Escolar Documentos
Profissional Documentos
Cultura Documentos
1 Scope 1 0 1
- General 1.1
- Application (Exclusions, if any) 1.2
3 Updated positions
5 Management Responsibility 5 resp. 3/01/05 7
- Management Commitment 5.1
- Customer Focus 5.2
- Quality Policy 5.3
- Planning 5.4
- Quality Objectives 5.4.1
- Quality Management System Planning 5.4.2
- Responsibility, Authority & Communication 5.5
- Responsibility & Authority of Managers 5.5.1
- Management Representative 5.5.2
- Internal Communication 5.5.3
- Management Review 5.6
- General 5.6.1
- Review Inputs 5.6.2
- Review Outputs 5.6.3
6 Resource Management 6 0 2
- Provision of Resources 6.1
- Human Resources 6.2
- General 6.2.1
- Competence, Awareness & Training 6.2.2
- Infrastructure 6.3
- Working Environment 6.4
Issued by: Ralph Sulser Edition : 01
Approved by: Keith Shepard Date: 09/13/04
Rev. 1
MUSASHI SOUTH CAROLINA INTRODUCTION DOC NO.:MSC-QM1
Page 5 of 70 SECTION#: 00
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Introduction
0.2 FOREWORD
This Quality Manual describes the Quality Management System Requirements adopted by Musashi South Carolina.
The Manual lists the Procedures and measures stipulated for ensuring the quality of products manufactured by this unit.
The Quality Management System has been formulated on the basis of ISO/TS 16949:2002(E) for MSC. This Section
titled "Introduction" explains the Structure, Issue and Updating procedure of the Quality System Manual. This Manual
and the information incorporated herein are the property of Musashi South Carolina. It must not be reproduced in whole
or in part or otherwise disclosed without prior consent in writing from MSC.
This Quality Manual is structured as shown in the content pages of the Manual. Different sections are arranged
sequentialy as per clause number of ISO/TS 16949:2002(E) and ISO 9001: 2000 (herein after called QMS Standard).
The main clause number of QMS Standard has also been indicated along with title of each Section. For all Sections,
relevant sub-clause numbers under the main clause of QMS Standard have been indicated in the text. Quality System
Manual pages are numbered serially with page number indication. All pages of the Master Copy of each Section of the
manual contain electronic signature(s) of the Issuing and Approving Authority of the manual. The current revision
numbers and edition numbers on each page is also indicated. Revision no. 0 has been given to first issue of the
Section. This master manual is available in English Language only, and copies may be available in Japanese if required
The TS16949 Coordinator/Management Representative is authorized by the Quality Control Manager, and the President
to carry out the activities of preparing, issuing, maintaining and updating of this Quality System Manual.
The distribution of the Manual and the amendment(s) are controlled and the TS16949 Coordinator/ Management
Representative carries out this activity.
The Master Copy contains the electronic signature of the approving and issuing authority in original. The Master files are
in the controlled in the TS16949 Coordinators computer files, with restricted access. Printed Controlled Copies are red
stamped "Controlled Document" on the first page. Uncontrolled copies issued to designated individual s (as per
distribution list) are legibly photocopied from the Master Copy.
Printed documents are not controlled copies-check master computer files for latest
revisions.
Additional copies of the Manual, required by external agencies, if any, are issued by the TS16949
Coordinator/Management Representative and such copies of the Manual issued are not stamped in red. This indicates that
the copies are not controlled by virtue of the non-red stamp due to the copy process. These uncontrolled copies do not
come under the control of the document amendment procedure, and are used for reference only, and are not used within
the Company.
The TS16949 Coordinator / Management Representative maintains a record of the distribution list of the Quality System
Manual. This list is used as reference for updating of the respective controlled copies.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
The TS16949 Coordinator/ Management Representative in consultation with the related departments reviews the Quality
System Manual periodically. No revision is implemented unless it has been approved by the Senior Manager Quality
Control, then formally issued.
Each revision is introduced formally by the TS16949Coordinator/ Management Representative by issue of revised
section(s) for each of the copies as per the Distribution List.
When revisions take place, the revisions are indicated by the revision number in each of the revised sections and recorded
in the Amendment Sheet (Refer Amendment Sheet) supplied with the controlled copies of the Manual. If there are more
than 20 revisions, the complete manual is revised to the next edition number.
The insertion of the additional/amended sections and the removal of the old sections in the individual controlled copies
as per the distribution list of the Manual are the responsibility of the person holding the individual copy. All old sections
so removed are crossed with an inscription of the marking "OBSOLETE" and returned to the TS16949 Coordinator/
Management Representative who ensures that the same are destroyed.
In 1938, Musashi Seimitsu Industry Co. LTD, Toyohashi, Japan started its first
Manufacturing operation in Musashino City, Tokyo. Business flourished and
they soon became a major supplier of precision automotive components worldwide.
Musashi Seimitsu has grown to include facilities in the United States, Thailand,
United Kingdom, Brazil, Indonesia and Canada.
Musashi South Carolina, Inc. was established on October 25th, 1999, and started production in 2001. The 120,000 square
foot main plant and 10,000 square foot assembly plant were built on 40.4 acres of land near Bennettsville, South
Carolina. MSC produces ATV gears and assemblies and automotive differential gears.
MSC is dedicated to the Team Philosophy. Teamwork is essential, and open communication is the cornerstone of all our
processes.
MSC's production areas are supported by several departments, including General Administration, Human Resources,
Purchasing, Engineering, E/H/S, Quality Control, Maintenance and Tool and Die.
QUALITY, CUSTOMER FOCUS, AND CUSTOMER SATISFACTION is a way of life at Musashi South Carolina.
Our products are sold in the international automotive and ATV markets. Musashi products have an established reputation
in the world market for excellence in quality, and customer focus.
Musashi continually upgrades technology and customer focus for quality, to optimize product performance, superior in
international world-class quality expectations.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
DISTRIBUTION LIST
(Distributed uncontrolled copy by electronic e-mail)
Posted on the "shared" computer file
Note: Printed documents are not controlled copies-check master computer files for latest revisions
1.1 General
MSC has adopted Technical Specification, ISO/TS 16949:2002(E) and Visteon Customer Specific Requirements, which
specifies the requirements for a Quality Management System in order to:
Application
a) Demonstrate ability to consistently provide product(s) that meet(s) customers standards, and applicable regulatory
requirements, and
b) Enhance customer satisfaction through the effective application of the system, including the processes for continual
improvement of the system and the assurance of conformity to customer and applicable regulatory requirements.
The established system is applicable to the activities of the company plant located at One Musashi Drive,
Bennettsville, SC. The scope of implementation of this standard is as given below:
1.2
The following ISO/TS16949:2002 requirement is not applicable to MSC QMS, and therefore excluded from our scope:
Clause 7.3 activities related to Product Design and Development.
MSC does not have product design responsibility. All products are manufactured to customer drawings.
In this Quality System Manual and related procedures / instructions, following terms / definitions and
abbreviations have been used:
Supplier: Organizations supplying the materials, parts and /or services to MSC
Customer: The Customer /end user who buys the MSC products. It is also used for Internal
Customers
3.2 Abbreviations:
Note: Printed documents are not controlled copies-check master computer files for latest revisions
The MSC has established, documented, and implemented a Quality Management System. The company maintains and
continually improves the effectiveness of our QMS in accordance with the requirements of ISO/TS 16949:2002
a) identified the processes needed for the quality management system, and their application throughout MSC, except for
the exclusion as mentioned at Section 1.0 (Refer 1.2), The outsource processes, if any, that affect product conformity with
requirements, have also been identified. Apart from their identification, the Company has also identified the controls over
their processes in order to ensure product conformity.
b) determined the sequence and interaction of these processes (QC-PM-001 &001b) , and a typical bevel
gear Process Flow Diagram(s) shown in each parts PPAP/QAV booklet. (located in the front of manual)
c) determined the criteria and the methods needed to ensure that both the operation and control of these
processes
d) are effective.
ensured This has
the availability been doneand
of resources while planning for
information the processes.
necessary (Refer
to support Section 7.1).
the operation and monitoring of
these processes (Refer Section 6 & 7.1). These have been determined and verified at the time of planning the
processes.
e) decided to monitor, measure and analyze the above identified processes (Refer Section 8), and
f) implemented actions necessary to achieve the planned results and deciding, the continual improvement of
these processes.
These processes are managed by MSC in accordance with the requirements of the QMS Standard.
4.1.1 MSC assures control over any outsourced processes and responsibility of same conforming to all customer
requirements.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
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MUSASHI SOUTH CAROLINA Page 15 of 70 SECTION#: 4
4.2.1 General
a) Documented statement of Quality Policy and Quality Objectives, (Refer Section 5.3 & 5.4.1 of this Manual)
b) Quality System Manual,
c) Documented procedures wherever required by ISO/TS 16949:2002 and where the absence of these
procedures can affect the quality of the product.
d) Applicable documents needed by the Company to ensure the effective planning, operation and control of its
processes, and
e) Quality Records specified by this standard required for demonstrating the objective evidence of having
carried out the activity.
The Company has developed document structure as given below:
MSC has established procedures to conform with those specified in the Standard and identified as
Documented Procedures. These have been established, documented, implemented and maintained. While
planning for the processes, apart from the required procedures, other procedures and guidelines / work
instructions have also been identified based on the type of the activity, complexity of the processes and the
existing competence of the personnel.
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
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Note: Printed documents are not controlled copies-check master computer files for latest revisions
a) To approve documents for adequacy prior to issue, from designated approving authorities,
b) To review and update, as necessary, as a part of improvement of the management systems and re-approve
the documents after modifications by the designated approving authorities,
c) To ensure that changes and the current revision status of documents are identified through establishing
distribution and maintaining revision / issue number.
d) To ensure that relevant versions of applicable documents are available at the points of use.
e) To ensure that documents, while distributing and use, remain legible and are readily identifiable by their
document numbers, revision status and/or titles,
f) To ensure that documents of external origin like customer drawings, international / other national standards are
identified and updated periodically and their distribution controlled.
g) To prevent the unintended use of obsolete documents by eliminating same and substituting with revised version, and to
apply suitable identification to them if they are retained for any legal / reference purposes.
4.2.3.1 A system has been established and maintained to assure timely review distribution
and implementation of all customers engineering standards/specifications and
changes. Timely review shall not exceed two working weeks.
A record will be maintained of the date each change is implemented, and corresponding document changes
While planning for the processes (Refer Section No. 7.1), the MSC has determined, established and maintained
applicable Quality Records which provide evidence of conformity to requirements [including regulatory and
customer requirements] and of the effective operation of the Quality Management System. These quality
records serve as the objective evidence and are part of the Quality Management Systems. Quality records are
maintained in such a manner that these remain legible, readily identifiable and retrievable.
MSC has established a documented procedure which defines the controls needed for identification, storage,
protection, retrieval, retention time, and disposition of records.
4.2.4.1 Records retention controls shall satisfy regulatory, and customer requirements if these differ from MSC
company policies. Procedure No.: QC SP 004 - Control of Records
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
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Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
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a) Communicating to all employees of the company: the importance of meeting customer as well
as statutory and regulatory requirements through regular training programs, display of documents
and departmental meetings, communication meetings, and manag
b) Establishing the quality policy based on the improvement objectives,
c) Ensuring that quality objectives are established,
d) Conducting regular management reviews, and
e) Ensuring the availability of resources for improvements when required.
f) Product realization process and support processes are reviewed for their effectiveness and efficiency
Methods of determining customer requirements, expectations and satisfactions are defined in the procedures
The Management of the company has defined the quality policy ensuring that the quality policy
a) is appropriate to the purpose and organizational goals of the company,
b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality
management system,
c) provides a framework for establishing and reviewing quality objectives,
d) is communicated to all employees of the company and is understood at all levels in the company,
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
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The Policy of the company has been displayed at strategic locations and also distributed to all employees. Periodic Training
Programs are held for understanding by all the functions through out the organization. Quality Policy distribution and
display records are maintained.
The policy of Musashi South Carolina is to achieve total customer satisfaction by delivering products and providing services
that meet or exceed customer quality requirements and expectations. Deliver on time, and at the most competitive prices in
domestic and export market for our entire product range.
It is implied that all people at all levels in our organization be committed to comply with requirements and continually
improve the effectiveness of the Quality Management System and their performance. Ultimate goal of working towards
achieving zero defects. Necessary measures are also taken towards product safety, and environmental needs to minimize
potential risks to employees, and subsequent end users.
Our mission is to make Musashi South Carolina a synonym for a world-class organization excelling in gear, and gear
assembly manufacturing.
MSC Senior Management, Department Managers, Assistant Managers, and area Team Leaders shall ensure that this policy is
understood, implemented and maintained by all personnel in their respective division / department / section.
QUALITY POLICY
MSC will continually strive to produce quality products that meet
or exceed customer expectations, cost competitiveness, and timely
deliveries QCD (Quality, Cost, Delivery) through exercise of
continual improvement, employee support, and customer
communication.
Process interactions of achieving product realization are described on QC-PM-001. Outlined below are
typical duties, and inputs of the department management to focus on objectives, and
customer satisfaction. Current plant organizational charts are on file in H.R.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
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5.4 Planning
5.4.1 Quality objectives
Top management ensures that quality objectives, including those needed to meet requirements for product [see 7.1 a)] are
established at relevant functions and levels within the organization. The quality objectives are measurable and consistent
with the quality policy.
Top management defines quality objectives and measurements that are included in the business plan and used to deploy the
quality policy.
Quality objectives address customer expectations and achievement goals within a defined time period.
5.4.2 Quality management system planning
Top management ensures that
a) the planning of the quality management system is carried out in order to meet the requirements given in 4.1, as well as
the quality objectives, and
b) the integrity of the quality management system is maintained when changes to the quality management system are
planned and implemented.
Preventive/Predictive Maintenance, Tool/Die, Mechanical, Electrical, Compressor, pump house and LPG and all utilities
Manages, and coordinates any modifications to be carried out in the existing operations or enhancing the efficiency of
the plant.
Responsible for building the required competency level in the employees reporting to him.
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
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Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
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Representing the needs of the customer in internal functions addressing the product realization planning (APQP) for
ISO/TS 16949 requirements (e.g. selection of special characteristics, setting quality parameters.
Develops manufacturing process design quality controls including Process Flow Diagram, FMEAs, Control Plans and
Process Standards, and Inspection Standards.
Authorized to STOP PRODUCTION if systems are not being implemented.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 23 of 70 SECTION #: 5
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
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Reviewing, recommending and providing guideance for effectiveness of the procedures on Product requirement
Review Manufacturing Process Designing and Development; Plant Facilities and Equipments Provisioning,
Developing guidelines of new products planning.
Reviewing customer engineering specifications and standards.
The Management of the company has appointed the TS16949 Coordinator, as Management Representative, who,
irrespective of other responsibilities, has the responsibility and authority that includes:
Management Representative (MR) / TS16949 Coordinator, Quality Controlare responsible for
Establishing, implementing and maintaining quantity system in accordance with ISO/TS 16949:2002 (E)
Reporting the performance of the Quality System for Management Review, which forms the basis for
improvement of Quality System.
Liaison with internal and external parties on matters relating to Quality System.
Ensuring timely management review of the Quality System.
Organizing Audit Summary Report, and summary of the Preventive Actions for Management Review.
Approving and ensuring effectiveness of procedures on Document Control, Quality Management System
Auditing and Records Control.
Preparation and issue of Quality System, and Procedures Manuals
Maintaining original documents and their master lists and issue of Quality System Manual, all Quality System
Procedures, all work instructions, and samples of all formats
Identification of training needs for building a team of internal quality auditors
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
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5.5.2.1 The Sr. Manager-Quality Control has been designated as Customer Representative to assure customer requirements
are addred within MSC. Visteron will be notified of any changes to customer rep., or senior mgmt.
5.5.3 Internal communication
The Management of the MSC ensures that appropriate communication processes are established within the company and
that communication takes place regarding the effectiveness of the quality management system, and actions to be taken on
non-conformances encountered in the activities including customer communication.
Top Management of MSC reviews the companys quality management system, at planned intervals to ensure its continuing
suitability, adequacy and effectiveness. The Quality Management System of the company is reviewed by the Management
Review Team that comprises all Managers of Departments under the Chairmanship of the President.
The review includes assessing opportunities for improvement and the need for changes to the quality management system,
including the quality policy and quality objectives. Management Representative maintains records of management reviews.
5.6.1.1 Quality Management System Performance-Input
- All requirements of the quality management system, performance, and trends for continual improvement.
- Monitoring quality objectives
- Regular reporting and evaluation of cost of poor quality
- Evidence of achieving: quality objective specified in the business plan
- Evidence of customer satisfaction with products supplied
5.6.1 Review input
The input to management review in the form of Agenda for Management Review Team meeting includes information for the
period under review on sections of applicable QMS STANDARDS. However, more focus is placed on the following:
a) Business Plan/Quality objectives
b) Cost of poor quality
c) Customer satisfaction, feedback, (Customer perceptions & Complaints)
d) Analysis of actual and potential field failures and their impact on quality, safety or the environment
e) Follow-up actions from previous management reviews,
f) Results of internal/external audits including the trends,
g) Process performance and product conformity,
h) Status of preventive and corrective actions,
i) Planned changes that may affect the quality management system, and
j) Recommendations for improvement especially for product / process characteristics,
k) Status and results of Quality objectives and Quality Improvement Programs,
l) Performance of Suppliers, e.a., monthly ratings for quality, and delivery
5.6.2.1 Additional Review Inputs
a) Management analysis of actual and potential field failures, and their impact on quality, safety, or the environment.
b) Measurements at specified stages of design and development will be defined, analyzed, and reported with summary
results. Items such as quality risks, costs, lead times, critical paths, and others as appropriate.
5.6.3 Review output
The minutes of the management review meeting are recorded and maintained for a specified period. The output from the
management review in the form of minutes of meeting and action plans include any decisions and actions related to:
a) Improvement of the effectiveness of the quality management system and its processes,
b) Improvement of product related to customer requirements, and
c) Resource needs support
Procedure No. QC SP 001 Management Review
Management Review Form: QC-F-MR418
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Edition: 01
Issued by: Ralph Sulser
Date: 08/31/05
Approved by: Keith Shepard
Rev. 4
RESOURCE MANAGEMENT DOC NO.: MSC-QM1
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6 Resource Management
MSC determines and provides the resources, such as competent personnel, proper working environment and adequate
infrastructure needed to implement and maintain the Quality Management System and continually improve its effectiveness.
Equipment and instruments needed for work and verification are identified, procured. Procedures are issued to ensure that
these are fit for use in carrying out work and verification activities.
Department Managers identify the resources required for implementing, performing and verification activities related to
MSCs quality management systems. These are further examined, reviewed and provided as and when required to enhance
customer satisfaction by meeting customer requirements. These resources are identified at the time of planning for product
realization and periodically reviewed (Refer Section No. 7.1). Necessary identified resources are planned and provided to
meet the requirements.
6.2.1 General
MSC has identified the competence level required for the personnel carrying out the activities in different areas of
operations and production departments. The Job Description (Profiles) for all functions have been defined on the basis of
requirements related to appropriate education, training, skills and experience for the specific jobs. Hence the personnel
performing such work, which affects product quality, are assigned the tasks on the basis of defined competence. The job
descriptions are also used for identifying the training needs of the personnel to ensure they are competent to do their
assigned activities.
MSC has established a documented procedure for Training. Through this procedure, the training needs of personnel are
identified to ensure competence for carrying out their activities. The controls exercised for making the personnel competent
are:
a) To determine the required minimum competence for the personnel performing work affecting product quality in terms
of criticality of the process through defined Job Description (Profiles) (Refer Section 6.2.1 above),
For process design responsible personnel this includes competence on design tools and techniques
a) To provide structured / unstructured training (i.e. technical college courses, on job training / coaching under the
supervision of their seniors) to the identified personnel to satisfy and meet their training needs. On the job training is
provided to all the personnel including temporary/contract personnel whenever there is any new or modified job/process
affecting product quality is incorporated. During this training, associates are informed of the consequences to the customer
of non-conformity to quality requirements.
b) To evaluate, after a defined period, the effectiveness of the structured / unstructured training provided, toward progress
in their achievements:
c) To ensure that the MSC associates are fully aware of the relevance and the importance of their activities including their
involvement and contribution to the achievement for the identified quality objectives.
d) To maintain records of education, training, skills and experience of all associates as quality records. These records also
help in determining the need for multi-skill training requirements, if any. (Refer to Skill Maps for each department)
f) A documented procedure has been established and maintained for employee motivation and empowerment for achieving
quality objectives, continual improvement and promote innovation. A process is in place to ensure that personnel are aware
of the relevance and importance of their activities and contribution in achieving quality objectives.
Procedure: HR SP 001 Training
Edition: 01
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Date: 04/02/03
Approved by: Keith Shepard
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6.3 Infrastructure
MSC identifies and determines, with a multidisciplinary approach, the required infrastructure at the time of Planning for
Product Realization (Refer Section No. 7.1). The infrastructure considered during planning includes:
a) adequate buildings for storage, processing, inspections
b) adequate workspace for working and house keeping, processing and storage
c) required associated utilities like power, compressors, water supply, fuel supply, utilities etc.;
d) required process equipment / machinery (both hardware and software) which can meet needs for converting the inputs
into required outputs at relevant stages of processing, and can meet the customer requirements.
e) supporting services, such as transport for movement within and outside of MSC and required means of
communication.
f) Plant layout is developed in such a way so that it optimizes material travel; handling and value added use of floor
space, and facilitates a synchronous flow of material. A system is in place to evaluate and monitor the effectiveness of
existing operation.
g) A contingency plan is prepared and followed in all manufacturing departments to ensure supply of products in the
event of emergency such as utility interruptions, labor shortage, key equipment failure and field returns.
As per the identified requirements, MSC provides the infrastructure needed to achieve conformity to product requirements.
MSC has also established a documented procedure, and preventative maintenance schedule matrix for maintaining the above
infrastructure by conducting preventive, condition monitoring and break-down maintenance in order to ensure continuing
suitability. The data related to maintenance is analyzed and maintenance objectives are established for continual
improvements.
MSC determines and manages the required work environment needed to achieve conformity
to product requirements as per documented process. At the time of planning for Product Realization
(Refer Section No. 7.1), the requirements of Work Environment are considered and examined and
wherever required, reviewed upgrading. The following applicable work environment factors
are considered at the time of planning:
Temperature, humidity, vibration, air quality, noise, lighting, as appropriate to the nature of the work being performed.
Cleanliness of premises is maintained using 5S check lists to ensure the premises in a state of order, cleanliness and repair.
Edition: 01
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Date: 04/02/03
Approved by: Keith Shepard
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The work conditions and environment are continually improved for meeting the product requirements. These requirements
are met by providing the adequate facilities and conducting regular maintenance for their upkeep.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
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Approved by: Keith Shepard
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MSC uses a multi-disciplinary approach for Planning for the products realization [using advance product quality process].
While Planning for product realization, it is ensured that the requirements of the other processes of the Quality Management
System (see 4.1) are consistent with the anticipated requirements.
Product and process regulatory requirements are also given due consideration during the development and preparation of
relevant Process Control Documents. The resources, infrastructure, work environment and competency of required
personnel are identified.
7.1.1 Customer requirements and references or differences to the specified technical specifications are included in the planning.
The following are considered, as appropriate, at the time of development, updating / modification for improvement in the existing
process:
a) identified quality objectives and requirements for the product; [7.1.2 Acceptance criteria are defined by the company, and approved
by the customer if required. The acceptance level for attribute data sampling is always zero defects.]
b) the need to establish processes, documents, and provide resources specific to meet the requirements of the product;
c) required verification, validation, monitoring, inspection and test activities specific to the products processed at relevant stages of
processes and the criteria for the product acceptance; Acceptance criteria for attribute data sampling is zero defects.
d) 7.1.3 Confidentiality of customer contracted product/projects and related product information.
e) records needed to provide objective evidence that the realization processes and resulting product fulfill requirements.
The business risks, the FMEAs (failure modes), their current status (i.e. Severity, Occurrence, Detection criteria) are studied and the
required controls are identified. If upgrades are required for improvements, then action plans are initiated.
The output of this planning in the form of a Control Plan, FMEA, Operator Process Instructions, or process control standards (PCS),
quality inspection plans are made and provided at the relevant stages of processing for implementation.
7.1.4 A system is in place to control and react to changes that impact product realization. Assessment, verification, validation is done for
the changes including the changes by the supplier.
Procedure No. MGT-SP-001 Contract Review
Procedure No. QC SP 023 Advanced Product Quality Planning
- requirements related to product including those specified by the customer, not stated by the
customer and statutory and regulatory requirements;
- conformity to customer requirements for designation, documentation, and control of special
characteristics;
- review of requirements related to product prior to supply and resolving any differences;
- amendments of relevant documents if product requirements are changed;
- investigating, conforming and documenting the manufacturing feasibility of the proposed product
- determining and implementing effective arrangements with the customer; and
- ability to communicate necessary information in customer specified language and format
7.2.1.1 Customer designated special characteristics are identified for conformance according to
customer requirements of the designation, documented and controlled
7.2.2 Review of Requirements Related to Product
MSC reviews the requirements related to the product. This review is conducted via a check list prior to the organization's commitment to
supply products to the customer and ensures that:
a) Product requirements including delivery schedules, packing requirements are clearly defined. Where the customer provides no
documented requirements, the customer requirements are confirmed before acceptance by: phone calls, e-mails, meetings, letters.
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b) Contract or order requirements differing from those previously expressed are resolved, and
Note: Printed documents are not controlled copies-check master computer files for latest revisions
c) MSC has the ability to meet the defined requirements.
d) Manufacturing feasibility including risk analysis is investigated, confirmed and documented before contracting.
e) In case any formal review of the contract is not applicable, prior authorization from the customer is obtained before proceeding
with the contract.
Records of the results of the review and actions arising from the review as quality records are also maintained.
If any amendments to product requirements are received from the customer, MSC ensures that these are reviewed for ability to supply,
and the relevant documents are amended accordingly. The modified documents are conveyed to relevant functions for making them
aware of the changed requirements for immediate compliance.
Procedure No. MGT-SP-001 Contract Review
Procedure No. QC SP 023 APQP
MSC has determined and assigned responsibilities for implementing effective arrangements for communicating with customers in
relation to:
a) Product information through customer visits, meetings, letters, e-mails, and web site.
b) Inquiries, contracts or order handling, including amendments, and
c) Customer feedback, including resolving customer complaints. Such feedbacks from customer are reviewed and analyzed for root
cause of the problems through problem solving techniques. The decisions taken for corrective and preventive actions including further
improvements in the products / processes.
d) Where required by the customer, necessary information including data is communicated to customers in their specified language
and format. (web sites, e-mail, electronic data exchange)
MSC only manufactures products from customer provided designs and specifications, and therefore performs only manufacturing
process design and development activities in conjunction with Planning for product Realization.
Upon receiving a Letter of Intent (LOI) or Purchase Order (PO) from the customer the organization develops a process design and
development plan defining the development stages design review, verification and validation requirements and responsibilities /
authorities for design and development.
7.3.2.1 The organization uses cross-functional teams for manufacturing process design and development. The team carries out feasibility
studies, prepares process flow diagrams, PFMEA, (process failure mode and effective analysis), develops Control Plans and identifies
special characteristics for products giving due care to product safety, utilizing appropriate mistake proofing methodologies with efforts
on defect prevention rather than detection and, creating internal awareness on safety considerations.
7.3.2.2 The design and development inputs are then identified, documented and reviewed based on product and customer requirements
and experience from previous developments.
Control Plans are developed at the system, sub system and component levels for the products supplied at the different phases via
Prototype, Pre-launch and Production as appropriate including listing all controls used for process control.
7.3.2.3 Manufacturing design outputs consist of process control guidelines, i.e., FMEAs, Control Plans, Process Standards and Operator
Process Instructions. These are marked with the customers special characteristics symbols, if specified by the customer on the
drawings/documents supplied.
All production processes, which directly affect the quality of products, are considered during quality planning. Control Plans are
reviewed and updated if the product or process changes, or becomes in-capable / unstable. Inspection methods, and frequencies are also
revised if necessary.
Process approval acceptance criteria data for quality, reliability, maintainability and measurability results of error-proofing activities.
Methods of rapid detection and feed back of manufacturing process non conformities are defined, as appropriate as an output, of the
design and development activity in the form of procedures, work instructions or process standards.
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maintainability SECTION#:
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activities.
Methods of rapid detection and feed back of manufacturing process non conformities are defined, as appropriate as an output, of the
design and development activity in the form of procedures, work instructions or process standards.
Programs of design and development is monitored at defined stages / frequency, analyzed and reported with summary results in the
management reviews.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
7.3.6.3 A procedure has also been established for production part approval process (PPAP) addressing the following activities as
applicable:
-identification of need for submission / preparation of PPAP
-decision on submission level
-Preparation of Part Submission Warrant and submitting a copy of PPAP document / sample to customer, as appropriate
-Maintaining original PPAP documents / records
-Maintaining master sample (s)
-Incorporating changes required by customer in the documents and processes
Part approval process is used for suppliers. The system ensures that the engineering changes are properly validated. Review, verification
and validation of the newly designed and developed manufacturing process is carried out at sample / prototype, production part approval
and pre-launch stages of production respectively. Developed product is reviewed at sample / prototype stage, verified and validated after
production part approval. Records of results of reviews, verification and validation of manufacturing process design and development
activities are maintained.
7.4 Purchasing
7.4.1 Purchasing process
MSC has established a documented procedure to ensure that purchased products conform to specify purchase requirements [including
conformity to applicable regulatory requirements]. The type and extent of control applied to the supplier and the purchased product
depends upon the effect of the purchased product on subsequent product realization or the finished / final product. The Company
evaluates and selects suppliers based on their ability to supply product in accordance with the Companys requirements [where specified
by the customer, purchasing is done from customer approved sources only unless waived by the customer.
Criteria for selection, evaluation and periodical re-evaluation have been established [monitoring of the supplier is done using
documented process which considers the indicators like quality, delivery schedule performance, premium freight, field return and special
status, customer notification]. Records of the results of evaluations and any necessary actions arising from the evaluation at company or
supplier end are maintained.
MGT-SP- 001 Contract Review (Sr. Manager Production Control and President)
PH-QP- 4.6 Purchasing Materials/Components (Production Control Manager)
PH-SP- 002 Approved Supplier List
7.4.2 Purchasing information
MSC has established criteria for detailing adequate Purchasing Information in the Purchase Documents (in hard copies / through e-
mails) for the products to be procured. The product and supplier details are described in Purchase Documents or e-mails, including where
applicable:
a) Requirements for approval of product, procedures, processes, and equipment,
b) Requirements for qualification of personnel, and
Quality management system requirements.
The authorized Production Control Manager or Purchasing Manager reviews the purchase information to ensure the adequacy of
specified purchase requirements prior to their communication or issue to the suppliers.
MGT-SP- 001 Contract Review (Sr. Manager Production Control and President)
PH-QP-4.6 Purchasing-Materials/Components (Production Control Manager)
PH- SP- 005 Purchasing Indirect Materials, Tooling, Supplies (Purchasing Manager)
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Note: Printed documents are not controlled copies-check master computer files for latest revisions
A goal has been established for quality management system development of suppliers That goal is eventual supplier conformity with
ISO/TS 16949-2002. As a first phase suppliers are encougred to pursue and obtain third party certification to ISO 9001-2000 and finally
to ISO/TS16949-2002 if applicable.
7.4.3 Verification of Purchased Product
a) MSC has established a documented procedure for implementing the Inspection / Testing or Verification of the products, as
necessary, for ensuring that purchased products meet the specified purchase requirements. The company ensures that through this
procedure for receiving inspection and testing, all material at incoming stage are inspected, tested/verified for conformance to the
specified requirements.
b) During verification of purchase product one of the methods as given below are followed:
- Receipt and evaluation of statistical data
- Receiving inspection and testing on the basis of sampling
- Assessment of supplier by customer or third party supported through acceptable product quality record. (Rec.Insp.)
- Test Report from accredited laboratory.
- Other methodology as advised by the customer.
c) If contractually agreed, the company also allows its customers or their representatives to verify that the purchased materials at
supplier end for ensuring materials conformance to specified requirements. When it is proposed to verify the purchased product at the
supplier's premises by either customer or companys representatives, the verification arrangements and the method of product release are
specified in the purchase order or its attachments.
Procedure No. QC SP 014 Receiving Inspection-Bar Stock
Work Instruction PD-WI-017 Receiving Steel Bars
Work Instruction PD-WI-HF-109 Receiving and inspection of ATV Billets
7.5 Production and service provision
7.5.1 Control of Production and Service Provision
Servicing, and Appearance Items are not currently a contractual part of Musashi South Carolina customer requirements, and not part of
MSCs current manufacturing operations. If in the future these become a requirement, we will address them in accordance with the
applicable specification, and/or standards.
Production is controlled by way of preparing and implementing Operator Process Instructions, Work Instructions, Check Sheets, and X
bar & R Charts. Suitable equipment, and monitoring and measuring devices are provided and maintained. Release and delivery activities
are implemented.
MSI Engineering Departments during Manufacturing Process Designing and Development process prepares initial FMEAs, Control
Plans, and Operator process Instructions. These are then modified to reflect MSC actual conditions.
7.5.1.1 Controls Plans are developed at the system, subsystem, component and / or material level for the product supplied, for different
stages of process development i.e. prototype pre-launch and production, from the process FMEA output.
Control Plans are reviewed and updated when any change occurs effecting product, manufacturing process, measurement, logistics,
supply source or FMEA.
7.5.1.2 The manufacturing departments carry out production based on the Operator Process Instructions and prepare any additional work
instructions necessary, and checklists for employee responsible for the operation of process including set up personnel, which are
accessible for use at the work station.
7.5.1.3 First piece set up is approved, before allowing mass production by authorized person during each job change of each operation.
7.5.1.4 Detailed checklists developed for each process equipment are used for preventive maintenance and predictive maintenance as per
the maintenance plans developed yearly and reviewed monthly.
Equipment, tooling and gages not likely to be used for a considerable time are packaged and preserved per a checklist.
A system has been established to assure minimum stocks of replacement parts for all key manufacturing equipment.
Maintenance objectives are developed in the beginning of financial year which are evaluated and improved at planned intervals.
7.5.1.5 A system for maintenance of production tooling has been established including maintenance personnel storage and recovery,
setup, tool change program for perishable tools; tool and tool design modification, documentation, tool identification and tool status.
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7.5.1.5 A system for maintenance of production tooling has been established including maintenance personnel storage and recovery,
setup, tool change program for perishable tools; tool and tool design modification, documentation, tool identification and tool status.
7.5.1.6 The production scheduling is customer order/ forecast driven and supplies are made just in time based on customer
schedules/releases and electronic dispatch instructions (EDI).
7.5.1.7 Customer feedback from service or field performance concerns is transmitted to the company via web customer web site, e-mail,
and phone calls.
7.5.1.8 MSC currently does not have any service agreements with customers. If in the future Service Provisions become a requirement,
we would develop a procedure to incorporate those requirements
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Related procedures/Instructions:
The Company has established a system for product identification and traceability, which requires that products be identifiable to the
applicable specifications, as appropriate. Incoming materials, WIP, and finished packaging are identified by a lot tag giving details of part
lot numbers, part name, and part number. Identification of all products at different stages of activity in the plant is maintained from the
beginning billet shear operation through finished product to final packaging operation to the customer for all products.
Work In-Process is also identifiable and traceable by part number lot tags. The products lot traceability is also identified through the data
documented on the each parts check sheets. These sheets become quality records at each operation, and are traceable to date of
production operations, inspection/testing / packing. The traceability lot tags are assigned at each operation and logged in and out, and is
also provided on packaged products sent to the customers.
The inspection and test status of items are identified through lot identification tags, inspection records, designated staging/storage areas
and placards, as applicable. The identification, inspection and test status of incoming items are identified based on suppliers tags/labels,
and certificate of conformance and / or the inspection and tests performed. These are then stored at designated locations. Separate areas
have been identified and marked for incoming materials, and non-conforming items.
MSC takes due care with customer property while under the MSCs control, or being used by the MSC. MSC may receive products,
samples, drawings and packaging from the customers. A documented procedure identifies, verifies, protects and safeguards the customer
property provided for use or incorporation into the product. If any customer property is lost, damaged or otherwise found to be unsuitable
during verification for further use, it is reported to the customer and the necessary records are maintained.
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Note: Printed documents are not controlled copies-check master computer files for latest revisions
Every employee is responsible for safe handling of the products at various stages of processing.
Handling, storage and transportation of products is to be controlled to prevent damage, deterioration or loss. When necessary, for
particular items, special instructions are issued and monitoring is carried out to check satisfactory implementation. The appropriate
handling of products is followed to avoid any deterioration of quality of product while in transit.
7.5.5.1 Appropriate storage areas are provided for materials and products for protection, and to prevent damage and deterioration of the
product quality, including suitable preservation wherever necessary. The condition of the products in stock is assessed at appropriate
intervals.
All raw materials are issued on First In-First Out basis. An inventory management system is also used to optimize inventory turns. Work
instructions have been established for inventory management. FIFO is utilized for issuing and using stock. Obsolete products are treated
as non-conforming.
A system for packing, packaging, marking, considering customer packaging standard and labeling / marking requirements have also been
established.
PC SP 001 Handling, Storage, Packing, Preservation
PC WI 002 Production Planning
PC WI 010 Monthly Inventory Corrections in the AS400
PC WI 011 Process Count Inventory Adjustment
The range of measurements and required accuracies are determined by the gage control technician. Measuring devices, including test
software if necessary, used for conforming product quality, are selected based the capability of meeting the necessary accuracy and
precision. This ensures that the measurement uncertainty is known and is consistent with the required measurement capability.
The measuring devices that can affect products are identified and calibrated / verified / adjusted / readjusted at prescribed intervals,
against measurement standards traceable to national / international measurement standards.
Where no such standards exist, the basis used for calibration is recorded. If applicable, test software and test hardware used for
inspection purposes are checked at prescribed intervals to assess their capability to verify the acceptability of product.
Master list and calibration records containing necessary details are maintained in a controlled computer "Master file" by the QC Gage
Calibration Technician, for all such devices. They are identified with a suitable indication through use of an engraved code number, a
label, or color coded mark indicating the calibration status, and due dates for re-calibration.
Persons using the calibrated equipment are trained to handle, store and preserve them appropriately to prevent damage and maintain the
accuracy and fitness for use.
Provisions to safeguard the calibrated equipment from adjustments and setting are also made as and where applicable.
The calibration is carried out under controlled conditions as detailed in the relevant procedures.
Any measuring devices that fail during operation, are suspect, known to be outside its designated criteria or show evidence of physical
damage affecting accuracy are removed from the location of use and isolated by the Gage Control Technician. Validity of inspection and
test results of parts checked with measuring devices found to be out of calibration is assessed as applicable. If it has been determined that
suspect material has been shipped, MSC will recall that material from transit, or notify customer if already delivered. Edition: 01
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Any measuring devices that fail during operation, are suspect, known to be outside its designated criteria or show evidence of physical
damage affecting accuracy are removed from the location of use and isolated by the Gage Control Technician. Validity of inspection and
test results of parts checked with measuring devices found to be out of calibration is assessed as applicable. If it has been determined that
suspect material has been shipped, MSC will recall that material from transit, or notify customer if already delivered.
7.6.1 Measurement System Analysis is carried out for each type of measuring and test equipment, referred in the control plan, using
appropriate statistical techniques. The analytical methods and acceptance criteria used conform to those in customer reference MSA
manual.
7.6.2 Records of calibration / verification of all measuring devices include: equipment identification, measurement standard used for
calibration, revisions following engineering changes, any out of specification reading as received for calibration with their assessment of
impact, statement of conformance to specification after calibration and notification to customer if suspect material or product may have
been shipped are maintained as defined in the relevant procedure.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
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7.6.3.1 MSC has an established system and procedure for the internal laboratory with a defined scope, which includes the capability to
perform the required inspection, test and calibration services.
The technical requirements for compliance by the laboratory include: adequacy of the laboratory procedures, qualification of the
laboratory personnel conducting test, testing of commodities and capability to perform these test correctly, traceable to relevant process
standard (e.g. ASTM) and review of related records.
7.6.3.2 External laboratories selected for inspection, test or calibration purposes are based on capability to perform the required
inspection/ test / calibration, and its accreditation of ISO / IEC 17025 or national equivalent or its acceptability to customer.
Computer Software, when used in the monitoring and measurement of specified requirements, are validated at the time of installation
and records are maintained. The ability of computer software to satisfy the intended application is confirmed. As and when such software
is updated, the same are again re-validated and the results are re-confirmed. Such software is re-confirmed at specified frequency as
referred in the documented procedure.
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8.1.1 Appropriate statistical techniques are determined during manufacturing process design and included in control
plan.
8.1.2 Training on basic statistical concepts, such as variation, control (stability) process validity and over adjustment is a
competency requirement throughout the organization.
Related Procedures
QC SP 006 Control Plans
QC SP 007 FMEA
HR SP 001 Human Resource Training
QC SP 013 Statistical Process Control
Currently MSC does not have service, or aftermarket provisions required by customers. In the event service applications are
required, products with visible nonconformances detected will not be reworked without prior approval of customers.
Prior written customer approval is obtained whenever the product or process, that affects the final product, is different from
that approved in Production Part Approval Process (PPAP). (Ref. Also SCR-Supplier Change Request)
Quantity/time criteria for this approval is maintained. The system ensures that the product / process conforms to original or
superceding specifications on expiration of this approval. Material shipped after customer approval is appropriately
identified.
When non-conforming product is detected after delivery or use has started, necessary actions, including customer
notification appropriate to the effect, or potential effect, of the non-conformance is taken. Records pertaining to control of
nonconforming products are maintained as per relevant procedures.
8.3.1 Related Procedures
QC SP 016 Control of Non Conforming Product
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Note: Printed documents are not controlled copies-check master computer files for latest revisions
8.4 Analysis of Data
The organization prepares and maintains trends in quality, productivity, delivery, cost, safety and other performance
measures. This demonstrates the suitability and effectiveness of the quality management system. The data is used to evaluate
/ identify opportunities for continual improvement of the effectiveness / performance of the quality management system.
This includes data relating to customer satisfaction, conformance to product requirements, characteristics and trends of
processes and product and suppliers.
The trends are compared with progress towards overall business objective, and appropriate benchmarks.
Key customer related trends are determined and action plans prepared and prioritized for prompt solutions to customer
related problems. The trends are presented in the Management Review Meeting, where they are reviewed along with actions
plans if necessary.
8.5 Improvement
A procedure has been established defining a method for controlling the process for continual improvement, and for
continually improving the effectiveness of the quality management system and the performance of the organization.
The continual improvement process also focuses on control, reduction of variation in product characteristics, and
manufacturing parameters. This occurs once manufacturing processes are capable and stable and product characteristics are
predictable and meet customer requirements.
All customer complaints, customer returned products, reports of product non-conformances identified during the process are
analyzed, using disciplined problem solving methods; causes relating to product, process and quality systems are
established; and countermeasures are taken to eliminate the causes.
Non-conformances observed and reported by customer if any, are responded to in manner prescribed by the customer.
The effectiveness of the corrective action is verified from the quality of subsequent product processes, or internal audits.
Wherever applicable the successfully implemented corrective actions and controls are applied to other similar processes and
products to prevent possible non-conformances.
Mistake proofing methods are used as part of corrective and preventive action process, appropriate to the magnitude of the
problem.
Trends in non-conformances observed in internal quality audits, incoming material, production process, final inspection,
customer complaint, delivery performance, process capability, vendor delivery performance, customer satisfaction index,
etc. are analyzed to determining potential non conformances and preventive action taken to prevent their occurrences.
Effectiveness of the preventive action is reviewed. Changes in quality system / processes are documented and summary of
the preventive action taken are submitted for Management Review.
Records of results of corrective and preventive actions including analysis of customer returned products are maintained.
Documented procedures established for corrective and preventive action are as follows.
8.5.1 Related procedures
QC SP 019 Corrective Action
QC SP 020 Preventive Action
QC-SP 021 Continual Improvement
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MSC will adhere to its customer specific requirements in relation to TS16949:2002, or other standards as necessary.
See Visteon Customer Specific requirements. Currently, we do not have any other business with the companies who have
requirements in Section 2. In the future, should business with customers be realized that have these requirements, MSC will
fulfill their specific requirements.
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MUSASHI SOUTH CAROLINA QC-Flow.Doc.-101
PROCESS INTERACTION VISTEON BEVEL GEARS Rev. 2 8/15/03
OPERATIONS
Quallity Decisions Start Bevel Gear INPUT INPUT
Intructions/Methods Manufacturing
Customer Inputs
APQP: R.F.Q., P.O.
Work Instruction Steels bars from Feasibility, Control Plan, Design Drawings
Receive Steel
FMEA, Process Design, Build Schedules
Accept approved supplier Non-conformance
Process Validation(CPk) Delivery Schedules
yes PPAP
no -------------------------->
C.O.A.
Deliver to Sizing
yes no -------------------------->
Inspect-
checksheet, +
X&R
Deliver to Lathing staging area
yes no -------------------------->
Inspect/Test
checksheet, +
X charts
Route thru to shot peen/blast
CUSTOMERS
Customers
Customer Contact Contracts Review Plan Defines Establish Data Analysis Customer Launch Mass Ship on
Liaison RFQ Feasibility Review Process Processes Capability Review Approval Product Production Time
Inputs Order Info Delivery Reqmnts. Product PPAP Monitor Monitor
Business decisions - Refine controls CPks Analysis Analysis Outputs
Feedback - Instructions OPIs
- Training Meas. Equip.
Continual Improvement Communicate
5.2,7.2 MSC
President & Sr, Contract Review
Mgr.PC/Sales ..\Procedures\MGT-SP-001.doc
Regulatory. legal
requirements Payroll
* Additional SOP
Inquirey/R
FQ Review all customer requirements
with Contract review team-MSC
MGT-SP-001
Determine timing & Determine machines & Determine manufacturing Determine quality criteria,
Define total manufacturing & delivery equipment feasibility, customer requirements
tooling costs availability
Receive prototype
Source & Receive, tooling if needed Resources Staffing Establish Quality
Planning & Procure Raw inspect &
Receive P.O. for Plans-APQP
Prototype Material store Prototype Build
Prototype build if reqd. QC-SP-023
Build
PH-SP-002 Determine & procure
Gaging systems
QC-SP-017 Gage Control
Control Plans QC-SP-006
Source tooling and Order & receive Mass Establish training FMEAs 007 OPIs SP010
timing production tooling needs Cpk development
Customer feedback and communications -e-mails, Ph. Calls, 8D info--gathered & dispersed to appropriate function(s), countermeasures meeting to close all issues and concerns
Customer
Feedback Corrective Action Corrective Action QC-SP-019 Corrective/ Preventive Action
Management Responsibility
Operational Management
QMS Planning and Objectives
Quality Policy - Business Planning..\Policies\QUALITY POLICY.doc
QMS Performance Analysis
Management Review..\Procedures\QC SP 001.doc
C Internal Communication
C
----------------------------------------------------
U Control of Documents..\Procedures\QC SP 003.doc
U
Control of Records..\Procedures\QC SP 004.doc
S S
T Resource Management Measurement, Analysis, Improvement T
O Human Resources Maintenance..\Procedures\MT-SP-001.doc Data Analysis..\Procedures\QC
Customer Issues..\Procedures\QC SP 011.doc SP 013.doc O
Tool & Die
Training..\Procedures\HR-SP-001.doc
M EHSEHS.policy.doc Tool Management
Improvement
Internal Auditing..\Procedures\QC Projects
SP 018.doc
Inspections, Testing..\Work Instructions\PD-WI-015.doc
Corrective Action..\Procedures\QC SP 019.doc M
Employee Motivation
E Preventive Action..\Procedures\QC
Control of NC Product..\Procedures\QC SP 016.doc SP 020.doc
E
R Product Realization R
S Process Planning..\Procedures\QC-SP-023.doc
Purchasing..\Policies\4.6.doc S
Engineering Realization Processes
Receiving ..\Procedures\QC SP 014.doc
Support Processes
Production Control..\Production Control\PC-WI-002Prod.Plan.doc
Storage..\Procedures\PC-SP-001.doc
Shearing..\Work Instructions\PD-WI-SH-101 Shear Oper..doc
Inventory Control
Hot Forging..\Work Instructions\PD-WI-HF-102. 630&800TP.doc
Quality Control
Require- Cold Forging
Calibration and MSA..\Procedures\QC SP 017.doc
Bevel Gear Lathing..\Work Instructions\PD-WI-L103.doc
Satis-
ments ID/Traceability..\Procedures\QC SP 015.doc Parts faction
ATV Gear Lathing
Production Tooling
Heat Treating..\Heat Treat.5.20.02\100.doc
Laboratory..\Procedures\QC SP 008.doc
ATV Gear Assembly..\Work Instructions\PD-WI-A001.Gearing test and inspection.doc
Input Shipping..\Production Control\PC-WI-003Visteon Shipping instruction.doc Output
ORGANIZATIONAL CHART
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ORGANIZATIONAL CHART DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA
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a) Communicating to all employees of the company: the importance of meeting customer as well
as statutory and regulatory requirements through regular training programs, display of documents
and departmental meetings, communication meetings, and management meetings.
b) Establishing the quality policy based on the improvement objectives,
c) Ensuring that quality objectives are established,
d) Conducting regular management reviews, and
e) Ensuring the availability of resources for improvements when required.
f) Product realization process and support processes are reviewed for their effectiveness and efficiency
Methods of determining customer requirements, expectations and satisfactions are defined in the procedures
The Management of the company has defined the quality policy ensuring that the quality policy
a) is appropriate to the purpose and organizational goals of the company,
b) includes a commitment to comply with requirements and continually improve the effectiveness of the quality
management system,
c) provides a framework for establishing and reviewing quality objectives,
d) is communicated to all employees of the company and is understood at all levels in the company,
Edition: 01
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The Policy of the company has been displayed at strategic locations and also distributed to all employees. Periodic Training
Programs are held for understanding by all the functions through out the organization. Quality Policy distribution and
display records are maintained.
The policy of Musashi South Carolina is to achieve total customer satisfaction by delivering products and providing services
that meet or exceed customer quality requirements and expectations. Deliver on time, and at the most competitive prices in
domestic and export market for our entire product range.
It is implied that all people at all levels in our organization be committed to comply with requirements and continually
improve the effectiveness of the Quality Management System and their performance. Ultimate goal of working towards
achieving zero defects. Necessary measures are also taken towards product safety, and environmental needs to minimize
potential risks to employees, and subsequent end users.
Our mission is to make Musashi South Carolina a synonym for a world-class organization excelling in gear, and gear
assembly manufacturing.
MSC Senior Management, Department Managers, Assistant Managers, and area Team Leaders shall ensure that this policy is
understood, implemented and maintained by all personnel in their respective division / department / section.
QUALITY POLICY
MSC will continually strive to produce quality products that meet
or exceed customer expectations, cost competitiveness, and timely
deliveries QCD (Quality, Cost, Delivery) through exercise of
continual improvement, employee support, and customer
communication.
Process interactions of achieving product realization are described below outlining typical duties, and
inputs of the department management to focus on objectives, and
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Process interactions of achieving product realization are described below outlining typical duties, and
inputs of the department management to focus on objectives, and
customer satisfaction. Current plant organizational charts are on file in H.R.
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Preventive/Predictive Maintenance, Tool/Die, Mechanical, Electrical, Compressor, pump house and LPG and all utilities
Manages, and coordinates any modifications to be carried out in the existing operations or enhancing the efficiency of
the plant.
Responsible for building the required competency level in the employees reporting to him.
Assisted by Managers, and Assistant Managers for Forging, Lathing, Heat Treat/Assembly, for these activities.
Assisted by Manufacturing Engr. Mgr, Maint. Manager.
Authorized for approval of production processes in the plant.
Authorized for taking corrective & preventive action in case of deviations in the operations.
Authorized to STOP PRODUCTION in his area, if systems are not being implemented.
Developing facilities, processes and equipments.
Guiding and supporting QMS activities including regulatory requirement if any, for the products.
Reviews customer scorecards for Visteon, and other customers, on their web sites
Reports to the Plant President.
3. Accounting Manager
Overall responsibility for all accounting, finance, and supplies purchasing functions in the plant.
Assists in guiding and supporting QMS related activities in those functions such as purchased supplies, tooling, and
stores.
Assisted by the, Assistant Manager of Accounting, and the Assistant Manager Purchasing/Buyer, Accounting
Coordinator, and IT Administrator for these activities.
Reports to the Plant President.
Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
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Representing the needs of the customer in internal functions addressing the product realization planning (APQP) for
ISO/TS 16949 requirements (e.g. selection of special characteristics, setting quality parameters.
Develops manufacturing process design quality controls including Process Flow Diagram, FMEAs, Control Plans and
Process Standards, and Inspection Standards.
Reports to the Plant President
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Reviewing, recommending and providing guideance for effectiveness of the procedures on Product requirement
Review Manufacturing Process Designing and Development; Plant Facilities and Equipments Provisioning,
Developing guidelines of new products planning.
Reviewing customer engineering specifications and standards.
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5.4 Planning
5.4.1 Quality objectives
Top management ensures that quality objectives, including those needed to meet requirements for product [see 7.1 a)] are
established at relevant functions and levels within the organization. The quality objectives are measurable and consistent
with the quality policy.
Top management defines quality objectives and measurements that are included in the business plan and used to deploy the
quality policy.
Quality objectives address customer expectations and achievement goals within a defined time period.
5.4.2 Quality management system planning
Top management ensures that
a) the planning of the quality management system is carried out in order to meet the requirements given in 4.1, as well as
the quality objectives, and
b) the integrity of the quality management system is maintained when changes to the quality management system are
planned and implemented.
5.5 Responsibility, authority and communication
5.5.1 Responsibility and authority
Top management ensures that the responsibilities and authorities are defined and communicated within the organization.
5.5.1.1 Responsibility for quality
Managers with responsibility and authority for corrective action are promptly informed of products or processes that do not
conform to requirements.
Personnel responsible for product quality have the authority to stop production to correct quality problems.
Production operations across all shifts are staffed with personnel in charge of, or delegated responsibility for, ensuring
product quality.
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d) liaison with external parties on matters relating to the quality management system.
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5.5.2.1 The Sr. Manager-Quality Control has been designated as Customer Representative to assure customer requirements
are addred within MSC. Visteron will be notified of any changes to customer rep., or senior mgmt.
5.5.3 Internal communication
The Management of the MSC ensures that appropriate communication processes are established within the company and
that communication takes place regarding the effectiveness of the quality management system, and actions to be taken on
non-conformances encountered in the activities including customer communication.
Top Management of MSC reviews the companys quality management system, at planned intervals to ensure its continuing
suitability, adequacy and effectiveness. The Quality Management System of the company is reviewed by the Management
Review Team that comprises all Managers of Departments under the Chairmanship of the President.
The review includes assessing opportunities for improvement and the need for changes to the quality management system,
including the quality policy and quality objectives. Management Representative maintains records of management reviews.
5.6.1.1 Quality Management System Performance-Input
- All requirements of the quality management system, performance, and trends for continual improvement.
- Monitoring quality objectives
- Regular reporting and evaluation of cost of poor quality
- Evidence of achieving: quality objective specified in the business plan
- Evidence of customer satisfaction with products supplied
5.6.1 Review input
The input to management review in the form of Agenda for Management Review in Steering Committee meeting includes
information for the period under review on all elements of QMS STANDARDS. However, more focus is placed on the
following:
a) Business Plan/Quality objectives
b) Cost of poor quality
c) Customer satisfaction, feedback, (Customer perceptions & Complaints)
d) Analysis of actual and potential field failures and their impact on quality, safety or the environment
e) Follow-up actions from previous management reviews,
f) Results of internal/external audits including the trends,
g) Process performance and product conformity,
h) Status of preventive and corrective actions,
i) Planned changes that may affect the quality management system, and
j) Recommendations for improvement especially for product / process characteristics,
k) Status and results of Quality objectives and Quality Improvement Programs,
l) Performance of Suppliers, e.a., monthly ratings for quality, and delivery
5.6.2.1 Additional Review Inputs
a) Management analysis of actual and potential field failures, and their impact on quality, safety, or the environment.
b) Measurements at specified stages of design and development will be defined, analyzed, and reported with summary
results. Items such as quality risks, costs, lead times, critical paths, and others as appropriate.
5.6.3 Review output
The minutes of the management review meeting are recorded and maintained for a specified period. The output from the
management review in the form of minutes of meeting and action plans include any decisions and actions related to:
a) Improvement of the effectiveness of the quality management system and its processes,
b) Improvement of product related to customer requirements, and
c) Resource needs support
Procedure No. QC SP 001 Management Review
Edition: 01
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