Judgement Criteria

Supplier Name:
1) Rank A X (Not Acceptable)
Total Score:
Supplier Management :
Items
∆
Self Audit Date: TKM Audit Date (With Improvement Plan)
Checked By Approved By
2) Rank No.of "O" items /
B items
X, ∆ (With Improvement Plan) OK Ratio: Total items (70)
(Quality Incharge) (Quality Head)
Inspection Station: Over all
3) OK Ratio > 85% Acceptable
Judgement
No.of Parts Inspected in station Based on Critera 1), 2) & 3) the Overall Judgement will be ( O, ∆ ,X,)

QUALITY INSPECTION ASSURANCE SYSTEM - Check Sheet TKM QCD

Score
Judgeme Category
Cat Sub-Cat. Sl No. Check item Ranking Remarks/Comments/Improvement Plan Evidence
nt Result
0 1 2 3 4

1 Skilled inspectors (level : can do inspection without support ) are being designated to perform inspection A Inspector Skill level chart availability at each location
Training Content

2 Training plan and schedule available for each inspector B Training plan

Basic Skills - Sensory skills (visual,smell,noise),use of measuring instruments(Checking Fixtures),inpection

3
equipment,use of boundary sample,Drawing reading should be part of training curriculum A Training content

Training material must consist Know-How of Part,Process,Defects and its effects,Critical

4
items(safety,regulation)
B

5 Training on (i)Repair/Rework procedure (ii)Abnormality handling (iii) Standard work should be available A
MAN- Inpector with Right Skill,Knowledge,Attitude

Inspector Evaluation system

6 Inspector Skill evaluation Plan is available with pre decided frequency A Skill Evaluation plan

7 Master Trainer is available for each inspection process and sufficient master trainers are available B Master trainer certification

Checksheet for evaluation of the inspector is available in areas of (i) Basic Skill (ii)Technical Know-How Evaluation checksheets for dummy check,sensory
8
(iii)Operation Area (Standard workCheck,Inspection sequence check, Dummy Test)
B check,parts knowhow check

9 Skill Matrix to be available for each inspector A Skill matrix record

10 Actual Confirmation of adherence to established procedures should be done periodially B Evaluation checksheets should contain these points
Handling

11 Inspector must have awareness on handling major Quality Defect - Stop Call and Wait and inform supervisor A Question Inspector
Defect
Parts

12 Supervisor role during major Quality defect should be clearly defined B Question Supervisor

13 Confirm availability of equipments,tools for good condition as per pre-authorised schedule B Supervisor Daily activity should have these items

14 Check safety key points around inspection area B

Supervisor Role

15 Supervisor ensures Training and Evaluation of each inspector as per schedule B Supervisor authorization of training and evaluation

16 Daily Defect Monitoring and feedback to process is ensured A Supervisor authorization on inspection report

17 Supervisor Role during 4M change has been made clear and visaulized A 4M change confirmation method(checksheet)

18 5S should be ensured daily by supervisor around the inspection area B 5S audit checksheet

Sufficient area for inspection - easy movement of part and inspector during inspection ( inspection area layout
19
) A Inspection Area Genchi
MACHINE/TOOL - Facility for inspection with essential tools and its efficient

Facility for Inspection

20 Area for before inspected and after inspected parts has been identified clearly A

21 Good Lighting for good visibility of the part condition - Required lux level ( for appearance aspect of part ) A Lux level Standards

22 Noise around the inspection area - Decibel level ( for inspection of functional parts ) B Decibel level Standards

23 Inspection area is well seperated (Barricated) to avaoid disturbance of Standard Work B

24 Display of Inspector Skill Matrix at inspection process B

management

Measuring Instruments

B
Inspection tools and

25 Daily/Regular pre-operation check for good condition is available Pre-operation checksheet

26 Instruction to use Checking Fixtures/Gauges/Tools/Equipments should be available and displayed B Instruction procedure

27 Plan for calibration of inspection tools at set frequency should be avialable and adhered A Calibration plan

Pokayoke list,confirmation method,Preventive maintenance

28 Pokayoke Management ( if any in inspection process ) is available B checksheets
sample management

B Boundary Sample list

Boundary/reference

29 List of Required Boundary Samples should be available

30 Plan for Review of boundary samples as per SQAM section 3-3 (temporary or permanent boundary samples) B Boundary Sample check plan

31 Boundary Sample/Limit Sample to be displayed at inspection for judgement A Genchi at inspection

32 Condition of boundary sample is good and usuable A

 Score Remarks Judgeme Category
Cat Sub-Cat. Sl No. Check item Evidences
nt Result
0 1 2 3 4
management of Consumables aiding inspection
Condition of consumable used for inspection should be controlled (consumables eg :
Material Management 33 solvents,developers,cleaning agents,gloves,cloth for cleaning / parameters eg: concentration,cleanliness,SOC B Consumables management (checksheets,visualization)
MATERIAL - Efficient

(Which Aids compliance)

Inspection) 34 Ensure good condition of identification of tags,markers used for inspection,stickers etc. B condition of tags, makers,frequency of replacement

Ensure the good condition of the all the display sheets in inspection area (skill matrix,inspection instruction
35
sheets,one point lessons,defects list and all the standard documents)
B
Storage and recording of all the inspection documants (checksheets,inspection reports,training
36
material,evaluation sheets) for future reference and traceability B Check data recording and storage system

37 List of Check items decided are available - Master check item list B Master check item list

38 Rule for revision of Inspection Instruction sheet is available - addition or deletion or modification of check items B Authorised Rule/Procedure
(check items)

Each inspection item has Sequence of check,Inspection instruction (what to check) with inspection time
Inspection

Check Sequence Operation Sheet,Inspection instruction

39
defined. A sheet,Standard work chart
Check items in Inspection Instruction sheet should be based on Parts Inspection Standard,Drawing,Internal
40
rejections,Customer defects,ECI(Engineering Change Instruction)
A Compare with PIS,Drawing

41 Criticality of each check item to be mentioned in IIS ( Rank ,Kaku S ) A Check Inspection instruction sheet

42 Quality Key point to be mentioned in IIS A

Inspectio Sampling inspection of parts for which destructive check is necessary are adequately defined ( weld cut
B Sampling inspection items list,plan frequency
METHOD - Well defined systems for effective inspection

n 43 check,chemical reports,strength check,Precision measurements,Layout inspection etc)with predetermined frequency

Frequenc
Defect Parts Handling

44 Red Bins (reject parts) Yellow Bins (rework parts) at each inspection table are available A Genchi at inspection

Inspection report & Defects classification for severity,type of defect,defect description,responsibility are
45
available
B Inspection report

46 OK part and NG parts to be displayed at inspection to create awareness B Genchi at inspection

47 NG parts are counted at end of shift and red paint is applied to prevent Mixup B

48 Approved Repair/Rework procedure are available with inspector A Repair/Rework Procedure

Repiar/Rework
Confirmation

49 Elementary Instruction Sheet for major repairs (Repair Checksheet-to confirm all affected areas) B Repair checksheet

50 Lincensed Repair member are made available for repair confirmation B Licensing of repair member

51 Record of Repair/rework details are recorded daily A Repair record

Approved abnormality handling procedure established - (abnormality in terms of defect in part,breakdown of

A
Mangement System

52 Abnormality handling procedure

equipment ,dropped part etc)
Abnormality

Instant feedback to process,to immediately confirm quality assurance level when a serious quality defect is
53
detected (forum to discuss quality defects ) A

54 Stop Call Wait display to create awareness to inspectors B Display at inspection line

Dropped part handling - Dropped parts should not be passed without inspection
55
Non Regular part - Trial part,first off sample,try out part - ensure no mixing with mass prod parts A Rule for non regular parts handling

Forums to address Major quality defects should be available - Emergency meetings,Internal Quality problem
Feedback

56 B Meeting reports and minutes

system

reports

57 Counter measures are made available for major Quality Problems at morning meeting area B Countermeasure reports
Improve Std Work is modified continuously to improve defect detectability (based on suggestion by operators and
ments/ 58
observation by supervisors B Kaizen activity
kaizens Management confirm daily quality status at Cross Functional Team Meetings in the quality review area
59
/Monitoring area
A Management attendance monitoring in meetings

60 Management follow up and confirm the countermeasures for major quality defects at work place A Meeting reports and minutes

61 Reccurence Prevention/Horizontal deployment are seen in Morning Meeting area B

62 Customer Defects, internal Defects ,CounterMeasures monitoring are well established A

Management Involvement

63 Quality Targets are set & Available for monitoring and targets are revised dynamically B Signatures on all documents
MANAGEMENT

64 Monthly Top Rejections are prioritized and action to reduce is evident B

65 Internal audit by management to assess Quality Status by genchi A Display at inspection line

Quality Promotional Activities - Awards,Appreciation,Recognition to Inspectors,Quality Month,QC Circle are

66
evident in the shop floor B Reports and concept sheets

Problem solving capability of Engineers are developed by use of Quality Tools in analysing defects with
67
Management Review
B Audit reports

Sub-Supplier Quality Assurance -1) Receiving parts inspection (sampling and 100% inspection) 2) Quality
68
status monitoring of subsuppliers (ppm,defects monitoring) 3) Management visits to sub-suppliers
A Evidence

Problem solving reports-method adopted (5Why analysis,8D

69 Management should review and authorize all standard documents used for inspection process B report etc)
Establish Quality gates at processes to control defects outflow (Quality gates should be audited as per the
70
above 4M points) B Sub-supplier quality status reports