Lucas-TVS-SQA Manual PART A 23.04.2011final New 1

SQA Manual
Lucas-TVS
Supplier Quality Assurance
Lucas - TVS
Lucas-TVS
Issue: 1 23.04.11
SUPPLIER QUALITY ASSURANCE
Appreciation
Alignment
Action
Awareness
Advancement
Partner
Perform
Progress
Lucas-TVS Ltd
Revision : 0, Date 23.04.2011
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Contents
Foreword
Page.No
4
Quality policy
Environmental, Health And Safety Policy
Part - A
1. Introduction
2. Supplier selection and approval process
12
3. New part development process
16
4. Development of PFD, PFMEA, Control Plan and Operational Standards
22
5. Validation of Production aids
26
6. Calibration system
30
7. Measurement system analysis
34
8. Process capability
38
9. Management of Limit samples
42
10. Product approval process
46
11. Purchasing system
56
12. Scheduling system
60
13. Guidelines for container selection
64
14. Incoming inspection control at LTVS
68
15. Handling of rejections at LTVS & field complaints
72
16. Supplier performance QCDS Rating
76
17. Implementation of changes
82
18. Control of LTVS supplied tools / equipment
86
19. Sub-supplier management
90
20. Supplier QMS requirements
94
21. Supplier EHSMS requirements
96
22. Supplier audits
98
23. Training and up-gradation of Operators skills
102
24. Records and retention periods
106
25. Traceability
108
26. P- Chart
116
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27. Value Engineering and Innovation
120
28. Shop Floor Controls
124
29. Kanban
130
Part B
134
30. Guidelines
135
a. PFMEA
136
b. Measurement System Analysis
162
c. Process Capability Study
174
d. Procedure for calculating Process Capability
178
e. Agreement of Inspection
186
f. Procedure for plotting P- Chart
192
g. X-bar R Control Chart
196
h. Target Area Control ( TAC ) chart
202
i.
Total Quality Management
204
j.
Total Productive Management
214
k. Lean Manufacturing
224
l.
230
Lucas TVS Electrical Suppliers Association (LESA)
31. Annexure
233
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Foreword
Today we are witnessing in the MARKET PLACE a changed environment of unprecedented
complexity. Customers demand the best in the market at competitive prices with ANY TIME
AVAILABILITY and LIFE TIME RELIABILITY. This throws up enormous challenges to organisation
and a race with accelerating pace and we find a very thin line differentiating the WINNER and the
LOSER. The critical success factors are - QUALITY which is non-negotiable, COST, DELIVERY
coupled with SPEED.In this scenario, traditional approaches and prescriptions are no longer adequate.
Today the slogan is not SURVIVAL OF THE FITTEST but SURVIVAL OF THE FITTEST AND
FASTEST, that means the organisation has to shift the focus to HIGH PERFORMANCE mode from
traditional mindset to be better than the competition.
We understand in Lucas-TVS that high performance mode is to achieve a fine blend of present needs
and future opportunities. We have to consistently strive to get ahead of competition because todays
competitive advantage is only transitory because of volatile market conditions.
At Lucas-TVS we are focusing the following five areas this year with a view to retain our leadership
position and be competitive in business place:
Make the organisation process centric.

Continuously upgrade technology both in Lucas-TVS and with the suppliers in meeting the
growing demands in Quality and Productivity.
Flawless launch of New Products.
Achieve single digit PPM in Quality levels on all our products with all our customers.
Strengthen corporate constitution by promoting Total Employee Involvement.
We are conscious that for any initiative being taken by us to raise our levels of performance, we have to
necessarily align and partner our supplier fraternity with us to enable them to perform better resulting in
mutual growth and prosperity. Hence the need to bring out a Supplier Quality Assurance Manual.
This manual has two parts:
Part A deals with the elements of processes to be followed in meeting QCDS requirements of the
company.
Part B deals with insight into TQM, TPM and Lean Manufacturing Concepts/Practices.
We strongly believe that the release of the manual is yet another effort on the part of Lucas-TVS to
raise standards of their suppliers so that they share and support in transforming Lucas-TVS vision into
reality and to be the preferred supplier by all the vehicle manufacturers in India and overseas.
Dr N Ravichandran
Date : 23.04.11
Chief Executive Officer
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QUALITY PHILOSOPHY
POLICY
We are committed to achieving ever increasing levels of Customer satisfaction through
continual improvements to the Quality of our Products and Services by adopting and
continually improving an effective Quality Management System.
It will be our endeavor to increase Customer trust and confidence in the label
Made by Lucas-TVS.
OBJECTIVES
Achieving OE Customer line rejections less than 10 PPM

Continual reduction of warranty returns
Providing warranty services to customers within 24 Hrs of receiving the complaints
Deliver products to customers in right quantity on time, every time
PRINCIPLES
Quality
Quality
Quality
Quality
Quality
Quality
Quality
Quality
levels
begins with a comprehensive understanding of changing customer needs

means providing value to customer in the use of our products and services
is built into the design of products, processes and materials
improvements lead to productivity and cost improvements
Means preventing defects and not detecting them only after occurrence
demands commitment by all employees, suppliers and dealers
is achieved through total employee involvement and training
cycle begins again with a comprehensive understanding of customer satisfaction
PRACTICES
Practice quality individually and as team

Do Right first time on time and every time
Enhance employee performance through training, motivation and small group activities
Understand the increasing Customer needs and expectations and satisfy them
Eliminate activities which do not add value
Standardise processes and systems with SOP and practice
Implement systematic supplier/dealer development programmes for improved quality
Application of Statistical Tools extensively across the organization
Practice continual improvement as a way of life in all activities
Next process is your customer, satisfy him
Revision : 2
T K BALAJI
Date : 29.08.2009
MANAGING DIRECTOR
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PART - A
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1. INTRODUCTION
Chapter 1
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1. Introduction
1.1 Purpose
Purpose of this manual is to
a. Communicate to all our suppliers regarding Lucas-TVS expectations and requirements for
assuring quality of parts / materials supplied .
b. Specify the procedures and documents to be followed by suppliers to achieve Zero Defect
supplies, consistency in quality, on time delivery, competitive cost , timely service and other
requirements of Lucas-TVS.
1.2 Scope
Applies to all Parts, Sub- Assemblies and Raw materials Supplied to Lucas-TVS by Suppliers.
1.3 Supplier Quality Assurance flow chart
Supplier Quality Assurance requirements are described in the flow chart ( Refer page : 7 )
Chapter 1
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1.3 Supplier Quality Assurance flow chart
Chapter 1
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2. SUPLLIER SELECTION AND

APPROVAL PROCESS
Chapter 2
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2. Supplier selection and approval process
Supplier Identification
Self Evaluation by the Supplier
Onsite Evaluation by Lucas-TVS
Feedback report to the Supplier
Re audit the
Supplier
Restricted
Approval
Corrective action report by the Supplier
70 ~ 79 %
Audit
Score ?
Below 70 %
Reject the
Supplier
Above 80 %
Approve the supplier
Chapter 2
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Supplier selection and approval process

Objective: To explain the procedure for supplier selection and approval for a totally a new
business and adding new business to the existing suppliers.
Supplier Responsibilities :
Review of Lucas-TVS Supplier evaluation check list
Submitting filled-in Supplier evaluation check list to Lucas-TVS
Readiness for on-site assessment
Inputs :
Filled-in Supplier evaluation check list
Documents related to on-site assessment
Description :
Lucas-TVS will conduct an on-site assessment, basically intended to evaluate supplier technical
capabilities and operating system for adequacy and adherence of the above.
Evaluation criteria:
1. Management
- Organisation
- Professionalism
- Financial stability
2. Technical
- Technical strength
- Capability
- Infrastructure
3. Quality Management system
- QMS certification to ISO/TS16949 or ISO9001
- Incoming / In process / Final Inspection control system
- Sub Supplier Control
Audit observations will be sent to the supplier and the supplier shall submit a time bound action
plan for correcting the non-conformities / opportunity for improvement points.
Follow up audit will be carried out at suppliers site as necessary to ensure the effectiveness of
the corrective action implementation.
Decision on assessment can be:
1. Approved
or
2. Restricted Approval
or
3. Rejected
Suppliers scoring above 80% will be approved and included in the Approved Suppliers list of
Lucas-TVS.
Note: Refer Annexure - 1 for the Supplier Evaluation Check list.
Chapter 2
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Chapter 2
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3. NEW PART DEVELOPMENT

PROCESS
Chapter 2
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Chapter 3
Concept & Approval
Prototype Samples
Tooled Up Samples
Phase II
Product Approval Process(PAP)
Phase III
Mass Production
Phase IV
Phase V
Phase I
Feedback & Corrective Action
Early Supplier Involvement
Product design & development
Process design & development
Product & Process validation
3. New part development process
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New part development process

Objective : To explain development stages for supplier developing new parts.
Shall form CFT (Cross Functional Team) for new part development and nominate representative
for interactions with Lucas-TVS.
Shall follow APQP guidelines for New Part Development. (Please refer to the APQP reference
manual of AIAG for details).
Development stages being practiced at LTVS are covered in the following 5 phases.
Inputs :
Drawings
Quality Targets
Cost Tables
Capacity requirements
Process Technology
Description :
Phase I (Before submission of Prototype samples) Prototype Phase
Supplier shall perform the following:
Supplier should interact with Lucas-TVS after studying the drawing with the following information:
a. Feasibility of producing the part
b. Cost break up of producing the part
c. Suggestions for improving QCD
d. New investment requirement, if any
1. On approval of the proposal, supplier shall develop mutually agreed time-bound activity plan for
development and the suppliers for monitoring the progress of the development should effectively
use the same.
2. Prepare process flow diagram, process FMEA and control Plan. (For more information on process
flow diagram, FMEA and control plan, refer to the annexure and guidelines in the manual and
APQP & FMEA reference manuals of AIAG).
3. In case of suppliers with proprietary design, review completeness of design FMEA in addition to
the above requirements of LTVS in accordance with FMEA reference manual of AIAG.
4. Dispatch samples to LTVS with the inspection report, material test report and performance test
report for developing prototype or customer evaluation samples.
5. Discuss with LTVS for any difficulties encountered / improvement in the process.
6. Review the activity plan based on the results of the prototype trials at LTVS.
Chapter 3
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7. Review the progress of facility / tool development and report the status of facilities / tool to LTVS
preferably with digital photographs.
Phase II (Before submission of Tooled up samples) Sample Approval Phase

Develop detailed plan, for procuring the tools, gauges, test rigs, etc. required for mass production
based on the volume requirement indicated by LTVS.
Forward detailed product and tooling cost details to LTVS.
1. Discuss and agree upon for any changes to the earlier agreed process flow and control plan
with LTVS.
2. LTVS will conduct a joint inspection where required at the supplier premises before the
submission of tooled up samples for which the supplier shall
a. Agree to a date of inspection
b. Make available all the gauges planned and equipment required for inspection as agreed in the
Inspection Standards.
3. Despatch tooled up samples with dimensional report, material test report & performance test
report. (Lot size of minimum 30 nos shall be made by suppliers and sample shall be taken
from the lot and sent to LTVS as per Annexure 10 or as agreed with LTVS) for sample
approval at LTVS.
4. Review the activity plan based on the feed back from LTVS.
5. Review the progress of facility / tool development and report the status with digital photos of
facilities / tool to LTVS on weekly basis.
Phase III (Before submission of samples for pilot production) Product Approval Process
Phase
On approval of tooled up samples, the supplier shall perform the following:
1. Verification of mass production capability for quality and quantity during Quality proving stage.
2. Despatch pilot batch along with the PAP documents (submission level 3) as agreed with
LTVS.
3. Correct all deviations observed during Quality proving and maintain records.
4. Audits may be conducted at the supplier works by LTVS during the quality proving stages.
Phase IV (Before mass production) Mass production & Ramp up phase

LTVS should finalize the cost before commencing mass production and release regular scheduling
agreement.
Chapter 3
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1. Correct all the deviations observed during the Quality Proving stages before commencing
mass production.
2. Update PAP documents based on the pilot production feedback and submit to
LTVS for approval.
3. Finalize part cost before commencing mass production and get the regular scheduling
agreement. (This may include annual cost reduction plan also)
4. Develop mutually agreed plan for ramping up the production capability based on the
projected volumes indicated by LTVS.
Phase V Feedback & Corrective action
1. Correct the deviations observed during mass production by initiating appropriate corrective
actions.
Chapter 3
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Chapter 3
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4. DEVELOPMENT OF PFD,
PFMEA, CONTROL PLAN &
OPERATION STANDARDS
Chapter 4
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4. Developments of PFD, PFMEA, Control Plan & Operation Standards

Preliminary process
flow chart
Approved
Drawing
PFD
PFMEA
Decide the recommended actions based on

high severity, occurrence & detection
Process
Improvements
Poka Yoke
Capability study
& Improvement
Effective Process
Control
Reduced severity & occurrence

and improved detection
Control Plan (in accordance with

ISO/TS 16949 requirements)
Approved of PFD, PFMEA & Control

Plan
Operation
Standards
Chapter 4
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Developments of PFD, PFMEA, Control Plan & Operation Standards

Objective: To describe the procedure for the developments of PFD, PFMEA, Control Plan and
Operation Standards.
Supplier Responsibilities
Development of Process flow diagram with inputs from (preliminary process flow chart ,
approved drawings & CFT discussions.
Development of PFMEA and actions to reduce risk of failures in the process.
Development of Control Plan to build process controls to prevent failures as per ISO/TS
16949 requirements.
Development of Operation Standards to execute the process in controlled condition and to

ensure consistency.
Inputs
Preliminary process flow / layout
Approved drawings
CFT discussions
Description
Process flow diagram maps the processes stepwise clearly defining the product characteristics and
the process characteristics relevant at each step indicating the characteristics including special
characteristics as applicable and flow sequence
Process Failure Mode Effects analysis is a technique to capture potential failure modes in each
process step and quantify risk of failures based on severity ranking, occurrence ranking and detection
ranking. The exercise is carried out by a CFT using format in annexure 12. The process risks are
prioritized based on severity ranking, occurrence ranking and detection ranking and actions are
planned by CFT to reduce defective parts. Actions could be process improvement, Poka Yoke,
process capability improvements or better process controls. PFMEA is a live document and should be
reviewed whenever changes take place in process or when major failures occur. By default, PFMEA
should be reviewed once in three months based on actual internal and external failures.
Chapter 4
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Control plan is used to define process control criteria and methods of control, from incoming raw
material to receipt of part to customer. Control plan is made based on PFMEA and Process Flow
Diagram. Control plan is used by supervisors / quality inspectors / quality engineers and line
managers to control process. Control plan should be developed in accordance with ISO/TS
requirements. (Refer annexure 8).
To control each operation "Operation Standards" (Annexure 16) are used by operators to carry
out their operation effectively. Operation standard should include How to do and What to do
during processing and what to inspect before sending to next process (Internal customers).
Operators' involvement are necessary in developing these documents, which
brings their
ownership. Suggestions for continual improvement of operation standard shall be reviewed and
incorporated to stabilize the process outputs and improve the process capability.
Chapter 4
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5. VALIDATION OF
PRODUCTION AIDS
(TOOLS AND GAUGES)
Chapter 5
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5. Validations of Production Aids (Tools & Gauges)
Part
Drawing
CFT discussion
inputs
Control
Plan
Preliminary process
flow chart
List of Tools
List of checking aids (Gauges)
Tool Design
Checking aids (Gauges) Design
Tool manufacturing
Checking aids (Gauges) manufacturing
Tool try out - soft
Calibration
Soft tool fine tuning
Tool
approval
Attribute guage R&R

(as per MSA manual of AIAG)
No
Yes
Hard Tool
Approval
No
Tool trial
Yes
Rework or redesign /
Training to operators
Hard tool fine tuning

Hard Tool
approval
No
Yes
Periodic Tool
Management
Calibration
status and
periodic
calibration
Maintain Tool
Management /
History cards
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Validations of Production Aids (Tools & Gauges)

Objective: To establish manufacture of reliable tooling and checking aids (Gauges), which are
capable of producing and checking parts, conforming to drawing.
Supplier management is responsible to:
Prepare a detailed itemized plan for design, development, acquisition, installation and
validation of facilities, tools, jigs & Fixtures, Machines and measuring equipment.
Ensuring that tooling is manufactured to produce the parts that conform to nominal of the part
drawing.
Ensure that mass production tooling and checking aids are fully ready before the first
production trial or the checking fixture trial is conducted.
Ensure that a good system for management of tools, jigs, checking fixtures is established to
ensure that tools are maintained to provide quality parts till they are in use.
Inputs
1. Approved part drawing
2. CFT discussion points
3. Control plan
4. Preliminary process flow / Layout
Description
The tooling and inspection aid requirement shall be in accordance with the quality, reliability and
productivity requirements of parts. Supplier should ensure that tooling and inspection aids are
amenable to quick changeover they are capable of preventing and/or detecting possible errors
during manufacturing.
Each tool and inspection aid (Gauges) development shall be tracked through a planned "Tool &
Gauges Progress Report".
Tooling and inspection aids shall be designed and reviewed by appropriate authority.
Manufacturing and inspection shall be done with respect to approved drawing.
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Validation trials should be carried out before or during pilot manufacturing stage and suitable
modification shall be carried out to make it fit and easy to use by Suppliers.
Each tooling and inspection aid shall be managed for proper use, due checks after use,
maintenance, fixed location, identification with colour codes with status (OK or Not OK) through a
history card. Based on similar application experiences the tool life and replacement parts shall be
specified or shall be established through wear trend.
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6. CALIBRATION SYSTEM
Chapter 6
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6. Calibration System
Current inventory of
measuring equipment
Control
Plan
Identification of measuring
equipment needed
following 1/10 rule for
resolution
Procurement of
needed measuring
equipment
Master list of measuring equipment
Identification
of users
Training for
use &
handling
In-house calibration
External calibration
for masters &
instruments
Calibration procedure
Identification of
accredited lab and
calibration of reference
and instruments
Calibrated masters
Calibration records
Recall for periodic calibration

or incase of mishandling
(Dropped) or doubt by operator
Calibration of
measuring equipment
OK
Calibration
Status
Not OK
Use of measuring
equipment
Chapter 6
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Investigate for suspect

parts shipment and
escalate
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Calibration System
Objective: To establish system for calibration of measuring and test equipment against
standards, having National / international traceability.
Ensuring calibration of gages, measuring and testing equipment needed for measurement of
product or controlling process parameters mentioned in control plan.
Ensuring calibration of measuring and testing instruments and setting standards are carried
out in controlled conditions.
Ensuring that the masters used as reference for in house calibration are duly calibrated by
accredited laboratory having traceability to National / international standards.
Ensuring visible calibration status on the equipment preferably with colour code identification
or calibration due date sticker.
Ensuring mistake proofing in system for periodic recalibration.
Inputs
Control plan
Current inventory of measuring equipment
Approved drawings
Calibration procedures and standards
Description
The quality of measurement data is defined by the statistical properties of multiple measurements
obtained from a measurement system operating under stable conditions. The statistical properties
are the location of the data with respect to reference (Master) & the spread of the data for
repeated measurement. Calibration is focused upon the location error in the measuring device
through repeated measurements on a master or by a master.
Bias: Difference between "Reference" and the observed average of repeated measurement. (The
observed value shall follow normal distribution)
Calibration Frequency: Shall be decided based on use of the measuring devices and its
deterioration pattern or wear pattern. In the beginning frequency should be higher than normal
and depending upon successive calibration trend frequency shall be decreased.
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Permitted Bias Error: is 1/10 of the permitted error for the characteristics being measured (i.e)
tolerance specified on drawing or in inspection standard whichever is less. The master used for
calibration shall be 1/10 of permitted error on the instruments. The unit of measure (Least Count)
for the selected measuring device shall also follow this 1/10 rule as a minimum.
In case 1/10 rule is not being followed due to logical constrains a waiver shall be obtained from
LTVS.
Linearity: This measures how accurate the measurements are through the expected range in
percentage. Linearity for a gauge should be close to Zero.
Stability: This measures whether the error because of bias & Linearity will remain unchanged
over the period of time. This is normally studied over a series of calibrations unless and until
measurement system is not unstable in nature. In such cases setting standards are provided to
for calibration just before use.
Calibration Environment: Controlled temperature and humidity levels are needed for the
calibration activity. Calibration area shall be free of dust and dirt.
Recall System for Re-calibration:
Recall system for re-calibration shall be mistake proofed by visual reminder (colour code) of
due week / month or computerized reminder or colour code system.
On recall and calibration if the instruments are found out of calibration it shall lead to
investigation of possible shipment of parts with wrong measurement and its consequences. If
the consequences are indicating a possibility of problem in fitment or performance, it should
be escalated to senior management of supplier, which in turn shall be escalated to LTVS
without any undue delay.
Training for All Users: shall be conducted periodically for proper use and handling of measuring
instruments along with importance of calibration and not using instruments beyond due date of
calibration, but this shall not be treated as substitute for recall system.
Storage and Use Conditions: Instruments and standards used for reference and setting purpose
shall be kept free of dirt, dust and shall be preserved to avoid any rust, dents and scratches.
Proper cleaning of working surface shall be done before use.
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7. MEASUREMENT SYSTEM
ANALYSIS (MSA)
Chapter 7
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7. Measurement System Analysis (MSA)
Inventory of
checking aids
Inventory of measuring
devices (Duly calibrated)
Instruments / checking aids

identification for MSA study
Samples
from Pilot or
PPAP run
Control Plan
Special and/or Major

charecteristics
Operators &
inspectors
measuring Special
and/or Major
characteristics
Samples for MSA
Establish Measurement
method, train operators
and inspectors
Conduct measurement system analysis and

calculate Guage R&R or Kappa value
(refer MSA manual of AIAG / Chapter 30.b)
Analyze the
causes of
variation
impove the
measurement
Not
Acceptable
Guage
R&R &
Kappa
value
Acceptable
PPAP records for

approval
Carryout MSA studies for the identified

instruments / gauges atleast once in a year as
per the annual MSA plan
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Measurement System Analysis (MSA)

Objective: To quantify total error present in applicable measuring system and reduce them to an
acceptable level.
Ensuring the team is trained on the various concepts of statistical analysis for conducting
MSA.
Ensuring that Gauge R&R < 10% (Variable) or Kappa value> 0.75 (Attribute).
Inputs
Control Plan
The measuring devices are calibrated.
Sufficient number of actual product samples is available. (Minimum 10 for variable and 20
for attribute MSA studies)
Personnel doing actual measurements and master evaluator are identified.
Method of measurement shall be defined and users are trained by master evaluator.
Description
Quality of measurement data is defined by the statistical properties of multiple measurements
obtained from a measurement system operating under stable conditions. The statistical properties
are location with respect to reference & the spread of the data for repeated measurement.
Gauge R&R analysis is a method to establish the spread of data in measurement system and make
sure that this is an ignorable fraction of total process spread for which it is used. This study has two
primary components explained below:
Repeatability: is the variation in measurements obtained with one measuring instrument when
used several times by one appraiser while measuring the identical characteristics on the same part.
Traditionally it is also referred as within equipment variation. Some established causes for high
repeatability are:
Instrument needs maintenance.
The gauge needs to be redesigned to be more rigid.
The clamping or location of gauging needs to be improved.
There is excessive variation within part
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Reproducibility: is the variation in the average of the measurements made by different appraisers using
the same measuring instruments when measuring identical characteristics of the same part. Traditionally
it is also referred as within appraiser variation. Some established causes resulting in high repeatability
errors are:
The appraiser needs to be better trained in how to use and read the instrument.
Gauge dial markings are not clear.
A fixture of some sort may be needed to help appraisers to use gauge more consistently.
Note: Gauge R&R analysis values for one measuring device and for a set of persons cannot be
extended to another measuring device and/or another set of operators.
Attribute Measurement System Study: is the measure of agreement of the actual evaluations by two or
more raters, from that of the true status of the object, determined by reference evaluator. It is measured
as Kappa Value.
Reference: Latest revision of "Measurement System Analysis" by Automotive Industry Action Group
(AIAG) or Guidelines given in this manual ( Chapter 31.b )
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8. PROCESS CAPABILITY
Chapter 8
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8. Process Capability
Part Drawing
PFMEA
Control Plan / QCPC
Any special
Characteristics
NO
(SC)?
Adhere to control method

as per CP/QCPC
YES
Ensure Gauge R&R % < 10%
Establishing X R Control
Chart
Monitor the process using X-R

Control
Take corrective action
Calculate the Cpk every month
(Refer Guidelines)
100% inspection till
Cpk
> > 1.67
No
Is Cpk> 1.67
Yes
Monitor Trends of Cpk and maintain

records
Submit monthly Cpk report to Lucas TVS
SQ
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Process Capability
Objective
To calculate the process capability (Cpk) in order to meet customer requirement and enhance
satisfaction
Ensuring the team is trained on SPC Concepts
Ensuring that Gauge R& R < 10%
Inputs
Part Drawings
PFMEA
Control Plan
SPC Concepts
Calibration of measuring device
Customer requirement on (Cpk > 1.67)
Description
Process capability is a measure of the ability of the process to meet design specifications .
Suppliers shall ensure that the special characters identified in the Drawing are addressed in PFMEA
and control plan (QCPC). It is more important to ensure that the process is stable and brought under
statistical control before calculating the process capability for any processes.
It is important to ensure that R&R % is less than 10% for the measuring system used for measuring
and controlling the special characters. Control charts ( X R) are to be established and monitored for
the identified processes and Special characteristics as per the guidelines given in this manual
(Chapter 31.g)
Process capability (Cpk) is to be calculated every month as per the guidelines given in this manual
and acceptable minimum value of Cpk is > 1.67 . Suppliers shall carry out 100% inspection when
the required Cpk (> 1.67) is not achieved. Root cause analysis are to be carried out and corrective
action to be taken by suppliers. Monthly Process capability (Cpk) reports are to be submitted by
suppliers to Lucas TVS SQ
Refer : Latest Edition of Statistical process control released by AIAG
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9. MANAGEMENT OF LIMIT
SAMPLES
Chapter 9
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9. Management of Limit Samples
Control Plan
Inspection
Standards
for Part
Workstation Vs Limit
sample matrix
Responsibility for
providing limit samples
LTVS approved
limit Samples
Inspection standards for

incoming components
Sub supplier provided

limit samples
Manufacture of limit
samples
Approval of limit samples
Registration of samples
limit
Maintenance and periodic

replacement of limit samples
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Management of Limit Samples

Objective: To explain steps for developing limit samples and using them as Inspection Standards.
Ensuring availability of limit samples for characteristics stated as "As per limit samples" in
inspection standard.
Ensuring that limit samples are produced representing current process which is capable of
meeting customer specifications and submitted to customer for approval.
Maintaining limit sample register, proper upkeep of the samples, and effective use of limit
sample by concerned in right decision making for acceptance and rejection of parts and
components.
Ensure periodic replacement of limit sample as processes improve to represent current

acceptance criteria.
Reviewing limit sample, in case of engineering changes and replacing it with new one if
needed.
Inputs
Control Plan
Inspection standards
Description
For subjective quality characteristics when judgment criteria cannot be described in measurable
terms in inspection standard, like texture of surface, profile, etching pattern etc; limit samples are
established to facilitate uniformity in judgment at sub supplier, suppliers and LTVS.
Limit samples provided by Suppliers shall be approved by LTVS.
Supplier shall establish the requirement of limit samples for their sub suppliers and follow the
same system for their proper use and upkeep.
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Limit samples represent current process status, which is expected to improve over time therefore
these should be periodically evaluated and renewed.
The limit samples may deteriorate over time or become obsolete due to process or material
changes. In such circumstances it should be replaced with new limit sample.
All the limit samples should be identified with validity date. Supplier shall maintain a limit sample
register showing the place of use and status of limit samples.
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10. PRODUCT APPROVAL

PROCESS
Chapter 10
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10. Product approval process
Submit the samples along with child

parts, raw material and SAN documents
to Lucas-TVS
(Dimensional report,
Material test Performance report,
AOI Part B, PSW )
Evaluation of samples and SAN

documents by LTVS
Submit PAP
documents to
SQ
OK
Not OK
Evaluation
Status
Take Corrective action

Proceed for Pilot production
Submit the Pilot lot
Evaluation
Status
Resubmit samples to LTVS
OK
Proceed for Mass

production
Not OK
Take Corrective actions
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Product approval process:

Objective: To describe the procedure for Product Approval Process (PAP) of all complete parts &
all child parts which are in line with Lucas TVS drawings. This procedure is applicable to all
suppliers of Lucas TVS
10.1 General
The supplier shall submit PAP documents & samples along with duly filled in PAP Submission
checklist (Annexure - 2) in the following situations. The supplier shall obtain approval from Lucas
TVS prior to first production shipment.
Initial Submission.
Engineering change(s)
Tooling Transfer, Replacement, refurbishment or additional.
Correction of discrepancy.
Tooling inactive for more than a year.
Change to optional construction / material.
Sub supplier or material source change.
Change in part processing
Parts produced at changed / additional location.
Others (To be specified)
10.2. PAP process requirements :

10.2.1 Significant Production Run :
Parts for Product approval process shall be taken from a significant production run. This production
run shall be with specific production quantity to total a minimum of 30 consecutive parts or as
agreed with LTVS using the tooling, gauging, process, machines, materials and operators from the
production environment.
10.2.2 PAP requirements :

The supplier shall submit the parts, documentation and records only when all the specified
requirements as per drawing & specifications are met. In case of results falling outside the
specification, every effort shall be made to correct the process so that all the requirements are met.
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If the supplier is unable to meet any of the drawing requirements, Lucas TVS shall be contacted
for determination of appropriate corrective action.
A qualified laboratory shall perform inspection & testing for PAP Commercial / Independent test
laboratories used shall be accredited facilities / qualified laboratories. When a commercial
laboratory is used, the supplier shall submit the test results on the laboratory letter head, or on the
normal laboratory report format.
10.2.2.1 Part or Component drawings:

The supplier shall have the LTVS drawing for the part or component as per issue level indicated in
the purchase order / amendment to purchase order.
10.2.2.2 Process Flow Diagrams:

The supplier shall have a process flow diagram in Lucas - TVS specified format (Refer Annexure 3) that clearly describes the production process steps and sequence as appropriate and meets
LTVS needs, requirements and expectations.
10.2.2.3 Failure mode and effects analysis (FMEA) Process:

Process FMEA is to be carried out for all potential failure modes likely to occur at each operation
consistent with process flow diagrams and suitable action to be taken to eliminate the cause(s) or
reduce its occurrence. If both are not feasible detection of failure mode/cause is to be improved.
Guidelines for carrying out process FMEA are given in the Supplier Quality assurance manual.
(Chapter 31.a). FMEA shall be carried out by supplier as per FMEA reference manual of AIAG.
10.2.2.4 Dimensional results:

The supplier shall provide evidence that the dimensional verifications required by the drawing,
control plan & Agreement Of Inspection have been completed and results indicate compliance with
specified requirements. The supplier shall have dimensional results for each unique manufacturing
process (e.g. cells or production lines, all cavities, molds, patterns, dies) for a minimum of 5 parts.
The Dimensional results report form in Annexure - 4 of Supplier Quality assurance manual may be
used for this purpose. The supplier shall identify one of the parts measured as master sample.
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10.2.2.5 Records of material / performance test results :

The supplier shall have records of material and/or performance test results for tests specified by the
drawing, control plan & Agreement of Inspection.
10.2.2.5.1 Material test results:

The supplier shall perform tests for all child part and product material when chemical, physical or
metallurgical requirements are specified by the drawing, control plan & Agreement Of Inspection.
All tests required by the drawing or control plan and related specifications should be listed in a
convenient format along with the quantity tested and the actual results of each test. (Annexure 5)
10.2.2.5.2 Performance test results:

The supplier shall perform tests for all part(s) or product material(s) when performance or functional
requirements are specified by the drawing or Control plan.
Note: Results for all tests required by the drawing or related specifications should be listed in an
understandable format and include the quantity tested. The Performance Test Results form in
Annexure - 6 of Supplier Quality assurance manual may be used for this purpose.
10.2.2.6 Initial Process Capability studies :

The supplier shall carry out preliminary process capability study (Ppk) for all new manufacturing
process/parts having special characteristics and other characteristics as required by Lucas-TVS
and customers.
The minimum acceptable value of Ppk is 2.00 or as required by the customer of Lucas- TVS. The
minimum acceptable value of Cpk is 1.67 or as required by customer during regular production run.
Note 1: The purpose of this requirement is to determine if the production process is likely to
produce product that will meet the requirements of Lucas - TVS.
Note 2: Initial process studies are short term and will not predict the effects of time and variation in
people, materials, methods, equipment, measurement systems and environment. A short term
study should be based on a minimum of 30 readings from consecutive parts of the significant
production run. The format as per Annexure - 7 shall be used for this purpose.
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10.2.2.7 Measurement System Analysis Studies :

Measurement System Analysis studies shall be conducted to analyze the variation present in the
measuring system, consisting appraiser and equipment variation for all instruments/gauges used to
monitor Lucas-TVS specified Special Characteristics (SCs).
Guidelines, acceptance criteria and format for conducting measurement system analysis are given
in Supplier development manual.
Acceptance Criteria :
The instrument used is acceptable if % R&R < 10.
Conditionally acceptable if % > 10 and < 30 and not acceptable if % R&R > 30.
Number of Distinct Categories (NDC) < 1 Instrument unacceptable for estimating process
parameters and indices.
NDC 2 4 Generally acceptable for estimating process parameters and indices since it only
provide gross estimates.
NDC > 5 - Recommended.
For attribute characteristics Kappa value > 0.75
10.2.2.8 Control Plan :

The Supplier Shall have a control plan as per the Lucas TVS format (Annexure - 8) that defines all
control used for process control. The Supplier shall obtain approval from concerned product unit
supplier quality team prior to PAP submission.
10.2.2.9 Part Submission Warrant (PSW) :

Upon satisfactory completion of all required measurements & tests, the supplier shall record the
required information on the Part Submission Warrant (PSW). Refer Annexure 9. (Sample
submission Challan replaced with Parts Submission Warrant)
The supplier shall verify that all of the measurement and test results show conformance with
Lucas TVS requirements and that all required documentation is available. A responsible supplier
official (Head of Quality) shall approve the PSW after satisfactory verification of PAP requirements
including comparison of process capability , Dimensional results , Material test results , Straight
through ratio before and after for the changes as applicable and indicating the date and
designation.
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10.2.2.10 Sample Production Parts:

The supplier shall draw sample products from the parts produced during the significant production
run and provide parts from each unique manufacturing process (e.g. cells or production lines, all
cavities, molds, patterns, dies) as per the sample production parts requirement specified in
Annexure - 10.
10.2.2.11 Master Sample :

The supplier shall retain a master sample for the same period as the production part approval
records, or until a new master sample is produced for the same Lucas TVS part number for Lucas
TVS approval. The master sample shall be identified and shall have the customer approval date on
the sample. The Supplier shall retain a master sample for each position of a multiple cavity die,
mold, tool or pattern, or production process unless otherwise specified by Lucas TVS.
10.2.2.12 Checking Aids :

The supplier shall submit with the PAP submission any part-specific assembly or component
checking aids list & details.
The supplier shall certify that all aspects of the checking aid match with part dimensional
requirements.
10.2.2.13 Agreement of Inspection :

The Agreement of Inspection shall contain,
Part A: Inspection standard indicating the Appearance, dimensional, performance, material /
surface treatment & durability parameters applicable to the final part, specifications, inspection
method & sampling frequency as per the enclosed format. Annexure 11a.
Part B: Details of sub supplier & raw material source for all the child parts as per the enclosed
format Annexure 11b. For products with LTVS developed material specifications and LTVS
approved subcontractor list, the supplier shall procure materials and/ or services (e.g. plating,
heat treatment) from subcontractors on that list.
Part C : Packaging Standards / Container details
Agreement of Inspection Part C Packaging Standards / Container details are required for all
direct materials supplied to Lucas-TVS . Refer guidelines given in this manual ( Chapter.30.e )
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The supplier shall submit the Agreement of Inspection and obtain approval from the concerned
Product Unit supplier quality team (on both Part A: Inspection Standard & Part B: Details of sub
suppliers / raw material source), Part C Packaging Standards at the time of PAP submission.
The guidelines for preparation of Agreement Of Inspection are given in the Supplier Quality
assurance manual ( Chapter 30.e )
On obtaining PAP approval from Lucas TVS, suppliers shall submit Pre delivery inspection reports
in line with Agreement of Inspection along with each consignment at the time of bulk supplies.
10.2.3 PAP documents submission / retention requirements :

The following documents (Submission level: 3 as per PPAP reference manual of AIAG) are to be
submitted to Lucas TVS / retained by supplier during PAP submission along with samples:
Drawing provided by Lucas TVS / Lucas TVS approved drawing ( to be retained by supplier)
Process Flow Diagram

Process Failure Mode And Effects Analysis (PFMEA)
Dimensional Results Report / Straight through ratio / OK ratio
Records of Material / Performance Test results / Straight through ratio / OK ratio
Initial Process capability studies for significant characteristics (SC) / before & after for changes .
Measurement System Analysis Studies
Control Plan
Parts Submission Warrant (PSW)
Sample Production Parts
Master Samples (To be retained by supplier)
Details of Checking Aids
Agreement Of Inspection (AOI)
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10.2.4 PART SUBMISSION STATUS

10.2.4.1 General
The supplier shall be notified by Lucas-TVS of the disposition of the submission. After production
part approval, suppliers shall assure that future production continues to meet all the requirements.
10.2.4.2 PAP / PSW Approval status

10.2.4.2.1 Full Approval indicates that the part meets all Lucas - TVS specifications and
requirements. The supplier is therefore authorized to ship production quantities of the product
subject to releases from the Lucas - TVS scheduling activity.
10.2.4.2.2 Interim Approval permits shipment of material for production requirements on a limited
time or piece quantity basis. Interim Approval will only be granted when the supplier has:
- Clearly defined the root cause of the non-conformities preventing production approval.
- And prepared an interim approval action plan agreed upon by Lucas TVS. Re-submission to
obtain full approval is required.
Material covered by an interim approval that fails to meet the agreed-upon action plan either by the
expiration date or the shipment of the authorized quantity will be rejected. No additional shipments
are authorized unless an extension of the interim approval is granted.
10.2.4.2.3 Rejected means that the submission, the production lot from which it was taken, and
accompanying documentation do not meet customer requirements. Corrected product and
documentation shall be submitted and approved before production quantities may be shipped.
10.2.5 RECORD RETENTION:

Product Approval Process ( PAP) records shall be maintained for the length of time that the part is
active Plus one calendar year.
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11. PURCHASING SYSTEM
Chapter 11
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11. Purchasing System
RFQ to Supplier
Supplier Quotation
Zero Based Costing by LTVS
Price finalisation with supplier
Release of Annual Purchase

Orders by LTVS
Amendments to Purchase Orders

(during any change)
Chapter 11
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Purchasing System
Objective : To explicitly communicate the suppliers on supply conditions with clear terms and
order conditions meeting all statutory obligations to be fulfilled by supplier and to meet 100 % on
time delivery.
Submission of Quotation and cost table along with process sequence
Inputs :
Drawing
Specification
Type of Parts / Materials
Description :
1. Lucas-TVS Shall release annual purchase orders at the beginning of the financial year or
issue an amendment for extending the validity of the existing purchase order.
2. Lucas-TVS shall issue amendment to purchase orders as and when changes take place in
the annual Purchase Order for price, payment terms, delivery terms, tax rates, agreement
conditions, freight terms, addition and deletion of parts, change of address, drawing issue
level change, etc.
3. All supplies, whether it is samples or products shipped for regular production shall be made
only against scheduling agreement.
4. Supplier shall review and commit to all the terms and conditions of the purchase order and
scheduling agreement.
5. All the invoices made to Lucas TVS shall have the valid Purchase Order number printed on it.
6. Price shall be finalized before beginning of mass production and finalized price will come into
effect once the PPAP approval is obtained.
7. Supplier shall inform us if there are any changes in the organization structure, address, and
contact number.
8. Any issues related to goods receipt / payment shall be referred to purchase to resolve within a
month of Invoice date.
9. Supplies shall be made as per latest or operating drawing issue with final inspection report for
every lot as agreed.
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12. SCHEDULING SYSTEM
Chapter 12
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12. Scheduling System
Annual projection given to Suppliers

during Annual Suppliers Meet
Three months rolling projection through

RASIS
Monthly plan through RASIS
Daily / Weekly / Two bin Schedules to

Supplier along with Delivery Instruction
(DI) number through RASIS
Delivery of materials to LTVS by

Supplier against Delivery Instruction (DI)
number
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Scheduling System :
Objective : To enable supplier to have effective production planning to meet Lucas-TVS
delivery requirements.
Supplier responsibilities:
1. Supplier to equip with adequate facilities like phone, fax, and computer with internet
connection, barcode printer and scanner for better communication.
2. Suppliers shall look at schedules released on the RASIS (Remote Access Supplier
Information System) www.lucastvs.co.in at the start of the week for production planning and
supply accordingly.
3. In the case of Kanban, the schedule quantity released is only to enable the planning process
and the actual delivery of parts shall be only against the Kanban Card.
4. 4. In case of concern / likely to fail in meeting the confirmed scheduled quantity requirements,
supplier shall inform the concerned business unit (Feed back report) purchase within first
working day of week through LEAPS feedback screen.
5. Suppliers shall cascade schedules to Tier II suppliers and RM suppliers to ensure on time
delivery.
Inputs :
Delivery schedules
Internet facilities
Description :
Annual projections are given to Suppliers during annual Suppliers meet.
In addition three months rolling projections are given through RASIS. Monthly plans are sent
Suppliers through RASIS .
Daily / Weekly / Two bin schedules to Suppliers along with Delivery Instruction ( DI ) Number are
sent through RASIS.
Suppliers shall ensure 100% on-time Delivery of Materials as per schedules to Lucas-TVS as per
agreed logistics arrangements.
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13. GUIDELINES FOR

CONTAINER SELECTION
Chapter 13
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13. Guidelines for Container selection
Container shall be made as per the

guide lines given in this manual
( Chapter 31.e )
Submit the sample container to LTVS

along Agreement of Inspection (AOI)
Part C
Evaluation
by LTVS ?
Not
Satisfactory
Satisfactory
Start supplies in new container
Carryout modifications and

resubmit
Maintenance of Containers
( Ensure cleanliness,
No damages & replenishment )
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Guidelines for Container selection

Objective: To ensure the container selection is as per the transportation and handling
requirements of the product.
Supplier responsibilities :
Develop containers as per guidelines
Maintenance of Containers
Inputs :
Length
Width
Height
Gap to be left from the top.
Description :
1. The type container shall be made as agreed by LTVS in Agreement of Inspection

(AOI) Part C.
2. The size of the Container shall be one of the following.
Height(mm)
Gap to be left from the
Max
top (mm)
300
250
15
600
400
250
15
600
500
250
15
Length (mm)
Width (mm)
400
* Not applicable for pole pieces and fixing brackets
3. Total weight (container weight + weight of components) shall not exceed 15 kg.
4. The container should have SUPPLIER NAME
LTVS written on both sides. Colour
of letters - white; Size of letters minimum 1 inch height.

5. The container shall have card holders on both sides
6. Container shall be Clean and free from damages, dirt, oil and any other contamination.
7. Each container most have lid to protect the parts.
8. Locators shall be provided in the containers for the brittle materials.
9. Container samples to submitted to Lucas-TVS and approval to be obtained through AOI-Part-C
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14. INCOMING INSPECTION

CONTROL AT LTVS
Chapter 14
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14. Incoming inspection control at LTVS :
Supplier shall submit inspection reports, process capability reports &

Material test report (as agreed) along with parts as per AOI
Rejected
Accepted
Inspection by LTVS
SQ
Material moved to stores
Chapter 14
Material sent back to supplier
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Incoming inspection control at LTVS :

Objective: To communicate controls at receiving inspection of Lucas-TVS .
Supplier Responsibilities:
The following reports shall be submitted along with the supplies as per the agreed
norms:
S.No
Reports
Norms
Supplier final inspection report
Process
capability
performance reports
Material test reports
reports
With every lot

and With every lot
With every lot / as per Agreement of
inspection
Inputs :
Agreement of Inspection
Measuring Instruments and gauges
Quality plan.
Description :
A) Supplier final inspection reports:
1. Submit in the prescribed format (Annexure : 15) as per agreement of inspection.
2. Carry out 100% inspection for all appearance items / for visual defects.
3. Certified inspectors name & Sign.
B) Requirements on special characteristics:
Supplier shall maintain process capability reports for special characteristics once in a
month and keep records / control charts for any verification if required (As per agreement
of inspection / control plan). Acceptance norms for process capability (Cpk) of the
parameters shall be > 1.67.
In case the processes become non-capable or unstable, supplier shall introduce 100%
inspection for the parameter till the process is corrected and again becomes stable and
capable. A list of such unstable and non-capable processes shall be submitted to LTVS
every month end.
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C) Raw Material test reports
1. Supplier shall carry out tests and submit as agreed in PAP / when requested by LTVS.
(Original raw material source details)
2. In case supplier does not have facility, Tests can be carried at the LTVS approved / NABL
approved laboratories.
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15. HANDLING OF REJECTION

AT LTVS & FIELD COMPLAINTS
Chapter 15
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15. Handling of rejections at LTVS & field complaints
Rejections identified by LTVS - SQ in the

incoming supplies, customers and field
Supplier Problem Quality Report (SPQR)

raised by LTVS - SQ in RASIS
Immediate measures taken by the supplier:

a. Containment activity for the parts at LTVS, at the supplier end
in transit
b. Short term / temporary countermeasure with time line
c. Method of segregation or sorting
d. Identification after segregation or sorting
and
Permanent counter measures (8D report) by

Supplier through RASIS within 7 days
Revisit the analysis and

counter measure
Not effective
Validation of
8D report &
Incoming
supplies by
LTVS SQ
Effective
SPQR Closed in RASIS
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Handling of rejections at LTVS & field complaints

Objective: To specify the method for handling of rejections at LTVS & field complaints
Viewing the RASIS on a daily basis
Containment actions
Corrective action / Submission of 8D reports and closure of
SPQR in the RASIS
within 7 days
Inputs :
Type of rejections , Quantity involved , Production batch codes / Traceability
Process capability status
Problem solving skills
Description :
1.
In case LTVS determines the supplied part is non- conforming, the suppliers are notified
through Supplier Problem Quality Report (SPQR) on the web (RASIS). The supplier shall
ensure corrective actions on receipt of flash report and communicate the causes of failure.
2.
Flash reports issued for non-conformance shall be replied within 24 hours through E-Mail,
Fax, courier, or in person
3.
After mutual agreement on non-conformance, parts will be moved to rejection stores. Then
the parts will be sent back to the supplier.
4.
As an immediate measure supplier shall indicate the following:

a. Containment activity for the parts at LTVS, at the supplier end and in transit
b. Short term / temporary countermeasure with time line
c. Method of segregation or sorting
d. Identification after segregation or sorting.
5.
For all the rejections, the supplier shall submit a long-term action plan within 7 days after
receiving the SPQR. It should contain:
6.
a.
Systematic problem analysis through 8D methodology available in RASIS
b.
Time-bound action plan for implementing the countermeasure
Short-term measures shall be continued until the permanent countermeasures are found
effective at Supplier end.
7.
Improved lot shall be separately identified and submitted with prior information to LTVS.
8.
Every action plan to ensure problem does not repeat.
9.
The supplier shall monitor and track quality performance of individual components and
take actions towards continuous improvement.
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16. SUPPLIER PERFORMANCE

QCDS RATING
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16. Supplier performance QCDS Rating

Objective : To describe the procedure for monitoring the supplier performance and give
feedback for improvement.
Review the QCDS rating

Ensuring corrective action for low QCDS rating as required
Inputs :
Quality Status RSN, DRSN , SPQR

Cost reduction details
Delivery performance
QMS certification status
Timely Response
Description :
QCDS Rating System :
QCDS rating is a composite rating of Quality, Cost, Delivery and Service of the Supplier for the
month.
QCDS Rating system covers all preferred suppliers supplying components, sub-assemblies & raw
materials to Lucas-TVS - Padi and Puducherry plants. (except imports, Consumables, Packing
materials). QCDS rating shall be communicated to the supplier through RASIS on monthly basis.
As per the rating, the Suppliers may be any one of the following categories.
QCDS Rating %
Remarks
91 up to 100%
Excellent
81 up to 90%
Good
71 up to 80%
To be improved
Below 70%
Poor
QCDS Rating Calculation Methodology :

QCDS rating = (0.4 x Quality Rating) +
(0.25 x Delivery Rating) +
(0.20 x Cost Rating) +
(0.15 x Service Rating)
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Quality Rating :
Cost Rating :
Cost Rating = 70% of Relative price as compared to other suppliers +
30% of Value Focus Based on YOY Cost Reduction.
a. Relative Price As Compared to Other Suppliers:

If the supplier is single source for the part, then rating will be 100 points
If the item is multi source item, then 100 points for lowest cost supplier
For other supplier the rating will be Calculated as = (Lowest price of the part / Price of the
Supplier) * 100
Overall relative price rating will be the average of relative prices of all the parts
b. Value Focus Based on Year on Year Cost Reduction:

Cost Reduction %
(Last Year Weighted Average Price -Year to date Weighted
Average Price)
Chapter 16
Last Year Weighted Average Price
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Cost Reduction %
Points
> 3%
100
2 to upto 3 %
60
1 to upto 2%
40
0 to upto 1%
20
Delivery Rating :
Quantity Supplied against the DI on DI date
Schedule Adherence of each DI by supplier =
Total Quantity of DI on the DI date

Overall Schedule adherence rating of a supplier will be the average of adherence percentage of
all DIs raised for the month.
Service Rating :
Parameter
Weightage Calculation Methodology
1.Quality Management System
10
ISO/TS 16949:2002 Certified

ISO 9001:2000 Certified
No QMS Certification
- 10
-5
-0
2. Environmental Management
System
ISO 14001:2004 Certified

No EMS Certification
-5
-0
3. NCR / Observations Closure
10
Closing the NCR in 7 Days

else
- 10
- 0
4. 100 PPM / SQ Mark Launch
Launched
No Launch
- 5
- 0
5. 100 PPM / SQ Mark

Certification
Certified
NO Certification
-5
-0
6. 100 PPM / SQ Mark

Certification Maintenance
Sustenance
No Sustenance
-5
-0
7. Use of IT
(Computerized Invoice, Bar
code, RASIS Usage ASN)
Use of IT
No use of IT
-5
-0
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Service Rating contd :
8. Cp, Cpk / Inspection Report
Cp, Cpk / Inspection Report submission - 5

No submission
-0
9. SPQR timely closure
Less than 7 days

More than 7 days else
-5
-0
10. Technology and infrastructure

upgradation
Upgradation
No upgradation
-5
-0
11. Right first acceptance of

samples
First acceptance
Second acceptance
Third acceptance
12. Premium fright because of

Supplier
Input from PU Purchase
Input from NPIT / Engg / PU - Purchase
Input from PU Purchase
Input from PU Purchase and Supplier

Development .
16. Inspection facilities

Development
17. Deficiency / Discrepancy in

compliance to backlog / over
shipment / Material
discrepancy (Qty) / Packing &
labeling and communication
10

Development
-5
-2
-0
13. Early involvement in New
Product development
14 Containerization (Supplies
using Re-usable containers)
15. Uniqueness and support to
LESA
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17. IMPLEMENTATION OF
CHANGES
Chapter 17
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17. Implementation of changes

Change initiated by LTVS
Engineering
Change initiated by supplier
Design change
- Sub-supplier, Raw material, Die

- Process, man , machine, method
- Location , Technology , layout etc..
Process change
Design or
process change?
Send the request (Ref Annexure-26) to

LTVS purchase for supplier proposed
change
Send the supplier process change request

(Refer Annexure - 26) to LTVS Purchase
Review of Process change by LTVS Supplier

Quality
Release the revised drawing to suppliers
No
Feasibility review by LTVS Engineering
Review the design change and send SPCR

(Annexure - 26) for LTVS proposed
changes
Is the change
approved?
Send the "NOT APPROVED"
SPCR to supplier
Yes
Prepare time bound action plan for change

implementation
Send the "APPROVED" SPCR to supplier
Submit PAP documents and Parts

Submission Warrant (PSW) to
Lucas - TVS
Submit PAP documents and Parts

Submission Warrant (PSW) to
Lucas - TVS
Obtain approval in the Parts Submission

Warrant (PSW)
Obtain approval in the Parts Submission

Warrant (PSW)
Implement the change as per agreed date
Implement the change as per agreed date
Maintain records of design changes
Maintain records of process changes
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Implementation of changes :Objective: To specify the procedure for implementation of design and process changes.
Timely implementation of design or process changes only after approval from Lucas-TVS in
writing.
Inputs :
Revised Drawings
Issue / Revision level
Details of design changes or process changes such as Sub-supplier, raw material, die, process,
man , machine, method , location , Technology , layout etc..
Required date of implementation and Stock status of materials
Description :
Supplier shall
1. Send the Supplier Process Change Request ( Refer Annexure 26 ) for proposed design or
process changes to Lucas-TVS purchase .
2. Review the following details before proposing the design or process changes.
a. Manufacturability of change
b. Effect on Capacity
c. Tool development / modification lead-time.
d. Associated cost effect with the detailed break up
e. Investment details for addition of facility, if any.
f.
Tool and gauge modification / new tool development charges with break up
3. Obtain approval in the Supplier Process Change Request ( SPCR- Ref.Annexure-26) for the
design or process changes
4. Prepare time bound action plan for implementation of design or process changes .
5. Compare the results of Process capability , Dimensional , Material , Straight Through Ratio / First
Time Through Ratio (FTTR) before and after the change during trials / implementation .
6. Submit PAP documents and Parts Submission Warrant ( PSW ) to Lucas-TVS purchase .
7. Obtain approval from Lucas-TVS in Parts Submission Warrant (PSW).
8. Finalise implementation date jointly with Lucas-TVS, once the PSW approval is obtained. Ensure
sufficient stock levels are built up for smooth change over.
9. Implement the design or process changes only after approval from Lucas-TVS and maintain
records of changes
NOTE: No tools and gauges can be scrapped / modified without written consent of LTVS.
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18. CONTROL OF LTVS SUPPLIED

TOOLS / EQUIPMENTS
Chapter 18
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18. Control of LTVS Supplied tools / equipment
Identify the Lucas TVS owned tools

and guage as "Property of Lucas-TVS " . Eg PDC
Dies, Month Tools, Inspection Equipments
Maintain master list of Tools / Equipments owned
Maintain history cards for all dies and press tools

Practice tool Management system
Practice tool Management system
Obtain approval for any Die changes from
Lucas-TVS
Submit report on Tool history / life of Lucas TVS

on request
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Control of LTVS Supplied tools / equipment

Objective: To specify the procedure for control / maintenance of LTVS supplied tools /
equipment
Identification of Lucas-TVS owned Tools / Gauges
Maintenance of Master lists
Maintenance of Tools history cards
Preventive maintenance of Tools
Inputs :
Tools / Equipment supplied by Lucas-TVS
Tools life
Description :
1. Maintain master list of all items supplied by LTVS. Ex: press tools, PDC dies, plastic
moulds, machine tools, inspection equipment / instruments / Gauges
2. Maintain history card for all dies and press tools
3. Define and practice preventive maintenance schedule to achieve intended tool life and
part quality requirements.
4. Obtain approval for any Die changes from Lucas-TVS.
5. Submit copy of history card / report on usage condition, on request.
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19. SUB SUPPLIER

MANAGEMENT
Chapter 19
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19. Sub - Supplier Management

Approved
drawing
Make - Buy
decision
LTVS approved
suppliers
Line failure / field failures

attributed to sub supplier
Existing sub supplier

with proven quality and
delivery
Identification of sub
suppliers
Final LTVS approved

sub supplier list
Decision on degree of
control
CFT Feed back
Current experience of
quality with sub suppliers
Dimensional
Controls
Material / treatment
controls
Performance
Controls
Special processes
Controls
Poka Yoke
Test certificate for

each lot
Type approval
Process & operator

qualification
Corrective
actiion
Sub supplier control plan, operation

standard and inspection standard
Corrective
actiion
Evaluation of sub supplier quality (Incoming

+ line rejection)
Periodic Sub suppliers audit by suppliers
Monitor Quality performance of Sub Suppliers
Root cause
analysis
Yes
No
Sub
supplier
PPM < 100
Recognise the sub suppliers
Maintain records of Quality Performance of Sub Suppliers
No
Any Changes of
Sub Suppliers?
Yes
Obtain approval from Lucas TVS
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Sub - Supplier Management

Objective:
To provide minimum requirements / guidelines for managing Sub-suppliers.
Identification of reliable Sub-Suppliers capable of meeting Lucas-TVS requirements in terms
of Quality , Cost , Delivery and Service
Periodic audit of Sub-Suppliers
Monitoring Quality and Delivery performance of Sub-Suppliers
Obtaining approval for any changes of Sub-Suppliers
Inputs :
Delivery requirements
Capability of Sub-Suppliers
Performance of Sub-Suppliers
Description :
Supplier shall
1. Maintain master list of all sub-suppliers with clear details of the operations carried out and
provide a copy to LTVS along with PPAP.
2. Inform and obtain the approval for any change of sub- supplier from LTVS.
3. Inform and obtain the approval for any change of operations at the sub-supplier end.
4. Carry out special processes like heat treatment, plating, painting, powder coating etc only at
the mutually approved sources.
5. Ensure sub-suppliers procure raw materials only from mutually agreed sources.
6. Monitor and improve QCDS performance of all sub-suppliers
7. Deploy supplier best practices to sub-supplier on periodic basis.
8. Maintain the data on production capacity for the parts supplied by sub-suppliers.
9. Encourage QMS certification (minimum of ISO 9001:2008) for sub-suppliers.
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20. SUPPLIER QMS

REQUIREMENTS
Chapter 20
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20. Supplier QMS requirements

Supplier shall demonstrate the ability to establish, document, and implement an effective
quality system that comprises all applicable elements of ISO/TS16949: 2009 or its latest
version. Supplier shall ensure that quality policy is thoroughly distributed, understood,
maintained and that adequate levels of authority have been established to ensure continual
improvement of quality system.
LTVS expects its suppliers to get themselves not only to get accredited with ISO/TS 16949
immediately but also keep such accreditation valid at all times and constantly upgrading
themselves in line with the revisions to standard in order to maintain continuity of QMS.
Suppliers who do not meet this requirement should immediately forward detailed action plan
to fall inline with this requirement.
Supplier shall update certification status to LTVS during the renewal of the certificate and
during the upgradation of the certificate by forwarding the copy of the same.
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21. SUPPLIER EHSMS

REQUIREMENTS
Chapter 21
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21. Supplier EHSMS requirements
Supplier shall demonstrate the ability to establish, document, and implement an effective
Environment, Health & Safety Management System (EHSMS) that comprises all applicable
elements of ISO 14001 & OSHAS 18001 or its latest versions. Supplier shall ensure that EHS
policy is thoroughly distributed, understood, maintained and that adequate levels of authority
have been established to ensure continual improvement of EHSMS system.
Supplier shall update EHSMS certification status to Lucas-TVS during the renewal of the
certificate and during the upgradation of the certificate by forwarding the copy of the same.
Chapter 21
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22. SUPPLIER AUDITS
Chapter 22
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22. Supplier Audits
Audits conducted by LTVS

on the Suppliers
Quality Management
Systems Audit
Manufacturing process audit
Periodical Audit
Unscheduled Audit
Annual audit plan by LTVS
Performing audit in case of

1. Serious Quality abnormality
2. Unacceptable quality performance
3. Major changes in manufacturing
process
4. After submission of sample parts
Performing audit by LTVS

Raise non - conformities / observation for
improvement
Submit the corrective action plan / Improvement
action plan ( By Suppliers )
Countermeasure effectiveness check by LTVS
Counterme
asure
effective?
No
Yes
Close the Audit Report
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Supplier Audits
Objective: To describe the procedure to carryout audits at Suppliers for improvement.
Adequate support to carryout audits at Suppliers premises
Review of Non-conformities / Observations
Timely corrective action / Improvement actions
Inputs :
Annual audit plan of Lucas-TVS
Serious Quality issues
Unacceptable Quality performance
Major changes in Manufacturing processes.
Description :
1. Lucas-TVS will carry out formal System audit on Quality Management Systems requirements as
per audit checklist (Annexure: 13) and audit frequency may be once a year or more depending
on how the supplier meets QCD performance targets.
2. In case of any major quality problem reported on supplies, Lucas-TVS shall decide to carryout
detailed audit on the manufacturing process on immediate basis as per the audit check sheet
(Annexure: 14).
3. Lucas-TVS will communicate the non-conformities, areas of concerns that require improvement.
4. Supplier shall forward time bound action plan for closure of non-conformities.
5. Countermeasures will be verified during subsequent audit for effectiveness and cleared if found
effective. Otherwise returned to supplier for further improvements.
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23. TRAINING AND UP-GRADATION

OF OPERATORS SKILLS
Chapter 23
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23. Training and Up-gradation of Operators Skills

Master list of
Operators
Required Skill
level
Skill Assessment for

operators
Skill Matrix for all

operators
Annual training plan for

all operators
Conduct the training

Program
Verify the
training effectiveness
Not Effective
Chapter 23
Effective
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Training and Up-gradation of Operators Skills

Objective: The purpose is to ensure skilled manpower availability for each process stage.
Evaluation of current skills of operators.
Up gradation of skills through structured classroom and on the job training.
Multi skilling for operators.
Maintenance of skill matrix
Inputs :
Selection method of operators
Evaluation method of Operators
Description :
Operator skill level should be identified through an evaluation process that includes reference to
his understanding of the process and his ability to produce good parts. Skill level of each
operator shall be ranked on a 4 level scale.
1.Job Performance Skills: Capability to perform the assigned job in line with customer's
requirements.
2.Technical Skill: Understanding and controlling the technical and technological aspect of the
processes, behavior and performance aspect of machines and tool used and their failure modes.
3.Skill Levels:
Level 1: Requires guidance always ( Can be engaged under the close
supervision ) ; Level 2: Requires guidance occasionally ; Level 3: Can work independently

without any supervision; Level 4: Expert in operation and can train other operators on that
operation.
Skill Matrix to be maintained for all Operators.
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24. RECORDS AND RETENTION

PERIODS
Chapter 24
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24. Records and retention periods

Below table gives the details of minimum retention period for various types of records and such
records should be made available to Lucas-TVS for verification on request. Supplier shall return
the old drawings to Lucas-TVS after receiving the latest drawings.
S.no
Type of Record
Minimum retention
Example
period
Inspection standards, Inspection reports,

Tooling maintenance reports, Control
Quality System
records
chart, Material test reports, Performance

test reports, Calibration records, Machine
3 Years
capability study reports, Audit reports,

Flash reports, Action plans, Kaizens, QC
Story
Drawings, PPAP
For the life of the
documents and
products + 1 Year
master samples
Purchase /
transaction
records
Chapter 24
Purchase
orders
and
amendments, For the life of the
quotations, purchase orders for tooling
products + 1 Year
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25. TRACEABILITY
Chapter 25
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25. Traceability
Traceability refers to the completeness of the information about every step in a process chain.
Traceability is ability to chronologically interrelate the uniquely identifiable entities in a way that is
verifiable. It is the ability to verify the history, location, or application of an item by means of
documented recorded identification.
Traceability is closely linked with Product identification. Traceability is related to the origin of
Materials and Parts, the Product processing / manufacturing history and the distribution and
location of the product after delivery. Concept of Traceability has been linked to parts identification
recall procedure.
How does the identification help to ensure Traceability ?
Automotive Products / Components require individual piece traceability as per Customer

requirements with identification
Identification ensures that each Part / Product

- is the corrective type
- has passed all tests
- can be traceable back to specific lots and or inspections
- has a complete historical process data
Why Traceability ?
Ensures fast Product Recall
To limit damages to your reputation
Customer Specific Requirement
Safeguard the Company from huge penalty payments
Legal requirements in some countries
Reduces the effect of Product liabilities issues
Chapter 25
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Factors deciding Traceability requirements:
Product liabilities laws applicable in the market place
Country of exports and Customers
Regulatory Requirements
Types of Traceability
1. Forward or Down Stream Traceability:
Ability to locate defective or suspected defective products in all stages of Product life
Subsequent to the stage in which defect was discovered with the aim to repair or
replace such products.
2. Backward or Upstream Traceability:
Ability to find out the History of a defective product in various stages of product life cycle
previous to the stage of discovery of defect with the aim to investigate the causes of
occurrence and to take countermeasures to improve process / Systems
What is the Customer Requirement?
Supplier shall ensure that the products supplied can be traced back in the
manufacturing process, item by item and by their manufacturing date & shift, in order to
define the Quantity of items and period affected by the non- conformity / defect and
facilitate therefore the identification and isolation of non- conformed /defective products
As soon as Supplier identifies a problem associated with Quality, logistic or delivery schedule,
Supplier shall inform Customer and disclose all relevant information to ensure a quick solution
which shall be agreed by both parties
Scope of Lucas- TVS Traceability Standard:
Chapter 25
Finished Products
Sub- Assemblies
Components
Raw Materials
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Traceability Implementation Flow Chart
Establish a Traceability System with ability to trace

Parts from raw Materials to Finished Products
Keep records of Components used from Suppliers
Keep records of which Customers you have

Supplied
Link records to test Results
Inform Customer In case of serious issues /

problems
Identify all semi- finished and finished parts

appropriately to ensure traceability
Work within a Preventive & Integrated QMS
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Traceability Chain :
Sub- Suppliers
(Identification & TSR)
Suppliers
(Identification & TSR)
Mfg & Testing

(Identification & Insp)
Receiving Inspection
(Verification of TSR)
Materials stores
(Identification & FIFO)
Final assy & Testing

(Identification & Insp)
Despatch
(Despatch records)
Start
End
* TSR Traceability System Requirement
Lucas- TVS Traceability System :

21 - 08 - 06 - 01
Shift
Day
Year
International Week no.
Example :
WW - YY - DD - SS
Shift
Day
Year
International Week no.
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Traceability Record requirements:

Part Name & No.
Date , Week code , Day code , Shift code
Product & Process characteristics as per Control plan / QCPC
Qty Produced
Qty Rejected
Rejection and Rework details
Concession if any
Operator code as applicable
Raw Materials / Input Materials Batch reference
Change History
Shift wise Built / Traceability Record
Actions by Suppliers for Traceability:

1. Training to Operators / Supervisors on Traceability
2. Implement the Traceability System at Stores
3. Implement the Traceability System at Mfg & Assy
4. Maintain Inspection Record for Process , Product, Rejections, Rework etc..
5. Create Build record / Traceability record
6. Indicate the Traceability codes in the Delivery challan
7. Ensure retention period of Records - 3 Years for inspection Records and 10 Years for
SCs/ CCs/ SPC Data.
Traceability code / Lot code / Batch code marking requirements:

Batch code shall be marked / Stamped by Suppliers
At a Location where it is easily visible
It should not affect function of the part
It should be legible
Should be linked with Inspection Records (Process / Product)
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Traceability Vs Manufacturing History :
The Traceability coding method and System of keeping records shall be such a way that
it should be possible to know the minimum following from a Traceability code.
Size of the lot (Quantity Produced in the Lot)
Operating Conditions (Process parameters / Setting Conditions)
Inspection Results
Dates on which the lot was supplied to Lucas- TVS
Key Requirements for Traceability

FIFO (First In- First- Out)
Good Identification System of Parts
Inspection Status (Accepted, Rejected, Awaiting Inspection, Under Rework)
Traceability in all stages from raw material receipt up to finished products
Inspection Records
Traceability of changes:
Suppliers must keep the records in case of following changes

Materials change
Design change
Process change / Machine change
Sub- Vendor change
Concession
Part indigenization
Operators Change
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26.
Chapter 26
Lucas-TVS
- CHARTS
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- Charts
Determine the characteristics to be monitored
No
Are the data

attribute type
(G / NG)?
Refer control
charts for
Variable
characteristics
Yes
No
Is the sample
size is variable?
Use np chart
Yes
Decide to use P chart
Train / Provide knowledge on chart to

operating personnel
Decide the area of application to use chart

E.g. Assembly operations where 100%
inspection is carried out
Plot chart as per the guidelines given in

this manual ( Chapter 30.f )
Take corrective actions for out of Control

situations
Monitor the assembly / process using
chart
Maintain records of Charts
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- Charts
Objective: To monitor Assembly Operations having attribute characteristics ( G / NG ) .
Decide the area of application of P - charts.
Training on P-charts to the operating personnel
Establishing and monitoring the P- charts
Inputs:
Control plans
Inspection Standards
Checking aids
Assembly process with high rejections (Attribute characteristics G / NG)
Description:
- Charts are used when the Quality Characteristics is represented by the number of defective
units or fraction defective when sample of varying size. Suppliers shall decide the area of
application to use the
- chart Eg. Assembly Operations where 100% inspection is carried out
for the attribute characteristics ( G / NG ) and include in the Control plan/ QCPC.
- Charts are
plotted as per the Guidelines given in this Manual. Out of control situations are
identified in the
-chart and corrective actions are taken for the assignable causes resulting out
of controls conditions. ( Refer Section 31.C ).
Assembly Process shall be monitored by Suppliers using Charts and records are maintained.
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27. VALUE ENGINEERING

AND INNOVATION
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27. Value Engineering & Innovation
Long term goal setting
Identify value engineering and

innovation opportunities
Strategic direction &

change management in
place
`
Knowledge of new
technologies
Motivated &
empowered team
Emerging
customers /
Low cost differentiated

product by way of
1. Improved attributes
2. New attributes
3. Environment friendly
attributes
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Value Engineering & Innovation

Objective: To promote the use of value engineering and innovations to achieve breakthrough
improvement in quality and reduction in cost through improved design, material, processes and
technology.
Supplier management is responsible to:
Measure performance through savings made through value engineering and innovations.
Encourage creativity within the company to implement breakthrough improvements.
Establish stretched targets for product and business performance improvements.
Value Engineering:
Suppliers shall establish structure of evaluating each elements of cost that constitutes the
total cost of the part (E.g. material, labor, cost of quality, consumables, power etc.).
Set annual cost reduction targets and apportion the target value to each element of cost.
Assign lead responsibility and appropriate cross-functional team to work towards value
engineering.
Team to focus and identify value adding activities and non value adding activities
throughout value stream and develop ideas to eliminate or compress non value activities
with technical limits as benchmark and implement them.
Innovation:
Based on specialist knowledge, learning from emerging technology in competitive and

non-competitive fields supplier management should promote innovative improvements,
like:
1. Change in material
2. Combining many components into one component to improve reliability and reduce
cost
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3. Combining many parts into one module

4. Developing maintenance free product for a life cycle
5. 100% recycling
6. Zero discharge factories
7. Performance mapping with competitive product and provide higher reliability cost
8. Introduction of new technology to get quantum jump in terms of quality, quantity
and cost.
Collaborate with research institutions and customers to identify opportunities for

innovation.
Provide best resources to give innovative idea a concrete shape.
Conduct cost benefits analysis of such efforts and recognize to motivate similar activities
at an accelerated pace in the organization over time.
Chapter 27
Create an environment that supports and promotes innovation.
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28. SHOP FLOOR CONTROLS
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28.Shop Floor Controls

1) 3C
2) 5S.
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3) SOP
4 ) QCPC / Control plan
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5) Inspection & Testing
6) Tool Management
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7) Poka Yoke
8) Instrument / gauge control
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9) Visual Control
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29. KANBAN
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29. Kanban
Kanban (kahn-bahn) is a Japanese word that when translated literally means visible record or visible
part. In general context, it refers to a signal of some kind. Thus, in the manufacturing environment,
kanbans are signals used to replenish the inventory of items used repetitively within a facility. The
kanban system is based on a customer of a part pulling the part from the supplier of that part. The
customer of the part can be an actual consumer of a finished product (external) or the production
personnel at the succeeding station in a manufacturing facility (internal). Likewise, the supplier could be
the person at the preceding station in a manufacturing facility. The premise of kanban is that material will
not be produced or moved until a customer sends the signal to do so.
The typical kanban signal is an empty container designed to hold a standard quantity of material or parts.
When the container is empty, the customer sends it back to the supplier. The container has attached to it
instructions for refilling the container such as the part number, description, quantity, customer, supplier,
and purchase or work order number.
Some other common forms of kanban signals are supplier
replaceable cards for cardboard boxed designed to hold a standard quantity, standard container
enclosed by a painting of the outline of the container on the floor, and color coded striped golf balls sent
via pneumatic tubes from station to station.
Kanbans serve many purposes. They act as communication devices from the point of use to the previous
operation and as visual communication tools. They act as purchase orders for your suppliers and work
orders for the production departments, thereby eliminating much of the paperwork that would otherwise be
required. In addition, kanbans reinforce other manufacturing objectives such as increasing responsibility of
the machine operator and allowing for proactive action on quality defects. However, kanbans should not
be used when lot production or safety stock is required because the kanban system will not account for
these requirements.
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Push vs. Pull System:
The kanban system described is a pull system. Traditionally, a push system is and has been employed.
The push system is also more commonly known as the Materials Requirements Planning (MRP) system.
This system is based on the Planning Department setting up a long-term production schedule which is
then dissected to give a detailed schedule for making or buying parts. This detailed schedule then
pushes the production people to make a part and push it forward to the next station.
The major
weakness of this system is that it relies on guessing the future customer demand to develop the schedule
that production is based on and guessing the time it takes to produce each part. Over-estimation and
under-estimation may lead to excess inventory or part shortages, respectively.
One of the major reasons kanbans are used is to eliminate or reduce the above mentioned wastes
throughout an organization due to the pull system that is employed.
Waste can come from over-
production (inventory) and therefore, the need for a stockroom. This waste is eliminated. Part shortages
(under-production) are also eliminated. Costs are reduced by eliminating the need for many of the
purchasing personnel and the paperwork associated with purchasing.
The planning departments
workload is also reduced as they no longer need to produce work orders.
Types of Kanban :
1. Dual-Card Kanban :
This kanban system is more commonly referred to as the Toyota kanban system as Toyota was the first
to employ this system in full scale use. It is a more useful kanban technique in large-scale, high variety
manufacturing facilities. In this system, each part has its own special container designed to hold a
precise quantity of that part. Two cards are used: the production kanban which serves the supplier
workstation and the conveyance kanban, which serves the customer workstation. Each container cycles
from the supplier workstation to its stockpoint to the customer workstation and its stockpoint, and back
while one kanban is exchanged for another. No parts are produced unless a P-kanban authorizes it.
There is only one C-kanban and one P-kanban for each container and each container holds a standard
quantity (no more, no less).
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2. Single-Card Kanban :
The single-card kanban system is a more convenient system for manufacturing facilities requiring less
variety in their parts. Essentially, the single-card kanban system is simply a dual-card kanban system
with the absence of the production kanban and designated stock points. This system is demonstrated
using the following diagram.
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SQA Manual

SUPPLIER QUALITY ASSURANCE

Revision : 0, Date 23.04.2011

Supplier Quality Assurance

Environmental, Health And Safety Policy

2. Supplier selection and approval process

3. New part development process

4. Development of PFD, PFMEA, Control Plan and Operational Standards

5. Validation of Production aids

7. Measurement system analysis

9. Management of Limit samples

10. Product approval process

11. Purchasing system

12. Scheduling system

13. Guidelines for container selection

14. Incoming inspection control at LTVS

15. Handling of rejections at LTVS & field complaints

16. Supplier performance QCDS Rating

17. Implementation of changes

18. Control of LTVS supplied tools / equipment

19. Sub-supplier management

20. Supplier QMS requirements

21. Supplier EHSMS requirements

22. Supplier audits

23. Training and up-gradation of Operators skills

24. Records and retention periods

Revision : 0, Date 23.04.2011

Supplier Quality Assurance

28. Shop Floor Controls

b. Measurement System Analysis

c. Process Capability Study

d. Procedure for calculating Process Capability

f. Procedure for plotting P- Chart

g. X-bar R Control Chart

h. Target Area Control ( TAC ) chart

Total Quality Management

Total Productive Management

Lucas TVS Electrical Suppliers Association (LESA)

Revision : 0, Date 23.04.2011

Supplier Quality Assurance

Make the organisation process centric.

Chief Executive Officer

Revision : 0, Date 23.04.2011

Supplier Quality Assurance

Achieving OE Customer line rejections less than 10 PPM

begins with a comprehensive understanding of changing customer needs

Practice quality individually and as team

Revision : 0, Date 23.04.2011

Supplier Quality Assurance

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Supplier Quality Assurance

Revision : 0, Date 23.04.2011

Supplier Quality Assurance

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Supplier Quality Assurance

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Supplier Quality Assurance

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Supplier Quality Assurance

1.3 Supplier Quality Assurance flow chart

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Supplier Quality Assurance