Sunteți pe pagina 1din 70

MUSASHI SOUTH CAROLINA AMENDMENTS DOC NO:MSC-QM1

Page 70 of 3 SECTION: AMENDMTS

TS Manual Amendment Record

REVISION REVISION APPROVED


DATE NUMBER CLAUSE CHANGE BY
7/30/03 1 5- Mgmt. Resp. Updated for organization changes RSS
7/6/04 2 5- Mgmt. Resp. Updated for organization changes RSS
9/13/04 1 Forward Distribution list revised to post on "S" RSS
3/1/05 3 5- Mgmt. Resp. Updated for organization changes RSS
5/3/05 1 1-Scope Revised scope statement, & expanded RSS
7.3 Product design exclusion detail
8/31/05 4 5- Mgmt. Resp. Updated for organization changes RSS
of responsibilities

Issued by: Ralph Sulser Edition: 01


Approved by: Keith Shepard Date: 04/02/03
Rev. 0
MUSASHI SOUTH CAROLINA INTRODUCTION DOC NO.:MSC-QM1
Page 4 of 70 SECTION#: 00

CL. REVISION NO. OF


SECTION NO. TITLE REF. NO. PAGES
0 Introduction 0 5
- Table of Contents 0.1
- Foreword 0.2
- Structure of the Manual 0.3
- Manual Issue Procedure 0.4
-Manual Revision, Updating & Amendment Procedure
0.5
- Company Profile
- Distribution List + 0.6 -0.7 1

1 Scope 1 0 1
- General 1.1
- Application (Exclusions, if any) 1.2

3 Terms and Definitions 3 0 1

4 Quality Management System 4 0 3


- General Requirement 4.1
- Documentation requirement 4.2
- General 4.2.1
- Quality Manual 4.2.2
- Control of Documents 4.2.3
- Control of Records 4.2.4

+May not be part of the "Uncontrolled Copy”


of this Manual which is meant for distribution to External Agencies.

CL. REVISION NO. OF


SECTION NO. TITLE REF. NO. PAGES

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

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 6 of 70 SECTION#: 00

CL. REVISION NO. OF


SECTION NO. TITLE REF. NO. PAGES
0 7
7 Product Realization 7
- Planning of Product Realization 7.1
- Customer Related Processes 7.2
- Determination of requirements related to the product 7.2.1
-Review of Requirements related to the product 7.2.2
- Customer Communication 7.2.3
- Design & Development 7.3
- Purchasing 7.4
- Purchasing Process 7.4.1
- Purchasing Information 7.4.2
- Verification of Purchased Product 7.4.3
- Production & Service Provision 7.5
- Control of production and service provision 7.5.1
*Validation of processes for 7.5.2
production and service provision
- Identification & Traceability 7.5.3
- Customer Property 7.5.4
- Preservation of product 7.5.5
-Control of Monitoring and Measuring Devices 7.6
- Measurement system analysis 7.6.1
- Calibration/verification records 7.6.2
- Laboratory requirements 7.6.3
- Internal Laboratory 7.6.3.1

CL. REVISION NO. OF


SECTION NO. TITLE REF. NO. PAGES
8 Measurement, Analysis and 8 0 3
Improvement
- General 8.1
- Monitoring & Measurement 8.2
- Customer Satisfaction 8.2.1
- Internal Audit 8.2.2
- Monitoring & Measurement of Processes 8.2.3

- Monitoring & Measurement of Products 8.2.4

- Control of Non-conforming Product 8.3


- Analysis of Data 8.4
- Improvement 8.5
- Continual Improvement 8.5.1
- Corrective Action 8.5.2
- Preventive Action 8.5.3

9 Section 2- Customer Specific requirements 1


10 Amendment Record 1

Annex Product Process Flow Chart , Process Approach 0 4


Charts

Annex Organization Chart 0 1


Note: Printed documents are not controlled copies-check master computer files for latest revisions 36

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 7 of 70 SECTION#: 00

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.

0.3 STRUCTURE OF THE MANUAL

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

0.4 MANUAL ISSUE PROCEDURE

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 con-trolled 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 Coordinator’s 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 uncon-trolled copies do not
come under the control of the document amen-dment procedure, and are used for reference only, and are not used within
the Company.

The TS16949 Coordinator / Management Representative maintains a record of the distribu-tion 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

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 8 of 70 SECTION#: 00

0.5 MANUAL REVISION, UPDATING AND AMENDMENT PROCEDURE

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 Represen-tative 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.

The TS16949 Coordinator/Management Representative retains one copy of the


earlier version of the Section(s) in archives for Five Years.

0.6 COMPANY PROFILE

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

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 9 of 70 SECTION#: 00

DISTRIBUTION LIST
(Distributed uncontrolled copy by electronic e-mail)
Posted on the "shared" computer file

TS16949 Coordinator (Printed Controlled copy) Master


Copy

Note: Printed documents are not controlled copies-check master computer files for latest revisions

Issued by: Ralph Sulser Edition : 01


Approved by: Keith Shepard Date: 09/13/04
Rev. 1
MUSASHI SOUTH CAROLINA SCOPE DOC NO.:MSC-QM1
10 of 70 SECTION# :1
1 SCOPE

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:

“Manufacture of Gears, and Gear Assemblies for the Automotive Industry”

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.

Issued by: Ralph Sulser Edition: 01


Approved by: Keith Shepard Date: 05/03/05
Rev. 1
MUSASHI SOUTH CAROLINA SCOPE DOC NO.:MSC-QM1
11 of 70
Note: Printed documents are not controlled copies-check master computer files for latest revisions
SECTION# :1

Issued by: Ralph Sulser Edition: 01


Approved by: Keith Shepard Date: 05/03/05
Rev. 1
DOC NO.:-QM1
MUSASHI SOUTH CAROLINA TERMS and DEFINITIONS
12 of 70 SECTION#:3

3.0 TERMS, DEFINITION & ABBREVIATIONS

In this Quality System Manual and related procedures / instructions, following terms / definitions and
abbreviations have been used:

3.1 Terms and definitions:


Organization:
Musashi South Carolina (MSC)

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:

QMS Quality Management System NC Non-conformance


OPI Operator Process Instructions FMEA Failure Mode Effect Analysis
T/L Team Leaders PPAP Production Part Approval Process
PC Production Control APQP Advanced Product Quality Planning
MT Maintenance PH Purchasing
PC Production Control PD Production
MGT Management CP Control Plan
SP Standard procedure CAR Corrective Action Request

Issued by: Ralph Sulser Edition: 01


Approved by: Keith Shepard Date: 04/02/03
Rev. 0
DOC NO.:-QM1
MUSASHI SOUTH CAROLINA TERMS and DEFINITIONS
13 of 70 SECTION#:3

Note: Printed documents are not controlled copies-check master computer files for latest revisions

Issued by: Ralph Sulser Edition: 01


Approved by: Keith Shepard Date: 04/02/03
Rev. 0
QUALITY MANAGEMENT SYSTEM DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 14 of 70 SECTION#: 4

4.0 Quality Management System

4.1 General Requirements

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

MSC has therefore:

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 part’s 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) ensured are effective. This has
the availability been doneand
of resources while planning necessary
information for the processes. (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
QUALITY MANAGEMENT SYSTEM DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 15 of 70 SECTION#: 4

4.2 Documentation Requirements

4.2.1 General

The Quality Management System documentation of the MSC includes:

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:

Level 1- Quality System Manual


Level 2- Standard Procedures
Level 3 -Operator Process Instructions
Work Instructions
Process Flow Diagrams
Drawings / Specifications
Level 4- Checksheets, Charts, Forms, Tags

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
QUALITY MANAGEMENT SYSTEM DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 16 of 70 SECTION#: 4

Note: Printed documents are not controlled copies-check master computer files for latest revisions

4.2.2 Quality Manual


MSC has established and maintains a Quality Manual that includes the applicable Scope of the Quality
Management System (Refer Section 1.1). Procedures established have been referenced in the relevant Sections.
Wherever no procedures are required, the required methodology as adopted and implemented to meet the
requirement of the standard have been explained in the Manual itself. The interaction between the
processes(QC-PM-001) of the Quality Management System have also been described in the Manual and by
including the Process Flow Diagram(s) of the product(s) processed by the Company.

4.2.3 Control of Documents


Documents required by Quality Management Systems (refer documentation structure under 4.2.1) are
controlled. The Company has established a “Documented Procedure” which defines the controls needed to
effectively implement the Quality Management Systems.

The controls defined in the procedure include the methods:

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

Procedure No.: QC SP 003 -Document Control

4.2.4 Control of Quality Records

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
QUALITY MANAGEMENT SYSTEM DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 17 of 70 SECTION#: 4

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

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
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 18 of 70 SECTION #: 5

5.0 Management Responsibility


5.1 Management Commitment
The MSC management is committed to the development and implementation of the quality management system
and continually improve its effectiveness by:

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

5.2 Customer Focus


The Top Management of MSC ensures that customer requirements are determined and fulfilled with the aim of enhancing
customer satisfaction. While reviewing the requirements, the implied needs and expectation of the customer are also
identified. These are conveyed to the respective functions for ensuring that they are met. As a part of Management Review
(Refer 5.6 below), a focus is made for communicating the customer requirements to all functions and ensuring product
conformance.

Methods of determining customer requirements, expectations and satisfactions are defined in the procedures

MGT SP 001 Contract Review (Product Requirement Review)


QC SP 023 APQP (Planning for product realization)
QC-SP-007 Failure Mode And Effect Analysis

5.3 Quality Policy

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,

e) is periodically reviewed for continuing suitability.

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 19 of 70 SECTION #: 5

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.”

Dated: 03/20/2003 S. Okubo President

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
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 20 of 70 SECTION #: 5

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.

1. President - Musashi South Carolina


• The senior most executive at the plant and designated as President, and has responsibility for the entire operation..
• Approves customer and supplier contract review actives.
• Approves the company's policies and gives directions for managing the objectives, and company activities.
• Approves the MSC's quality policy and objectives.
• Responsible for providing essential resources and personnel for implementation of the quality policy, and quality
management system.
• Responsible for effective implementation of the quality management system.
• Through leadership and actions, the President creates an environment where people are fully involved, and in which a
QMS can operate effectively.
• Reviews customer scorecards for Visteon, and other customers, on their web sites
• Chairman of the Management Review Committee.

2. Senior Manager Engineering/Maintenance


• Overall responsibility for planning, coordinating & managing activities related to functions of Manufacturing
Engineering, Maintenance, Projects.

• 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 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” if systems are not being implemented.
• Developing facilities, processes and equipment, and contingency plans.
• Supporting QMS activities including regulatory requirement if any, for the products.

• Reports to the Plant President.

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 21 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
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 22 of 70 SECTION #: 5

3. Senior Manager – Quality Control


Responsible for quality systems, procedures, and instructions for the plant
• Monitoring the Process for outputs.
• Providing Test Status on In-coming, In-process and Finished Products
• Documenting trends in quality and current quality levels.
• Controlling of non-conforming products.
• Authorized for dispositioning deviations on Non-conforming products for use at next stages.
• Authorized for release of finished product.
• Obtaining waivers from customer on non-conforming finished products.
• Developing and implementation of plans for customer complaint resolution.
• Assessment of Preliminary (Ppk) and on going process capabilities (Cpk).
• Preparing details for Production Part Approval Process.
• Inspection and testing at incoming, in process and final stages
• Controlling the procedures for In-coming, In-process and Final Inspection Stages
• Calibration of all identified inspection, measuring and test equipment.
• Authorized for providing inspection and test status on all products.
• Identifying and implementing statistical technical techniques for process and product.
• Verifying the effectiveness of corrective and preventing actions.
• Issuing and maintaining originals and withdrawal of obsolete APQP documents, process standards, drawing and
documents of external origin.
• Production Part Approval Process (PPAP&PSW) and liaison with customers for same
• Establishing, and maintaining customer communication channels.
• Monitoring and Measuring Customer Satisfaction metrics.
• Representing the needs of the customer in internal functions in addressing the ISO/TS 16949 requirements.
• Assisted by Quality Control Mgr. QC, QC Technicians, QC Associates, TS16949 Coordinator
• Reviews and maintains scorecards for Visteon, and other customers, weekly on their web sites
• Designated as Customer Representative to ensure customer requirement are met, and contact for quality issues.

· 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.

• Reports to the Plant President

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

4. Senior Manager Production/Production Control/New Sales


• Overall responsibility for planning, coordinating & managing activities related to functions of Production
• Purchasing of manufacturing materials, and supplier monitoring.
• Production scheduling of all products
• Control of customer-supplied products, and packaging
• Receiving, storage and issue of products, and packaging.
• Reviewing, approving and maintaining effectiveness of the procedures for the above activities.
•• Disposal
Handling of scrap, preservation,
storage, and waste. identification and test status of all products during receipt, storage,

• Ensuring 100% on time delivery to customer.


• Inventory management of purchased products, WIP and finished product.
• Checking adequacy of FIFO.
• Supplier performance tracking
• Supporting QMS requirements related to these functional areas.
• Assisted by Production Control Manager, and Coordinators.
• Reviews customer scorecards for Visteon, and other customers, on their web sites
• Preparing and submitting the quotation offer to customers.
• Receipt of order / dispatch schedules from customer.
• Review of customer’s order for correctness.
• Resolving any differences between the inquires and potential orders.
• Communicating customer’s requirement to concerned personnel in the company.
• Interaction with Customer for product development and all contract review activities
• Also responsible for EHS, ISO14001 and assisted by the EHS Administrator
• Assisted by Managers, and Assistant Managers for Forging, Lathing, Heat Treat/Assembly, for these activities.
• Guiding and supporting QMS activities including regulatory requirement if any, for the products.
• Reviews customer scorecards for Visteon, and other customer rating systems
• 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.

• Reports to the Plant President


5. 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.

6. Manager– Human Resources


• Responsible for coordinating with departmental heads to obtain staffing.
• Determine the training needs related to managers, staff, associates, temporaries, probationers, and trainees.
• Identifies, and implements training, and employee motivation needs.
• Also responsible for public affairs, and industrial relations to enhance productivity.
• Assisted by the H.R. Assistant, and Payroll Coordinator.
• Reports to the Plant President.

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 24 of 70 SECTION #: 5

7. MSI Engineering- Japan

• 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.

8. President - Sales and Marketing-Musashi North America, Detroit, MI


• Receipt of Inquiries from the customers, review, and passes thyrough to Musashi South Carolina
• Coordinating with MSI, MSC President for planning future business
• Assists in assessments of customer satisfaction.
• Reports to President Musahi North America

9. Management Representative ( Ref. 5.5.2 )

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

5.5.1.1 Responsibility and authority of managers


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.

5.5.2 Management representative


Top management has appointed the TS16949 Coordinator-Quality Control who, irrespective of other responsibilities, has
the responsibility and authority that includes:
a) ensuring that processes needed for the quality management system are established, implemented and maintained,
b) reporting to top management on the performance of the quality management system and any need for improvement, and
c) ensuring the promotion of awareness of customer requirements throughout the organization.
d) liaison with external parties on matters relating to the quality management system.
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 25 of 70 SECTION #: 5

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.

5.6 Management review


5.6.1 General

Top Management of MSC reviews the company’s 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
MUSASHI SOUTH CAROLINA Page 26 of 70 SECTION#: 6

6 Resource Management

6.1 Provision of Resources

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
MSC’s 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 Human Resources

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.

6.2.2 Competence, Awareness and Training

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
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev.: 0
RESOURCE MANAGEMENT DOC NO.: MSC-QM1
MUSASHI SOUTH CAROLINA Page 27 of 70 SECTION#: 6

HR SP 002 Resource Management


Note: Printed documents are not controlled copies-check master computer files for latest revisions

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.

Procedure: QC SP 024 Contingency Plan


MT-SP-001 - Procedure for Preventative Maintenance(update-CG)

6.4 Work Environment

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.

6.4.1 Personnel safety to achieve product quality


Product safety and means to minimize potential risks to employees, and customers are addressed by MSC, especially in the
design and development process and in manufacturing process activities.
• Human factors such as ergonomics (space required for effective working), and need for the use of personal protective
equipment (PPE).

6.4.2 Cleanliness of premises


MSC maintains the premises in a state of order, cleanliness, and repair consistent with the product and manufacturing needs.

Cleanliness of premises is maintained using 5S check lists to ensure the premises in a state of order, cleanliness and repair.

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev.: 0
RESOURCE MANAGEMENT DOC NO.: MSC-QM1
MUSASHI SOUTH CAROLINA Page 28 of 70 SECTION#: 6

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

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev.: 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 29 of 70 SECTION#: 7

7.0 Product Realization


7.1 Planning of Product Realization

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

7.2 Customer Related Processes


7.2.1 Determination of Requirements Related to Product
The organization has established a documented procedure to determine:

- 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.

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 30 of 70 SECTION#: 7

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

7.2.3 Customer communication

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)

Procedure No. MGT SP 001 - Procedure for Contract Review


QC SP 019 - Corrective Action (Includes Customer complaint response)
QC SP 011 - Procedure for internal & External Customer Satisfaction

7.3.2 Design and Development Planning

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 customer’s 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.
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 31 of 70 SECTION#: 7
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.
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.

Procedure No. QC SP 009 – Parts Submission Warrant/PPAP

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 Company’s 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)

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 32 of 70 SECTION#: 7

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 company’s 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
MSC’s 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.
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 33 of 70 SECTION#: 7
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:

Shear Operations PD-WI- SH-101


Hot Forging Press Start Up PD-WI- HF- 102 &103
Hot Forging Press Die Change PD-WI-HF-105
Heat Treatment PD-WI-HT-100
Shot Blast-Billets and Forged Gears PD-WI-FSB-101
Handling, Storage, Packing, Preservation PC SP 001
Customer Supplied Parts and Packaging PH SP 001
Final Inspection & Packing of Visteon Gears PD-WI-HT-109

7.5.2 Validation of Processes for Production


Before starting mass production, validation of processes, equipment and personnel is performed.
A system has been established and maintained for revalidation of the processes. Validation is performed by determining CPks at run rate
on customer designated characteristics, and records are maintained. The validation process is defined by the customer, or PPAP for
specific criteria for review and approval, equipment approval, personnel qualification, methods / procedures, records requirements and
revalidation.
Procedure No. QC-SP-009 PSW/PPAP

7.5.3 Identification and Traceability

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 part’s 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 supplier’s 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.

Procedure No. QC SP 015 Product Identification & Traceability


Procedure No. QC SP 005 Lot Control

7.5.4 Customer Property

MSC takes due care with customer property while under the MSC’s 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.

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 34 of 70 SECTION#: 7

Procedure No. PH SP 001 Customer Supplied Parts and Packaging

Note: Printed documents are not controlled copies-check master computer files for latest revisions

7.5.5 Preservation of Product


MSC has established a documented procedures for preserving the product quality from receipt of materials through internal processing
up to the delivery of finished products to the intended destination. This preservation includes the product identification, handling,
packaging, storage and protection of the products.

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

7.6 Control of monitoring and measuring devices

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
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 35 of 70 SECTION#: 7
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

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 36 of 70 SECTION#: 7

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.

Procedure Nos. QC SP 017 Gage Control


QC SP 026 Gage Calibration Scope
QC SP 008 Internal Laboratory Scope
PD-HT-703&705SM Laboratory System –Skill Maps

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
PRODUCT REALIZATION DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 37 of 70 SECTION#: 7

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
MEASUREMENT, ANALYSIS, IMPROVEMENT DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 38 of 70 SECTION#: 8

8. Measurement, analysis and improvement


8.1 General
Processes have been established for monitoring, measuring, analysis and improvement needed to demonstrate conformity of
product, ensure conformity of the quality management system, and continually improve the effectiveness of the quality
management system, including determination of applicable methods and statistical techniques.

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

8.2 Monitoring and measurement


8.2.1- A procedure has been established for evaluation of customer satisfaction, expectations and applications of measures to
enhance customer satisfaction.
Customer satisfaction and expectations are evaluated on both perceptive as well as performance measures.
Information on customer performance measures are obtained from our customers’ electronic web site postings of supplier
rating systems. These measures include quality, delivery, and systems. Sr.Mgr.QC or Asst.Mgr. QC monitors weekly.The
information on perceptive measures are developed by the organization for additional customer feedback, such as phone
calls, e-mail, sales communications, related to customer perceptive/performance measures.
Countermeasures are developed and monitored for any unsatisfactory areas identified from the customer ratings, and
customer satisfaction expectations.
The customer satisfaction ratings are monitored, and maintained continually and evaluated for performance of the product
realization process. Customer web site information is updated monthly for key scoring criteria.
8.2.2- The organization has a procedure for performing internal audits at planned intervals to determine if the quality
management system conforms to the planned arrangements and is effectively implemented, covering all quality
management related process, activities and shifts.
Audit frequency is appropriately increased when internal / external non-conformances or customer complaints occur.
Specific checklists are developed for the audits. Corrective actions are taken on the non-conformance observed, in meeting
the planned results, during the audits. The audits also aim at determining the effectiveness of the manufacturing process, and
products.
8.2.3 Performance monitoring measures are decided for the quality management system processes. Processes performance
on each measure is measured by the concerned process owner, and measured as: Percents /$ /PPM / DPM and results
presented in Management Review Meetings.
Corrective actions are taken as appropriate when planned results are not achieved.
8.2.3.1 Process capability of each new process is studied and verified during production part approval process (PPAP).
Control plans are reviewed and revised for additional control needed, if any, based on the PPAP results. PPAP results are
documented.
The output of the manufacturing process design and development process is in the form of Operator Process Instructions.
OPIs define inspection, standards, frequencies, and methods, and other instructions to provide necessary information as
means of production measurement, test and maintenance instructions. Also includes objectives for manufacturing process
capability, validity, maintainability and availability as well as acceptance criteria.
Process control procedures established within the organization ensures maintaining manufacturing capability or performance
as specified by the customer part approval process requirement by following the manufacturing process design and
development process output documents such as process / inspection / packaging standards and other work instructions.
Significant process events are noted on the control charts and inspection records maintained for controlling the
manufacturing process.
Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
Process control procedures established within the organization ensures maintaining manufacturing capability or performance
as specified by the customer MEASUREMENT, ANALYSIS, IMPROVEMENT
part approval process DOC
requirement by following the manufacturing process design NO.:MSC-QM1
and
MUSASHI SOUTH CAROLINA Page 39 of 70
development process output documents such as process / inspection / packaging standards and other work instructions. SECTION#: 8
Significant process events are noted on the control charts and inspection records maintained for controlling the
manufacturing process.
Note: Printed documents are not controlled copies-check master computer files for latest revisions
Appropriate reaction plans in the Control of Non-Conforming Product, and Corrective Action Procedures have been
developed and are followed for characteristics that are either unstable or non-capable.
The reaction plans include containment, and segregation of product, 100% inspection, and root cause analysis as
appropriate. Corrective actions plans are developed and implemented to assure that the process become stable and capable.
The plans are reviewed and approved by the customer, if required.
8.2.4 Operator Process Instructions, check sheets, and X bar & R charts have been established for monitoring and measuring
the characteristics of the product to verify that product requirements have been met.
Product releases for delivery to customer do not proceed until all the planned operations, inspections and tests have been
satisfactorily completed, unless approved otherwise by a relevant authority or via customer communications.
The O.P.I.s also includes product audit and layout inspections of products at appropriate stages of production and delivery,
and at frequency defined for each product.
Currently MSC does not have any customer requirements for “appearance items”. In the event this becomes a future
requirement the necessary controls, including appropriate lighting, master samples and qualifications of personnel, will be
defined.
Related procedures
QC SP 023 APQP
QC SP 017&026 Gage Control, and Gage Calibration Scope
QC SP 016 Control of Non Conforming Product
QC SP 018 Internal Quality Auditing
QC SP 011 Customer Satisfaction
QC SP 001 Management Review
PD SP 001 Process Control

8.3 Control of nonconforming product


A procedure for control of nonconforming products has been established, defining a system for identification, control,
evaluation, documentation, disposition, containment, segregation (where practicable), rework / repair and prevention of
unintended use of nonconforming / suspect products at various stages during manufacturing.
According to this procedure nonconforming products are reviewed by authorized personnel for action required to eliminate
cause, determine rework, acceptance without repair by waiver (through deviation from customer, if and where necessary), or
for the rejection / scrap. Reworked / repaired products are re-inspected according to the original specified requirements.
Products with unidentified or suspect status are classified as nonconforming.
Nonconforming / suspect material is placed in designated color-coded product bins at operations, and the products in the
bins containing then are visually identified.
Rework instructions are established, accessible and utilized by appropriate personnel in their work area. Reworked parts are
re-inspected prior to release. Nonconforming products are quantified, analyzed and a prioritized reduction plan instituted as
necessary.

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

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
MEASUREMENT, ANALYSIS, IMPROVEMENT DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 40 of 70 SECTION#: 8

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.

8.4.1 Related procedure

QC SP 001 Management Review

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

Edition: 01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
MEASUREMENT, ANALYSIS, IMPROVEMENT DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 41 of 70 SECTION#: 8

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
CUSTOMER SPECIFICS DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 42 of 70 SECTION#: 9

Section 2: Customer Specific Requirements

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.

Edition:01
Issued by: Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
CUSTOMER SPECIFICS DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA Page 43 of 70 SECTION#: 9

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
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 Receive Steel Steels bars from Feasibility, Control Plan, Design Drawings
FMEA, Process Design, Build Schedules
Accept approved supplier Non-conformance
Process Validation(CPk) Delivery Schedules
yes PPAP
no -------------------------->
C.O.A.

Operator Process Cut Billets Shear cut steel bars


Instruction into billets
yes
Inspect- no ---------------------------> Process Owners Customer Oriented Process Support Processes
checksheet President (Key Processes) Marketing Sales
Deliver to shot blast Plant Manager RFQ Process Human Resources
Sr. Production Manager Customer P.O. requirements Training
Operator Process Shot Blast Shot blast removes Managers: (APQP) Quallity Control & Calibration
Instruction Billets rust and scale Forging/Sizing Design Process Engineering
Lathing Product/Process Validation Maintenance
Deliver to Hot Forging Heat Treat & FI (PPAP) E/H/S
Operator Process Hot Forge Forge billetts into gears Team Leaders Mass Production Purchasing Material/Supplies
Instruction Associates Delivery Production Control
yes Feedback
Inspect- no ---------------------------> Management Oriented Process
checksheet Business Planning
Resource Planning
Management Review
Operator Process Normalizing / Gears enter directly inline Continous improvement
Instruction Annealing Anneal forged gears Analysis of Data
Corrective/ Preventive actions
Customer satisfaction feedback
yes Product/process perfomance
Inspect- no -----------------
-----------> Internal audit
checksheet,
+ X&R
Deliver to shot blast

Operator Process Shot Blast Shot blast cleans residue


Instruction

Deliver to Sizing

Operator Process Sizing Trims & Sizes


Instruction preliminary dimensions

yes Inspect- no -------------------------->


checksheet, +
X&R
Deliver to Lathing staging area

Operator Process Lathing CNC precision lathe,


Instruction dimensions
Non-Conforming HOLD Tag, Log Book
yes HOLD AREA
Inspect- no --------------------------> Review for Disposition by QC
checksheet, +
X&R

Operator Process During lathing operations: SORT REWORK


Instruction Broach/Champher/ Broach, champher, burnish REJECT/SCRAP
Burnish
ACCEPT ACCEPT
Place gears on racks RETURN TO MANUF. DISPOSE BY QC
yes Inspect- no -------------------------->
checksheet, +
X&R
Deliver to Heat Treat Dept.

Operator Process Degrease Degrease lathing lubricants


Instruction
Identify Lot #s, and route thru
Heat Treat furnaces

Operator Process Heat Treat Caborize, harden cycles


Instruction Time & temp.

yes no -------------------------->
Inspect/Test
checksheet, +
X charts
Route thru to shot peen/blast

Operator Process Shot Blast/Peen Removes heat treat resudue


Instruction

Route to wash on roller conveyor

Operator Process Final Wash Detergent wash, and dry


Instruction Time & Temp.

Operator Process Final Final Inspection of dimensions


Instruction Inspection/Pack Apply rust preventative
QC selects samples for SPC
measurements & documentation
yes
QCAudit SPCs no --------------------------->
checksheet, +
X&R
Output to Customer :
OUTPUT Acceptable Finished Gears, Customer
Stage/ Ship Delivered on time Satisfaction &
Perceptions of
M.S.C.

56379874.xls Bevel Gears R. Sulser 04/21/2011


External & Internal Process Inputs to Musashi South Carolina Process
QC-Flow.Doc.-102
Rev. 2 5/26/04
Material/Components Inputs
Customer
Designated
Raw Steel /Supplied Honda(Assy.)
Material Parts/Pkg. Parts& Pkg.

Musashi South Carolina


Customer Process Planning Process Production Process
Musashi Review Team Feedback
North America President - Tooling Communicate Review
Sales Office Sr. Mgr. PC/Sales/Proj. - Engineering Facility & Equipment Controls
Detroit, MI Sr. Mgr. Prod./Engrg./Maint. - Maintenance

CUSTOMERS
RFQ Info-Pass thru Sr. Mgr. QC Machine
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

APQP FMEAs Control Plans Process Info Parts

Musashi - Japan (MSI) Inputs of Information and Parts


Develops preliminary draft plans input for each new product
MSC takes ownership upon receipt and finalizes to conform to MSC processes
May supply finished, or W.I.P. Parts

file:///opt/scribd/conversion/tmp/scratch2743/56379874.xls 04/21/2011 External Inputs


Process Map: Interaction and Sequence Musashi South Carolina

Management QC-SP-021.doc QC SP 013.doc 8.2.1 Customer Satisaction/feedback QC-SP-011


5.6
Oriented 5.2,5.4 Business Planning/ 6.0 8.5.1 Continual 8.4 Analysis of data = Key processes
Management
Processes Resource Planning improvement PD-SP-001.docProcess
Control
Review 7.5.1 Product/process conformance
QC-SP-016 Non-Conforming control
MGT-SP-002 BOP 5.4 Management Resp-planning-MSC.xlsQC-SP-001 8.5.2 Corrective & 8.5.3 Preventive actions QC-SP-019 8.2.2 Internal audit
QC-SP-020 QC-SP-018

Planning APQP Production Delivery


QC-SP-023.doc
Delivery req. Mat'l cost Mat'l req. 7.5.1.6 Production Control
Support 4.6.doc Purch. Raw Matls./Components
Oriented tooling/equip
mat'l type run rate capability 7.3.2.2Engineering
Processes ment 7.5.1.4 Prev.
6.2 HR HR-SP-001
& Regular MT-SP-001 Prev. Maint.
maint.
HR-SP-002
7.6 Calibration Process
QC-SP-017 parameters
Gage
Control
Design/Order/Receive/
7.5.1.5 7.4 Raw
Validate Gaging Manpower
Tooling P.O. Mat'l P.O.
requirements

5.2,7.2 MSC
President & Sr, Contract Review
Mgr.PC/Sales ..\Procedures\MGT-SP-001.doc

Voice of customer No Review


Cause QC SP 006.doc Control Plan
QC SP 007.doc FMEA QC SP 010.doc OPIs
Customers' QC-SP-006 (PPAP) QC-SP-009 PSW/PPAP PD-SP-001.doc Process Control
Order/ Accept Receive Product/Order
Request Quote Yes P.O. QC-SP-007 QC-SP-002 Cust Process.flo.xl.xls QC-SP-015 ID & Trace
Requirements 7.5.2 Product /
7.3.2.2, Process 7.5.1 Mass Production Stage FG,
MGT-SP-001 7.3.3.2 OK 7.5.5 Packaging 7.5.5 Delivery ASN Transport
Customer Oriented Processes Verification / Label
Drawings, Design PC-SP-001
Validation
specs. Packaging & Process QC-SP-025 Dock Audits
Price, quantity, labeling Utilities
delivery, requirement IP
No inspection,test ..\Procedures\QC SP 008.doc Lab Scope Specified carrier, etc.
requirements Schedule & Final
Inspections OPIs
..\Procedures\QC SP 010.doc
QC-SP-010
Release
Quanities, specifications, etc. Order
QC SP 002.doc Customer Specs. Data QC-SP-013 SPC/Cpk
Collection Insp. Results
Scrap

Regulatory. legal
requirements Payroll

Company culture & 6.2 HR


mgmt objectives
* Additional SOP
comptetancy, skill, addt'l training
manpower needs
education, etc. needs
6.2.2 Training Skilled workforce

HR-SP-001 ..\Heat Treat.5.20.02\PD-HT-705SM.xls


HR-SP-002 QC-TM-41 Training Matrix.xls Prepared by: Ralph Sulser
Approved by: Keith Shepard

file:///opt/scribd/conversion/tmp/scratch2743/56379874.xls Doc No.: QC-PM-001 Rev. Date: 5/28/04 Rev. 1


Process Map: Interaction Sequenced Internal audit QC-SP-018
MSC
Continual improvement QC-SP-021
Management Business Planning/ Management
Oriented Resource Planning Review Customer Satisfaction/feedback QC-SP-011 Prepared by: Ralph Sulser
Processes
MGT-SP-002 QC-SP-001 Data analysis Approved by: Keith Shepard
QC-SP-019 & QC-SP-020
Corrective & preventive actions
President, Production Engineering
Support Sr. Mgr. PC/Sales Control Mgmt. Maintenance Production HR Quality
Oriented Sr. Mgr. Prod/Eng
-Process design
Processes

Receive RFQ from customer

Inquirey/R
FQ Review all customer requirements
with Contract review team-MSC

MGT-SP-001
r Oriented Processes
Establish major product/component and cost targets.
Review for costs/manufacturing/volumes/ lead times /feasibility
Define material cost Define tooling and Gage Determine cost of labor
cost as required
Calculate Plant
Manufacturing cost

Determine timing & Determine machines & Determine manufacturing Determine quality criteria,
Define total manufacturing & delivery equipment feasibility, customer requirements
tooling costs availability

Develop price/cost. Determine materials &


,delivery. Review with packaging
RFQ team

Submit quote to customer

Follow-up quote and


review w/customer

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
Determine & procure
PH-SP-002
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

Tooling set up and production trials PPAP/PSW QC-SP-009

Source & Receive, Training HR-SP-001 + Department Skill Maps


Receive P.O. for mass Procure Raw inspect & OK Production scheduled
Mass production Material store
Equipment Gage calibrations
Production
PH-SP-002 Preventive Maint. Plan QC-SP-017 Gage Control
Contingencies Production operations
NG
MT-SP-001 Process PD-SP-001
Handle per QC-SP-024 Control
QC-SP-016
Inspections/each process Inspection
NG
QC-SP-010 QC-SP-004 Data Collection and
OPIs Records analysis (SPC) for Handle per
Stage/Store Packing improvement and QC-SP-016
monitoring & prevention
PC -SP-001 of possible errors.

Delivery Ship to customer-ASN


QC-SP-010,
QC-SP-004

Payment Invoice Customer

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

Doc No.: QC-PM-001.b Rev.Date: 5/28/04 Rev.: 1


CONTINUAL IMPROVEMENT OF THE QMS

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
• Customer Issues • Data Analysis
..\Procedures\QC ..\Procedures\QC SP 013.doc
SP 011.doc O
• • Tool & Die
Training ..\Procedures\HR-SP-001.doc
M • EHS EHS.policy.doc• Tool Management
• Internal Auditing
• Inspections, Testing ..\W
• Improvem
..\Procedures\QC
•ork
SPent
Corrective
Projects
018.doc
Action I-015.doc
Instructions\PD-W ..\Procedures\QC SP 019.doc M
• Employee Motivation
E • Control of NC Product • Preventive Action
..\Procedures\QC ..\Procedures\QC SP 020.doc
SP 016.doc
E
R Product Realization R
S
Realization Processes
• Process Planning ..\Procedures\QC-SP-023.doc
S

Support Processes
• Purchasing ..\Policies\4.6.doc
• Engineering
• Receiving ..\Procedures\QC SP 014.doc
• Production Control ..\Production Control\PC-W • I-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
Requir • Cold Forging
• Bevel Gear Lathing
• Calibration and MSA ..\Procedures\QC SP 017.doc Satis-
..\Work Instructions\PD-W •I-L103.doc Parts
ID/Traceability ..\Procedures\QC SP 015.doc
e- • ATV Gear Lathing
• Production Tooling
factio
• Heat Treating ..\Heat Treat.5.20.02\100.doc
ments • ATV Gear Assembly
• Laboratory ..\Procedures\QC SP 008.doc
..\Work Instructions\PD-WI-A001.Gearing test and inspection.doc
n
Input
• Shipping ..\Production Control\PC-WI-003Visteon Shipping instruction.doc Output

Musashi South Carolina, Inc. Quality QC-QMS.Process-100


Rev. 0 5.29.03
Management System
ORGANIZATIONAL CHART DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA
Page 49 of 70 APPENDIX

ORGANIZATIONAL CHART

The most recent organizational chart is maintainrd by the Human Resources


department, and is on file.

Edition :01
Issued by:Ralph Sulser
Date: 04/02/03
Approved by: Keith Shepard
Rev. 0
ORGANIZATIONAL CHART DOC NO.:MSC-QM1
MUSASHI SOUTH CAROLINA
Page 50 of 70 APPENDIX

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
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 51 of 70 SECTION #: 5

5.0 Management Responsibility


5.1 Management Commitment
The MSC management is committed to the development and implementation of the quality management system
and continually improve its effectiveness by:

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

5.2 Customer Focus


The Top Management of MSC ensures that customer requirements are determined and fulfilled with the aim of enhancing
customer satisfaction. While reviewing the requirements, the implied needs and expectation of the customer are also
identified. These are conveyed to the respective functions for ensuring that they are met. As a part of Management Review
(Refer 5.6 below), a focus is made for communicating the customer requirements to all functions and ensuring product
conformance.

Methods of determining customer requirements, expectations and satisfactions are defined in the procedures

MGT SP 001 Contract Review (Product Requirement Review)


QC SP 023 APQP (Planning for product realization)
QC SP 023 APQP (Planning for product realization)

5.3 Quality Policy

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,

e) is periodically reviewed for continuing suitability.

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 52 of 70 SECTION #: 5

Note: Printed documents are not controlled copies-check master computer files for latest revisions

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.”

Dated: 03/20/2003 S. Okubo President

Process interactions of achieving product realization are described below outlining typical duties, and
inputs of the department management to focus on objectives, and
Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 53 of 70 SECTION #: 5

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.

Note: Printed documents are not controlled copies-check master computer files for latest revisions

1. President - Musashi South Carolina


• The senior most executive at the plant and designated as President, and has responsibility for the entire operation..
• Approves customer and supplier contract review actives.
• Approves the company's policies and gives directions for managing the objectives, and company activities.
• Approves the MSC's quality policy and objectives.
• Responsible for providing essential resources and personnel for implementation of the quality policy, and quality
management system.
• Responsible for effective implementation of the quality management system.
• Through leadership and actions, the President creates an environment where people are fully involved, and in which a
QMS can operate effectively.
• Reviews customer scorecards for Visteon, and other customers, on their web sites
• Chairman of the Management Review Committee.

2. Senior Manager Production


• Overall responsibility for planning, coordinating & managing activities related to functions of Production,
Manufacturing Engineering, Maintenance, Projects.

• 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.

4. Manager– Human Resources


• Responsible for coordinating with departmental heads to obtain staffing.
• Determine the training needs related to managers, staff, associates, temporaries, probationers, and trainees.
• Identifies, and implements training, and employee motivation needs.
• Environmental/Safety/Health.

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 54 of 70 SECTION #: 5

• Also in charge of public affairs, and industrial relations to enhance productivity.


• Assisted by the Administrator of EHS. ,H.R. Assistant, and Payroll Coordinator.
• Reports to the Plant President.

Note: Printed documents are not controlled copies-check master computer files for latest revisions

5. Senior Manager – Quality Control


Responsible for quality systems, procedures, and instructions for the plant
• Monitoring the Process for outputs.
• Providing Test Status on In-coming, In-process and Finished Products
• Documenting trends in quality and current quality levels.
• Controlling of non-conforming products.
• Authorized for dispositioning deviations on Non-conforming products for use at next stages.
• Authorized for release of finished product.
• Obtaining waivers from customer on non-conforming finished products.
• Developing and implementation of plans for customer complaint resolution.
• Assessment of Preliminary (Ppk) and on going process capabilities (Cpk).
• Preparing details for Production Part Approval Process.
• Inspection and testing at incoming, in process and final stages
• Controlling the procedures for In-coming, In-process and Final Inspection Stages
• Calibration of all identified inspection, measuring and test equipment.
• Authorized for providing inspection and test status on all products.
• Identifying and implementing statistical technical techniques for process and product.
• Verifying the effectiveness of corrective and preventing actions.
• Issuing and maintaining originals and withdrawal of obsolete APQP documents, process standards, drawing and
documents of external origin.
• Production Part Approval Process (PPAP&PSW) and liaison with customers for same
• Establishing, and maintaining customer communication channels.
• Monitoring and Measuring Customer Satisfaction metrics.
• Representing the needs of the customer in internal functions in addressing the ISO/TS 16949 requirements.
• Assisted by Asst. Mgr. QC, QC Technicians, QC Associates, TS16949 Coordinator
• Reviews and maintains scorecards for Visteon, and other customers, weekly on their web sites
• Designated as Customer Representative to ensure customer requirement are met, and contact for quality issues.

· 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

Note: Printed documents are not controlled copies-check master computer files for latest revisions

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 55 of 70 SECTION #: 5

6. Senior Manager Sales/Production Control/New Model Projects


• Purchasing of manufacturing materials, and supplier monitoring.
• Production scheduling of all products
• Control of customer-supplied products, and packaging
• Receiving, storage and issue of products, and packaging.
• Reviewing, approving and maintaining effectiveness of the procedures for the above activities.
•• Disposal
Handlingof scrap, preservation,
storage, and waste. identification and test status of all products during receipt, storage,
work in-process and
dispatch to customer.
• Ensuring 100% on time delivery to customer.
• Inventory management of purchased products, WIP and finished product.
• Checking adequacy of FIFO.
• Supplier performance tracking
• Supporting QMS requirements related to these functional areas.
• Assisted by Production Control Manager, and Coordinators.
• Reviews customer scorecards for Visteon, and other customers, on their web sites
• Preparing and submitting the quotation offer to customers.
• Receipt of order / dispatch schedules from customer.
• Review of customer’s order for correctness.
• Resolving any differences between the inquires and potential orders.
• Communicating customer’s requirement to concerned personnel in the company.
• Interaction with Customer for product development and all contract review activities
• Reports to the Plant President

7. MSI Engineering- Japan

• 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.

8. President - Sales and Marketing-Musashi North America, Detroit, MI


• Receipt of Inquiries from the customers and passes thyrough to Musashi South Carolina
• Coordinating with MSC President for planning future production
• Assists in assessments of customer satisfaction.
• Reports to President Musahi North America

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 56 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: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 57 of 70 SECTION #: 5

9. Management Representative ( 5.5.2 )


The Management of the company has appointed the Senior Manager-Quality Control, as Management Representative,
assisted by the TS16949 Coordinator, who, irrespective of other responsibilities, has the responsibility and authority that
includes:
Management Representative (MR) and TS16949 Coordinator are 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

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.

5.5.2 Management representative


Top management has appointed the Senior Manager-Quality Control who, irrespective of other responsibilities, has the
responsibility and authority that includes:
a) ensuring that processes needed for the quality management system are established, implemented and maintained,
b) reporting to top management on the performance of the quality management system and any need for improvement, and
c) ensuring the promotion of awareness of customer requirements throughout the organization.

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 58 of 70 SECTION #: 5

d) liaison with external parties on matters relating to the quality management system.
Note: Printed documents are not controlled copies-check master computer files for latest revisions

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 59 of 70 SECTION #: 5

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.

5.6 Management review


5.6.1 General

Top Management of MSC reviews the company’s 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
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 60 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: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 61 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 62 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 63 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 64 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 65 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 66 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 67 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 68 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 69 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1
MANAGEMENT RESPONSIBILITY DOC. NO.;MSC-QM1
MUSASHI SOUTH CAROLINA Page 70 of 70 SECTION #: 5

Edition: 01
Issued by: Ralph Sulser
Date: 07/30/03
Approved by: Keith Shepard
Rev. 1