Guideline

On
Mahindra Part Approval
Process

(For Bought-Out Parts)

Mahindra Quality System (A. S.)

AUTOMOTIVE SECTOR
 Guideline on Mahindra Part Approval Process
For Bought –Out parts

Mahindra Quality System (A. S.)

Guideline on
Mahindra Part Approval Process
For Suppliers

First Edition, Revision 03,Oct.2004

This Manual is prepared by the MQS Core Team, located at - 2 nd floor, AD Building, A.S.
Kandivli.
For any further information, clarification or suggestions, you may contact the following :

Name e-mail Tel. No./Extension

Subir Das Das Subir 28864300, Extn.2083
Naresh Patil Patil Naresh 28467111, Extn. 2111

Nandakumar Walve Walve Nandakumar 28467292 /2292

Vinayak Atre Atre Vinayak 28467292/ 2292
Sanjay Murzello Murzello Sanjay (Nasik) 95253 -25808236
Uday Bhaskar Uday Bhaskar 08451-284241-4 / 242

M N Parelkar Parelkar Murari 28874620 Extn.: 2480

Acknowledgment: Mr. David Prakash (PD&C – Kandivli)

Mr. Atul Karkhanis (Supplier Upgradation - Kandivli)
Mr. Dipak Shinde (Supplier Upgradation - Igatpuri)

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CONTENTS

Introduction 4

Part - I

Purpose and Applicability 5

MPAP Requirements 5

Details of MPAP Submissions 7

MPAP Records & Sample Retention 17

Situations Requiring Notification 18

Part - II

MPAP Formats 20

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Introduction

This guideline sets the structure and procedure for carrying out Mahindra Part Approval
Process (MPAP) for all direct material suppliers, supplying to M&M Automotive Sector.
This guideline intends to illustrate:
Ø MPAP requirements
Ø MPAP applicability & submissions
Ø how to carry out MPAP activity
Ø MPAP approval
Ø MPAP effectiveness

All direct material suppliers shall comply with this guideline. Head – PD & C / Supplier
Upgradation must approve exceptions to this requirement via waivers. Waiver requests
are to include duly filled up Risk Assessment Form.

MPAP is a part of Advance Product Quality Planning, therefore while carrying out MPAP,
a cross-functional APQP approach is recommended.

Supplier MPAP is a prerequisite for M&M In-house Manufacturing PPAP.

While conducting MPAP, parts are required to be produced from significant production run
at production site using production tooling and gauging and as a follow up to quality
planning steps. Inspection & checking is done as per Production Control Plans to ensure
the product conforms to all the customer input requirements / design requirements. After
establishing conformance to the requirements, the Supplier submits the MPAP documents
to Head – PD &C / Supplier Upgradation for approval.

MPAP approving authority is the Head – PD & C / Supplier Upgradation. For High impacts
components joint approval from PD&C / Supplier Upgradation and Product Development
is required. For existing parts with minor changes through ECN, MPAP will also be carried
out by PD & C / Supplier Upgradation.

Approving authority reviews the submissions and gives the approval. Only after obtaining
MPAP approval, the Supplier can supply production parts as per production schedule.

Supplier cannot dispatch production quantities without MPAP approval.

The guideline intends to cover all situations normally occurring during Projects, ECN,
PCRN implementation. However if there are any queries, Supplier should contact the
Head – PD &C Office / Supplier Upgradation for guidance.

MQS OFFICE
Mahindra & Mahindra Ltd.
Automotive Sector

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Part - I

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MAHINDRA PART APPROVAL PROCESS (MPAP)

1.0 MPAP Purpose:

To determine whether all engineering design and specification requirements are properly
understood by the Supplier and the process has the potential to produce products
consistently meeting the requirements during an actual production run at the quoted
production rate.

2.0 Applicability:

The guideline covers generic requirements for production part approval for all
products supplied by Supplier to any of the M & M, Automotive Sector locations /
PUs / Areas or to any of M&M supplier’s & dealers.

3.0 Approach:

It is recommended that all Suppliers should adopt Advanced Product Quality Planning
methodology for part / product development.

Cross-functional team approach should be followed in identifying and carrying out

applicable MPAP requirements. The Supplier should nominate CFT for MPAP
implementation.

4.0 MPAP Requirements:

Suppliers are required to obtain Production Part Approval prior to the first production
shipment of product in the following situations,
1) A new part or product (i.e. a specific part, material or colour not previously
manufactured).
2) Development of new supplier for existing part.
3) Change in manufacturing site.
4) Product modified by an engineering change (ECN) for specifications or materials.
5) Process change (PCRN).
6) Significant change in production rate.
7) Any other situation as mentioned in Customer Notification.

Supplier should take a production run at the production site using the production tooling,
gauging, process, material, operations, environment and process setting like feed/speeds,
cycle time/ pressure/ temp & with regular workmen. This also means that the production
run should conform to the Process Flow Diagram, Control Plan and SOP.

MPAP requirements, which are listed in Retention / Submission Requirements, are

generic requirements, which are to be carried out during MPAP and records / documents
to be retained at Supplier’s end and the same is to be submitted / shown to approving
authority at the time of PSW approval.

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The CFT at Supplier’s end along with M&M representative shall review the PCRN / ECN
or any other trigger of MPAP initiation and decide the applicability of all the MPAP
requirements.
If there is strong justification for not attempting one or more of the MPAP requirements,
waiver can be sought from the approval authority. Supplier should seek the waiver by
filling up a Risk Assessment Form stating the justification and risk involved for not
attempting the MPAP requirements. A written approval is to be obtained from the
approving authority for waiving the requirement.
Refer PSW Format Part - II for Risk Assessment Form
MPAP is a part of Advanced Product Quality Planning. It is expected that APQP approach
is followed for part development and resultant documents viz., Customer Input
Requirements including Design, Quality and Reliability Goals, Team Feasibility
Commitment, DFMEA, DVP&R, etc. are attached in MPAP documentation or appropriate
reference is made. Mahindra specific requirements / Customer Input requirements will be
given by M&M to suppliers along with MPAP requirements identified in PSW. The
applicable APQP requirements are to be reviewed and verified by Suppliers with PD &C /
Supplier Upgradation.
MPAP Retention / Submission Requirements
Following are the 19 Requirements for MPAP & submission requirements.

S. Submission Levels
Requirements
No. Level 1 Level 2 Level 3 Level 4 Level 5
1 Design Records. S S S * R
2 Engineering Change Documents. S R R * R
3 Customer Engineering Approval. S R S * R
4 DFMEA S S S * R
5 Process Flow Diagram S R S * R
6 PFMEA. S R S * R
7 Dimensional Results. S S S * R
8 Material Performance Test Results S S S * R
9 Initial Process Study. S R S * R
10 Measurement System Analysis S R S * R
11 Qualified Laboratory Documents S S S * R
12 Control Plan. S R S * R
13 Part Submission Warrant (PSW) S S S S R
14 Appearance Approval Report (AAR) – if S S S * R
applicable.
15 Bulk Material Requirement Checklist - S R R * R
for bulk material MPAP only
16 Sample Products. S S S * R
17 Master Sample R R R * R
18 Checking Aids. S R R * R
19 Customer Specific Requirements S R S * R

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S = The Supplier shall submit to Head – PD&C / Supplier Upgradation and maintain
the same at appropriate locations, including manufacturing

R = The Supplier shall retain at appropriate locations, including manufacturing and

make readily available to Head – PD &C / Supplier Upgradation.

* = The Supplier shall retain at appropriate location and submit to Head – PD&C /
Supplier Upgradation.

The Supplier shall retain all the MPAP documents (as per requirements given in above
table) at appropriate location and make available to Head - PD & C / Supplier Upgradation
during the approval process. Any additional submission requirements identified by Head -
PD & C / Supplier Upgradation should be mentioned in the Part Submission Warrant.

Approval for Waiver through Risk Assessment Form is mandatory.

Details of MPAP Requirements:

4.1 Part Submission Warrant:

Part Submission Warrant (PSW) is a document on which an approval is formalised.
Supplier is required to submit Part Submission Warrant (PSW) for approval along with
other documents for verification prior to approval. Head – PD &C / Supplier Upgradation
would give approval on the PSW.

Supplier must verify that all of the measurements and test results show conformance with
drawings and specification requirements and that all required documentation are
available.

A separate Warrant is required for each part number.

The approval authority would review the documents and authorize the disposition. The
Copy of approved PSW would be given back to Supplier. Supplier is required to retain the
entire MPAP documentation till the part is active plus one calendar year. A copy of the
approved PSW is to be retained with the Head - PD &C / Supplier Upgradation Office.

4.2 Design Records:

Design Records:
The supplier should retain Controlled Copies of product drawing/Engineering Standards
received from M & M. Proprietary part supplier should retain Controlled copies of M & M
approved drawings/standards. The part drawing of details for assembly and relevant
standards should also be available with supplier.

Supplier must possess with him copies of general standards such as ISO, SAE etc.
mentioned on the drawing(s).
Supplier must verify the change letter and revision date mentioned on the
drawings/standard with the one on P.O./P.O. Amendment received. In case of mismatch,

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the same should be brought to the notice of the respective PD & C / Supplier Upgradation
representative and get it amended, as appropriate.

Latest drawing / standards and design records must be followed during MPAP and
retained.

The above mentioned design records should be submitted when requested by the
approval authority.

4.3 Change Documents (If Any)

It is possible that during product development a change is suggested in the product, part
or tooling by R&D / Engineering but not yet incorporated in the drawing / standard. If such
changes are incorporated in the part / product submitted for Production Part Approval, the
authorised engineering change documents also must be submitted along with the PSW.

4.4 Design Approval:

In case supplier require certain changes in M & M drawing or specification,
R&D/Engineering approval should be obtained by the supplier, prior to the submission for
part approval. The request regarding the change should be communicated through the
respective M&M representative (PD&C/ Supplier Upgradation). If the changes are not
incorporated in the drawing pertaining to the submission, the approved document must be
submitted along with the PSW.

4.5 Design FMEA: (If supplier is Responsible For Design)

Design Failure Mode & Effects Analysis (FMEA) is a powerful Quality Tool to analyse a
design for potential failure mode and its effects. Supplier should carry out the same in
accordance with FMEA Reference Manual (3rd edition) of QS-9000 Quality System
Requirements.

FMEA should be carried out by a cross-functional approach. Actions on prioritised failure

modes must be completed and the revised rating should be documented.

Recommended action must be identified for all CCs and SCs on priority basis to reduce
the Occurrence and Detection. Thereafter, recommended actions for failure modes having
high RPN must be identified to reduce the RPN.

FMEA document should be submitted to M & M along with PSW.

Refer Part - II for DFMEA rating tables

4.6 Process FMEA:

Process Failure Mode & Effects Analysis (FMEA) is a powerful Quality Tool to analyse a
process for potential failure mode and its effects. Supplier may develop the same in
accordance with FMEA Reference Manual (3rd edition) of QS-9000 Quality System
Requirements.

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FMEA should be carried out by a cross-functional approach. Actions on prioritised failure

modes must be completed and the revised rating should be documented.

Critical Characteristics (CC) & Significant Characteristics (SC) to be identified as per M&M
recommended Characteristics Classification as given below

Characteristics Severity Occurrence Related to

Rating Rating
CC 9 –10 ----- Safety & Government regulations

SC 5-8 4 & above Customer Satisfaction.

Recommended action must be identified for all CCs and SCs on priority basis to reduce
the Occurrence and Detection. Thereafter, recommended actions for failure modes having
high RPN must be identified to reduce the RPN.

The completed FMEA document should be submitted to M & M along-with PSW.

Refer Part - II for PFMEA rating tables

4.7 Process Flow Diagram:

Supplier must submit a process flow diagram in M & M format. The production process
steps and the sequence should be clearly described, as appropriate.

It should give a good overall picture of all the processes that the supplier is responsible to
carry out from start to finish. Typically it would start from Incoming material inspection to
packing and pre-dispatch inspection. All operations should be depicted with symbols.
Details of Product & Process Characteristics along with its Characteristic Classification
(SC / CC), time, quantity and distance to be filled-up in the format.

In case a waiver is required for submitting the details of time and distance, the same to be
asked for to the approval authority.

4.8 Control Plan:

The supplier should develop a control plan that defines all controls in the process.

4.9 Production Trial Run

Production trial run should be conducted for 300 pieces. In case 300 pieces are not
feasible, due to cycle time, production rate & complexity of part, then 100 / 50 / one shift
production or minimum 30 pieces can be taken up for production trial run.

CFT should decide the sample size for production trial run judiciously. Minimum batch size
must be 30 Nos.

Production trial run should be conducted with quoted maximum production rate and
parts should be produced within one shift.

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As a very special case where volumes are so low that 30 samples are not feasible,
interim approval may be given with less than 30 part. However it has to fulfill the following
conditions
a) PIST must be 100% for the entire lot (based on 100% inspection, no sampling
inspection allowed).
b) Plan for ongoing Cp/ Cpk is available and acceptable to M&M.

Supplier should use the products only from the production trial run for MPAP submissions
such as, Dimensional Results, Material Tests, Performance Tests, Initial Process
Capability studies and Measurement System Analysis studies.

4.10 Dimensional Results:

Supplier must submit dimensional results for parts produced from the production run
mentioned earlier. The no. of parts to be checked would be indicated on PSW given to the
supplier. By default the minimum 5 parts should be checked.

Actual results should be recorded against all dimensions, characteristics and

specifications as noted on the design record and Control Plan. Blanket statement of
conformance (OK / Not OK) is not acceptable. M & M recommended format is given in
PART II

Based on the inspection results, Percentage Inspection points Satisfying Tolerance (PIST)
shall be calculated and recorded in PSW - Part C as given in Part - II .

One of the parts measured is to be identified as ‘Master Sample’. Dates on which these
readings were taken should be indicated. It is supplier’s responsibility to meet all
applicable specifications.

M & M recommended format is given in Part - II.

4.11 Fitment Trials

Fitment trials reports is to be obtained from the PD&C / Supplier Upgradation.

4.12 Material Test Results / Qualified Laboratory Documents:

4.12.1 Material Test Results:

Supplier should perform Material test for all parts and product materials where
chemical/physical/metallurgical requirements are specified by the design record or control
plan.

All material tests required by drawings and related specifications should be listed along
with quantity tested and the actual results of each test. If the supplier can not perform the
required tests, it can be done from a reputed outside laboratory. The report should be on
letterhead of the laboratory.

Blanket statements of conformance are unacceptable. Supplier should indicate the date
on which the testing took place.

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Material supplier's name and in the case of sub-contracted services such as plating,
painting and heat treatment) names of the sub-contractors should be added. If 'Approved
Sources' are specified by M & M for the subject material, it must be complied.

M & M recommended format is given in PART- II.

4.12.2 Qualified Laboratory Documents:

All material tests specified in drawings and related specifications should be listed along
with quantity tested and the actual results of each test. In case facilities for conducting the
required tests are not available in the plant, accredited laboratory can be approached for
carrying out tests and reports attached.

Blanket statements of conformance (OK / Not OK) are not acceptable. Date on which
testing is conducted has to be mentioned on the report.

4.13 Performance & Reliability Test Results:

Performance and Reliability test should be conducted for all parts and aggregates where
performance (or functional) requirements are specified by Customer Input Requirements.
The test results are to be shown in the Design Verification Plan & Report (DVP&R) format,
wherein the sample size and acceptance criteria are clearly defined.

For ongoing production, reliability checks are to be conducted on a defined frequency by

M&M suppliers. Reliability tests and their frequency are to be finalised jointly by M&M and
Suppliers. Suppliers will develop facilities for the agreed reliability tests.

All tests required / conducted and related specifications should be listed along with
quantity tested and the actual results of each test.

If the supplier can not perform the required tests, it can be done from a reputed outside
laboratory.

The report should be on letterhead of the laboratory. Blanket statements of conformance

are unacceptable. Supplier should indicate the date on which the testing took place. M &
M recommended format is given in PART II.

4.14 Initial Process Studies / Process Capability Plan:

4.14.1 Initial Process Studies:
For all Significant and Critical characteristics, the concerned processes should be stable
and under statistical control with preliminary process capability index (Ppk) above 1.67 in
production trial run & on-going process capability index (Cpk) above 1.33 in regular
production.
The purpose of such studies is to gain confidence on the production process having the
potential to produce products that will meet the customer requirements and result in
customer satisfaction.

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The Ppk study should be based on 100 (minimum 30) consecutively produced parts
when process is in statistically stable condition where only Common Causes of variation
are present. Performance index (Ppk) should be calculated using the formula mentioned
below for standard deviation.

∑ (X )
n
2
i −X
i =1
s=
(n − 1)

The performance index (Ppk) should be above 1.67.

Prior to potential process capability study, Normality / Stability to be verified by calculating

Skewness and Kurtosis with the help of MS - Excel or Minitab software. Skewness and
Kurtosis must be within acceptable limits, then only further studies are to be conducted.

Percentage Indices Process Capable (PIPC) shall be calculated and recorded in

PSW - Part C.

Measurement System Evaluation (MSA) should be performed prior to the initial process
capability studies. Percentage Gauge R & R value should be less than 10%.

When performing the initial short-term study, data should be plotted from consecutive
parts taken from the production trial run. These studies could be replaced by long term
results from the same or similar process run on the same equipment.

When the estimated production volume is less than 500 in case of aggregates /
components, the Supplier shall document in their control plan that they will either perform
100% inspection and record the results or conduct an initial process capability study with a
minimum of 30 production parts and maintain SPC control charts of the characteristics
during production.
For special characteristics that can be studied using variable data, the Supplier shall
utilise one of the following techniques to study the stability of the process:
X –Bar and R charts, no of samples =5, plot minimum 6 subgroups.
Individual X – Moving Range, plot minimum 30 data points.
For monitoring on going process capability (Cp / Cpk) sigma is to be calculated by using
σ= Rbar/d2 formula.

4.14.1.1 Acceptance Criteria for Initial Study

For initial process capability studies using 30 to 300 parts, the Supplier shall use the
following as acceptance criteria for Potential Process Capability index for processes that
appear stable:

Sr. No Sample size during MPAP Pp /Ppk

1 30 ≥ 1.79
2 50 & above ≥ 1.67

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For tool dominant operation such as press components with inherently low variation,
target nominals (X bar) may be purposely shifted from required nominals to favor
assembly or to allow tool wear or die life. In such cases Pp to be estimated.

If Ppk requirement is not met because of inherent low variation or Skewed distribution,
target nominals may be purposely shifted from required nominals to favor assembly or to
allow tool wear or die life. Decisions on changing dimensional targeting should be agreed
by CFT & then only process capability to be calculated. Approval from Head – PD &C /
Supplier Upgradation to be obtained.

Acceptance criteria for unilateral specifications should be discussed with the approving
authority.

Supplier may use Statistical Process Control Reference Manual of QS 9000 Quality
System Requirements.

M&M recommends the use of authentic software such as Minitab for conducting initial
process capability studies & for ongoing SPC studies.

4.14.2 Process Capability Plan:

The plan assures that the functional, critical & special characteristics of the product are
produced by the processes, which are capable of controlling them within the required
tolerances having preliminary process capability, Ppk more than 1.67.

Supplier should carry out process capability study for all special characteristics (SC, CC)
identified in Engineering Drawing, through DFMEA and PFMEA.

Supplier should note down the actual dimensional values of the part, condition and the
settings done for the capability study.

Supplier should select the machine, equipment & tooling parameters, which vary while
producing the parts for the capability study and identify those which had predominant
effect on the product dimensions, as the controlling factors to ensure the product
dimension within tolerance, and should incorporate in the Product Control Plan.

4.15 Measurement System Analysis Studies:

Supplier must do accuracy, bias and linearity studies for all used or new equipment, new
or modified gages, measuring tools and test equipment.

Gauge Capability studies is to be conducted for all new gauges which are required to be
procured & the same is to be verified before it’s use.

In addition, Gauge Repeatability & Reproducibility (GRR) studies should be done for
equipments used for measuring critical and significant characteristics. It is recommended
that stability studies of these equipment are also conducted and monitored.
For attribute characteristics such as finish, feel, dent, rundown etc. attribute MSA is to be
carried out as per M&M requirements (PD & C / Supplier Upgradation representative to be
contacted).

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4.16 Appearance Approval Report:

Appearance Approval Report applies for parts with colour, grain or texture requirements
and are visible to Vehicle owner. It is recommended to take a photograph of the item,
preferably by digital camera with good resolution and submit the photograph along with
the MPAP submissions.

Requirement of Appearance Approval Report to be discussed in CFT meetings & with

Head - PD & C / Supplier Upgradation about submission requirement. Approval for
appearance item from R&D / Engineering and Marketing will be sought by PD &C /
Supplier Upgradation.

4.17 Bulk Material Requirement Checklist:

For bulk material such as paint, the Bulk Material Requirements Checklist will be jointly
agreed upon by M&M and supplier of bulk material, Bulk Material Checklist to be followed.

M & M recommended format is given in PART II.

4.18 Sample Product:

Supplier should submit 5 samples of the product to M&M, unless agreed and mentioned
on the Part Submission Warrant, along with Risk Assessment Form.

4.19 Master Sample:

The supplier should retain the master sample as long as the part is active or until a new
master sample is produced for the same M & M part number an M & M approval is taken.

Supplier should retain a master sample for each position of a multiple cavity die, mold, tool
or pattern, or production process unless otherwise specified by M & M.

Waiver for Master Sample retention can be taken from Head – PD & C / Supplier
Upgradation. Master Sample is mandatory for pressed components, appearance items &
attribute characteristics.

4.20 Checking Aids List:

Checking aid can include fixtures, gages, models, templates, Mylar specific to the product
being submitted. The list of the same should be submitted along with PSW format on M &
M specified format.

If requested by the approval authority, any part-specific assembly or component checking

aids may be required to be submitted for verification.

Supplier should certify all aspects of checking aid are in agreement with part dimensional
requirements. Supplier must have drawings for all checking aids, other than the standard
instruments. The supplier shall document all released engineering design changes that
have been incorporated in the checking aid at the time of submission.

Supplier is responsible for preventive maintenance of such checking aid for the life of the
part.

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Measurement System variation studies (Gauge R & R, accuracy, linearity and stability
studies) shall be conducted in compliance with M & M requirements.

4.21 Mahindra Specific Requirements:

Any specific customer requirements identified by the customer or Head – PD&C / Supplier
Upgradation is to be sought and mentioned in the PSW and to be carried out by the MPAP
implementation CFT.

The following Control Plan formats are required to be submitted.

Product Dimensional Control Plan (For Bought Out Parts), Product Dimensional Control
Plan (For In-house Mfg. Parts), Product Dimensional Control Plan (For Assembly Parts).

Formats for both the types of Control Plan are given in PART-II

5.0 MPAP Effectiveness Evaluation:

MPAP effectiveness evaluation is carried by monitoring indicators such as:
1. PIST – PIST (Percentage Inspection points Satisfying Tolerance) is calculated as per
formula given in PSW format - Part C. PIST of 100% means all product characteristics
are within specifications. PIST to be calculated for 5 samples.
2. PIPC – PIPC (Percentage Indices Process Capable) is calculated as per formula given
in PSW format - Part C. PIPC of 100% means all special characteristics (SC/CC) are
having Ppk value equal to or more than 1.67.

6.0 MPAP Approval

MPAP approving authority will review the documents & MPAP effectiveness targets in
form of PIST / PIPC and designate the MPAP as Approved.
In exceptional cases only, Interim approval can be given under following conditions:
i. As a very special case where volumes are so low that 30 samples are not feasible,
interim approval may be given with less than 30 part. However it has to fulfill the
following conditions
a) PIST must be 100% for the entire lot (based on 100% inspection, no sampling
inspection allowed).
b) Plan for ongoing Cp/ Cpk is available and acceptable to M&M.
ii. If Gauge R&R is between 10 to 30 % and action plan for improvement is available
and acceptable to M&M.
iii. 100% PIPC is not achieved, action plan is available and acceptable to M&M.
However to confirm the action plan and monitor the achievement of 100% PIPC
more quantity is required to be produced.
Note :
1. In all such above cases, special containment actions are required to be taken at the
supplier’s end to protect the customer and to ensure that fit, function, performance and
reliability requirements are not affected.
2. As a special case for sheet metal components if certain dimensions are not achieved
after employing the best possible controls. M&M authority can give interim approval if the
deviation does not affect the fit, function, performance and reliability of the component /

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subsystem/ system. Interim approval cannot be granted in case there any dimension
which is identified as SC or CC is not achieved.

Interim Approval can be given for certain period or for specific quantity only.

Approving authority will monitor the status of MPAP for which Interim Approval is given.
Supplier to complete the activity within the time frame mentioned in PSW. After reviewing
the adequacy of the completed activities, Head - PD & C / Supplier Upgradation will
update the MPAP Status from Interim Approved to Approved.

7.0 MPAP RECORD & MASTER SAMPLE RETENTION:

Ø Suppliers are required to maintain MPAP files part-wise.
Ø Records should show conformance to all the specifications.
Ø Complete record of findings and master sample(s) including SPC results to be
retained.
Ø Master samples to be identified and approval date to be mentioned.
Ø For parts of sizes that are difficult to maintain, the part approving authority could waive
retention. The waiver should be documented in Risk Assessment Form.
Ø Suppliers are required to complete and retain copies of all the documents mentioned.
Ø Records of production part approval are to be maintained for the length of time that the
part is active plus one calendar year. The same is also applicable for master sample.

Supplier must never dispatch production quantities of their products before

receiving approval on PSW.

8.0 Notification after MPAP Approval:

After the MPAP approval, Suppliers are responsible for ensuring further production follows
the MPAP requirements and meets M&M expectations. It is recommended that Supplier
has to review the process half yearly with the documents submitted for approval.

Subsequent to obtaining approval from M&M, if there is any design change at component /
assembly level or process change, Supplier is required to notify the same to the
concerned M&M approving authority. The changed situation would be reviewed and if
required Supplier shall be asked to submit a fresh Part Submission Warrant.
Even in cases, where the fresh PSW submission is not asked, Supplier would be required
to review and update all the documents in the MPAP file, as necessary, to reflect the
current process.

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APPENDIX - A

Situations requiring notification to Head – PD &C / Head Supplier Upgradation for

approval:

It is important to identify any changes that might affect the further processes at next
customer or ultimate purchaser of the vehicle or component. Therefore, in the following
additional situations Supplier must notify Head - PD & C / Supplier Upgradation regarding
the changes. The written documentation should be addressed to the approving authority.

The authority will communicate to the Supplier whether a submission for MPAP approval
is required.

Change Situations:

• Use of optional construction or material other than one used in the previously approved
part or product.
• Production from new or modified tools (except perishable tools), dies, moulds, patterns
etc. including additional or replacement tooling.
• Production following refurbishing or rearrangement of existing tooling or equipment.
• Production from tooling and equipment transferred to a different plant location or from
additional plant location.
• Change of source for subcontracted parts, materials or services (heat-treatment,
plating etc.).
• Production ramp up.
• Product re-released after the tooling has been inactive for volume production for twelve
months and more.
• Product and process changes related to components manufactured internally or
manufactured by subcontractors that impact fit, form, function, performance and/or
durability of the product.
• Changes in test/inspection method (A new inspection technique to be used).
• Process improvement through initiation of new Poka Yoke.

Approving authority may waive a formal submission for approval for these additional
situations for a subject part. A written waiver should be obtained from the approving
authority by filling up Risk Assessment Form. The same should be attached in the MPAP
file.

In spite of waiver, Supplier would be required to review and update all the documents in
the MPAP file, as necessary to reflect the current process.

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Part - II

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M PAP Formats & Softwares

Formats Format No.
• APQP Status Report MQS/APQP/F/01
• Mahi ndra Specif ic Requirements MQS/MPAP/CIR/F/02
( Customer I nput Requirement )
• Team Feasibili ty Commitment MQS/ MPAP/ TFC/ 24
• Process Flow Diagram MQS/MPAP/PFD/F/04
• Design Failure Mode & Effect MQS/MPAP/DFMEA/F/05
Analysis
• Rating Tables Handout MQS/ MPAP/DFMEA / M/01
• Process Failure Mode & Eff ect MQS/MPAP/PFMEA/F/06
Analysis
• Rating Tables Handout MQS/MPAP/PFMEA/M/02
• Control Plan MQS/MPAP/CP/F/07

• Dimensional Results MQS/MPAP/DR/F/08

(Recommended Format)
• Material Test Result MQS/MPAP/MTR/F/09
(Recommended Format)
• Material Master Check Sheet MQS/MPAP/MMCS/F/10
For Metallic Parts
(Recommended Format)
• For Non-metallic Parts MQS/MPAP/MMCS/F/11
(Recommended Format )
• Perf ormance Test Results MQS/MPAP/PTR/F/12
(Recommended Format)
• I nitial Process Studies
Summary Report MQS/MPAP/SR/F/13
• Control Chart
• Variables MQS/MPAP/CC-V/F/14
• Attributes MQS/MPAP/CC-A/F/15
• M&M Sof tware for variables
1) Normality MQS/MPAP/COQ - SPC
2) Pp / Ppk SOFTWARE
3) Cp / Cpk
• Process Capability Plan MQS/MPAP/ PCP /F/16

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• Measurement System Analysis

Studies ( GRR )
• M&M Sof tware For MSA - GRR MQS/MPAP/ MSA-GRR
Software
• Checking Aids List MQS/MPAP/ CAL /F/17
• Appearance Approval Report MQS/MPAP/ AAR /F/18
• I ncoming Material Control Plan MQS/MPAP/ I .M - CP /F/19
For Raw Material & Bought-out parts
• Product Quality Assurance Plan MQS/MPAP/ PQAP /F/20
For Final I nspection
M ahindra Speci fi c Requir ements
• Fitment Trial Report MQS/MPAP/ FTR /F/21
• SOP MQS/MPAP/ SOP /F/22
• Product Dimensional Control Plan
( Current CQA (VP) Formats)
For Bought out parts MQS/MPAP/ PD - CP /F/23/1
For Assembly parts MQS/MPAP/ PD - CP /F/23/2
• For in - house manuf acturing parts MQS/MPAP/ PD - CP /F/23/3

• MPAP Summary & Si gn- Off MQS/MPAP/ QPSO/F/24

( Product Quali ty Planning
Summary & Si gn –Off)
• Part Submissi on Warrant MQS/MPAP/PSW /F/03

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