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ROOP AUTOMOTIVES LTD.

Supplier Quality Assurance

Manual

RAL-SQAM-001 Rev.00

COPYRIGHT STATEMENT

This document is the property of Roop Automotives Ltd. and no part of this may be reproduced without prior written permission.

Effective since 01.01.2016

of 38

Revision Status of Supplier Quality Assurance Manual RAL-SQAM-001

S. No. Revision detail Rev. No. Rev. Date

1 First Edition 00 01.01.2016

Supplier Quality Assurance Manual

Page 2 of 38

Table of Contents Page

1.0 Introduction 6

2.0 General 7

2.1 Vision 7

2.2 Mission 7

2.3 Quality Policy 7

2.4 Environmental Policy 8

2.5 Health & Safety Policy 9

3.0 Scope 10

4.0 Objective of Supplier Quality Assurance manual 10

5.0 Prerequisite for Supplier Approval 11

5.1 Supplier Quality Assurance System Site Self- Assessment 11

5.2 On-Site Quality System Site Assessment 11

6.0 Requirements for existing suppliers 12

6.1 Requirements for existing & New suppliers 13

7.0 RAL’s Specific Requirements 13

7.1 Quality System 13

7.2 Right of access 13

7.3 Advanced Product Quality Planning (APQP) 13

7.4 New Product Development by Supplier 13-14

7.5 Special Processes 15

7.6 Material and Print Specifications 15

7.7 Proprietary items 15

7.8 Engineering Source Approval 15

8.0 Hazardous Material 15

9.0 ELV Compliance 16

10.0 Supply Chain Management 17


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11.0 Education & training 17

12.0 Managing Change 17

13.0 Special Characteristics 18

14.0 Samples 19

15.0 Label Identification Requirements 19

16.0 Production Part approval Process (PPAP) 20

17.0 PPAP documents required from supplier 20-21

18.0 Material / Product Deviations 22

19.0 Traceability 22

20.0 First In First Out 23

21.0 Verification of Purchased Product 23

22.0 Cleanliness Requirements 23

23.0 Non-Conforming Product/ Corrective & preventive action/ Supplier charge back 23-24

24.0 Shipment and Packaging Requirements 25

25.0 Supplier evaluation 26

26.0 Record Retention 27

27.0 Re-validation/Layout inspection 27

28.0 Pre-dispatch Inspection report 27

29.0 Supplier Audits 28

30.0 Other Requirements 28

Additional Information 28

31.0 Controlled Shipping 28

32.0 Implementation criteria for Controlled shipping 29

33.0 Exit criteria for Controlled shipping 29

34.0 Mistake – Proofing 29

35.0 Continual Improvement Process 30

36.0 Statistical Techniques 30

37.0 Cost Reduction and Continuous Improvement 31


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38.0 Government and Safety Compliances 31

39.0 Supporting Documents 31

40.0 Examples of Records for Retentions May Include but are not limited to 32

Forms/Tags 34-38


Page 5 of 38

Management Message

The release of our first “Supplier Quality Assurance Manual” is a unique opportunity to come to the

same platform unitedly with our suppliers to meet and exceed the needs of our Customers

This manual shall be the window through which we share key business requirements and

performances with our supplier partners in order to

1. Increase Suppliers Participation.

2. Implement Proven Quality & Management Practices.

3. Improve our products.

4. Create Opportunities for sustainable and mutually profitable business.

In today’s technology driven world, assurance of innovative & learning environment is a key issue in

assuring effective & nurturing/developing quality practices.

Quality develops strong partnership with people, communicate their shared purpose high standards &

values, undertake regular & ongoing evaluation & are open & honest in sharing information.

The technique of TQM with the concept of sustainable development has been the key to success of

many small & big organisation, as TQM is a management philosophy that supports the process of

continuous improvement within an organization, where total emphasis is placed on customers. In

manufacturing that too auto components, the conditions are tougher & we believes & practice two

points;

-Quality is seen: which is overall view & perception when customer enters our premises & judge how

company believes in Quality, as measurement & checking follows later.

-Quality in Mind (QIM): as everything starts on your thinking & believe in Quality.

We want to take this opportunity to reinstate that “Our focus on Training and Development to the

Team” must not be ignored. Our investment in skill up-gradation and new skills acquisition will not only

help team grow into better professionals but also yield qualitative results for your organisation. This will

directly impact your Top and Bottom line.

We as partners welcome you all to our Training programs that happen at our facilities time to time, and

shall keep you abreast with the events and appreciate your participation.

Roop Automotives acknowledge, appreciate and applaud efforts of all our business partners in terms

of quality, cost & service. Thus we want this manual to serve as a roadmap for our continued

partnership towards Global Leadership.

Mohit Oswal P. K. Salhotra Gaurav Jain


Page 6 of 38

1.0 Introduction

Presently, Roop operates out of three geographical locations in India

GUJARAT (upcoming)

UNIT IV: Plot PE 121, Sanand II, Industrial Estate, Near Village Bol,

Ahmedabad- 382110

HARYANA

UNIT I: Plot 19, 30, 31 and 210, Rozka Meo Industrial Area, Sohna, Gurgaon, 122103 UNIT II: Plot 439, 440, Sector 8, IMT Manesar, Gurgaon, 122050

TAMIL NADU

UNIT III: PLOT A 10 1 (A), Sipcot Industrial Park, Irrungattukottai,

Sriperumudur – 602 105


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2.0 General

2.1 Vision

“Aim for operational excellence and consistently enhance our technical capabilities and know how, hence becoming a supplier and employer of choice”

2.2 Mission Compete: To become No. 1 supplier with all customers Develop: To develop world class teams including strategic business partners Deliver: To exceed our customer requirements and deliver values to all stakeholders Build: To build an organisation based on fair practices

2.3 Quality Policy

To continuously upgrade systems and methods to improve quality of our Products;

To meet & exceed Customers’ requirements.


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2.4 Environmental Policy

Roop Automotives Ltd, engaged in the manufacturing of automotive components, is all set to achieve brilliance in its environmental performance through sound environmental management systems (EMS).

To attain this we obligate ourselves to:

Integrating environmental friendly practices in all our business processes and practices by elimination or minimization of environmental impacts of the same, with specific consideration to the substitution of potentially unsafe chemicals which pose a serious threat to the ecosystem or have the potential to do so in case of an accident.

The effective treatment of smoke & dust, waste water and other industrial effluents through sound effluent management.

Developing, implementing, achieving, reviewing and maintaining the environmental policies in accordance with the applicable legislations.

Keeping the consumption of renewable resources within the limits of their replenishment by conservation of resources like oil, water, electricity, paper, etc. and wise consumption of others.

Instilling awareness among employees for maintaining a pollution free environment and enhancing environmental consciousness among our business associates, suppliers and contractors.

Ceaseless product innovation to improve environmental compatibility.


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2.5 Health & Safety Policy

Roop Automotives Ltd. exhibits total commitment to the better health and full safety

of its employees and other persons who may be affected by its operations. We envision

that safe work practices results into better business performance, raised level of

motivation of workforce and higher productivity. Hence we commit ourselves to

implement the formulated polices; equally, fairly & without and exception; to create a

safe and healthy work environment a culture of our organization.

We shall attain this by:

Integrating health and safety matters in all our activities

Creating healthy mindset and developing wellness & fitness attitude among all employees by educating adequately, imparting practical training, empowering and motivating properly so that they are safety conscious and they follow safety rules in full and practices safe work habits at all the hours.

Applying proper techniques for the execution of the tasks and adhering to the injury prevention & safe practices. Will work for the continual improvement in OH & S management & OH & S performance

Follow all the applicable legal & other requirements

Promoting health & safety awareness amongst suppliers and contractors.

Control of man, machine performance and physical environment for prevention as well as correction of unsafe conditions & circumstances.

Regular identification of unsafe conditions and timely corrective actions for the same.

Planned and systematic effort in the execution of the task to minimize accident frequency rate and to achieve longer accident free period continuously.


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3.0 Scope

The requirements given in this manual are applicable to all the suppliers supplying

material to any plant of Roop Automotives Ltd.

Exclusions:

Customers who supplies Raw Material/BOP to RAL.

Tooling/Machineries/Gauges/General consumable item suppliers

Job workers who does rough machining for RAL (not a finished dim. as per

Customer drawing)

4.0 Objective of Supplier Quality Assurance Manual

The objective of this Supplier Quality Assurance Manual of Roop Automotives Ltd.

hereafter called RAL is to communicate clearly the conditions of doing business with

RAL and to develop systems that drive continual improvement, prevent defects, and

reduce variation and waste in the entire supply chain. Information presented in this

manual are RAL precedence, unless officially notified by authorized RAL personnel.

Suppliers are responsible for the quality of their products and services.

Our suppliers are expected to have;

Zero incidents for

a. Minor issue- Which does not affect production or assembly at RAL.

b. Repetitive issue- Which does not affect production or assembly but is a

recurring nonconformance.

c. Major Non-conformance- Which directly affects production and assembly.

A DAR (Defect Analysis Report) may be issued to the supplier when non-conforming

material is detected (Format attached)


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Zero disruptions

– Cases of failure in supplying the material on time which resulted into line stoppages

at RAL/Customer.

Zero defect

– Supplier is expected to deliver defect free products

Flawless delivery performance

– Supplier is expected to deliver defect free product on time.

On-time responsiveness to issues

– Supplier is expected to be responsive on the issues related to customer complaints,

new product development, RFQ’s etc. on time

The original RAL Supplier Quality Assurance Manual is a controlled document.

5.0 Pre-requisite for Supplier Approval

5.1 Supplier Quality System Site Self-Assessment

A potential supplier will complete the supplier self-assessment in order to provide RAL

with a general understanding of their quality management system.

5.2 On-Site Quality System Site Assessment

An on-site quality system assessment is required prior to issuance of any initial

purchasing agreement.

The supplier shall be evaluated based on the following criteria.


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Manufacturing feasibility.

Commercial viability.

Quality assurance Systems.

Capacity available

Fair Business Practices.

Safe working environment

Supplier to provide proof of financial stability in the form of balance sheet or auditor

certificate that there is no default of financial repayments and that funds from

operation are sufficient for normal operations.

6.0 Requirements for Existing Supplier

As part of RAL quality surveillance program.

The assessment will be conducted by a RAL representative(s) and who will verify

the existence of a quality system and the disciplines necessary to meet its

requirements in the following conditions

Prior to placement of significant new business.

As a result of not meeting required quality performance/quality issue.

When there is a significant change (refer PPAP manual table 3.1 customer

notification) in the supplier facility.

A change in ownership (transfer of stake >15%, cumulative).

Change in facility / change in use of equipment.

A significant change in the nature of the product previously supplied e.g. if a

supplier is supplying hot forgings & sets up a cold forging facility, the same

would be subject to a fresh audit.

During development of the new parts, RAL Purchase department will consider the

supplier rating & for selection, consideration will be given on the past performance.


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6.1 Requirements for Existing & New Suppliers

7.0 RAL’s SPECIFIC REQUIREMENTS

7.1 Quality System: Suppliers must have a documented quality system in

compliance with latest version of either ISO: 9001 or TS16949 and agree

to on-site assessment by RAL. It is preferred that suppliers be registered

to one of the standards listed above.

7.2 Right of Access: Supplier must offer the right of access at their premises

to RAL & its customer. In case of emergency, RAL/ RAL’s Customers can

visit supplier even without intimation to supplier.

7.3 Advanced Product Quality Planning (APQP): As requested, the

Supplier must have resources available and capable of performing APQP

and Production Part Approval Process as per latest AIAG manual.

7.4 New Product Development by Supplier

Any new product offered to the supplier has to follow the process flow

chart as follows:


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Process Flow Chart

Not OK

OK

OK

Selection of Supplier

Issue of Drgs /Applicable Std. to

Supplier

Quotation received from Supplier

with detailed break up.

Finalise the supplier/ Commercial Settlement

Issue of L.O.I./P.O.

Request for Quotation

Formation of CFT

Team Feasibility

Submit Development

plan

Submission of Samples

with Report

Insp. of

samples

Capacity, Capability, Quality Verification

Approve the PPAP.

Go ahead to

Supplier for PPAP

run

Reject the PPAP.

Not OK

Not OK

OK

RAL SUPLLIER

PPAP Run


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7.5 Special Processes

Supplier supplying the material with the below mentioned processes must qualify the

below standards. An audit for the same will be conducted by RAL on annual basis.

a) Heat Treatment------CQI 9

b) Plating------------------CQI 11

c) Any other mentioned in customer requirements & or considered as special process.

7.6 Material and Print Specifications

Suppliers must produce products for RAL to the print specifications. The same is

expected from their sub-suppliers too. IMDS for all the Raw material/BOP items is

essential wherever applicable.

7.7 Proprietary items

In case of proprietary items (whose design & testing responsibility is of suppliers),

specification once freezed can’t be changed without prior approval from RAL. IMDS for

all the material is essential wherever applicable.

7.8 Engineering Source Approval

RAL specified material or sources must be adhered to. Any changes shall require prior

approval from RAL.

8.0 Hazardous Materials

Suppliers must supply all information related to Hazardous Materials, and satisfy all

governmental and safety requirements. Suppliers will be required to submit Material

Safety Data Sheets (MSDS) for all identified items.


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9.0 ELV Compliance

Suppliers must submit the compliance report of not using the banned elements in their

parts during PPAP. Banned elements are Lead (Pb), Mercury (Hg), Hexavalent

Chromium (Cr6+), Cadmium (Cd) & Bromine (Br) of the chemical form specified

following shall not be present in the final product.

Polybrominated biphenyl (PBB) and Polybrominated diphenyl ether (PBDE).

Subsequently this report is to be submitted to RAL annually

Below is the maximum acceptable limit for these elements

Element Specified limit max.

Lead(Pb) 1000PPM

Mercury(Hg) 1000PPM

Cadmium(Cd) 100PPM

Hexavalent Chromium(Cr6+) 1000PPM

Both Polybrominated biphenyl (PBB) and Polybrominated diphenyl ether (PBDE) 1000PPM

Suppliers must supply material free from radioactivity. A compliance report/declaration

of not using the radioactive material is required to be submitted during the first supply.


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10.0 Supply Chain Management

Suppliers must identify and manage their entire supply chain. It's is the suppliers

responsibility to ensure that the products coming from its supply chain and those that

may be recommended by RAL meet the RALs' product requirement.

11.0 Education & Training

Supplier should develop education & training program for all manpower including

contracted manpower across all levels. A training plan to be made & shall be carried

out as per training plan. Effectiveness of training to be assesses by a suitable method.

12.0 Managing Change

Suppliers must notify RAL of any intended process change and obtain RAL

approval prior to implementation of same.

Suppliers must also make this a condition of their own entire supply chain. In

some cases, samples and documentation will be required as part of the approval

process.

Supplier must submit a report of 4M change to RAL on monthly basis.

There shall be no change to the Specifications, Part Drawings and

Purchase Order Requirements or to the Process without written approval

from RAL

ECN procedure is to be followed to get the approval of any change.

Complete status of the obsolescence of material/tooling/gauges etc. is to

be decided jointly with RAL.

https://www.google.co.in/search?rlz=1C2VFKB_enIN662IN662&biw=1366&bih=667&q=obsolescence&spell=1&sa=X&ved=0ahUKEwj98NTQj5XLAhVEQI4KHRXUBYAQBQgYKAA


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If the supplier has an improvement or concern that can only be resolved with a

process change, a Supplier Change Request containing a complete description of

the change with the reason accompanied by supporting documentation, should be

submitted to the RAL Purchasing Department.

13.0 Special Characteristics

Special Characteristics are shown on current drawings using symbols that

identify the importance level.

It is the supplier’s responsibility to incorporate these Characteristics into the

Control Plans, PFMEA’s, and Work Instructions of all products supplied to RAL

Other important characteristics shall be conveyed by the Quality Manager or

the Purchasing Department of RAL.

Suppliers are expected to have their processes under statistical control

consistent with the guidelines of the current ISO 9001 or TS 16949 Standard

and related reference manuals.

Features or properties (dimensional, visual, functional, mechanical, or material)

which are designated to communicate to either manufacturing operations or

suppliers the significance of these characteristics and the need to ensure the

production process has inherent capability or sufficient control for meeting the

specification / tolerance limits.

Critical is a characteristic where special due diligence is required since the

consequence of an assembly or manufacturing variation outside of specification

could cause unsafe product function.

Safety is a characteristic where the failure to maintain that feature can lead to

an accident.


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14.0 Samples

Whenever samples are submitted to RAL for approval, it should be thoroughly checked

by supplier. The sample inspection report should cover all the dimensions & tests

specified in print. The S. No. in the inspection report to be marked in the ballooned

drawing. The ballooned drawing with the inspected Samples & Sample Inspection

Report including the steel mill certificate, chemical, mechanical & metallurgical

report to be submitted to RAL. Inspected samples to be separately packed &

should be traceable to the submitted report. Supplier to ensure the S. Nos. on the

inspected samples.

If the die/ mould are having the multiple cavity, report of all the cavities to be submitted

for approval. Die/mould number to be marked on the samples.

15.0 Label Identification Requirements

The initial PPAP submission to RAL and the first production run after PPAP approval

shall be clearly identified on the packing box with the words & the tag sample given in

the last pages of this manual:

Attn: Quality Department – PPAP Submission “or” – First Production Shipment

Notification. The supplier should clearly specify whether the shipment is for PPAP or

production. Any deviations to this requirement must be approved by the RAL Quality

Department prior to shipment.

NOTE: Any shipment of first production lots shall be preceded by a PPAP submittal and

approval. Any deviation to this requirement must be approved by the RAL Quality

Department.


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16.0 Production Part Approval Process (PPAP)

Level 3 PPAP is required for all submissions unless otherwise specified by the RAL

SQA or as otherwise identified on the purchase order. PPAP is to be done at supplier

premises in presence of RAL SQA representative. PPAP’s are to be submitted directly

to the RAL SQA of the respective locations shown on the purchase order. Final PSW

sign-off will be done after achieving the run @rate. The review of PPAP submissions

from Tier 2/Tier 3 suppliers may also be required.

NOTE: PPAP shall be submitted in accordance with the AIAG manual. Additional

requirements may also be specified by RAL

17.0 PPAP Documents required from Supplier

Given on next page


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Reference AIAG Production Parts Approval Process (PPAP) 4th Edition Table 4.1

Retention/Submission Requirements Table Submission Level

# Requirements 1 2 3 4 5

1 Design Records (Drawings, Specifications) R S S * R

- for proprietary components/Details R R R * R

- for all other components/Details R S S * R

2 Authorized Engineering Change Documents, if any R S S * R

3 Customer Engineering Approval, if required R R S * R

4 Design FMEA (if applicable) R R S * R

5 Process Flow Diagram R R S * R

6 Process FMEA R R S * R

7 Control Plan R R S * R

8 Measurement Systems Analysis Studies (Gage R&R) R R S * R

9 Dimensional Results R S S * R

10 Material & Performance Test Results R S S * R

11 Initial Process Study R R S * R

12 Qualified Laboratory Documentation R S S * R

13 Appearance Approval Report (AAR), if applicable S S S * R

14 Sample Product R S S * R

15 Master Sample R R R * R

16 Checking Aids R R R * R

17 Records of Compliance with Customer-Specific Requirements R R S * R

17.1 Manufacturing Feasibility Sign-off S S S * S

17.2 Capacity Planning & Verification S S S * S

17.3 Packaging Information/Instructions w/Sample Label R R S * R

17.4 ELV Documentation S S S * S

17.5 Sub-Supplier PPAP (Warrants) S S S * R

17.6 Balloon Print R R S * R

17.7 Rework/Repairs Procedures R R S * R

17.8 Safe Launch Plan (Final Inspection Standard) R R S * R

17.9 Control Characteristic Matrix/List S S S * R

17.10 Engineering Specification (ES) Test Planning R R S * R

17.11 Product or Process Qualification Plan R R S * R

18 Part Submission Warrant (PSW) S S S S R

Bulk Materials Requirement Checklist (bulk material PPAP only) S S S S R

R - The supplier shall retain at appropriate locations, including manufacturing, and material Readily available to the customer representatives, when requested.

S - The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at appropriate location, including manufacturing.

* - The supplier shall retain at appropriate locations and submit to RAL upon request.


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18.0 Material/Product Deviation

The supplier shall not deviate from RAL engineering drawings, specifications or other

RAL requirements without written approval and/or deviation authorization. The supplier

is responsible for the quality level of all material and/or product delivered to RAL If the

supplier detects a non-conforming condition, he shall submit a Request for Deviation for

review of product. The written request shall be submitted to the RAL Purchase

department along with the following information:

Part number and latest engineering change letter

Quantity of parts affected

Specification(s) involved

Statistical analysis of the non-conforming characteristic(s), as applicable

A statement of the requested deviation

The containment plan to be implemented

Corrective/preventative action to be taken along with the time line for

implementation which shall include the date and or lot number for the

completed actions.

RAL Purchase department will internally get it approved if feasible & will communicate

accordingly to supplier. The material if approved by RAL to be clearly identified to

prevent mix up.

19.0 Traceability

When product traceability is required, suppliers must provide unique identification of

product as per print. Parts should be traceable till raw material stage.


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20.0 First in First Out

Supplier shall implement & follow First in First out (FIFO) system for all incoming, in-

process & finished product.

Shelf life of the parts mainly rubber parts like O- ring, oil seal, v belts etc. to be assessed

at regular frequency.

21.0 Verification of Purchased Product

RAL has full right to verify the purchased products at its premises.

22.0 Cleanliness Requirements

RAL requires that all material shall be clean and free of contamination including debris

adhered through residual magnetism. The supplier is responsible for ensuring that all

material/product delivered to RAL shall be clean and free of contamination from

debris/burrs, and packaged in such a manner to assure material cleanliness. Other

drawings and/or Purchase Order requirements may apply at times.

23.0 Non-Conforming Product/Corrective & preventive action/ Supplier

charge back

Suppliers must only ship product that meets specification, or obtain a written deviation

prior to shipment for any nonconforming product.

A Defect Analysis report (DAR) shall be issued to the supplier when a RAL facility

detects non-conforming product.

In the event of a quality issue related to a supplier’s products, A Corrective Action Report

must be furnished that outlines the problem using a formal problem resolution method

DAR.

The supplier’s initial response including containment plan, shall be provided to RAL

within 24 hours (one working day) from the date the supplier receives notification of the

non-conformance.


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A written preliminary corrective action must be sent to the RAL Quality Department

within ten (10) days identifying the root cause.

Final resolution of the corrective action will be made within fifteen (15) days of the

supplier’s submittal.

Any request for additional time should be directed to the Quality Department and shall

be in writing. The written request shall include the action plan and time line for

implementation.

If product is found to be non-conforming at RAL, the supplier is expected to provide the

resources necessary to contain, evaluate, sort and/or scrap the non-conforming product

It will be determined whether product is sorted on site or returned to the supplier. If time

does not allow the supplier’s personnel to arrive for sorting, RAL may elect to execute

the sort due to need. If it is determined that inspection alone cannot detect the defect,

the product will be returned to the supplier or scrapped as agreed. Segregation to sort

defective product does not relieve the supplier of their responsibility for the quality or

delivery of product.

RAL will identify any costs incurred for doing any sort and will initiate a chargeback to

the supplier.

If the supplier fails to fulfill the requirements for complaint responsiveness and

effectiveness of problem resolution they may have Controlled Shipping invoked and be

put on new business hold until resolved.

A supplier shall comply with RAL process to recover costs associated with a supplier’s

unacceptable performance.

RAL shall be entitled to recover all costs and expenses reasonably incurred in

taking corrective action/sorting from the supplier.

The cost to process a DAR is Rs.1000/- and that will be the minimum charge that

is passed on to the supplier for each occurrence

All cost & expenses occurred in case of cost recovery by customer due to

supplier fault will be charged back from supplier


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Cost recovery for machining where parts are found defective on the line on

account of supplier’s fault is also to be charged back to supplier.

24.0 Shipment and Packaging Requirements

RAL & suppliers must agree to a packing & transportation plan prior to start of supplies to

RAL. Reusable packing is recommended. Suppliers must comply with specifications for

shipping and packaging. This includes safeguarding the products by applying rust

preventive if applicable & following the labeling specifications. RAL requires that all

suppliers provide packaging that is adequate to protect material/product from damage and

contamination for a suitable period of use. RAL reserves the right to require specific

packaging practices such as, packing materials and restrictions on packaging size.

These requirements shall be communicated through drawings and/or purchase order

requirements. Products are to be packaged in such a manner to provide adequate

protection against subsequent product degradation and contamination.

Each container shall be clearly marked and identified with the following:

Supplier Name

Part Name

Part Number

P.O. No.

Invoice No & date

Quantity

Signature

Sample Tags given at the last pages.


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25.0 Supplier Evaluation

Measurement Weightage Target

Overall Rating 100% 100

Quality Rating 40% 100

Delivery Rating 40% 100

Service 20% 100

CLASS COLOUR RATING STATUS

Excellent Supplier 90-100 On Approved Supplier List

Good Supplier 80 - 89 On Approved Supplier List

Acceptable Supplier 70 - 79 On Approved Supplier List, Request Corrective Action

Suspect Supplier 60 - 69 Place On Master List, Re-evaluate

Unacceptable <60 Review for removal From Master List

Quality Rating Formula

Q.R.= Component Rating (CR) -2* Instances of Segregation-10 X Repeated QPCR -5 X New QPCR -5 X Open QPCR -15*QPCR at customer end due to supplier

CR= (Q1+0.5Q2-1.25Q3-0.75Q4)100/ Q

Where: Q1= Qty. Accepted Q2= Qty. Accepted under deviation Q3= Line Rejection Qty. Q4= Quantity accepted after rework Q= Total Qty. Received

Delivery Rating Formula

Demerit points for DAR will be limited to one (either customer or at RAL)

DR= Quantity received on time X 100 – 10 (no of instances of line stoppage) - 5 (no of instances of premium freight paid by RAL)/ Quantity as per schedule

Service Rating Criteria

1. Response in emergency = 25 points

2. RFQ response = 25 points

3. PPAP documents = 25 points

4. On time development support = 25 points


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Note: If any parameter is not applicable then rating will be calculated from balance

parameters, e.g. if there is no PPAP documentation, then the rating will be calculated

from 75 points. In case the performance of supplier does not improve in spite of support

& time given, RAL management may develop an alternate source or further business

will be on hold till supplier shows improvement in performance.

26.0 Records Retention

Suppliers must maintain quality records (hard or soft copies) for special

processes for a minimum of 15 years unless otherwise specified on the

purchase order.

All the PPAP & changed records to be kept till the life of product+5 years.

This requirement may be extended by RAL as required.

These records shall be stored in an environment that does not allow document

deterioration and are readily accessible upon request by a RAL representative.

It is also expected that the supply chains records pertaining to RAL products

shall be retained in the same manner.

27.0 Revalidation/Layout inspection

Supplier to submit the re-validation/layout inspection report of all the products

annually. Non-conforming parameters if any to be discussed with RAL.

28.0 Pre-dispatch inspection report

While dispatching the material, supplier to ensure the PDIR (pre-dispatch inspection

report) as per agreement of inspection with RAL for the products. Samples inspected

must be identified & separately packed. For Gauges, tooling (customized) & Jigs &

Fixtures critical, fitment & functional dimensions are to be checked by supplier & report

to be submitted with material. (Customer supplied products are exceptions). Failure

to do this may result in rejecting the material without inspection.


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29.0 Supplier Audit

A yearly supplier audit plan will be issued where every supplier will be covered at least

once. QA department will carry out the quality system audit at the supplier

premises as per the plan as per the audit check sheet. Supplier has to submit the time

bound action plan against the audit observations. Verification of the corrective action

shall be done either by asking evidence of countermeasures by RAL or by visiting

suppliers.

Apart from the above, RAL reserve the right to audit the supplier facility with a short

notice in case of any complaint/quality issue.

30.0 Other Requirements

Ex. Employees of RAL

Supplier cannot employ directly or indirectly RAL’s ex-employees for a min. period of

10 years after his/her leaving RAL. This would apply to any consultancy or other

methodology, directly or thru any agency or entity.

The supplier may expect other specific requirements in addition to the requirements of

this Manual. If applicable, these requirements shall be communicated to the supplier

through RAL Purchasing Department.

Additional Information

31.0 Controlled Shipping

Controlled Shipping is a demand by RAL that a supplier put in place additional inspection

process at the supplying location to 100% sort for a specific and specified nonconformance

to isolate RAL from receipt of nonconforming parts/material. The additional inspection must

be in addition to the normal process controls.


Page 29 of 38

32.0 Implementation criteria for Controlled Shipping

Repetitive issue

Suppliers current controls are not sufficient to ensure conformance to requirements

Duration, quality, and/or severity of the concern

Major disruptions

Quality concern at OEM and/or in the field

33.0 Exit criteria for Controlled Shipping

One month data (from implementation of corrective action) which verifies that the normal

production controls are effective for controlling the discrepancy identified in the

Controlled Shipping activity.

Volume to be determined by RAL where suppliers use batch processes.

Documentation showing root cause was identified and verified.

Documentation indicating that corrective action was implemented and validated.

Copies of all documentation revised as required (Control Plan, PFMEA, operator

instructions, etc.)

Documentation indicating that every effort was taken to implement error proofing.

Note: RAL approval must be given prior to supplier stopping Controlled Shipping. An

audit by RAL may be required prior to approval.

34.0 Mistake – Proofing

RAL expectation is zero defects. Achieving this level of quality requires capable

processes combined with statistical process control techniques and the utilization of

mistake-proofing methodology. When causes of non-conformance are determined, the

supplier shall employ solutions in the process to prevent or detect these non-

conformances. These solutions shall be independent of operator’s actions. Solutions

shall be designed and installed integral to the process to prevent or detect defects.


Page 30 of 38

35.0 Continual Improvement Process

The supplier should promote and implement a continual improvement philosophy

applying proven methodology and processes. These methods and processes shall be

used throughout the Supplier organization to continually improve the quality, delivery,

cost and service of supplier products.

Recommended tools of the continuous improvement process are:

Benchmarking

Brainstorming

Pareto Analysis

5-Way Analysis

Cause and Effect

4M change

Process Capability/Performance

Process Mapping, etc.

36.0 Statistical Techniques

It is strongly recommended that Suppliers monitor process performance using the

appropriate statistical techniques in accordance with AIAG Statistical Process Control

manual. The determination of need is based on the ability to control and verify the process

capability and product characteristics. The use of quality planning tools such as Design

Failure Mode and Effects Analysis (DFMEA) and/or Process Failure Mode and Effects

Analysis (PFMEA) are essential. The supplier shall submit capability data for RAL

characteristics identified on the drawing. Supplier is encouraged to use statistical

techniques including:

Gauge R&R Study

Predictive Maintenance

Defect Analysis


Page 31 of 38

Sampling and Process Analysis

Process Analysis with Control Charting Methods

And other Graphical Methods

37.0 Cost Reduction and Continuous Improvement

Cost reductions are viewed as an essential aspect of maintaining a competitive position

for both the supplier and RAL

The supplier shall endeavor to provide cost reduction and continuous improvement

suggestions to RAL

All proposals shall be submitted to the Purchasing Department.

A supplier may be asked to provide a commercial review for a cost or continuous

improvement proposal.

38.0 Governmental and Safety Compliance

All the Government & safety compliances are necessarily to be followed by supplier for

doing the business with RAL

39.0 Supporting Documents

The supplier must have the current editions of the following documents and any other

reference documents available for review at all appropriate manufacturing locations.

Supporting documents are requirements of ISO 9001, TS16949 and information

referenced in this Manual:

Quality System Requirements (ISO 9001)

Advanced Product Quality Planning (APQP) and Control Plan Manual *

Production Part Approval Process (PPAP) Manual*


Page 32 of 38

Failure Mode and Effects Analysis (FMEA) Manual*

*These documents are available from the Automotive Industry Action Group

(“AIAG”) and may be purchased from:

Automotive Industry Action Group

26200 Lahser Road, Suite 200

Southfield, Michigan 48034

Phone: (248) 358-3570

Fax: (248) 358-3253

Internet: www.aiag.org

40.0 Examples of records for retention shall include, but are not limited to

Measurement Data

Measurement System Analysis Data

Gauge Calibration and Maintenance Records

Capability and SPC Data

Heat Treatment Processing Data

Destructive and Non-Destructive Testing Data

Functional and Performance Test Data

Quality Rejections and Disposition Records

Corrective Action Requests and Responses

Major Process Change data

Production Lot / Product ID / Traceability

Initial Sample Inspection Report

http://www.aiag.org/


Page 33 of 38

Any existing supplier can’t get a new business unless he agree to follow the

requirements mentioned in this manual.

This manual covers all products supplied by the suppliers that may have been

awarded before the date of release of this manual & shall covers all parts that may be

awarded in future.

End of Supplier Quality Assurance Manual


Page 34 of 38

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Page 37 of 38

DOC. NO. : F-05-02

REV. NO. : 01

DATE : 19.12.2015

PAGE : 1 OF 1

Customer : Part Name :

Part No. :

Feasibility Considerations :

YES NO

Conclusion :

Feasible

Feasible

Not Feasible

Sign-Off :

Team Member /Title / Date: Team Member /Title / Date:

___________________________ ___________________________

Team Member /Title / Date: Team Member /Title / Date:

___________________________ ___________________________

Design revision required to produce product within the specified requirements.

Changes recommended (see attached).

Product can be produced as specified with no revisions.

Where statistical process control is used on similar products:

Are the processes in control and stable?

Are Cpk’s greater than 1. 33?

TEAM FEASIBILITY

COMMITMENTROOP AUTOMOTIVES LTD.

Does the design allow the use of effcient material handling techniques?

Our product quality planning team has considered the following question, performing a feasibility evaluation. The

drawings and / or specifications provided have been used as a basis for analyzing the ability to meet all specified

requirements. All “no” answers are supported with attached comments identifying our concerns and / or proposed

changes to enable us to meet the specified requirements.

Can Engineering Performance Specifications be met as written?

Can product be manufactured to tolerances specified on drawing?

Can product be manufactured with Cpk’s that meet requirements?

Is there adequate capacity to produce product?

CONSIDERATION

Alternative manufacturing methods?

Is statistical process control presently used on similar products?

Is product adequately defined (application requirements, etc.) to enable feasibility

evaluation?

Can the product be manufactured without incurring any unusual:

Costs for capital equipment?

Costs for tooling?


Page 38 of 38

Part No……………………..………………...……

Rev. No……………………..………………...……

Part Name……………….…………….…………

P.O. No……………………………….…………..

Invoice No & Date………….……...……….

Qty………………………………..………………..

Signature……………………..…...……………

Production supplies

Supplier name……………..…..……………….

6”

4”

Part No……………………..………………...……

Rev. No……………………..………………...……

Part Name……………….…………….…………

P.O. No……………………………….…………..

Invoice No & Date………….……...……….

Qty………………………………..………………..

Signature……………………..…...……………

PPAP SAMPLES

Supplier name……………..…..……………….

6”

4”

ROOP

ROOP AUTOMOTIVES LTD. CORPORATE OFFICE

(Location -1) 19, Rozka Meo Industrial Area, Sohna

Gurgaon – 122103 (India) Phone: +91 8396969522-26, Fax: +91 124 2362568

Email: [email protected]

(Location- 2) Plot No- 439, Sector – 8, IMT

Manesar, Gurgaon – 122050 (India) Phone: +91 124 4959800

Fax: +91 124 4959639

(Location- 3) Plot No- A10 A(1), Irrungattukottai,

Sipcot Industrial Park, Chennai – 602105, (India)

Phone: +91 44 67103600-620

( Location- 4)

UNIT IV: Plot PE 121, Sanand II, Industrial Estate, Near Village Bol,

Ahmedabad- 382110 (India)

www.roopauto.com

mailto:[email protected]

http://www.roopauto.com/