REVISION RECORD SHEET

TITLE : PROCEDURE FOR

REV.NO 00 CONTROLLING NONCONFORMING PRODUCT. DESC. OF AMENDMENT DATE OF AMENDMENT PROCEDURE RE-STATED. 16.03.1997

PR.NO : QP-13-01 PAGE NO : 1 OF 5 ISSUE NO : 01 REV NO : B DATE : 04.07.1997 REASON FOR AMENDMENT QS 9000 ; 1995 UPDATION

DISTRIBUTED TO :
SL.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PREPARED BY: DESIGNATION NAME & SIGNATURE OF THE RECEIVER

APPROVED & REVIEWED AND RELEASE CONTROLLED BY: .

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Controlling Non-Conforming
Product. PURPOSE : Scope :

PR.NO : QP-13-01 PAGE NO : 2 OF 5 ISSUE NO : 01 REV NO : B DATE : 04.07.1997

To define the procedure for control and disposition of Non Conforming Products (N. C. P.) All N. C. P. identified during incoming, inprocess and final inspection in the organisation including customer returns. AGM - QA for LS & Dy. Mgr - QA for STB 01.The discovery of NCP can occur during the following stages: Incoming Inspection Inprocess , Final Inspection, Customer Returns 02. The control system for handling NCP shall be as described as further The system is common for all the stages identified above and whenever specific for a particular stage, the same shall be indicated). The overview of the system are as follows : Discovery Identification Segregation Review for disposition Approval Documentation Disposal Close out Tracking

Responsibility : Procedure :

The details of each are as follows : A) DISCOVERY A NCP shall be discovered by : At Receipt Inspection QA Engr. / Lab incharge At Inprocess & Final Inspection - Operator / QA Inspector Customer returns shall be brought to the notice of respective QA Incharge by Mktg. Heads. A REJECTED/ REWORK/ HOLD Tag / Sticker shall be put on such NCPs. Such NCP shall be shifted to respective Quarantines from shift to shift. The NC shall be logged in the respective NC register : RG-13-01 For Incoming Inspection RG-13-02/A For Inprocess & Final Inspection where Arepresents L for Leaf spring and S for stabilizer bar. RG-13-03/L For Assy. Inspection RG-13-04/L & RG-13-03/S For Customer returns.

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Controlling Non-Conforming
Product. The incoming NC register shall have the following information: Sl.no Date Vendor with MRN no. Section / Diameter Specifications Process drawing with revision status Disposition - (a) Reject (b) Use as it is Total Qty. Corrective Action Inspected by & remarks comments, if any

PR.NO : QP-13-01 PAGE NO : 3 OF 5 ISSUE NO : 01 REV NO : B DATE : 04.07.1997

The inprocess NC register shall have the following information: Sl.no Date & shift Process drawing no. with revision status Opn no. & Desc Part no & Desc Nature of defect No. of NCP Total Batch Qty. Disposition - (a) Reject / Scrap (b) Rework Salvaging Corrective Action Remarks Approved by.

(c) Use as it is

(d) Regrade (e)

B) IDENTIFICATION : Upon the discovery of the NCP, all such material shall be identified by putting a tag / stickerREJECTED/ REWORK/ HOLD TAG by respective Inspector/operator. In the incoming inspection the tag shall have information about the vendor, MRN no., the inspectors sign on the tag & the Qnty. In the inprocess & final inspection, the tag shall have information about the operation no., date, shift, disposition operator and qnty & the operators/inspectors sign on the tag along with cross reference to product route card.

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Controlling Non-Conforming
Product. C) SEGREGATION

PR.NO : QP-13-01 PAGE NO : 4 OF 5 ISSUE NO : 01 REV NO : B DATE : 04.07.1997

Having clearly identified NCP, the respective Inspectors/ operators shall segregate / quarantine to the area identified at the respective work stations until the decision has been reached on disposition. This shall be under the strict super vision of the Inspectors. D) REVIEW FOR DISPOSITION
+

The Material Review Board (MRB) / comprising of Managers of QA & Production, shall review the NCP every day for all the three stages. In the absence of MRB for any reason, the respective shift engineer/inspector shall put a HOLD tag on the non conforming product, stored at the identified area till the MRB meets and reviews for disposition. The review shall be carried out in the following methodology : Stage I: Assess the source documents that whether the specifications are clearly / adequately defined and that the NCP is actually a non conformance or defective or both. Stage II : Assess the criticality of the NCP based on two aspects: The maximum deviation from specification The qnty or rate of items non conforming E) APPROVAL The NC Register shall be completed to indicate disposition, liability and actions required, which affected parties sign to signify their approval. The responsibility for obtaining & overall control of the process shall be that of MRB. Whenever MRB is not in a position to decide on disposition, the same shall be referred to GM(O)/AGM-STB and decided accordingly. F) DOCUMENTATION INVOLVED Based on the disposition decided, the following documents as appropriate shall be raised. When the decision taken are: USE AS IT IS - a deviation note, which is a written authorization prior to use or release of a qnty of items produced which do not conform to the specified requirements. REWORK INSTRUCTION/PLAN- to indicate the nature the type of rework to be carried out. SCRAP NOTE - Authorisation to dispose the material which cannot be reworked, repaired or used for any other purpose.

QUALITY ASSURANCE PROCEDURE

TITLE : Procedure for Controlling Non-Conforming
Product.

PR.NO : QP-13-01 PAGE NO : 5 OF 5 ISSUE NO : 01 REV NO : B DATE : 04.07.1997

RETURN NOTE - Notification to a vendor of the reason for returning material This document sometimes incorporates the corrective action request document. SALVAGING - Authorisation to salvage the material which cannot be reworked, repaired or used for any other purpose. CORRECTIVE ACTION - Any immediate corrective action shall be recorded in the respective NC register and shall be informed to the operators concerned. G) DISPOSAL After approval & disposition identified QA Inspectors shall get the disposition done as documented. H) CLOSEOUT AGM - QA for LS & Dy. Mgr.(QA) for STB shall ensure that follow up actions , approved on NC Register, for correction or prevention are implemented. For rework or repair this shall require reinspection of the items. I) TRACKING Records of NCP shall be maintained by AGM - QA for LS & Dy. Mgr.(QA) for STB to determine whether actions taken are effective in reducing the no. of Ncs. AGM - QA for LS & Dy. Mgr.(QA) shall ensure that a weekly summary of NCPs is made and analysed for corrective & preventive action as per Proc. No. QP-14-01. The summary is discussed & analysed jointly with respective Production & Engg. incharges. The overall effectiveness is determined by plotting the quantity of NCPs discovered monthly. Engineering Approved Product Authorisation : The situation when changes are to be incorporated in any of the parameters of process set up prevailing at the time of sample approval, prior approval from the customer shall be obtained if the product is different from the currently approved one. Refer PPAP requirements as detailed in procedure QP-21-01. Similar control of products shall apply on products purchased from sub-contractors . This situations of change in product nature if approved by customer for a specific period or quantity, Marketing / Engg. Incharge shall communicate the details to Q. A. Incharge who in turn shall maintain record of quantities supplied with customer authorization. After expiration of this concession / authorisation he shall ensure meeting with original quality requirements. The material shipped under authorisation shall be marked or identified separately.