Você está na página 1de 45

Quality Assurance Manual

PT. INDOMOBIL SUZUKI INTERNATIONAL

Table of Content
Introduction 3 1. Quality Assurance Manager ... 8 2. Preparation for Production . 10 3. New Process / Process Change . 12 4. Process Control standard 15 5. Inspection Standard 21 6. Inspection Result Sheet .. 27 7. Operation Standard . 29 8. Initial Parts Control 31 9. Initial Production Control ... 34 10. Lot Control 37 11. Disposition of Quality Problems .. 39 12. Maintenance of Inspection Machinery and tools .. 44 13. Quality Control Audit .. 46 14. Quality Control Education 48 15. Vendor Evaluation 49

Introduction
This Manual is a summary of the fundamental requirements for Quality Assurance activities that PT. Indomobil Suzuki International ( PT. ISI ) expects its vendors to fulfill under the supply / purchase agreement. PT. ISI has prepared this manual to assist vendors in reaching a good understanding of PT. ISIs basic policy and quality assurance activities. Vendors are required to deliver parts to PT. ISI in strict accordance with the PT. ISIs quality assurance requirements. To use this manual effectively, it is necessary that vendors understand PT. ISIs basic policy of Quality Assurance. Hereunder, you will find PT. ISIs basic quality requirements and definitions of terms which will help you carry out your quality control activities. Follow all items and quality control activities. 1. Basic Requirements The parts to be delivered to PT. ISI must meet any of the following : 1). The drawings, specifications, inspection standards, designated standards prepared and lent to vendors by PT. ISI or similar standards and data. 2). The drawings, specifications or documents and other data prepared by vendors and approved by PT. ISI or similar documents and data. 3). The officially specified standards such as JIS, JASO, and ISO which do not belong to the above items (1) and (2). 2. Definition of Terms : 1). A Parts .. those parts and components which are essential for the safe operation of vehicles under normal use, and if defective, could result in incidents of personal injury or fatality by causing loss of vehicle control or fire. 2). A Items those quality features of A parts that, if defective, could result in incidents of personal injury or fatality by causing loss of vehicle control or fire. 3). Functional Parts those parts and components of the engine and transmission that, if defective, could result in a reduction or total loss of vehicle motive power and performance. 4). Functional Items those quality features of functional parts that, if defective, could result in a reduction or total loss of vehicle motive power and performance. 5). General Parts . those parts and components not already designated as A Parts or Functional Parts. 3. Quality Control Activities Vendors are required to promote Quality control activities in accordance with total flow of the Quality Assurance System between Vendors and PT. ISI .

4. Submission of Data In order to promote quality control activities between vendors and PT. ISI, vendors are required to submit such data as requested in page 5, List of data to be submitted to PT. ISI. As to the details of each data, please refer to the text of this manual.

List of Documents Required by PT. ISI


A No. Item Part F Part G Part Submission Period Within one New 1 Quality Manager Assurance o o o month after purchase agreement Within Change o o o month change Before trial New o o mass production 2 Process Standard Control Change o o One before of parts week delivery Inspection Div. Submit the number copies requested in the of Inspection Div. one after Procurement Dept Submit the original Procurement Dept. Submitted to Remarks

distribution column plus one copy

for vendor. Before New 3 Inspection Standard o o o mass production One week Change o o o before delivery of parts Before Application for 4 Approval of New A Process / Process Change Change o New o mass production One month before the desired date of change Attach 5 Inspection sheet Products of Result Initial o o o On the delivery date designated by PT.ISI Designated delivery Place the products together with Initial Production Part Tag the to Procurement Div. trial Procurement Inspection Div. Submit the original trial Inspection Div. Submit the original

A No. Item Part

F Part

G Part

Submission Period Submitted to Remarks

Report 6 Inspection Sheet Result By 10


th

on

of the

Inspection Div.

the

items in

following month

specifie

Inspection o Standard

Investigation on Capability

Report Process o o -

By

the

date by Inspection Div.

designated

Inspection Div.

1. Quality Assurance Manager


Vendors should designate a staff that will be responsible for planning, implementing and monitoring the Quality Assurance Program as well as coordinating inter departmental Quality activities. The following are the qualifications for the Quality Assurance Manager and his (her) assistant. His ( her ) name should be notified to PT. ISI in accordance with the following formalities : 1. Qualification and Appointment of Quality Assurance Manager. 1). QA Manager QA Manager is assigned responsibility and accountability concerning Quality Assurance by President of each vendors. 2). Assistant to QA Manager The QA assistant Manager should be a person who can take the leadership in the area of Quality Assurance. 2. Notification of the Name of QA Manager The attached form Notification of Appointment / Change of QA Manager should be filled in and submitted to PT. ISI Procurement Dept. within one month after signing of supply / purchase agreement. In case of any change in the Notification due to an organizational change or any other reasons, the form Notification of Appointment / Change of QA Manager shall be filled in and submitted to PT. ISI Procurement Dept. The form Notification of Appointment / Change of QA Manager is available from PT. ISI Procurement Division. 3. The form Notification of Appointment / Change of QA Manager shall be filled in as follows : 1). Notification : New . Circle Appointment Change .. circle Change 2). Vendor Name : Write the Vendors name, code number, and telephone number. 3). Address : Write the address of vendors 4). Business : Write the main line of business. 5). Plant Site : Circle the name PT. ISIs Plant site to where the approved parts are delivered. 6). Date of Appoint- : Write the date when the Quality Assurance Manager ment / Change is Appointed / Change. 7). QA Manager : Write the title and name of a person who is responsible for QA. His signature is needed. 8). Assistant : Write the title and name of a person who can assist Manager the QA Manager. His signature is needed.

PT. INDOMOBIL SUZUKI INTERNATIONAL

Date : ..

To : _______________________________

Notification of Appointment / Change of Quality Assurance Manager


Control No:
Code : TEL : Fax : Email :

Vendor Name

Address

Business Plant Site Date of Appointment / Change Title Name


Plant TB I (2W), Plant TB II (4W), Plant CK (E/G)

QA Program Staff ( Senior )

Implementation

Signature

QA Program Staff ( Junior )

Implementation

Signature

2. Preparation for Production


In order to achieve the required quality of products for mass production, the following are the Control points and methods to be carry out by vendors before production. 1. Specification Meeting When the vendors receives an order for new parts from PT. ISI, a specification meeting shall be held between vendors and PT. ISI Inspection Div. The purpose of the meeting is to understanding the functions and features of such new parts prior to the production. The date of meeting shall be fixed between the vendor and PT. ISI Inspection Div. It is most important to make a careful study about the issues on the agenda prior to the meeting. 1). Matters to be discussed at the meeting (1). Functions and features of the parts ( notes specified in the drawing, correlation with other parts, etc) (2). Manufacturing key points (accuracy, manufacturing method, etc ) (3). Correct understanding of the manufacturing process and control points. (4). Indicating method and place of manufacturing Lot No. (5). Arrangement concerning Inspection (6). Schedule Adjustment 2). Documents Required (1). Process Control Standard ( the brief outline of the process ) (2). Application for Approval of New A Process / Process Change ( if a Subcontractor is used for A process ). (3). Proposal for drawings, molds, jigs, and equipments. (4). Preparation schedule of drawings, molds, jigs, and equipment. (5). Any other documents which are considered useful for the control of manufacturing process. 2. Designing Process When a process is designed, attention must be paid to the following points to prevent defects from being produced. 1). The accuracy of each part shall be carefully observed, and Process Capability must be secured so that required quality level of the parts can be achieved and maintained. 2). Past records of defects of similar parts must be investigated so that Poka-yoke ( fail-Proofing ) may be incorporated into every activity, from design through to actual mass Production. This mechanism will prevent defects from being produced or passed on to subsequent process operation. 3). The flow of parts between the processes must be carefully inspected in order to prevent any foreign matter from getting mixed in the parts.

10

3. Schedule Control In order to manufacture parts promptly in the regular process, stabilize their manufacturing quality and deliver the parts on the designated delivery date, molds, jigs, tools, machine and equipment must be prepared according to the schedule. For these purpose schedule control is very important. To control a schedule, a control chart must be prepared so that the progress of the schedule may be checked at each meeting. 4. Transmission of Information All the information such as control points, inspection items change clarified at a specification meeting shall be distributed to all the departments concerned in writing without omission. 1). The information transmitting channel must be established clearly by a flow chart, etc. 2). To ensure the distribution of information to all the departments concerned, it is necessary to established a check system in the company.

11

3. New Process / Process Change


In the events that vendors make a new process / process change, the following applications shall be submitted to PT. ISI. 1. Scope If any of following cases should apply to A parts, submit the Application for Approval of New A Process / Process Change to PT. ISI Procurement Dept. 1). If some or all of the manufacturing process of the parts ordered by PT. ISI be subcontracted ( as a rule, A items of A parts are not allowed to be subcontracted ). 2). If a subcontractor is changed. 3). If the Manufacturing Plant is changed. 4). If the Manufacturing Method is changed. Vendors can obtain a form Application for Approval of New A Process / Process Change from PT. ISI Procurement Dept. 2. Time of Submission 1). In case of New Process, an application shall be submitted to PT. ISI before Trial Production. 2). In case of Process Change, an application shall be submitted to PT. ISI one month before the desired date of change. 3. The form Application for Approval of New A Process / Process Change shall be filled in as follows : * Notification : New Process circle New Process Change . circle Change * Vendor Name : Write the name of vendor and code number * Plant Site : Circle the name of PT. ISIs Plant Site to where the approved parts are delivered. * Part Name : Write the Part Name as stated on the purchased order * Part No. : Write the Part No. as stated on the purchased order. * Subcontractor Name : ( only in case of New Process or Process Change made at the Subcontractor ). - Subcontractor Name : Write the name of subcontractor - Address : Write the address of subcontractor - Capital : Write the paid-up capital of the subcontractor. - No. of employees : Write the number of employees of the subcontractor. - Business : Write the main line of business of the subcontractor. - QA Manager : Write the name of QA Manager. * Process Allocation : Write either new process or process change clearly. If the work subcontracted, write the details of process allocation to be subcontracted. * Reason for New Pro- : Write the detailed reasons for New Process / Process cess/Process Change Change.

12

* Scheduled date of New : Write the scheduled date of New Process/Process Process/Process Change Change. 4. Procedures to Change the Process The following shows a flow from the submission of Application for Approval of New A Process / Process Change to the delivery of parts after the Process Change.

Submission of Application ( a copy will be returned to vendor after judgment )

Receipt by PT.ISI

Revision and Submission of Process Control Standard Revision and Submission of Inspection Standard ( in case of revision )

( See No.4 Process Control Standard )

( See No.5 Inspection Standard )

Approval by PT.ISI

Inspection of Initial Products

( See No.8 Initial Product Control )

Delivery to PT.ISI * Initial Production Part Tag to be attached * Initial Product Inspection result sheet to be attached

( See No.8 Initial Product Control )

13

14

4. Process Control Standard


For the purpose of thoroughly understanding the parts manufacturing process and the control points, this standard provides that vendors should develop and maintain a Process Control Standard. In this Standards, control characteristics for each process are to be identified and documented. The Vendors are required to submit copies of the Process Control Standard to PT. ISI. 1. Scope The Process Control Standard shall be prepared for all the parts ordered by PT. ISI including their components parts. However, among the component parts purchased by the vendors and the parts supplied by PT. ISI may be excluded from the Process Control Standard. 2. Issuance and Revision To ensure proper issuance and revision of the Process Control Standard, vendors are required to set up a clear system in the organization.. 3. Submission The Process Control Standard for A Parts and Functional Parts shall be submitted to the PT. ISI Inspection Div. The Process Control Standard for General Parts shall be also submitted if so instructed by PT. ISI. Vendors are required to take the following procedures by the form, Process Control Standard Establishment and Revision Procedures . 1). In case of newly designed parts, submit the original document to PT. ISI by the time of pilot run Production. 2). In case of revision resulting from the design or process change, submit the document to PT. ISI in number of copies requested in the distribution column plus one copy for the vendor by one week before the delivery of parts. In case of the Process Change of A Parts, notify PT. ISI in accordance with the section 4 of A Process New issuance and change Notification. 3). In case of other revision, submit the number of copies requested in the distribution column plus one copy for the vendor with the clear reason for revisions. When the Process Control Standard is revised for some reasons, the original document shall be submitted to PT. ISI. 4. Acknowledgement of Receipt 1). The original document of the Process Control Standard shall be carefully examined and signed by PT. ISI Inspection Division and it will be returned to the vendor.

15

2). In case the vendor submits to PT. ISI a copy of the Process Control Standard, it will be carefully examined by the PT. ISI Inspection Div. The vendor will receive one copy of this standard bearing the stamp for receipt. 5. Method of Preparation 1). Forms The Process Control Standard May be prepared in any style at the vendors option, subject to the following items being included. The vendor may use the Process Control Standard form provided by PT. ISI. Please contact the PT. ISI Inspection Div. 2). How to Fill in the form : * Vendor Name : Enter the name of vendor. * Plant site : Enter the name of PT. ISIs plant to where the approved parts are supplied. * Page : Enter the page number. * Date of issue : Enter the date of issue * Applicable model : Enter the name of model for which the parts are used. * Part No. : Enter the part No. as stated on PT. ISIs purchased order In case of set, assembly or Complete respective parts number shall be quoted. In case of essential components parts, their parts number shall be also quoted. In case of A Parts, mark suffix A . If the applicable parts are too many to be quoted in the column, a list of such applicable parts may be attached. * Part name : Enter the Part name as stated on PT. ISIs purchased order. * Part classification : Select the appropriate part from among A Part ; Functional Part and General Part. * Flowchart : To understand the total flow, prepare a flow chart with reference numbers in serial order starting from 1. * Process : Enter the name of each manufacturing process in order and show clearly whether it is in-house manufacture or outsourcing. For the operation process applicable to item A , mark suffix A . For the operation process applicable to the Functional item, mark suffix F . * Subcontractor Name: In case of outsourcing, enter the name of subcontractor. * Name of facilities : Enter the name of facilities to be used for the process. * Control points : Enter the control points that are necessary to maintain the quality in the process as well as the quality characteristic to be controlled. * Control standard : Enter the control level and allowable limits for the above control points in specific numerical value.

16

* Checking Methods : Enter the frequency of check and the time of check for control conditions. Also enter the number of samples, the frequency of check, and the time of check necessary for the check of quality characteristic. * Inspection equipment : Enter machines, inspection apparatuses, inspection methods necessary for checking each control item.. * Data form : Enter the name of form and check sheet to be used for controlling each item. * Allotting duties : For each item, state rules for allotting duties of checking staff. * Related materials : Specify the standards and instructions required for controlling each process. * Reason for revision : Describe the reasons for revision in consecutive order starting from page 1 in accordance with the following : < Submission due to new preparation > Enter the reasons for submission in the last column This standard has been newly prepared by the reason of .. In case of design modification, state the design modification number, too. < Submission due to revision > Enter the reasons for revision ( Ex. Due to design modification number 000-0000 ) in the column of reasons for revision. Also state the date of revision in the designated column.

17

Issuing and Revising Procedures of Process Control Standard

Vendor 5. Inspection Standard

PT .ISI

To ensure conformance to the specified quality requirements by PT. ISI, vendor are required to established and maintain an Inspection Standard in which on going inspection characteristics, methods, equipments, number, frequency, etc, are designated. 1. Scope The Inspection Standard shall be prepared for all the parts that are ordered by PT. ISI. 2. Issuance and Revision To ensure proper issuance and revision of the Process Control Standard, vendors are required to set up a clear system in the organization.. 3. Submission The Inspection Standard shall be documented on the form provided by PT. ISI. It is not necessary to include standard parts and some special standard parts for general use in the Inspection Standard. Submit the Inspection Standard to the PT. ISI Inspection Div. as follows : As for the procedures, refer to the attached Inspection standard Issuing and Revising Procedures. 1). In case of Newly established parts, submit the original document to PT. ISI by the time of pilot run production. 2). In case of Revisions from design or process change, submit the document to PT. ISI in the number of copies requested in the distribution column plus one copy for the vendor one week before the delivery of parts. 3). In case of other revision, submit the number of copies requested in the distribution column plus one copy for the vendor with the clear reasons for revisions. When the Inspection Standard is revised for some reasons, the original document shall be submit to PT. ISI. The Inspection Standard shall be submitted to each and every plant of PT. ISI, as and when necessary. 4. Acknowledgement of Receipt 1). The original document of the Inspection Standard shall be carefully examined and signed by PT. ISI Inspection Division and it will be returned to the vendors.

18

2). In case the vendor submits to PT. ISI a copy of the Inspection Standard, it will be carefully examined by the Inspection Division. The vendor will receive one copy of this Standard bearing the stamp for receipt.

5. Method of Preparation 1). Form The Inspection Standard shall be documented on the form provided by PT. ISI. When attaching any rough drawing, the size of such drawing shall be A3 (29.7 cm x 42.1 cm) at the largest. Both part number and part name shall be stated in the Inspection Standard. The specified form is available from PT. ISI Procurement Division. 2). How to fill in the form : * Part classification : Encircle the appropriate part. * Vendor name : Enter the vendor name and its code number * Page : Enter the page number * Date : Enter the date of issue, revision or renewal * Part Name : Enter the part name as stated on PT. ISIs purchased order. * Part No. : Enter the Part No as stated on the purchased order In case of A Part, mark suffix A . If the applicable parts are too many to be filled in the column, the applicable parts list may be attached. * Reference Number : Enter the reference Number for the items of large group ( in the left column ) and for the items of small group ( in the right column ). - Large Group : 1. Appearance 2. Dimensions 3. Function and performance 4. Endurance / Strength Test 5. other, etc in serial number. : For each inspection item in the large group, allocate the serial number. As regards dimensions, circle the serial number so that cross reference sketch can be made between the dimension number and the drawing number. * Inspection items : Enter the characteristic or the name of operation which is the object of inspection. Each of A item and Functional item shall be inspected. * Judgment criteria : Specify the criterion for inspection items so that right adjustment ( Pass or Fail ) may be made. * Inspection Method: Enter criteria, conditions, measuring, position, etc, necessary for performing the inspection. - Small group

19

* Inspection Equip.

: Enter the meters, inspection apparatuses, etc, to be used for each checking item. * Delivery Inspection mode : Enter the Inspection frequency and the number of samples necessary for assuring the quality level of parts to supplied to PT. ISI. * Inspection : Enter the classification of process to be inspected. Classification * Reason for revision : Describe the reasons for revision starting from page 1 in accordance with the following : < Submission due to new preparation > Enter the reasons for submission in the column This standard has been newly prepared by the reason of . In case of design modification, also state the design modification number. < Submission due to revision > Enter the reasons for revision ( Ex. Due to design modification number 000-0000 ) in the reasons for revision column. Also state the date of revision in the date revised.

20

Issuing and Revising Procedures of Vendors Inspection Standard

Vendor

PT .ISI

21

Preparation of the original plan

Concept Examination ( original ) Approval Copy ( original ) Approval Copy ( copy ) ( original ) Filling Distribution to Related Section Distribution to related Section Filling

Revision of Original

Examination ( original ) Approval Approval ( copy ) Copy

Copy

( original )

Distribution to Related Section

Distribution to Related Section

22

6. Inspection Result Sheet

23

The Inspection result Sheet shall be submitted to PT. ISI periodically during the period of mass production, as follows : 1. Submission of Inspection Result Sheet If the Indomobil Suzuki Inspection Standard ( ISIS P )bears the following rubber stamp, vendors shall submit their inspection results as follows : Vendors are required to submit some or all of the following data to PT. ISI in accordance with the requirements specified in ISIS - P. 1). Items marked A Every inspection record according to ISIS P 2). Items marked F One record inspection per month 3). Items marked X Inspection records and broken parts after the breaking test. Vendors are required to keep inspection data for each and every part so that its past quality levels may be traceable in the method of series comparison. 2. Time and Place of Submission of the Inspection Result Sheet 1). Time : Before the 10th day of each month ). 2). Place : PT. ISI Inspection Division to where the parts are delivered. If the same parts are delivered to more than one Plant, submit the Inspection Result to each Plant Inspection Division.

3. Entry in the Inspection Result Sheet 1). Form Any form can be used, but the following items must be included. 2). Items to be included : * Vendor Name * Classification of Parts ( A Parts, Functional Parts or General Parts ) * Inspection items * Judgment Criteria * Inspection Method * Inspection Result : In case of Total Inspection : Write the number of defects / number of part inspected. In case of Sampling Inspection : Measured values must be quoted instead of OK or NG if quality judgment is made by such values. * Judgment Result * Date of Inspection * Inspectors signature and QA Managers signature * Inspection Lot No. 4. Filling of Inspection Records

24

Vendors are required to keep their inspection results for two years so that they may submit these records promptly when they are requested by PT. ISI.

7. Operation Standard

25

In order to ensure the required quality of parts always without depending upon a specific skilled operator, vendor should establish an Operation Standard that documents process operation condition and inspection methods. The operation Standard should be posted in a conspicuous location so that the operators can verify that their work conforms with the Operation Standard. 1. Scope An Operation Standard shall be prepared for each and every process of production. 2. Issuance and Revisions To ensure proper issuance and revisions of the Operation Standard, vendor are required to set up a clear system in the organization. The supervision of each manufacturing section shall be responsible for the issuance and revision of the Operation Standard. 3. Designing Method 1). Form Any form can be used, but the items having an important effect on the quality of all process and at least 5 to 6 items of check points for the ease of observation by operators should be shown clearly by the picture and others. The Operation Standard of A Parts should have the mark A in the title column, and the manufacturing process of A items should be clearly framed red. The Operation Standard of Functional Parts should have a clear indication of Functional Parts in any place such as the upper part of the marginal space where it can be easily seen by operators. 2). Items of the operation Standard * Operation Procedures : Write the working conditions, the order of work and working points having important effects upon quality. * Matters to be attended : Write important matters and prohibitive matters during the work by showing some examples in the past. * Items for Quality : Write items such as quality checking, standard of checking judgment, checking frequency, etc. * Action for troubles : Write the scope and action for troubles, measures to be taken by operators, and the reporting system to their supervisors. * Record of Past Defects: Write the outline and causes of serious quality problems occurred in the manufacturing process. To prevent similar troubles in future, it is important for operators to refer to the past records. 4. Important Points for Preparing Operation standard

26

The Operation Standard shall be used for making good products and not for inspecting the parts manufactured. So, it is important to take preventative measures against all kinds of causes creating troubles. These important points should be shown by pictures, charts, graphs, etc, instead of sentences so that operators may understand their work clearly. 5. Periodical Check Factory supervisors must regularly check whether or not the operation standard is observed by operators. If there is any lack of observance on the part of operators, it is necessary to call such negligence to operators attention. At the same time, it is necessary to amend the operation standard if there is any unreasonable demand which does not suit the actual operation. The standard should not impose a heavy burden on operators.

8. Initial Parts Control

27

In order to prevent problems arising from initial parts, this standard explain the special quality control procedures which shall be applicable to the initial parts, manufactured at the stages of trial production, trial mass production, after engineering changes and process modifications. 1. Definitions of Initial Parts The Initial Parts mean any of the following first parts which are supplied to PT. ISI. These initial parts shall be subject to special control procedures. 1). The Parts from the trial production and trial mass production. 2). The first parts produced after changes in the engineering drawings. 3). The first parts produced after changes in the manufacturing location and processes, such as, a). a new part b). a different manufacturing c). a modified process lay out d). a different condition or method for manufacturing, or e). a modified die, machine, jig, or tool 2. Identification of Initial Production Part Tag and Inspection Result of Initial Parts. Initial Parts defined in the above item a) must be very clearly identified including a Initial Production Parts Tag and a Inspection result Sheets which are attached to each delivery box or container ( or parts themselves ). The Initial Production Part Tag is available from PT. ISI Procurements Division to where the parts are supplied. 3. Initial Parts Inspection 1). Inspection Items The Initial Parts shall be inspected and tested for conformance to quality requirements in the following manner : a). Certain events that occur in the vendors parts development process require Initial Parts Inspection that is, parts inspection for all characteristics outlined in the drawings, Part Inspection Standard or otherwise identified by PT. ISI. This process is to be carried out at the stages of trial production, trial mass production and for new parts. b). For changes in Engineering drawings, part inspection standards or the manufacturing processes, all initial parts need only be inspected for those characteristics affected by the changes. c). For the renewal of dies and jigs, the parts shall be inspected for those affected by the dies and jigs. 2). Part Inspection data sheet

28

Vendors shall submit their inspection results in any appropriate form which should state the following items : * Model * Part No. * Part Name * Category of Initial Parts ( In case of design modification, the design modification number should be quoted ) * Process ( Temporary process or regular process ) * Date inspected and name of inspector * Inspection Items * Judgment Criteria ( in case of dimension, the measurement criteria should be specified ) * Results of measurement * Judgment 3). Number of samples for Inspection In principle, the number of sample for inspection shall be five. For breakdown test, at least one and for casting parts at least one per die ). If the quantity less than five (5), all the samples shall be inspected. 4). In case of the failure in the initial inspection by PT. ISI : If the initial parts fail to pass the initial inspection, PT. ISI Inspection Division will issue an Inspection result sheet to be sent to the Vendors showing the defects. Such parts rejected by PT. ISI shall be handled as Initial Parts until they pass the Inspection. Therefore, all the initial parts must be delivered to PT. ISI together with Initial Production Part Tag and Initial Part Inspection Result Sheet. 5). Retention of Inspection Records All the original documents of inspection records shall be kept for two years and be ready for prompt submission to PT. ISI upon request.

29

9. Initial Production Control


The initial production control must be carried out at a time of starting Mass Production as follows : 1. Definition of Initial Production Control The Initial Production control means such special control as required at a time of starting mass production to judge the appropriateness of the manufacturing process. 2. Establishment of Initial Production Control System Vendors are required to establish their initial production control system which specifies the initial production control items and the control period. The following is an example of the initial production control : 1). Initial Production Control Items * Lot Control * Investigation of Process Capability ( important checking items ; checking method ; and checking frequency to be determined and carried out ). * Removal of problems and improvement * Verification of effectiveness of measures against the problems which occurred during the trial production. * Inspecting methods during the Initial Production Period ( more strict standard than the standard for the process control shall be adopted), etc. 2). Initial Production Period The period shall be fixed as three (3) month. But this period may be not needed depending on the characteristic of design changes or process changes. 3). Abolition of Initial Production Control Upon the expiry of the initial production period, the initial production control may be abolished if any of the following conditions is satisfied. * The process capability could meet all the standard * The measures against the problems during the trial production are considered effective. * The measures have been taken effectively against the problems during the initial production period. 3. Report of process capability investigation result If process capability investigation is requested by the Inspection Division of PT. ISI at the specification meeting, the vendor shall submit a report to PT. ISI as follows : 1). PT. ISIs instructions : * Quality feature which require investigation of process capability.

30

* Sampling method ( number of samples, sampling frequency, etc. ) * Period, etc. 2). Investigation of process capability Process capability must be investigated according to PT. ISIs instructions. Vendors are required to submit their results in the form provided by PT. ISI, Process Capability Investigation Report to the PT. ISI Inspection Division.

31

10. Lot Control


To facilitate trace-ability of parts and components that may be discovered to be defective at the vendors location, at PT. ISI, or in the market place, vendors are required to establish a lot control system. This allow PT. ISI to gain quick access to the history of all parts and components. Rapid identification and solution of problems will minimize losses and costs related to these defects. 1. Format of Lot Identification on the Parts For A Parts and Functional Parts, as a rule, the date of manufacture ( including lot number ) must be recorded on the parts. Such lot identification must be easily recognized even after the parts are assembled to the vehicle. The format of lot identification system must be approved by PT. ISI Inspection Division or Design Department well in advance for production. 2. Concept of Lot A lot means a group of part produced from the first setting of working condition to the next setting of work conditions. In case of continuous production, a lot means a group of parts produced per day. 3. Production Records The following items must be recorded for each Lot No. * Lot size ( the number of parts produced ) * Working conditions * Inspection results * Delivery records to PT. ISI Those parts without batch no. shall be controlled by the date of delivery to PT. ISI and the manufacturing history including the date of manufacture. 4. First In ; First Out ( FIFO ) In order to make the lot identification system meaningful, it is important to implement First In ; First Out delivery. Careful attention shall be paid to the following points : * Be careful not to skip over any process while moving Parts in Process. * Defective parts shall be repaired promptly so that they may continue to travel through the production and delivery process with the same lot in which there where originally produced. It is extremely important not to mix these repaired parts with another lot. * Parts from different production lots may not be mixed in the same container or pallet. Each container ( pallet ) shall accommodate the parts of the same production lot.

32

5. Identification of Parts To eliminate any unidentified parts throughout the manufacturing process, parts shall be identified as follows : * Identification of defective parts To be distinguished from other good parts by red/yellow paint, or red/yellow indelible ink or by a tag ( NG ). * Identification of Inspection records Inspected lots shall be distinguished from Non Inspected lots, and Accepted lots shall be distinguished from rejected lots. Each lot shall be identified at a glance. * Identification of materials and Parts To prevent a mixture of similar materials and parts, each container ( pallet ) shall show part no; part name; manufacturing date; and delivery date.

33

11. Disposition of Quality Problems


Vendors shall establish a system for resolving problems discovered at the vendors location, PT. ISI, or in the marketplace in a prompt and proper manner. 1. Defective Parts discovered at PT. ISI When discovered parts are discovered at PT. ISI, and deemed to be the responsibility of the vendor, PT. ISI will request that the vendor resolve the problem. Vendor must take appropriate corrective action to prevent recurrence an submit the Problems Analysis and Countermeasure Sheet in the form provided by PT. ISI inspection division. 1). Disposition of Products in process ( Temporary Action ) In the event that any particular lot should contain some defective products, such lot must be promptly identified and isolated from others lot. This may involved sorting or rework of the parts, whether or not they have been assembled onto vehicle. Vendors are required to try every possible means so that any suspect parts may not be used for vehicles, KD Parts or spare parts. In the event that any suspect lot has been shipped to PT. ISI, the vendor is requested to notify PT. ISI in order to receive instructions. The vendor should take corrective action in accordance with the instructions from PT. ISI inspection division or Quality Assurance division. At the same time, the vendor should notify the process operators in order to stop producing defective parts at once. 2). Investigation of Causes of Defective Parts To discover the causes of the quality problems, Investigation in the following areas shall be made at once : * Defective Parts * Manufacturing processes * Standards * Engineering drawings * 4 M ( Man, Machine, Methods, Material ) * Records of defective products or defective lot * Prospect of occurrence of quality problems in the marketplace 3). Basic countermeasures ( Corrective action to prevent recurrence ) As a result of the above-mentioned investigations, the vendor is requested to take countermeasures to prevent similar occurrence of defects in the future. When it comes to taking the countermeasures, the following points must be taken into consideration :

34

* In addition to quality control education / training program, vendors should take an appropriate action to improve the control method and to revise the relative standards. * Every vendor is requested to review its processes and equipment to make continuous efforts to develop Poka-yoke ( Fail-Proofing ) as is commonly said, to consistently achieve PT. ISI quality requirements. * It is necessary to check if there is any fear of similar occurrence of quality problems among similar parts in similar processes. Preventative action shall be taken to prevent recurrence of problems. 4). Checking the effect of countermeasures After the implementation of countermeasures, it is necessary to check the effect of such countermeasures by the reproduction test of defective parts. 5). Submission of Problem Analysis and Countermeasure Sheet Vendors is requested to submit this document to the PT. ISI Inspection Division by the designated date of submission. ( If it cannot be submitted by the designated date because of the delay in finding the causes of problems or in taking corrective action, vendors has to request PT. ISI to change the date of submission ). If the document is not satisfactory to PT. ISI , the vendors may be requested to resubmit it to PT. ISI.

35

PT. ISI Issuance of Problem Analysis and Countermeasure Sheet

Vendor Receipt of Problem Analysis and Countermeasure Sheet

Disposition of Products in Process (Temporary Action)

Investigation of causes of occurrence

Basic Measures (Corrective Action to Prevent Recurrence )

Checking of effect of Measures

Report of Problem Analysis and Countermeasure Sheet

Signature of Quality Assurance Manager

Acceptance of Problem Analysis and Countermeasure Sheet

Submission of Problem Analysis and Countermeasure Sheet

2. Defective Parts Discovered at the Vendors When defective parts are discovered at the vendors location, the vendors must take prompt action in accordance with the same procedures as describe in the paragraph 1 ( one ). The following action must be taken by the vendors :

36

* If suspect parts have been shipped to PT. ISI, the vendor is requested to notify PT. ISI inspection division in order to receive instructions. * As to the defective parts, the vendors must record in one sheet of form, if possible, all the details such as nature of defect, background of occurrence, disposition, causes, corrective measures, etc. * The vendors shall establish a system for resolving quality problems. * When heat treated parts are heat-treated again, vendors shall submit the part and their heat treatment records to PT. ISI inspection division for approval. 3. Application for Special Limited or Provisional Acceptance When a vendor produces a quantity of non-conformance parts that can be used without adversely affecting appearance, performance, durability, assembly, etc., a limited quantity of such parts may be accepted. However, these parts will not considered for acceptance unless the vendor has submitted the necessary application to the PT. ISI procurement division prior to shipment. * This case shall be applicable only when shipping schedules are delayed considerably by the discovery of defective parts, causing PT. ISI to lose heavily by the delay in production. Besides, the provisional acceptance of defective parts shall not affect adversely assembly, function, performance, service warranty, regulations or standards. The application form ( at the vendors option ) must show the nature of defects, the number of defective parts, causes of problems, shipment date, etc. The parts must be submitted together with the application.

37

12. Maintenance of Inspection Machinery and Tools


In order to ensure that their products meet all of PT. ISIs quality requirements, vendor have all the necessary inspection machinery and tools at their disposal. Vendors are required to maintain and record the accuracy of all inspection machinery and tools. 1. Periodic Inspection of Accuracy The following instruments must be inspected periodically. 1). Measuring Instruments : Dial gauge, Micrometer, Slide Caliper, Cylinder Gauge, Torque Wrench, etc. 2). Gauges : Snap Gauges, Plug Gauges, Width Gauge, Ring Gauge, etc. 3). Machine and Instruments : Tension / Compression Tester, Roughness gauge, Hardness Tester, Spring Tester, etc. 2. Vendors are expected to identify selected check items for inspection machinery and tools that are to be verified on a frequent basis ( daily, prior to use, etc ). This is to ensure proper calibration prior to inspection or testing. The following table is an example of inspection frequency : Inspection instruments Measuring instruments Gauge Machinery When used in the manufacturing section Once / 6 month Once / 1 months Once / 12 months When used in the Inspection section Once / 12 month Once / 6 month Once / 12 months

3. Preparation of Inspection Standard Vendors are required to prepare a control standard in order to specify check items, judgment criteria, inspection frequency, etc. This is to ensure proper calibration prior to inspection or testing. 4. Indication of the term of validity As to inspection instruments that have passed the accuracy testing, it is necessary to specify the term of validity by a label or colors. 5. Accuracy test of Master Instrument

38

It is essential that vendor shall check accuracy of each and every master instrument at least once a year 6. Registration of Inspection Instruments Inspection instrument should be registered in the Machinery Control List quoting the name of instrument, model, manufacturer, date of acquisition, place of installation, place of use, name of operator , control number, etc. 7. Annual schedule of Periodic Inspection To avoid any omission of inspection for products, vendors are required to make an annual schedule for periodic inspection. 8. Retention of Inspection Records Calibration procedures are to be well-documented, and the periodic accuracy inspection results shall be kept for one year by vendors or independent laboratories.

39

13. Quality Control Audit


In order to maintain and improve the vendors manufacturing facilities and Quality Assurance system, the vendor audit shall be conducted periodically by the PT. ISI Quality Assurance Division. On the other hand, each vendor shall be responsible for conducting the proper implementation of quality audit in their own company and at their contractors. 1. Audit by PT. ISI 1). Type A. Periodic audit * This audit shall be conducted according to an annual schedule on the basis of result of vendor ranking. ( As for the ranking, refer to 15. Vendor Evaluation ) B. Temporary audit * This audit shall be conducted as and when necessary at PT. ISIs judgment in the following events : a. In the event that market claims and defects attributable to vendors abnormal quality problems are discovered at the marketplace. b. In the event that the manufacturing process for parts has been changed. c. In the event that quality problems are discovered at PT. ISI plant in the prototype stage ( production prototype or pilot run ). d. In the event that PT. ISI has ordered new parts whose mechanisms or the method of manufacture are different from those of conventional parts. 2). Submission of corrective action program In compliance with the instructions resulting from the above audit by PT. ISI, vendors are required to submit a corrective action program to PT. ISI Quality Assurance Division. 1. Voluntary Audit 1). Type * Executive Audit : Audit by President or Executive. * Plant Manager Audit : Audit by Plant Manager * QA General Manager Audit : Audit by Quality Assurance Manager

40

* Subcontractor Audit

: Each vendor shall be responsible for ensuring the proper implementation of quality audit at their subcontractors.

2). Standardization of Quality Audit System In order to implement a quality audit system periodically, it is necessary to standardize the audit system specifying the number of audit, frequency, time of audit, methods, etc. 3). Purpose of Audit The audit will be performed for the purpose of evaluating and improving, if necessary, the vendors manufacturing facilities and quality assurance system, with an emphasis on the completeness and effectiveness of : * the total quality assurance system * In-process quality control performance * the part inspection system, and * corrective action plan to prevent recurrence of quality problems

4). Annual Audit Schedule Vendors are required to conduct an audit according to their annual audit schedule for each fiscal year. 5). Retention of Audit Results The results of audit shall be retained so that vendors may investigate the process which has produced the defects. It is most important for the audit section to follow up the problems and to ensure the proper implementation of corrective measures.

41

14. Quality Control Education


The success of a quality assurance program depends ultimately on the people involved. Vendors must consider the people factors of their quality assurance program and take the appropriate action to maximize the effectiveness of their human resources. It is essential that vendors develop and implement a training program throughout the organization. In order to maintain and improve the quality, vendors must promote quality control activities by giving their employees the following education : 1. Quality Control Education or training Program Education and training program must be given regularly to those who are engaged in quality control. Their knowledge and skills necessary for the quality control shall be acquired through the self-development and mutual enlightenment. The quality control education should be directed at different functions and levels. Some examples are : * Education for beginners * Education for operators * Education for supervisors * Education for inspectors PT. ISI recommends that these courses be conducted by staff inside the company and also taken through independent instruction from outside the company, as necessary. 2. Promotion of Quality Control Education It is essential to establish quality control education promotion section in their own company. This section must make and implement an annual quality control program.

42

15. Vendor Evaluation


PT. ISI will evaluate Vendor Quality performance as follows : 1. Vendor Evaluation PT. ISIs intention is to evaluate vendor quality performance once a year. The evaluation will be based on two elements : * The frequency and seriousness of quality problems caused by the vendor. * An on-site audit of the manufacturing facilities and Quality Assurance Program. PT. ISI will assign the vendor a ranking of A through E, with A being the highest mark. 2. Formula of evaluation points The evaluation points will be determined by the following formula : Evaluation points = 100 ( total of quality problems points for one year) x 0.7 + ( average of vendor audit points for one year ) x 0.3

* Quality problems points Evaluation points will be given to vendor when Problem Analysis and Countermeasure Sheet and/or Claim Application Form are issued ( including disadvantage points which will be given defective parts are discovered at PT. ISI plant ). * Vendor Audit points. Evaluation points will be given to vendor when the vendor audit is conducted periodically by PT. ISI and also at a time of opening an account. N.B If the vendor audit has not yet been completed, the evaluation points shall be given as follows : Evaluation ranking 90 points

3. Ranking of Vendors As a result of the evaluation, Suzuki will assign the vendor a ranking of A through E according to the numerical evaluation points as follows :

43

Rank A B C D E

Ranking Criteria 91 ~ 100 71 ~ 90 51 ~ 70 31 ~ 50 < 50

4. Application of ranking As a result of the ranking, PT. ISI will determine the frequency of vendor audits for the following year. In principle, the vendor audit shall be conducted periodically in accordance with the following table :

Rank

Vendor who supplies A Parts Or Functional Parts 1 time / 24 month 1 time / 12 month 1 time / 6 month 1 time / 4 month 1 time / 3 month

Vendor who supplies General Parts

A B C D E

1 time / 48 month 1 time / 12 month 1 time / 6 month 1 time / 4 month 1 time / 3 month

44

QUALITY ASSURANCE MANUAL


June 1999

PT. INDOMOBIL SUZUKI INTERNATIONAL

1. Plant Tambun I (2W) Telp. (021) 880 1235, 880 1251 Fax. (021) 880 1297 2. Plant Tambun II (4W) Telp. (021) 880 1235, 880 1251 Fax. (021) 880 7401, 8828479 3. Plant Cakung Telp. (021) 460 9214, 460 9215 Fax (021) 4609216

Establised : Juni 1999 1st Revised : December 2003 2nd Revised : February 2004

PT. INDOMOBIL SUZUKI INTERNATIONAL

45