SUPPLIER PROCESS SURVEY CHECK SHEET (PAINTS)

SUPPLIER Thai Kansai Paint Co., Ltd LOCATION Samutprakarn Thailand SUPPLIER ATTENDEEDS H. Nagaoka san, M. Minami san, M. Miyazaki san, H. Noguchi san, K. Yamashita san, KP (Japan) : A.Tsuge san, H. Sanada san RESULTS ITEMS
A : RAW MATERIAL

PRODUCT Paints DATE August 03. 2005 9:00-17:00 TOYOTA ATTENDEES TMT-QA : Siriluck P san, Songwit K san Chutinat N san TMC-QCD : M. Sugiura

Auditor Sugiura Siriluck Songwit

POINTS(%) 55/60 (92) 56/65 (93) 56/60 (93) 167/180 (92.7) 135/155 (86) 138/160 (86) 125/155 (80.6)

COMMENTS Please carry out personal computer control as planned. Two or three stacking of the palette of raw material is not good.

AVG.(%) B : MANUFACTURING Sugiura PROCESS Siriluck

Songwit
AVG.(%) C : INSPECTION PROCESS

Sugiura Siriluck Songwit

AVG.(%)

D : EDUCATION

Sugiura Siriluck Songwit

AVG.(%)

E : QUALITY ASSURANCE SYSTEM

Sugiura Siriluck Songwit

AVG.(%)

TOTAL

Should leave the record of manufacturing abnormalities. Management in a transition figure of equipment conditions. The description to batch ticket is required in the loading actual weight measurement of raw material. 398/470 (85.6) The exit of finished product warehouse is opening. Furthermore, please carry out the reduction activities of cratering. 44/50 (88) Need the reduction of paint variation of color inspection panel. 46/50 (92) Trend control of inspection date of finished products is required. 48/50 (96) It is by waterborn paint introduction about reinforcement of 138/150 temperature/humidity control of spray booth. (92) Consider introduction of colormeter CM-512m3 (under TMC use). 23/25 (92) In order to improve color adjustment technology, please consider training by KP (Japan). 24/25 (96) 25/25 (100) 72/75 (96) 36/40 (90) The quality check in initial control period needs to be substantial. 34/40 (85) 36/40 (90) 106/120 881/995 (88.5)

ORIENTATION of IMPROVEMENT 1) More visual control and fool-proof required. (batch ticket, R.M. PC control) 2) Trend control (Manufacturing abnormalities, equipment conditions, finished products date) 3) Prevention of dusts and comtamination (R.M and finished product warehouse) 4) Enrichment of equipment (spray booth temp./humidity control, colormeter) 5) Improved quality (cratering, spray variation of color panel) NEXT FOLLOW SCHEDULE Periodical follow of improvement activities towards new paint introduction (1time/half a year). TARGET and ACTUAL RESULT 100 90 80 70 60 50
88.5

Target

85%

03/08/05

TOYOTA MOTOR THILAND CO., LTD / TOYOTA MOTOR CORPORATION

A. RAW MATERIAL
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3
Although it talks with a supplier and being decided, there is no inspection standard.

0
With no standard

It talks with a supplier and The maintenance situation manages by the inspection of a raw-material receiving standard.

inspection standard

The method of a rawmaterial receiving inspection

50% or more of real Less than 50% of real Only supplier data check Nothing inspection ratios inspection ratios It is actually inspecting 100%. Since the transportation of an import (Japan) in Thailand is not good, getting wet with water, breken, etc. are checked. There is data as regulation It is kept although it is not With no storage

Acceptance of raw material

Data is kept as regulation. Storage and management and it is arranged well. as regulation. of raw-material receiving inspection record It is kept for every kind of raw material. It manages with Lot No. Keeping during four years. It is acting as the regular Tendency management is monitor by original not performed but a cause Only judgment of management width as is investigated at the time abnormalities tendency management. of abnormalities. Tendency control is carried out in graph every day. Tendency control is requested also from a Japanese raw-material maker (local maker is made). The check method is There is regulation, it It is not carried out indefinite, although there It carries out, when carries out periodically and periodically, although there is regulation and being necessity arises. the check method is clear. is regulation. carried out periodically.

Practical use of rawmaterial acceptance data

It does not use.

Raw-material maker's audit

Nothing

There are a plan and a actually record. Last year 28 maker enforcement. Self-valuation is also made a supplier in advance. The shelf life after All raw materials prescribe The rule of disposal is not Only specific raw material manufacturing is specified the term of validity after stipulated although there is specified. Expiration Nothing to all raw materials. delivery. Expiration are some which are disposal stipulates. Expiration disposal disposal stipulates. specified. stipulates. The shelf life after 100% manufacture prescribes. Expiration is a prior check 15 days ago. Expiration indicates by a yellow card and moves to somewhere else. Reexamination O.K. is the extension of term of the first half. There is a disposal rule and recurrence prevention is also carried out. Recurrence prevention is inadequate although there is a disposal rule. Nothing

Regulation of the shelf life of raw material Regulation of the disposal rule of expiration

Acceptance

Disposal route and recurrence prevention when problems occurred.

Note: * Mark (Check place) A;Office B; Work-site

- 1/12 -

(A-2/13)

A. RAW MATERIAL
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0
It is the storage which took It is the storage which took into consideration into consideration Although an improvement preventing of rain water and preventing rain water and Rain water and mixing of a required is considered, it is mixing of a foreign mixing of a foreign foreign substance is not the level which a substance to material substance to material anxious. problem produces. packing bag etc. A storage packing bag etc. A storage place is clean. place is disorderly. Two or three stacking of the palette of raw material is not good. There is a problem quality sides, such as a tear of a paper bag, 4S is carried out every day and is OK. It is good to have shown regulation of entering in the photograph of the cleaning at warehousing. A brand display and a Although division and an classification display are Although division and an indication are given, they With no division and no precision and the state indication are given, they are visually display where it is made orderly are disorderly. incomprehensible. and a mistake cannot happen easily. It manages on the board in a warehouse. It is manual control (it is not personal computer control) now. A storage place is distinguished on a floor (3rd floor : raw material of FIFO, 2nd floor: pigments and a part of resin, 1st floor : resin). Those with fool-proof by an automatic reading system. The directions document in a place, and the check of raw material. It is extraction by memory of a worker.

Storage condition of raw material

Raw material storage

Division of the storage place of raw material, a brand display

10

Raw-material extraction rule

The double-check in an extraction check and two tags (green & orange). Those with a system, it carries out. It does not carry out, although there is a system. With no system

11

First-in first-out of raw material

First-out materiala are kept on the 3rd floor. It checks by two persons. It is better to display by first-out card.

12

Distinction of under uninspecting and inspection, an acceptable product, and rejected goods of raw material (a space, display, etc.).

It is the system which is not mixed from clarification of a space, and a display.

Those with a possibility that it will be mixed if a worker is not careful, Mixture or indefiniteness although it is distinguishable once. After inspection OK, green seals stick (paper bag : every palette, a drum and a can : every can).During inspection, drums and cans keep in an outer temporary tent to a temporary space, paper bags keep in a temporary space in a warehouse. Rejected goods display a red card and move to somewhere else.

Note: * Mark (Check place) A;Office B; Work-site

- 2/12 -

(A-3/13)

B. MANUFACTURING PROCESS
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
A picture and a photograph are used, and the point is clear and intelligible.

3
The contents are complicated although a settlement is good.

1
Inadequate in the contents of directions, although it is. Nothing

The contents of the work instruction sheet.

Working instruction sheets using a picture or a photograph is each process and according to equipment.

Work instruction sheet

Revision rule of a work instruction sheet

A rule is clear and is kept. There is the change column. It is put up for the position which is easy to view.

The rule is not kept although it is clear.

With no rule

Notice state of a work instruction sheet and a quality identification point

A place is unsuitable although notified.

It is not notified.

Near is notified for every process. However, a part is in the distant place for a while. A instruction sheet and recognition suit and are observed. It is not observeed although a instruction sheet and recognition are correct. Recognition differs from a instruction sheet and is not observed.

Worker's recognition and observance condition over a work instruction sheet.

A worker and an engineer create working instruction shhet together. It is intelligible and there is the check column (there is With no check column, nothing and good, if there although it is intelligible. is a check sheet The contents of batch ticket independently). There is no description of the tolerance of the loading amount (additive agents : 1%, others : 2%). There is the double-check column of loading raw material. The double-check by the Only a person's in charge person in charge and a check Last check method of batch supevisor

Batch tickt

It is complicated and may make a mistake.

With no check

ticket after manufacture

The double-check of the Div chief and a supervisor.

Unusual disposal instruction sheet

The definition of abnormalities and who do The contents of the unusual what, or it is a judgment etc. and is intelligible. disposal instruction sheet

Although the definition of abnormalities and who do what or there is judgment etc., its contents is complicated.

Inadequate in the contents of directions

With no unusual disposal instruction sheet

The definition of abnormalities is not detailed. There are its displays at plant. - 3/12 -

Note: * Mark (Check place) A;Office B; Work-site

(B-4/13)

B. MANUFACTURING PROCESS
No * A B Unusual disposal instruction sheet Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
An unusual disposal person is decided and it is educated about a definition and the disposal method of abnormalities.

3
Education is inadequate although the unusual disposal person is decided.

0
With no setup of an unusual disposal person.

Setup of an unusual disposal person

Abnormality manual prescribes. Judgment is production engineer. An item and the contents

Past record management of are clear and the past record is left behind. unusual generating
It has not left the record. A change factor is grasped and it is reflected to conditions.

The past record is not left behind although an item and the contents are clear.

An item and the contents are indefinite and a past record is also nothing.

10

Equipment condition management

Setting method of an equipment operating condition

An examination method (temperature, humidity, setting tolerance) is inadequate in a change factor.

With no idea of a change factor

Since equipment differs from Japan, it carries out uniquely. It is recorded on a check sheet and the required item is managed in the numerical value or the graph.

11

Controlled state of equipment conditions

It is recorded on the check sheet.

With no check sheet

12

There is a rule and the Correspondence at the time record which is carrying out the quality identification of equipment condition based on it is also kept.

Enforcement is inadequate although there is a rule. Record is kept.

With no rule

change

There is a rule. Since there is no example, record is nothing.

13

Cleaning of equipment, daily and a scheduled inspection, and record Loading process

There is a standard and it is kept as record.

Although there is a standard, it has no record.

There is no standard.

It carries out every three months using a check sheet. Record is kept for three years. Automatic reading, record, the system by two or more more persons to doublecheck Description of survey data, With description of survey With no record only with a the double-check by one data, and no doublecheck person check

14

Measurement and loading system

Although it is a double-check by two persons, it is not description of an actual weight measurement. Note: * Mark (Check place) A;Office B; Work-site - 4/12 -

(B-5/13)

B. MANUFACTURING PROCESS
No * A B Check item State of a loading and a measurement place Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
Only a required quantity has a required thing.

3
There is every one time and a little complicated.

0
It is complicated and may makes a mistake.

15

Loading process

16

Prevention correspondence of mixing the foreign substance and dust at the time of a raw-material loading. Washing of a raw-material loading container and a measurement can Incorrect filling prevention at a filling (canned) process.

17

The process which the measure against mixing a The process depending Those with mixing on a worker's foreign subsutance was possibility consciousness made and was anxious about mixing. A tank washes regulation. Lids are four division (loading side). Cleaning at the time of carrying into a factory from a warehouse is carried out. Piping is not nitrogen gas washing. There is a instruction sheet It is not kept although there There is also no instruction and it is kept. is a instruction sheet. sheet and it is dirty. There is a privention instruction sheet of mixing a foreign subsutance and it carries out at the process. The exclusive plastic cup is used and it is thrown away. However, there is no instruction sheet. The double-check by the fool-proof system and a worker. The check by a worker With no check by a worker

18

Filling process

Tank No is entered in the tag of green. There is a tank No also in a batch ticket. Although there are There is no prevention prevention corresondences corresondence of mixing of mixing the foreign the foreign substance and substance and contamination contamination, it is inadequate. Oscillating sieve + filter filtration is carried out. The entrance slot is covered with the poly sheet. All cans are washed. Further examination of covering filled up space. A place is decided and the A place is decided and the display (product No, display (product No, A place is unknown, 4S product name, address, product name, address, state is bad. quantity) is clarified, 4S quantity) is indefinite, 4S state is good. state is somewhat bad. Those with prevention correspondence of mixing the foreign substance and contamination An exit is an open state. The 2nd floor is covered with the poly sheet. A kind and classification are control on a board.

19

Prevention of mixing the foreign substance and contamination at a filling (canned) process.

Finished product place

20

The state of a finished product place

21

Distinction of under unThose with a possibility that inspecting and inspection, It is the system which is it will be mixed if a worker not mixed from clarification an acceptable product, and is not careful, although it is rejected goods of finished of a space, and a display. distinguishable once. product (a space, display, After Inspection O.K. it is filled. Rejected goods move to another warehouse. etc.).
- 5/12 -

Mixture or indefiniteness

Note: * Mark (Check place) A;Office B; Work-site

(B-6/13)

B. MANUFACTURING PROCESS
No * A B Finished product Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
Those with a system, it carries out.

3
It does not carry out, although there is a system.

0
With no system

22

First-in first-out of finished product

A warehouse keeps only one lot. Personal computer control. A green card (first-out) is displayed. A cleaning schedule is decided and 4S state is good. A zone person in charge is set up and carried out. Although the cleaning schedule is decided, 4S state is inadequate.

4S state is bad.

23

4S state of the whole manufacturing process

24

The deployment situation to It is developed. the manufacturing process of manufacturing quality chart.

Although developed, it is different partly.

It is not developed.

Manufacturing process whole

25

A worker's dress, wear of protective gear.

There is a standard and it is kept.

It is not kept although there is a standard.

There is no standard.

26

An important process, important work.

There is a view and a display.

With no display although there is a view.

With no view

Although there is no notice of an important process, the common important item of each process is put up on a board. A check item is clear and carries out using a check sheet. It is carried out although the check item is indefinite.

It is not carried out.

27

Process check by an administrator

A supervisor carries out once per week and reports to a manager.

28

Improvement target of product quality (Inside of a manufacturing process, inspection process, following process).

A target is clear and reduction activities are carried out.

Although there is a target, its contents of activity are inadequate.

With no target value

Paint residue reduction activities are carried out (target: 0.8mg/16kg, results: 0.4-0.5mg/16kg).

Note: * Mark (Check place) A;Office B; Work-site - 6/12 -

(B-7/13)

B. MANUFACTURING PROCESS
No * A B Manufacturing process whole Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0

29

The true cause is pursued and it is coped with including whether correspondence with a Correspondence at the time design post and Production Engineering of fault generating post is required.

True cause investigation is inadequate.

Only an immediate measure

Their related posts, such as technical, are put in and examined. Tendency management is performed and an acceptance result is reflected. With no reflection of tendency management and an acceptance result

N.A.
30

Only reflection of an acceptance result

Measure to a color control

Others

31

Measure to seeds (paint filtration residue) reduction

Those with a measure towards reduction (generation source investigation, improvement

Only the present process control (4S, electrostatic dress wear, etc.)

Only control by residue examination

Paint residue reduction activities are carried out (target: 0.8mg/16kg, results: 0.4-0.5mg/16kg). Improvement matter: SUS-izing of a tank, a glove is changed into rubber from cotton, a palette is changed into resin from a wood, A bag filter is changed into a Cuno filter. Those with a measure towards outflow prevention. Those with a positive measure also to Although there is a measure towards outflow prevention, the cause investigation at the time of

With no measure towards outflow prevention

32

Measure to cratering

The cratering check of each process and submaterials is carried out. Note: * Mark (Check place) A;Office B; Work-site

- 7/12 -

(B-8/13)

C. INSPECTION PROCESS
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
There is the shelf life and it

3
With no periodical maintenance, although there is the shelf life.

0
Those with apparatus in which the shelf life went out.

Maintenance of the maintains periodically. measurement apparatus for inspection

Physical-properties inspection

Temperature and humidity control of a testing laboratory

It is controlled by a regular temperature and humidity.

Only a regular temperature is controlled.

With no control

The temperature and humidity of a testing laboratory is controlled by 20+-2 degree C and 65+-10%RH (the width of humidity is somewhat large). It is by waterborn paint introduction about reinforcement of temperature/humidity control of spray booth. A picture and a photograph are used, and the point is clear and The contents are complicated although a settlement is good. Inadequate in the contents Nothing of directions, although it is.

Work instruction sheet for inspection

Inspection result record sheet

Not entry of only a number but those of O.K. and NG with judgment.

Entry of only a number

With no sheet

Color difference inspection

Directions method of the spray conditions of color panel for color inspection

There is a condition instruction sheet. Those with correspondence to

With no correspondence to spray variation, although there is a condition

There is no condition instruction sheet.

A body is REA auto and a bumper is hand air. Need the reduction of paint variation of color inspection panel. It is carried out in the decided environment and is visible like the Although carried out in the decided environment, it is not visible like the With no regulation about environment

Environment at the time of color control (lighting, place)

Colormeter uses CR-300 and Exrite RH68. Please consider introduction of colormeter CM-512m3 (under TMC use). Color inspection and color arrangement check is carried out in the same Although color inspection and color arrangement check is different Environment of color inspection and color arrangement check is

Environment of color inspection and color arrangement check

Note: * Mark (Check place) A;Office B; Work-site The system whose correspondence can perform tendency management about a control item, and is possible before becoming a problem.

- 8/12 -

Practical use of inspection result data

Data is graph-ized and it is monitor enforcement.

It is not utilizing.

(C-9/13)

ers

C. INSPECTION PROCESS
8

No

* A B

Practical use of inspection result Check item data

Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0

There is a system which can be prevented rightly (unless it is O.K., neither Outflow prevention of under the following process shift inspection or an inspection nor shipment can be NG product performed).

Although there is a system, a person in charge carries out judgment to stop.

Others

There is nothing as a system.

10

Shipment stop, regulation of amendment

There is regulation and the contents are suitable.

Its contents are inadequate although there is regulation.

With no regulation

Note: * Mark (Check place) A;Office B; Work-site

- 9/12 -

(C-10/13)

D. EDUCATION
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
Each one of educational plans are made and it is obligation about periodical attendance.

3
Participation is judgment of an individual although the educational opportunity is carried out periodically.

0
An educational plan is nothing. A lecture is taken at worker's hope.

Worker education and training schedule

Each worker's educationand-training past record

Each one of attendance lists of all are fixed, and an educational plan is promoted along with this.

With no practical use, although each one of attendance lists of all are fixed.

With no attendance list

Worker education

Method of the work education to a worker

The education which includes a reason (why is the work necessity?) at the time of education was performed, and the degreeof-comprehension-up is aimed at.

It explains, only when there is a question.

About a reason, it is ambiguous and has not answered.

Education about a quality control (QC)

QC education is considered as all staff indispensable education, and is carried out. Please carry out QC education to all the staff. There is a system checked for every step. It cannot step up without O.K. of a supervisor.

Although there is a QC educational system, participation is his dependence on an intention.

QC education is not carried out.

Skill level judging of a worker

Although education is carrying out, the check for Only educational every step is un-carrying implementation out (only in case of the last check).

5 rnks estimate. Only two persons require a B rank level by color adjustment. In order to improve color adjustment technology, please consider training by KP (Japan). Note: * Mark (Check place) A;Office B; Work-site - 10/12 -

(D-11/13)

E. QUALITY ASSURANCE SYATEM

No * A B Check item Understanding and N.A. correspondence situation of SQAM(*) contents. * SQAM : Supplier Quality Assurance Manual Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
The persons concerned have full knowledge of the contents mostly, and it is as Toyota expecting.

3
It uses, when the necessity that the persons concerned are correspondence comes out.

0
Existence of SQAM is not known.

SQAM relation

In addition to the inspection data which Toyota is demanding, Item specially carried out to there is a check item an initial stage control independently carried out period. within a process, and the period is also clear. Three lots are carrying out FMEA examination. It is specified by letter, and the contents are also concrete and it is easy to understand them.

Inspection data picking is increased and it is checking that it is satisfactory.

Required data is taken according to initial stage control of Toyota.

The method of the quality identification at the time of process change.

Although there is regulation, it is not enough grasped even to a business person in charge.

There is no regulation.

There are a point of the quality identification for every process, frequency, The contents of manufacturing quality chart record, etc., and it is intelligible. Technical posts enters and creates. It is specified by letter and information deployment is carried out at its required post timely.

The contents are complicated although a settlement is good.

Inadequate in the contents Nothing of directions, although it is.

Disposal route of a customer claim

Although specified by letter, it is not developed timely at its required post.

With no regulation with a document

System

It carries out by Product Problem Report and Countermeasures Sheet.

Recurrence prevention, widespread implementation, the structure and enforcement situation that carries out and follows up prevention before it happens.

There is a mechanism in which a left item is carried out and it carries out certainly.

Although there is no structure, recurrence prevention is certainly carried out at the time of problem generating.

There is no structure and There is no structure and recurrence prevention is recurrence prevention etc. also the dependence on a is not carried out. person in charge.

Note: * Mark (Check place) A;Office B; Work-site

- 11/12 Although there is regulation, it is not enough grasped even to a business person in charge. There is no regulation.

Conditions of jurisdiction change to the manufacture from the trial production of a new product.

It is specified by letter, and the contents are also concrete and it is easy to understand them.

(E-12/13)

tem

E. QUALITY ASSURANCE SYATEM

No
7

* B A

Conditions of jurisdiction Check item change to the manufacture from the trial production of a new product.

Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0

Three lots are checked by Cross Functional Team. There is a system carried out periodically. There is There is a system carried actual results carried out out periodically. along with it this year also. Although there is no system carried out periodically, there is actual It is to carry out if needed. It is not carrying out. results in the current fiscal year.

Enforcement time of an incompany process audit, one's enforcement post, a standard.

System

It carries out twice per year periodically. It is late for a plan for a while, and it will carry out next manth this year. There is a measure by a quality control group etc. and it is reported periodically. Although there is a measure by a quality control group etc., there is little enforcement.

Measure to the improved quality within a process

With no measure

Note: * Mark (Check place) A;Office B; Work-site

- 12/12 -

(E-13/13)