SUPPLIER QUALITY MANUAL

January’ 2018

Issue No. : 03, Revision No. : 01

1
 GABRIEL INDIA LIMITED

SUPPLIER QUALITY MANUAL

This manual is the property of GIL and shall not be copied or reproduced in full
(or) part without the written permission of the Head Central Supplier Quality,
Gabriel India Limited

MANUAL ISSUE NO. : 03

MANUAL REVISION NO. : 01

DATE : 1st January 2018

TOTAL NO. OF PAGES : 99 no’s

STATUS : CONTROLLED

REVIEWED BY : HEAD CENTRAL SUPPLIER

QUALITY ASSURANCE

APPROVED BY : HEAD CENTRAL QUALITY

2
Foreword:
Gabriel India Ltd. promises its Customers Zero Defect product at competitive
price and assured delivery. This is possible only if all the processes move from
“Quality by Inspection” to “Quality by assurance”. We need to achieve a condi-
tion where inspection of products supplied (and received) by Gabriel will not be
necessary. In order for this objective to be achieved, it is necessary that all func-
tions within Gabriel and its valued Supplier Partners operate on the "Zero De-
fect" philosophy. We must both strive for a fundamental quality system that
provides for continuous improvement in the quality of product, delivery and ser-
vices. Emphasis should be on defect prevention and the reduction of variation
and waste in the supply chain. We at Gabriel realize and appreciate the fact that
without strong and continuous support of our supplier partners, we can never
be successful in our endeavor.
The Gabriel Supplier Quality Manual addresses detailed requirement of Sup-
plier qualification and selection, Quality System requirements, and Flawless
product launch via robust Safe Launch Planning. This Supplier Quality Manual is
aimed at defining broad guidelines for Gabriel – Sourcing and Supplier Quality
team and Suppliers so that we all work towards a common Goal.
My best wishes to all for an exciting and mutually beneficial journey of being
“First time Right and Every time Right” so that we ensure complete customer
satisfaction.

Manoj Kolhatkar
Managing Director
Gabriel (I) Ltd.

3
Preface:
Auto Component industry expectations for Quality, Cost, Service, Delivery
and Technology require finely honed processes which support high level of busi-
ness efficiency and resourcefulness for profitable growth which is important for
long term survival. For Gabriel (I) Ltd. (GIL) suppliers form a very important part
of business. GIL is determined to maintain its leadership position in Shock Ab-
sorber industry by working collaboratively with all its supplier partners to make
sure that all the requirements and expectations are clearly understood and that
its suppliers share and act with a common sense of urgency that our customers
demand.
GIL Supplier Quality Manual addresses detailed requirement of Supplier qual-
ification and selection, Quality System requirements and Flawless product
launch via robust Safe Launch Planning. To assist our suppliers in helping us to
achieve our strategic goal, GIL Sourcing and Supplier Quality Team will utilize
Supplier Quality Manual. We once again reinforce that all the resources in the
form of Development Engineering personnel, Product Engineering guidance and
use VSME approach will be made available to the Suppliers to be successful. We
recognize that GIL cannot succeed without the superior quality, cost, service and
technology offered by its supplier partners.
We look forward to a very long partnership in this mutually beneficial journey.

Rajiv Khoche
Head Central Quality Assurance
Gabriel (I) Ltd.

4
Acknowledgement:
We are very proud in releasing Gabriel Supplier Quality Manual. All the top-
ics covered in this manual start with Gabriel requirements from supplier’s part-
ners includes all standards in-line with AHQC, IATF & other customer’s require-
ments.
Manual provides the relevant information at forest level to the wood level –
start with Process Map of each process, detailed requirements of process,
check sheets & formats. I am sure that users will find it convenient to practice
the systematic Quality tools & follow the Gabriel standards provided in this
manual, I firmly believe that the tools & procedures used or evolved in this
manual are universal and can be used in variety of situations across the Globe.
At the same time, I want to point out a word of caution. As is true with most of
the system/ process implementation is also not a quick fix. It requires diligence
& persistence from top leadership for a fair amount of period. But one of thing
I am sure; the fruits would justify the amount of efforts put in the implementa-
tion of all the tools.
Major changes in this manual are new vendor rating, new DOL & de-grada-
tion policy, AHQC requirements, Change management, supplier escalation,
new part development, VSME, New supplier system & Process audits, EHS re-
quirements (Business Continuation).
Last but not the least I must applaud the people who made this happen.
Specially Mr. Rajiv Khoche & Mr. Sudesh Deshpande & CSQA Team of all loca-
tions.

Abdul Wahid
(GM & Head CSQA/VSME T2)
Gabriel (I) Ltd.

5
 Introduction to Supplier Quality Manual
Purpose:
This manual is based on the concept of Gabriel philosophy of “Zero Defect”
product delivery to Customers and explains activities required for assuring the
quality of the purchased parts and services. Zero Defect approach is necessary
to meet and exceed the expectations of Gabriel requirements.

Scope:
This manual is applicable to all supplier partners during component devel-
opment phase and mass production to achieve the desired quality level ex-
pected by Gabriel.

Background:
Over the years, Gabriel & its suppliers have worked together in a collabora-
tive approach to secure and constantly improve quality. In order to achieve
next leap in Quality and maintain a stable and assured supply chain, Supplier
are expected to set up a quality management system with stable organization
and having culture of continuous improvement. In view of continuously chal-
lenging expectations all activities related to Gabriel Supplier Quality Manage-
ment have been consolidated into one easy to understand manual.
The Suppliers are expected to ensure that all quality management system at
Suppliers’ end are maintained at all the time, delivered parts conform to the
specifications and the parts meets Gabriel requirements of Durability & Relia-
bility.

6
 TABLE OF CONTENTS

SR.NO. TITLE PAGE

A) QUALITY MANAGEMENT SYSTEM (QMS)
1.0 Quality System & Environmental Requirements 10,11

2.0 Management Responsibility 11,12

B) SUPPLIER EVALUATION & SELECTION PROCESS

3.0 Supplier Selection Process 13,14,15,16
ADVANCED PRODUCT QUALITY PLANNING
C)
(APQP)
4.0 New Part Development 17,18,19

5.0 Production Part Approval Procedure (PPAP) 20,21

6.0 PPAP Requirements 22,23,24

7.0 Document Review 24

8.0 Production Trial Run(PTR) 24,25

D) MASS PRODUCTION
9.0 Supplies During Mass Production 26,27

10.0 Quality Abnormalities 27,28

11.0 Handling Deviations 28

E) SUPPLIER ENGAGEMENT
12.0 Purchase Agreement 29

13.0 Training and Supplier Engagement 29

14.0 VSME/ASME 30,31

F) SUPPLIER QUALITY IMPROVEMENT

15.0 Supplier Audits 32

16.0 Supplier Performance Rating 33,34,35

17.0 Quality Targets 35

18.0 Quality Escalation Process 36,37

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SR.NO. TITLE PAGE
19.0 Continuous Improvement 37
20.0 Anand House of Quality Culture (AHQC) 38

G) SUB-SUPPLIER MANAGEMENT 39

H) CHANGE MANAGEMENT
21.0 Supplier Change Management Guidelines 40,41,42,43
DIRECT ON LINE – CERTIFICATION/DEGRADA-
I)
TION CRITERIA
22.0 Direct On Line (DOL) 44,45

J) ETHICS
23.0 Anand Code of Conduct 46

K) ACKNOWLEDGEMENT FORM
24.0 Supplier Quality Management Agreement 47

L) FORMATS 48
25.0 LIST OF FORMATS
1) Supplier Purchase Agreement 49
2) Supplier Selection for New Development 50
3) Supplier Initial Evaluation Form (Self) 51,52,53
4) New Supplier Assessment Check List 54,55,56,57,58,59
5) APQP Timing Plan 60
6) PPAP KIT

a) PPAP Requirement Check List 61

b) Part Submission Warrant (PSW) 62
c) Contract Review Form (CR) 63
d) Agreement of Inspection (AOI) 64
e) Process Flow Diagram (PFD) 65
f) Process Failure Mode and Effect Analysis (PFMEA) 66
g) Dimensional Report 67
h) Statistical Process Control Study ( SPC) 68

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SR.NO. TITLE PAGE
i) Gauge Repeatability & Reproducibility - Variable 69,70
j) Gauge Repeatability & Reproducibility - Attribute 71,72
k) Qualified Laboratory for Testing and Calibration 73
l) Control Plan 74
m) Checking Aids 75
n) List of Approved Suppliers 76
o) Packaging Standard 77,78
p) Capacity Confirmation Letter 79
q) Production Trial Run (PTR) Observation Sheet 80
r) Functional Trial Run Format 81
7) Supplier Monthly Performance Report 82
8) GIL Corrective & Preventive Action Report (G8D) 83,84
9) Corrective Action Plan – 6W 2H (Line Issues) 85
10) Supplier Audit Check Sheet 86,87,88,89,90
11) Process Audit Check Sheet 91,92,93
12) Supplier Change Request Note (SCRN) 94
13) Risk Assessment Check Sheet 95
14) Manufacturing Feasibility Study 96
15) Lot Rejection Intimation Note 97
16) Line Rejection Intimation Note 98
17) Annexure for Special Process Audit Check Sheets 99
a) Process Audit Check Sheet for hardening process
b) Process Audit Check Sheet for Welding
c) Process Audit Check Sheet for hard chrome plating
Process Audit Check Sheet for powder coating (Ferrous &
d)
non-ferrous)
e) Process Audit Check Sheet for Zinc Plating
f) Process Audit Check Sheet for Nickel Hard Chrome Plating

9
 A) QUALITY MANAGEMENT SYSTEMS (QMS)

1.0 QUALITY SYSTEM & ENVIRONMENTAL REQUIREMENTS

1.1 Quality System Requirements

All Gabriel India Limited (GIL) Suppliers must be ISO 9001 certified with de-
finitive plan to up-grade system to IATF: 16949 as a part of continual improve-
ment. Suppliers shall have to comply with GIL Customer requirements for QMS
like IATF 16949, VDA 6.3 etc. as applicable. Suppliers must establish a quality
system as per the requirements given in this manual.
GIL shall carryout periodical assessment of Supplier Quality System to verify
conformance to QMS as per the manual. The Supplier shall take timely correc-
tive actions on the discrepancies reported during assessment audits.
In case of proprietary parts like Seal, Bearing, Paint, Powder and raw material
parts like Tubes, Bars, Sintered parts etc., the Suppliers are expected to proac-
tively work towards product up-gradation.

1.2 Environmental Requirements

Gabriel is committed in carrying out environmental friendly manufacturing
and management practices, and takes a step towards green technology on
yearly basis. GIL expects the Supplier partners to confirm to requirement of ISO
14001/OSHAS 18001 or minimum have definite plan to comply requirements
laid down under ISO 14001/OSHAS 18001. All Suppliers must ensure compliance
to appropriate legal, environmental and Government regulations. Following
shall be ensured by the Suppliers so that GIL & Suppliers will have a fair share in
caring for the environment:
• Usage of environment friendly raw materials
• Avoiding contamination of land
• Safe & systematic disposal of hazardous wastes
• Optimum utilization of resources and minimizing wastes
• Legal compliances like pollution board consent
• Assurance of safety
• Clean work environment
• Spreading awareness of the environmental friendly practices through train-
ings

10
 GIL Suppliers must submit Pollution Board Consent certificate as applicable
to GIL on yearly basis. Wherever GIL Suppliers use outside facility (Tier - 3 ser-
vices) Suppliers are responsible for Tier 3 compliance to requirements set by re-
spective Pollution Board. Minimum requirement in this case is PCB Consent.
MSDS requirements for chemicals must be adhered to & MSDS documents
must be available.
GIL Suppliers should adhere to GIL standard for “Procedure for Identification
of Automotive Restricted Hazardous Substances in Products during Product De-
sign (GP 111).

2.0 MANAGEMENT REPOSNSIBILITY

In order to ensure suitability and effectiveness of Quality Assurance system,
following shall be ensured.

2.1 Organization Chart

An organization chart shall be available showing relationships of each individ-
ual in the organization. Responsibilities and authorities of different personnel
must be documented & persons should be aware of their role. Quality Head shall
have authority to stop operations in case any deviation is observed in a quality
management system or product non-conformity. He shall not have any direct or
indirect role in production. His reporting should be to Plant head / CEO.

2.2 Customer Representative

The Supplier shall nominate a customer representative and clearly define the
responsibilities and authorities related to the position. The responsibilities of
customer representative shall include –
• Understanding Gabriel requirement of QMS and communication of same
within organization.
• Ensuring proper and timely response to GIL on all issues.
• Controlling and proper storage of documents received and submitted to
GIL.
• Ensuring that the specific requirements laid down in the manual and agreed
during contract review are met.
Any change in the customer representative shall be intimated to GIL.

11
2.3 Management Review
Supplier’s top management shall review the quality system, GIL specific re-
quirements, performance ratings and process & product audit results at regular
intervals and set targets to improve upon it. These targets shall be established
in line with requirement communicated by GIL.
In case of special cases (high PPM/customer concerns), Supplier’s top man-
agement will be required to visit GIL as per plan and discuss countermeasures
for improvements.

12
 B) SUPPLIER EVALUATION & SELECTION PROCESS
3.0 SUPPLIER SELECTION PROCESS
In case of new Supplier addition, Strategic Sourcing will identify potential sup-
plier(s) & get Supplier Information details on Supplier Initial Evaluation Form.
Potential Supplier shall complete the form and send back to GIL. Based on the
evaluation of initial report, GIL Strategic Sourcing and Central Supplier Quality
Assurance (CSQA) will conduct the assessment audit at the Supplier end. The
assessment will be conducted based on the criteria for Initial Assessment
(PRM/SSCM/01). The Central Supplier Quality will release the audit report to
Strategic Sourcing. If Supplier meet the QMS criteria and is able to demonstrate
availability of adequate capacity, Strategic Sourcing will move to sign off supplier
purchase agreement. After completion of sign off Strategic sourcing will get the
approval from MD for addition of new Supplier. Once the approval is given to
the Supplier new vendor code will be released in SAP. Supplier assessment re-
port will be released to respective GIL plants and master list of approved Suppli-
ers will be updated for new Supplier.
Collaborator recommended Suppliers vendor code will be allocated in SAP
and master list will be updated.
Existing Suppliers who want to supply other commodity, process audit will be
conducted for that commodity. If found satisfactory, master list will be updated
or else re-audit will be done.

13
 SUPPLIER SELECTION PROCESS
START
In case of customer specifies criteria for new
supplier assessment follow CSR.
New supplier needed due to - R: SSCM
a) Capacity b) Quality or delivery performance c) New project
d) New part / commodity e) New GIL plant Certificate has logo of IAF or IATF or certifying body is rec-
f) Expansion ognised by IAF MLA as per website
R: SSCM a) www.iatfglobaloversight.org at menu IATF certification
bodies for IATF 16949.
b) www.iaf.nu at menu IAF Members & Signatories -
Identify approvals through internet, known Menu - view list by name for ISO 9001
acquaintances, competitor information R: SSCM
R: SSCM A: SQA

Commodity manager receive supplier infor-

mation filled in evaluation form (SSCM/006) Communicate to supplier for on-site
and supplier profile PPT. evaluation. R: SSCM
R: SSCM
YES

Supplier on-site evaluation

as per format (SQA/004)
R: SQA & SSCM
Is supplier rec- Is supplier ISO- NO
NO
ommended by 9001 / IATF-
customer? 16949 Certified?
R: SSCM R: SSCM In case suppler is for special pro-
cesses (like plating, welding,
coating, hardening etc.), use spe-
cial process check sheet in addi-
YES tion to Supplier Assessment
check sheet
R: SQA

Supplier to meet criteria for spe-

cial process audit & new Supplier
Assessment.
R: SQA

Score < 5 Score between 5 to 6.4 & not
meeting criteria of b & c
A Potential for development. Must
improve to achieve score 7.5 by
providing action plan
R: SQA & SSCM
Re-audit to achieve score of 7.5
R: SQA
B
Score between 6.5 to 7.4 & not a) If Score ≥7.5
meeting criteria of b & c b) With minimum score in each cat-
egory to be minimum 7.0
c) In business continuity score to be
Development can be initiated in- minimum 9.0
case of emergency if approved by
SQA-Head. Supplier must im-
prove & achieve score of 7.5 min.
before PTR / PPAP
R: SQA & SSCM
D
C

14
 C

B
Submit approved report to SSCM
R: SQA Head

For customer recommended sources,

decide further actions - MD Approval for New Supplier
- Either to follow GIL-process, or Addition
- Otherwise as advised by customer R: SSCM Head A: MD
and take appropriate actions
R: SSCM
In case existing supplier wants
Allocate Vendor code in SAP to start supplies for other com-
modity.
R: SSCM Head
R: SQA

Purchase agreement signed with Plan for process audit of new

supplier. R: SSCM commodity.
R: SSCM
Collaborator recommended
supplier
Process audit for new com-
modity as per format.
Circulate supplier assessment re- R: SQA
port to GIL-Plants.
R: SSCM
Allocate Vendor code
Yes
in SAP. R: SSCM If satisfactory
A: SQA
Include / Update approved sup-
plier list for a commodity No
R: SSCM & Plant SCM
Conduct re process audit.
R: SQA
Start Development
R: SSCM

A Stop D

15
 SUPPLIER QMS DEVELOPMENT PROCESS
START

Conduct stage one audit

Prepare list of Local suppliers "QMS certifi- using supplier readiness
cation status. R: SCM review checklist (Use qual- A
ified QMS Internal audi-
tors.) R: SQA

Prepare list of suppliers "QMS certification

status. R: SCM

1. Prepare annual audit plan

2. Conduct audit using checklist to meet ISO
Are they certi- 9001 requirements. R: SQA
Yes fied to ISO 9001
or IATF 16949
by third party,
R: SSCM
Any non-con-
formities?
R: SQA
No
Yes

1. Raise non-conformity report

Can conformity to ISO
9001 be demonstrate
& verified by second
party audits (GIL)?
R: SQA
Yes
2. Distribute & request to close the NCR with
time bound. R: SQA

No
Verify
1. Correction
2. Root cause analysis
Check for IAF MLA LOGO on QMS Does specially
3. Corrective action. R: SQA
Certificate. R: SCM designated No
small supplier
criteria apply?
R: SSCM
No
Prioritize & shortlist ISO 9001 certified Is the result ef-
supplier for up-gradation to IATF16949. fective? R: SQA Communicate
Yes
R: SQA
Grant waiver for certain
Yes
specified element of ISO
Communicate to Supplier 9001. A: SQA Review Audit Report. R: SQA
R: SSCM / SQA

Maintain record for waiver Award conformity certificate

Obtain IATF implementation roadmap granted. R: SCM A: SQA
from Supplier. R: SCM
Conduct surveillance audit at least an-
A nually but gap between two audits
Track the progress & record in MRM cannot be more than 12 calendar
R: SCM months. R: SQA
1. Look for alternative supplier who
can demonstrate conformity to ISO:
STOP 9001 STOP
2. Track & record in Management Re-
view meeting. R: SSCM

16
 C) ADVANCED PRODUCT QUALITY PLANNING (APQP)
4.0 NEW PART DEVELOPMENT
After selection of a Supplier for supply of a part, a letter of intent is issued by
GIL. At this stage the following documents/parts will be issued by GIL Strategic
Sourcing.
• Part drawing
• Sample part (if available)
• Applicable GIL Standards

4.1 Feasibility Confirmation

In order to clearly understand the function/specification of the part, GIL en-
gineering, Strategic Sourcing and CSQA shall hold a joint meeting with the Sup-
plier once the Supplier has gone through the standards and specifications is-
sued. Following points shall be discussed and agreed:-
• Drawing Feasibility Study
• Contract Review
• Timeline/Plan of Development
• Functions of the part
• Criticality and Critical Characteristics Identification
• Testing requirements
• Capability requirements
• Previous failures if any in part or similar parts
• PPAP requirements

Feasibility meeting records must be prepared and properly preserved for fu-
ture references. In case certain specifications/ test requirements are not ac-
ceptable/ feasible, a deviation request must be submitted to GIL for review and
agreement.
Once the specifications are finalized, a contract review will be signed be-
tween GIL and Supplier. The contract review in addition to technical specifica-
tions must also cover areas like testing, layout inspection, cleanliness levels,
packaging etc.

17
4.2 Initial Sample Submission
Supplier shall submit initial samples to GIL for verification/testing along with
the following documents: -
• Layout Inspection report (all parameters as per drawing)
• Material test reports
• Functional Test reports as per specification meeting records as applicable
• Durability Test Reports as applicable

In case of use of multi dies/molds, inspection reports for all dies/molds must
be submitted for approval.
If any tooling modification/changes are done after the approval of samples,
Supplier shall intimate GIL and submit fresh samples before witnessing a pilot
lot.

4.3 Initial Sample Approval

GIL QA will carry out required checks & tests on the samples submitted by
Supplier & release Sample Evaluation Report (refer process flow for New Part
Development).

18
 NEW PART DEVELOPMENT PROCEDURE

START

Project Kick off

R: Marketing

Design Review for manufacturing feasi-

bility. R: Program Manager
No
Design / Drawing/ Std. release
R: R & D
Does Techno commercial
Techno commercial proposals & review with Supplier. proposal submission &
R: SSCM approval from marketing
received?

Supplier finalization, Technical contract review & APQP Yes

time plan sign off with Supplier. R: SQA + SSCM

Proto Sample Development

R: SQA + SSCM

No No
Is sample ap- Corrected samples from supplier
proved by QA? with CAPA. R: SSCM

Yes No
Yes
Obtain Interim approval from R&D
Product sample built up as per Customer re- R: SSCM
quirement. R: SSCM
Yes

OTS drawing released by R&D & Tooling Develop-

ment review & approval at supplier end.
R: SSCM

OTS Samples Development

R: SSCM

No
Is sample approved Corrected samples from Supplier
by QA? with CAPA. R: SSCM

Yes Yes No

Obtain Permanent Deviation ap-

Follow Supplier Part Approval procedure
proval from R&D (CR)
(PRM/SSCM/03) for Product Approval (PPAP)
Yes R: SSCM

STOP

19
5.0 PRODUCTION PART APPROVAL PROCEDURE (PPAP)
PPAP Approval from GIL will be required for new / changed parts prior to
volume production from all the Suppliers (including job works) at level 3. For
Imported parts (except China Suppliers) no PPAP approval required.

5.1 Parts requiring PPAP

PPAP submission is required for all parts prior to first supply to GIL.
Production Part Approval shall be obtained from GIL when any of the following
conditions occur, prior to dispatch of bulk production:-
1. For new part
2. For a design change:-
• For a process change (any changes in machine capacities or equivalent
machines are considered as process changes)
• When previous submission is rejected
• Production from new/modified press tools/molds
• Sub-Supplier (Tier – 3) change
• Raw material change
• Location change
• New/up-gradation in machine
• Out-Sourcing or In-Sourcing of process or machine
• Change in process flow
• Change in machine parameters
• Changes against initial PPAP approval by GIL.
3. No supply for minimum 12 months or more.
5.2 Parts not requiring Full PPAP
PPAP submission is not required for Suppliers of Steel, Aluminum, Powder,
Paint, Grease, Oil, Chemicals and Imported parts except China Parts. However
for cut rods and cut tubes following documents are to be submitted for PPAP
process -
• Part Submission Warrant(PSW)
• Dimensional and other test reports
• Two samples
• Control Plan
• Process Flow Diagram
• Others as and when required.

20
 PRODUCTION PART APPROVAL PROCEDURE (PPAP)
START

SQA Engineer to take decision for no PTR based

on below criteria:
Receipt of Sample Evaluation /Approval report from • Bulk material like -Paint,Powder,Chemi-
QA & drawing in OTS/Production Stage. R: SSCM
cals,Steel,Al ingots, cut
rods,Oil,grease,Imported Parts except
China, cut tubes, consumable parts
Conditions of PTR
• Fasteners, Catalogue parts
• New supplier / new part /alternate source/new mfg. process • Suppliers having no Quality issues for
• New commodity of part at existing supplier similar parts being developed.
• Critical/Safety process (Special Processes - Welding, Harden- • Similar part with Supplier with small
ing, Powder Coating, Plating)
changes
• Customer specific requirement if any • Customer approved parts.

Is On-site PTR No Receive PPAP documents from the Supplier as per

to be done? PPAP Check List (SQA /013) referring Sample formats
A: SQA
given in PPAP Kit. R: SSCM

Yes
Get confirmation about readiness of
pilot lot from Suppliers & finalise date
for PTR at Supplier. R: SSCM
Review documents for its correctness/adequacy of
contents as per reference formats given in PPAP Kit.
PPAP kit is guideline. Intent of these can be achieved
by Supplier in similar formats. R: SQA

Note down all observation in PTR observation sheet

Conduct PTR at Supplier premises
(SQA/028).During
R: SQA / VD PTR conduct Ppk study for Safety,
Critical, Significant parameters as identified through
drawing. Ppk target 1.67 minimum. R: SQA/SSCM No
Does this Send gap details to
meet require-
ment? Supplier. R: SQA

Does the product meet all re-

quirements of dimensional, ma- Yes Yes
terial, functional & performance
& Ppk ≥ 1.67?
Sign PSW as per guideline format
A: SQA
given in PPAP Kit R: SQA

No
Ensure deviation SSCM to provide PSW & QM Info
Obtain concession from R&D for Interim required to CQA for release of
is reflected in
Approval & sign-off Contract Review. open PO/SOP. R: SSCM
AOI
R: SSCM A: R & D
R: SQA/SSCM

No
Meets Re- Complete required
Check Product Approval Document
Handover quirement? actions. R: SSCM
as per PPAP checklist. R: SQA
AOI to QA
R: SSCM Yes
Yes If QM Info cleared, release PO & to
Meets Re- Supplier. R: SSCM
Follow Process for quirement?
In-coming
Inspection. No STOP
R: RQA Reject submission & ask
for corrective action &
resubmission.
R: SSCM

21
6.0 PPAP REQUIREMENTS
Supplier shall submit PPAP as per PPAP KIT which specifies the complete set
of requirements applicable to the part along with all standard documents (Level
3).
Before initiating PPAP, following activities needs to be carried out by the Sup-
plier and duly verified by the GIL SQA team to ensure defect free and un-inter-
rupted supplies. Refer process flow for PPAP.

6.1 Process Design

“Process Failure Mode and Effect Analysis” (PFMEA) needs to be carried out
by the Supplier. A cross functional team shall carry out this analysis. In case de-
sired by GIL or requested by the Supplier, GIL SQA representatives shall also sup-
port. Problem history of the parts/ similar parts as discussed during specification
review meeting should also be taken into account. AIAG Manual guidelines shall
be used for Severity, Occurrence and Detection rating. Any Severity ranking 9 &
10 and where Severity x Occurrence ranking greater than or equal to 36 shall be
taken for improvement action by the Supplier. Otherwise prioritization will be
as per severity Ranking & RPN value.PFMEA should be reviewed at least yearly
& as & when for Customer or internal rejection complaint.
The supplier shall review FMEA by using Reverse FMEA (R-FMEA) tool for all
parts supplied to Renault.

6.2 Equipment Planning

As a part of APQP process for new development, process and product
changes, quality improvements and capacity enhancement, Supplier shall do the
equipment planning before and communicate to GIL. Wherever required/re-
quested by the Supplier, GIL TSG shall support the Supplier for equipment selec-
tion and source finalization.

6.3 Process Flow Chart

Supplier shall prepare a process flow chart and submit to GIL. Process flow
chart must indicate process numbers, inspections to be carried out, outsourced
processes, critical processes. Process flow chart must have a linkage to the con-
trol plan

6.4 Control plans

Supplier shall prepare a control plan and submit to GIL for review. Approval
of the same should be done during witness of the actual production parts. Fol-
lowing information has to be clearly mentioned in the control plans:-
• Process description-whether in-house or subcontracted. In case of critical/
significant characteristics, it shall be clearly mentioned

22
 • Equipment description indicating name, capacity of the equipment used
for production
• Standard Specifications with tolerances.
• Control specifications with tolerances. Control specifications should always
be tighter than / equal to the standard specifications
• Inspection method along with the name of the instrument/equip-
ment/gauges used for inspection
• Sampling frequency
• Recording format (if to be recorded)
• Reaction Plan indicating actions during failure
• Control plan must have linkage to Process Flow Chart & PFMEA.
Control plan should be reviewed at least yearly and as & when for any Cus-
tomer or internal rejection complaint.

6.5 Capability Analysis

Supplier shall carry out capability study on critical/significant parameters as
discussed during specification review meeting / as given in drawing and submit
the results to GIL. Initial process capability index Pp/Ppk should be 1.67 mini-
mum & for regular Cp /Cpk should be 1.33 minimum or as per CSR if any. Regular
process capability study should be conducted once in 3 months or as agreed and
submit the reports to GIL. In case of poor capability results, Supplier shall also
submit a time based action plan to improve the capability. Supplier shall also
demonstrate a foolproof inspection method in the process to ensure that the
non-conforming parts cannot pass on to GIL.

6.6 Operator Training/operator Skills

Supplier shall focus on training and skill enhancement for operators. Training
plans shall be made and training shall be imparted. Focus should be given both
for system development and process knowledge. In addition to the internal
training by Supplier, GIL SQA shall also conduct regular trainings to support the
Supplier. GIL SQA shall specifically focus on improvement tools like 5S, ROP,
QRQC, Zero rework, Work Instructions, System Development and Problem Solv-
ing Tools. In addition to this, any gaps identified during discussions and audits
can be covered individually with the Supplier teams.

6.7 Identification and Traceability

Supplier shall have well defined traceability system as agreed with GIL .It
should be able to trace the history, application or location of a part by means of
recorded identifications.

23
 The identification tag/label must remain on the lots. Identification tag should
contain – Supplier name, part name, part number, lot quantity & date, checked
by.

7.0 Document review

Suppliers should submit PPAP documents after ensuring readiness for sup-
plies. GIL SQA shall conduct review of PPAP documents submitted by Supplier.
Based on the findings of document review, Supplier shall take appropriate ac-
tions. GIL SQA team shall review the improvement actions taken and their effec-
tiveness during production trial run. In case it is observed that the actions initi-
ated are not satisfactory, SQA team reserves the right to stop the development
process till improvement results are evident.

8.0 PRODUCTION TRIAL RUN (PTR)

GIL SQA shall witness the production trial run at the Supplier location. Fol-
lowing points need to be verified during the trial run:-
• Review of the gaps and actions taken during the document review
• Inspection status of the parts for critical/significant parameters
• Suitability of the operation standards & methods
• Verification of the process parameters with regards to the control plan sub-
mitted
• Effectiveness of inspection firewalls being used by Supplier
• Training and skill levels of the manpower deployed
• Process Capability for critical characteristics
• ROP (Packaging) standard
• Capacity confirmation activity may be carried-out as and when required.
• Agreement of Inspection (AOI)

Supplier must implement corrective actions for documents & PTR observa-
tion & confirm to GIL SQA.
RE-PTR will also be conducted for repeated/Customer/Warranty complaints
as and when required.
8.1 Identification of PPAP Lot
Samples must be taken from a significant production run (300 numbers min-
imum) or at least one day production and submitted to GIL incoming inspection
for approval along with the inspection reports.
Supplier shall identify PPAP samples using separate tag.
Gaps if any will be informed to Supplier.

24
8.2 PACKAGING REQUIREMENTS (ROP – Respect of Product)
Packaging shall be finalized between GIL and Supplier during contract review.
Wherever possible, reusable type of packing must be finalized having the name
of Supplier and GIL clearly marked.
Proper labeling shall be ensured by the Supplier to avoid mixing of different
parts or parts from different Suppliers.
The consumption pattern, cleanliness levels required at input, cost and other
factors must be considered while finalizing the packaging. The finalized packag-
ing shall be listed down and signed off between GIL and Supplier.

8.3 AGREEMENT OF INSPECTION (AOI)

Before the start of supplies, it is necessary for Supplier and GIL RQA team to
have a clear understanding regarding the inspection parameters, inspection
methodology, sample sizes, frequency of inspection, packaging methods and
cleanliness levels required. The agreement of inspection should be signed off by
GIL SQA, GIL RQA and Supplier. Whenever there is a need for revision, a fresh
copy of the AOI must be drafted and signed by GIL RQA and Supplier.
For the parameters which are subjective and their judgment criteria cannot
be clearly established, limit samples must be established and duly approved by
GIL SQA, GIL RQA and Supplier. These shall be available at Supplier location as
well as at GIL incoming inspection.

8.4 PPAP Approval

GIL SQA will release PSW, based on confirmation of
• Implementation of corrective actions for PTR observations.
• Document revision
• Pilot lot approved by QA
• Sign off of AOI and Contract Review (If applicable)
Supplier can start supplies on receipt of PSW from GIL.

25
 D) MASS PRODUCTION
9.0 SUPPLIES DURING MASS PRODUCTION
Every lot submitted by the Supplier shall accompany following documents:-
• Pre-dispatch inspection report (PDI Report) in line with AOI
• Material test report. Third party test report once in 3 months or as agreed
from NABL accredited lab.
• Other functional test reports/Performance test.For Plating, Pow-
der/CED/Paint coating salt spray test report during development & there-
after once in 6 month for regular supply.
• Layout inspection report should be submit along with samples once in six
month or as agreed.
• Rubber Suppliers – rubber test button with each batch for hardness verifi-
cation. TGA & FTIR report should submit during initial development stage
and as and when required by GIL.

Failure on account of the Supplier in submission of any of the above shall lead
to rejection of the lot at GIL incoming. In addition to the above, the Supplier shall
submit the layout inspection reports, material test reports by NABL accredited
/Govt. approved labs, capability reports, and other relevant records on periodic
basis as per AOI.

9.1 Process Control

• Supplier should conduct required process controls as specified in
control plan. Records as required as per control plan should be available
at Supplier & should be reproduced as & when required.
• Supplier should conduct in-process checks & maintain records as per con-
trol plan.
• Wherever required control charts should be used for process controls and
monitored monthly basis.
• Supplier should identify & deploy mistake proofing (Poke Yoke) to deliver
zero defect to GIL.
• List of Poka Yoke at Supplier should be available & daily Poka Yoke audit
should be conducted.
• Final Inspection Standard must be as per GIL guidelines.
• All stations of 100% inspection must have red bins for rejection.

26
 These should be preferably fixed & closed.
• Supplier must maintain Rejection Record & analysis should be carried-out
on monthly basis to ensure Continuous Improvement in Rejections &
Scrap Cost.
• For Special Processes, Yearly Re-qualification/Validation must be con-
ducted & record of minimum 5 years should be available.
• Supplier should ensure Process Controls for Surface Treatment Process
(Including T3) as per GIL guidelines.

10.0 QUALITY ABNORMALITIES

Quality abnormalities can be reported at three stages
• Incoming inspection at GIL during lot inspection
• Line rejection at assembly
• Failure reported by OEM during assembly on vehicle
• Failure reported by OEM in field as warranty

When an abnormality is detected at the incoming sample inspection, the en-

tire lot is blocked by GIL for segregation/rework/scrapping/return back. Hence,
the entire lot is counted as NG.
On intimation of the quality problem to the Supplier, the Supplier shall take
following actions:-
1. Containment Action -
• Segregation of the parts at GIL incoming and line.
• Segregation of the parts at various locations at Supplier end, at ware-
house, in transit. Supplier shall resume immediate supplies to GIL after
proper identification for 100% checking for defect. Affix containment lot
sticker on lot.
2. Submission of 8D format duly filled by the Supplier indicating the root cause
of the failure, permanent corrective and preventive actions (GIL CAPA/Cor-
rective Action Plan 6W-2H (for line issues)) to avoid defect recurrence.

Supplier shall submit the Containment action report within 24 hours of the
reported failure and a completed 8D within 7 days (with proper plan of improve-
ment).CAPA must be implemented within 10 days or as agreed with GIL.
For the abnormalities observed at Supplier location, a proper documented
procedure shall be established indicating the handling, disposal, rework proce-
dure, rework approval, analysis tools and recording mechanism.

27
 Quality performance is tracked monthly in terms of PPM & Quality Rating and
the same is communicated to the Supplier through auto generated mail by GIL
SAP system.

10.1 Handling Warranty/field returns

Supplier shall involve with GIL for reduction of warranty for parts /assem-
blies. The Supplier shall support or jointly analyze the failed samples with GIL
whenever required. As per the root cause, appropriate actions shall be imple-
mented and the necessary documents shall be updated and submitted to GIL by
the Supplier in order to reduce the warranty in future.

11.0 HANDLING DEVIATIONS

Gabriel requires adherence to a formal deviation procedure when Supplier
discovers at its premises any type of non-conformance in a lot/batch of product
which is urgently needed to meet the Gabriel production schedule.
In this situation, the Supplier must obtain prior written approval from Gabriel
before making shipments. The acceptance of a deviation request will be depend-
ent on the nature and extent of the non-conformance and will be authorized in
writing to the Supplier by Gabriel QA / R&D.
When a deviation request is required, the Supplier will notify the plant SCM
team. The plant SCM will request approval from Gabriel QA and the plant head
to review the technical & fitment impact. QA will get inputs from R&D / TSG, if
required.
The Supplier must include the copy of the approved deviation notice with the
shipment of parts to GIL. The deviation number must be clearly marked (can be
hand written) on all shipping papers /containers.

Note: The deviation number must be placed on PDI, so there is no Material Re-
jection Report and reflection on the Supplier's Quality Performance Rating.
If the deviation request is denied, the plant SCM team will notify the Supplier
and coordinate resolution activities.
If any suspected non-conforming part/lot is already dispatched, the Supplier
shall inform GIL about the clear description of the non-conformance and the
dispatch details.

28
 E) SUPPLIER ENGAGEMENT
12.0 PURCHASE AGREEMENT
The Supplier shall read, understand and agree to all the relevant clauses of
the Purchase Agreement. This Purchase Agreement will be reviewed periodi-
cally. All GIL approved Suppliers shall abide by the purchase agreement. Any is-
sues between GIL and Suppliers will be resolved in line with Purchase Agree-
ment and Supplier Quality Manual.

13.0 TRAINING AND SUPPLIER ENGAGEMENT

The Supplier shall constantly upgrade the skill and knowledge of the available
human resources through various trainings and events. The training needs of
various employees shall be identified & appropriate trainings shall be planned
and conducted.
Following initiatives are taken by GIL as a part of Supplier Engagement:-
• VSME Meets
• VSME Community Meets
• Yearly Awards based on Performance
• Trainings
• Kaizens Competition
• Yearly Vendor Meet
• Visit of GIL Senior Management to Suppliers
GIL encourages the Suppliers to take initiatives in suggesting VA/VE improve-
ments. GIL also encourages the Suppliers to take part in the various events and
trainings that are conducted in GIL throughout the year.

29
14.0 VSME/ASME

I) Visionary Small and Medium Scale Enterprises (VSME):

Gabriel initiates Supplier development through special program as VSME &
ASME.This program outline is as below. Gabriel felt the need to revisit its man-
ufacturing paradigm. Many of the problems such as uneven manufacturing
load over the month, delivery defaults from Supplier, quality issues surfacing at
regular intervals were found to be present in its plants. Therefore a transfor-
mation journey was launched, with guidance from Prof Shoji Shiba and Prof Fu-
ruhashi from Japan. The model of transformation is summarized below:
VSME Program
Survival in Globaliza-
Start tion 2X/3X Growth

Workplace
Transfor- Organisation &
mation Indian Way
Management of Win-Win
Layout & 5 S Transformation
Quality Common
Machine Goal
Maintenance
Heijunka flow
Efficiency of In-
across & within
dividual cell Continual gain in
Tiers
Productivity

Use V map as a tool

Heijunka
Optimum use of resources

As seen from the above, there are three key elements to this process of
transformation:
VSME journey cover in three phases
• Design of Flow
• Control the Flow
• Improve the Flow
Gabriel select Strategic Suppliers for this improvement program every year
and cover following modules training in one year span.
• 3S Map - Improving 5S,Layouts & Removal unwanted things
• Quality Transformation - to ensure process capability of the processes

30
 • Machine Maintenance drive, to ensure the reliability and availability of
the machine
• Operational Flow :-includes Delivery flow, Production Flow & Procure-
ment flow
• Heijunka
• Standard Work
• Pull System :- KANBAN
After completion of VSME training Supplier becomes community member as
per location. Responsibility of community member is to attend the community
meeting and follow community rules.
Every year targets for AHPS and other performance indicators need to ad-
dress community formation & other related details are agreed upon between
VSME & ASME Suppliers and GIL. Audits as per AHPS check sheet are con-
ducted on periodic basis.

II) Anand Small and Medium Scale Enterprises (ASME): -

In this program there are five modules identified for implementation at se-
lected Supplier end:-
• Observation Skill
• 3- S mapping
• Quality Transformation
• Machine Transformation
• Heijunka planning
Duration of this training is of one year. After completion of this training pro-
gram, Supplier is certified as Graduate ASME and become member of ASME
community. Targets are set every year for each Supplier and reviewed yearly.
AHPS audit is conducted every year.

31
 F) SUPPLIER QUALITY IMPROVEMENT
15.0 SUPPLIER AUDITS
GIL SQA team will plan annual system audit plan for all local Suppliers. For
Imported Suppliers (except China) no audits will be conducted. Suppliers audit
frequency will be based on below given criteria. The audit shall be conducted as
per Supplier Audit Check Sheet / other guidelines as per Customer specific re-
quirements.
Audit Score Audit Frequency
< 60% Once in 3 months
61 – 79% Once in 6 months
>80% Once per year
In certain cases like major lot/line and repeated rejection at GIL or quality
problem reported at Customer line or field, unscheduled/Process audits will also
be conducted.
After the audit report is submitted to the Supplier, the Supplier shall submit
an improvement plan after gap analysis within two weeks. The same shall be
reviewed, approved and verified by the GIL SQA team. All improvement actions
must be implemented within 30 days of audit or as agreed with GIL.
The Supplier shall also conduct internal audits covering both system and pro-
cess functions for continual improvement. Internal audit reports and improve-
ment actions of internal audits and audits conducted by GIL SQA shall be main-
tained.
Supplier Audit Score shall be improved on yearly basis & targets should be
mutually agreed upon.

15.1 CAPA Verification Audit

GIL may conduct CAPA verification /Process audit at Supplier as & when re-
quired for closure of G8D /GIL customer complaint & warranty complaint.

32
16.0 SUPPLIER PERFORMANCE RATING
The Suppliers will be rated every month based on their previous month’s per-
formance. This rating comprises of Quality performance, Delivery performance
and Audit score.

16.1 Quality Rating

Individual Lot Receipt Quality Rating is evaluated for every lot.

No. of lots for the month = N

 
ILR = x LAF

  
Where LAF – Lot Acceptance Factor, as follows:

Criteria LAF
Direct Pass (DOL) 1.0
Sample Inspection Plan 0.9
Lot Rejection 0
Rework & Segregation 0
Under Deviation 0.7

   ⋯   2 This is a sample.

Receipt Quality Rating (RQR) =( )
 The PPM targets
are given com-
Quality Rating, Q = RQR x [M1XM2] x 100 modity wise
Where M1 and M2 are de-rating factors
De-rating Factors PPM Value
0-100 1
101-150 0.9
M1 – Line Rejec- 151-200 0.8
tion 201-300 0.7
301-450 0.6
451-99999 0.5
0-50 1
M2 – Zero km Re-
51 - 55 0.9
turns & Warranty
56 - 60 0.75
Returns
> 60 0.6

PPM target is based on the commodity targets in all 16 commodities.

33
Note: Calculation of Quality Rating is based on three month moving Average of
supplier PPM, Current month and two previous months.

Months: APR MAY JUN JUL AUG SEP OCT NOV DEC

Example: Quality Rating of September includes July and August, moving average
of three months.

16.2 Delivery Rating

The delivery rating will be calculated for each Supplier for a maximum score
of 100 depending on their schedule adherence on time and quantity.

16.3 Audit Rating

The Supplier audit score achieved in the audits conducted at the Supplier end
as per the plan is considered for audit rating.

Audit Score Factor Audit Rating

< 60% 0 Audit Score x Factor (< 60 x 0) = AR
61 – 79% 0.15 Audit Score x Factor
80% – 100 % 0.30 Audit Score x Factor

• Score < 60% “RED CATEGORY” (Audit Frequency 1 / 3 months)

• Score between 61– 79% “YELLOW CATEGORY” (Audit Frequency 1/6
Months)
• Score >80% “GREEN CATEGORY” (Audit Frequency 1/Year)
# If supplier Audit Score > 80% - Good supplier new business, SOB increase, can
be initiated without any prior SQA approval.
# If supplier Audit Score between 61% -79% - Supplier need improvement, new
business, SOB increase decision can be taken jointly depending on the com-
pany requirements.

34
# If supplier Audit Score < 60% or Vendor Rating = D for consecutive three
months, then Supplier called as Un-Satisfactory Non-source able Suppliers, Im-
mediate mail information will go to Supplier and Plant SSCM, grace period of
one time can be granted from Supplier quality for three months. That three
months’ grace period starts from the day of vendor rating generation. For Sec-
ond deviation, only Central Quality Head is authorized after three months if
supplier doesn’t improve.
• If Supplier Audit Score < 60% - Supplier quality to conduct audit within
three months to confirm the improvement.
• If Vendor Rating is D - Supplier Should submit the action plan and improve
within next three months to avoid de-listing.

16.4 Supplier Performance Rating

Supplier Performance Rating = 0.4(QR) + 0.3(DR) + 0.3(AR)

Score Rat- Remarks

ing
Above 90 A+ Excellent
80 to 89 A Very Good.
71 to 79 B Satisfactory
61 to 70 C Needs improvement. Action plan must be submitted.
Below 60 D Must improve immediately to avoid delisting. Action
plan must be submitted. Move to escalation.

17.0 Quality Targets

GIL & Suppliers will mutually agree for the quality targets as a part of contin-
ual improvement projects and communicate to GIL. GIL SQA shall monitor the
progress on the targets and actions during system audits and visits to the Sup-
plier locations. In addition to this, for specific improvement projects, Supplier
shall be asked to give a presentation at regular frequencies on the status and
results.

35
 18.0 QUALITY ESCALATION PROCESS
To ensure continual improvement for quality performance of the Suppliers,
periodic reviews between GIL management & Suppliers will be conducted as
per below escalation process. It is mandatory for Suppliers to attend these re-
views as per mentioned organization hierarchy.

Location - Location - Location - Location -

Plant GIL HO GIL HO MD Office
/Supplier
Site COO+QA
GIL Head +SSCM MD
SQA Head + Head
Suppliers with
Plant Head Commodity Recurring PPM /
Local SQA+ Q Rating-C / D
Mgr. + Plant
Plant SCM Head CEO/
CEO/ Owner
ACTIONS
Owner
PH/
- SOB Reduction
PH/QA Owner - Stop new Business/
Development
HEAD - De-listing
- Debit/Penalty

Supplier Min. rd
-3 party firewall
Level -Debit/Penalty

For 3 Months After 3 Months After 6 Months After

9 / 12 Months

Level 1 Level 2 Level 3 Level 4

36
Escalation Level 1 Meeting: For high PPM Supplier on monthly basis and for
less audit score Suppliers
• Location: Respective GIL Plant
• From Supplier: Plant Head and QA Head
• From GIL: Plant Head ,Local SQA and Plant SCM Head

Escalation Level 2 Meeting: (After 3 months) if Supplier continue in high PPM

for 3 months
• Location: GIL HO, Pune/Supplier Plant
• From Supplier: Plant Head/Owner
• From GIL: SQA Head, Commodity Manager

Escalation Level 3 Meeting: if Supplier continue in high PPM for six month
• Location: GIL HO Pune
• From Supplier: CEO/Owner
• From GIL: COO,QA Head, Sourcing Head , SCM Head

Escalation Level 4 Meeting: if Supplier continue in high PPM for one year
• Location: GIL MD Office
• From Supplier: CEO/Owner
• From GIL: MD

The following actions will be initiated in absence of improvements in Supplier

Quality Performance.
• SOB reduction
• Stopping new business/development with the Supplier
• Debit/Penalty
• De-listing of Supplier

19.0 CONTINUOUS IMPROVEMENT

The Supplier shall define and monitor a system for continuous improvement
in aspects of quality, productivity, cost, delivery, safety and morale.

37
20.0 ANAND HOUSE OF QUALITY CULTURE (AHQC)

AHQC a broad perspective:

Gabriel India Ltd. Aims to be The First Choice of its Customer through sus-
tained quality performance.
In March 2017, Ms. Anjali Anand Chairperson Anand Automotive launched
AHQC initiative in presence of senior management team of Anand Group. With
this Gabriel (I) Ltd embarked on new journey of creating Total Customer Satis-
faction through Zero Defect Supplies and proactive response.
AHQC (Anand House of Quality Culture) is based on value based system where
management is committed to Zero Tolerance towards poor quality, total trans-
parency with Customers and systemic approach which will stand test of time.
Anand House of Quality has strong foundation in the form of:

• Vision and Values

• Top Management Commitment
• Organizational capability and
• Standards and Procedures
It is supported by 7 pillars namely:
• Safe product launch
• Supplier Quality
• Change Management
• Learning organization
• Enforcing standards
• TPM, TQM and Infrastructure
• Rewards and recognition

Entire Gabriel organization is committed to follow requirements of AHQC to

create Sustainable Quality Culture. Supplier Quality is an important pillar. This
edition of Supplier Quality Manual has additional requirements incorporated
to address requirements of AHQC.

38
 G) SUB-SUPPLIER MANAGEMENT
The Supplier shall constantly aim to improve its sub-suppliers (Tier 3 Suppli-
ers). In order to achieve this, the Supplier shall:-
• All GIL Suppliers must select Gabriel approved Tier -3 Suppliers.
• Inform and obtain the approval of GIL for any change of tier-3 Supplier
• Carry out special processes like heat treatment, plating, painting, powder
coating, welding, etc. at the mutually agreed sources
• Ensure that the Supplier procures raw material from mutually agreed
sources
• Monitor of PPM levels of the sub-supplier
• Conduct audits at the sub-supplier
• Provide training
• Sign off target agreement for continual improvement of product and pro-
cess with the sub-supplier
• GIL encourages T3 Supplier up-gradation by VLMI Communities.

39
 H) CHANGE MANAGEMENT
21.0 SUPPLIER CHANGE MANAGEMENT GUIDELINES:

Process/Engineering Change Authorization

Gabriel reserves the right to approve or deny a request made by the Sup-
plier to change a process or product. A change requiring this approval is de-
fined as follows:
A change to the Supplier's process that was presented at time of PPAP (Pro-
duction Part Approval Process) significant enough to require a change to -
• Modification in tooling
• New Tooling
• New Process Flow or changes in existing process flow
• Process outsource at sub supplier end.
• New Machine /Modification in existing machine
• Tooling shifted at sub supplier end.
• Process/machine parameter modification
• Process in-sourcing from sub-supplier
• Change of sub-supplier, RM Supplier
• Change of chemicals for coating, plating

Gabriel Strategic Sourcing Commodity Manager must be notified of any de-

sign or process changes prior implementation. To inform Gabriel the Supplier
shall use the Gabriel Supplier change request note (SCRN) with Risk assessment
feasibility. This worksheet must include details of the change, in detail for anal-
ysis by Gabriel.
In case of any rejection, changes without prior/GIL SQA written authoriza-
tion will result in the Supplier’s financial responsibility for time spent for analy-
sis, replacement or destruction of product built with parts with unauthorized
changes. It may result in the Supplier being unable to participate in new busi-
ness bids/stoppage of existing business, penalty. Initial penalty will be mini-
mum Rs. 30,000 and thereafter multiple of Rs. 30,000 for repeated violation of
change management procedure.
The Strategic Sourcing Commodity Manager will review the cost impact, if
any. Then Sourcing will send deviation request in the Gabriel (SCRN) Format
and request approval from Gabriel SQA to review for technical & fitment im-
pact. If required, inputs from R&D will be taken.

40
In case of engineering change, R&D will release the revised Drawing/Specifica-
tion if change is applicable. SCM will communicate and send changed drawing
to Supplier accordingly.
Based on written approval from GIL QA/SQA, the Supplier shall submit the
samples through SCM/SS. The Supplier will be required to submit a new PPAP
(Level 3) as per Gabriel PPAP submission process. Changes shall not be imple-
mented prior to PPAP approval. Sourcing will ensure closure of open action
items of PTR. PSW will be signed off by SQA.
GIL plant requirements other than below if any will be communicated to
supplier separately if required.

Process Map for Change Management for supplier requested changes

The following is the process map for change management for changes that
are requested by the Suppliers.
Criteria: Changes at Supplier End:
1. Modification in tooling
2. New Tooling
3. New Process Flow or changes in existing process flow
4. Process outsource at sub-Supplier end.
5. New Machine /Modification in existing machine
6. Tooling shifted at sub-Supplier end.
7. Process/Machine Parameter modifications
8. Process out-sourcing from sub-Supplier.
9. Change of Sub-Supplier, RM Supplier
10. Change of Chemicals for coating, plating.
11. Change in material.
12. Change in specification
13. Quality Improvement
14. Change in packaging, delivery method
15. Change in location
16. Change in inspection method.
17. Any of above changes at sub-supplier.

Criteria: Customer Approval required:

1. Check Customer Specific Requirements.
2. If change affects Customer Approved Assy. Drawing,
Part drawing & Specification.

41
 GIL CHANGE MANAGEMENT PROCESS – GIL INITIATED
Customer complaint, War-
ranty, Line Rejection, Produc- GIL Initiated Change
tivity Improvement,
Tool/Gauge modification, new PEN
process/location/machine.
Log changes in Supplier Change Log (MAT/017)
R: Materials

Customer Ap- No
proval Required Plan actions for changes using checklist for Man-
R: Initiator
A: QA Head aging and tracking the change (MAT/018)
R: Materials

Yes
End Supplier communication about change Form (MAT/016)
R: Materials, Sourcing
Customer Ap-
proval Received
R: Initiator
No A: QA Head

Yes
Log changes in Supplier Change Log (MAT/017)
R: Materials

Plan actions for changes using checklist for Managing

and Tracking the change (MAT/018)
R: Materials

Risk Analysis & Feasibility confirmation from Supplier.

(MAT/019, MAT/020)
R: Materials, Sourcing

Sample submission for checking

R: Supplier

Sample approval after change

R: QA

Validation/Trials in plant (SQA/029)

R: SQA, Materials

PTR/PSW sign off

R: SQA

RIS change (If applicable QA/001)

R: RQA

Decision on stock available

R: Materials

Implement & track action toward change validation.

Update change log (MAT/017) End
R: Materials

42
 GIL CHANGE MANAGEMENT PROCESS – SUPPLIER INITIATED

Supplier Initiated Change

Product
Change Process Change

Supplier Request for Engineering

Supplier Request for Engineering
Approval (SREA) Form (MAT/015)
Approval (SREA) Form (MAT/015)
R: Supplier
R: Supplier
No
End SREA Approved by CFT
SREA Approval by CFT
No Yes
Yes
Raise ECR (RDPE/001)
R: Materials

Log changes in Supplier Change Log (MAT/017)

R: Materials

Plan actions for changes using checklist for

Managing and tracking the change (MAT/018)
R: Materials

Risk Analysis & Feasibility confirmation from

Supplier (MAT/019, MAT/020)
R: Materials, Sourcing

Sample submission for approval

R: Materials, Sourcing

Sample Approval
R: QA

PTR/PPAP
R: SQA

Validation/Trials in plant
(SQA/029)
R: SQA, Materials

PSW sign off

R: SQA

RIS change (QA/001)

R: RQA

Decision on stock available Implement & track action toward change

validation. Update change log (MAT/017) End
R: Materials R: Materials

43
 I) DIRECT ON LINE – CERTIFICATION / DEGRADING CRITERIA
22.1 DIRECT ON-LINE CERTIFICATION CRITERIA
1. Suppliers are encouraged to earn Direct On-Line (DOL) status for each of
the parts supplied. A DOL part goes directly on to the line/store, thus skip-
ping the regular sample inspection at incoming. However, the following
criteria shall be met to be eligible to earn DOL status:-
• Zero PPM for the part at line/receiving for the consecutive 6 months
• Zero customer complaints due to the part for the consecutive 6
months
• GIL audit score of 60% minimum
• Firewall implemented for critical/fit/functional dimensions
• Contract review, AOI and PSW signed off
• For all Imported (except China)/Consumable parts should be consid-
ered for DOL based on their last six months zero PPM. For that no
documentation is required,
2. The following documents shall be submitted to GIL to certify a part as
DOL:
• Part Submission Warrant
• Process Flow Diagram
• PFMEA
• Control Plan
• Agreement of Inspection
• Contract Review
• Layout Inspection report
• Firewall details
3. The Supplier shall continue to send the PDI report and the MTC (wherever
applicable). The approval of the lot in DOL will be based on these reports
except import and consumable parts.
The Supplier is expected to affix a stamp on the material box/pack & / or
PDIR as follow: LOT UNDER ‘DOL’
APPROVAL BASED ON PDI REPORT
4. The Part conversion in DOL is based on the part criticality. Critical parts will
be given priority for conversion in DOL.If plant QA/SQA want to keep under
NON DOL category they are authorized even after zero PPM more than six
month.

44
 5. Status of DOL parts will be reviewed jointly by plant SQA and RQA heads on
Quarterly basis.
# All DOL parts should have inspection criteria as per RIS (Receiving Inspection
Standard) once in six month at Gabriel.
# Suppliers to submit layout inspection report once in a year except Import (non-
China) and consumables parts.

22.2: - DOL PARTS DE-GRADATION CRITERIA

1. Any part found non-confirming during periodic GIL inward inspection or
customer complaints will be removed from DOL and be taken for regular
incoming inspection.
2. Whereas in case of line rejection and after stock segregation if non-con-
firming quantity found equal to or more than 10 then the part will be re-
moved from DOL list.
3. If the line rejection and after stock segregation if non-confirming quantity
found less than 10 no’s then the part will not be removed from DOL list, but
CAPA and action verification is required by GIL SQA.
4. But if the same parts from same Supplier get rejected within two month
and even less than 10 no’s then the part will be removed from DOL.
5. In case of plant booked DOL parts in SAP as rejection, notification will gen-
erate to SAP team for DOL category removal from system, if rejection quan-
tity booked equal to or more than 10 no’s. SAP team will remove the parts
from DOL list within 5 days from notification date after confirmation from
SQA/RQA. In case QA/SQA found parts was booked by mistake they can ask
SAP team to convert the part again as DOL. If part converted again as DOL
plant QA/SQA should keep the records of conversions.
6. For part re-certification of non DOL to DOL will be done after
• Onsite CAPA verification
• Zero PPM for three consecutive months.
The mentioned procedure shall be followed to bring back the part into DOL
again.
Note: Inter plant transfer parts cannot be considered for inspection in second
Gabriel plant if they want to check they will, all types of consumable also not to
be consider for inspection.

45
 J) ETHICS
23.0 ANAND CODE OF CONDUCT
The Supplier shall read and agree to the clauses of the Anand Code of Con-
duct and shall report any witnessed violation to the Ethics Helpline.

CODE OF CONDUCT
1. Respect Law of the Land
2. Maintain Financial Reporting and Records
3. Always Protecting Company Assets
4. Deny Gifts and Donations
5. Follow Ethical Conduct
6. No Concurrent Employment
7. Avoid Conflicts of Interest
8. Ensure Confidentiality of Information and Data. No Insider Trading
9. Be Equal Opportunities Employer
10. Obey Anti-Harassment Policies
11. Join Community Service
12. Consistent Use of the ANAND brand
13. Encourage Reporting of Concerns

Phone: 1-800-102-2100
Email: anandgroup@ethicshelpline.in
Fax: 1-800-102-2100 select option @2

Postal Address: PO Box No 71

DLF Phase 1, Qutub Enclave
Gurgaon - 122002

46
 K) ACKNOWLEDGEMENT FORM

24.0 SUPPIER QUALITY MANAGEMENT AGREEMENT

We have gone through the given document. We understand all the Quality
related requirements of Gabriel Ind. Ltd. We ensure the adherence to the pro-
cesses mentioned in the GIL Supplier Quality Manual.
We extend our full support to all the activities and compliance to Gabriel –
Quality Standards.
Gabriel Ind. Ltd. and the Supplier have both agreed for execution of content
of this manual signed on the day and date as mentioned here in above.

For: ________________ (Supplier) For GABRIEL IND.LTD.

Authorized Signatory: Authorized Signatory:

By: __________________ By: __________________

Name: ________________ Name: ________________

(Signature for & behalf of (Signature for & behalf of GIL)

Supplier)

47
FORMATS

48
 PURCHASING AGREEMENT

This Agreement made and executed as of

Between

Gabriel India Limited, a Company registered under the Company Act, 1956 and having its
th
Registered Office at 29 Milestone, Pune Nashik highway, Village Kuruli, Tal: Khed, Pune
410501 (hereinafter referred to as ‘GABRIEL’, which expression shall, unless it be repugnant
to the context or meaning thereof, mean and include its successors and permitted assigns)

And
, a Company incorporated

under the Companies Act, 1956 and having its Registered Office at
or

, (hereinafter referred to as the

‘Supplier’, which expression shall, unless it be repugnant to the context or meaning?

thereof, mean and include its successors and permitted assigns.

WHERE AS
1. GABRIEL is engaged business of design, development, manufacture, and selling of
shock absorbers, struts, front fork and other auto parts (hereinafter collectively
referred to as ‘Gabriel Products’) of the kind used for 2/3 Wheelers, Passenger
Cars, Commercial Vehicles and Railways and parts thereof for various customers in
India and abroad, has its plant in Hosur, Chakan, Ambad, Dewas, Khandsa &
Parwanoo.
2. Supplier is engaged in the Business
Of .

3. GABRIEL wishes to purchase components and / or Bought out parts (hereinafter

collectively referred to as ‘Products’) for Gabriel Products from the Supplier and
the Supplier is willing to sell these Products to GABRIEL. Both the parties wish to
enter into this Basic Purchase Agreement.

4. It is the objective of the Parties herein to ensure the supply of Products to

GABRIEL, as mutually agreed herein, so that GABRIEL can meet its obligations to
its customers.

The Parties herein have proposed to execute this agreement recording the terms
and conditions in the following manner:

49
 Supplier Selection For New Part Development
Date :-

Project Name (For New Product Development) :- SOP Date :-

Part Name:-

Drg no./ description :- Drg.Rev.no :-

Drg.Released :- Proto / OTS / Production

Customer Name :-

Commodity Manager :-

Component Development Incharge :-

CSQA Incharge :-

Probable Supplier Name :- Location :- Name of GIL Plants Where Supplies are
done :-

Finalised Supplier :- Reason For selection :-

Actions Indentified to bring Supplier to GIL QA Standards :-

Commodity Manager CD Representative CSQA Head Sourcing Head

50
 SUPPLIER INITIAL EVALUATION FORM (SELF)
1) Date of Evaluation:

2) Name of the Organisation:

3) Plant address ( From which components would be supplied ):

Telephone/ Fax:

4) Office address:

Telephone / Fax:

E Mail address:

Contact person:

5) Weekly off:

6) No of people in organisation:
Production: Skilled:
Semiskilled:
Unskilled:
Quality: Engineer:
Inspectors:
Other Staff Function:
7) List of Production equipment:

Equipment Specification Year of Manufacture

51
 SUPPLIER INITIAL EVALUATION FORM (SELF)
8) List of Tool room & Laboratory equipment’s.
Equipment Specification Year of Manufacture.

9) List of measuring equipment’s.

Equipment Specification Year of Manufacture

10) List of Existing customers.

11) List of Processes Being Carried Out:

Is Any Special Process Involved: Yes No

If yes does qualification done: Yes No

12) List of Test Equipment

13) List of Tier – 3 (Sub-contractors) Suppliers

14) Customer PPM Trend of Last 3 Years

52
 SUPPLIER INITIAL EVALUATION FORM (SELF)
15) Internal PPM Trend of Last 3 Year

16) GST No:__________________________

17) Approximate Investment: ____________________________

18) Turn over last year: ____________________________

19) Expected T/O current year: ____________________________

20) Supplier Location from GIL (Distance): ____________________________

21) Name of the sister concern under the same management:

_______________________________________________________

18) Would there be any objection to the quality system maintenance and improvement audit by
us: Yes / No

Remark:

SUPPLIER SIGNATURE

53
 New Supplier Assessment Check Sheet
Issue date 01/10/2016 Revision No:- 6 Revision date: 9-Oct-17 Final Judgement

Supplier Details Final Score Fail

Not Recommended
Supplier Name
Commodity
0.00
Not Recommended


Action plan defined: Next Update:
Location

10

Assessment date: Previous assessment date:

Supplier Contact information WEB 9

Name Title Phone E-mail

8

EHS
7

QUALITY MANAGEMENT
5 0.00

0.00 0.00

Targeted Business OE Business

0.00 0.00
4
Supplier Status New Special Processes NO Coating

Score < 5 Not Recommended 3

Score - 5 - 6.5 Potential for Development SUB SUPPLIER BEST PRACTICE

2
Can be recommended after Re-verification at supplier
Supplier Selection Criteria Score - 6.5 -7.5
end

Score > 7.5 Recommended 1

Note: To qualify Minimum score in each category should be 7 & In

Business Continuity Must be 9 Minimum 0
1
Assessment Author SQA: Signature

Assessment Author SSCM: Signature

TARGET

0 1 2 3 4 5 6 7 8 9 10
Categories Score

0.0
1. Business Continuity

0.0
2. Quality Systems & Document control

0.0
3. Control on Purchasing Material

0.0
4. Work Practice

0.0
5. Process Control

0.0
6. Control on finished goods

0.0
7. Customer Complaint

0.0
8. Maintenance

0.0
9. Management of testing/quality resources

10. Training & Motivation 0.0

11. Sub Supplier management 0.0

0.0
12. Cost Control Initiative

Good Observations - Comments

Area Of Improvements - Comments

Head Central Supplier Quality

54
Scoring Guideline
— 0 - Requirements not met, Major non-conformity - ( Action plan required )

— 1 - Requirements partially met, Minor non-conformity - ( Action plan required )

— 2 - Requirements mostly met, opportunity for improvement

— 3 - Requirements fully met

Category Check Points What does it mean for Supplier? Weightage Obseravtions

Ranking
-1- Business Continuity
Whether a appropriate approvals from Pollutions control boards are 1.Whether consent to establish under air/water and hazardous waste is available ?
0 3
available? 2.Whether consent to operate under air/water and hazardous waste is available ?

0 Whether ISO 14001/OHSAS 18001 certificate is available ? ISO 14001 / OHSAS 18001 certification 3

0 Has the plant obtained Factory license ? Factory Licence copy 3

1.Whether Approved Building Plan is available ?

0 Are other supporting documents of Factory license available ? 3
2.Whether Building Stability Certificate is available ?

1.Whether Fire NOC is available ?

2.whether extinguishers are available in adequate no. and whether they are quarterly
0 Are all fire safety requirements adequately met ? 3
checked ?
3.Whether Fire hydrant or sprinkler system is available ?

1.Whether ETP available in operating condition ?

Whether the plant has an ETP and it is run as per the conditions 2.Whether Flow meters available for taking water readings at inlet and outlet ?
0 3
mentioned in the consent ? 3.Whether PH level, ETP flow meter readings and chemical dosing information is
maintained in a register ?

1.Whether Waste water parameters testing is conducted by SPCB approved laboratory

atleast once in a year ?
Are all environmental testings conducted regularly as per conditions
0 2.Whether Ambient Air Quality and Stack monitoring conducted once in a year (Stack 3
under consent to operate ?
monitoring applicable for all stacks including DG) ?
3.Whether environmental return is filed every year in form 5 ?

0 Whether all employees undergo medical tests regularly ? Medical test report for employee 3

1.Are electrical fittings in good condition,plug points used for making electrical connections
Whether critical parameters related to electrical safety are complied and wires laid only after proper ducting (No loose wiring should be seen) ?
0 3
with ? 2.Are rubber mates provided before electrical panels ?
3.Are all earth pits painted and numbered and checked yearly ?

1.Whether Hazardous waste disposal is carried out as per menifest system Form 13
Whether the hazardous waste disposal is carried on time as per the
0 through an approved waste recycler ? 3
guidelines in consent ?
2.Whether hazardous waste return is filed every year in Form IV ?

SCORE 0

55
 -2- Quality System and
Document control 1.QMS certificate shall have accreditation mark of recognised IAF MLA (International
Which Quality System is followed to ensure effectiveness of Quality Accreditation Forum Multilateral Recognition Arrangement) member.
0 3
of product 2. Quality manual to verify for role & responsibilities, Organisation chart
3. Periodical Internal & external audits plan as per ISO /TS system. & closure status

How periodic review is done to ensure that the latest documents from Customers are
0 Latest drawing & inspection standard available 3
available
-2- Quality System and
Whether the available process flow diagram is adequate which contains all the process
Document control 0 Process flow diagram 3
details

Whether the available control plan is adequate which has all the process details inline with
0 Control Plan 3
PFC

0 Process FMEA Whether the available process FMEA is adequate which contains all the process details 3

Product modification & validation systematically validated & traceability system exists. All
0 Is the system of product modification & validation followed? 3
documents are updated.

Process modification & validation systematically validated & traceability system exists. All
0 Is the system of process modification & validation followed? 3
documents are updated.

Check for any change in Raw Material, Method, Machine, Raw

0 Material Supplier or any other Tier 3 Supplier, Process flow, Is change management followed and written joint approval from Customer QA/SQA. 3
Tooling, Insourcing / Outsourcing in last one year.

Annual calibration schedule prepared & all instrument and gauges calibrated with
0 Are the measuring instrument and gauges calibrated? 3
traceability to NABL

Whether the layout inspection checking of all parameters on drawing is done. What is the
0 Frequency of Layout Inspection of incoming parts. 3
frequency?

0 Is the document retension period defined and followed? Record to be verified 3

Is material and parts flow secured against mix ups/exchanges by

0 Whether part traceability system defined and followed? 3
mistake and traceability guaranteed?

SCORE 0.0

-3- Control on All the incoming parts need to be stored in the defined way & preservation plan must be
Purchasing Material 0 Is there a system of storage of purchased product? available. 3
( FIFO, Proper identification & Location for material , etc.)

0 Is there a system of Inward inspection & disposition? All materials needs to checked for Quantity and quality in Inward Inspection 3

0 Are scrap,suspected lots kept separate and identified? Quarantine stores and quarantine areas must be clearly identified. 3

0 Is there a system of Input output monitoring?(Job Work Only) Incase of raw material INPUT & OUT PUT to be done in decided Frequency 3

SCORE 0.0

-4- Work Practice 0 5S organization,5s map or 5S check sheet is there 3

0 No unwanted items lying on the shop floor 3

0 There is place for each and every things and the items should be on its place 3
Is there a system of 5S activity on shop floor?
0 How often supplier reviewed for improvement 3

0 Machine cleaning to be done as per CLIT sheet by operators 3

0 There is a audit system on the defined frequency and the best team being awarded 3

SCORE 0.0

56
5- Process Control
0 There should be fixed rejection box on each machine 3
Are the red boxes being used on each line / machine for keeping
the setting / process rejection?
0 There is accountability for rejection shift wise 3

0 Set - up Approval (Process Parameter) There should be system of Set up approval for each line 3

0 Is there a system for First Off and Last Off Piece approval? Inline with In process inspection The first and last pieces to be verified by third person 3

Are work instruction available for each process and are at the point Documented and validated WI available in local language for all
0 3
of use? direct(Machining/assembly) and indirect(material handling/transportation etc) processes

0 In-process Inspection Is in process checking done and checks are recorded? 3

The process audit is being done for process parameters in a defined format and on a
0 Is there a system of process Audit? 3
regular frequency

Is there a system for issue of mould,tool , dies and gauges for new There is a tool issue system on line 3
0
setup?
Monitoring of tool life card & Operator awareness for tool change 3

0 Final Inspection Check list covers all the SC/ CC Parameters. SC & CC parameter list are displayed at final inspection station. 3

0 Availability of defect sample. Whether the defective samples or photo are displayed at respective work station 3

Categorization of rejection & rework.Anaysis & Action plan for reduction.Analysis tool use-
0 What system is used to address internal rejection and reworks? 3
Why Why, FTA, PDCA, etc.

Are the operators involved for analysis of rejection and corrective

0 The line operator being involved for ANALYSIS and corrective action Identification 3
action?

List of improvement actions for horizontal deployment on same Whether the preventive actions are taken for all types of similar components of rejected
0 3
parts or family of parts parts

0 Are rework instruction accessible on work station? Rework work Instruction must be displayed on the respective work station 3

Is process stability ( X bar and R chart ) and process capability

0 Whether the system of process capability is available and monitored continuously 3
(Cpk ) study done on regular basis?

0 Control charts available for critical parameters Control chart monitoring is done 3

0 Are any Poke-Yoke operating and being monitored? Poke-yoke Verification plan should be available 3

SCORE 0.0

-6- Control on finished Is there an effective system of ensuring the quality of outgoing
goods 0 PDI/Doc audit report 3
product?

0 Is PDI system adequate and being done as per sampling? The sample pieces to be dispatched separately (Wherever Possible) 3

Is PDI having check points for confirming the Dispatches as per

0 The PDI must have the check points that for Material as per ROP given by Customer 3
ROP?

Is PDI having check points for confirming the dispatches as per

0 If applicable PDI must have the check point for contamination ok / not ok 3
contamination standards?

0 Is customer approval available for packaging? Check existing customers approvals, procedure. 3

0 TC & PDI sent with each lot Each lot must be despatched with PDI report and Applicable Test certificate 3

SCORE 0.00

57
-7- Customer Complaint Does the supplier use a systematic approach for the customer
0 Why-why analysis, fishbone diagram with 8D report. Action plan is available 3
complaint?

0 Is there a visual display of customer complaint at Inspection Area? Customer complaint details month wise need to be displayed on station 3

Are the documents (Control Plan,PFMEA,PFS,Tool Drawings ETC)

0 All the applicable documents must be changed in relation with corrective action 3
changes evident in line with Customer Corrective Actions)

0 Does supplier has CFT approach for problem solving? CFT team to be formed for related functions. Evidence to be shown for all QCD concerns. 3

0 Are the operators aware about the customer complaint on the line? The customer complaint must be known to the concerned operator 3

SCORE 0.0

-8- Maintenance 0 0 0
Is there a system of machine break down monitoring & Break down Daily break down monitoring is in place for each machine 3
0
reduction?
Monthly trend is available and showing the down ward trend 3

Is there a system of planned maintenance of machine/equipment

0 PM plan & check sheet is available of machine/equipment and tooling 3
and tooling?

0 Is there a system of storing spare parts for critical machine? Storage and stock of spare parts 3

0 Organisation structure in Maintenance/Tooling Mechanical Maintenance and electrical Maintenance team is available?? 3

SCORE 0.0

-9- Management of What is the Design & Development facility available with the
Testing/quality 0 Qualifying GIL requirement for new part development 3
supplier.
resources
What are the type of equipment being used in supplier's
0 manufacturing line & can it meet GIL drawing spec.?Check against Measuring instruments where you can check all the dimension related to GIL drawing. 3
Cp/CpK.

Is there a testing facility as required for testing GIL parts as per GIL
0 Metallurgical or other testing equipments 3
drawing available in house or close proximity (outside)

Are the documented procedure for Quality Policy and Quality

0 A quality policy and quality objective need to be defined 3
Objective available?

Is there a contingency plan available to prevent delivery defaults to

0 Contingency plan should be there at-least for 4M to avoid delivery defaults. 3
customer?

Are the optimum capacity known to supplier and acceptance of The capacity calculation sheet to be available and acceptance of schedule must be in Line
0 3
schedule as per that. with the capacity

Supplier must monitor the delivery rating and quality rating. Actions should be in place if it
0 Is the delivery & quality rating being monitored? 3
is less than the Target.

SCORE 0.0 1

-10- Training & Are trained person deployed for the process(
Motivation 0 Skill matrix for all employees 3
Production/assembly/Packing/Inspection)?

0 Is there any Idea scheme running? There should be idea scheme for the operating personnel and should be documented 3

0 Is there a training calendar available? Training Calendar for all levels of employees covering staff & Line employees 3

0 Is training provided as per training calendar? Training records to be available 3

SCORE 0.0 1

58
-11- Sub Supplier
management
0 Whether supplier PPM Monitored? Supplier PPM monitored and communicate to supplier 3

0 Are the supplier process & system audits carried out? Audit should be done as per audit plan 3

Customer approved sources if recommended by Customer. Supplier selection criteria

0 Are only approved quality capable supplier Used? 3
should be there

Includes Special process requirements as per Customer Standard, ie Plating thickness ,

0 PDIR from Sub Supplier for each lot / Batch 3
Hydrogen Embrittlement , SST

Are target agreement for continual improvement of product and

0 Target agreement signoff with Sub Supplier 3
process made and implemented with the supplier?

SCORE 0.0 1

12- Cost control

What is the level of inventory in day for raw material/WIP/Finish
0 Inventory level should be monitored & record available. 3
Good?

0 Does the Supplier has a sound financial background Check for financial records 3

Does the supplier shows a willingness for future expansions based

0 Possible at same location or Plan for out side. 3
on the increase in the volumes.

0 COPQ Monitored? COPQ Monitored for Internal & External for Sales% 3

Is there system for continuous improvement in the all aspect of

0 product and Process ,such as Productivity Continuous improvement project should be defined & monitored 3
,quality,cost,delivery,safety and Morale?

SCORE 0.0 1

59
 APQP TIMING PLAN

PART NUMBER: PART NAME :

DRG. NO : - SUPPLIER :
Project:
GABRIEL INDIA LTD SUPPLIER CODE:

Month
Status Month Month Month Month Month Month Month
Week

APQP Time
Sl. No. ACTIVITIES 1Wk 2 Wk 3 wk 4 wk 1Wk 2 Wk 3 wk 4 wk 1Wk 2 Wk 3 wk 4 wk 1Wk 2 Wk 3 wk 4 wk 1Wk 2 Wk 3 wk 4 wk 1Wk 2 Wk 3 wk 4 wk 1Wk 2 Wk 3 wk 4 wk
Phase %

Plan
1 Drawing Release
Actual

Plan
2 Quality Targets
Actual

Plan
3 Supplier Selection
Actual
Phase 1 15%
Plan
Feasability
4
Commitment
Actual

Plan
5 Capacity Review
Actual

Plan
6 Commercial Agreement on Part and Tooling cost
Actual

Plan
7 Contract review
Actual

Plan
Identification of Product / Process Special
8
Characteristics
Actual

Plan
New equipment, Tooling & Facilities
9
requirements
Actual

Plan
New gauges /
10
Test equipment plan
Actual
Phase 2 60%
Plan
Preliminary Process Flow /
11
PFMEA / Control plan
Actual

Plan
12 Sample Submission
Actual

Plan
Correction to sample
13
submmision
Actual

Plan
14 Part approval
Actual

Plan
PPAP documents
15
as per PPAP Kit
Actual

Plan
16 Prodution trial run
Actual

Plan
Operator Training &
Phase 3 15% 17
Skill review
Actual

Plan
18 SPC Study
Actual

PPAP Documents, Plan

19
Review and C.A.
Actual

Plan
20 Packaging Evalution
Actual

Plan
Agreement on Mass
21
production Inspection (AOI)
Actual

Plan
Phase 4 10% 22 PSW Sign Off
Actual

Closer of GIL process Plan

23
audit points
Actual

Plan
Product handover
24
to plant purchase
Actual

60
 PPAP REQUIREMENT CHECK LIST

Supplier: Supplier Code

Part:

Part No.:

Sr. No. Document Title Remark

1 Part Submission Warrant

2 Design Records of Saleable Product (Part Drawing)

3 Engineering Change Documents (If applicable)

4 Contract Review

5 Agreement Of Inspection (AOI)

6 Process Flow Diagram

7 Process FMEA

8 Dimensional Results

9 Material / Performance Test Results

10 Initial Process Study/Process Capability

11 Measurement System Analysis (Variable/Attribute)

12 Qualified Laboratory Document

13 Control Plan

14 PAP Lot (300 Nos.)

15 Checking Aids

16 List of Approved Suppliers

17 Packaging Details

18 Capacity Confirmation Letter

19 Functional Trial Report - In-house

20 TGW's during PTR's if any with CA's

61
 Part Submission Warrant

Part Name Cust Part Number

Shown on Drawing No._________________________________ Org Part Number:______________________

Engineering Change Level Dated:____________________________________

Additional Engineering Changes:______________________________ Dated:______________________________

Safety and/or
Yes No
Government Regulation
Purchase Order No. Weight(Kg)
Checking Aid No. Checking aid Eng. Change Level:____________________ Dated:_____________

SUPPLIER MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

Supplier Name & Supplier/vendor Code

Customer Name / Division

Street Address Buyer / Buyer Code

Application
City Region Postal Code Country

MATERIAL REPORTING
Has customer required Substance of Concern information been reported? Yes NO N/A
Submitted by IMDS or other customer format: _____________________________________________
______________________________________________________
Are polymeric parts identified with appropriated ISO marking codes? Yes NO

REASON FOR SUBMISSION(Check at least one)

Initial Submission Change to Optional Construction or Material
Engineering Changes(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report). Submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.

Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4- Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS

The results for dimensional measurements material and functional tests appearance criteria statistical process package
The results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required)
Mold/ Cavity / Production Process_________________________
DECLARATION

I hereby affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all
Production Part Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced
the production rate of ______/______ hours. I also certify that documented evidence of such compliance is on file and available for review.
I have noted any deviation from the declaration below
EXPLANATION / COMMENTS:

Is each customer tool properly tagged and numbered?

Yes NO
Organization Authorised Signature:___________________________________________________________Date:_________________

Print Name Title Phone No. FAX No.

email________________________________________________________________ Date:_________________________
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Part Warrant Disposition: Approved Rejected Other

Customer Signature_________________________________________ Date

Print Name:___________________________________________Customer Tracking Number(optional)______________________________

62
Gabriel
(Location) CONTRACT REVIEW FORM
Supplier: Date:
Part Name :
Drg/ Specs. Rev No. Dated :
General Information:

GIL Specific Requirement:

Applicable / Not
# Parameters GIL Generic requirement Agreed Requirement
Applicable
Cp, CpK to be consider for SC CC charatrctic in production stage(Gabriel
1 Once in a month
Standard GP611-6/A to be refer)
2 Layout Inspection Once in six months

3 Corrective & Preventive Action for raised Flashes/deviations Within 3 working days

4 Raw material Test certificate (Mechanical & Chemical) Once in 6 months ( outside lab)

5 Inspection Reports For every consignment

6 Rubber Test buttons For every batches

7 If overall PPM level exceeds above 500 PPM Corrective Action has to be submitted within 7 days

8 Salt Spray - Plating, Powder Coating, Painting & ED Coating Once in a six months

9 IMDS report to be submitted if mentioned in drawing Once in a two years

10 TSDS - Plating, Powder Coating, Painting & ED Coating Initial submission / Source change

Review of Technical requirement:

A. Material specification:

1 Chemical composition:

# Elements (%) Specification SC/CC Supplier Comments Remarks

2 Mechanical properties:

3 Microstructure:

B Dimensional tolerances:

# Dimension Specification SC/CC Supplier comments Remarks

C Appearance Characteristics.
# Item Specification SC/CC Supplier comments Remarks

CLEANING/ CONTAMINATION STANDARDS

PACKING STANDARDS:

Summary:
A All the requirements about chemical composition, mechanical tests and microstructure analysis are
understood and agreed to. In case of non agreement following deviations are required:

B Gabriel specific requirements have been understood and agreed to. In case of non agreement following deviations are required:
Details of Qty Time
deviation
with
justification
Note: 1) Deviation w.r.t. Engineering Drawing & GP specifications to be approved by respective R&D.
2) Deviation w.r.t.Process not leading to any deviation w.r.t.engineering drawing & GP specifications to be approved by Plant QA Head.

C Surface finish/ texture/appearance requirement are understood and limit samples agreed to/ shall be agreed at the time of PPAP.
D Gabriel requirement of inspection reports/ tests/ layout inspection are understood.

Requested by Proposed by Approved by Approved by

Authorised Supplier Person Componenet Developmet Commodity Manager GIL - QA GIL - R & D
(If any deviation)

Remarks:

63
Gabriel Issue No.:
Location Agreement of Inspection(AOI) Issue Date :
Supplier Name: Page: ------------------------------

Part Name:

Part Number

Drwg No : Date: Rev No: Date:

Inspection/ Test method Range / Least
# Inspection Item Specification Supplier Sampling plan
Gabriel Supplier Count
A) Material Specification:

B) Dimension:

Note:- S
or S-Satety /Regulation 1 or F- Critical/major fit /function, 2
Leading to rework/rejection W Leading to warranty rejection
C) Mechanical properties:

D) Performance characteristics:

E) Visual (including appearance item):

F) Packing Standard:

G) Cleaning / Contamination Standard:

H) SUPPLIER IDENTIFICATION AND TRACEABILITY (Tag photo should be clear OR attach separate sheet; if required) :

I) MODE OF TRANSPORT :

Note:
1.) All the Dimensions are in 'MM'
2.) Samples for appearance items to be decided jointly.

Gabriel Sampling Plan

0-100 101 - 1000 1001 - 2500 >2500

Sample size Dimensional
S,F & M Characters
Other non-defined requirements will be in accordance with applicable National/ International standard
(to be specified).

Signed by: Signed by: Signed by:

(GIL - QA) (GIL - SQA) (SUPPLIER)

64
 PROCESS FLOW DIAGRAM DOCUMENT NUMBER:

Customer: Dwg No.:

Part No.: Dwg Rev/Date.:
Part Desc.: Date:
Process # & Incoming Source of Symbols Machine(s) / Desired Outcome / Process Characteristics
Description Variation Equipment(s) used Product characteristics

65
 GABRIEL INDIA LIMITED
PROCESS FMEA
PART DESCRIPTION : DOCUMENT NO. : DATE (ORIGINATED) : REVISION NO. : EFF DATE : PAGE : of

CORE TEAM : REFERENCE NUMBER: CSQA01-00/11:07 PROCESS RESPONSIBILITY:

RESP./
OPN. OPERATION POTENTIAL FAILURE POTENTIAL EFFECT(S) OF POTENTIAL CAUSE(S) / CURRENT PROCESS CURRENT PROCESS RECOMMENDED
SEV CLASS OCC DET RPN TARGET ACTION TAKEN SEV OCC DET RPN
NO. DESCRIPTION MODE FAILURE MECHANISM(S) OF FAILURE CONTROLS PREVENTION CONTROLS DETECTION ACTIONS
DATE

66
SUPPLIER :
DIMENSIONAL REPORT Page --- of -----.

CUSTOMER : HOMOLOGATION
Yes No
Challan No: NO. OF SAMPLES : APPROVED BY :
ADDRESS : NEW PART : NEW TOOL : MODIFIED PART : REPORTS REQUIRED YES NO
MATERIAL TEST
FINISH MOULD/DIE : DEVELOP PART : ENGINEERING TEST
FUNCTIONAL TEST
PART NAME : PART NO : ENGG. LEVEL : ENGG. DATE :
OBSERVATIONS
Sr. No CHARACTERISTICS INSTRUMENT REJECT
# # # # #

REMARKS : DISPOSITION : APPROVED REJECTED SIGNATURE

DIMENSIONAL
MATERIAL
ENGG. TEST DATE :
FUNCTIONAL

67
 STATISTICAL PROCESS CONTROL STUDY
PART NAME : MACHINE : INSTRUMENT : DATE:
PART NO : SPECIFICATION: LEAST COUNT :
SAMPLE SIZE : OPERATION : NO.OF DECIMALS:
DATA COLLECTION: -
SNO. 1 2 3 4 5 6 7 8 9 10 U.T.L. 0.000 SAMPLE D2 A2 D4
1 1 1.123 2.560 3.270
2 2 1.128 1.880 3.270
3 L.T.L. 0.0000 3 1.693 1.020 2.570
4 4 2.059 0.730 2.230
5 5 2.326 0.590 2.110

XLARGE 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Xmax. = 0.0000 NO.OF NON CONFORMING PART = 0 NOS.
XSMALL 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 Xmin. = 0.0000
RANGE 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 R - BAR = 0.00000 NO. OF PARTS ABOVE U.T.L. = 0 NOS.
AVG. #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! X - BAR = #DIV/0! NO. OF PARTS BELOW L.T.L. = 0 NOS.
Process Width ( P ) = 0.0000 Specification Width(S) = 0.000000 Index (K)={2 x (D-XBAR)/S} = #DIV/0! INTERVAL FREQ. CU. FREQ.
Design Centre ( D ) = 0.0000 Interval = 0.000000 Selecting no. of classes = 5 0.0000 0.0000 0 0
Starting Point = 0.0000 No. of readings = 0 Shift Of 'X-BAR' from 'D' = #DIV/0! 0.0000 0.0000 0 0
HISTOGRAM 1.0000 X-CHART AVG. 0.0000 0.0000 0 0
1 U.C.L.
0.9000
L.C.L. 0.0000 0.0000 0 0
0.8000
0.9 X - Bar
0.7000
0.0000 0.0000 0 0
0.6000
0.8 0.0000 0.0000 0 0
0.5000

0.4000
0.7 0.0000 0.0000 0 0
0.3000

0.2000 0.0000 0.0000 0 0

0.6 0.1000

0.0000
0.0000 0.0000 0 0
1 2 3 4 5 6 7 8 9 10
0.5
0.0000 0.0000 0 0
0.4 R- CHART 0.0000 0.0000 0 0
1.0
0.9
0.0000 0.0000 0 0
0.3 0.8
0.7 RANGE
U.C.L.XBAR = #DIV/0!
0.6 U.C.L.
0.2
L.C.L L.C.L.XBAR = #DIV/0!
0.5
R - Bar
0.4
0.1 U.C.L.RBAR = 0
0.3
0.2
0 L.C.L.RBAR = 0
0.1
0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
0.0 Std.Dev."s" = #DIV/0!
0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 1 2 3 4 5 6 7 8 9 10

Pp=(S/6s) = #DIV/0!
Ppk={1-K}xPp) = #DIV/0!
CONCLUSION : - #DIV/0!

68
 GAUGE REPEATABILITY & REPRODUCIBILITY - Variable

Part No. & Name Gauge Name Date

Characteristics Gauge No. Performed By

Specifications Gauge Type L. C.

Appraiser Name / PART #

Trial # 1 2 3 4 5 6 7 8 9 10

1
2
3

Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

1
2
3

Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

1
2
3

Average #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Range 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

CALCULATIONS

REPEATABILITY
R bar = SUM R i j /30 = 0.00000
UCL R = D4 * R bar = 0
LCL R = D3 * R bar = 0.000

As all individual ranges are within control limits, Repeatibility is consistant

σ = R bar/d2 = 0

Estimated Repeatability Variation (AV1) = 5.15 * σ = 0

69
 GAUGE REPEATABILITY & REPRODUCIBILITY - Variable

Part No. & Name Gauge Name Date

Characteristics Gauge No. Performed By

Specifications Gauge Type L. C.

REPRODUCEABILITY:

Appraiser Average:

0 = #DIV/0! Range (R) = #DIV/0!

0 = #DIV/0! σ =R/d2 = #DIV/0!

0 = #DIV/0!

Estimated Reproducibility Variation (ERV) = 5.15 * σ = #DIV/0!

Adjusted Reproducibility variation (AV2) = Sqrt(ERV2 - (AV12/nr)) = #DIV/0!

2 2
TOTAL R & R VARIATION Sqrt (AV1 +AV2 ) = #DIV/0!

R & R % wrt to tolerance (R & R/ Tolerance)*100 = #DIV/0! %

#DIV/0!

#DIV/0!

TOTAL VARIATION

Actual Part to Part variation = #DIV/0!

σ = R/d2 = #DIV/0!

Estimated Part to part variation (PV) = 5.15 * σ = #DIV/0!

2 2
Total variation (TV) = Sqrt (PV +R & R ) = #DIV/0!

R & R % wrt to total variation (R & R/ TV)*100 = #DIV/0! %

#DIV/0!

CONCLUSION

1 #DIV/0!

2 #DIV/0!

70
 Doc .No.
Gauge Repeatability & REV DATE
GABRIEL
Reproducibility -Attribute Study
PAGE 01 OF 02

PARTIAL KAPPA METHOD

APPRAISER Date:
Part
A-1 A-2 A-3 B-1 B-2 B-3 C-1 C-2 C-3 Part Name:
1 1 1 1 1 1 1 1 1 1 Part No:
2 1 1 1 1 1 1 1 1 1
3 1 1 1 1 1 1 1 1 1 Parameter
4 1 1 1 1 1 1 1 1 1 Specification
5 1 1 1 1 1 1 1 1 1 Gaug Type
6 0 0 0 1 0 0 0 0 0 Appraiser A:
7 1 1 1 1 1 1 1 1 1 Appraiser B:
8 1 0 0 0 0 0 1 0 0 AppraiserC:
9 1 1 1 1 1 1 1 1 1
10 0 0 1 1 0 0 0 0 0 Data to be enter
11 1 1 0 1 1 1 1 1 1 here only 1 for
12 0 0 1 0 0 1 0 0 0 OK & 0 for not Ok
parts
13 1 1 1 1 1 1 1 1 1
14 0 0 1 0 0 0 0 0 0
15 1 1 1 1 1 1 1 1 1
16 0 0 0 0 1 0 0 0 1
17 1 1 1 1 1 1 1 1 1
18 0 0 0 0 0 0 0 0 0
19 1 1 1 1 1 1 1 1 1
20 0 0 0 0 0 0 0 0 0
21 1 1 1 1 1 1 1 1 1
22 0 0 1 0 0 0 1 0 0
23 1 1 1 1 1 1 1 1 1
24 0 0 0 0 0 0 0 0 0
25 1 1 1 1 1 1 1 1 1
26 0 0 0 0 0 0 0 0 0
27 1 1 1 1 1 1 1 1 1
28 0 1 0 0 1 0 0 0 0
29 1 1 1 1 1 1 1 1 1
30 0 0 0 0 0 0 0 0 0
31 1 1 1 1 1 1 1 1 1
32 1 0 1 1 0 0 0 0 0
33 1 1 1 1 0 1 1 1 1
34 0 0 0 0 1 1 0 0 0
35 1 1 1 1 1 1 1 1 1
36 0 0 0 0 0 0 0 0 0
37 1 1 1 1 1 1 1 1 1
38 1 1 0 1 1 1 0 0 0
39 1 1 1 1 1 1 1 1 1
40 0 0 0 0 1 1 0 1 0
41 1 0 1 1 0 1 1 1 1
42 1 1 1 1 1 0 0 0 0
43 1 1 1 1 1 1 1 1 1
44 0 0 0 1 1 0 0 0 0
45 1 1 0 1 0 1 1 1 1
46 1 1 1 1 1 1 1 0 0
47 0 1 1 1 1 1 1 1 1
48 1 1 1 1 1 1 1 1 1
49 1 1 1 1 1 1 1 1 1
50 1 1 0 1 1 1 1 1 1

NOTE : 1 indicates good part and 0 indicates bad part

71
 DOC REF

Gauge Repeatability & REV DATE

GABRIEL
Reproducibility -Attribute Study
PAGE 02 OF 02

B
Total
.00 1.00
.00 Count 38 14 52
Expt Count 15.9 36.1 52.0
A
1.00 Count 8 90 98
Expt Count 30.1 67.9 98.0
Count 46 104 150 0.85 Po
Total
Expt Count 46.0 104.0 150.0 0.56 Pe

C
Total
.00 1.00
.00 Count 40 6 46
Expt Count 17.8 28.2 46.0
B
1.00 Count 18 86 104
Expt Count 40.2 63.8 104.0
Total Count 58 92 150 0.84 Po
Expt Count 58.0 92.0 150.0 0.54 Pe

C
Total
.00 1.00
.00 Count 44 8 52
Expt Count 20.1 31.9 52.0
C
1.00 Count 14 84 98
Expt Count 37.9 60.1 98.0
Count 58 92 150 0.85 Po
Total
Expt Count 58.0 92.0 150.0 0.53 Pe

Kappa A B C
A - 0.67 0.68
B 0.67 - 0.65
C 0.68 0.65 -

Kappa > 0.75 indicates good to excellent agreement.

Kappa < 0.40 indicates Poor agreement.

RESULT : Acceptable

Prepared By Approved By

72
 QUALIFIED LABORATORY Page: 01/01
Gabriel India Limited Date:
FOR TESTING & CALIBRATION

Reviewed : Approved:

Approved Agencies
NABL
Sr. No. For Testing And Testing/Calibration Equipment Used
Accreditiation
Calibration

73
 CONTROL PLAN
Prototype Pre Launch Production

Control Plan Number: Key Contact/Phone DATE (Org) : DATE (Rev) :

Core Team : Customer Engineering Approval Date(If Reqd)

Part Name/Description : Supplier/Plant ApprovalDate Customer Quality Approval date(If Reqd)

Supplier/Plant : Other approvalDate(If Reqd) Other Approval Date(If Reqd)
Supplier Code :
Charecteristics / Parameters Methods
Spl.
Process Name/ Operation Machine, Device, Jigs, Tools for
Part/ Process Number Char. Sample Reaction Plan Corrective Action
Description Mfg. Product/Process Specification/ Evalution Mesurements Current Process
No. Product Process Class Error Proofing
Tolerance. Technoque Size Freq Controls

74
 CHECKING AIDS
PART NUMBER :
PART NAME :
REVISION/DATE:

LEAST
SR. CHARACTERISTICS DIMENSION MEASURING INSTRUMENTS ID NO. RANGE
COUNT

Prepared By: Approved By:

75
 List of Approved Suppliers
Page: 1
Gabriel India Limited (Raw Material & Outsourced
operations)

Part : Part Description:

Sr. Name & Address of Raw Material Suppliers Supplies

Sr. Name & Address of Sub-Contractors Type of work being done

Reviewed : Approved:

76
 Gabriel Packaging Standard (GPS)
Plant Plant Valid Supplier Supplier Usage

No. Location From Name Location Supplier Customer

A - Parts - Data Project Name :

Customer Part No Supplier Part No Part - Name Part Weight
Kg
B - Shipping Unit (SU) Box/Bin
Packaging Part Description Packaging Part No. Dimension L X B X H (Outside) Parts Per Pack
mm
C - Weights, Volumes, Stacking Factor & Shelf Life
Packaging Material Part Weight (in Kg) Gross- Weight Volume Stacking Factor Stacking Factor Shelf Life
Weight in Kg in Container in Kg in (m³) Transport Storage in Months
0 0.00 0.00 1 1 1
D - Packaging material (PM) / Bill of Material (BOM)
Sr No PM- Mat.- No. Amount Unit Description Comment / Quantity (Box Ply/ Color etc)
1
2
3
4
5
Note: Plastic Paper thickness must be above 40 microns,
Trolley Repair & Maintenance Report should be submitted periodically to Gabriel
E - Pack Description & Remarks
Sr No Designation Part
1 Photo
2
3
4
5
6
7
8
9
10
11 Part Dimension L X B X H
12 mm
F - Photo for GPS
1 Outside Packaging 2 Inside Packaging

Note: Note:

Release Area: Supplier Sourcing Material Store SQA

Name:

Date & Sign:

Comments: Page
1 of 2

77
G - Photo-Documentation of the Packaging Process

Plant Location Customer Part No Supplier Part No Part - Name Part Weight

3 Packaging Photo 4 Packaging Photo

Note: Note:

H: Alternate Packaging, Packging Slip Details & Antirust Oil Details

5 Alternate Packaging Photo: Packing Slip Details:

L
Supplier:

Part No
W
Part Name

Qty Nos.

Packaging Silp Dimension L X W

mm

Antirust Oil Details :-

Oil Type :-

Shelf Life :-

Note: Note:

I: First Level, Secondary Level Pack, Expceted Life of Packaging & Handlinng Requirements at Dock
First Level Pack: Handling Requirements at Dock:

Returnable(Y/N) Fork Lift

Collapsable: (Y/N) Stacker

Manual pulling

Others

Secondary Level Pack: Expected Life of Packaging:

Returnable(Y/N) Single Use

Collapsable: (Y/N) Limited Use - No of Cycles :

Long life ≤ 3 years:

Long life ≤ 8 years:

Comments: Page

2 of 2

78
 CAPACITY CONFIRMATION LETTER

To, Letter No.:

Gabriel India Ltd. Date:

Kind Attention:

Subject: Capacity Confirmation for

Dear Sir,

With reference to above we confirm that we have sufficient spare capacity to produce the
above mentioned parts with following details.

Part Name:

Part Number:

Monthly Capacity:

Average Lead Time:

We assure you timely delivery in specified quantity & quality for all the components that we are
supplying to you. In case of increase in market demand we assure that we will enhance our capacity
supplying to you.

With Regards,

Signature
Name of the authorized person
Designation

79
 PTR Observation Sheet
Part Name & No :-
PTR Date :- For GIL -
Project Name :- For Supplier-
Material :-
Part Produced Qty :-
PTR For DRG/Rev No:

Sr.No What To Check Observations Action Plan Resp. Target Date

1.00 Drawing
Availability of the OTS drawing, correct revision number, quality of the
printout/hard copy available/internally controlled or not, Availability of the relevant
standards given in the drawing

2.00 Documents

PFD maching with the actual flow seen during PTR, Control parameters matching
with the control plan, PFMEA capturing all the possible modes, severity/occurance
and detection rating given correctly, SC /CC parameter should be highlighted in CP
& Control method for SC /CC parameter. Packaging standard,Other documents
correctness as per PPAP Kit

3.00 Dimensional Issues

Layout inspection of the part- wrt drawing. Parts taken during PTR randomly and
stage wise.
Process capability study should be carried out for SC / CC parameter.

4.00 Gauges Issues

All Fit/Function parameters- availability of the instruments/gauges to check the

dimensions along with calibration certificate. Gauge identification

5.00 Tooling Issues

Capability of the tooling to meet the drawing requirements consistently,
damages/cracks/Jugaad in the tooling which can lead to inconsistency in the
future
verify the tool drawing, tool inspection report. Tool material.
Tool life monitoring system,tool identification

6.00 Testing Issues

All testing done as per the drawing/standard given to the supplier. Try to do the
testing (whatever possible) during the PTR/or on the PTR parts.testing fixture
availability mentioned in part drawing

7.00 Process issues

Observations during the PTR -

Check whether process takes as per defined PFD & control plan.
Look for poka-yoke/controls in the process which can lead to failures during mass
production;bottleneck process,critical operation.
Check for initial process capability i.e. Pp & Ppk index,it should be 1.67 minimum.If
not achived get action plan for improvement.

8.00 Cycle Time

Look for how much time required for making the PTR lot. Cycle time for the
part/machine wise. Also look for abnormal time used for set-ups etc

9.00 First through ratio

10.00 Improvement points

80
 FUNCTIONAL TRIAL RUN FORM FOR SUB VENDORISED / NEW PARTS
TRIAL RUN Trial No :-
( SQA Issue to Inprocess QA )

Part No :- DATE /ISSUE BY:

QTY :- nos
Part Name :- PRODUCTION DATE :-
Application:-

REASON :-

FLOW OF DEPTS.
INSTRUCTIONS : Sign & Date

MACHINING
REMARKS :- OK / NOT OK : FOR PRODUCTION
IF NOT OK, GIVE REASONS :

INSTRUCTIONS : Sign & Date

SUB - ASSEMBLY
REMARKS :- OK / NOT OK : FOR PRODUCTION
IF NOT OK, GIVE REASONS :

INSTRUCTIONS : Sign & Date

ASSEMBLY
REMARKS :- OK / NOT OK : FOR PRODUCTION
IF NOT OK, GIVE REASONS :

INSTRUCTIONS : Sign & Date

FINAL ASSLY
REMARKS :- OK / NOT OK : FOR PRODUCTION
IF NOT OK, GIVE REASONS :

QA INSPECTOR REMARKS :- Sign & Date

QUALITY ASSURANCE

QA MANAGER ( REVIEW & SIGN OFF DATE ) :-

PRODUCTION MANAGER PRODUCTION MANAGER ( REVIEW & SIGN OFF DATE ) :-

MANUF.ENGINEERING
MANUFACTURING ENGINEERING MANAGER ( REVIEW & SIGN OFF DATE ) :-
MANAGER

RETURN TO SQA REMARKS BY SQA :-

81
 SUPPLIER MONTHLY PERFORMANCE REPORT
FOR THE MONTH OF ..
Vendor Code : ………..
Supplier Name : ………… Report for: GIL Plant Name
Address

Dear Sir,
Please find below the details of your performance rating for the month of ……
Quality Rating:
Month Apr Mar Feb
Total no. of Lots Received
No. of lots in DOL
No. of lots in Inspection
No. of lots Rej./Reworked/Segregated
No. of lots under Deviation
Line Rejection PPM
Customer Return/Warranty Failure PPM

Quality Rating (Max. 100)

Delivery Rating:
Month Apr Mar Feb
Delivery Rating (Max. 100)

Audit Rating:
Month Current Previous
Audit Score (Max. 100)

Supplier Performance Rating = 0.40(Q) + 0.30(D) + 0.30(A)

Score =
Comments

Summary of Past Performance:

Delivery Audit Performance Performance

Month Quality Rating
Rating Rating Score Rating
Apr
May
Jun
July
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Score Above 90 80 TO 89 71 TO 79 61 TO 70 Below 60
Rating A+ A B C D

82
 8D No :-
GIL CORRECTIVE & PREVENTIVE ACTION REPORT
Page No. : 1 of 3
8D Open Date :
SUPPLIER NAME : 8D Submission Date :
8D Close Date :

D1. PROBLEM DEFINITION DATE :

Part Name / Number :
Qty Reported:
A PROBLEM (Reported by Customer) / Symptom :

B PROBLEM STATEMENT : ISSUE REPORTED : REPEAT 1'ST TIME

What? When? If repeated problem,What was the corrective action:
Where? How? (Attach previous 8D as annexure)

Who? Why?

D2. EMEREGENCY RESPONSE ACTION DATE :

C TEAM

Name Dept Designation Contact No Quality Alert Flash

Team Leader / Champion

Member 1 YES NO

Member 2

Member 3 Ref. No:

Member 4

Member 5 Location :

Date:

D ACTION TAKEN TO DISPOSE NON -CONFORMING PARTS / ICA :

Identificatio
Part checkes at Date OK Not OK Mfg date & shift traceability for Rej qty
n on Ok part

1 At Gabriel end

2 In Transit or Godown

3 At Supplier end

4 At Sub Supplier End

Total
PHOTO Of
Identification of Not OK Parts : Identificatio
Disposal of the Not OK Parts : n on OK
Part :
Cutoff date of 1st ok part from /Invoice Number/ traceability no

Despatch Details

8D No :-
CORRECTIVE & PREVENTIVE ACTION REPORT
Page No. : 2 of 3

D3. ANALYSIS FOR NON DETECTION DATE :

5 WHY ANALYSIS (ANALYSIS FOR NOT DETECTING THE DEFECT PHENOMENA )

WHY 1 WHY 2 WHY 3 WHY 4 WHY 5

Sr. No. Non Detection Root causes identified Action Plan PA CA Action By Target Date Comp. On
1
2

D4. ANALYSIS FOR OCCURANCE OF DEFECT DATE :

Measurement Method Environment

DEFECT

Man Material Machine (Mould)

83
VALIDATION OF POTENTIAL ROOT CAUSE (Induce the cause where possible to reproduce the defect) DATE :

Sr.No Potential Root Cause (shortlisted) Verification Validation Significant Non significant

2
3

4
5
WHY-WHY ANALYSIS of SIGNIFICANT CAUSES FOR CONVERGING INTO ROOT CAUSE (for Occurance)

CAUSE # WHY1 WHY2 WHY3 WHY4 WHY5

8D No :-
CORRECTIVE & PREVENTIVE ACTION REPORT
Page No. : 3 of 3
CORRECTIVE & PREVENTIVE ACTION PLAN:
D5. DATE :
(Actions planned to avoid recurrence & to prevent potential causes)
Sr. No. Root causes identified Action Plan PA CA Action By Target Date Comp. On

D6. HORIZONTAL DEPLOYMENT DATE :

Consider Yes No Comment (If Yes) along with referance of deployment plannification

Other GIL similar parts

D7. SYSTEMATIC PREVENT RECOMMENDATIONS DATE :

Description Doc.Affected Existing Current Doc. Enclosed

Sr Yes/No Date & Rev.No Date & Rev.No Yes/No
Remarks
(Insert doc. no. if applicable)

1 Work instructions

2 Inspection Standards

3 Process Flow

4 PFMEA

5 Control Plan

6 Drawing

7 Gauges

8 Sub Supplier Documents

9 Updation of any standard

10 Lesson Learnt Card

D8. TEAM & INDIVIDUAL RECOGNITION DATE :

EFFECTIVENESS MONITORING BY GIL

1st lot After Action Implementation 2nd lot After Action Implementation 3rd lot After Action Implementation
Date:- Date:- Date:-
GRR No:- GRR No:- GRR No:-
Qty:- Qty:- Qty:-

Sign:- Sign:- Sign:-

VERIFIED BY :- APPROVED BY :-

84
Supplier Name CORRECTIVE ACTION PLAN - 6 W 2H
Month -
Legends : What – Defect Phenomenon Why - Cause Side-Indicate Root cause. Who – Responsible Person
Which – Shop / Cell / M/c /Stage How Much – Defective Qty. When - Target date for action completion.

Where – Process / Operation

How to Do – Indicate What is change in inspection side & Then what is cause side action taken & for sustenance updation in JH / PM / WI format.

Sr. How Much How to do Inspection Side Cause Side

Why-why
What Which Where
(Occurrence)
INSPECTION CAUSE
No. Actual Target Who When Status Who When Status
SIDE SIDE

85
GABRIEL INDIA LTD. SUPPLIER AUDIT CHECK SHEET
0 - Requirements not met, Major non-conformity - ( Action plan required ) Audit Score Criteria
1 - Requirements partially met, Minor non-conformity - ( Action plan required ) Score ≤ 60% - Un satisfactory
2 - Requirements mostly met, opportunity for improvement Score 61% - 79% - Need Improvement
3 - Requirements fully met Score ≥ 80% - Good

Rev : SS/011- 05 Date : 09/10/2017

Supplier Name Vendor Code Audit Date

Location Quality System Certificate issue Date

Critical Part supplied Auditor Auditee

Contact Phone Contact Fax

Contact Person
E mail
Overall Turn Over ( In Rs Crores )
Manpower - Detail
Other Major Customers Operator (Permanenr & Temporary ) Staff Total
P T

Previous Audit Rating

Assessment Summary
Current Audit Score
Obtained Marks Max. Marks

Business Continuity 0 30

Production Preparation / New Product Development 0 12

Quality system & Document Control. 0 27

Control of Purchased Material. ( Store ) 0 9

Work Practice 0 21

Process Control 0 27

Inprocess Control. 0 21

Control on Finished Product. 0 18

Customer Complaint. 0 15

Heijunka Planning 0 15

Maintenance. 0 12

Contamination 0 12

Management & Quality Resources. 0 15

Training & Motivation 0 6

Sub Supplier 0 15

Cost Control 0 9

TOTAL 0 264

86
GABRIEL INDIA LTD. SUPPLIER AUDIT CHECK SHEET
S.No Check Points What does it mean for Supplier? Weightage Score % Observation

Business Continuity plan 30 0 0%

1.Whether consent to establish under air/water and hazardous waste is available ?

1 Whether a appropriate approvals from Pollutions control boards are available? 3
2.Whether consent to operate under air/water and hazardous waste is available ?

2 Whether ISO 14001/OHSAS 18001 certificate is available ? ISO 14001 / OHSAS 18001 certification 3

3 Has the plant obtained Factory license ? Factory Licence Copy 3

1.Whether Approved Building Plan is available ?

4 Are the supporting documents of factory license available ? 3
2.Whether Building Stability Certificate is available ?

1.Whether Fire NOC is available ?

5 Are all fire safety requirements adequately met ? 2.whether extinguishers are available in adequate no. and whether they are quarterly checked ? 3
3.Whether Fire hydrant or sprinkler system is available ?
1.Whether ETP available in operating condition ?
2.Whether Flow meters available for taking water readings at inlet and outlet ?
6 Whether the plant has an ETP and it is run as per the conditions mentioned in the consent ? 3
3.Whether PH level, ETP flow meter readings and chemical dosing information is maintained in a
register ?

1.Whether Waste water parameters testing is conducted by SPCB approved laboratory atleast
once in a year ?
7 Are all environmental testings conducted regularly as per conditions under consent to operate ? 2.Whether Ambient Air Quality and Stack monotoring conducted once in a year (Stack monitoring 3
applicable for all stacks including DG) ?
3.Whether environmental return is filed every year in form 5 ?

1.Whether Hazardous waste disposal is carried out as per menifest system Form 13 through an
8 Whether the hazardous waste disposal is carried on time as per the guidelines in consent ? approved waste recycler ? 3
2.Whether hazardous waste return is filed every year in Form IV ?

1.Whether all employees undergo medical tests regularly ? 1.Medical test report for employees
9 3
2.The focus on employee safety is provided and ensured? 2.List of PPE provided on line/no of daily accidents on line record to be verify

1.Are electrical fittings in good condition, plug points used for making electrical connections and
wires laid only after proper ducting (No loose wiring should be seen) ?
10 Whether critical parameters related to electrical safety are complied with ? 3
2.Are rubber mats provided before electrical panels ?
3.Are all earth poits painted and numbered and checked yearly ?

Production preparation / New Product Development 12 0 0%

Do you define the procedure for Product development including the following ? -scope of parts,
11 Regarding implementation rule of production preparation 3
responsibility of each department, control contents / items?

Do you implement follow-up to control the schedule and progress of production preparation items?
12 Regarding management / implementation by production preparation plan / report (master plan) 3
Incl top management

Do you consider following items and implement corrective and preventive action to the processes
and standards before regular production?
13 Defect prevention on the stage of process design by using FMEA/Matrix diagram -Troubles in the past; -Defect items expected; 3
-Defect items unable to capture at customer;
-Defect items difficult to repair;

Do you prevent defects by quality improving activities of cross-function team to evaluate quality
14 Product/process evaluation at the quality evaluation meeting in each trial 3
performance?

Quality Systems & Document control 27 0 0%

1.QMS certificate shall have accreditation mark of recognised IAF MLA (International
Accreditation Forum Multilateral Recognition Arrangement) member.
15 Which Quality System is followed to ensure effectiveness of Quality of product 3
2. Quality manual to verify for role & responsibilities, Organisation chart
3. Periodical Internal & external audits plan as per ISO /TS system. & closure status

16 Latest drawing & inspection standard available How periodic the review is done to ensure that the latest documents are available 3

Whether the available PFD / CP / PFMEA is adequate which contains all the process details
Are all documents reviewed & updated periodically.
17 Process flow diagram / Control plan / Process FMEA review mechanism IS R-PFMEA carriedout to check if defects are detected on line/any subsequent 3
processes or preventive controls are adequate to avoid defect generation?Is this
carriedout by actually simulating the activity on line? for Renault parts.

Product / Prcoess modification & validation systematically validated & traceability system exists. All
18 Is the system of product / Process modification & validation followed? 3
documents are updated.

Check for any change in Raw Material, Method, Machine, Raw Material Supplier or any other Tier 3
19 Is change management followed and written joint approval from Gabriel QA and SQA. 3
Supplier, Process flow, Tooling, Insourcing / Outsourcing in last one year.

Annual calibration schedule prepared & all instruments and gauges calibrated with traceability to
20 Are the measuring instrument and gauges calibrated? Check calibration of Maintenance equipments 3
NABL

Whether the layout inspection checking of all parameters on drawing is done. What is the
Frequency of Layout Inspection of incoming parts.& finish parts .
21 frequency? 3
Whether AOI available for all parts ?
Signed off AOI should be available for all parts

Record to be verified -( Min.03 years & PPAP live )

22 Is the document retension period defined and followed? # Inspecton reports ( set up ,inprocess , final ) 3
# Test reports ( RMTC - third party test report , performance test reports )

23 Is material and parts flow secured against mix ups/exchanges by mistake and traceability guaranteed? Whether part tracebility system defined and followed? 3

Control of purchased material.(Stores) 9 0 0%

87
GABRIEL INDIA LTD. SUPPLIER AUDIT CHECK SHEET
S.No Check Points What does it mean for Supplier? Weightage Score % Observation

All the incoming parts need to be stored in the defined way & preservation plan must be available.
24 Is there a system of storage of purchased product? 3
( FIFO, Proper identification & Location for material , etc.)

25 Is there a system of Inward inspection & disposition? All materials needs to checked for Quantity and quality in Inward Inspection 3

26 Is there a system of Input output monitoring?(Job Work Only) GIL raw material reconcilation (INPUT & OUT PUT) to be done at decided Frequency 3

Work Practice 21 0 0%

27 5S organization,5s map or 5S check sheet is there 3

There is place for each and every things and the items should be on its place.no unwanted items
28 Is there a system of 5S activity on shop floor? lying on the shop floor ( prevent from dust ,rust,scratch & rain water ) 3
Whether the material handling Bins / Trolley cleaning frequency defined ?

29 There is a audit system on the defined frequency and the best team being awarded 3

30 Representation of material flow & Travel distance 3

• Future Map is visualized based on leaders conceptualization.

31 Workplace Transformation 3
• Improvements identified to reach the same.

• Level of WIP at different stages is defined & mapped.• Standardization – Handling of Materials,
32 Parts, Tools.• WIP in 3C form defined • Tier Structure defined & understood at manufacturing 3
Head.

Do you implement inspection or critical operation under the properly controlled environment
33 Location of production site 3
(luminance /temperature/humidity/vibration/noise/work table, etc.)

Process Control 27 0 0%

34 There should be fixed rejection box on each machine 3

Are the red boxes being used on each line / machine for keeping the setting / process rejection?
Achieve internal process PPM Tragets
35 There is accountability for rej shift wise 3

36 Set - up Approval (Process & product) There should be system of Set up approval for each line 3

Is the abnormal situation clearly defined ?

37 Has the Mechanism defined for handling abnormal situation ? 3
Procedure for handling abnormal situation.

Documented and validated WI available in local language for all direct (Machining/assembly) and
38 Are work instruction available for each process and are at the point of use? 3
indirect(material handling/transportation etc) processes

39 In-process Inspection ( First piece , inprcoess inspection & last piece ) Is in process checking done and checks are recorded? 3

40 Is there a system of process & product Audit? The process & Product audit is being done as defined format and on a regular frequency 3

1. Tool PM plan & check sheet

2. Monitoring of tool life card & Operator awareness for tool change
41 Is there a system for Tool PM plan & its Monitoring 3
3. Initial inspection report for tooling.
4. Critical spare part list & monitoring for tooling

SC & CC parameter list are displayed at final inspection station.

42 Final Inspection Check list covers all the SC/ CC Parameters. 3
Whether the defective samples or photo are displayed at respective work station

In process Control 21 0 0%

Categorization of rejection & rework.Anaysis & Action plan for reduction.Analysis tool use-Why
43 What system is used to address internal rejection and reworks? Standards for non conforming parts 3
Why, FTA, PDCA, etc.

Daily QRAP sheet to be maintained for all issues related to quality, process, tooling &
44 • Line QRQC is practiced every shift & problems are noted in QRAP sheet 3
maintenance.

45 List of improvement actions for horizontal deployment on same parts or family of parts Whether the preventive actions are taken for all types of similar components of rejected parts 3

Rework work Instruction must be displayed on the respective work station

46 Are rework instruction accessible on work station? Process Instruction 3
Rework rejection is recorded separately and verified and monitored.

Whether the system of process capability is available and monitored continuously

47 Is process stability ( X bar and R chart ) and process capability (Cpk ) study done on regular basis? Control charts available for critical parameters 3
Safety parameters are identified and monitored

Do you have special checks / inspection for Maru A parameters of Maru A part are available
48 Maru A Parts Management ( Applicable for only Maruti child parts ) Do you have indentification of Maru A process / Operator on shop Floor 3
Do you keep the repair history when repairing & using Maru A items.

49 Are any Poke-Yoke operating and being monitored? Poke-yoke Verification plan should be available 3

Control on finished product 18 0 0%

50 Is there an effective system of ensuring the quality of outgoing product? PDI/Doc audit report 3

1. Sampling plan must be defined & followed

51 Is PDI system adequate and being done as per sampling? 3
2. All checks in PDI are in line with GIL RIS

88
GABRIEL INDIA LTD. SUPPLIER AUDIT CHECK SHEET
S.No Check Points What does it mean for Supplier? Weightage Score % Observation

52 Is agreed packaging standard available & displayed at respective station ? GIL approved packaging standards for all parts are available & followed 3

All the FG parts need to be stored in the defined way & preservation plan must be available.
53 Storage of FG Parts 3
( FIFO, Proper identification & Location for material , etc.)

54 TC & PDI sent with each lot ( Control on Delivery process ) Each lot must be despatched with PDI report and Applicable Test certificate 3

List of DOL parts

55 Control on DOL parts ( Direct on line ) Fire wall & monitoring for DOL parts 3
Action plan for D-grdae parts.

Customer Complaint 15 0 0%

1. Customer wise PTDB for end Customer Complaint , Warranty & GIL Line & Incoming rejection.
Does the supplier have customer complaint register for End Customer Complaint, Warranty Issues, &
56 2. Periodic Verification by Supplier. 3
Gabriel Rejections?
3.Verify for all the actions are in place.

1.Why-why analysis, fishbone diagram with 8D report. Action plan is available

Does the supplier use a systematic approach for the customer complaint? 2. Action plan effectiveness monitoring
57 3
Does supplier has CFT approach for problem solving? 3.CFT team to be formed for related functions. Evidence to be shown for all QCD
concerns.

1. Customer complaint details month wise need to be displayed on station ( Q-alert )

58 Is there a visual display of customer complaint at respective Area? 3
2. The customer complaint must be known to the concerned operator

Are the documents (Control Plan,PFMEA,PFS,Tool Drawings ETC) changes evident in line with
59 All the applicable documents must be changed in relation with corrective action 3
Customer Corrective Actions). Prevention of Recurrence

List of improvement actions for horizontal deployment on same parts, family of parts or similar part 1. Whether the preventive actions are taken for all types of similar components of rejected parts.
60 3
problem reported at other GIL supplier end. 2. Horizontally deployement of similar problem reported at similar Supplier end.

Heijunka Planning 15 0 0%

61 Planning for Heijun'ka • Pattern revised after management actions with periodic review (PQ, Pattern and Sequence) 3

• Window timings agreed and signed off with Customer & every 28th preliminary notice is issued
62 Linkages for Supplier Planning from customer based on month hejunka plan. 3
• Containers are Standardized (3C) to avoid dent,scrach, counting etc.

63 Achieving Heijun'ka Conformation Ratio: Sequence • Tracking done & non-conformance escalated as per defined mechanism 3

• Tracking done Hourly and non-conformance escalated. (Tracking Frequency, Planning Flexibility
64 Achieving Heijun'ka Conformation Ratio: Quantity 3
and Recovery Slots)

Achieving Synchronization Ratio: Customer • SR tracked for All part numbers with real time data.
Enabling standard work for WU • Practiced at all work stations as per Standard Work Chart. Machine Productivity • Unit/machine hrs Linked to overall loading time as per work load calculation.
65 3
Human Productivity • Manpower assigned as per Target Productivity & tracked every Shift for all work
unit.

Maintenance 12 0 0%

Daily break down monitoring is in place for each machine

66 Is there a system of machine break down monitoring & Break down reduction? Monthly trend is available & analysis in details . 3
MTTR & MTBR monitoring

67 Improve machine availiblity Implementing Autonomus Maintenance by operator ( CLIT check sheet ) 3

Is there a system of planned maintenance of machine/equipment and tooling? Control on equipment PM plan & check sheet is available of machine/equipment and tooling
68 3
condition PM check sheet should cover check points from M/c manual & past Brake down history.

Machine parts storage Place is at 3S level.

69 Spare parts management 3
• Zero break down time due to non availability of spare parts (ABC analysis approach).

Contamination 12 0 0%

70 Are the Gabriel contamination standard available? The Gabriel Product contamination standard must be available 3

71 Is there a system to ensure the Contamination in the product? There should be process of cleaning to ensure the contamination standard 3

72 Is there a facility available to check the contamination in the parts. There should be facility for checking the contamination in the product 3

73 Are the frequency defined for checking the contamination of the parts? There should be contamination checking on defined frequency & record to be maintained 3

Management of Quality & Resourses 15 0 0%

• Visit and Review with Customer monthly.

74 • Monthly meeting with employees & staff. Plan for customer visit daily meeting at War room and results 3
• Daily Operation Review.

89
GABRIEL INDIA LTD. SUPPLIER AUDIT CHECK SHEET
S.No Check Points What does it mean for Supplier? Weightage Score % Observation

75 Are the documented procedure for Quality Policy and Quality Objective available? A quality policy and quality objective need to be defined 3

76 Is there a contingency plan available to prevent delivery defaults to customer? There should be 4M+1E contingency plan 3

Are the optimum capacity known to supplier and acceptance of schedule as per that .
The capacity calculation sheet to be available and acceptance of schedule must be in Line with the
77 Capacity planning • Capacity enhancement plan based on Customer business growth for next 3 3
capacity
years.

Is the delivery & quality rating being monitored?

Supplier must monitor the delivery rating and quality rating. Actions should be in place if it is less
78 • Production supervisors share the plan at start of shift & plan vs. actual at end of shift to team 3
than the Tgt.
members

Training & Motivation 6 0 0%

Skill matrix and training plan & record should be available

79 Are trained person deployed for the process( Production/assembly/Packing/Inspection)? Skill Matrix is used for Identifying gaps and On Job Training (OJT) conducted.People has been 3
trained under Anand Heijunka Production system & training plan for gaps available.

Is there any Idea scheme running?

Promotion of Kaizens • Ideas are recorded, Recognized & published as kaizen.
80 • Results are shared, contributions are recognized & awarded.(space, travelled distance, rejection & 3
Are best performer for Quality,Productivity,Idea etc being rewarded?
production etc.)

Sub Supplier 15 0 0%

Supplier PPM monitored and communicate to supplier

81 Whether supplier PPM Monitored? 3
Action plan should available in case of non confirmity

82 Are the supplier process & system audits carried out? Audit should be done as per audit plan & audit action plan should be available 3

83 Are only approved quality capable supplier Used? GIL approved sources if recommended by GIL.Supplier selection criteria should be there 3

Includes Special proces requirements as per GIL Standard ie Plating thickness , Hydrogen
84 PDIR from Sub Supplier for each lot / Batch 3
Embrittlement , SST

Are target agreement for continual improvement of product and process made and implemented with
85 Target agreement signoff with Sub Supplier 3
the supplier? Target Control on current products

Cost Control 9 0 0%

86 What is the level of inventory in day for raw material/WIP/Finish Good? Inventory level should be monitored 3

87 What is the COPQ- Internal & External (% of sell)? COPQ should be monitored 3

Is there system for continuous improvement in the all aspect of product and Process ,such as
88 Continuous improvement project should be defined & monitored 3
Productivity ,quality,cost,delivery,safety and Morale?

Declaration from Supplier

M/S _ _______________ hereby confirm that no changes for Raw Material, Method, Machine, Raw Material Supplier or any other Tier 3 Supplier, Process flow, Tooling, Insourcing/Outsourcing are carried out in last one year.

M/S _____ __________ hereby confirm that changes for Raw Material, Method, Machine, Raw Material Supplier or any other Tier 3 Supplier, Process flow, Tooling, Insourcing/Outsourcing are carried out in last one year with written joint approval from Gabriel QA and SQA.

M/S ____ __________ hereby confirm that changes for Raw Material, Method, Machine, Raw Material Supplier or any other Tier 3 Supplier, Process flow, Tooling, Insourcing/Outsourcing are carried out in last one year. However written joint approval from Gabriel QA and SQA not taken.

Other Observation (if Any)

For Gabriel India Ltd For Supplier Rep. Supplier Plant Head / CEO

Auditor Name: Name and Designation : Name and Designation

Sign : Sign : Sign :

90
 PROCESS AUDIT CHECK SHEET
Supplier Name : Process Name:
Audit Date: Machine Name/Number:
Part Name / Number : Operator Name:
Audit done by :
SR No. Checkpoints Spec. Evidence/ Observation Satisfactory Action Plan Resp Target date
Yes No

1 Input Material

Raw material (as per Control plan)

* Sub-supplier

* Grade

* Identification of material

* Inspection status of material

2 Process

a) Process parameters as per Control Plan

b) Set up controls & approval

* Job set up records-First Piece approval

* Work Instruction/Operating procedure

c) Fixture Controls (if any)

* Fixture wear out(Tool Life monitoring)

d) Daily machine checks

* Daily machine checklist filled up and are effective.

91
 PROCESS AUDIT CHECK SHEET
Supplier Name : Process Name:
Audit Date: Machine Name/Number:
Part Name / Number : Operator Name:
Audit done by :
SR No. Checkpoints Spec. Evidence/ Observation Satisfactory Action Plan Resp Target date

3 Process Output

Final Inspection as per control plan

a)

b)

c)

d)

4 Measuring instrument

a) *Calibration status of process measuring and product measuring instruments

5 Material handling, packaging and preservation

6 Safety & housekeeping

a) * Machines are cleaned, and are neatly maintained

b) * Does safety work environment provided for operator?

7 Operators awareness, skill Matrix, competency

* Sufficient Knowledge about the process

* Awareness of special characteristics

* Aware of reaction plan

* Stopping the process when problem observed

* Appropriate limit sample for visual parameters

92
 PROCESS AUDIT CHECK SHEET
Supplier Name : Process Name:
Audit Date: Machine Name/Number:
Part Name / Number : Operator Name:
Audit done by :
SR No. Checkpoints Spec. Evidence/ Observation Satisfactory Action Plan Resp Target date

8 Revision level of specification and standards

* Process change Records (IF ANY)

9 Data recording
* Inspection records indicating date, shift, M/C no., parameter inspected and
operator name.

* Does data recorded and records maintained?

10 SPC practices

* mistake proofing methodology(Poka-yoke)

* Control charts used

* Knowledge of process variation and capability

* Cp, Cpk for the process

* significant process events like tool change , power failure recording

11 Non conforming materials control

* Visual identification of suspected product

* filling up details / reasons/record of nonconformity

* handling of input or processing material, at sudden breakdown of M/c or

power failure

* Rework instruction

* Rework verification

12 Corrective action

* Customer complaint because of this process in past (if any), then resolution

*Does FMEA/CP/PFD updated for the customer complaints

13 OTHER OBSERVATIONS

a) *Does Quality objectives defined?

b) *Does process takes place as per PFD?

c) Records of process parameters validation available.

AUDIT BY: AUDITEE :

Date : Date :

93
 Supplier Request for Engineering Approval (SREA)

Supplier Description of Request / Change

Contact For :

Telephone number By:

email Name:

Date submitted (Signature for & behalf of Supplier)

Type of Change Specific parts affected

Design Sub-Supplier Gabriel Part Number Gabriel Drawing number Drawing Revision Description Comments

Tooling Sub-Contractor

Process Mfg. Location

Material Other (Detail below)

Other =

YES
Affects Gabriel Documentation (Drawings, Specifications, etc.)
(Change management request and/or TD Required)
NO

Timing

Permanent Temporary

Start Start

End End
Apx number of Piece Part Cost Impact DECREASE INCREASE NEUTRAL
pieces

Stipulations Gabriel Part number Old price (Rs/pc) New price (Rs/pc) Description / Justification

1. All changes require an approved Part Submission Warrant (PSW) before parts can be used in
production.
2. An approved SREA acts as Gabriel approval as long as the change does not affect Gabriel
documentation.
3. Suppliers must meet all conditions of

This portion for Gabriel use

Tooling Cost Impact YES NO

Change Mgt No Status of SREA: Gabriel Part Number Tooling Amount Description of Tool Comments

Product Line

Trigger date PENDING

Closer date

Customer ACCEPTED

Model

Buyer REJECTED

Telephone

94
GABRIEL RISK ASSESSMENT CHECKSHEET
Supplier Name :
Part Name : Part No.: Date : Rev No :

Reason For Change:

Proposed Modification:

Dept 4M High Medium Low

Applicable Applicable Applicable
Risk Preception Risk Preception Risk Preception
(Y/N) (Y/N) (Y/N)
- High skill to operate a special measuring eqpt - Moderate skill to operate a special measuring eqpt - Current skills are adequete

MAN - Special training required to Inspectors - Moderate training required to Inspector - No training required to Inspector

- Addition of skilled / special man power - Upgradation of skills in existing man power - No Addition of man power

- New / complex technology for measurement - Moderate upgradation of measurement technology - No change in current measurement set up

MACHINE - Heavy capex investment in Lab / inspection facility - medium capex investment - no capex investment

- Major change in Lab layout - Minor change in layout - No change in layout

QUALITY
- Major validation / testing required - Minor / additional validation / testing required - No additional validation / testing required

MATERIAL - New matl - Customer validation / approval required - Only Customer initimation / approval required - No Customer initmation / approval required

- Directly affecting process chara. - Not directly affecting process chara '- No effect on process chara

- Customer validation / approval required - Only Customer initimation / approval required - No Customer initmation / approval required

- Method of measurement not known / tedious - Method of measurement less known / needs expertise - No change in current measurement processes
METHOD
- Effects human safety / fatigue / Product safety (CC) chara - Effect only Product SC characteristics / human fatigue only - not affecting safety / fatigue

- Heavily effects productivity / efficiency of inspection - Medium effect on productivity / flow of material -not affecting on productivity

- Special High skill set required for design / upgradation - Moderate skill set required for design / upgradation '- Current skill set adequate

MAN - Special training required for Design engineer - Moderate training required for Design engineer '- no specific training requird

- Heavy addition of Skilled man power - An additional resource required - No additional resource required

- New/complex technology (Hardware / software within CAD / CAE) - Moderate upgradation in current technology (within CAD / CAE) - Current technology (within CAD / CAE) is adequete
MACHINE
- Heavy capex investment / Collaborator inputs required for design /
- Medium capex investment required for design / validation - no capex investment
validation
Design
- New material - Special validation / testing required - Equivalent material - Minor validation / Lab testing required - regular material - No validation required
MATERIAL
- Material severely affects other product Design chara. - Material has moderate affect on other product Design chara. - Material has no effect on other product Design chara.

- New Validation method needs to be devised - Current Validation method needs to be revised - Current Validation method is adequete

METHOD - New / Major review or change required in DFMEA - Minor change / review required in DFMEA - No change / review required in DFMEA

- Completely new design feature / design need - Relatively new design feature / design need - No new design feature / design need

- High skill required to operate - Moderate skill required to operate '- Low or no skill to operate

MAN - Special training required for Operator - Moderate training / OJT required '- no specific training requird

- Heavy addition of man power - Few additional man power (not budgeted for) - No addition of man power

- New/complex technology/process - Upgradation of current technology/process - Simple / current technology/process

- Heavy capex investment - medium capex investment - no capex investment

- Major change in layout - Medium change in layout - No change in layout

MACHINE
- Major change in cycle time '- Meduim change in Cycle time - No change in Cycle time
Production /
Mfg Engg - Affecting safety chara. - Partially affecting safety chara. - Not affecting safety chara.

- New material - Major process / tooling validation reqd - Minor process / tooling re-validation reqd - No process / tooling re-validation reqd
MATERIAL
- Directly affecting process chara. - Not directly affecting process chara '- No effect on process chara

- Major change in process flow - Minor change in process flow - No chang in process flow

METHOD - May severely affect human safety/ fatigue / ergonomics - less affect on human safety / fatigue - not affecting human safety / fatigue

- Effect productivity / flow of material Medium effect on productivity/flow of material - not affecting on productivity

- New supplier needs to be explored / developed - Major development with current source - No new development / Current source adequete
MAN
- Support in commodity skills required for Part development to existing
- Special commodity skill set required for Part development '- Current skill set is adequete
engineers

- New/complex technology - Upgradation of current technology - Simple technology

MACHINE
- Heavy capex investment - medium capex investment - no capex investment

- New material - customer approval required - No new material required - customer approval required - regular material - customer approval not require
Materials
MATERIAL - High RM cost / direct import - Moderate RM cost / direct import '- No cost impact / Local source

- Not easily avaliable - Not easily avaliable easily avaliable

- Major change in Logistics - Moderate change in Logistics - No change in current Logistics

METHOD - May call for heavy liasoning / legal approvals with Govt agencies - May call for moderate liasoning with Govt agencies - No liasoning with Govt agencies

- Effect productivity / flow of material Medium effect on productivity/flow of material - not affecting on productivity

CONCLUSION :
a] Risks known and acceptable.
b] Risks known and acceptable with identified actions.
c] Risks unknown & high. May not be worth to accept project/changes.

Developed and Reviewed by Supplier CFT

Product Engineering / R & D Dept. Head Q.A. Dept. Head Process Eng. Head Materials Dept. Head Production Dept. Head

Verified By Materials(Gabriel) :

95
 MANUFACTURING FEASIBILITY STUDY
Gabriel
(To be submitted to GIL before/With samples)
Supplier Name: Part Number : Part Name : Date :
FEASIBILITY CONSIDERATIONS:

Gabriel product quality planning team has considered the following questions, for the purpose of feasibility evaluation. The drawing and / or specifications provided have been used as a basis for
analyzing the ability to meet all specified requirements. All ‘No’ answers are supported with attached comments identifying concerns / proposed changes / Alternatives to enable us to meet the
specified requirements.

Change Details:

Reason for Change: Proposed modification :

Department Considerations Yes / No Comment

1. Is proposed modification adequately defined & understood to

enable feasibility evaluation?

2. Is validation required?
Design

3. Is Customer Approval required?

4. All the requirements given in the drawing/ Specifications are

understood?

1. Can product be manufactured as per the specification

(Chemical, Physical and other properties as given in the drawing)?

2. Can product be manufactured to tolerances specified on

Drawing?
Manufacturing Engg.
3. Can product be manufactured with existing process?
& Process
4. Can the product be manufactured with Cpk’s of 1.33 min for the
dimensions having tolerances?

5. Can the product be manufactured without incurring any

unusual cost for equipment & toolling?

1. Is statistical process control required for product or process?

2. Is new gauge or inspection method required?

Quality 3. Can all the dimensions as given in the drawing be measured
internally?

4. Can all the tests (Mechanical /Special) as per the

drawing/specification be conducted in house?

Materials & 1. Supplier capacity confirmation.

Stores
2. Raw material availability confirmation

1. Is productivity affected?

Production 2. Whether change affects operator ergonomics?

3. Whether the proposed change affects on cell 5S?

CONCLUSION:

Feasible Product can be produced as specified with no revision.

Feasible with Actions Action recommended/ decided (refer enclosed details)

Not Feasible Design revision required to product within the specified requirements.

Developed and Reviewed by Supplier CFT

Product Engineering/R&D Dept.Head Q.A. Dept. Head Process Eng. Head Materials Dept. Head Production Dept. Head

Verified By Materials(Gabriel) :

96
Gabriel Lot Rejection of Supplier Parts-Intimation Note

Vendor Name : Vendor Code :

Notification Number: Notification Date :

Notification Completion Date :

Defect Defect Description Part No. Part Name Quantity Total

Location

Action:-

Description:-

Your Immediate reply to this note reqd. within 24 hrs to given below contact person by
phone,fax,email or Personal visit & also send 8D within 5 days for this quality rejection.

Created By: Approved By

Fax No.: Contact No.: Email :

gilpune.rqa@gabriel.co.in

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 LINE REJECTION DUE TO SUPPLIER PARTS- INTIMATION NOTE

Vendor Name : Vendor Code :

Notification Number: Priority :
Notification Date : Notification Completion Target Date :

GIL Part Vendor Vendor Vendor GIL Part Vendor

Defect Part GIL Part Vendor Part Vendor Part
Location GIL part No GIL
Name Defect in GIL Defect Weight Part No Part Part Defect Part Qty. Total Total
Details Qty. Name Defect Value
Details Value

SAP Total Cost :

SAP Total Weight :

Actual Total Weight :

Your Immediate reply to this note reqd. within 24 hrs to given below contact person by phone, fax, email or personal v i s i t & also send 8D
within 7 days for this quality rejection.
Initiated By: Prod.Head: Approved By(QA): Purchase : Finance: Received By: Posted By:

Fax No Email ID:

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 L) Annexure for Special Process Audit Check Sheets

1. Process Audit Check Sheet for Hardening Process

2. Process Audit Check Sheet for Welding
3. Process Audit Check Sheet for Hard Chrome Plating
4. Process Audit Check Sheet for Powder Coating (Ferrous & non-ferrous)
5. Process Audit Check Sheet for Zinc Plating
6. Process Audit Check Sheet for Nickel Hard Chrome Plating

Note: All process audit check sheets are available at respective GIL plants.

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