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

7/21/2019 Lucas-TVS-SQA Manual PART A 23.04.2011final new 1

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Revision : 0, Date 23.04.2011 Page 1

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Supplier Quality AssuranceLucas-TVS

Lucas - TVS

SUPPLIER QUALITY ASSURANCE

Lucas-TVS

Lucas-TVS Ltd

Alignment

Advancement

Appreciation

ActionAwareness

Partner Perform Progress


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ContentsPage.No

Foreword 4

Quality policy 5

Environmental, Health And Safety Policy 6

Part - A

1. Introduction 9

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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Page.No

27. Value Engineering and Innovation 12028. 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 174d. 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. Lucas TVS Electrical Suppliers Association (LESA) 230

31. Annexure 233


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Foreword

Today we are witnessing in the MARKET PLACE a changed environment of unprecedentedcomplexity. Customers demand the best in the market at competitive prices with ANY TIMEAVAILABILITY and LIFE TIME RELIABILITY. This throws up enormous challenges to organisationand a race with accelerating pace and we find a very thin line differentiating the WINNER and theLOSER. The critical success factors are - QUALITY which is non-negotiable, COST, DELIVERYcoupled 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 ANDFASTEST, that means the organisation has to shift the focus to HIGH PERFORMANCE mode fromtraditional 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 todayscompetitive 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 leadershipposition and be competitive in business place:

Make the organisation process centric.

Continuously upgrade technology both in Lucas-TVS and with the suppliers in meeting thegrowing 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 tonecessarily align and partner our supplier fraternity with us to enable them to perform better resulting inmutual 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 thecompany.

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 intoreality 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 PHILOSOPHYPOLICY

We are committed to achieving ever increasing levels of Customer satisfaction throughcontinual improvements to the Quality of our Products and Services by adopting andcontinually improving an effective Quality Management System.

It will be our endeavor to increase Customer trust and confidence in the labelMade 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 begins with a comprehensive understanding of changing customer needs

Quality means providing value to customer in the use of our products and services Quality is built into the design of products, processes and materials

Quality improvements lead to productivity and cost improvements

Quality Means preventing defects and not detecting them only after occurrence Quality demands commitment by all employees, suppliers and dealers

Quality is achieved through total employee involvement and training

Quality cycle begins again with a comprehensive understanding of customer satisfactionlevels

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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Chapter 1 Revision : 0, Date 23.04.2011 Page 9

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1. INTRODUCTION


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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.

1.2Scope

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 )


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1.3 Supplier Quality Assurance flow chart


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2. SUPLLIER SELECTION AND

APPROVAL PROCESS


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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

Corrective action report by the Supplier

Approve the supplier

Audit

Score ?Restricted

Approval

Reject the

Supplier70 ~ 79 %

Above 80 %

Below 70 %

Re audit the

Supplier


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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.


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3. NEW PART DEVELOPMENT

PROCESS


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Concept & Approval

Prototype Samples

Tooled Up Samples

Product Approval Process(PAP)

Mass Production

Phase I

Phase II

Phase III

Phase IV

EarlySupplierInvolvement

Productdesign&development

Processdesig

n&development

Product&Process

validation

Feedback&CorrectiveAction

Phas

eV

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.


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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 PhaseSupplier shall perform the following:

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 thesubmission 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.


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Supplier shall perform the following:

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.


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4. DEVELOPMENT OF PFD,PFMEA, CONTROL PLAN &

OPERATION STANDARDS


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Preliminary process

flow chart

Approved

Drawing

PFD

PFMEA

Decide the recommended actions based on

high severity, occurrence & detection

Poka YokeProcess

Improvements

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

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


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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.


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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.


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5. VALIDATION OFPRODUCTION AIDS

(TOOLS AND GAUGES)


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No

Yes

No

Yes

No

Yes

PartDrawing

Preliminary processflow chart

CFT discussioninputs

ControlPlan

List of Tools

Tool Design

Tool manufacturing

Tool try out - soft

Tool

approval

Hard Tool

Tool trial

Hard Tool

approval

Periodic Tool

Management

Maintain ToolManagement /

History cards

List of checking aids (Gauges)

Checking aids (Gauges) Design

Checking aids (Gauges) manufacturing

Calibration

Attribute guage R&R

(as per MSA manual of AIAG)

Approval

Rework or redesign /

Training to operators

Calibration

status and

periodic

calibration

Soft tool fine tuning

Hard tool fine tuning

5. Validations of Production Aids (Tools & Gauges)


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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 points3. 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 suitablemodification 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


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6. Calibration System

Control

Plan

Identification of measuring

equipment needed

following 1/10 rule for

resolution

Current inventory of

measuring equipment

Procurement of

needed measuring

equipment

Master list of measuring equipment

Identification

of users

Training for

use &

handling

External calibration

for masters &

instruments

Identification of

accredited lab and

calibration of referenceand instruments

Calibration records

In-house calibration

Calibration procedure

Calibrated masters

Calibration of

measuring equipment

CalibrationStatus

Investigate for suspect

parts shipment and

escalate

Recall for periodic calibration

or incase of mishandling

(Dropped) or doubt by operator

Use of measuring

equipment

OKNot OK


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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 ofproduct 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 measuringinstruments 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)


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7. Measurement System Analysis (MSA)

Inventory of

checking aids

Control PlanInventory of measuring

devices (Duly calibrated)

Instruments / checking aids

identification for MSA study

Special and/or Major

charecteristicsOperators &

inspectors

measuring Special

and/or Major

characteristicsSamplesfrom Pilot or

PPAP run

Samples for MSA

Conduct measurement system analysis and

calculate Guage R&R or Kappa value

(refer MSA manual of AIAG / Chapter 30.b)

Establish Measurement

method, train operators

and inspectors

GuageR&R &

Kappa

value

PPAP records forapproval

Analyze the

causes ofvariation

impove the

measurement

Carryout MSA studies for the identified

instruments / gauges atleast once in a year as

per the annual MSA plan

Acceptable

Not

Acceptable


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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 usingthe 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


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Calculate the Cpk every month

(Refer Guidelines)

Take corrective action

100% inspection till

Cpk > 1.67

Monitor Trends of Cpk and maintain

records

Submit monthly Cpk report to Lucas TVS

Is Cpk> 1.67

Monitor the process using X-RControl

Establishing X R ControlChart

NO

Control Plan / QCPC

Adhere to control method

as per CP/QCPC

Part Drawing

PFMEA

Ensure Gauge R&R % < 10%

Any specialCharacteristics

SC ?

8. Process Capability

YES

Yes

>

SQ

No


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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 LIMITSAMPLES


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Workstation Vs Limitsample matrix

Responsibility forproviding limit samples

Manufacture of limitsamples

Approval of limit samples

Registration of sampleslimit

Maintenance and periodic

replacement of limit samples

LTVS approvedlimit Samples

Inspection standards forincoming components

Sub supplier providedlimit samples

Control Plan

InspectionStandards

9. Management 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


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EvaluationStatus

Proceed for Massproduction

OK Not OK

OK

Evaluation of samples and SANdocuments by LTVS

Proceed for Pilot production

Take Corrective action

Resubmit samples to LTVSSubmit the Pilot lot

Take Correctiveactions

Not OK

Submit the samples along with childparts, raw material and SAN documentsto Lucas-TVS (Dimensional report,Material test Performance report,

AOI Part B, PSW )

EvaluationStatus

Submit PAPdocuments to

SQ

10. Product approval process


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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 productionrun 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 dimensionalrequirements.

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 enclosedformat 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


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Price finalisation with supplier

Release of Annual Purchase

Orders by LTVS

Amendments to Purchase Orders

(during any change)

RFQ to Supplier

Supplier Quotation

Zero Based Costing by LTVS

11. Purchasing System


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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


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Annual projection given to Suppliersduring Annual Suppliers Meet

Three months rolling projection throughRASIS

Daily / Weekly / Two bin Schedules toSupplier along with Delivery Instruction

(DI) number through RASIS

Delivery of materials to LTVS bySupplier against Delivery Instruction (DI)

number

Monthly plan through RASIS

12. Scheduling System


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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.inat 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


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Container shall be made as per theguide lines given in this manual

( Chapter 31.e )

Submit the sample container to LTVSalong Agreement of Inspection (AOI)

Part C

Evaluation

by LTVS ?

Start supplies in new container Carryout modifications andresubmit

SatisfactoryNotSatisfactory

Maintenance of Containers( Ensure cleanliness,

No damages & replenishment )

13. Guidelines for Container selection


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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.

Length (mm) Width (mm)Height(mm)

Max

Gap to be left from the

top (mm)

400 300 250 15

600 400 250 15

600 500 250 15

* 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 INSPECTIONCONTROL AT LTVS


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Inspection by LTVSSQ

Material moved to stores Material sent back to supplier

AcceptedRejected

Supplier shall submit inspection reports, process capability reports &

Material test report (as agreed) along with parts as per AOI

14. Incoming inspection control at LTVS :


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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

1 Supplier final inspection report With every lot

2 Process capability reports andperformance reports

With every lot

3 Material test reportsWith 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 REJECTIONAT LTVS & FIELD COMPLAINTS


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15. Handling of rejections at LTVS & field complaints

Not effective

Effective

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 andin transit

b. Short term / temporary countermeasure with time line

c. Method of segregation or sorting

d. Identification after segregation or sorting

Permanent counter measures (8D report) by

Supplier through RASIS within 7 days

Validation of

8D report &

Incoming

supplies by

LTVS SQ

SPQR Closed in RASIS

Revisit the analysis and

counter measure


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Handling of rejections at LTVS & field complaints

Objective:To specify the method for handling of rejections at LTVS & field complaints

Supplier responsibilities : 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. Thenthe 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:

a. Systematic problem analysis through 8D methodology available in RASIS

b. Time-bound action plan for implementing the countermeasure

6. 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 givefeedback for improvement.

Supplier responsibilities:

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) / Last Year Weighted Average Price


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Delivery Rating :

Quantity Supplied against the DI on DI dateSchedule 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 10ISO/TS 16949:2002 Certified - 10ISO 9001:2000 Certified - 5No QMS Certification - 0

2. Environmental ManagementSystem

5ISO 14001:2004 Certified - 5No EMS Certification - 0

3. NCR / Observations Closure 10Closing the NCR in 7 Days - 10

else - 0

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

5. 100 PPM / SQ MarkCertification

5Certified - 5NO Certification - 0

6. 100 PPM / SQ MarkCertification Maintenance

5Sustenance - 5No Sustenance - 0

7. Use of IT(Computerized Invoice, Bar

code, RASIS Usage ASN)5

Use of IT - 5No use of IT - 0

Cost Reduction % Points

> 3% 100

2 to upto 3 % 60

1 to upto 2% 40

0 to upto 1% 20


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Service Rating contd :

8. Cp, Cpk / Inspection Report 5Cp, Cpk / Inspection Report submission - 5No submission - 0

9. SPQR timely closure 5Less than 7 days - 5More than 7 days else - 0

10. Technology and infrastructureupgradation

5Upgradation - 5No upgradation - 0

11. Right first acceptance ofsamples

5First acceptance - 5Second acceptance - 2Third acceptance - 0

12. Premium fright because ofSupplier

5 Input from PU Purchase

13. Early involvement in NewProduct development 5 Input from NPIT / Engg / PU - Purchase

14 Containerization (Suppliesusing Re-usable containers)

5 Input from PU Purchase

15. Uniqueness and support toLESA

5Input from PU Purchase and SupplierDevelopment .

16. Inspection facilities 5Input from PU Purchase and Supplier

Development

17. Deficiency / Discrepancy incompliance to backlog / overshipment / Materialdiscrepancy (Qty) / Packing &labeling and communication

10Input from PU Purchase and SupplierDevelopment


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17. IMPLEMENTATION OFCHANGES


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17. Implementation of changes

Design change Process change

Change initiated by LTVS

Engineering

Change initiated by supplier

Design or

process change?

Send the request (Ref Annexure-26) to

LTVS purchase for supplier proposed

change

Feasibility review by LTVS Engineering

Release the revised drawing to suppliers

Review the design change and send SPCR

(Annexure - 26) for LTVS proposed

changes

Prepare time bound action plan for change

implementation

Submit PAP documents and Parts

Submission Warrant (PSW) to

Lucas - TVS

Obtain approval in the Parts Submission

Warrant (PSW)

Implement the change as per agreed date

Send the supplier process change request

(Refer Annexure - 26) to LTVS Purchase

- Sub-supplier, Raw material, Die

- Process, man , machine, method

- Location , Technology , layout etc..

Review of Process change by LTVS Supplier

Quality

Is the change

approved?

Yes

No

Send the "NOT APPROVED"

SPCR to supplier

Send the "APPROVED" SPCR to supplier

Submit PAP documents and Parts

Submission Warrant (PSW) to

Lucas - TVS

Obtain approval in the Parts Submission

Warrant (PSW)

Implement the change as per agreed date

Maintain records of process changesMaintain records of design changes


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Implementation of changes :-

Objective:To specify the procedure for implementation of design and process changes.

Supplier responsibilities :

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. Investm

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