 Appearance approval report (AAR) The parts appearance verification results such as textures or colors.
4.1 14 Sample products Provide mass production parts
4.1 15 Master sample Limit sample
2.12,4.2 16 Inspection aids Submit jigs

The requirements unique to the
4.4,4.8 17 customer
All the requirements and documents presented by customers.
4.4,4.5,4.8 18 Part submission warrant (PSW) Mass production parts warrant

The changes on Adhesives, Sealing agents, Chemical products, Coating agents,
※ 19 The change of bulk materials
Coolant, Rubbers and so on.
※ It is not APQP related item but its submission is required if necessary.

It is the list showing the outputs that to be deployed with APQP.
The difference between PPAP and Quality Safety Declaration
PPAP Quality Safety Declaration Remarks
The performance on the 300 pieces produced in 0
0 The performance on the 200 pieces produced in 2 hours
to 8 hours
1 Deign documents Drawings (CAD) and SPEC in former HGT
2 Engineering change documents “Self-controlling initial production parts” described on SQM
The approval from the engineering department in The approval on Drawings,
3 It has been applied at former HGT?
customers SPEC etc.
4 Design FMEA It has been applied at former HGT? Substitution: FTA
5 Process flow chart 9) Process quality control sheet and Work Instructions
4) Conduct PFMEA
6 Process FMEA
(The conditions value and setting value set on processes)
7 Control plan 9) Process quality control sheet and Work Instructions
The validity verification on the
8 Measurement system analysis inspection No requirements
measurement device
9 Dimensions measurement results 3) Matching the quality characteristics described on drawings or
specifications
10 Materials・Performance test results (Validity verification test, Accuracy on dimensions, Operation,
Appearance etc.)
11 Initial process inspection 6) Process capability (Cpk) Note : One-sided standard is Cp
12 The documents for the certified test place No requirements The adequacy as the test place
13 Appearance approval report (AAR) “The textures and colors” described on SQM
14 Sample products 8) The ease of assembly to Honda products
15 Master sample 5) The accuracy on dedicated inspection jigs
16 Inspection aids (Including Master samples and Limit samples)
The records showing the matching the
17 All items on Quality security declaration, 1) to 11)
requirements unique to the customer
18 Part submission warrant (PSW) Quality Safety Declaration document
19 The change of bulk materials “Self-controlling initial production parts” described on SQM
※ Followings are preconditions on PPAP.

1) Permanent dies, casts, injection molds, equipment, jigs, checking fixtures etc. 3) Logistics (test on transportation)
2) Production capability (CT etc.) 4) The associates for mass production
Quality Safety Declaration is former HGT control item and does not collect the results about
“Verification of tribal knowledge (know how) built into Work Instruction”.
The level of PPAP submission
Required
The level of submission 1. The difference among S, R and * in the level of submission.
items
1 2 3 4 5
1 R S S ＊ R S : Its submission is essential and recording it is required. (Submit)
R : It must be available for customers and recording it is required. (Retain)
2 R R R ＊ R ※ : If necessary, submitting it to customers and recording it.
3 R S S ＊ R
4 R S S ＊ R
2. The level of submission from 1 to 5
5 R R S ＊ R
6 R R S ＊ R Lv Warrant
Appearance
Requirements
Physical check at
sample the site
7 R R S ＊ R
1 〇〇 - -
8 R R S ＊ R
2 〇〇〇 (Partial) -
9 R S S ＊ R
10 R S S ＊ R 3 〇〇〇 -
11 R R S ＊ R 4 〇〇〇 (Designated) -
12 R S S ＊ R 5 〇〇〇〇
13 S S S ＊ S ※ There is not only 5 patterns above but the details are to be
14 R S S ＊ R determined based on the negotiation with customers.
15 R R R ＊ R
16 R R R ＊ R
17 R R S ＊ R
18 S S S S R
19 S S S S R
It depends on the historical actuals between OEM and supplier and the change point on the
products.
Structure of SQM 81
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Overview
・ C/M：C/M is taken at site & Approval is done based upon Severity. The appropriateness, effect, and standardization is verified
・ Reflection into NM ： There is structure that the Know-hows for defects are accumulated and past troubles are verified on NM.
・ Horizontal development：There is structure to horizontally develop to similar process, other section, other site (globally) and is
implemented.
Problem Dan
D Hin
H Ryo
R M/P
MP
C/M NM
Check past trouble on NM
Cause Measure taken Put past trouble information

analysis into NM process and check
the effect.
Check the progress of C/M
on the report at the actual Past trouble list (DB)
site. Report Accumulate defect information (DB)/
Know-how collection
Check at actual site, actual
status, and on actual product. Horizontal
development Horizontal development and example
Check analysis report Effect Past trouble was checked on 08ACC and 08FIT
and implement the verification
measure. Other factory
・Similar process
Stability verification and Stability ・Other section
safety declaration is process
verification
conducted based on
Horizontally developed to
effectiveness criteria. Critical problems are horizontally
similar process/other
developed to whole company and
section and is assessed.
assessed.
Requirements 83
 The supplier shall, in the case where nonconformity is detected at the supplier site
and where there is a possibility of the nonconforming product being flowed out
to the delivery destination, take corrective action in accordance with SQM 5.4 Non-
conforming Product Containment and Corrective Action. If there is no possibility of an
outflow, the supplier shall follow its own procedure to take corrective action and
maintain records.
 Where “Problem Countermeasure Request” or 5 principles for problem solving
worksheet (5 why)” is issued by HCIL, the supplier shall take corrective action in
accordance with SQM 5.4 Non-conforming Product Containment and Corrective
Action. Response to HCIL shall be submitted directly using “Problem Countermeasure
Request” or 5 principles for problem solving worksheet (5 why)”. (Refer to SQM 5.4
Non-conforming Product Containment and Corrective Action) within due date (A Rank- Rule
5 Days, B Rank-8 Days, C Rank -10 Days). compliance
 The supplier shall identified rules of trouble countermeasures and judgment criteria
of severity of Problem. ＰＤ
 The supplier shall defined Problem Countermeasure approvers based upon
severity of Problem. ＡＣ
 In the case where the response due date cannot be met, the supplier shall consult with
Actual and effect
HCIL, and if necessary, issue an interim report on “Problem Countermeasure
Request”, or “5 Why” or “Analysis Record.
 The supplier shall implement change point control for the initial parts to which
corrective action was taken in accordance with SQM 5.5 Change Point Control .
 The supplier shall provide feedback on the results of corrective action to the new
IPP
model section and to the problem-causing source. The information shall be utilized for
recurrence prevention of nonconformity and/or prevention of potential problems.
 If non-compliance or quality non-compliance originating from a sub-supplier occurs,
the supplier is responsible for implementing reliable countermeasures and preventive
measures refer to (SQM 6.2 Sub-supplier Management)
Corrective Action Report 84
What is a corrective action report?
It is a form developed to prevent recurrent problems when a defective product occurs by observing and
understanding the facts and events well on the actual place, part, situation, natural law and general rules
basis, and taking appropriate actions.
Structure of Corrective Action report (5 Principles of Problem Solving)

The analysis report has six important steps.
1) a) Problem Definition: Clearly state the symptom, content of complaint, frequency
and content of action taken.
1) b) Grasping of facts: Clearly state the quality condition of current production and
range of occurrence.
2) Identifying causes: Identify true causes by why-why analysis.
3) Corrective actions: Key point is action on hardware.
4) Confirmation of effects of actions: If actions do not have immediate effects, be sure to check
effects after.
5) Feedback to upstream sources: Standardization for continued actions on hardware
(e.g. Horizontal development for similar models or reflection
of the knowledge when deciding on monitoring items for new
models.)
Cautions when filling out Corrective Action report

It is important to identify true causes why-why analysis in order to avoid assuming that the mistake is simply
a human error, ending up in emphasizing importance of better guidance and instruction.
HCIL-MPQ
CONTROL NO. -
PROBLEM STATEMENT
X X - Y Y - Z Z 5 PRINCIPLES FOR
PROBLEM SOLVING
WORKSHEET
HCIL - MPQ
ISSUED BY
DATE
SECTION OR SUPPLIER NAM E
PREPARED BY CHECKED BY APPROVED BY
REPORT TO
BE
MADE T O
APPROVED BY APPROVED BY
85
DATE
WRITE THE ACTUAL PROBLEM REPORTED.
Part check results, factor analysis, quality condition

Symptom, content of Who,What,When,Where.
1-A PROBLEM DEFINITION complaint frequency… Why, How, How many. 1-B of current part / process
PROBLEM DEFINITION(GRASPING THE
1)WRITE HERE THE DESPATCH DETAIL OF THE PROBLEM LOT 5) IDENTIFY ACTUAL CAUSE IN THE PROCESS FLOW CHART
PART NO : WRITE HCIL PART NO. WRITE HOW MANY PARTS WERE MADE & WHEN & IN HOW MUCH QTY THESE WERE SHOW IN THE PROCESS FLOW CHART WHERE THE PROBLEM
PART NAME:WRITE HCIL PART NAME DESPATCHED TO HCIL. IDENTIFY THE PROBLEM LOT. (SEE A TYPICAL EXAMPLE)TABLE 2 ACTUALLYHAPPENED & HOW IT BYPASSED THE EXISTING
SUPPLIER : SUPPLIER NAME SUPPLIER DATE DATE DATE DATE DATE CHECKING PARAMETERS.
PROBLEM: WRITE ACTUAL PROBLEM REPORTED IN THE VEHICLE LOT QTY 520
DATE: PROBLEM REPORTED DATE DESPATCH TO UNIT 2 520 CHECK WHY IT OUTFLOWED.CRITICAL POINTS OF OUTFLOW TO BE
HOW IT HAPPEN: WRITE HOW THE PROBLEM WAS ACTUALLY OBSERVED IN VQ/AF/INCOMING RECVING AT UNIT 2 520 SEARCHED.
HOW IT BECAME :WRITE THE IMMIDIATE CAUSE OF THE PROBLEM WHICH IS EVIDENT VISUALLY/BY
MEASUREMENT
DESP TO HCIL
SEC 1B – GRASPING OF FACTS
LOT HAVING PROBLEM PART TO BE SEGREGATED.TAKE JUDGEMENT FOR WITHDRAWL
220 300 METHOD OF FINDING THE CAUSE:
-IN WHICH PROCESS IT HAS OCCURRED
HOW MANY: WRITE QTY & BATCH CODE
WHERE:WRITE STAGE AT WHICH THE PROBLEM WAS REPORTED.
BASED ON PART CHECKING
OF THAT LOT IF REQD.WRITE THE ACTUALS IF WITHDRAWL DONE.
WRITE THE MEASURE TAKEN FOR CARS FROM WHERE THE WITHDRAWL IS NOT POSSIBLE.
-HOW THAT PROCESS IS CONTROLLED
-WHY IT OUTFLOWED WITH EXISTING CONTROL METHOD
SEC 1A- DEALS WITH PROBLEM WRITE THE REASON WHY THE LOT OTHER THAN THE TROUBLE ONE IS TO BE USED.
RESULT, SIMULATION TRIALS & -HOW IS THE RULE TO PREVENT OUTFLOW & CAN RULE BE
FOLLOWED
DEFINITION
NOW WRITE THE OK /NG STATUS OF THE PART AT LINE & WARE HOUSE 2)EXTERNAL OVERVIEW OF THE SITUATION.
ANALYSIS OF QUALITY CONDITION
WRITE LOT DEATIL AT SUPPLIER END & CONFIRMATION RESULT OF ALL PARTS CHECKED.
-WAS THERE ANY PROBLEM WITH THE USUAL WORKING METHOD.
(TABLE 1.) PLACE LOT QTY SEG QTY REJ QTY IDENTIFICATION DO THE CRITICAL POINT ANALYSIS FOR THE PROBLEM OCCURRED
HCIL
PLACE
AF LINE
LOT QTY SEG QTY REJ QTY STATUS
OF PART/ PROCESS ETC.
MENTION WHERTHER ANY WITHDRAWL FROM LINE WAS REQD
SEARCH METHOD FOR CRITICAL POINTS & RAISE ALL THE CRITICAL POINTS
LIKE MAN,MACHINE,TIME,CONVEYOR METHOD,RAW MATERIAL,CONTROL
W/H MACHINE ,RULE ETC.(I.e. MAKE CAUSE & EFFECT)
3)SHOW ANALYSIS OF THE NG PART .ATTACH RANK TO THE CRITICAL POINTS CONNECTING TO PROBLEM.
WRITE QTY: SHOW DIMENSIONAL ANALYSIS/PERFORMANCE REPORT STRIKE OUT THE CRITICAL POINTS WHICH ARE TAKEN CARE AT ACTUAL WORK
A RANK PROBLEM – 5 DAYS

OK: COMPARE SPEC VS ACTUAL & FINAL RESULT. PLACE.FOR REMAINING CRITICAL POINTS JUSTIFY THEM BY DOING THE
NG: PARAMETER SPEC OBSD RESULT SIMULATION TEST.
NOTE:MATCH QTY OF TABLE 1 & TABLE 2.
CONCLUDE THE PROBLEM AREA IN THE PART & SHOW PHOTOGRAPH IF REQD 6)CONFIRM THRU SIMULATION TRIAL FOR THE OUTFLOW CAUSE
B RANK PROBLEM – 8 DAYS

IDENTIFIED.
4)THE PROBLEM WHICH HAS OCCURRED ,CAN IT OCCUR IN ANY OTHER CAR IN METHOD OF UNDERSTANDING THE FACTS.:
AF/VQ/CBU/MARKET.CONFIRM THE RESULT THROUGH SIMULATION TRIAL ALL THE REPLIES YOU GET FOR INVESTIGATION POINTS TO BE WRITTEN IN
IF IT CAN HAPPEN THEN DEFINE CLEARLY WHAT THE MEASURE WILL BE TAKEN & HOW. MEMOS & THEN ARRANGED IN PROPER ORDER.
C RANK PROBLEM – 10 DAYS

Question and answer analysis
problem and occurrence process
2-A IDENTIFY ROOT CAUSE ( QUESTION AND ANSWER ) From Fishbone Chart 2B duplication test
IDENTIFY ROOT CAUSE
WHY WHY WHY WHY -WRITE THE MECHANISM OF OCCURRED PROBLEM(I.e. OCCURRENCE ROUTE CAUSE)
WHY
(IF WE DO THE SIMULATION TEST WE WILL UNDERSTAND THE MECHANISM)
-DONOT WRITE THE MECHANISM OF VEHICLE PROBLEM .WRITE THE SIMULATION TEST RESULT.
WRITE THE CAUSE OF OCCURRENCE
-WRITE ROUTE CAUSE OF PROBLEM IN PART.DONOT WRITE VEHICLE PROBLEM CAUSE.
SEC 2A – ASKING REPETITIVE DO WHY-WHY ANALYSIS DO IT TILL ROOT CAUSE

SEC 2B – ROOT CAUSE
-WRITE WHY THE CAUSE EXISTED .(IF THERE IS ONLY ONE CAUSE.)
PROBLEM
WHY’S TO REACH ROOT CAUSE
WRITE ACTUAL -OUTFLOW CAUSE: ESTABLISHMENT (BOTH
WRITE THE CAUSE FOR TROUBLE OUTFLOW.
REPORTED
FOR OCCURRENCE & OUTFLOW) &
(THERE IS ONLY ONE CAUSE)
• CAUSE OF OCCURRENCE
WRITE THE CAUSE OF OUTFLOW
REASON FOR EXISTANCE OF
• CAUSE OF OUTFLOW.
DO WHY-WHY ANALYSIS DO IT TILL ROOT CAUSE
ROOT CAUSE
Content of c/m prediction of effects,
3 potential problem analysis. 4 5 HORIZONTAL DEPLOYMENT
CORRECTIVE COUNTERMEASURES CONFIRM COUNTERMEASURE(S) Actual effects
RESP TDC
COUNTERMEASURE FOR OCCURENCE CAUSE: CONFIRM THE C/M TAKEN & WRITE THE RESULTS OF EFFECTIVENESS AFTER
THE C/M IMPLEMENTATION DATE.
-TAKE COUNTERMEASURE FOR THE FINAL ITEM OF WHY WHY ANALYSIS. IDENTIFY THE PROCESSES IN WHICH THE SIMILAR
(COUNTERMEASURE CONTENT IS ONLY ONE.) TYPE OF C/M CAN BE IMPLEMENTED TO AVOID ANY
-IF CAUSE COULDN'T BE SQUEESED THEN THERE ARE MORE COUNTERMEASURES FURTHER OCCURENCES.
-IN CASE IT IS TAKING LONGTIME FOR PERM C/M THEN TAKE TEMP C/M.
-IMPLEMENT IT BY MAKING A PLAN.
-C/M FOR OUTFLOW CAUSE:
SEC 3 – COUNTERMEASURE FOR

-TAKE C/M FOR THE FINAL ITEM/OUTCOME OF WHY-WHY ANALYSIS
SEC 5 – HORIZONTAL
(WHEN C/M CONTENT IS ONLY ONE)
-IF CAUSE COULDN'T BE SQUEESED THEN THERE ARE MORE COUNTERMEASURES SEC 4 – CONFIRMATION
BOTH OCCURRENCE & OUTFLOW
-IN CASE IT IS TAKING LONGTIME FOR PERM C/M THEN TAKE TEMP C/M. DEPLOYMENT OF
OF COUNTERMEASURE
NOTE:
CAUSE ESTABLISHED,
-MUST ADD C/M DATE COUNTERMEASURE,
APPLIED LOT TO BE WRITTEN. TAKEN & EFFECTIVENESS
RESPONSIBILITY & T.D.C. IF APPLICABLE.
FOLLOW-UP
DATE
“Why-Why Analysis” Key Points 86
Key Point (1) Key Point (8)

Steps need to be completed before performing analysis.
Repeat why questions until the
1) Review the problem & identify the facts exactly.
2) Understand the system (structure) and roles (functions) of the root cause (system/structure)
problem area. that will lead to prevention
3) Focus on the occurrence area and top phenomenon, and measures is found.
express principles of cause for the first “why.”
Problem (symptom/ Why ? Why ?Root Cause

cause)
Why? Why ? Periodic clean-up
Pump shaft
A machine stopped A fuse was Bearing area was
not lubricated was worn.
・・・ was not
because of XX. blown. sufficiently. standardized.
(Stopgap measure) (Stopgap measure) (Stopgap measure) (Permanent C/M)
Change the Lubricate it. Replace the • Make OPS for the
fuse. shaft. periodic clean-up.
• Install a filter.
Key Point (2)
Check if all problems
are listed. Why ? Why ? ・・・ Why ?
Key Point (3): Write briefly as much as possible. Use the simple form of sentence such as “ XX did XX”
and avoid using more than two verbs (causes) in a sentence.
Key Point (4): Write down only that what did not seem right (what seemed abnormal) to you.
Key Point (5): Avoid writing excuses or unspecific explanation (e.g. carelessness, poor)
Key Point (6): Verify from a viewpoint of Sangen Shugi (genba / actual part / actual situation).
Key Point (7): Check for any inconsistent theories by reading from the back.
Structure of SQM 87
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Change Point 88
What is change point? Change
in method Production Change
To ensure a stable production of high quality products on the genba, it is activity in man
important to organize 4M (man, machine, material, and method), which
are a main cause of a quality problem, and continuously control them.
In daily production activities, various unusual 4M-related events

occur. They are called “change point.” If they are left untouched, a
variety of quality problems occur. Change in
Change point is any deviation from process quality control table. Change in machine
material
< Example of 4M-related change point >
Classification of Example (Ex.)When welding equipment is repaired,
4M
Change in man A operator called off unexpectedly in sick and
another did work to fill thevacancy.
Change in Equipment was modified,repaired, or checked.
machine
Change in Paint of a new material specification wasused After the repair is finished,
material If being left need to check the followings.
untouched  Appropriate welding conditions are set up.
Change in The process allocation and work steps were  Quality not inferior to that before repair is
method changed. assured.
 Reason why change are not controlled Otherwise,
 Went unnoticed- change point not come to knowledge Moat likely defective parts will be
 Ignored – impact on product quality not known/ understood. produced and leak.
 No action taken to ensure product quality in spite of change &

impact known i.e. Controls not established/ maintained.
What is change point control? 89
Flow of change point control and example of problem occurrence

The activities to grasp a fact that a change point occurs and prevent a quality problem arising from the change point are called
“change point control.”
When a change point occurs, it is necessary to ensure “quality assurance” and “traceability” while accurately recognizing the change
point, sharing information, and making an appropriate judgment.
< Flow of change point control >
Check if condition Establish a rule based on them to ensure

Recognize and Record Reflect on
and quality are handling and control as specified in the
handle change point check results standards
as expected
procedure.
Share information and make appropriate judgment
< Example > Serious quality problem arising from poor change point control
= Partial omission of spot welding =
Change point
Record check
Replace motor Perform Check if Check if quality is
Original result and
in welding robot teaching of teaching is comparable with
judge by
welding robot finished original
administrator
Omission as
result of
everything left
Spot location, to person in
Not checked if Record and
What Teaching not quantity, and charge
teaching was judgment were
happened? completed misalignment were
completed not enough
not checked Occurrence
and leak of
Rules and control documents for change point control to be originally made were unclear ;therefore, It repeated Jyu-hin
omissions and caused occurrence of Critical Quality Problem.
Importance of Change Point Control 90
Normal State
Man Material
Dwg/ Process that followed PQCT/OPS

Spec
Machine Method
Abnormal
State Process that doesn’t followed PQCT/OPS
< Change point example = occurrence factor > < Outflow/growth factor > Change point that
・Letting untrained associate to work (Man) ① no one notices Critical quality
・Changed component part supplier (Mat’l) ② wrong handling, judgment taken. problems in
・Broken robot returning to zero point. (Machine) ③ no records are available. market
・Hand worked on NG parts (Method)
Challenge: Strengthen the change point control.

(① notice a change…→ ② handle it, judge it correctly…→ ③ document it!)
Change point and its control Examples 91
REASON FOR CHANGE CONTROL
CHANGE
STANDARD CHANGE POINT RESP.
• New Part/
•Training New Operator
Model
Operator • Update Skill Matrix Head-
Man • Capacity Up New Operator • Install Extra Checks MFG &
Skill matrix QA
• Turn over • Lot Approval by QC
•Prior Info to HCIL for

Advance Approval
•New Part/ • Make Trial Lot Head- Pur.
Model New / Deviated & QA
• Check Process
Material Qualification
•Shortage of Contractual
Material Material • Propose HCIL for Approval
Contr. Head- Pur.
Material Standard Source Change • Update PQCT/Insp. Std., if & PQ
Required
•Design
• follow IPP Route
Change Expired Shelf Life
Head-
•Disposition of Old Design Develop.
Material as per Design
& QA
Change Rank
• Make Plan of Incorporation
of changes in Process/ Tool
Head- Pur.
• Propose HCIL for Approval & PQ
• Update PQCT/Insp. Std., if
Required
REASON FOR CHANGE CONTROL
CHANGE
STANDARD CHANGE POINT RESP.
Standard Changes in •Check Process Capability
•New Part/ Control Parameter • Raise ECN
Model Parameter Changes in • Approval of QC
Capacity of M/c due • Revise OPS/ WI
• Capacity Standard to Original M/c
Up/ New capacity M/c • Info to HCIL as Advance Head-
under Breakdown or Approval & Changed PQCT
Machine Machine as per PQCT MFG &
New Machine QA
• Process •Prior Info to HCIL for Advance
Tooling Change Approval
Improvement Approved Head- Pur.
Tooling Repair •Tryout with New Changes & PQ
Tooling
• Breakdown Tooling Design • Check Process Capability
of M/c or Tool Change • Approval of QC
Shifting Within Plant • Follow Advance Voluntary
IPP Procedure
Shifting Within • Update PQCT/Insp. Std., if
Location Required
Sister Concern
To Sub Supplier/
Sub Supplier •Prior Info to HCIL for Advance
Approval
Change
•Tryout with New Changes
• Check Process Capability
• New Part/ Head-
• Approval of QC
Model PQCT/ MFG &
Method Proposed Change • Follow Advance Voluntary
OPS/ WI/ QA
• Process Tryout IPP Procedure
INSP
Improvement • Update PQCT/Insp. Std., if Head- PQ
Standard Required
STANDARD CHANGE CHANGE CONTROL
TRAINED MANPOWER NEW MANPOWER •Training New Operator

• Update Skill Matrix
• Install Extra Checks
• Lot Approval by PQ
SKILL LEVEL 100% - TRAINED SKILL LEVEL 25% - UNTRAINED
MAN MAN
•Prior Info to HCIL for Advance

SPECIFIED MATERIAL UNSPECIFIED MATERIAL Approval
• Make Trial Lot
% CARBON 0.10~0.15 % CARBON 0.12
• Check Process Qualification
% SILICON 0.05~0.10 % SILICON 0.18
• Propose &get HCIL Approval
UTS 1760~1920 UTS 1880
•(Do not apply with out HCIL
% RA (Min) 35 MIN % RA (Min) 10 approval)
MATERIAL AS PER - SPEC DEVIATED MATERIAL • Update PQCT/Insp. Std., if
Required
STANDARD CHANGE CHANGE CONTROL
SPECIFIED MACHINE UNSPECIFIED MACHINE •Check Process Capability
• Raise ECN
TYPE AUTO TYPE MANUAL • Approval of PQ
FEED FEED
• Revise OPS/ WI
CAPACITY 100 TON CAPACITY 100 TON
• Info to HCIL as Advance Approval
MACHINE AS PER PQCT MACHINE NOT AS PER PQCT & Changed PQCT

SPECIFIED PARAMETER UNSPECIFIED PARAMETER Approval
• Make Trial Lot
PRESSURE (BAR) 50 -60 PRESSURE (BAR) 54 • Check Process Qualification
SPEED (MM/MIN) 20-22 SPEED (MM/MIN) 18 • Propose HCIL for Approval
TEMPERATURE(°C) 30-35 TEMPERATURE(°C) 39 • Update PQCT/Insp. Std., if
Required
HUMIDITY (%) 55-60 HUMIDITY (%) 57
PARAMETER AS PER PQCT PARAMETER NOT AS PER PQCT
OK PROCESS FLOW NG PROCESS FLOW

Approval
PROCESS A PROCESS A
•Tryout with New Changes
PROCESS B PROCESS B • Check Process Capability
• Approval of PQ
PROCESS C PROCESS C
• Follow Advance Voluntary IPP
PROCESS D PROCESS E Procedure
• Update PQCT/Insp. Std., if
PROCESS E PROCESS D Required
PROCESS F PROCESS F
SEQUENCE AS PER - PQCT SEQUENCE NOT AS PER PQCT

G-IPP Deployment 95
■ GIPP Rule - To strengthen the change point control at suppliers, mainly lead by their
quality managers, to completely eliminate critical quality problems.
Old System New System
To: ____________________________ Advance Notice of Initial production Parts Company/Section Name:________________________________________
Issued On QA Rep Confimration PIC
Part No Planned
Part Name Sudden
Affect Quality Characteristics
Part Characteristic Yes/No Change Items Change Details Reason for Change
Yes/No Affected
Inspection Method Change

Important Quality
Process Series Change

Only planned change Characteristics
Adding an unscheduled change
packaging change
Transport, delivery
Process condition/
Machine change
method change
Jig, tool change
Tooling Change
New Supplier
Part Inspection Criteria
Others
Part Approval
Indicating change point Chemical Substance
Others
Adding supplier’s risk assessment and
only, no risk assessment how to handle change Supplier Evaluation Results
Scheduled Date
HCIL response
Completed
Schedule Schedule
Date
Assessment Items Evaluation Details Production Delivery
Date Date
No judgment by quality Process Function Adding suppliers quality

manager representative’s sign-off section
Mass production critical
monitoring items after
Validity Test transition to mass
production
Process FMEA
(Prevention), (Outflow
Prevention),(Past Trouble
HCIL giving instructions Verification) Date Confirmation Submitter Receipt
and judgment IPP Measurement HCIL to confirm the result

Control No: HCIL Confirmation
・ Process Quality Control Table
・ Operation Control Standards Department Name Department Name
・ Revision/Establishment
・ Operator Training Practice
Homologation Date Confirmation Submitter Receipt Date Confirmation Submitter Receipt
Others
HCQF CM 0020/APR'17 Original to be retained untill:
G-IPP will require a risk assessment/approval by supplier’s quality assurance

representative, HCIL can expect to see their closer cooperation in their organization, from
Genba through management, while raising their awareness.
IPP Tag flow 96
ACTIVITIES RESP.
ADVANCE INFORMATION OF VOLUNTARY
SUPPLIER
INITIAL PRODUCTION PARTS (GIPP) IF NOT OK,
REJECT
PROPOSAL
CONFIRMATION BY HCIL HCIL - MPQ
IF OK
PRODUCTION & QUALIFICATION CONFIRMATION
SUPPLIER
OF INITIAL LOT AS PER AGREED PROCESS
ATTACH IPP WITH INITIAL LOT IF NOT OK SUPPLIER
CARRY OUT RECEIVING CHECK & RECORD

HCIL - MPQ
RESULTS
IF OK
CHECK PROCESSING, WE/PA/AE/
ASSEMBLING,WORKABILITY & RECORD AF
APPLICABLE VIN/ ENG NO & RETURN TO PQ
CONFIRM & RECORD APPLICABLE VIN/ ENG

NO & RETURN TO PQ, IF DESIGN CHANGE VQ
RELATED COPY TO SPEC CONTROL ALSO
Initial Production Parts 97
Example of Self Control IPP Example of IPP tag
# Conditions -IPP tag to be filled by supplier
Specification change e.g. Changed due to
1
improvement request for Quality improvement
Quality Improvement e.g. New supplier/sub
2
supplier introduced
New supplier e.g. New supplier/sub supplier
3
introduced
Material change e.g. Raw material of part/ child
4
part changed
Manufacturing change e.g. Process / location
5
changed
Manufacturing sequence change e.g.
6
Sequence changed
Machine change e.g. Automation / upgradation/
7
different capacity
8 Jig/tool change e.g. New or repaired – jig / tool
Die/mould change e.g. New or repaired – die /
9
cavity
Inspection method change e.g. Different
10
instrument/ method used
Transportation method/type of packing change
11 e.g. mode of transport i.e. road, air etc. /
trolley, bin type change or qty/ bin changed
CIRCLE APPLICABLE NO.
1.INITIAL PRODUCTION PARTS 1 CIRCLE APPLICABLE NO (1,2 OR 3, AS GIVEN IN
OF SPEC. CHANGE
2.QUALITY IMPROVEMENT ACTVITY THE GUIDELINES PAGE 5 AND 6 OF THIS
① 3.VOLUNTARY INITIAL PARTS CONTROL
(1. ADVANCED QUALITY CONFIRMATION) PROCEDURE)
TO BE COMPLETED BY SUPPLIER EXCEPT WHERE INDICATED IN BOLD LINES (2. SUBMIT ACTUAL INITIAL PARTS)
2 CONTROL NO : AS EXPLAINED IN 4.2 OF PAGE 2 IN
CONTROL NO. ②
IN IT IA L P R O D U C T IO N P A R T S THIS PROCEDURE
DATE OF ISSUE ③
3 DATE OF ISSUE : DATE ON WHICH IPP IS ISSUED
WHERE "A" AND "B" ARE COMMON, STRIKE OUT "A"
A
SUPPLIER OF DEPARTMENT ISSUING PERSON ISSUING DATE QUANTITY LOT NO.
4~8 NAME OF SUPPLIER/DEPARTMENT, PERSON WHO
B ④ ⑤ ⑥ ⑦ ⑧
IS RESPONSIBLE, DATE, QUANTITY OF IPP PARTS,
FIRST SUPPLIER PERSON ISSUING DATE QUANTITY LOT NO. LOT NO OF IPP
IPP (INTIAL PRODUCTION 9PARTS) CONTROL
LATEST PART NO TO BE WRITTEN
PART NO. - SYSTEM MAINTAINS THE TRACABILITY
⑨ 10 PART NAME AS PEROFPARTTHE
LIST
PART NAME - ⑩ HOW CHANGED
11 WRITE CORRECT SPEC NOTICE NO AS PER PART
SPEC NOTICE NO. - PRODUCT IN CASE OF ANY
⑪ CHANGE
LIST IN THE ⑫
PART / MFG PROCESS (DESCRIBED

12 IN THE
INDICATE SPECIFICALLY, FOR WHAT CHANGE IPP
IS RAISED, DRAW A FREE HAND SKETCH, IF
⑬ 1 SPEC CHANGE
MANUAL) HAS OCCURRED ATPOSSIBLE.
SUPPLIERS END
6 MACHINE CHANGE
2 NEW SUPPLIER 7 JIG/TOOL CHANGE 13 INCIRCLE THE DETAIL ITEM, AS THE CASE IS
3 MATERIAL CHANGE 8 DIE/MOULD CHANGE
(REFER DETAILS OF CHANGE POINTS GIVEN IN
4 MANUFACTURING METHOD CHANGE 9 INSPECTION METHOD CHANGE
5 MANUFACTURING PROCESS ORDER CHANGE 10 TRANSPORTATION METHOD/TYPE OF PACKING CHANGE PAGE 5 & 6 OF THIS PROCEDURE)
CIRCLE APPLICABLE NO.
DELIVER INITIAL PRODUCTION PARTS WITH INSPECTION RESULT SHEETS

1) SHEET 1 MUST BE KEPT BY SUPPLIER OR DEPARTMENT ISSUING
14 1,2,3, & 4 : TO BE FILLED BY SUPPLIER (IF
2) SHEET 2 3 4 MUST BE PASSED TO NEXT PROCESS WITH SIGNATURE OF RESPONSIBLE PERSON FOR PROCESS
SUPPLIER IS TAKING PARTS FROM SUB
SUPPLIERS THAN 1,2 & 3 TO BE FILLED AND
SIGNATURE OF RESPONSIBLE PERSON PRODUCTION LINE COLUMN 4 TO BE SIGNED BY HCIL'S DIRECT
1 2 THIRD SUPPLIER DATE 3 SUPPLY JUDGEMENT
FOURTH SUPPLIER DATE SECOND SUPPLIER DATE
PASS - FAIL SUPPLIER) NO 5 : TO BE SIGNED BY MS SECTION
⑭
OF HCIL NO 6 : TO BE SIGNED BY PARTS QUALITY
4 FIRST SUPPLIER DATE 5 HCIL/ RECEIPT DATE 6 HCIL/ INSP. DATE
⑱ OF HCIL
⑮ ⑯ ⑰
15 TO BE GIVEN BY PARTS QUALITY AFTER
DUPLICATE FOR SUPPLIER OR DEPARTMENT ISSUING RETENTION PERIOD ⑲ YEARS
HCQF CM 0053 /APR'17
CHECKING THE IPP PARTS
16 NO OF APPLICABLE ENGINE WITH IPP (TO BE
FILLED BY AE IN CASE OF IPP APPLICATION IN
ENGINE PARTS)
17 NO OF APPLICABLE FRAME WITH IPP PARTS (TO BE
FILLED BY AF, IF PART IS TO BE FITTED IN FRAME,
ENGINE NO ALSO TO BE WRITTEN BY AF ALONG
WITH FRAME NO)
18 BATCH- NO
19 MODEL NAME (TO BE WRITTEN BY DEPARTMENT
USING IPP PARTS)
20 DATE OF APPLICATION : DATE OF APPLICATION OF
IPP PARTS
21 TO BE GIVEN BY USER DEPARTMENT, ALONG WITH
REMARKS IF ANY
22 ROUTE OF IPP TAG TO BE INDICATED BY
MANUFACTURING DEPARTMENT IN CASE OF IPP
GENERATED IN-HOUSE, OR PQ IF GENERATED BY
SUPPLIER AND MS FOR OTHERS.
23 BASED UPON ROUTE OF IPP, USER DEPARTMENT
SHALL GIVE JUDGEMENT OF OK / NG
24 SIGNATURE OF HOD/PERSON INCHARGE FOR IPP
PARTS (AS PER IPP ROUTE)
25 VQ HOD / PERSON INCHARGE FOR IPP PARTS TO
GIVE FINAL JUDGEMENT.
26 IN CASE OF TEMP USE / NG PLEASE WRITE
SPECIFICALLY, ALSO IF IPP PART IS OK AND VQ
WANTS TO GIVE ANY SPECIFIC INFORMATION TO
GENERATING DEPARTMENT.
Structure of SQM 100
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
QAV-1 Implement purpose 【Basic thinking】 101
Category of Audit
The supplier shall receive a supplier’s quality audit conducted by HCIL.
There are two types of audits: a regular audit and an occasional audit of suppliers’ quality conducted by HCIL.
# Types of Audit Detail
Quality audit carried out to review the quality system of a supplier and to verify the status of
1 Regular Audit implementation of the quality system (also called Quality Assurance Visit-1” or “QAV-1”).
This also includes verifying the suppliers’ audit results through documents.
Of those which correspond to the following criteria, a supplier’s quality audit which will be
conducted when deemed necessary by HCIL (also referred to as QAV-2), and this will be
performed by specifying the scope of confirmation and verification in accordance with the
purpose of the audit.
Occasional
2 1) At occurrence of serious problem which is attributable to the supplier
Audit
2) When a new manufacturing process is used for the production of new models or new
derivatives, etc.
3) When establishing new business relationships with new suppliers.
4) Others
Regular audit
Supplier Subject to Regular Audit
A supplier subject to regular audit shall be selected from among those with whom HCIL has entered into the
General Agreement for Purchase of Parts and on the basis of the following.
1) Suppliers produce important safety parts
2) Other suppliers for which HCIL deems a quality audit is necessary.
Frequency of audit
The frequency of regular audits shall be at least once every two years in principle. However, it may be changed
in accordance with the discretion of HCIL taking into consideration the supplier’s status for quality.
Periodically Verify, Evaluate and give instructions for assuring the quality system of
Important and Safety Related parts.
Background of Global QAV-1 Deployment 102
Supplier Part’s Quality Verification（JPN） Present status of QAV-1Deployment at

major overseas base
Purpose ： Not just prevention of problem
Supplier In-process Verification but prevention from main
reason for the problem.
Implementation of QAV-2 1～5 step Application ：Deviation in application
M/P Verification by Regular Audit（QAV-1） happens at each site/base.
Global thought process
Uniform Deployment
（G-HQS＝HQS）
Direction for Global Deployment Progress of QAV-1 Audit
Quality Rating
◎
ＧＱＩ
Advance Prevention
Supplier Self Audit
Link
Re-occurrence
×
Prevention
Audit focuses on
reality of Shop Floor
Global Procurement Supplying Side

Improvement in Audit linking with GQI
Expansion Assurance
Difference of QAV-1 and QAV-2 【Timing】 103
Evaluation Ｐ２ E1 E2 E3
PLANNING D-1-DWG F-PROTO MP DWG

Drawing
Tooling status TOOL GO T1 T3 LT MP
DAN HIN RYO MP

Event
QAV 2(Step1 to 5) : Development stage QAV1: MProd.
QAV 1
QAV2: Step1 QAV2: Step2 QAV2: Step3 QAV2: Step4 QAV2: Step5
•System Index
Planning stage Supplier Action Progress Quality Maturation Capacity verify & * Quality Assurance Sys.
Feasibility study Plan confirmation Confirmation Verification Safety Declaration * Design/Devp. system
Ｑ．Quality Ctl Item
Ｑ．Quality target Organization, Plan vs Actual （ＳＰＥＣ，Accuracy) Quality Standardization
Ｃ．Cost Target Target; Date - Investment Facilities Ｃ．Set-up Cost
Ｄ．Delivery target Timing - Tooling Machine Accuracy QAV2
Ｄ．Tooling Leadtime When a critical problem is
Ｍ．Management - Facilities Cycle time Prodn Capability occurred under supplier’s
Target - QA Equipment Process Maturation Ｍ．Process & Organisation responsibility
- Kakotora Defect flow condition Maturation
【Production prepare step】 ⇒ QAV-2 (step1-5)

【After start M/P】⇒ Classified into QAV-1 (System audit) and QAV-2 (when defect occurred)
Supplier Quality Audit ( QAV-1) 104
Explain QAV-1 contents ... from what viewpoints (13 viewpoints)
Large category Medium category Overview
・Corporate quality policy and linkage among sectional
1. Business policy and -1. Quality Policy policies
organization -2. Organization Structure ・Grounds of target setting
・R&R of quality control
・Reflection of customer requirements in internal rules and
-1. Rules and Procedures control method of the latest editions
2. Quality system
-2. Quality Assurance System Chart ・Operational system from product development to
sales/after service
-1. Spec Control
-2. Regulatory Compliance Verification
・Storage of DWG/spec sheets, etc. and control method of
3. Spec and design -3. Product Chemical Substance
the latest editions
control Management
・Reflection of past quality troubles, etc. in design/spec
-4. Product Design Control
-5. Process Design Control
-1. Inspection Standard
・Creation, maintenance and revision methods of
4. Control of -2. PQCT
standards/record documents, etc. mainly used at genba
Standards -3. Operation Standard
・Reflection and compliance with customer requirements
-4. Inspection Data Sheet
-1. Contract ・Agreements on quality control items with suppliers
-2. Audit / Evaluation / Guidance ・survey/instruction methods to assure quality at suppliers
5. Supplier control -3. Receiving Inspection (Delivered ・Reception inspection items, method, record control and
Parts) handling when troubles are found
-4. Change Point Control ・Change point control methods at suppliers
-1. Change Point Control ・Definition, handling and record status of change points
-2. Lot Control -3. ID Control ・Method and records of lot control (including lockout)
6. Parts control -4. Quality Deterioration Preventive ・Method and records of product identification when
Control change points occur
-5. Honda-supply Parts Control ・Quality deterioration prevention method
Explain QAV-1 contents ... from what viewpoints (13 viewpoints)
Large category Medium category Overview
・Setting and compliance of manufacturing condition
-1. Manufacturing Condition Control
control items
-2. In-process Inspection
7. Process control ・Setting and implementation of in-process
-3. Improvement on Non-conforming
inspection items and standards
Parts in Process
・Handling and records of in-process trouble parts
8. Manufacturing ・Maintenance inspection items, frequency, method,

-1. Manufacturing Equipment Control
Equipment control plan, records and results
-1. Final Inspection ・Final inspection (quality) items, standards, records

9. Final inspection and
-2. Reliability Test / Feasibility ・Handling, analysis and evaluation of trouble parts
reliability test
Confirmation Test ・Items and standards of reliability test
10. Inspection device ・Rules and plan-actual of daily/regular check and

-1, Measuring Devices/QA machines
control calibration of inspection devices
・Handling and records when troubles occur (at

11. Trouble countermeasure -1, Trouble Countermeasure &
customers, in-house) and prevention/recurrence
and deviation acceptance Deviation Acceptance
prevention activities
・Regular internal quality survey (rules, organization,

12. Internal quality Audit -1, Internal Quality Audit
plan) to assure in-house quality
・Organization, plan, records and implementation of

-1, Quality Education(For Each Level) corporate-wide quality education (quality control
13. Quality education and
-2, Department Quality Education/ method, etc.)
training
Training ・Organization, plan, records and implementation of
quality education and training at genba
Implementor
6月 19日 HM購買にて
Participants Implement the prior meeting of QAV-1 (Implement purpose, method, others)
Flow from QAV-1 implement ~ until finished HM:昨間様､安達様武蔵:天野
106
Implementor
Please enter the 7月 4日武蔵社内にて
Prior meeting of internal visitor
武蔵:堀部､加藤､翠
Participant main participants. 8月3日 HM購買にて Visitor adjustment meeting and report the details of weak point in arrangement last time
Position 氏名 Gｒ所属氏名 Gｒ
ＶＩＳＩＴＯＲ (所属･氏名) 8月23日武蔵社内にて
HM:昨間様､安達様武蔵:堀部､加藤､翠(Schedule confirm, confirm viewpoint (About changed point, implement method, others)
2 武蔵:堀部､加藤､翠､他関係者 Implement of prior QAV-1(Focus on weak point last time 9:00～17:00)
【QAV-1 report sample】 9月 25日～26日武蔵にて

HM､武蔵:左記出席者参照
10月3日武蔵社内にて
Implement QAV-1
Honda technical research

2 Correct adjust meeting of comment details (Advance by 5 why analysis sheet)
Honda technical
research center
武蔵:堀部､加藤､翠､他関係者
ＶＩＳＩＴＯＲ 2
Participant
center
12月14日武蔵社内にて
2 出席者：左記参照 Hold the Quality Jikon
(所属･氏名)
Confirming area Systen, structure of QA and management condition

SA Measures for fact ・ phenomenon Improvement of system・structure
COMMENT REASON
Finish
CONFIRM ITEM Continue Tangible Fact ・ Phenomenon (What is the concern item in system & Advance
Finish confirm Real Cause C/M
Advance
Finish
No.
structure) S UG DETAILS person
period person's （Extract by 5 WHY analysis）（Improvement for real cause）in charge period
person Finish confirm person's sign
in charge
sign
1. Management policy & Organization 1 Busi ness pl an i s i mpl ement ed based on Busi nessConcer L L Mt oRevised Business plan control instruction
pl an n t hat i t wi l l not connect 村松(000501A-
10/31 When making the document Revised
of Business plan control regulations (M0005)
河口 11/30
and
control outline (M0005-01 4 vers.). In that, company's policy certainly making until the end of next Ki. Q001xx), and wrote that will make the making what that already implemented,
Business plan control guideline (M0005-1),
-1 Quality policy will be made within the end of Ki, but the making date of period of division and section Business planning didn't enter the making period
and made clear the time for making.
division and department level was uncleared. within the end of Mar because thought that it is on a routine basis.
However, actual of this Ki is as the following
Whole company policy 2007.03.28
Quality planning department Business

2007.03.28
planning paper
Quality planning administration division

2007.03.30
Business planning paper
2.Quality system 2 The r evi si on of r egul at i ons t ype i s i mpl ement ed

Concer
based M M Noticed to all division that will newly enact
hat t he management at M Genba
n ton 実重 10/19 Because up to now, the big problem
・RevisedRegulations
didn't occurred
control guideline(G0300-1)
宮沢 9th
11/30
condition
-1 Regulations several rules control regulations (G0300, 5 vers.) and and distribution of newest version of quality document
the receipt confirmation rules when distribute by the newest document control,
by add the condition about receipt
sever al r ul es cont r ol gui del i ne ( G0300- 01, 7 ver

wi ls.
l )be
. damaged. r egul at i ons t ype so the recognition that the confirmation
receipt when distribute.
The main department of every each document and address of distribution are made clear, confirmation is necessary ・Revised Quality manual (M2041) item 4.2.3 実重 11/30
but not have the rule of receipt confirmation when distribute. when distribute is weak. stipulated that when ditribute the quality system document,
However, receipt confirmation about external document is have to confirm the receiption.
written clear.
Temporary Analysis / Root cause ->
Problem Finding
０７０５１
（Note） SA：Condition analysis S：Impact importance U：Time tension
C/M G：LeavePrexpansion
Permanent C/M 1
oc e dur e Making Primary issue Quality Jikon Real issue 6
(High level：H, Middle：M, Low：L)
原本保存期限：年月
Audit comment item/Comment reason Temporary measures/schedule Permanent C/M /schedule Horizontal
STEP Submit within 1 operation week Within 2 weeks Complete within 3 months development
Supplier to improve quality weak points that is identified by QAV-1 by themselves, and
horizontal expand to all companies.
QAV-2 Audit 107
Purpose :To stabilize and improve the quality of parts by reviewing the quality assurance systems
at supplier's end.
Plan :
A) Plan is prepared for next coming month taking into consideration the yearly plan of HS/ HA
parts, last month mass production problems & conditions mentioned in table .
B) The concerned group of PQ notifies the supplier about the exact date of audit in advance. Over
and above audit can be planned based upon mutual consent of supplier and HCIL-PQ. In case of
serious defects qav-2 can be conducted on short notice by informing supplier verbally.
Implementation
• Auditor shall implement QAV-2 audit at the supplier end based upon "QAV-2 check sheet"
Report
• Auditor shall prepare report based upon facts and findings observed during audit and
communicate to supplier refer qav-2 report.
• Auditor shall indicate specifically if supplier is not allowed to take production till countermeasure
is finished. Take confirmation of person responsible of supplier . also note down the
countermeasure plan submission & implementation date on qav-2 report.
Countermeasure Of QAV -2 Report
The supplier shall prepare countermeasure plan of audit conducted by HCIL and submit it to HCIL
indicating date of C/M completion, responsible person, causes etc. On qav-2 report
QAV-2 Audit 108
Verification & Approval Of Countermeasure Of QAV -2 Report
Auditor shall confirm the countermeasure received from the supplier for qav-2 findings based on
following :
•Visit to supplier
•Discussion with supplier
•Taking evidences from supplier.
If any major nonconformity, with regard to quality assurance, is observed then report shall be given
to CEQ for approval and if required information shall be given to head of department - purchasing
S.No Control Items Major Check Points

1 Business policy and organization Objectives & Target Setting, QA representative Appointment
2 Quality system Document Control System & QA Chart
3 Spec and design control Drawing control System for Customer Drawing, Jig/Fixture tool
Rules for PQCT,OPS, Inspection standard Control for HCIL & In-house
4 Standards control
parts
5 Supplier control Supplier Selection, Audit & Monitoring & Incoming inspection Control
6 Parts control Change Point Control & records, Lot Control , Identification & Traceability
Process parameters setting, In-process Inspection & Non conforming Part

7 Process control
handling
8 Manufacturing Equipment control Preventive Maintenance of equipments & Jigs
9 Final inspection and reliability test Final Inspection Items & Reliability testing
10 Inspection device control Calibration of Inspection Equipment
Trouble countermeasure and

11 Countermeasure effectiveness, Horizontal deployment
deviation acceptance
12 Internal quality Audit System Audit, Process audit & Product Audit
13 Quality education and training Education & training plan
14 Safety,5S, Kaizen & QC Circle Performance Indicator for Safety, 5S

QAV-2 Audit 110
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
GQI Background
■ Global purchased parts increase
・KD and purchased
parts from other
countries are
increasing
・Transactions with
mega suppliers are
increasing
KD parts were mainly provided from Japan Global purchasing increase
■ Production increase From HCIL
• Number of components increase
• Number of suppliers increase
• Volume of parts increase
*Quoted form GSM materials
Number of parts and suppliers are expected to increase because of global purchased parts
and production increase. Accordingly, much more efforts would be required to handle
troubles and keep stable production (quality/delivery troubles)
GQI Background 113
１．HONDA Supplier Quality ２．Each site Delivery performance
Evaluation Evaluation
W.R.T Ｊ・ＨＱＳ・・○：same、△：different、×：Original Standard
Evaluation
item
Importance
level ○ ○ △ △ ○～×
Difficulty
level △ × × × ○～×
Improvement activity according Rejection % ○ No No △ ○～No
to evaluation result
Equal Thought Process Globally Verification at Each plant by
Ｇ･ＨＱＳ=Ｊ・ＨＱＳ same method
３．Global Commercial ４．Utilization of GQI Result

Distribution
Summarizing each Site
Quality × Evaluation Result Quality ◎
ＧＱ Evaluation
improvement
Quality
utilization
Active
It is important for Honda to grasp and share the results of entire
evaluation conducted by all sites.
Globally unified evaluation standards Global improvement / utilization of
(GQI) are necessary quality for future business
Unify the standards, as GQI, for all Honda to improvement & utilize the result for suppliers
quality performance. GQI=Global Quality Index
Utilization of GQI Evaluation Result
Setting up of GQI trigger as an measure for Quality Improvement
Quality Utilizing
GQI Trigger
Improvement Competitiveness
A級
４．Utilization of GQI Result

Trigger Line
Quality × 全拠点評価結果を集約 Quality ◎
Trigger 1 Future
Yellow Card 積
Improvement Business
【Advise 品ＧＱＩ評価極 continue
Improvement
improvement】質的
改活
Trigger 2
No
善用
Red Card
【Guide improvement
（Command）】
Global improvement / utilization of
quality for future business
Future business
Logic :- Trigger System ： Japan Method stop
70% of A Rank problem, GQI score more than 66 points or B Rank
Quality issue- 3 case / month or
triggers/ indication are B Rank quality issue continue for 3 month
available well before 1
year before it occurs.
Efforts towards “proactive
utilization" of supplier
competitiveness .
Perform forecast prevention activities of critical problems by capturing the trigger/

indication thru monitoring of GQI Evaluation result.
GQI-Trigger Methodology 115
3. Function strategy and
Manufacturing operation
area
Step 1 Capture the trend/indications and give guidance
GQI ；Standardization of Delivery Quality Indicators Importance level +no. of defects Improvement Guidance
Indication１
70% of A Rank ● A Rank A Rank Yellow Card
Issue Advise Improvement
problem, triggers/ Ｇ
Ｑ Improvement Plan submission
indication is Trigger line
Ｉ Red Card
available well before
1 year before it Recommend Improvement (order)
ｎ
occurs. （月）
Safety Declaration by Plat Head/CEO
Step 2 Forecast Prevention activity Step 3 M/L Cancelation discussion
Thorough Guidance to the supplier where If improvement is not seen even after
Improvement is not progressing giving guidance discuss this issue with
•Evaluate Quality constitution using QAV1 departments related to DEB
•Improve weak areas thru S-QCD •Impact on M/P (Yes/No)
M/Layout
• In case Global M/L, Support Measure •Availability of alternate supplier Cancel
Consensus with Mother Plant (GO-Global •Feasibility of Development schedule
Office)
STEP1 Major measures Content Index
Red card
【Improvement Direction ]
improvement
2 Yellow card in consecutive GQI

detection &
Safety declaration request (Plant Head/CEO)

Predictive
guidance
months or 1 A rank problem

[Recommendation for improvement]
Yellow card
1. Improvement plan submission by Plant Head/QA
GQI single month 66 points or 3 or GQI
representative.
more B Rank problem
2. QAV-2 for countermeasure confirmation
GQI Trigger Set as GQI>66 similar to Global Standard as we are supplying parts & CBU to
oversees operations
GQI Trigger Method 116
GLOBAL QUALITY INDEX :

A) RANK INDEX B) QUANTITY INDEX
PROB RANK INDEX REJ/REPAIR INDEX
RANK A 100 1 2
RANK B 20 2~9 10
10~99 50
RANK C 4
>100 70
Q. INDEX = RANK INDEX(A) + QTY INDEX(B)
GQI TRIGGER (GQI>66) STARTED FROM

JUL’15 PERFORMANCE
WARNING SYSTEM (YELLOW/ RED

CARD) TO BE STARTED FOR
TKR + EXPORT
GQI: Global Quality Index introduced & Suppliers Q Evaluation based on GQI Trigger jointly
for TKR+EXPORT
1 Supplier
Selection

Validation

Development

Application
5.2 Control Chart

systems

Flow Chart
requirements
6 General
Designation of QA representative 118
HCIL SUPPLIER A
QA Rep. - Window for QA activities HEAD OFFICE
(Company Executive–Head Office)
- Corporate level contact
- Resp. for constitution improvement
- Deploy SQM requirement in company FACILITY 1
HCIL- QD - Represent suppliers in periodic
Window Person audits (G.QAV-1).
FACILITY 2
Facility QA Rep.
( Plant Head/GM-Quality)
- Entrusted by QA Rep.
Revised Form is reqd : Guidelines for

■Every Six Months filling are given
■Incase of QA Rep change in SQM
The suppliers are requested to submit revised Notification form Every six months or
incase of change in QA Rep.
119
Incase of any issues/unclear point write to us

Kapil Gupta- kgupta@hondacarindia.com-9818303826

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Honda Cars India Ltd.

Supplier Quality Manual

Rev 10, Date 21.06.23

SQM - Supplier Quality Manual

• SQM Purpose is to establish Quality assurance requirements for

• It includes all Quality assurance activities performed by suppliers .

• Suppliers are required to comply with each of the requirements

• Global SQM issued in Apr’23 based upon each Location SQM

Global SQM Issued by Honda considering all Genpo requirements

◆ Honda revised SQM as below to facilitate communication with

1 Reviewing Honda’s SQM based on IATF16949 Chapter 1 to 6

1-3 Review requirements of SQM Chapter 1 to 6

◆Requirements by current SQM (Excerpt from preface.)

【 Current SQM structure 】 【Revised SQM structure】

SQM own system ISO9001

Current SQM:4 chapters ◆Revised SQM:6 chapters

Chapter 2: Product Design and Development

Chapter 4: Product and Process validation

Tool as reference Chapter 6: General Requirements

◆Image Current vs revised

6.4 Quality Record

5.5 Change point

6.3 Supply Parts

4-4 Change point

Revised SQM restructured 6 chapters.

1) Process 4) Materials resources／5) Skills

One of requirements from

Restructured SQM requirements reviewed with 6 processes of “Process Approach (*2)”.

Added existing development work as apart of requirements in SQM.

◆Description in new SQM

Compiled essence of requirements from each site.

【Cases/Y】 1. Insufficient rules

Total 171 JUHIN occurred

20 2. Insufficient risk analysis

4 9. Insufficient stock control of consumables

◆ Analysis example ◆ Reflection example to SQM

Examined the recurrence prevention measures from the causes of

【Structure of New SQM】

零件特性 有无对象 有无影响 变更项目 变更内容 变更理由 受影响的品质特性

Nº da Peça Planejada Para:

Alteração de condição de processo/método

Alteração de sequência de processo

Nº Ctrl: Nível de alteração:

Please follow the SQM structure for detailed requirements

② SQM Procedure ③ Designated Form

Refer HCIL Format

4 Product and Process

2.2 Statutory and regulatory requirements

2.3 Verification of Past Problems

and Corrective Action

5.4 Non-conforming Product Containment and

4 Product and Process

2.2 Statutory and regulatory requirements

2.3 Verification of Past Problems

and Corrective Action

5.4 Non-conforming Product Containment and

4 Product and Process

2.2 Statutory and regulatory requirements

2.3 Verification of Past Problems

and Corrective Action

5.4 Non-conforming Product Containment and

What Supplier’s Need to Do: Identification Method:

• Supplier should verify the actual usage in all its

【 Current SQM structure 】【Revised SQM structure】

零件特性有无对象有无影响变更项目变更内容变更理由受影响的品质特性