Hero - Motocorp - Supplier - Quality - Manual Rev2

HERO MOTOCORP LTD
SUPPLIER QUALITY
MANUAL
Effective Date 01.0.2013

Revision No. 2
Revision-02 Page 1 of 148

MESSAGE FROM WORTHY CHAIRMAN
I am very pleased to note that your company has prepared an enriched

Quality Manual. This would be a very good beginning and I am sure, will go
a long way in guiding all our associates and employees towards attaining
highest standard of Quality.
Brijmohan Lall Munjal
My best wishes to all of you for its success and meaningful application.
With warm regards
Revision-01
Revision-02 Page 1
2 of 148
MESSAGE FROM MD & CEO
As we continually strive to maintain our position as a two wheeler market leader,

our focus must always be on quality, delivery, cost and service. We are
committed to achieve highest quality in our products and services, which meet
and exceed growing aspirations of our customer through continuous
improvements and innovation in quality management system. As a supply chain
partner, you play a critical role in this endeavor.
Pawan Munjal
Our quality management system emphasizes upon supplier development by proactively identifying
& implementing improvement opportunities. It also enables us to track performance of our supply
chain and take timely corrective measures for continual improvement.
We believe that building and maintaining mutually beneficial supply relationship and two way
communication is vital to enable you to supply what we need. Therefore we must clearly state our
requirements. We have prepared this document which shall fulfill this need and provide consistent
guidelines with which we can work together to produce desired results effectively.
From now onwards, all our supply chain partners must adopt and comply with the requirements as
detailed in "Supplier Quality Manual". We trust, this manual will assist you in your efforts to meet
our business requirements consistently.
We also expect our suppliers to take initiatives in the direction of addressing environmental
concerns and take concrete steps towards "Greening of Supply Chain".
Best wishes for continued future success.

• Be a world class manufacturer
• Be a market leader
• Provide highest level of customer satisfaction
• Achieve excellence through teamwork
• Create enduring relations with stakeholders
Pawan Munjal
(MD&CEO)

QUALITY POLICY
EXCELLENCE IN QUALITY IS THE CORE VALUE OF HERO

MOTOCORP'S PHILOSOPHY. WE ARE COMMITTED AT ALL
LEVELS TO ACHIEVE HIGH QUALITY IN WHATEVER WE DO,
PARTICULARLY IN OUR PRODUCTS AND SERVICES WHICH
WILL MEET AND EXCEED CUSTOMER'S GROWING
ASPIRATIONS THROUGH:
INNOVATION IN PRODUCTS, PROCESSES AND SERVICES.
CONTINUOUS IMPROVEMENT IN OUR TOTAL QUALITY

MANAGEMENT SYSTEMS.
TEAMWORK & RESPONSIBILITY.
Pawan Munjal
PLACE: NEW DELHI (MD & CEO)

SAFETY POLICY
HERO MOTOCORP IS COMMITTED TO SAFETY AND HEALTH OF

ITS EMPLOYEES AND OTHER PERSONS WHO MAY BE AFFECTED
BY ITS OPERATIONS. WE BELIEVE THAT THE SAFE WORK
PRACTICES LEAD TO BETTER BUSINESS PERFORMANCE,
MOTIVATED WORKFORCE AND HIGHER PRODUCTIVITY.
WE SHALL CREATE A SAFETY CULTURE IN THE ORGANIZATION
BY:
INTEGRATING SAFETY AND HEALTH MATTERS IN ALL OUR
ACTIVITIES.
ENSURING COMPLIANCE WITH ALL APPLICABLE
LEGISLATIVE REQUIREMENTS.
EMPOWERING EMPLOYEES TO ENSURE SAFETY IN
THEIR RESPECTIVE WORK PLACES.
PROMOTING SAFETY & HEALTH AWARENESS AMONGST
EMPLOYEES, SUPPLIERS AND CONTRACTORS.
CONTINUOUS IMPROVEMENTS IN SAFETY
PERFORMANCE THROUGH PRECAUTIONS BESIDES
PARTICIPATION & TRAINING OF EMPLOYEES.
THE POLICY SHALL BE APPLIED EQUALLY, FAIRLY & WITHOUT
EXCEPTION.
Pawan Munjal
Page 6 of 122 Revision-02

ENVIRONMENT POLICY
WE AT HERO MOTOCORP ARE COMMITTED TO DEMONSTRATE
EXCELLENCE IN OUR ENVIRONMENTAL PERFORMANCE ON A CONTINUAL
BASIS, AS AN INTRINSIC -ELEMENT OF OUR CORPORATE PHILOSOPHY.
TO ACHIEVE THIS WE COMMIT OURSELVES TO:
INTEGRATE ENVIRONMENTAL ATTRIBUTES AND CLEANER
PRODUCTION IN ALL OUR BUSINESS PROCESSES AND PRACTICES
WITH SPECIFIC CONSIDERATION TO SUBSTITUTION OF HAZARDOUS
CHEMICALS, WHERE VIABLE AND STRENGTHEN THE GREENING OF
SUPPLY CHAIN;
CONTINUE PRODUCT INNOVATIONS TO IMPROVE ENVIRONMENTAL
COMPATIBILITY;
COMPLY WITH ALL APPLICABLE ENVIRONMENTAL LEGISLATION AND
ALSO CONTROLLING OUR ENVIRONMENTAL DISCHARGES
THROUGH THE PRINCIPLES OF "ALARA" (AS LOW AS REASONABLY
ACHIEVABLE);
INSTITUTIONALISE RESOURCE CONSERVATION, IN PARTICULAR, IN
THE AREAS OF OIL, WATER, ELECTRICAL ENERGY, PAINTS AND
CHEMICALS;
ENHANCE ENVIRONMENTAL AWARENESS OF OUR EMPLOYEES AND
DEALERS /VENDORS, WHILE PROMOTING THEIR INVOLVEMENT IN
ENSURING SOUND ENVIRONMENTAL MANAGEMENT;
WE SHALL COMMUNICATE THIS POLICY TO ALL OUR EMPLOYEES AND
WOULD MAKE IT AVAILABLE TO INTERESTED PARTIES.
Pawan Munjal

GREEN
CHARTER
We at Hero Motocorp Ltd are continuously
striving for synergy between environment &
technologies, by providing products and
services that meet the quality, performance and
price aspirations of our customers. While doing so,
we maintain the highest standards of ethics and societal
responsibilities.
At Hero MotoCorp environmental protection and preservation is one of the

core business values. As a responsible corporate citizen, we believe that we can improve
environmental management not only in our premises but also partner with vendors to
ensure that they adopt similar environmental management strategies. Hero MotoCorp,
expanding the horizons of its environmental practices, is launching a Green Vendor
Development Program (GVDP) in collaboration with our business partners.
WE WOULD LIKE OUR VENDORS TO UNDERTAKE THE FOLLOWING ACTIONS &

DEMONSTRATE CONTINUAL IMPROVEMENT IN THEIR ENVIRONMENTAL PERFORMANCE :
Establish the environmental footprint of their operations.

Develop green management policies to promote conservation of natural resources.
Institutionalize an effective Compliance Management tool within the business
strategy.
Monitor the pollution load (emissions, effluents, wastes; hazardous non-hazardous /
other types, etc.) released in the ambient environment.
Set targets to reduce water, energy utilization and waste generation from the
processes.
Improve environmental performance by adopting pollution prevention strategies.
HMCL-GVDP initiative shall help Hero Motocorp in accomplishing its environmental aspirations
through effective deployment of a monitoring mechanism and also strengthen the vendor's image as
an environmentally aware and conscious organization. The program shall build a cadre of vendors
with least environmental liabilities thereby reducing the environmental footprint of the company inthe
supply-chain.
Date : 5th June 2007 PAWAN MUNJAL

Place : New Delhi Managing Director

SOURCING PHILOSOPHY / POLICY
PHILOSOPHY
Follow Ethical Processes & Practices
Treat Supplier as an extension of Hero MotoCorp - Operations
Be Cost Competitive , Agile , Responsive & Risk free.
Promote environment Friendly Processes & Practices
POLICY
Adopt new Cost-effective Approach & Processes in line with-business

environment demands.
Reach to Global Supplier base for cost - ef fectiveness
Business on QCD performance
Source Technological Sensitive Parts through Associates / Ancillaries where Confidence

to Technology Protection is there.
Create business growth opportunity for Supply Chain Partners & forge strategic &
Long lasting relationships with suppliers.
Extend Technical, Financial & Management support.

SUPPLIER QUALITY MANUAL
AMENDMENT NOTE : This Manual is amended dated 01.06.2014. Primary amendment is due to
change in the company name from HERO HONDA MOTORS LIMITED to HERO MOTOCORP
LIMITED and other amendments are as mentioned.
SECTION CLAUSE AMENDMENTS DT 01.08.2013

1.0 1.2 It shall be the sole responsibility of Tier-1 supplier to ensure
implementation of systems as per the Supplier Quality Manual
or further enhanced at Tier-2 suppliers for parts and offloaded
processes to ensure overall quality in product & service.
5.2 5.2.4 Cp / Cpk minimum 1.67 for CTQs
5.0 Annex 6 Duration of key events added.
5.0 Annex 7 SUPPLIER SELF EVALUATION REPORT & PLIR
REPORT added.
5.0 Handing over report of New model parts added.
6.0 6.5 Process Control added
7.0 SYSTEM AUDIT SHEET MODIFIED (AUDIT
METHODOLOGY REMOVED & SCALE CHANGED TO
10)
6.0 6.1.4 Aesthetic Manual Added.
6.11 Fixture validation System added
# IN VQR CRITERIA , NEGATIVE MARKING FOR SEGREGATION HAS BEEN ADDED
# CAPA & PDI REPORTS CAN BE UPLOADED ON SUPPLIER PORTAL NOW.
AMENDMENTS DT 01.06.2014
# HMCL SPECIFIC REQUIREMENT HAVE BEEN UNDERLINED IN BLUE COLOUR
# SUPPLIERS SHALL ACCESS THE PORTAL EVERY MONTH TO ENSURE
ALIGNMENT WITH HMCL SPECIFIC REQUIREMENTS .
Note : Whenever any amendment is brought out in the manual, the amended manual shall be
uploaded on the portal.

Page No.
SECTION CONTENTS
From To
1.0 INTRODUCTION 16 16
2.0 HMCL EXPECTATIONS FROM SUPPLY CHAIN PARTNERS 17 19
3.0 SUPPLIER'S INTERFACES 20 20
4.0 SUPPLIER'S MANAGEMENT RESPONSIBILITIES 21 24
5.0 NEW MODEL DEVELOPMENT SYSTEM 25 32
6.0 MASS PRODUCTION QUALITY MAINTENANCE SYSTEM 33 41
7.0 DIRECT-ON-LINE SUPPLIES 42 46
8.0 PARTS IDENTIFICATION & TRACEABILITY 48 48
9.0 PACKING STANDARDIZATION FOR OE, SPARES, EXPORTS 49 49
10.0 INITIAL PRODUCTION PART TAG SYSTEM 50 50
11.0 SUPPLIER QUALITY APPROVAL SYSTEM 51 52

SECTION ANNEXURE DETAILS
NO. NO
2.0 1 DASHBOARD PARAMETERS CALCULATION

METHOD AND DETAILS
4.2 2 MANAGEMENT REVIEWS & ITS DISCUSSION

WITHHHML
4.13 3 BROAD ROLES , RESPONSIBILITIES &

AUTHORITY OF QUALITY CUSTODIAN
5.0 4 NEW MODEL DEVELOPMENT SYSTEM
5.0 5 HS / HS / HB DEFINITION
5.2.3 6 QAV AGENDA
5.2.5 7 MULTISOURCE PART DEVELOPMENT SYSTEM
6.1.5 8 DOCUMENTATION SUBMISSION REQ

UIREMENTS
6.3 9 PROBLEM SOLVING PROCESS
7.1 10 PROCESS FLOW-DOL
7.1 11 AESTHETIC MANUAL
7.4 12 CONTAINMENT ACTION FOR DOL DETERIORATED

SUPPLIERS
7.5 13 REVALIDATION OF DOL STATUS
10.0 14 INITIAL PRODUCTION PART TAG SYSTEM
11.0 15 SUPPLIER Q UALITY APPROVAL SYSTEM
6.11 16 FIXTURE MAINTENANCE SYSTEM

List of Formats referred to in this Quality Manual
FORMAT NAME FORMAT NO. REV .NO REF. SECTION
MANAGEMENT REVIEW ML:BP:DOL:FF:06 00 SECTION 4.0

INSPECTION PLAN IMDM:QA:BP:IP:00 00 SECTION 5.2.5
LEVEL 1 QAV CHECK SHEET 00 SECTION 5.2.5
LEVEL II nd QAV CHECK SHEET 00 SECTION 5.2.5
LEVEL III rd QAV CHECK SHEET 00 SECTION 5.2.5
LEVEL IV th QAV CHECK SHEET 00 SECTION 5.2.5
LEVEL V th QAV CHECK SHEET 00 SECTION 5.2.5
QUALITY FLASH REPORT IMDM:QA:BP:CF:16 00 SECTION 6.2.3
COUNTERMEASURE & EFFECTIVENESS HMCL BP:DOL:FF:ll 01 SECTION 6.3
MONITORING
CONDITIONAL ACCEPTANCE MAM:SP:05:FF:01 00 SECTION 6.4
QAV 2 CHECK SHEET SECTION 6.5
TOP QAV CHECK SHEET (QAV -1) HMCL:BP:DOL:FF:04 01 SEC 7.0
SYSTEM AUDIT SHEET HMCL:BP:DOL:FF:07 SECTION 7.2.5
PQCS ( PAGE I & II) HMCL:BP:DOL:FF:01 SECTION 7.3.1
CRITICAL PROCESS / WORKSTATION HMCL:BP:DOL:FF:08 01 SECTION 7.3.3
CONTROL
TOOLS /DIES / MOULD STATUS HMCL:BP:DOL:FF:09 01 SECTION 7.3.5
JIGS & FIXTURES STATUS HMCL:BP:DOL:FF:10 01 SECTION 7.3.5
MOU CONDITIONS ( DOL ) HMCL /DOL/COND/0 00 SECTION 7.4
INITIAL PRODUCTION PART CONTROL SECTION 10.0.
CHANGE APPROVAL REQUEST FORM
INITIAL SAMPLE INSPECTION REPORT IMDM:QA:BP:FF:02 SECTION 10.0
METALLURGICAL / SURFACE TREATMENT IMDM:QA:LB:CF:01 SECTION 10.0
INSPECTION REPORT
IPP TAG FORMAT IMDM:QA:BP:FF:04 00 SECTION 10.0
PDI INSPECTION REPORT IMDM:QA:BP:FF:03 00 SECTION 10.0
4M EVALUATION FORMAT 00 SECTION 11.0

ACRONYMS USED IN THIS QUALITY MANUAL
4M MAN, MACHINE, MATERIAL, METHOD
ANNEX. ANNEXURE
BOP BOUGHT OUT PARTS
BOF BOUGHT OUT FINISHED PARTS
BOSF BOUGHT OUT SEMI FINISHED PARTS
C/Ms COUNTERMEASURES
CEO CHIEF EXECUTIVE OFFICER
CFTS CROSS FUNCTIONAL TEAMS
CKD COMPLETE KNOCKED DOWN
CLIT CLEAN, LUBRICATE, INSPECT & TIGHTEN
CTQ'S CRITICAL TO QUALITY
DFMEA DESIGN FAILURE MODE EFFECT ANALYSIS
DOL DIRECT-ON-LINE
DRG. DRAWING
ECN ENGINEERING CHANGE NOTE
E-MAIL ELECTRONIC MAIL
ENG.ASSY. ENGINE ASSEMBLY
ENGR. ENGINEER
FRAME ASSY. FRAME ASSEMBLY
HMCL HERO MOTO CORP LTD.
HOD HEAD OF DEPARTMENT
INSP. INSPECTION
IPPT INITIAL PRODUCTION PART TAG
LAB LABORATORY
MATLS. MATERIALS
MD MANAGING DIRECTOR
MFG. MANUFACTURING
MGMT. MANAGEMENT
MOU MEMORAMDUM OF UNDERSTANDING .
MP MASS PRODUCTION
MSA MEASUREMENT SYSTEM ANALYSIS
PDI PRE DELIVERY INSPECTION
PFMEA PROCESS FAILURE MODE EFFECT ANALYSIS
PLIR PILOT LOT INSPECTION REPORT
PP1 PILOT PRODUCTION
PPAP PRODUCT PART APPROVAL PROCESS
PPM PARTS PER MILLION
PQCS PROCESS QUALITY CONTROL SHEET
QA QUALITY ASSURANCE
QABOP QUALITY ASSURANCE BOUGHT OUT PARTS
SQA SUPPLIER QUALITY ASSURANCE
QAV QUALITY ASSURANCE VISIT
QIP'S QUALITY IMPROVEMENT PROJECT
QTY. QUANTITY
R&D RESEARCH & DEVELOPMENT
REF. REFER
REJNS. REJECTIONS
RPN RISK PRIORITY NUMBER
SAP SYSTEM APPLICATION PRODUCT
SPC STATISTICAL PROCESS CONTROL
SPEC. SPECIFICATION
SUB-ASSY. SUBASSEMBLIES
VD VENDOR DEVELOPMENT
WIP WORK IN PROGRESS

UNDERTAKING OF CONFIDENTIALITY
1. HMCL reserves the right to modify this Manual, by way of addition or deletion of any
clause, at any time without prior notice to the Supplier, which shall be binding on the
Supplier for all purposes.
2. This Manual as a whole and all the articles/documents/material/information supplied by

HMCL to Supplier under this manual shall remain exclusive intellectual property of HMCL.
More so, all information/guidelines supplied vide this manual and/or any development job
created by supplier there under shall also be the property of HMCL. Supplier shall not claim
any ownership of the same and shall not disclose the same to any other party at any time
during the currency of the Supply contract or any time thereafter, unless and otherwise
permission is granted in writing by HMCL.
3. The Supplier, its employees or its subcontractors shall not, either during the period of Supply
contract or at any time thereafter, use or disclose to any one any information/
guidelines/specifications of this Manual. Further, Supplier shall indemnify and keep
indemnified HMCL from any loss or damage arising from any breach of this undertaking.
4. That immediately upon termination of the Supply Contract, the Supplier shall return back
the Original Manual together with all its copies, any other relevant data/material provided
and/or any development created under the guidelines of this manual.

1.0 INTRODUCTION
WE WELCOME OUR SUPPLY CHAIN PARTNERS AND ARE PLEASED TO INTRODUCE
THE SUPPLIER QUALITY MANUAL
1.1 BACKGROUND:
We are successful in maintaining the World no 1 position in Two wheeler market since year
2001. Our achievements and accomplishments are the result of unstinted support of our
Supply Chain partners.
Globalization of auto industry has generated a demand to produce vehicles of World class
standards.
At Hero Motocorp Limited, it is our company mandate to support the change with customer
focused business plan keeping in sight the interest of all its stakeholders.
We believe in enhancing the market share by leveraging business around Quality and
focusing customer delight as our main motto.
1.2 SCOPE :
This manual applies to all Tier-1 suppliers supplying motorcycle & scooter parts , spare parts,
consumables and output of offloaded processes to Hero Motocorp Limited at all locations.
1.3 PURPOSE: The purpose of this Supplier Quality Manual is:
a) Comprehensive communication of Quality policy, Philosophy & HMCL

requirements , to assure the quality of supplied parts so as to ensure defect free
material.
b) To develop an overall plan to ensure a smooth start up ( New model / New part) at
both HMCL & supplier end based on effective planning & communication.
c) Define the Quality Assurance procedures & documents that suppliers shall follow to
assure application of an effective quality system that is based on continual
improvement, built in quality & preventive approach.

2.0 HMCL EXPECTATIONS FROM SUPPLY CHAIN PARTNERS
HMCL measures Supplier Performance customer satisfaction using "key indicators" such as :
Quality
Cost
Delivery
Management
Focus on Environment , Safety , Development & Technology are also seen as a measure of
alignment with HMCL requirements.
QUALITY:
HMCL measures quality of incoming parts from suppliers broadly on the basis of following
quality Dash Board parameters:
1) Warranty 0 kms (unsold) quantity.

2) Warranty (0~90 days ppm)
3) Warranty (> 90 days ppm)
4) Carry-in-defect ppm
5) BOP ppm
6) BOSF ( Bought out Semi Finished) ppm
7) Vendor Quality Rating
The suppliers shall meet the Quality targets , given by HMCL annually , based on Quality
Dashboard Parameters mentioned above .
NOTE : FOR CALCULATION METHODS & DETAILED DESCRIPTION
REFER ANNEX. 1 ON PAGE 19.
COST:
It shall be evaluated as per HMCL norms laid down by materials department.

2.0 HMCL EXPECTATIONS FROM SUPPLY CHAIN PARTNERS
DELIVERY:
HMCL measures delivery broadly on the following parameters:
• Compliance with delivery schedules & its tracking.
• On time delivery of material as per specified quantity & frequency
• Packing conditions as per HMCL norms ( as mentioned in this manual)
• Logistics control (as mentioned in this manual)
MANAGEMENT:
Management responsibilities are mentioned in this manual in Section 4 .
ENVIRONMENT & SAFETY:
• Ensuring legal compliances
• Support in HMCL initiatives ,e.g, Green Vendor Development Programme
• Reducing & eliminating use of hazardous materials.
• Contribution towards addressal of global environment concerns
• Self initiatives, e.g, ISO:14001 ,OHSAS:18001, etc
DEVELOPMENT & TECHNOLOGY:
• Ensure a robust development setup w.r.t. Man, Machine, Material, Methods.
• Adherence to development deadlines by adopting APQP .
• Acquiring latest technology, process to improve upon quality & cost

ANNEXURE-I
DASHBOARD PARAMETERS CALCULATION

METHODS AND DETAILS
REJN. QTY. ( 0 -90 DAYS ) / MONTH

WARRANTY PPM (0-90 DAYS) : x 10 LACS
RECEIVED QTY. (AVG OF THREE MONTHS)
REJN QTY. (> 90 DAYS) / MONTH

WARRANTY PPM ( >90 DAYS) : x 10LACS
SALE OF VEHICLES (I YRS DESPATCH)
CARRYING - IN - DEFECT PPM : PPM OF DEFECTS CARRIED OVER TO LINE IN BOF

PARTS ( FINISHED PARTS FITTED DIRECTLY INTO FRAME ASSY / ENGINE ASSY.)
( SEGREGATED REJN. QTY + LINE REJN QTY ) / MONTH

CID PPM = x 10 LACS
RECEIVED QTY ( BOF PARTS )/MONTH
BOP PPM : PPM OF DEFECTS OBSERVED IN SUPPLIES RECEIVED FROM SUPPLIER

& DETECTED AT BOP INSPECTION AREA.
FULL LOT REJECTION QTY ( BOF & BOSF ) / MONTH

BOP PPM = x 10 LACS
RECEIVED QTY ( BOF & BOSF PARTS ) /MONTH
BOSF PPM : PPM OF DEFECTS OBSERVED CARRIED OVER TO LINE IN BOSF PARTS
( SEMI FINISHED PARTS ) .
( SEGREGATED REJN QTY + LINE REJN. QTY )/ MONTH

BOSF PPM = x 10 LACS
RECEIVED QTY ( BOSF PARTS )/MONTH

3.0 SUPPLIER'S INTERFACES
INTERFACES AT HMCL FOR BOUGHT OUT PARTS SUPPLIER RELATED ACTIVITIES

SUPPLIER'S INTERFACE AT HMCL
ACTIVITY SUPPLIER MATERIALS QA WARRANTY
R&D MATERIALS
(V.D.) (SEM) (BOUGHT OUT PRODUCTION SERVICE ANALYSIS
PARTS) ENGG.
CELL
NEW MODEL/NEW PART
ISSUE OF DRAWINGS, STANDARDS &

ENGINEERING CHANGE NOTES
FREEZING OF INSPECTION STANDARDS /

ACCEPTANCE CRITERIA
RELEASE OF INSPECTION GAUGE DRAWINGS
SAMPLE SUBMISSION
APPROVAL REPORT RELEASE
CAPACITY ASSESSMENT & VOLUME INDICATION

FOR MASS PRODUCTION
PILOT LOT SUBMISSION (PP1 & PP2 LOT)
PILOT LOT APPROVAL REPORT RELEASE
5 LEVEL QUALITY ASSURANCE VISITS
PLANNING OF SMALL LOTS FOR RAMP

UP TO MASS PRODUCTION
SMALL LOTS APPROVAL FOR RAMP UP TO MASS

PRODUCTION
MASS PRODUCTION
INSPECTION & APPROVAL OF MASS PRODUCTION LOTS
ANALYSIS & ACTIONS TO CONTROL NON

CONFORMANCES OF PRODUCT IN LOTS
TARGET SETTING ON QUALITY DASHBOARD

PARAMETERS
ROADMAP TO MEET QUALITY TARGETS & ACTIONS TO

ACHIEVE THE SAME
SUPPLIERS' PERFORMANCE REVIEWS AGAINST

HMCL TARGETS
INITIAL PRODUCTION PARTS (IPP) CONDITION CHANGE

INTIMATION & SAMPLE SUBMISSION
SAMPLES APPROVAL REPORT RELEASE
IPP LOTS SUBMISSION
INITIAL PRODUCTION PARTS LOTS APPROVAL
VENDOR QUALITY RATING COMMUNICATION
DIRECT ON LINE SUPPLIES STATUS
WARRANTY SETTLEMENT
JOINT INSPECTION & ANALYSIS OF WARRANTY CLAIMS
ACTIONS AGAINST FIELD FAILURES & MONITORING
PRIMARY RESPONSIBILITY
SUPPORTING DEPARTMENT
DIRECT FLOW OF INFORMATION
INDIRECT FLOW OF INFORMATION

4.0 SUPPLIERS' MANAGEMENT RESPONSIBILITIES
4.1. Alignment of Quality Policy with HMCL requirements & its deployment across the
organization through an annual & mid term plan.
4.2 Management reviews & its discussion with HMCL Refer Annexure 2
4.3 Provide necessary infrastructure for quality improvement.
4.4 Enhancing employee engagement through various initiatives & training
4.5 Deployment of trained manpower at critical work stations.
4.6 Accreditation of ISO: TS: 16949 certification
4.7 Continual up gradation in product performance & manufacturing processes
4.8 Adherence to DOL MOU conditions (for DOL suppliers)
4.9 Strive to achieve DOL status (for Non-DOL suppliers)
4.10 Ensuring process / system audits by middle & top management as perHMCL check sheets
4.11 Actions against findings of audits & submission to HMCL
4.12 Benchmarking with world class best practices
4.13. Roles, Responsibility & Authority for following activities in the organization, shall be
defined very clearly.
Refer Annexure 3
Quality Custodian
New product development
Quality function deployment
Documents control, review & standardization.
System audits
IPPT system implementation
Evaluation and establishment of product realization infrastructure (4m adequacy)
Evaluation of corrective and preventive measures for internal and external customer
satisfaction
Quality Improvement Proj ects
Facilitation and evaluation of suppliers
Product reliability w.r.t design and warranty

4.14 Single window customer care setup:
Supplier's Top Management shall define a Customer care cell setup , to facilitate addressal of
quality and delivery issues communication between HMCL & Supplier Management.
Details shall be submitted to HMCL (HOD QA & Materials) in the following format and
amendment shall be communicated to HMCL as & when changed.
SUPPLIER NAME & ADDRESS
RESPONSIBILITY NAME RESP DATE OF DESIGNATION CONTACT E-MAIL REPORTING

FOR JOINING NO. I.D TO
(MOBILE (NAME/MOBIL
NO.) E NO.)
QUALITY
CUSTODIAN
DEPUTY QUALITY
CUSTODIAN
CUSTOMER HMCD
CARE HMCG
REPRESENTATIVE HMCH

ANNEXURE 2
MANAGEMENT REVIEWS BY SUPPLIER'S MD/CEO

& AUDITS BY UNIT HEAD/Q.A HEAD
Reviews shall be conducted internally every month on below mentioned Dashboard
Parameters against annual targets given by HMCL.
A) Vendor Quality Rating at HMCL
B) In house Rej. ection Trends (Bought Out Parts & In-process)
C) Warranty PPM (0-90 Days) /> 90 Days
D) Carry-in-Defect PPM
E) BOP PPM/BOSF PPM
F) Addressal of HMCL Top QAV Issues
G) Response time to resolve HMCL Complaint (Quality flash reports)
H) System Audit Rating
I) Management Issues
J) Status of New Model / New Product Development
K) Self Evaluation Audits & Actions for Findings
L) Disposal Status of HMCL Returned Rejection
M) Addressal of III Party (Deployed by HMCL) Audit Findings
Outcome of the management reviews shall be reviewed Quarterly (for Poor & Average
category suppliers) with Section Head Materials (Supply Coordination) / QA-HMCL by
Quality Custodian of supplier.
HMCL may use its discretion to review the suppliers in Good & Excellent category
Refer Format HMCL : BP:DOL:FF:06 (OUTCOME OF MANAGEMENT REVIEWS)
Vendor Quality Rating (VQR ) is calculated on the basis of Quality Status on Dashboard
Parameters as per the followingweightage :
WARRANTY QUALITY SYSTEM
PPM CARRY IN BOP BOSF
FLASH AUDIT
PARAMETER (0-90 DAYS) DEFECT PPM PPM PPM
REPORTS RATING
WEIGHTAGE 25% 25% 15% 15% 10% 10%
Categorization of Suppliers is done on basis of following slabs ( as per VQR ) :
CATEGORY EXCELLENT GOOD AVERAGE POOR
SLAB 90.01 ~ 100 75.01 ~ 90 50.01 ~ 75 BELOW 50
Note : # Criterion for VQR & Categorization may be changed without prior notice. The data shall be retrived
from HMCL portal on 5th of every month by supplier, for dashboard parameters and Quarterly for VQR.
# Negative marking of 10% shall be done in VQR in the event of inevitable
segregation in lots received from a supplier

Roles , Responsibility & Authority Of Quality Custodian
To establish, maintain & improve process / systems so as to bring in higher reliability.
Sub vendor quality up gradation
New model development and quality establishment of new line
Midterm Quality Business Plan based upon competition / customer requirements, major
quality issues, and future bench marks.
Strategic road map for continual improvement of product, process & systems.
Monthly reviews on Quality Dashboard Parameters
Redressal of issues related to Quality Assurance emerging out of internal & external audit.
Retrieval analysis and monitoring of Quality status from HMCL portal.

5.0 NEW MODEL DEVELOPMENT SYSTEM
5.1 Process:
HMCL has a defined system for New Model parts' development . Please refer Annexure 4 for New
Model Development Process flow.
5.2 Responsibilities of suppliers:
5.2.1) Drawing study:
First level drawings, specifications, samples are given to selected suppliers. Suppliers' team shall
study the drawings on basis of problems observed in similar parts of earlier models, feasibility of
manufacturing / inspection and any value engineering ideas. After study, comments on these
drawings shall be discussed & submitted along with drawing change request.
5.2.2 ) Project team finalization :
The supplier shall form a project team. The team shall have members who are capable of doing
process engineering, dies /jigs / fixture's design , development & calibration, gauge's design,
DFMEA, sub-vendor development etc. to align with HMCL requirements. This team shall have a
leader who shall regularly interact with HMCL team regarding development progress.
5.2.3) Preparation by project team:
Understanding function of the part (purpose, use conditions, relation with mating parts,
categorization like safety ( HS,/HA/HB),performance & general ). PI Refer Annexure 5
DFMEA/PFMEA
Identifying performance & testing requirements surrounding detail of Parts
Gauges , Machines, Tooling identification & procurement
Critical Quality and process parameters identification (along with HMCL team)
Process Capability requirements
Appearance Quality requirements (establishing limit sample)
Regulatory requirements
Measurement system analysis requirements
Process Flow Charts
Part Trace ability study (for identification of location of marking for vendor code, batch code)
Past problems study on similar parts (reported at HMCL, vendor end and warranty)
Packing and handling requirements
Making of overall development schedule (activity based e.g. dies, m/c, tooling, equipments,
training of man power etc.)
Submission of pre-launch PQCS
Finalization of requirements like manufacturing of no. of samples, preparation of inspection
reports, performance reports, material test reports, details such as r/m supplier, child parts
makers name etc.
Note: After completion of all above, supplier to submit the details to concerned coordinator from
HMCL Materials (Vendor Development).

5.2.4) Critical to Quality (CTQ) characteristics realization activities:
Cp / Cpk requirements:
1.33 minimum for CTQs
1.67 minimum for HS, HA &HB category parts (CTQ Parameters)
Adherence to 4m's requirements to be ensured for above realization.
Refer following example for such adherence:
Only specified trained operator to be deployed on safety category parts processes

(HS, HA. HB & CTQs) on an automatic control machine maintaining complete
trace. ability of Raw Material used in the process.
5.2.5) Sampling plan & Inspection Plan approval
All the components being supplied to HMCL shall be inspected before despatch. This
Inspection shall be done as per Inspection Plan which is approved by HMCL.
All the information which is required in the format shall be furnished. Component
wise Inspection plan shall be derived from its Drawing / Standards and submitted for
approval to HMCL ( R&D ). Identification of Critical parameters & Sampling /
Inspection frequency shall be done & finalized with HMCL team.
Sampling Plan:
Sampling plan to be used for components shall be selected on basis of following

categories:
a) Critical : Parts which affect the safety of the rider (HS/HA/HB)
b) Major : Performance,Functional parts, Appearance, Fitment related
c) Minor : General parts (Fasteners 6.6 class, Washers,Collars, Tool

kit, Natural rubberparts,)
After approval of Sampling Plan, it shall be incorporated into inspection plans.
5.2.6) QAV activities:
For qav schedule: refer flow chart (annexure: 4)
For QAV agenda : Please refer annexure 6
For QAV check sheets : Please refer Level-1,2,3,4,5 QAV check sheets

5.2.7) PP1 ( Pre Production 1st Trial) Sample submission:
The supplier shall submit the samples of components as required by HMCL team. These
shall be produced using permanent tools except cases where special instructions are
available from HMCL. Supplier shall adhere to the schedules for the same. Samples shall be
accompanied with following details:
- Minimum 10 nos. samples unless specified by HMCL.
- Dimensional reports.
- Material / metallurgical evaluation report.
- Surface treatment report.
- Supplier self-Evaluation Report for the component, based upon PQCS.
- Performance report.
- Supplier self evaluation report for the past based upon its PQCS.
- DFMEA/PFMEA
- PQCS (Including Process Flow Chart & Sub Supplier details)
HMCL will release detailed report for same .Supplier shall make pilot lots based on report and
submit for PP1 trial. HMCL will assemble these parts & endurance testing would be done . After
study of results of testing, some parts may need correction for which the drawings will be corrected
& given to the supplier. Supplier shall do necessary corrections in the parts in subsequent lots.
5.2.8 ) Mass Production preparedness before PP2 ( Pre Production Ilnd Trial)
Before PP2 trials , following activities shall be completed by supplier as per agreed
timing plan of development.
- Gauges ,Machines, Tooling establishment & trials.
- Critical Quality and Process parameters finalization & controlling mechanisms.
- Initial Process Capability reports for CTQs
- Appearance quality Limit samples / Standards
- Applicable Regulatory & Homologation compliances
- Measurement System Analysis reports.
- Part trace ability system (for identification of location of marking for vendor code,
batch Code).
- Action report on past problems on similar parts (reported at HMCL, Supplier end
and warranty)
- Packing and handling standard
- APQP development schedule review & action plan to meet time line.
- Modified PQCS
- Approval of PQCS by HMCL

- Process Qualification record for Special / Critical processes
- Manpower skill matrix
- Volume confirmation based on tact time report (Tact time/Run rate to be frozen
inPQCS)
- Capacity declaration on 2 shifts of 8 hours @ 6 days / week.
5.2.9) Inspection & Validation of Fixtures and Gauges
- Tier-1 suppliers must ensure that Fixtures & Gauges are procured in a timely manner
to meet major bench marks (i.e., PP1 and functional evaluation & during submission
of IPP tag.
- Supplier must have a co-ordinate measuring machine (CMM) for inspection of
Fixtures, Dies & Moulds for the validation / standardization prior to mass production
and parts product layout inspection during prototype as well as periodical
inspection, as per the agreed norms with HMCL.
In case of non-availability of CMM , supplier shall get it done from external agencies
& submit reports to HMCL, as agreed for Fixtures / Dies / Moulds as well as for the
parts.
5.2.10 ) Quality Stabilization before mass production

In this phase, small lots shall be manufactured by the supplier under mass production
conditions (size of the lot = 50% of the quantity required in pp2 trial or 50 nos whichever is
higher). This shall ensure that at least two lots are manufactured . The main aim of these
activities is to stabilize the production process before PP2 trial.
5.2.11)Monitoring:
Supplier shall constantly monitor the product quality after the mass production trials (PP2)
have been conducted. As the time gap between PP2 & mass production would be around 3
weeks, monitoring & improvement actions will have to be very efficient. In this phase
supplier shall:
a) Monitor process capability for critical processes / parameters and control the
variation, the target would be achieve as per norms fixed earlier
b) Monitor straight pass & line rejection / problem PPM at HMCL & reduce the
rejection PPM.
c) Monitor straight pass at own PDI / In process rejection & reduce the rejection
PPM
d) Standardize the tools, jigs, fixtures to facilitate their duplication in future
e) Freeze the PQCS & submit it to HMCL
f) Review the PFMEA/DFMEA& submit it to HMCL
g) Start sending PDI reports as per the Inspection plan approved by HMCL
h) One sample duly inspected and identified to be preserved for future reference
Quality PPM of new model products shall be monitored from the start of supply of parts for
mass production of the vehicle.

NEW MODEL DEVELOPMENT SYSTEM PROCESS FLOW
ANNEXURE-4
DISPOSAL OF
PLANNING OF NEW MODEL OLD LOTS INTERNAL EVALAUTION
( SPEC. FINALIZATION), FOR VENDOR
BASE MODEL PROBLEM PREPAREDNESS
SUBMISSION HINANHYO CLOSURE
WITH SAMPLES & SIGN.
OF ISSUING
DEPTT./PERSON
PO DRAWINGS STUDY PP2 EVENT (JT. EVALUATION
BY R&D & QA)
STUDY OF MAKER QAV 4 OF CRITICAL

LAYOUT PARTS DURING LOT
MFG.
QAV 5 ( 2-3 SMALL P.LOTS
UNDERM.P.CONDITIONS)
JOINT EVAL. & ANALYSIS OF
ENDURANCE TESTING VEHICLE
BIG DIE GO/ALL DIE GO (HMCL TEAM) HINANHYO IDN.& CLOSURE
QAV 3 OF CRITICAL PARTS PROCESS STABALISATION

IDENTIFICATION
THROUGH SMALL LOTS PRODN.
OF CRITICAL PARTS
IDENTIFICATION OF HINANHYO JOINT INSPECTION &

HANDING OVER OF PARTS
IDENTIFICATION OF FAILURES
BASED UPON FIT/ FUNCTION/WRTY. PP1 EVENT
M.P.
SAP CODE UPDATION

& PO RAISED POST LAUNCH
IDENTIFICATION OF CRITICAL MODEL SURVEY
PARAMETERS &
PREPARATION
OFCTQCHECKSHEET
QAV 2 OF CRITICAL PARTS QUALITY STABILISATION
FOR PROBLEM PART BY DEV.
TEAM (QA & R&D) FOR
3 MONTHS AFTER LAUNCH
MENTIONING OF CRITICAL GUAGE CONCEPT

PARAMETERS IN CHECK & PARAMETERS FINALISATION
SHEET.
PROCESS SEQUENCE & CRITICAL

QAV 1 OF CRITICAL PARTS PROCESS IDENTIFICATION

ANNEXURE-5
DEFINITION:
IMPORTANT SAFETY PARTS:
Important safety parts are the parts whose failures may cause an accident resulting in injury or death
of rider or pillion rider, a vehicle fire , or violation of domestic and foreign regulations prescribing
safety, environment pollution, etc. e.g Caliper Assy., Wheel assy., Unit assy, fuel, Unit assy, tail
light.
IMPORTANT QUALITY CHARACTERISTICS:

An important Quality Characteristics is defined as the Quality Characteristics of some portion or
characteristics of an important Safety part, whose failure (Nonconformance to specifications ) may
cause an accident resulting in injury or death of rider or pillion rider , a vehicle fire , or violation of
domestic and foreign regulations prescribing safety, environment pollution. That is , 'Q' shall be
designated to specification values (Dimensions, Materials, Characteristics, etc.) directly affecting
important functions ( Functional failures ) which determine the rank of importance of parts , e.g , In
Panel assy, rear brake , shoe lining to be free from grease is an important Quality Characteristics as
grease presence in this area will affect the performance of the brakes, compromising safety.
LEGAL REQUIREMENTS
The legal requirements covers test procedure, Parts & standards mentioned in C.M.V.R or any other
legal body which is entitled to issue notifications, e.g, In Head Light Assy. , the Supplier shall submit
the approval certificate from an approved test house
IMPORTANT SAFETY PARTS

Important safety Parts will be strictly marked as per indication on our drawings
IMPORTANT
RANK DEFINITION
SAFETY
PARTS
PARTS WHICH LOSE IMPORTANT FUNCTION AND
HS MAY CAUSE SERIOUS ACCIDENTS WHEN
FUNCTIONAL FAILURE OCCURS
PARTS WHICH LOSE IMPORTANT FUNCTIONS AND

MAY RESULT IN SERIOUS ACCIDENTS WHEN
HA FUNCTIONAL FAILURE OCCURS , BUT WHICH SHOW
SOME SIGNS SO THAT SAFETY PRECAUTIONS CAN
BE TAKEN.
PARTS WHICH LOSE FUNCTIONAL FAILURE OCCURS

HB BUT DO NOT RESULT IN SERIOUS ACCIDENTS

ANNEXURE-6
Details of QAVs process for Development
Details for lst LEVELQAV Details for 3rd LEVELQAV
• Sorting out the queries of the Vendor about Drawings, Data (If Process Re-Validation based on PP1 Problems
•
any) •
Gauge modification based upon critical gaps in vehicle &PP1
• Die design concept validation w.r.t component /. product Problems.
aesthetic / functional requirement. E.g.: Rear Grip parting • Verification of Mass Production readiness.
Line. • Revision of check sheets based upon critical gaps in vehicle &
• Firming up the development schedule, handing over the check PP1 problems.
sheet with critical control points and its discussion along • Hinanhyo discussion.
with maker team. • Confirmation of Operator Training. Inspection systems and
• Setting up the review mechanism with maker team; checks deployed.
• Material Handling, packaging and part identification systems
• Process sequence and concept finalization and
being deployed.
Identification of critical processes & failures.
Details for 4 th LEVEL QAV
• Gauge concept finalization.
• Verification of process capability/qualification under M.P.
• Discussion of problems faced in existing components with conditions.
similar design so that the same can be taken care in new model • Operator training status at critical stages.
• Firming up ramp up plan/maker capacities to supply
maximum/day.
Details for 2nd LEVEL QAV
? Part identification and trace ability.
• Verification and approval of PFMEA and process control plan.
• Overall vendor preparedness status before PP2
• Process Design Validation. Details for 5th LEVELQAV
• Verification of Equipments , Jigs , Fixtures being deployed • Approval of process capability/qualification under M.P.
from process capability point of view. and from the point of conditions.
view of the inplant manufacturing processes at HMCL. • Process speed as per M.P. conditions.
• Capacity Planning verification • Operator training status at critical stages.
• Firming up ramp up plan/maker capacities to supply
• Verification of softer issues like preparations of Process maximum/day.
Sheets, Work Standards etc.
• Packaging / transportation status.
• PP1 preparedness and verifying that whether tool / process is • Part identification and trace ability.
permanent or not.
• Overall vendor preparedness status before M.P.
DETAILS OF EVALUATIONS
i) EVl: VENDOR TO GIVE A PRESENTATION ON APQP COVERING DETAILS OF TOOLING, FIXTURE, GAUGES AND PART DEV.
SCHEDULE. QUERIES RELATED TO DRG., PROCESS AND TOOLING WILL ALSO BE RESOLVED. HMCL TEAM WILL VERIFY
THE SAME DURING QAV 1 / QAV 2
ii) EV2: VENDOR TO PRESENT ITS PREPAREDNESS OF TOOLING, FIXTURES AND PROCESS AND CAPACITIES w.r.t.
PROJECTED VOLUMES. HMCL TEAM WILL VALIDATE THESE DURING QAV3 AND TRY TO VERIFY THE PP1 SAMPLE LOT
WITH VENDOR.
iii) EV3: VENDOR TO PRESENT STATUS OF PROCESS VALIDATION THROUGH SMALL LOT PRODUCTION w.r.t. FORMAT
ATTACHED ALONG WITH ALL ECN IMPLEMENTED, PP 1 AND ENDURANCE TESTING HINANYOS ACTIONS.
• QAV CHECK SHEETS REFER FORMATS
INITIAL MONTH M2 M3 M4 M5 M6 M7 M8 M9 M10

SCHED ADG PP1 PP2 MP
BDG
ULE
TESTING
PROPOS- RESULTS EV.3
EV.2
ED EV.1 SMALL LOT
QAV1 QAV2 QAV3
ACTIVI- PR QAV4 QAV5
TIES 3 MONTHS Max. 1 Month Max 2 Month MAX 15 days Max

ANNEXURE-7
MULTISOURCE PART DEVELOPMENT SYSTEM
BASIC PROCESS FLOW RESPONSIBILITY DOCUMENTS
SOURCE IDENTIFICATION VENDOR DEVELOPMENT
QAV 1 (NEW SOURCE

VD / QA / R&D QAV 1 FORMAT
ASSESMENT BY R&D, VD,QA)
ON QCDDM PARAMETERS
ASSESMENT SHEET
ASSESMENT REPORT VD/QA/R&D
SUBMISSION TO
MANAGEMENT
SOURCE APPROVAL VENDOR DEVELOPMENT
VD/QA/R&D DRAWINGS, SPECS, LOI

HANDING OVER OF
DRAWINGS & SPECS. AND
DETAILS OF PAST
PROBLEMS
SAMPLE SUBMISSION TO R&D VENDOR DEVELOPMENT SIR,DIM,MATL,PERFORM

WITH SIR AND VENDOR'S ANCE,PQCS,PFMEA,DFM
SELF CERTIFICATION EA
HMCL EVALUATION AND R&D ISIR REPORT

APPROVAL. REPORT
RELEASE TO VENDOR
THRU VD
SELF EVALUATION REPORT

QAV BY SUPPLIER ON 4M&QAV-2 SUPPLIER REPORT
QAV 2 AT VENDOR TO ENSURE QAV 2 FORMAT

M.P. CONDITIONS w.r.t. 4M's VD/QA/R&D
REQUIREMENT ADHERENCE AND
SUBSEQUENT APPROVAL FOR
PILOT LOT SUBMISSION
03 CONSECUTIVE PILOT LOT R&D,QA PLIR REPORT, PDI REPORTS

JOINT APPROVAL BY R&D,QA WITH PROCESS CAPABILITY
REPORT
PQCS.DFMEA,PFMEA,R&D
HAND OVER TO QA
R&D,QA APPROVAL REPORTS
ALONGWITH RELEVANT
DOCUMENTS
NOTE: FOR MULTISOURCE PART, BASIC DEV. PHILOSOPHY WILL BE SAME AS NEW MODEL EXCEPT
DIFFERENCE IN ACTIVITY FLOW (AS SHOWN ABOVE)

6.0 MASS PRODUCTION QUALITY MAINTENANCE SYSTEM
Supplier shall establish a "QUALITY MAINTENANCE SYSTEM" which
encompasses all such quality assurance (corrective & preventive) correlated activities
which ensure defect free flow of parts to HMCL. This system shall consist of:
• Product inspection stages - Quality gates, Final inspection, PDI
• Control of non conformance
• Process control / improvement activities
• Bought out parts & offloaded process controls
Besides establishment of "QUALITY MAINTENANCE SYSTEM" the supplier
shall strive for implementation & accreditation of ISO:TS:16949 within a period of
two years after start of mass production.
6.1 Product inspection stages:

6.1.1 Quality Gate:
It is a product inspection stage set up to prevent the flow of non conformance to next
stage in process. Need of quality gate shall be determined by nature & occurrence rate of
defects. Suppliers shall deploy skilled Inspectors / Engineers at the Quality gate for
inspection of all critical to quality parameters (including HMCL concerns) in 100%
quantity.
Quality Gate procedure:

• Production (line) in charge shall ensure through visual displays:
• Daily monitoring of defects.
• Apprise the defects / rejections of previous day to shop floor personnel.
• Communication of proposed corrective & preventive measures adopted / to be
adopted.
• Monitoring of effectiveness of quality gate personnel .
• Analysis of defects identified at quality gate.
• Trace ability of inspectors by monitoring of escape rate.
Quality gate shall exist, till the generation of defects (rework / rejections) is arrested.
6.1.2 Final Inspection:

It is the finished product inspection stage to determine & ensure quality product in 100%
quantity as per inspection standards.
This stage shall exist at end of each line. Final inspection persons shall be responsible for
inspection of Critical to Quality Parameters in 100% material produced at the line. Well
defined Final inspection standards ( prepared in consensus with HMCL ) shall be followed
at this stage.
Straight pass shall be monitored for final inspection and actions shall be taken to improve
the straight pass at this stage.
Visual displays for monitoring of defects trends & corrective actions' effectiveness shall be
available at this stage.

6.1.3 PDI Inspection:
HMCL requires a designated PDI stage for inspection of the supplies before despatch to
HMCL. This stage shall exist separately from all the in process inspection stages , Quality
gate & Final inspection. An inspection plan duly approved by HMCL shall be followed for
inspection at this stage. Parts passed through PDI shall conform to Quality, Packing &
Handling requirements before despatch to HMCL. Specified rust preventive treatment
shall be done on bare parts before despatch.
PDI - Roles & Responsibilities :

• Inspectors / Engineers deployed at pre-delivery inspection (PDI) stage shall report to the
PDI in charge / Quality Custodian . They shall be competent with required skills who,
besides understanding the customer problems, shall strengthen the PDI by reviewing the
Inspection standards & frequency, to avoid flow of defects to HMCL.
• They shall have the authority to stop the despatch of non conforming material to HMCL and
give communication to PDI in charge / Quality Custodian for needful corrective &
preventive actions.
• PDI engineers.shall ensure the ok lots, duly identified with signatures on tags, with PDI
reports, fulfill the application of preservatives (oil, grease etc.) as applicable
6.1.4 Limit samples for aesthetically important parts:

For all aesthetically important parts like Painted / Plated parts, shade panels, aesthetic
standards & limit samples shall be followed for inspector at Final Inspection . These
shall be prepared by supplier & mutually agreed upon by HMCL & supplier These limit
samples shall be replaced and upgraded as per frequency planned by HMCL. For unpainted
parts also such as for CKD supplies (export), samples coated with lacquer shall be made &
followed. We expect the supplier to derive their in process limit samples to achieve desired
aesthetic quality in the finished product. For Aesthetic Manual Refer Annex:-
6.1.5 PDI reports:

As per the PDI Inspection plan of the component, report shall be generated & sent to HMCL
along with the lot as per frequency planned by HMCL. The reports are to be uploaded on
Supplier Portal .
For Documentation Submission Requirements Refer Annex. 8
6.1.6 PDI In charge
• Shall review the customer requirements/concerns on daily basis with Quality Gate/
Final Inspection /PDI inspectors & engineers
• Shall initiate actions with Manufacturing & QA heads
• Shall verify the execution of actions & monitor the effectiveness at respective
inspection stages.
• Shall apprise HMCL SQA section in charges regarding effectiveness of actions.
• Shall validate the limit samples jointly with HMCL for aesthetic requirements
• Shall ensure the use of calibrated measuring instruments & equipment at all inspection
stages
• Shall consolidate & summarize the quality status monthly for the lots inspection / ok /
rejections, part-wise / defect wise with counter measures & its effectiveness

6.2 Controls on Non-Conforming Product:
6.2.1) Supplier is responsible for despatch of defect free products to HMCL, but in the event of
detection of any non-conformity at supplier end itself, supplier shall ensure that same non-
conforming material is withdrawn from the pipeline & inform HMCL. Supplier shall
quarantine the non conforming material available at all stages at HMCL, under transit and
supplier's ware-house to prevent the usage in production of vehicles.
6.2.2 ) In the event of detection of any non-conformity in the lots received, the supplier shall take
back the rejected lot. Next lot shall be sent to HMCL only after ensuring & conforming the
quality of lot w.r.t. reported non-conformity.
6.2.3) If any problem is observed in HMCL assembly line, in process shops, supplier is
responsible to quarantine, segregate or rework the material in WIP / OK store . No rework /
segregation shall be allowed in the under inspection material.
All complaints related to line problems or lot rejections shall be communicated by HMCL
through Quality flash report to customer care interface . ( format) - Quality flash report
(Refer format IMDM:QA:BP:CF:16)
Any non-conformity leading to production stoppage shall be attended immediately by the
suppliers representative . In case of distant suppliers, local representatives shall attend the
same to avoid production stoppage. For stoppage because of the non-confirming product,
supplier is liable to be penalized
Non-conformity not leading to production stoppage shall be addressed promptly,
temporary & permanent countermeasure shall be communicated with in 24 hrs & 72 hours
respectively in response to Quality flash report. Response to quality flash report shall be
sent through mail as per the above said frequency.
For field failures, every month the supplier shall interact with HMCL SQA & Warranty
Analysis Cell for settlement of claims as per the process . However for safety related parts
(HS/HA/HB category ), the supplier shall attend the complaint within 24 hours of reporting.
P.S.:- Any non conforming material ,which is non rework able, shall be damaged at
HMCL with prior intimation to supplier before despatch.
6.3 Corrective & Preventive Measures with Effectiveness Monitoring:
Supplier shall focus upon poka-yoke (mistake proofing methods) to avoid re-occurrence of
problem, non-conformities shall be resolved using proper problem solving techniques
(Refer Annexure-9)
This shall be submitted to HMCL with evidence of implemented counter measures like
photographs, improved samples etc. quality of the material after implementation of counter
measures shall be monitored closely, effectiveness in terms of PPM level & instances of re-
occurrence of problem shall be monitored for a minimum period of six months. Refer
format. HMCL:BP:DOL:FF: 11
In addition to countermeasure & effectiveness monitoring format, duly filled five rule
sheets shall be submitted to HMCL for non conformities which are classified as follows :
safety critical parts (HS / HA/HB)
• functional & performance parts
• warranty complaints
• exports complaints
For general parts, corrective actions for complaints shall be submitted in response to quality
flash reports.CAPA are to be uploaded on Supplier Portal .

6.4 Conditional Acceptance:
Conditional acceptance request can be raised by supplier for the non conforming material
which can hot be rectified and in no way impairs the safety, function, performance, sales &
legal requirement of the motorcycle.
The authority of conditional acceptance lies only with HOD SQA through HOD (Materials-
Supply coordination). A conditional acceptance form shall be generated from materials
department on initiation by supplier. Conditional acceptance is in no way a right / privilege
of the supplier & it is the sole discretion of HMCL. Conditional acceptance shall be
considered for non conformity identified at supplier end only. It shall not apply to material
lying at HMCL. Refer Format IMAM:SP;05:FF:01
This conditional acceptance shall be temporary in nature & dead line shall be frozen in
terms of quantity & time, at the time of conditional acceptance itself. Conditionally
accepted material shall be identified for trace ability. Conditional acceptance shall be given
only when a concrete roadmap is submitted to remove the non-conformity by the end of
conditionally accepted quantity or time period.
Any non-conforming lot received after that permissible quantity / time shall be rejected &
considered as a serious fault on the part of the supplier.
6.5 Process Control & Improvement Activities:
Process Control
Daily management teams (Inproccess QA/Manufacturing) shall carry on shift wise product
& process control inspections and keep records which are auditable by HMCL teams.
Minimum requirement of these controls is given below :
l First off/last off pc approval
l Periodic inspection of product.
l Machine health check sheets based on CLIT.
l Periodic verification & recording of Critical process parameters.
l Trained manpower deployment verification at Critical processes.
Product , Process & System audit

Cross functional teams at supplier end shall conduct product & process audit on QAV 2
sheet to assess the adherence of process to PQCS & status of deployed actions. System
audits shall be conducted on System audit sheet .
The plan for this audit shall be drawn so as to cover all HMCL parts at least once in three
months.Priority shall be given to safety critical ( HS/HA/HB ) parts & performance parts.
Findings of this audit shall be compiled , discussed among the Cross functional teams & an
action plan shall be derived . The summary of total audit findings and implementation
status with action plan is auditable by HMCL team.

In the event of sudden & serious concern reported by HMCL, the audit shall be conducted
immediately by Quality Custodian & findings with actions shall be reported to HMCL
thereafter.
Warranty countermeasures audit
Quality custodian shall conduct monthly audit for the process & product to confirm the
adherence of counter measures implemented for warranty complaints. The evidence of
these audits is auditable by HMCL team.
Process improvements
Following indicators are the basis of objective evidence of process improvements
in enhancing the product quality for which supplies shall make efforts:
1) Process Capability Indices (Cp / Cpk) > 1.67 , in case it is < 1.0,100% inspection shall
be carried out
2) Straight pass % age (rejection/rework in process)
3) Mistake Proofing activities
4) Reduction in manual operations (technological up gradation)
5) Single piece flow of material
6) Measurement system accuracy
7) Quality status at HMCL
8) Review of PFMEA
6.6 Sub vendor (Tier I & Tier II Management):
The supplier shall establish a documented procedure for ensuring an effective " Quality
Management system " at their Tier 1 & Tier 2 suppliers in line with HMCL requirements.
The supplier shall also establish an evaluation mechanism to ensure sub vendors' eligibility
for supplying parts.Whenever required by HMCL, arrangement shall be done by supplier to
conduct the audit at tier 2 & tier 3 suppliers to verify the conformance of the specified
requirements. The supplier shall upgrade their Tier 1 & Tier 2 suppliers to ISO:9001.
The supplier shall ensure approval from HMCL for any new development of sub-vendor.
as per the IPPT system ( Section 10 ) .
6.7 Additional Requirements :
6.7 Raw Material & Special process control
Suppliers shall submit a list of approved vendors which includes Raw material and off
loaded special processes within one month after the receipt of HMCL Supplier Quality
manual, to HMCL's HOD Materials ( Supply chain deptt. & QA BOP at HMCL. This shall
apply to all raw material suppliers & sources for special processes , e.g, painting, plating,
heat treatment, powder coating, rubber compounding etc.
The list of Raw Material suppliers and sources for Special Processes shall be approved by
HMCL and any violation shall be treated seriously. HMCL has right to review the supply
share or discontinue business in case of any violation.
6.7.1 Export supplies

Supplier shall comply with following requirements related to export supplies:
a) Supplier shall ensure 100 % inspection, along with the inspection report, for export
consignment.

b) Identification after conforming the product quality.
c) Preservatives as applicable with the designated packing.
d) Duly approved performance tested products in case of proprietary & electrical parts.
Any other specific requirement shall be adhered by supplier as and when communicated by
HMCL.
6.7.2 Spare Parts supplies
Supplier shall comply with following additional requirements related to Spare Parts
supplies:
a) Packing standards as applicable to spare parts supplies.
b) Duly approved performance tested child parts in case of proprietary as well as
electrical parts.
6.7.3 Consumables & Shelf life sensitive parts supplies
Shelf life sensitive consumables , e.g, Paints , Stripes , Rubber parts , Adhesives ,
Chemicals-, Batteries etc shall be focused on following :
Self certification with clearly mentioned active shelf life
Adherence to first in first out during storage & delivery (manufacturing locations &
warehouse)
Environment, safety & legal compliance certificates (MSDS & Technical data sheet ) at the
time of development.
Storage & handling conditions shall comply with MSDS requirements at manufacturing
locations & warehouse, which may be audited by HMCL as & when required.
6.8 WORK STATION CONTROL FOR CRITICAL PROCESSES
Critical process shall be identified on the basis of following conditions.
a) Processes of critical parts (HS/ HA/ HB)
b) Process where any critical parameter (CTQ) is maintained
c) Processes whose RPN number in PFMEA is high (among top five)
d) Process due to which customer rejection/warranty rejection is high
e) Process due to which internal process rejection / rework is high
f) Raw material /Bop inspection & Final inspection
g) Special processes
All the critical process shall be listed down and on these work stations, only trained manpower shall
be deployed & effectiveness shall be monitored through escape rate. A sufficient spare pool shall be
identified for these processes and any replacement in case of absenteeism shall be done only from
this spare pool.
(Refer Format HMCL:BP:DOL;FF:08)

6.9 REVIEW OF PFMEA
As a part of the development process, PFMEA shall be prepared by suppliers' CFT to identify the
potential failures modes, their effects & reaction plan .All the data & experience related to similar
products shall be utilized for its preparation. Objective would be to enhance controls at critical
processes leading to reduction in the RPN
PFMEA shall be reviewed as per the following frequency
a) Once in three months or

b) Whenever a new failure is detected or
c) Whenever the occurrence of a failure has increased in field / HMCL / In process.
d) Whenever any Process Improvement is carried out attributing to Prevention & detection
As an outcome of PFMEA review, PQCS , Inspection plans & work standards shall also be reviewed.
Reviewed PFMEA is auditable by HMCL.
6.10 Standardization of PQCS/Control plan
HMCL's PQCS (Process Quality Control sheet) format consists of two sheets:
1st Sheet --- Indicates the identified components process flow and list of bought –out-
parts,its vendors and the off loaded processes.
2nd sheet --- Indicates the quality characteristics and control of manufacturing condition
for the identified components process flow. CTQs are identified for product/process in this
sheet. Any change in IPPT conditions shall call for review of PQCS & revised PQCS shall
be submitted as & when reviewed.
Note: Standardization of PQCS is mandatory. Control plan of the supplier is also acceptable,
provided it covers the contents of PQCS 1 & 2 of HMCL
(For PQCS FormatRefer Format HMCL:BP:DOL:FF:01)
6.11 Tool / Die / Jigs/ Fixtures Procurement, Validation & Standardization

Tools / Dies / Jigs / Fixtures availability , requirement & procurement plan shall be available
as per volumes. It shall be reviewed as & when volumes are enhanced. This status is
auditable by HMCL.
After standardization of Tools / Dies / Jigs / Fixtures and proper study of wear rate data,
preventive maintenance & validation schedules shall be derived . Preventive maintenance
& validation shall be carried out as per the schedules and is auditable by HMCL.
Refer Format HMCL:BP:DOL:FF:Q9 & HMCL:BP:DOL:FF:10

& ANNEXURE 16

6.12 Process Qualification records
(a) Process Validation /Qualification:
All the critical & special processes (as per TS:16949) shall be initially qualified & records
shall be maintained. Necessary trials shall be conducted by simulating different process
parameters including the input material & consumables. like paints chemicals etc. Actual
values shall be recorded for product results & process parameters. Wherever best results are
achieved, the process parameters' specifications shall be frozen & updated in the product's
PQCS.
This process shall be carried out at all manufacturing equipments available separately, i.e.,
if two heat treatment plants / furnaces are available - qualification shall be done separately.
In case of new manufacturing equipment, supply commencement shall take place only after
process qualification & adherence of IPP tag system.
For critical parts (HS / HA / HB) & high precision machined parts, process qualification
shall be done so as to achieve a minimum Cp of 1.67
(b) Process Re-validation:
All the qualified process shall be re-validated at a frequency of one year or as agreed upon'
and whenever there is a major overhauling in manufacturing equipment or change in input
material. In this re-validation, only the process parameters specifications which are already
frozen, needs to be validated against product specifications . If any change is done in
process at this stage, PQCS / Control plan shall be reviewed and is auditable by HMCL
6.13 Product Layout Inspection:

A comprehensive inspection shall be done for the parts falling in HS / HA / HB category,
Functional parts every three months. This report shall include all the raw material,
dimensional, metallurgical, surface treatment & endurance parameters specified in the
drawing / standards (including child parts multi - cavity, multi-source parts also).
These layout inspection reports shall be submitted to HMCL once in three months. These
reports shall be accompanied with inspected. Samples and an action plan for
correction of any parameters found out of specifications .
For general parts, layout inspection shall be carried out at a frequency of six months and
these reports areauditablebyHMCL.
P.S: Revalidation & Layout inspection shall be conducted at Tier 2 suppliers also at
same frequency in line with HMCL requirements & can be audited by HMCL any
time.

ANNEXURE 8
DOCUMENTATION SUBMISSION REQUIREMENTS
S.N0 DOCUMENT APPLICABLE FOR HS/HA/ HIGH PERFORMANCE & GENERAL

TIME / FREE QUENCY OF SUBMISSION TO BE SUBMITTED TO COPY TO
HB/Q/L AESTHET1C PARTS PARTS
QUALITY CUSTODIAN / DEPUTY QUALITY
1 HOD
CUSTODIAN /SINGLE WINDOW CUSTOMER CARE
0 0 0 NEW SUPPLIER/EXISTING SUPPLIER HOD MATERIALS
REPRESENTATIVE NOMINATION FORM ALL SUPPLIERS SQA
NEW 0 0 0 AT THE TIME OF DEVELOPMENT MATERIALS (V.D) R&D, QA SQA

2 DFMEA {FOR PROPERIETORY PARTS)
REVIEWED 0 0 0 ONGOING MATERIALS (SUPPLY) SQA
NEW 0 0 0 AT THE TIME OF DEVELOPMENT MATERIALS (V.D) R&D, SQA
3 PFMEA MATERIALS (SUPPLY
REVIEWED 0 0 0 ONGOING COORDINATION) SQA
4 PRE LAUNCH PQCS NEW 0 0 0 AT THE TIME OF DEVELOPMENT MATERIALS (V.D) R&D, SQA
5 SAMPLE INSPECTION REPORT NEW 0 0 0 AT THE TIME OF DEVELOPMENT MATERIALS (V.D)
NEW 0 0 0 AT THE TIME OF DEVELOPMENT MATERIALS (V.D) R&D, SQA
6 FINALPQCS
MATERIALS (SUPPLY SQA
REVIEWED 0 0 0 ONGOING
COORDINATION)
7 INSPECTION REPORT FOR IPP LOT AT TlME OF CHANGE IN IPP CONDITIONS MATERIALS (SUPPLY SQA
NEW 0 0 0 COORDINATION)
DAY WISE RESULT RECORDING IN
COMPILED FORMAT ONCE
0 0 IN A FIFTEEN DAYS
DOL SUPPLIER 0 COMPILED FORMAT ONCE IN A MONTH
8 PDI REPORTS FOR MASS PRODUCTION DAY WISE RESULT RECORDING IN SQA
LOTS (SOFT COPY BY E-MAIL) COMPILED FORMAT ONCE
0 0 IN A FIFTEEN DAYS
0 0 0 COMPILED FORMAT ONCE IN A MONTH
NON DOL SUPPLIER
NEW MODEL 0 0 AT THE TIME OF DEVELOPMENT R&D SQA
9 PROCESS CAPABILITY REPORTS
MASS PRODUCTION QUARTERLY
FOR INDICATED PARTS u u SQA
LOTS
10 PRODUCT LAYOUT INSPECTION MASS PRODUCTION QUARTERLY SQA
REPORTS LOTS 0 0
ACTION PLAN AGAINST QUALITY TEMPORARY CM WITHIN 24 HRS, MATERIALS (SUPPLY
11 0 0 0 COORDINATION) SQA
FLASH REPORT ALL PARTS PERMANENT C/M WITHIN 3 DAYS
WARRANTY ANALYSIS REPORTS WITH ACM
12 MONTHLY SQA
( AFTER COUNTRE MEASURE) ANALYSIS & TRENDS
MONITORING ALL SUPPLIERS 0 0 0
HIGH/AVERAGE PPM WITHIN ONE MONTH OF RECEIPT OF SECTION HEAD QABOP
ROADMAP TO MEET HMCL CATEGORY 0 0 0 TARGET LETTER
13
QUALITY TARGETS EXCELLENT/GOOD WITHIN ONE MONTH OF RECEIPT OF
u u u SECTION HEAD QABOP
CATEGORY TARGET LETTER
HIGH/AVERAGE PPM QUARTERLY MATERIALS (SUPPLY
0 0 0 SQA
OUTCOME OF MANAGEMENT CATEGORY COORDINATION)
14
REVIEWS EXCELLENT/GOOD MATERIALS (SUPPLY SQA
u u u QUARTERLY
CATEGORY COORDINATION)
MATERIALS
15 FULFILMENT OF DOL MOU CONDITIONS REVIEW EVERY THREE MONTHS SQA (SUPPLY
u u u
DOL SUPPLIERS COORDINATION)
16 ACTIONS AGAINST TOP QAV APPLICABLE WITHIN ONE WEEK OF QAV MATERIALS (SUPPLY
0 0 0 SQA
SUPPLIERS COORDINATION)
APPLICABLE
WITHIN ONE WEEK OF QAV MATERIALS (SUPPLY
17 ACTIONS AGAINST PERPETUAL QAV 0 0 0 SQA
SUPPLIERS COORDINATION)
0 DOCUMENTS TO BE SUBMITTED TO HMCL
DOCUMENTS AUDITABLE DURING AUDITS BY HMCL
u TEAM AT SUPPLIER END & TO BE SUBMITTED ON
REQUEST

7.0 DIRECT - ON LINE SUPPLIER
7.1 Objective:
• To establish , sustain & continually improve the reliability of supply chain, through:
• Transformation from reactive mode to preventive mode
• Arresting the generation of defects during manufacturing.
• Transformation from push to pull system
HMCL insists all the suppliers to achieve DOL status as it is important for HMCL business
requirements
7.2 Steps to achieve DOL status

7.2.1 Enrolment
As a first step, suppliers are enrolled into DOL program where in the supplier is made clear
about the requirements & expectations of HMCL from the supplier for this program. The
supplier is facilitated for the same
7.2.2 Internal audits

After enrolment, supplier is required to conduct internal audit on Product / Process / System
format as per the enclosures in manual and as per the frequency agreed mutually.
7.2.3 Management Review:

Management of the supplier shall review the status & discuss it with HMCL
PI Refer Annexure 2
7.2.4 Qualification criteria

a) Warranty 0-90 days PPM : < 125PPM
b) Warranty > 90 days PPM, : As per target
c) Carry-in-defectPPM : < 200 PPM
d) BopPPM : Zero
e) BosfPPM : As per target
f) Audit rating : > 8.0(HMCL AUDIT)
g) VQR : >75
h) Management issues* : To be accomplished prior to DOL certification
* Management issues:
Supplier MD / CEO / COO shall ensure resolution of management issues identified during HMCL
audit, prior to DOL certification, viz,
• Adequacy of infrastructure- machinery and manpower.
• Adequacy of inspection & testing facility
• Effective customer care setup and response time.
• Adherence of" Initial Production Part tag" system

7.3 Award of DOL status
Supplier shall be conferred " Direct On Line Supplier " status on successful qualification on
DOL qualification criteria including resolution of Management issues.
Recognition shall be done through "Direct-On-Line" certificate & a plaque . A
"Memorandum of Understanding" shall be signed by supplier and HMCL authorities for
restoring and sustaining the status.
For MOU Refer Format HMCL/DOL/COND/00
7.4 Containment Action

After the Award of DOL status , the supplier shall strictly adhere to the conditions
mentioned in DOL MOU and meet the DOL Qualification Criteria.
It is a pre - requisite for a Dol supplier to consistently maintain Vendor Quality Rating
more than 75 %, i.e, maintain minimum GOOD category.
Non adherence to DOL Qualification Criteria & violation of DOL MOU conditions by
Supplier shall invite penalty in the form of withdrawal of Dol status and / or review of
business share or both as per the Containment Action Policy for Dol deteriorated Suppliers
( For Containment Action refer Annexure 11)
7.5 Revalidation of Dol status

Dol status of awarded suppliers shall be re-validated after a period of THREE years or if the
Quality status doesn 't meet the Dol Qualification Criteria for one Fiscal Year.
For details of criteria and method of Dol Revalidation please refer Annexure-12)

PROCESS FLOW-DOL ANNEXURE 10
ENROLLMENT OF SUPPLIER INTO DOL PROGRAMME
FACILITATION AT SUPPLIER END REGARDING DOL'

METHODOLOGY & DOL QUALIFICATION CRITERIA WITH
ONE MOCK AUDIT ON HMCL APPROVED SYSTEM AUDIT SHEET.
PDI STAGE IMPLMN. AT SUPPLIER END AFTER CHECK POINTS /

METHODS COMMONISATION BETWEEN HMCL & SUPPLIER
100% INSPECTION FOR CRITICAL PARAMETERS AT QUALITY

GATE BEFORE PDI STAGE TO IDENTIFY DEFECTS & ITS EXTENT SYSTEM ADEQUACY
l MAN - TRAINED MANPOWER
IDENTIFICATION OF CRITICAL PROCESSES /WORK STATIONS DEPOLYMENT AT CRITICAL
BASED UPON DEFECTS & ITS PPM AT QUALITY GATE WORK STATIONS
l PROCESS CAPABILITY OF M/C
Cpk>1.33
IMPROVEMENT OF PROCESS CAPABILITIES OF IDENTIFIED
CRITICAL WORKSTATIONS TO STOP OCCURRENCE OF DEFECTS l RTY > 90
(IMPROVEMENT IN RTY) l MATERIAL - BOP PARTS RAW
MATERIAL CONTROLS
INTERNAL PROCESS / SYSTEM AUDIT ON QAV-2 & SYSTEM AUDIT l METHOD -
SHEET (HMCL APPROVED) BY SUPPLIER'S TEAM TO 1. JIGS/ FIXTURES
IDENTIFYTHE GAPS STANDARDIZATION &
VALIDATION
PROCESS & SYSTEM IMPROVEMENT BASED 2. TOOLS/DIES MOULDS LIFE
UPON GAPS IDENTIFIED IN THE INTERNAL AUDITS MONITORING & TIMELY
DUPLICATION
3. GAUGES COMPATIBILITY &
PROCESS / SYSTEM AUDIT BY HMCL DOL TEAM (VERIFICATION CALIBRATION'
OF SUPPLIERS QAV-2 AND SYSTEM AUDIT ON SYSTEM AUDIT SHEET)
4. PROCESS QUALIFICATION
C/Ms BY SUPPLIER TO ENSURE 100% PROCESS ADHERENCE
DOL QUALIFICATION CRITERIA

DECLARATION OF
READINESS BY l WARRANTY (0 ~ 90 DAYS ) PPM - <125 PPM
l CARRY-IN-DEFECT PPM - <200 PPM
SUPPLIER FOR DOL l BOP PPM = ZERO
l AUDIT RATING (32 ATTRIBUTE SHEET) : - >8, VQR > 75
l MANAGEMENT ISSUES - TO BE ACCOMPLISHED
SYSTEM ADEQUACY
VERIFICATION
l INTERNAL AUDITS & C/Ms FOR ITS FINDINGS (QAV-2 & SYSTEM AUDIT SHEET)
BY HMCL
DOL TEAM l PERIODIC FMEA REVIEW
l ACTIONS & EFFECTIVNESS FOR QUALITY STATUS AT HMCL
l PRODUCT LAYOUT INSPN
OK
SYSTEM ADEQUACY
VISIT BY HMCL SR l STRONG QA ORGN. STRUCTURE/SYSTEM
MGMT. TEAM FOR l SUFFICIENT INFRASTRUCTURE
FINAL CONFIRMATION l INTERNAL MANAGEMENT REVIEWS AT SUPPLIER END
(TOP QAV CHECK SHEET)
MONTHLY REVIEW WITH HMCL POST DOL SUSTAINENCE

BY SUPPLIER ON : AUDITS & REVIEWS BY
OK HMCL AT SET FREQUENCY AND
l INTERNAL AUDIT SUMMARY & IF NOT SUSTAINED THEN
DOL AWARD TO SUPPLIER
ACTIONS CONTAINMENT
ACTION TO BE FOLLOWED.
l MGMT. REVIEWS

CONTAINMENT ACTION FOR DOL
DETERIORATED SUPPLIERS
ANNEXURE 12
WRITTEN COMMUNICATION FROM
HMCL TO SUPPLIERS' SR.MGMT.
VERIFICATION OF ACTION
STRATEGY OF IMPROVEMENT TO BE IMPLEMENTATION BY HMCL
THRU FOCUSED AUDIT
EXPLAINED BY SUPPLIERS' SR.MGMT.
l ANY IPPT FAILURE

ATTRACTS A CAUTION
LETTER/TOP QAV.
l ADHERENCE TO DOL
QUALIFICATION
CRITERIA & MOU
CONDITIONS
OK QUALITY STATUS
REVIEW BY HMCL
l IMPORTANT IN PPM
NG LEVELS OF CID, BOP, BOSF
& WRTY. AFTER
VISIT BY HMCL TOP MGMT. AT VISIT/CAUTION LETTER.
SUPPLIER'S END OR CAUTION LETTER SENT. l RESPONSE TO LETTER
THROUGHT ROAD MAP.
l MONTHLY REVIEW BY
MONTHLY PROGRESS REPORTING BY SUPPLIER MGMT. WITH HMCL
SUPPLIERS' SR. MGMT. AT HMCL ON ACTION TAKEN FOR
IMPROVEMENT.
QUALITY STATUS l ACTION AGAINST IPPT

OK REVIEW BY HMCL AFTER FAILURE
TWO MONTHS
NG
NG
WITHDRAWAL OF DOL
l RESPONSE TO DOL
WITHDRAWAL LETTER
QUALITY STATUS THROUGH ROADMAP TO
OK REVIEW BY HMCL AFTER ACHIEVE DOL 'Q'
TWO MONTHS CRITERIA & GET DOL
REVALIDATED
NG l IMPROVEMENT IN PPM
LEVELS
REVALIDATIOIN OF DOL STATUS

ANNEXURE 13
SOP FOR DOL REVALIDATION
l REVALIDATION ONCE IN 03
IDENTIFICATION OF DOL YRS.
SUPPLIERS l -AND IF VQR<75 IN A
FOR REVALIDATION
FINANCIAL YEAR
TRAINING TO ASSOCIATE ON l EVALUATION CRITERIA

DOL AMENDED METHODOLOGY
l QUALITY STATUS BASED ON
DASHBOARD PARAMETERS OF
QUALITY
l ADHERENCE TO DOL MOU
DOL STATUS
CONDITIONS
REVIEW
l MGMT. REVIEWS (INTERNAL &
WITH HMCL)
PRODUCT / PROCESS AUDIT (QAV-2)

BY ASSOCIATE
PROCESS / SYSTEM AUDIT

(SYSTEM AUDIT SHEET) BY HMCL
SELF-EVALUATION BY ASSOCIATES
ON DOL AMENDED METHODOLOGY
IMPROVEMENT
ACTIONS AND
NG STATUS REVIEW
AT HMCL
DOL QUALIFICATION CRITERIA
OK l VQR > 75
l WTY. (0~90DAYS) < 125 PPM
NG AUDIT BY HMCL (EXCLUDING CONSEQUENTIAL

(SYSTEM AUDIT SHEET & FAILURE PARTS PPM)
QAV-2 VERIFICATION) l CID PPM < 200 PPM
l BOP PPM = ZERO
OK l AUDIT RATING . 8
l MANAGEMENT ISSUE- TO BE
ASSESSMENT OF SUPPLIER ON DOL

ACCOMPLISHED
l APPLICABLE FOR 03 YRS.
REVALIDATION CRITERIA
THROUGH TOP QAV
NG
OK
BUSINESS SHARE RECOGNITION AND AWARD

THROUGH DOL RECERTIFICATION DOL SUSTENANCE
REVIEW FOR
REDUCATION/
ALTERNATE SULLIER

HMCL TOP QAV CHECK SHEET
Supplier Visited -
Key Processes -
SR NO AUDIT POINTS JUDGEMENT OBSERVATION
ORGANIZATION
1 STRUCTURE 5 4 3 2 1
MOU*
MANAGEMENT
2 REVIEWS 5 4 3 2 1
MOU*
MANUFACTURING
INFRASTRUCTUR
3 5 4 3 2 1
E&
TECHNOLOGY
CUSTOMER
PROBLEM
4 5 4 3 2 1
REDRESSAL
SYSTEM
PRODUCT
QUALITY /
5 5 4 3 2 1
PROCESS
QUALITY
INTERNAL QA
6 5 4 3 2 1
CONTROLS
OPERATION
7 CONTROL & 5 4 3 2 1
EFFICIENCY
PREVENTIVE
8 MAINTENANCE 5 4 3 2 1
SYSTEM
9 OPERATOR SKILL 5 4 3 2 1
TIER 2
10 5 4 3 2 1
CONTROLS
CHANGE
11 5 4 3 2 1
MANAGEMENT
12 NEW MODEL 5 4 3 2 1
13 LOGISTICS 5 4 3 2 1
14 BEST PRACTICES 5 4 3 2 1
Yes No
OVERALL JUDGEMENT Yes No
Yes No
HMCL AUDITOR
SUPPLIER
AUDITEE
MOU* MEMORANDUM OF UNDERSTANDING BETWEEN DOL SUPPLIER AND HMCL

8.0 PARTS IDENTIFICATION & TRACEABILITY
Suppliers shall adhere to the following system for identification on parts so as to trace back the parts
in case of failure in the field.
8.1 Casting shall be traceable to

a) Maker identification
b) Heat no (for ferrous material only)
c) Pattern /Dieno
d) Month
e) Year
8.2 Forgings shall be traceable to

a) Maker identification
b) Heat no
c) Die
d) Month
e) Year
8.3 Proprietary parts shall have identification marks as per drawings.

Note: In addition to above mentioned categorized parts /drawings shall be referred for
provision , location, size, shape and orientation of identification marks. At visible locations
, only Hero Moto logo shall be used. Any clarification regarding identification required
shall be discussed with HMCL R&D.

9.0 PACKING STANDARDIZATION FOR OE, SPARES, EXPORT
9.1 Packing Requirements:
9.1.1 HMCL discourages the use of packing material which is not eco-friendly like
wood, cardboard, straws, gunny bags etc
9.1.2 Supplier shall follow the following steps for packing:
a) Approval of packing from HMCL through Materials department at the time of
part approval.
b) Send the material to HMCL in reusable packing based on 3 c concept - clean,
contact and count free.
c) Packing methods shall be standardized in terms of following parameters
i) Design of packing like partitions, label window etc.
ii) Quantity of parts
iii) Dimensions of packing like bin size, trolley size
iv) Packing colour (blue for bins / satin blue for trolleys).
v) Identification on packing as per HMCL requirement
d) Each plastic bin and trolley shall have following information on it
i) Vendor name, vendor code & HMCL packing code to be printed
ii) Packing slips with challan no / date, part number, part name, lot size to be
provided.
e) Supplier shall define an empties' retrieval system & get it approved from HMCL
f) Supplier shall reconcile empties' status on monthly basis with HMCL.
9.1.3 Any change in packing without communication will be violation of system, change in
packing method shall have to be approved by HMCL first & after approval, IPP tag system
shall be followed
9.1.4 Packing methods like plastic bins, trolleys shall have drawings at supplier end
9.1.5 A well defined system shall be implemented for preventive maintenance, cleaning &
upkeep of trolleys, bins etc.
9.1.6 Supplier shall ensure availability of sufficient number of bins and trolleys as per HMCL
requirements communicated from time to time
Note:
Mode of packing for spare parts division, export and manufacturing locations of HMCL, may
be different depending upon specific requirements.
Supplier shall ensure delivery of parts free of damage, water seepage, rust and dust through
usage of a robust logistics system duly approved by materials HMCL.

10.0 INITIAL PRODUCTION PART TAG SYSTEM
IPP tag system or initial production part tag system is the system implemented in the company to
ensure quality & trace ability of any new part. Suppliers are expected to adhere to this
system without fail. Here, new part will be a part which meets any of the followwing
sixteen conditions :
1. DRAWING/SPECIFICATION CHANGE
2. QUALITY IMPROVEMENT
3. NEW SUPPLIER /NEW LOCATION/ NEW LINE/ OFFLOADING
4. SUB VENDOR CHANGE /SUB VENDOR LOCATION CHANGE
5. MATERIAL CHANGE /ALTERNATE MATERIAL
6. MANUFACTURING METHOD CHANGE
7. MANUFACTURING PROCESS SEQUENCE CHANGE
8. MACHINE CHANGE
9. JIG/FIXTURE/TOOL DESIGN CHANGE
10. DIE /MOULD CHANGE
11. INSPECTION METHOD CHANGE
12. PACKING CHANGE ( WITH OR WITHOUT TRANSPORTATION METHOD
CHANGE )
13 RESTART OF SUPPLIERS & PARTS AFTER DISCONTINUATION FOR TWELVE
MONTHS
14 CHANGE IN MAN POWER AT CRITICAL STAGES
15 OFFLOADING BYTIER1 AND TIER 2 SUPPLIERS
16 SAME LINE/JIGS/FIXTURES/DIES/SHIFTING TO NEW LOCATION
Part manufactured after any change in any of sixteen conditions shall be considered as a new part.
First a sample lot shall be manufactured by the supplier. After self evaluation, duly filled
Initial Production Part Control Change Approval Request form shall be submitted to materials
(vendor development) at HMCL along with the following: REFER FORMAT: IPP CHANGE
APPROVAL REQUEST FORM
a) Samples of the part (minimum 10 nos) manufactured with new condition

b) Initial sample inspection report (Refer Format 1MDM:QA:BP:FF:02)
c) Metallurgical/surface treatment inspection report
d) Process Qualification report (special processes)
e) Revised PQCS
f) Performance. endurance test reports, wherever required
IPPT system has been made online and provided to Suppliers on Portal . The suppliers shall
submit IPPT information for lots ( after sample approval ) through online system only .
For details regarding the requirements of Initial Production Part Tag System pl refer
Annexure 14

11.0 SUPPLIER QUALITY APPROVAL SYSTEM
11.1 Process:
HMCL has a defined system for approval of production of parts from New Suppliers and New Plant
of existing Supplier. The system focuses on development of parts in an environment where all 4M
conditions are taken care of prior to trials. Through implementation of this robust system a smooth
transition from sample stage to Mass Production stage is achieved.
11.2 Responsibilities of suppliers:

11.2.1) Organization Structure :
Supplier's Management shall ensure the availability of a Plant Head & Quality Head at the new
facility prior to declaration & submission of samples. Sufficiency and adequacy of Organization
Structure to meet the operational needs of the organization shall also be addressed.
11.2.2) Training:
Class room as well as hands on training of operators shall be ensured before deployment on work
stations. Engineers / staff shall be experienced & trained according to their functional
responsibility. Training of process owners on Special processes viz. Heat treatment, Plating ,
Painting, Welding etc shall be ensured (if possible by expert organizations ) by Supplier's
Management.
11.2.3) Plant Erection & Commissioning:

Supplier's project team shall prepare a detailed Master Plan for Plant erection & Commissioning
including activities related to Quality establishment and Mass Production .This plan shall be
reviewed by Senior Management w.r.t progress against the plan. The same shall be updated to
HMCL as per the plan given by HMCL.
11.2.4) Process Planning & Machines Capability:,

Historical data shall be studied by Supplier team for planning of processes & infrastructure so as to
reduce the problems observed in past at HMCL on line & in field. Planning of infrastructure shall be
in accordance with 4M evaluation w.r.t capacity declared & shall be ramped up with ramp up in
production All the critical processes shall be qualified before start of any production. Critical
machines shall be accepted when Cpk > 1.67. Enough focus shall be laid on technology up
gradation w.r.t manufacturing &handling systems. Single pc flow shall be implemented so as to
minimize handling. (Refer 4M Evaluation Format.)
11.2.5) Mass Production Establishment:

Sufficient production trials shall be conducted under mass production conditions ,i-e, using mass
production toolings , machines , manpower & material. Results of these trials shall be evaluated
through Initial Process Capability studies (Ppk) wherever applicable.

11.2.6 ) Mass Production Quality Maintenance:
After the start of mass production from the plant, Quality shall be maintained in line with Mass
Production Quality Maintenance system (Refer Section 6.0)
Quality Policy shall be deployed to achieve short &long term objectives which are aligned with
HMCL business requirements . Systems shall be frozen through release of Quality Manual. Systems
shall be strengthened through implementation of ISO:TS: 16949 and progress towards DOL status.,
Supplier shall get the Product, Processes & Systems audited & approved by HMCL by
following the Supplier Quality Approval System.
For details refer Annexure 15.
Note : Supplies shall start only after HMCL approval . Violation of any condition of Supplier
Quality Approval System shall amount to an IPPT failure.

Revision-02
CRITICAL
CRITICAL ABC HERO MOTOCORP LTD.
MODEL CLASS MAJOR PROCESS QUALITY CONTROL SHEET (1)
GRADE
MINOR
PART NO. DOC NO. REV NO.
PART NAME
SOURCE DATE : PAGE.......1.........OF.........2.........
BASIC FOR PRODUCTION CHANGE PARTS PURCHASED FROM OUTSIDE/OFFLOADED PROCESS SUPPLIER
Critical Approval Test Prodn. Submit 1st
PROCESS FLOW DIAGRAM S. NO. Process & Required S. No. Part No. Part Name Supplier
checked Piece date
Description
HMCL APPROVAL VENDOR APPROVAL

AUTHORISED DATE MADE BY CHECKED APPROVED
DATE NAME SIGNATORY BY BY
LOT MARKETING
LOT CODE
Page 53 of 148
Revision-02
PROCESS OUALITY CONTROL SHEET (ID
DOC. NO:HMCL:BP:DOL:FF01
PAGE.--------2------------OF------2------------------
CONTROL OF MANUFACTURING CONDITIONS
QUALITY CHARACTERISTICS (Equipment, metal mold, fail-safe devices, hydraulic power,voltage, temperature etc.)
Process Name/Equipment
Name (Name of Supplier) Inspection Inspection Data From Control Item Specified value Inspected by Inspection Inspection Data from Detail of Process/Sktech
No. Control Item Specified Value Inspected by Method Frequency
Method Frequency
Trouble Mode
Important Item
Sequence of Process
Classification of trouble modes of completed vehicles (machine) : 1. Fire, 2. Fails to stop,3. Fails to run, 4. Receives clectric shocks,5. Fails to conform to legal requirements. 6. Outer appearance and commercial value.
Page 54 of 148
QUALITY ASSURANCE VISIT -2 REPORT
Revision-02
MODEL PARTS NAME DATE VENDOR HMCL
NAME HMCD
(VENDOR QUALITY RESPJPERSON) Q.RES. PERSON INCHAGE APPROVED CHECKED SURVEYED
ISSUE
HMCG
COMPANY NAME HMCH
FACTORY NAME OBJECTIVE :
DATE
POSITION NAME
VENDOR : COMPILATION:
COUNTER MEARURE
HMCL:
COUNTER MEARURE EXECUTION CHECK

* PROCESS NAME C.M. EXECUION CHECK (HMCL)
SL. * CHECK ITEM CONTROL ITEM JUDGEMENT OBSERVED DATAILS REASON COUNTER MEASURE
NO. * PART NAME RESP. TARGET INCHARGE DATE RESULT
Page 55 of 148
Revision-02
DOC. NO. HMCL: BP: DOL: FF: 05
HERO MOTOCORP LIMITED
SL. * PROCESS NAME CONTROL ITEM JUDGEMENT OBSERVED DETAILS REASON COUNTER MEASURE C.M. EXECUSION CHECK (HMCL)
NO. * CHECK ITEM RESP. TARGET INCHARGE DATE RESULT
* PART NAME
Page 56 of 148
Annexure -14
INITIAL PRODUCTION PART TAG

SYSTEM (IPPT)

SEQUENCE
l PURPOSE
l DEFINITION
l CONDITIONS
l CATEGORIES
l DESCRIPTION OF CONDITIONS
l FLOW FOR IPP TAG
l FLOW REQUEST FROM HMCL
l FLOW REQUEST FROM SUPPLIER
l FLOW FOR INTIMATION
l REQUIREMENT FOR IPP CONDITIONS
l CHANGE REQUEST FORM
l IPP FORM
l FEEDBACK FORM
l PPC INFORMATION FORM
PURPOSE
THE PURPOSE OF THIS SYSTEM IS TO DEFINE THE BASIC REQUIREMENT FOR
THE CONTROL OF INITIAL PRODUCTION PARTS (IPP) SUPPLIED BY
SUPPLIERS TO HMCL TO ENSURE THAT THE QUALITY & TRACEABILTY
OF THE IPP IS MAINTAINED PROPERLY

DEFINITION
IPPT SYSTEM:- This System applies to the lot for the Initial Production of
Parts, Raw Materials, Systems and Finished products in the production stages
of part Suppliers, supplying to HERO MOTOCORP LIMITED.
l However, the initial lot of exclusive parts at the launch of a New Model
production shall be outside the scope of this standards
l The New / Alternate Supplier after PP1 of New Model, shall follow the
IPPT system
CONDITIONS: There are Sixteen Conditions of IPPT System

1. DRAWING/SPECIFICATION CHANGE
2. QUALITY IMPROVEMENT
3. NEW SUPPLIER/NEW LOCATION/NEW LINE/OFFLOADING
4. SUB VENDOR CHANGE / SUB VENDOR LOCATION CHANGE
5. MATERIAL CHANGE/ALTERNATE MATERIAL
6. MANUFACTURING METHOD CHANGE
7. MANUFACTURING PROCESS SEQUENCE CHANGE
8. MACHINE CHANGE
9. JIG/FIXTURE/TOOL DESIGN CHANGE
10. DIE/MOULD CHANGE
12. PACKING CHANGE ( WITH OR WITHOUT TRANSPORTATION
METHOD CHANGE)
13. RESTART OF SUPPLIER & PARTS AFTER DISCONTINUATION
FOR TWELVE MONTHS
14. CHANGE IN MANPOWER AT CRITICAL STAGES
15. OFFLOADING BYTIER1 AND TIER 2 SUPPLIERS
16. SAME LINE /JIGS/FIXTURES/DIES/SHIFTING TO NEW
LOCATION

Revision-02
CATEGORY
There are Two Categories of I PPT System
2. Applicable to Changes For which

1. Applicable to Changes For which Intimation is Required to HMCL for
Approval is Required from HMCL consent of approval
(Sr.NO.1.2.3.4.5.6.10.13.of IPPT (Supplier's Self Approval Report is also
Conditions) required)
HIERARCHY (Sr. NO.7.8.9.11.12.14.15.16 of conditions
APPROVAL INTIMATION WITH

REQUIRED SUPPLIER'S SELF
APPROVAL REPORT
CAT-A CAT-B CAT-C

REQUEST REQUEST
FROM HMCL FROM SUPPLIER
EXPECTED CHANGE
PILOT LOT SUBMISSION PILOT LOT SUBMISSION INTIMATION TO HMCL FOR DECISION
FOR MASS PRODUCTION FOR MASS PRODUCTION OF SAMPLES SUBMISSION
AFTER AFTER OR PILOT LOT SUBMISSION
SAMPLE APPROVAL SAMPLE APPROVAL
Page 60 of 148
Revision-02
CONDITIONS, CATEGORY & TREATMENT
S.NO CONDITION CATEGORY TREATMENT
1 DRAWING /SPECIFICATION CHANGE A/B APPROVAL REQUIRED
2 QUALITY IMPROVEMENT A/B APPROVAL REQUIRED

3 NEW SUPPLIER / NEW LOCATION / NEW LINE /OFFLOADING BY HMCL A/B APPROVAL REQUIRED
4 SUBVENDOR CHANGE / LOCATION CHANGE B APPROVAL REQUIRED
5 MATERIAL CHANGE/ALTERNATE MATERIAL A/B APPROVAL REQUIRED
6 MANUFACTURING METHOD CHANGE B APPROVAL REQUIRED
MANUFACTURING PROCESS SEQUENCE CHANGE HMCL CONSENT & INTIMATION BY SUPPLIER

7 C WITH SUPPLIER'S SELF APPROVAL REPORT*
MACHINE CHANGE HMCL CONSENT & INTIMATION BY SUPPLIER

JIG / FIXTURE/ TOOL DESIGN CHANGE HMCL CONSENT & INTIMATION BY SUPPLIER
10 DIE / MOULD CHANGE B APPROVAL REQUIRED
INSPECTION METHOD CHANGE HMCL CONSENT & INTIMATION BY SUPPLIER

PACKING CHANGE (WITH OR WITHOUT TRANSPORTATION METHOD HMCL CONSENT & INTIMATION BY SUPPLIER
12 C
CHANGE) WITH SUPPLIER'S SELF APPROVAL REPORT*
13 RESTART OF SUPPLIER & PARTS AFTER DISCONTINUATION B APPROVAL REQUIRED

FOR TWELVE MONTHS
CHANGE IN MANPOWER AT CRITICAL STAGES HMCL CONSENT & INTIMATION BY SUPPLIER
OFFLOADING BY TIER 1 AND TIER 2 SUPPLIERS HMCL CONSENT & INTIMATION BY SUPPLIER
SAME LINE /JIGS/FIXTURES/DIES/SHIFTING TO NEW LOCATION HMCL CONSENT & INTIMATION BY SUPPLIER
Page 61 of 148
Revision-02
DESCRIPTION OF IPP CONDTIONS
N ITEM DESCRIPTION OF INDIVIDUAL CONDITION TREATMENT
# The case where a change to new specification is asked to HMCL
1 DRAWING /SPECIFICATION APPROVAL
CHANGE # The case where a specification change without interchangeability (WITH OTHER MODEL) is made.
REQUIRED
# The case where a specification change with interchangeability (WITH OTHER MODEL) is made
# The case where a Drawing / Specification change is made by supplier in Proprietary parts
The case where a quality improvement is made on the request of the HMCL & sought by Supplier APPROVAL
2 QUALITY IMPROVEMENT ease of fitment (Male part dimn. On lower side and Female part dimn. Of higher side of spec.). REQUIRED
Product life cycle enhancement
3 NEW SUPPLIER / NEW LOCATION / # The case where a supplier is added (Including an addition of the supplier's plant
APPROVAL
NEW LINE /OFFLOADING BY # The case where a supplier is replaced with another one (Including a change of the supplier's plant site)
REQUIRED
HMCL # The case where the destination of delivery is changed (HMCD/ HMCG/HMCH)
# The case where a switch from In-house parts to outsourced parts is made and vice versa
4 SUBVENDOR CHANGE/ LOCATION # The case where a switch from in-house parts to out-sourced parts is made and vice versa APPROVAL
CHANGE # Tier-ii Supplier added (Source change)
REQUIRED
5 MATERIAL CHANGE / ALTERNATE # The case where a material supplier is replaced with another one APPROVAL
MATERIAL # Material is changed (Alternate material as per drawing) REQUIRED
#The case where a change is made in casting or forging method (other than process qualified)
6 MANUFACTURING METHOD APPROVAL
#The case where a change madein.sintering
; conditions (Processing temperature, time, etc)
CHANGE REQUIRED
#The case where a change is made in Heat Treatment conditions (Temperature, time, heating .
method, cooling method etc.)
#The case where a change is made in rubber or synthetic resin molding conditions
#The case where a change is made in welding conditions
#The case where a change is made in Processing criteria or setting method
#The case where a change is made in plating, buffing or painting conditions
#The case where a change is made in assembling conditions
Page 62 of 148
Revision-02
DESCRIPTION OF IPP CONDTIONS
S.N ITEM DESCRIPTION OF INDIVIDUAL CONDITION TREATMENT
7 MANUFACTURING PROCESS # The case where Processes are consolidated into one or Process sequence HMCL CONSENT & INTIMATION BY
is changed or process is deleted. SUPPLIER WITH SUPPLIER'S SELF
SEQUENCE CHANGE
# The case where a temporary process becomes a regular process and Vice APPROVAL REPORT*
Versa
#The case where a machine is modified

8 MACHINE CHANGE HMCL CONSENT & INTIMATION BY
#The case where a new machine is used SUPPLIER WITH SUPPLIER'S SELF
#The case where a machine is relocated (Other location / other vendor) APPROVAL REPORT*
9 JIG / FIXTURE/ TOOL # The case where the parts processing Jig / Fixture /Tool Design changed
HMCL CONSENT & INTIMATION BY
DESIGN CHANGE SUPPLIER WITH SUPPLIER'S SELF
APPROVAL REPORT*
The case where a die or mould is modified or newly made/Design Changed APPROVAL REQUIRED
10 DIE /MOULD CHANGE
#The case where an inspection Jig or Fixture is newly made HMCL CONSENT & INTIMATION BY
11 INSPECTION METHOD CHANGE SUPPLIER WITH SUPPLIER'S SELF
#The case where a measuring instrument or measuring standard is changed
APPROVAL REPORT*
HMCL CONSENT & INTIMATION BY

12 PACKING CHANGE (WITH OR WITHOUT #The case where a change is made in transportation method, packing method
SUPPLIER WITH SUPPLIER'S SELF
TRANSPORTATION METHOD CHANGE) or container
APPROVAL REPORT*
RESTART OF SUPPLIES. PARTS AFTER # The case where theSupplier / Parts supplies are restarted after discontinuation APPROVAL REQUIRED
13 for Twelve months.
DISCONTINUATION FOR TWELVE MONTHS
14 CHANGE IN MANPOWER AT CRITICAL # The case where the manpower change at done at critical stations of the stage HMCL CONSENT & INTIMATION BY
where the critical to quality parameters are inspected. (if the change is made with SUPPLIER WITH SUPPLIER'S SELF
STAGES
the spare pool, then no intimation is required) APPROVAL REPORT*
15 OFFLOADING & ONLOADING BY TIER 1 AND # The case where a switch from in-house parts/process to out-sourced parts/Process HMCL CONSENT & INTIMATION BY
TIER 2 SUPPLIERS is made by Tier 1 and Tier 2 suppliers and vice versa' SUPPLIER WITH SUPPLIER'S SELF
APPROVAL REPORT*
#The case where a switch from in-house line /jigs / fixture /dies are shifted t o New HMCL CONSENT & INTIMATION BY
16 SAME LINE /JIGS/FIXTURES/DIES/
Location by tier 1 and tier 2 suppliers and vice versa SUPPLIER WITH SUPPLIER'S SELF
SHIFTING TO NEW LOCATION
APPROVAL REPORT*
Page 63 of 148
Revision-02
CAT-A&B-Mandatory
CAT-C -IF ASKED BY
FLOW FOR SAMPLE HMCL
Supplier Purchase/ Quality / R&D Section QUALITY

vendor dev. (HMCL) Final Insp.
Origination Sample process Sample inspection/ Vehicle trial Vehicle

go or no-go decision on inspection
transition To mass production)
NOTICE
(HARD COPY)
CYCLE TIME : 06 WORKING
Adjustments as to DAYS MIN. *
Processing /
Details of confirmation *MAY CHANGE DEPENDING
assembling
UPON THE TESTING TIME.
of sample
(10 NOS.) INFORMATION TO
QA / R&D (HARD COPY)
Fitment trials
SAMPLE Sample Inspection on vehicle
SUBMISSION
Vehicle Insp.
N (10NOS.
Confirmation of (If needed)
ALONG WITH Process ability /ease
REPORTS AS Testing if of assembly
PER Required
ANNEXURE 1
QAV AT VENDOR
END IF REQUIRED
Pilot lot Decision on

transition To Decision on transition To Pilot lot production
assembly
pilot lot (FEEDBACK FORM
Page 64 of 148
Revision-02
FLOW FOR IPP (REQUEST FROM HMCL) CAT (A)
AFTER SAMPLE APPROVAL
Supplier Purchase/ Quality / R&D Section Section Related
vendor dev. (HMCL) PPC (ENG./FR.Assy.) Final Insp. Other deptt.
Ipp inspection/ Material Confirmation of Vehicle Market Feedback

Ipp process
origination go or no-go decision on feeding to Process ability Inspection
transition To mass production line Ease of assembly
NOTICE
(HARD COPY) INFORMATION TO *--HMCL CAN ASK FOR
QA / R&D HIGHER QUANTITY IF
Processing/
Adjustments as to NEEDED
assembling
Pilot lot Details of confirmation
(100*nos.) CYCLE TIME :06 WORKING
INFORMATION TO DAYS #
QA / R&D (HARD COPY) # MAY CHANGE DEPENDING
PILOT LOT Material UPON THE TESTING TIME.
ALONG WITH IPP Inspection feeding to line
REPORTS AS
PER
Confirmation of Vehicle insp.
ANNEXURE 1 Testing if Process ability / ease
Required of assembly
-Q.C In plant
Decision on QAV AT VENDOR -R&D
Mass transition END IF REQUIRED -Purchase HMCD
production To Mass
-COST Account
production
Decision on transition To Mass production -Q.C Receipt
(FEEDBACK FORM) -Purchase HMCG
ck Engine No/ -Service HMCG

Feeba Frame No. -Marketing HMCO
information -Service
Feedback & -Centre (HMCO)
Record -SPD (HMCO)
Feedback -Customer
Feedback Feedback Wac
care
Page 65 of 148
Revision-02
FLOW FOR IPP (REQUEST FROM SUPPLIER) CAT (B)
AFTER SAMPLE APPROVAL
Purchase/ Quality / R&D Section Section Related Final Insp.
Supplier PPC Other deptt.
vendor dev. (HMCL) (ENG./FR.Assy.)
Ipp inspection/ Material Confirmation of Vehicle
go or no-go decision on Process ability Market Feedback
origination Ipp process feeding to inspection
transition To mass production line Ease of assembly
Adjustments as to
CHANGE Details of confirmation
EXPECTED CYCLE TIME :06 WORKING
REQUEST
CHANGE DAYS #
NOTE
INFORMATION TO # MAY CHANGE DEPENDING
QA / R&D (HARD COPY) UPON THE TESTING TIME.
PILOT LOT
Processing/ ALONG WITH Material
IPP Inspection
assembling REPORTS AS feeding to line
Pilot lot PER
(100*nos.) ANNEXURE 1 Confirmation of Vehicle insp.
Testing if Process ability / ease
Required of assembly
Decision on QAV AT VENDOR

Mass transition END IF REQUIRED
production To Mass -Q.C In plant
production -R&D
Decision on transition To Mass production -Purchase HMCD
(FEEDBACK FORM) -COST Account
-Q.C Receipt
Feedback Engine No/ -Purchase HMCL
Frame No.
information -Service HMCG
& Record -Marketing HMCO
Feedback Feedback Wac -Service Centre
Feedback (HMCO)
-SPD (HMCO)
-Customer care
Page 66 of 148
Revision-02
FLOW FOR IPP (INTIMATION) CAT (C)
AFTER HMCL APPROVAL
Supplier Purchase/ Quality / R&D Section Section Related
vendor dev.
PPC Final Insp. Other deptt.
(HMCL) (ENG./FR.Assy.)
INFORMATION
EXPECTED VERIFICATION CYCLE TIME :02 WORKING
CHANGE DECISION TO DAYS #
GO FOR
PILOT HMCL DECISION # MAY CHANGE DEPENDING
LOT/SAMPLE -(SAMPLE REQUIRED UPON THE TESTING TIME.
SUBMISSION -QAV REQUIRED)
Trial lot
Confirmation of
Processing / PILOT LOT Material Vehicle insp.
VERIFICATION Process ability /
assembling ALONG WITH feeding to line ease of assembly
of IPP (100 NOS) REPORTS AS
PER
ANNEXURE 1
Decision on TESTING /QAV AT

Mass transition VEDOR END
production To Mass IF REQUIRED
production
Decision on transition To Mass production
(FEEDBACK FORM)
-Q.C In plant
Modification Feedback -R&D -Purchase
Feedback Feedback HMCD -COST
Account -Q.C
Recording & Receipt
control of -Purchase HMCL
applied -Service HMCG
serial no. -Marketing HMCO
(Eng. / Fr.) -Service Centre
(HMCO)
Feedback -SPD (HMCO)
Feedback -Customer care
Page 67 of 148
Revision-02
FLOW FOR IPP TAG
Purchase/ Quality / R&D Section Section Related
Supplier PPC Final Insp. Other deptt.
vendor dev. (HMCL) (ENG./FR.Assy.)
origination Ipp process (Ipp inspection/go or no-go Material Confirmation of Vehicle Market Feedback
decision on transition To feeding to line Process ability / inspection
Mass production) ease of assembly
1
2
2
3 2
3 4 3
3 3
4 4 -Q.C In plant
4 4 3 R&D
1 4 -Purchase HMCD
2 -COST Account
COPY
COPY Information -Q.C Receipt
-Purchase HMCG
Feedback Feedback
WAC -Service HMCG

-Marketing HMCO
-Service Centre
(HMCO)
4 -SPD (HMCO)
3 -Customer care
3 3 Keep this 3
Keep this Copy on 4
Copy on file file
record
Engine No/
Destory 1 after Feedback to Destory 2 after Frame No.
3 is received supplier 4 is received information & Record
Page 68 of 148
DOCUMENTS REQIREMENTS FOR IPP CONDITIONS ANNEXURE 1
Revision-02
REQUIREMENT
SAMPLE SAMPLE SPECIAL SUPPLIER
R&D TESTING QAV APPROVER INTIAL PART METALLUR PROCESS
SUBMISSION INSPECTION CHANGE IPP PROCESS FIXTURE SELF REVISE OTHER IF
REQD/NOT SIR TO ALONG RESPONSI- INSPECTION GICAL CAPABILITY PQCS
SR. NO. & REQUEST REQUEST FORMAT VALIDATION VALIDATION APPROVAL OF PFMEA ANY
IPP REQD. WITH VD BILITY REPORT REPORT REPORT
APPROVAL (SIR) REPORT SUBVENDOR
CONDITION
DRAWING /SPECIFICATION
1 CHANGE YES R&D R&D & SQA R&D VD NOT NOT NOT NOT
O REQD.
O O REQD. REQD. O O O REQD. O
CONDITION SQA MATRLS NOT NOT
2 QUALITY IMPROVEMENT SQA Q.A. O O O REQD. O
BASED* SUPPLY CHAIN O REQD. O O
O O
NEW SUPPLIER / NEW LOCATION/ R&D R&D & SQA NOT NOT
3 YES R&D VD O O O O O REQD. O
NEW LINE/OFFLOADING REQD. O
O O
SUBVENDOR CHANGE VD NOT O O O
4 YES R&D R&D & SQA R&D O REQD. O O O O
O O
NOT NOT NOT NOT
5 MATERIAL CHANGE YES R&D R&D & SQA R&D VD O REQD. O O O
O O REQD. REQD. REQD. O
MATRLS O NOT NOT NOT NOT
6 MANUFACTURING METHOD YES R&D Q.A. O
CHANGE R&D & SQA SUPPLY CHAIN REQD. REQD. REQD. O O O REQD.
O O
MANUFACTURING PROCESS CONDITION MATRLS NOT NOT NOT NOT NOT
7 SQA SQA Q.A. NOT REQD. REQD. O
SEQUENCE CHANGE BASED* SUPPLY CHAIN O O REQD. REQD. REQD. O REQD.
O
CONDITION MATRLS NOT NOT
8 MACHINE CHANGE SQA SQA Q.A. NOT REQD. REQD. O O
BASED* SUPPLY CHAIN O O O O O REQD.
O
JIG/FIXTURE/TOOL DESIGN MATRLS NOT NOT NOT NOT NOT
9 NOT REQD. Q.A. NOT REQD. O O O
CHANGE
SQA SQA SUPPLY CHAIN O REQD. REQD. REQD. REQD. REQD.
O
CONDITION MATRLS NOT NOT NOT NOT NOT NOT
10 DIE/MOULD CHANGE SQA NOT REQD. Q.A. O O
BASED* SUPPLY CHAIN O REQD. O O REQD. REQD. REQD. REQD. REQD.
MATRLS NOT NOT NOT NOT NOT

11 INSPECTION METHOD CHANGE NOT REQD. SQA Q.A. NOT REQD. O O REQD. O
SQA SUPPLY CHAIN O O REQD. REQD. REQD. REQD.
MATRLS MATRLS NOT NOT NOT NOT NOT NOT NOT

12 TRANSPORT METHOD/PACKING NOT REQD. NOT REQD. NOT
CHANGE SQA SUPPLY SUPPLY CHAIN REQD. REQD. REQD. REQD. REQD. REQD. REQD.
O REQD. O O
CHAIN & Q.A
13 RESTART OF SUPPLIER & PARTS CONDITION MATRLS NOT

AFTER DISCONTINUATION FOR R&D R&D & SQA V.D. & R&D O O O O O O O
BASED* SUPPLY CHAIN O REQD. O O
TWELVE MONTHS
/VD
MANPOWER AT CRITICAL MATRLS NOT NOT NOT NOT NOT NOT NOT SKILL
14 NOT REQD. SQA NOT REQD. Q.A
STAGES SUPPLY CHAIN NOT REQD. O O O REQD. REQD. REQD. REQD. REQD. REQD. REQD. MATRIX
15 OFFLOADING BY TIER 1 AND NOT REQD. MATRLS IF IF IF

TIER 2 SUPPLIERS SQA NOT REQD. Q.A
SUPPLY CHAIN O O O O REQD. O REQD. O O O REQD.
SAME MATRLS IF IF IF
16 LINE/JIGS/FIXTURES/DIES/SHIFTI NOT REQD. SQA NOT REQD. Q.A O O O O O
SUPPLY CHAIN O O REQD. REQD. O REQD.
NG TO NEW LOACTION
NOTE:-DOCUMENTS NOT MENTIONED ABOVE MAY BE ASKED IF NEEDED.

*HS/HA/HB/L-PARTS ARE REQUIRED FOR TESTING PURPOSE FOR CONDITION BASED CATEGORY.
SIR TO BE GENERATED BY VD ONLY.
**ALL PLASTICS TO BE TESTED.
**CYL. HEAD TO BE TESTED.
**OIL SEAL TO BE TESTED.
Page 69 of 148
Revision-02
DOC. NO. IMDM : QA:BP:FF:05
S.Q.A. HMCL REV. NO. 01 DT. 01.04.2009
INITIAL PRODUCTION PART CHANGE APPROVAL REQUEST / INTIMATION FORM

SUPPLIER NAME & ADDRESS SUPPLIER CODE PART CLASS SAMPLE QTY.
HS / HA/ HB
FUCNTIONAL
GENERAL
PART NAME
PART NUMBER
NATURE OF CHANGE (TICK AS APPLICABLE )
1. DRAWING / SPECIFICATION CHANGE 9. JIG / FIXTURE/ TOOL DESIGN CHANGE
2. QUALITY IMPROVEMENT 10. DIE/MOULD CHANGE
3. NEW SUPPLIER / NEW LOCATION 11.INSPECTION METHOD CHANGE
4. SUBVENDOR CHANGE 12.TRANSPORT METHOD /PACKING CHANGE
5. MATERIAL CHANGE 13.RESTART OF SUPPLIER & PARTS AFTER

DISCONTINUATION FOR THREE MONTHS
6. MANUFACTURING METHOD CHANGE 14. MANPOWER AT CRITICAL STAGES
7. MANUFACTURING PROCESS SEQUENCE CHANGE 15. OFFLOADING BY TIER 1 AND TIER 2 SUPPLIERS
8. MACHINE CHANGE 16. SAME LINE /JIGS/FIXTURES/DIES/SHIFTING TO

NEW LOCATION
REASON & DETAIL OF CHANGE IDENTIFICATION ON SAMPLE
INSPECTION & TESTING CONDUCTED ENCLOSURES (TICK AS APPLICABLE) SUPPLIER V.D

INITIAL SAMPLE INSPECTION REPORT
METALLURGICAL / SURFACE TREATMENT INSPECTION REPORT
PROCESS QUALIFICATION REPORT PREPARED BY
REVISED PQCS
PERFORMANCE . ENDURANCE TEST REPORTS APPROVED BY RECEIVED BY
INITIAL EVALUATION DATE
COMMENTS: EVALUATION BY
QA BOP
COMMENTS:
R &D
COMMENTS:
V.D
ACCEPTED REJECTED
INTERNAL-GENERAL
Page 70 of 148
IPP FORMAT
Revision-02
DOC. NO. IMDM : QA : BP : FF : 04
PREP. BY CHKD. BY APPRD. BY SHEET 1/1 REV. NO. :-01
DATE : 01/04/09
INITIAL PRODUCTION PART TAG DATE REASON FOR I P P FLOW
PART NO. GR. NO./ DATE 1.DRAWING / SPECIFICATION CHANGE

PART NAME CH. NO./ DATE 2.QUALITY IMPROVEMENT
SUPPLIER
VENDOR ECN. NO./ DATE 3.NEW SUPPLIER / NEW LOCATION / NEW LINE /
MODEL QUANTITY 4.SUBVENDOR CHANGE / SUB VENDOR LOCATION
5.MATERIAL CHANGE / ALTERNATE MATERIAL
6.MANUFACTURING METHOD CHANGE
7.MANUFACTURING PROCESS SEQUENCE CHANGE:
RECEIPT STORE/
8.MACHINE CHANGE
MATERIALS
9.JIG / FIXTURE/ TOOL DESIGN CHANGE
10. DIE / MOULD CHANGE
12. PACKING CHANGE ( WITH OR WITHOUT QA BOP / INTERNAL
TRANSPORTATION METHOD CHANGE ) SUPP.
13. RESTART OF SUPPLIER & PARTS AFTER
DISCONTINUATION FOR TWELVE MONTHS
14. CHANGE IN MANPOWER AT CRITICAL STAGES
15. OFFLOADING BY TIER 1 AND TIER 2 SUPPLIERS
16. SAME LINE /JIGS/FIXTURES/DIES/SHIFTING TO
NEW LOCATION
PREPARED BY :
APPROVED BY :
ITEMS FOR INSPECTION DURING FITMENT

PPC
DEPARTMENT INSPECTION ITEM
1) PPC ENTER FRAME NO & ENGINE NO

MANUFACTURING
2) PRODUCTION WORK ABILITY CONFIRMATION & ASSY CONFIRMATION DEPTT.
3) FINAL INSP JUDGEMENT RESULT & FRAME NO/ENGINE NO CONFIRMATION.
INSPECTION DATE & TIME OF FEEDING PERSON INCHARGE IN SECTION HEAD PERSON IN CHARGE PPC SECTION HEAD FINAL
DATE TO LINE BY PPC PLANT /SQA MANUFACTURING INSP.
Page 71 of 148
Revision-02
FEEDBACK FORM
FRAME /ENGINE NOS. COMMENTS P
R
O
D
U
C
SIGNATURE
T
COMMENTS I
O
N
&
SIGNATURE
F
COMMENTS I
N
A
L
I
SIGNATURE
N
COMMENTS S
P
E
C
T
I
SIGNATURE
O
CONCLUSION BY SQA. / INPLANT N
Page 72 of 148
P LE
SAM
HMCL DHARUHERA
ENGG CHANGE / INDIGENISATION / NEW VENDOR

IMPLEMENTATION NOTE
From-PPC Date- 21/12/08
ECI NO. 08-31 ECN REF: N.A.
ECI DATE- 09/12/08 IPPT REF: 19/12/08
FRAME NO: MBLHA10EE89M14086 PART NO: 38110-KTC-9000
ENGINE NO HA10RA89M23229 QTY. 192 PCS
ON WARDS; VENDOR/SOURCE M/S. ADDON ENGG.
DETAILS OF CHANGE:
NEW SUPPLIER
CIRCULATION TO :
QC
SERVICE CENTER
R 'N' D
PUCHASE
COST ACCOUNTS
QC (RECEIPT)
MARKETING
SERVICE CENTRE
PURCHASE
SPD (HQ)
MOR CUSTOMER CARE
PREPARED BY : DY. MGR. AGM :

DOC NO. : IMDM:QA:BP:CF:16
QUALITY FLASH REPORT DATE :
REJ TYPE :
TO PART NAME PART NO MODEL
D
R GR. NO DATE LOT QTY INSP. QTY. DATE
PROBLEMS AREA DEF. QTY. DEFECT% PRELIMINARY ANALYSIS
ACTION ON DEFECTIVE LOT PROBLEM STATUS CREATED BY VALIDATED BY
ACTION PLAN TO BE SUBMITTED IN EITHER FIVE RULE SHEET OR ON WHY WHY ANALYSIS
REPORT OR THROUGH SUPPLIER PORTAL
ACTION PLAN
SL TYPE REASON COUNTER MEASURE
CONTER MEASURE RECEIVED : TARGET DATE FOR IMPLEMENT :
PROBLEM STATUS : BUYER CODE :
APPROVED BY : 000
REMARK :

DOC NO : IMAM: SP: 05: FF:01
CONDITIONAL ACCEPTANCE FORM REV NO : 00
Page No........of..........
Date :
Area: Details
a) Production Order No.:
Part / Activity Name : b) Production Date :
Identification / Part No. Gravity/Qty.
Deviation Detail
S. No. Description Spec. Observation / Actual
Trial Details:
Future Action:
Deviated By : Deviated for :

Qty :
Time :
Signature of HOD/Sec. Head
NOTE :
NOT APPLICABLE IN CASE OF SAFETY CRITICAL & PERFORMANCE RELATED

CHARACTERISTICS.
APPROVED PROPOSED
BY BY

Revision-02
IMDM : QA:BP:DOL:06
MANAGEMENT REVIEWS OUTCOME AGAINST HMCL'S QUALITY TARGETS & SYSTEM ISSUES
SUPPLIER :- MONTH:-
S.N. DASH BOARD TARGET FOR ACTUAL FUTURE COURSE OF ACTION TARGET
PARA METERS FY........ DATE
FY.. FY.. FY.. APR. MAY JUN QYR.-1 JUL. AUG. SEP. QTR.2
MARKET CLAIMS PPM

1
0-90 DAYS
CARRY-IN-DEFECT PPM
2
FOR BOUGHT OUT FINISHED PARTS
3 BOSF PPM
4 BOP PPM
5 SUPPLIER'S AUDITS RATING

>=8.0
SYSTEM AUDIT SHEET
6 HMCL AUDITS RATING

>=8.0
SYSTEM AUDIT SHEET
7 NO. OF QFR'S RAISED /CLOSED RAISED/CLOSURE

STATUS
8 VENDOR QUALITY RATING >75%
MANAGEMENT RELATED ISSUES NEEDED TO BE

9 1) INFRASTRUCTURE RELATED
(e>G EQUIPMENT, TEST FACILITIES, ACCOMPLSHED
FREQUENT CHANGE OF MANPOWER
ETC.
2) IPPT VIOLATION
Page 76 of 148
Annexure-9
Problem Solving Process
STEP 1: GENERATE A LIST OF PROBLEMS
By brainstorming create a list of problems (customer concerns or internal concerns i.e.

defects/rejections/reworks).
While identifying the problems, focus on customer raised issues or 3Ms (Muda/ Mura / Muri) or
Seven Wastes within the organization (Motion, Over production, Storage, Transportation,
Correction, Over processing, Waiting) or 4-Ms Man, Machine, Method, Material
STEP 2: SELECTION OF PROBLEM: (SPECIFYING THE TITLE)
a. Categorize Problems into'A"B'or'C

'A' Category: Warranty / field failure.
'B' Category: Defects /rejections (BOP/BOSF/CID) at HMCL
'C' Category: Defects/ Rejections / Rework at Suppliers end.
b. Use Pareto Analysis or Rating Method (based on some criteria i.e. Customer Satisfaction,
Manpower, Urgency, Safety, Time, Rejection / Cost, Quality, Delivery, Productivity) for
selection of problem.
Use a Road Map to plan the time required for the activities before starting, and to work within a time
bound frame.
Road Map
PROJECT:
NO. ACTIVITY WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TARGET ACTUAL
1 DEFINING THE PROBLEM
2 ANALYSING THE PROBLEM
3 IDENTIFYING THE CAUSES
4 FINDING OUT THE ROOT CAUSES
5 DATA ANALYSIS
6 DEVELOPING SOLUTION
7 FORESEEING POSSIBLE
RESISTENCE
8
TRIAL IMPLEMENTATION AND
CHECKING PERFORMANCE
9 REGULAR IMPLEMENTATION
10 FOLLOW-UP/REVIEW

STEP 3 : DEFINE THE PROBLEM (OCCURRENCE CONDITIONS)
Problem definition is explaining where the problem occurs, conditions prevailing at that time and
what are the difficulties and losses incurred in a general way.
Even though team members are from the same organisation it does not mean that all have clarity
about the problem selected. So it is necessary to define the problem.
First study the 'affected objects' against 'normal' & understand the differences. Next, by using a
'Flow Diagram' study the entire process related to that product considering the problem spots in
terms of occurrence & detection.
Use of flow diagram helps in having clarity of the problem by all members. There may be some
members who are not familiar with the entire process.
What Which process is involved?

What is wrong?
What is the gap or opportunity ?
How Big How big is the problem /gap /opportunity?
How will we measure it?
Impact What is the impact of the problem/ opportunity?
What are the benefits of action / consequences of inaction?
A comparison of the process 'as is' vs 'desired' may be done;
Deviations and differences need to be understood properly. ;
Use 4W 2H technique regarding details:
WHAT: What is the problem or NC or deviation from standard?
WHERE: Where in the Process or Operations or Object the problem is Observed or Detected?
WHEN: Since when is the problem observed or detected or known to exist? When is it seen to Occur
or gets Detected?
WHO: In whose area of work or process or operations the problem is Observed or Detected?
HOW: How the problem is seen to occur or gets detected? The conditions at that time.
HOW MUCH: Extent or Severity or Size of the problem's Occurrence or Detected conditions
STEP 4: ANALYSE THE PROBLEM (UNDERSTANDING FACTS OF ACTUAL

SITUATIONS)
Analysis calls for Data Collection on all possible aspects of the problem i.e. number of times the
problem occurred, effect of the problem in detail and data on the losses etc. With the help of the

Facilitator members collect the data and carry out analysis. So learning data collection and
categorizing them or stratifying them becomes an important activity here. Analysis is very essential
because there may be certain dimensions of the problems which are not understood by all. A
discussion will help in pooling up ideas.
Decide on Interim Action / Containment

• Simply conforming to given standards can help
• Temporary action to contain the problem and'fix'on short-term basis.
• Effective date.
STEP 5: IDENTIFICATION OF CAUSES (UNDERSTANDING FACTS OF ACTUAL

SITUATIONS-CAUSES ANALYSIS)
Since problem is in the work area of the team members they know the seriousness of it and also have
an idea or reason for this problem. The problem is persisting; either because no serious effort was
made to address it or they were not involved or only rectification kind of actions were taken, (no
corrective and preventive actions). Many times the solution is eluding them and they are unable to
pin point the actual cause. A close observation of the operations as the process is. going on, and
recording them would be helpful at this stage.
One important point to be remembered is that problems have multiple causes (variables). There are
variations occurring and some of them could be contributing to the problem. Before an analysis is
carried out it is necessary to find out the possible causes. They need to be collected and put in an
orderly manner for better understanding. The Cause and Effect Diagram helps in organizing them
for further study. Such an attempt will give clarity and will help to be cautious when some other
cause creeps in at a later date. All causes are expressed verbally.
STEP 6 : FINDING OUT THE ROOT CAUSES (ROOT CAUSE INVESTIGATION)

Ensure Root Cause Analysis (RCA) process:
• Takes advantage of team members' knowledge while preventing their biases from
controlling or misdirecting the course of investigation
• Shows evidence-based causal relationships between the primary effect and the root causes
and relevance of those facts can be verified
• Would help the team and the management understand what actions are to be taken to try out
the required solutions subsequently and who all in the organization need to take those
actions.
STEP 7: DATA ANALYSIS TO ESTABLISH ROOT CAUSES (ROOT CAUSE

INVESTIGATION)
Root cause has to be established with the help of data. In case, for any reason, it is not possible to
collect data it may be established based on experience. But experience has also to be quantified.

Analysis may call for further floor exercise, work area follow up and study or simulations. Teams
may use Histogram, Stratification, and Scatter Diagram etc. which would help easy comprehension
and make comparison possible for decisions.
The Five-Why method is inappropriate for any complicated problem, but quite useful when done for
small / minor problems that require some basic discussion of the occurrence to lead to causal
relationships. But again evidence has to be produced.
System level deficiencies also may be identified for the problem.
STEP 8: DEVELOPING SOLUTIONS (APPROPRIATE COUNTER MEASURES)

Once causes are confirmed the next step is to find appropriate solutions & make choice. As each root
cause may have different solutions members should select the best one based on some defined &
agreed criteria viz. Control, Appropriateness, Resource Availability, Time, Return on Investment
and Acceptability.
The solutions need to be preferably preventive oriented rather than corrective only and not consist of
just rectification measures.
While developing solutions to root causes, the members may use a tehnique called counter measure
matrix or an action plan which shows time bound and responsibility shared activity (suggested
below).
Such an action plan schedule is found to be very useful in involving every member of the team and
also for proper follow-up. The members may not be able to carry out every action as planned due to
many unavoidable reasons. However, the planned dates help them as a reminder to minimize the
wastage of time.
s. Root CMs/ Comp. Actual Results Remarks

Respon-
-
Causes Solutions, Date Comp.

No sibility
Action Plan planned Date
ACTION PLAN FOR DEPLOYING SOLUTION
STEP 9: FORESEEING THE PROBABLE RESISTANCE (POTENTIAL PROBLEM

ANALYSIS)
With the help of brainstorming identify the probable constraints or potential problems and
finding counter measures to overcome them. Make a presentation to all involved with the
solutions & contingencies & counter measures, (i.e. Dept. Head, Facilitator, other officials, and non

members involved with the implementation). Discuss and evaluate effectiveness of these and also a
system for implementation.
STEP 10: TRIAL IMPLEMENTATION & CHECK PERFORMANCE (CONFIRMATION
OF EFFECTIVENESS AND MEASURES)
Implement the solution on a trial basis and check performance. Collect data after implementation &
compare with the 'before' information. Collect fresh data, use control chart or any other method to
study process trends. Analyse the result, discuss and incorporate the changes needed. Do keep a
record of information for future reference.
STEP 11: REGULAR IMPLEMENTATION (CONFIRMATION OF EFFECTIVENESS)

Once validity of solution is checked and improvement observed with data, regular implementation
can be effected. Incorporate the changes in the working system (SOP) or work instruction sheets &
other relevant documents for standardization. Here too team must make a plan for regular
implementation using 4W 1H and ensure that actions are taken accordingly. Keep a track, compare
with data collected at steps 2,3 & 4.
Establish & satisfy that the process is capable of running with the changes made, to meet the
requirements. Study the tangible and intangible benefits.
STEP 12: FOLLOW UP/REVIEW (FEEDBACK TO THE SOURCE)

Implement an evaluation procedure and look for need for any change to be made.
Incorporate the changes in the working system (SOP) or work instruction sheets & other relevant
documents for standardization. Use Data Collection or Control Charts. Have periodic evaluation
reports. Complete the Activity Planning Chart (road map) with actual time spent & compare against
plan & reasons for deviations.
Reflect on the lessons learnt during the proj ect work & use it for the future.

Revision-02
DOC NO. : IMAM : SP:06.FF:01
SUPPLIER / IN-PLANT QUALITY PROBLEM ANALYSIS AND COUNTERMEASURE SHEET (5-RULE) REV NO. : 00
PROBLEM NO. PRODN. QA MGR. PREPARED

VENDOR /DEPTT: PART NAME: DATE
MGR. BY
PROBLEM PART NO. :
ACTUAL CONTENT ACTUAL INVESTIGATION (PRODN. END - MACHINE / METHOD / MATERIAL / JIG / EQUIPMENT)
PLACE OF OCCURENCE PROCESS RESULT ANALYSIS

MODEL: RANK MAN MACHINE FLOW
SAFETY/
REJ. QTY.:
PERFOR-
MANCE/
FIT FUNC-
OTHERS
TION
DETAIL OF PROBLEM (DATA/SKETCH)
MATERIAL METHOD
ROOT CAUSE COUNTERMEASURE DETAIL RESP. IMPL. DATE OBSERVATION / EFFECTIVENESS (GRAPH/Cp)
(SKETCH/DATA/DETAIL) CORRECTIVE ACTION:
PREVENTIVE ACTION:
WHY-WHY ANALYSIS: MONITORING SHEET (REOCCURANCE OF DEFECT) (QTY/GRAPH) FEED BACK TO OTHER
PROBLEM PROCESS (IF SAME TYPE
I II III IV 1 MONTH II MONTH III MONTH IV MONTH V MONTH VI MONTH REMARKS
PROBLEM)
Page 82 of 148
Hero Ist QAV Dtd.
Motorcorp
Sheet 1 of 1
Revision-02
MODEL: VENDOR : PART NAME
Memb HMCL Recorded by
VENDOR PP1 PP3 M.P.
S.No. Check Point Observation Future action plan Resp. Target Judge- Remarks
ment (o, x)
1 Development "Go"
2 Drawing / data Ecn. No.

3 Volumes Clarity
4 Status / Progress
-Raw material Procurement & source of all parts

- Die Design
-Process Flow / Sheets
-Gauge planning (inproccess/ final) and verification

5 Die Readiness / Dev. Plan
6 Die Life Finalization
7(a) No of Toolings Planned
7(b) Actual toolings required @.......Nos/day.

8 Inplant vs. outsourcing to process
9 Drawing / data clarifications
10 Schedule for submission of Critical parameters chekcsheets

& detailed checksheet for all
parameters, as per HMCL latest drg.
11 Communication of function of part

/distribution of critical parameter check Sheet to vendor
12 Schedule for preparedness of inprocess
jigs, fixtures.machines and process and its verifications
13 Existing model problems in similar part discussion
14 Preparedness of PQCS / FMEA & its submission schedule (Soft copy to be submitted to email id :
R&D: QA:
15 Dedicated Team' allocation for project & window person
16 Sample Submisstion Schedule
17 Material handling /packing planning from vendor end to HMCL
18 Internal review mechanism and progress reporting
19 Support required from HMCL, If any
20 Other
Page 83 of 148
Revision-02
Hero IInd QAV Check Sheet Dtd.
Motorcorp
Sheet 1 of 1
Members HMCL Recorded by
VENDOR PP1 PP3 M.P.
ment (o, x)
Status of QAV-1 pending points
-Drg Clarifications/Desing Related Querries
-Process flow sheets
-FMEA/PQCS
-Gauge Planning (bop/inprocess/final)
1 -Sample Submission Plan S. Component Previous Revised Reason S. Component Previous Revised Reason
No. Date Date For Delay No. Date Date For Delay
-Any Other Point

2 Drawing/Data ECN No
3 Any New ECN Expected from HMCL
4 HMCL Revised Volumes/Capacity planning verification
5(a) No of toolings planned
5(b) Actual toolings required @.....nos./day
6 Tools/Process permanent or not (for PP1)
7 Inplant vs. outsourcing of processes
8 Current Status/Progress:
-Dies
-Jigs/Fixtures/machines (Status, Availability & Approval Report)
-Exclusive equipments/Rigs/Facilities (Status & Availability)
9 -Inspection Gauges (Status, Availability & Approval Report and Actual
function vertification by HMCL)
10 Verification and approval of PFEMA and Process control plan
11 Process design validation
12 Verification of Equipments, Jigs/fixtures from process capability point of view
and from the point of view of in-plant manufacturing processes at HMCL
13 HMCL Sample report discussion (if submitted and checked at HMCL)
14 Availability of OK samples for PP1 trial along with vendor report (dimn,
raw matl., perf.)
15 Process constraint (qty. rejected during sample lot mfg. and reason of rej.)
16 Readiness of work standards
17 Support required from HMCL, if any
18 QAV 3 Plan
19 Other points, if any
Page 84 of 148
Dtd.
Hero IIIrd QAV Check Sheet
Motorcorp
Revision-02
Sheet 1 of 1
HMCL : Recorded by
Members
VENDOR : T1 PP3 M.P.
ment (o, x)
Drawing/Data ECN No. (Clarification pending-if any)
Verification and approval of PFMEA and Process control plan
Readiness of work standards
1 Process design Validation
T1 Samples tooled up or not
-Gauges (dop/inprocess/final) Concept verification & Present status
-Any Other Point
2 HMCL Revised Volumes/Capacity planning verification

3 Tool/Machine/Guage sufficiency as per revised volume.
4 Tools/Process permanent or not (for T1)
5 Tools/Process as per control plan or not
6 -Exclusive equipments/Rigs/Facilities (Status & Availability)
7 -Jigs/Fixtures (Status, Availability & Approval Report)
8 -Inspection Gauges (Status, Availability & Approval Report and

Actual function verification by HMCL)
9 HMCL Sample report discussion (if submitted and checked at HMCL)
10 Availability of OK samples for T1 trial along with vendor report

(dimn, raw mati, perf.)
11 Process constraint (qty. rejected during sample lot mfg. and reason of rej.)
12 Retainment of T1 samples by vendor for reference
Page 85 of 148
Revision-02
Hero Dtd.
IV th QAV Check Sheet
Motorcorp Sheet 1 of 1
HMCL : Recorded by
Members
Judge- Remarks
S.No. Check Point Observation Future action plan Resp. Target
ment (o, x)
- Verification and approval of PFMEA and Process control plan/PQCS

Revised PFMEA and Process control plan/PQCS date

Process constraint (qty. rejected during sample lot mfg. and reason of rej.)
- Inspection Gauges (Status, Availability & Approval Report and Actual function
verification by HMCL)
- Any Other Point
2 Revision of check points based upon T1 problems, assy and critical gaps
3 Modification of gauges based upon T1 problems, assy and critical gaps
4 Status of lmplemetation of all c/m of T1 and testing Hinanhyo
5 Evaluation of endurance/performance testing results (especially all proprietry parts)
6 Qty produced in front of HMCL team and next lot production schedule
7 Process capability status of all critical parameters
8 Process qualification of critical processes in front of HMCL team
9 Process as per control plan or not
10 Modifications required in control plan
11 Rejections observed in lot mfg., reason of rejection and action plan
12 Sufficiency verification at vendor end
13 Process tack time as per Mass Production conditions or not
14 Operator training status at critical stations
15 Packing approval at vendor end
16 Part identification and traceability status at all stations
17 Sufficiency verification at vendor end
18 Limit Samples to be freezed (wherever required)
Page 86 of 148
Hero Dtd.
V th QAV Check Sheet
Motorcorp Sheet 1 of 1
Revision-02
HMCL : Recorded by
Members
Judge- Remarks
S.No. Check Point Observation Future action plan Resp. Target
ment (o, x)
- Verification and approval of PFMEA and Process control plan/PQCS

Revised PFMEA and Process control plan/PQCS date

Process constraint (qty. rejected during sample lot mfg. and reason of rej.)
- Inspection Gauges (Status, Availability & Approval Report and Actual function
verification by HMCL)
Other Point, if any
2 Revision of check points based upon PPI problems, assy Pressent status of
revised check point based upon TI problems, assy and critical gap
3 Present status of Modification of gauges based upon T1 problems, assy and
critical gaps/any other modification based upon PP1 problems
4 Status of lmplemetation of all c/m of PPI and testing Hinanhyo
5 Evaluation of endurance/performance testing results (especially all proprietry parts)
6 Qty produced in front of HMCL team and next lot production schedule
7 Process capability status of all critical parameters
8 Process qualification of critical processes in front of HMCL team
9 Process as per control plan or not
10 Rejections observed in lot mfg., reason of rejection and action plan
11 Final mass production PFMEA/Control plan/PQCS and Approval of HMCL team
12 Process tack time as per Mass Production conditions or not
13 Operator training status at critical stations
14 Packing approval at vendor end
15 Part identification and traceability status at all stations
16 Limit Samples to be freezed (wherever required)
17 Sub vendor preparedness status
18 Firming up ramp up plan/maker capacities to supply maximum/day.
Page 87 of 148
ANNEXURE 15
HMCL’S SUPPLIERS’ QUALITY

APPROVAL SYSTEM

Revision-02
SUPPLIERS’ QUALITY APPROVAL SYSTEM
4M EVALUATION FORMAT
INTERNAL LINE TRIALS & RECORDING OF 4M
CONDITIONS AND CONFIRMATION
SUPPLIER’S BY SUPPLIER TO HMCL SAMPLES SUBMISSION TO HMCL
FOR TESTING
T1 EVENT (WHEREVER APPLICABLE)
(HINANYO IDENTIFICATION & CORRECTION

DURING SMALL LOTS PRODUCTION
ADHERENING TO 4M CONDITIONS
AS DEFINED IN PQCS)
SUPPLIER’S PP1 HINANYO CORRECTION
PP1 EVENT PLAN
PROCESS / EQUIPMENT / QUALITY
SYSTEM IMPROVEMENT & TRAINING
TO OPERATORS BY SUPPLIER IMPLEMENTATION OF C/M AT
SUPPLIER END
NG
SELF
EVALUATION BY
SUPPLER ON
PRODUCT, PROCESS
& SYSTEM
BY SUPPLIER OK
THROUGH
E1
E1 EVALAUTION QAV 2 & PRODUCT
MFG. SYSTEM SYSTEM AUDIT
EVALUATION SHEET HMCL
PROCESS
SYSTEM
BY PROCESS OWNER (HMCL)
Page 89 of 148
Revision-02
SUPPLIERS’ QUALITY APPROVAL SYSTEM
HINANIYO IDENTIFICATION DURING RAMP
UPTO MASS PRODUCTION LOT SIZE USING
MASS PRODUCTION CONDITIONS
HINANYO CORRECTION
SELF EVALUATION OF ESTABLISHED C/M IMPLEMENTATION AT

SUPPLIER’S QUALITY UNDER MASS PROD. SUPPLIER END
CONDITION (AT REQD. TACT TIME)
PRE MASS
PRODUCTION PROCESS CAPABLILITY
VERIFICATION
TRIALS NG SELF
EVALUATION
BY
SUPPLER
FINALIZATION OF
PQCS & QUALITY
OK STANDARDS
BY SUPPLIER
PRODUCT
PRE-E2 HINANIYO
HMCL’S NG PROCESS CLOSURE
HMCL VERIFICATION
PRE E2 EVALUATION
SYSTEM
OK
BY HMCL MIDDLE MANAGEMENT
E2
E2
HMCL’S
EVALAUTION TOP MGMT. PLANT
PLANT AUDIT AT SUPPLIER APPROVAL
END (PLANT APPROVAL) AUDIT
APPROVAL SHEET
BY TOP MGMT (HMCL)
Page 90 of 148
Revision-02
QUALITY ESTABLISHMENT PLAN
HINANIYO CORRECTION (PROCESS/MFG, EQUIPMENT)
QUALITY SYSTEM IMPLEMENTATION AND TRAINING TO OPERATOR
T1 PP 1
DAY 10
DAY 8 DAY 9
SMALL LOT
DAY 7 PRODUCTION
DAY 5 DAY 6 N = 100* *MINIMUM
DAY 4 SMALL LOT QTY
PRODUCTION
DAY 1 DAY 2 DAY 3 SMALL LOT N = 75*
PRODUCTION E1
LINE TRIAL SMALL LOT N = 50*
N = 25* PRODUCTION N = 25*
LINE TRIAL SMALL LOT PRODUCTION PLAN

AT SUPPLIER END BEFORE PP1 EVALUATION OF
ADEQUACY OF 4M AT PP1
STAGE (3-4 DAYS)
TOTAL 15 WORKING DAYS
BEFORE MP PROCESS/MFG. EQUIPMENT/QUALITY SYSTEM

DAY 20
VERIFICATION AND TRAINING TO OPERATOR
DAY 18, 19 SMALL

DAY 8 & 9 DAY 10, 11 DAY 12, 13 DAY 14, 15 DAY 16, 17
LOT
PRODUCTION
PP1 N = 300 /
HINANIYO DAY *
CORRECTION
& SMALL SMALL SMALL
VERIFICATION LOT LOT LOT
PRODUCTION PRODUCTION PRODUCTION E2
N = 100 / N = 150 / N = 200 /
DAY * DAY * DAY *
DAY 1 TO DAY 7 CONFIRMATION

MASS PRODUCTION
OF ADEQUACY OF
4M AT MP
STAGE (3-4 DAYS)
SMALL LOT PRODUCTION PLAN
AT SUPPLIER END BEFORE MP
TOTAL 25 WORKING DAYS
Page 91 of 148
Revision-02
PRODUCT EVALUATION CRITERIA
s. VERIFICATION ITEM CRITERIA METHOD
NO
1 DIMENSIONAL CONFORMANCE TO CHECK INSPECTION OF PARTS AS PER . INSPN.

STATUS SHEET & DRAWING STANDARDS (APPROVED BY HMCL)
2 AESTHETIC & MATCHING WITH LIMIT VISUAL ASSESSMENT
FITMENT STATUS SAMPLE / MATCHING PART
3 MATERIAL TESTING RAW MATERIAL SOURCE, LAB INSPECTION STANDARDS, / UTM

CONFORMANCE TO HARDNESS TESTER / SST
STANDARD.
4 PERFORMANCE CONFORMANCE TO PERFORMANCE TEST STANDARDS,
TESTING STANDARDS TEST RIG.
5 LIMIT SAMPLE AVAILABILITY & HMCL VERIFICATION
APPROVAL
6 MASTERSAMPLE PROCESSWISE VERIFICATION
AVAILABILITY & HMCL
APPROVAL
7 ENDURANCE TESTING CONFORMANCE TO ENDURANCE STDS. TEST RIG / DY NO.
STANDARDS VEHICLE TESTING
8 IDENTIFICATION FOR PROVISION OF A SUITABLY VISUAL ASSESSMENT
TRACEABILITY LOCATED IDENTIFICATION
MARK DESIGNATING NEW
LOCATION
MANUFACTURING
9 PACKING & HMCL APPROVED PACKING VISUAL ASSESSMENT / LOGISTIC
TRANSPORTATION TRIALS
10 HINANYOS CLOSURE OF HINANYOS C/M VERIFICATION
Page 92 of 148
Page 93 of 122Revisi
PROCESS EVALUATION CRITERIA
Revision-02
S. VERIFICATION ITEM CRITERIA METHOD
NO
-
1 PQCS •PROCESS CONTROL POINTS ADEQUACY DOCUMENT
•QUALITY CHARACTERISTICS ADEQUACY ASSESSMENT
•DULY APPROVED BY HMCL
R/M , BOP & OFFLOADED PROCESS LIST PROCESS AUDIT
AS PER PQCS ON
ADHERENCE TO PQCS QUALITY CHECKS &
QAV2 FORMAT
MANUFACTURING CONDITIONS
la INPROCESS INSPN. ADEQUACY OF CTQ PARAMETERS (PRODUCT &
PLAN / CHECK SHEET PROCESS ) & ADHERENCE TO THEM
DEPLOYMENT OF ACTIONS OF PAST PROBLEMS
AS PER PFMEA
lb FINAL INSPECTION ADHERENCE TO INSPECTION METHODS (INSPN.
PLAN (DULY APPROVED BY HMCL ) / USE OF
RIGHT INSTRUMENTS /GAUGES)
STRAIGHT PASS MONITORING & ACTIONS TO
ACHIEVE MIN 90%
lc PDI STAGE ADHERENCE TO INSPECTION FREQUENCY
ADHERENCE TO INSPECTION METHODS (INSPN.
PLAN (DULY APPROVED BY HMCL) / USE OF
RIGHT INSTRUMENTS /GAUGES)
4 VARIATION IN PROCESS CAPABILITY > 1.67 FOR CRITICAL PROCESS
CRITICAL PARAMETERS , USAGE OF NOT MORE THAN 80% CAPABILITY
DIMENSIONS OF TOLERANCE REPORT
5 SPECIAL PROCESSES PRODUCT VARIABILITY & STRAIGHT PASS OF PROCESS
QUALIFICATION PRODUCT ON STANDARD PROCESS PARAMETERS QUALIFICATION
REPORT
Page 93 of 148
Revision-02
SYSTEM EVALUATION CRITERIA
S. NO VERIFICATION ITEM CRITERIA METHOD
1 MAN POWER AVAILABILITY & ORGANIZATION STRUCTURE EVALUATION

TRAINING
2 OPERATOR SKILL OPERATOR TRAINING AT SKILL MATRIX

CRITICAL PROCESSES OPERATOR EVALUATION BASED ON :
?NON CONFORMITY LEVEL AT M.P. TACT TIME
?RECORDING OF M/C CHK SHEETS
?FIRST OFF & INPROCESS INSPN RECORDING
?RECORDING OF PROCESS PARAMETERS
3 MATERIAL HANDLING EQUIPMENT SUFFICIENCY AVAILABILITY STATUS VERIFICATION

MAINTENANCE SYSTEM ADHERENCE TO MAINTENANCE PLAN
4 DEAILS OF CHECKING SUFFICIENCY AVAILABILITY STATUS
INSTRUMENTS / GAUGES / TESTING
EQUIPMENT NEW INSTRUMENT CALIBRATION CALIBRATION REPORT
CALIBRATION SYSTEM ADHERENCE TO SCHEDULE (PLAN VS ACTUAL)
5 DETAILS OF MACHINES SUFFICIENCY INSTALLATION STATUS , AS PER LAYOUT (LINE)
ADEQUACY IF PROCESS CAPABILITY <1.67, STUDY OF M/C

CAPABILITY REQD.
MAINTENANCE ADHERENCE TO PREVENTIVE MAINTAINENCE
SCHEDULE
Page 94 of 148
SYSTEM EVALUATION CRITERIA
Revision-02
S. NO VERIFICATION ITEM CRITERIA METHOD
6 DETAILS OF DIES / MOULDS / SUFFICIENCY & ADEQUACY AVAILABILITY STATUS REPORT

FIXTURES VERIFICATION
INITIAL VALIDATION VERIFICATION OF VALIDATION
REPORTS
VALIDATION SYSTEM ADHERENCE TO VALIDATION
SCHEDULE (PLAN VS ACTUAL)
7 BOP PARTS INSPECTION FACILITY SUFFICIENCY & ADEQUACY VERIFICATION OF AVAILABILITY &
USAGE
8 LAB INSPECTION FACILITY SUFFICIENCY & ADEQUACY VERIFICATION OF AVAILABILITY &

USAGE
Page 95 of 148
Revision-02
QUALITY ORGANISATION STUCTURE
QUALITY CUSTODIAN
PROCESS SUPPLIER SYSTEM PDI &

QUALITY +QUALITY CUSTOMER CARE
(Q.A + F.INSP)
ASSURANCE PLANNING
LINE PART SYSTEM CUSTOMER CARE

SUPPLIER
SUPERVISORS INSPECTION AUDIT CELL REPRESENTTIVE
PROCESS /
&
SYSTEM
PDI INCHARGE
AUDIT
L1 L2 L3 -----------------------------------------------------------------------
Page 96 of 148
Revision-02
FOCUS REQUIRED FROM SUPPLIERS DURING APPROVAL
a) REGULAR COMMUNICATION TO HMCL'S TEAM (Q.A, R&D & MATLS.) REGARDING
ADHERENCE TO PLAN
b) DAILY STRAIGHT PASS AND TACT TIME MONITORING & COMMUNICATION TO HMCL'S
PROCESS OWNER FOR INITIAL 03 MONTHS THROUGH E-MAIL.
c) STRICT ADHERENCE TO IPPT SYSTEM AND COMMUNCIATION TO HMCL REGARDING ANY
CHANGE IN CONDITION.
d) SUPPLIER TO FURNISH CLOSURE OF PREVIOUS EVALUATION FINDINGS PRIOR TO
SUBSEQUENT EVALUATION.
e) SUPPLIER SHOULD REVIEW THEIR PLANT PROGRESS REPORT AS PER SET FREQUENCY
WITH HMCL
Page 97 of 148
HMCL's SYSTEM AUDIT CHECK SHEET
Revision-02
Focused critical Parts having High Rework / Rejection / Newly added part :-
Supplier Name : Date:-
Auditee Name Deptt / Designation：
Auditor Name Deptt / Designation：
Observations :- O b s e rv a tio n s :-
SL.
OPERATION CATEGOR MARKS
VERIFICATION POINTS Rating OBSERVATION
NO. CHECK POINT Y OBTAINED
Is the Plant and Q.A Organization Structure required Vs Actual defined. 0 0.5 1
Are the Roles & Responsibilities of the individuals defined ?. 0 1 2
Does the organization structure review mechanism exist & is up graded w.r.t Ramp-up in
0 1 2
production?.
1 ORGANIZATION STRUCTURE A Does the Organization have the Contigency to ensure Quality Management System, In case of
0 1 2
absentism and attrition?
How effectively has the organization dealt with IR issues ( if any ) in the recent past ? 0 1 2
Does the organization have any policy for monitoring & maintaining the ratio of Temporary /
0 1 2
Confirmed employees ?
Are the products / In Process drawings available at respective stages & requirements ( Stated /
0 1.5 3
implied) known to the concerned ?
DRAWING & STANDARDS (LATEST
Is the acceptance criteria developed & understood ? 0 1 2
2 B Is there any formal review mechanism, with HMCL buyer, available to ensure availability of latest
ECN ) 0 1 2
ECN?.
Are the Dimensional, Performance, Raw material ,Surface Treatment, Special Processes etc.
0 1 2
related Standards available as per drawing
Is the PQCS ( Control plans including process flow diagram, details of parts / raw material
purchased from outside vendor& off loaded processes ) developed, frozen for mass production & 0 1 2
approved by HMCL ?
Are the amendments communicated to HMCL in line with Supplier Quality Manual? 0 1 2
PQCS/PFMEA (ADEQUACY,
Are the Critical processes identified and Reviewed?
3 0 1.5 3
ADHERENCE & CONTROLS) A Are the CTQs addressed through increased inspection frequency in PQCS?
Are the linkages with Works Standards, Sops,M/c Check Sheet, Jig & Fixture Maintenance
0 1 2
sheet, Tool / Dies History cards available in PQCS
Is the PFMEA made & communicated to HMCL?
Is PFMEA reviewe mechanism available w.r.t HMCL problems (cid, wty. related) & in house 0 1 2
problems.?
Is the I.P.P standard & format available. ( Clarity & its applicable scope) 0 0.5 1
Are records for I.P.P document & its monitoring available 0 0.5 1
Are the employees aware of IPPT system & is the system adhered to for traceability and
INITIAL PRODUCTION PART TAG 0 1.5 3
4 SYSTEM (AWARENESS & identification ?
A Is there I.P.P rule between supplier & tier 2 supplier and in use ? 0 1 2
ADHERENCE)
Is operator able to explain regarding IPPT?. (Interview the operator or team leader) 0 1 2
Is the Product Approval done by HMCL before IPPT submission and amended PQCS endorsed
0 1 2
by HMCL?.
Is Inspection Standard,Sampling Plan & Non conformance addressal to control Incoming
0 1 2
Material Quality available & adhered?
Are the controls like PQCS , IPPT, QAV-2 , customer problems resolution procedure defined &
TIER II SUPPLIERS CONTROL frozen with supplier ? 0 1 2
5 (OUTSOURCED & OFF-LOADED B Are the Tier 2 and Tier 3 suppliers audits structured or based upon non coformities ?
PARTS / PROCESSES)
Is recording in QAV-2 report and confirmation of permanent countermeasures available? 0 1 2
Does the Tier 1 Supplier monitor the performance of Tier 2 Suppliers w.r.t Quality and Delivery
0 1.5 3
and ensure actions against Low Performers ?
Page 98 of 148
SL. OPERATION CATEGOR MARKS
NO. Y
Revision-02
CHECK POINT OBTAINED
Is the APQP/ PPAP system followed and simulated as per mass production conditions? 0 1.5 3
Does management understand the purpose/requirement of the Early Production Controls &
APQP / PPAP APPLICATION FOR NEW
6 B Check(EPC) process? (e.g- 100 % inspection of CTQ s,Inspection by Operator as well as by 0 1.5 3
MODEL DEVELOPMENT
Quality inspector also, Quality Gates etc.)
Is there any new model development under EPC in process , and is concerned defect data
0 1.5 3
captured ?
Does the company have a design change system ensuring control monitoring and reviews for
DESIGN CHANGE SYSTEM FOR
Electrical & Proprietary Parts ,Jigs & Fixture ,Process and Receiver Gauges, Trolleys & Bins 0 1.5 3
TOOLS / DIES / MOULD / JIGS &
7 B Etc.)
FIXTURE /PROCESS & RECEIVER
GAUGE ETC Are the changes communicated across all functions? 0 1.5 3
Are Changes also being communicated to customer? 0 1.5 3
Is the schedule for product layout inspection available & adhered in consensus with HMCL?
(dimensional , metallurgical ,performance & endurance including Bops considering number of 0 1.5 3
PRODUCT LAYOUT INSPECTION
cavities,moulds,dies,fixture and the child parts.
8 (RAW MATERIAL TILL FINISHED B
PRODUCT) Are the inspection reports sent to HMCL periodically as per schedule, and the actions for
0 1.5 3
variances addressed ( once in 3 months) ?
Are the variances noticed ,addressed in the new tooling while going for duplication? 0 1.5 3
Is there any system to demonstrate customer satisfaction? (Response Time, Information to
0 1.5 3
operator, Display on shop floor etc.)?
Is there any review mechanism available to ensure defect free supplies in subsequent lots? 0 1.5 3
9 CUSTOMER SATISFACTION B
Is key manufacturing information, including Quality Issues, customer returns, current Controls
0 1.5 3
& Checks communicated, displayed, shared with the entire organization, including operators?
Is the internal audit planned and execution done in actual? 0 1 2
Are Product / Process Audits (QAV-2) conducted as per HMCL S PQCS Contents, once a
INTERNAL AUDIT RECORDS & Month (One Product at-least a Month covering high Volume models as well as higher CC model 0 1 2
COUNTERMEASURES EXECUTION AS
parts)
10 PER HMCL CHECK SHEET , B
INCLUDING CONSOLIDATED Are the summary of findings and countermeasures execution in place and sent to HMCL
0 1 2
SUMMARY monthly?
Are they reviewed as per target dates? 0 0.5 1
Is the 5S maintained and is audited in internal audit ? 0 1 2
Is there an action plan for NCRs and communicated across relevant functions.? 0 1.5 3
HMCL AUDIT FINDINGS , ACTIONS
Are the corrective actions being monitored ? 0 1.5 3
11 &COUNTERMEASURES EXECUTION B
WITH CONSOLIDATED SUMMARY Is the summary of findings, actions & C/Ms updated & discussed during management Reviews ? 0 1.5 3
Are the management reviews (internal / with HMCL) regular ? 0 1.5 3

Is the road map made & discussed with HMCL to achieve HMCL targets ?
MANAGEMENT S PERIODICAL Does the supplier s current performance indicators trend meet the customer specific 0 1.5 3
12 REVIEW AGAINST HMCL S QUALITY A requirements w.rt Quality & Delivery ?
TARGETS Does the supplier consider other customers performance measures , as a benchmark , to
0 1.5 3
achieve HMCL s targets ?
Are the relevant documents against the DOL qualification criteria /Quality Targets discussed
0 1 2
with HMCL periodically?
Is the Organization aligned w.r.t HMCL Quality Policy,Business Plan,Annual Targets and are
0 1 2
Periodic Reviews conducted by Mgmt. ?
Does the Management ensure & adhere the HMCL s Mass production conditions during New
0 1 2
Product Development?
Does the Management ensure the compliance against PQCS & IPPT? 0 1 2
TOP MANAGEMENT INVOLVEMENT &
Does the supplier take actions to stop undesired activities like QFR,DFR ,Segregation & Rework
13 FOCUS TOWARDS PREVENTIVE A 0 0.5 1
APPROACH
at HMCL ?
Does the organization benchmark with similar business focused (Local / Global) organizations
0 0.5 1
and demonstrate the evidence for the Best practices adopted ?
Does the Organization ensure Quality,Safety & Enviromental Requirements?
0 0.5 1
(ISO/TS16949,OHSAS,ISO 14001)
Does the Organization ensure the fullfillment of 4M Condition w.r.t HMCL Ramp Ups ? 0 1 2
Is the identification & traceability system established to control Ok / Rework / Rejected material
mix up?
0 2.5 5
Is there any Standard available to control Incoming Material Quantity (Inventory Control) ?
MIX-UP AVOIDING SYSTEM
Is the Rejection Disposal System available & adhere t
14 (INCOMING, INPROCESS AND FINAL A
PRODUCT) Are proper storage areas available/in use, to prevent damage or deterioration of product quality
?
0 3 6
Is there an effective method to control "shelf life" of material wherever applicable ?
Is First in First out system in use for Raw Material / Bop s / Fi
Page 99 of 148
SL. OPERATION CATEGOR MARKS
NO. Y VERIFICATION POINTS Rating OBSERVATION
CHECK POINT OBTAINED
Is the Bop s and finished goods packing standardized in Consensus with HMCL ? 0 1 2
Revision-02
Does preventive maintenance system exist for trolleys and bins and are the monitoring records
available ? 0 1 2
PACKING STANDARDIZATION
15 B Are returnable containers handled / maintained properly to prevent quality issues?.
,HANDLING AND TRANSPORTATION
Is the Plant Layout adequate to avoid handling damages on Product? 0 1.5 3
Is the transportation system in consensus with HMCL?,
0 1 2
How is the outsourced transportation being monitored ?
Are all the required Insp.instrument & lab test equipment identified & available for use?
0 1.5 3
Is the availability of testing facility for Incoming Parts / In process Parts & processes ensured ?
Are these instruments / equipments being calibrated & maintained ?

INSPECTION Are the external calibrated instruments / equipments traceable to national standards ( accredited
0 1 2
INSTRUMENTS,EQUIPMENT & LAB to NABL or NPL) and identified?
16 A
TEST FACILITIES (AVAILABILITY & Measurement System Analysis: Is measurement system analys
USAGE)
Are the Product / Processe validation test facilities & calibration status available & adhered to ?
Is the performance & endurance test conducted periodically and actions against non-conformities 0 1.5 3
executed ?
Is Raw material testing done as per inspection plan & frequency either inhouse or through 3rd
0 1.5 3
party ?
Is the inspection data recorded and does it meet the specified requirements ?
0 1.5 3
Is the recorded data used for improvements to avoid recurrence of problems ?
Is the final inspection & quality gate implemented for CTQs ?
INSP.DATA RECORDING (Incoming,In- Is the formal review mechanism with HMCL available for final insp. & quality gate inspection 0 1.5 3
17 A
process,Final Inspection & PDI) check points / status ?
Is escape rate of Quality Gate / Final Insp./ PDI inspectors recorded and their training ensured
0 1 2
for elimination of Defect / Rejection.
Is the first of approval done after breakdown , preventive maintenance & shutdowns ? 0 1.5 3
Are the Process sheet / work inst. displayed at work stations and are the contents known to
0 1 2
concerned operator / person?
PROCESS SHEET / WORK Are the updated process sheets / work instructions available as per the revisions of PFMEA
0 1 2
INSTRUCTION /WORK STANDARD/ and the required controls documented,monitored and adhered ?
18 B
INSPECTION STANDARD (DISPLAY & Does the inspection standard sheet include important parameters like standard inspection
ADHERENCE)
0 1 2
method, frequency, inspection instrument and is same with PQCS ?.
Are the Inspection Frequency & CTQ s Controls linked with cp / cpk and actions against non
0 1.5 3
conformance available?
Is the process setting Inspection system established ? 0 1 2
Does the First Piece Approval System ensure the change in tooling,jig & fixture mould die,input
0 1 2
material,re sharpening of reamers,cutter,broach,hob etc.
PROCESS SETTING DATA Are the critical/ special processes verified and process parameters recorded,during set up
19 B
RECORDING approval? 0 1 2
Is proper first part and last part inspection performed by designated quality person?
Does a selected sample part meet specifications as required by the control plan and customer
0 1.5 3
product requirements?
Are the manpower required defined and available considering Cycle time & Volumes? 0 1 2
Are the critical processes identified and the deployment of trained manpower done for these
processes? 0 1 2
Are the deployed operators aware of the processes and their implications on product quality?
Is the contingency plan (spare pool) available in case of absenteeism to deploy on these critical
0 1 2
OPERATOR SKILL AND DEPLOYMENT processes?
20 A
ON CRITICAL WORK STATIONS Is the operator s training schedule & Module available, based upon the escape rate and adhered
to ? 0 1.5 3
Is the Cycle time recorded during training?
Does a strategic and effective training plan/ process exist that includes good communication,
training plan, career development and appropriate on the job training and follow up? 0 1 2
Does the organization monitor & ensure deployment of trained manpower at C
Is the internal rejection / rework/ segregation/ conditional acceptance data being recorded ?
Are the customer problems recorded like wty./ cid/ rework/ segregation/ conditional acceptance
0 2 4
related issue ?
Check Record of repeat problems & their counter
NON CONFORMITY / REWORK /
21 SEGREGATION RECORDS (INTERNAL A Is the data being analyzed for corrective & preventive Actions ?
& HMCL S )
Check Record of last one year Customers problem (Warranty, in-process & Incoming Quality- 0 2 4
cases & resolution)
Is RTY calculated ,maintained and Improved through actions against shortcomings?. 0 1.5 3
Page 100 of 148

SL.
OPERATION CATEGOR MARKS
NO. CHECK POINT Y OBTAINED
Revision-02
Is the approach for problem solving structured (Why-Why Analysis,5 rule sheet etc.) ? 0 1 2
Are the corrective & preventive actions monitored for effectiveness & discussed with HMCL on
0 1 2
regular basis?
Are the corrective and preventive measures for internal & external problems recorded
0 1 2
22 PROBLEM SOLVING & RECORDS. ,monitored for the effectiveness and Standardized ?
A
Does a documented procedure exist that is designed to proactively prioritize and implement
actions to correct known customer issues, prevent potential issues from occurring and promote 0 1 2
ongoing quality improvement?
Does the Mgmt. support & reinforce cross functional teams for reviewing historical data (Quality
Issues, Customer Issues, Pokayokes failures...etc) and utilizing structured problem solving for 0 1.5 3
improvement actions?.
Is there any detection / prevention Poke-Yoke system available to address outbreak & outflow for
POKA-YOKE SYSTEM,ITS EXISTENCE
0 2 4
23 the repeat / major problems?
AND MONITORING RECORDS B
Is the monitoring system available for poka- yoke on daily basis before start of production, ? 0 2.5 5
Are the TOOLS / DIES /MOULDS requirement Vs availability defined & Are the DESIGN
Available?.
0 1 2
Are the TOOLS / DIES /MOULDS, historical data available and addressed while duplicating the
same?.
Are the TOOLS / DIES /MOULDS Checked & maintenance done as per the check sheet?
Are the TOOLS / DIES /MOULDS life monitoring systems available on basis of volume and 0 1 2
TOOL / DIE / MOULD DESIGN,
24 DUPLICATION ,VALIDATION & LIFE adhered to?
A
MONITORING SYSTEM
Is there any contingency plan available for Duplication of TOOLS / DIES /MOULDS considering
Lead time and adhered to? 0 1 2
Is the validation of TOOLS / DIES /MOULDS carried out on the designated volumes?
Is there any contingency Plan available in case of Tools / Dies / Moulds major Breakdowns 0 1 2
Does the supplier have an effective system to monitor any outsourced tooling management
0 1.5 3
activities?
Total Marks Obtained =Sum of marks Obtained
Are the JIGS & FIXTURE identified & DESIGN Available.
0 1 2
Are the JIGS & FIXTURE ,historical data available and addressed in the duplication of the same.
Are the JIGS & FIXTURE Checked & maintenance done as per the check sheet?
0 1.5 3
JIGS & FIXTURE DESIGN, Are the JIGS & FIXTURE life monitoring systems on basis of volume available and adhered to?
25 A
DUPLICATION MAINT.& CALIBRATION
Is the validation of JIGS & FIXTURE carried out as per designated volumes? 0 1 2
Is there any contingency plan available for Duplication of JIGS & FIXTURE and adhered to? 0 1 2
Is the perishable parts inspection / replacement frequency defined? 0 1 2
PROC./ REC.GAUGES DESIGN,

Are the required Process / Receiver Gauges identified and available? 0 2.5 5
26 A Is the design for Process / Receiver Gauges available and Calibrated as per frequency based
DUPLICATION MAINT.& VALIDATION 0 3 6
upon the application and usage?
Is the processes validation done( eg .Welding, paint, plating & Heat-Treatment, casting, forging,
0 1 2
molding, riveting, grinding ,honing processes etc.)?
PROCESS QUALIFICATION RECORDS Is the Re-validation done on mutually agreed set frequency & records available? 0 1 2
27 B
(PERIODICAL RE-VALIDATION)
Is the process capability of identified CTQ parameters carried out & Cp/ Cpk maintained >1.67 ? 0 1 2
Are the Control Plans/ PQCS updated as per the qualification records? 0 1.5 3
Are the limit samples available for appearance items as agreed mutually with HMCL.? 0 1.5 3
LIMIT SAMPLES AVAILABILITY FOR Are the limit samples frozen, reviewed periodically & changed as per mutually agreed frequency
28 APPEARANCE ITEMS, AS AGREED 0 1 2
B ?
MUTUALLY
Are the Limit samples displayed at concerned stages and the application and usage known to
0 2 4
operator?
OVERALL LINE / EQUIPMENT
Is the TACT time Vs volume recorded for all Components covering all Lines ? 0 2 4
29 B Is there any improvement plan available for increasing the stage wise Straight Pass , OLE &
EFFICIENCY ( OLE / OEE ) 0 2.5 5
OEE ?
Are the M/c availability Vs requirement based on Cycle time? 0 1 2
Are New M/cs Installation and Initial Machine Capability Verified?.
0 1 2
Are Trial reports of New machines available and Acceptance Criteria identified?
M/C s REQUIREMENT , PREVENTIVE
30 MAINT.SCHEDULE AND ITS Is the Daily maintenance check sheet available & known to operator & adhered to ?
B 0 1 2
ADHERENCE Are the repeat / major break downs analyzed and actions are executed?
Is the M/c s preventive maintenance schedule available and adhered to ?
Is the preventive maintenance schedule amended periodically based upon repeat / major 0 1.5 3
breakdowns?
STATUS AND ITS CONTROLS FOR
31 NEWLY ADDED COMPONENTS AFTER Are the newly added components / processes maintained as per the Dol Qualification Criteria
A 0 5.5 11
DOL CERTIFICATION with in 03 months after the start of mass production.
ADHERENCE TO DOL MOU Are the DOL MOU conditions adhered to ?
32 A 0 5.5 11
CONDITIONS. (EVIDENCED) Does the review mechanism exist for adherence of DOL MOU ?
1. Evaluate each Attribute against the verification points
2. Rate each verification point in the box provided in front of every verification point
RATING METHODOLOGY
3. Add all the verification point rating and put it in the " MARKS OBTAINED " column against
each attribu
RATING Total Marks obtained / No. Of attributes Applicable = QUALIFICATION > 8
Page 101 of 148

MEMORANDUM OF MUTUAL UNDERSTANDING
FOR
DIRECT ON LINE SUPPLIES
WITH
M/s
DATE : 04th February 2009
This memorandum of Understanding (hereinafter referred as "MOU") is signed on 2009
DOC. NO.: HMCL /DOL / COND / OO

DOC. NO.: HCML /DOL / COND / OO
BETWEEN
M/S HERO MOTOCORP LIMITED, a Company incorporated under the Indian

Companies Act, 1956 having its Registered Office at 34, Basant Lok, Vasant Vihar, New
Delhi - 110 057 (hereinafter referred as "The Company" which expression shall mean
and include its successors, administrators and assigns) of the First Part.
AND
M/s.-----------------------------, a Company / Partnership Firm having its Registered Office at

---------------------------------(hereinafter referred as "The Supplier" which expression shall
mean and include its successors, administrators and assigns) of the Second Part.
WHEREAS the company is engaged in manufacturing and marketing of two-wheelers and the
supplier is engaged in manufacturing and supplying automobile components.
WHEREAS the supplier has been supplying components to the company since long and wishes
to continue uninterrupted business relations with the Company, and the company has also agreed
to the same on the following terms & conditions :
1. Supplier MD/CEO, Plant Head & QA Head shall conduct Monthly

Management Reviews against HMCL'S Dashboard Parameters (Market
Claims, CID PPM, BOP PPM, BOSF PPM, Audit Status, Management Issues)
& Targets and Outcome with the comments of Top Management, required to
be discussed at HMCL.
a) Quarterly in case of Excellent & Good Category Vendor, based upon VQR.
b) Monthly in case of Average & Poor Category Vendor, based upon VQR
2. Audits are required to be conducted by Supplier and a Consolidated Summary

of findings for the past one year (As per financial year) with execution of
Countermeasure's duly updated, shall be reviewed at HMCL, as per the
frequency given below.
a) Product / Process Audit as per HMCL'S PQCS Contents, once a Month

(One Product at-least a Month, Covering high Volume models as well as
higher CC model parts) and report shall be submitted & discussed with
HMCL once in 03 Months.
b) Process / System Audit as per HMCL'S System Audit Sheet shall be conducted by
Supplier once in 03 months and Consolidated Summary of findings with execution of
updated actions in the financial year, required to be discussed & submitted to HMCL,
once in 03 Months.

3. All parts covering entire models being supplied by a Supplier shall undergo the
comprehensive detailed report as per Drawing & Standard, which shall cover
right from Raw Material to finished product (Should cover all Sub-Suppliers,
Cavities, Moulds, Dies, Fixture, Lines etc., including Durability, Performance
and Endurance tests), shall be made, discussed & submitted at HMCL, once in
03 Months by Supplier.
4. Supplier shall adhere to the IPPT Conditions Strictly and Prior to any change,
inform HMCL and Consent in writing to be sought, Prior to Mass Production Trials.
5. Supplier shall update the Poka -Yoke Summary with before and after date &
Photgraphs, once in 03 Months to HMCL.
6. Supplier Plant Head & QA Head shall give the presentation at HMCL once in
03 Months, for the Best Practices adopted, considering the Global Competition
with respect to Man, Machine, Material, Method, Management & Mother
Earth.
7. Re-validation of DOL Certification shall be done by HMCL, once in three years
or any deviation noticed against the said conditions.
8. HMCL has full right to withdraw DOL Certification in case of Non-adherence
to any of the above conditions. (Containment Action / Strategy enclosed)
For Hero Moto Corp Limited For .------------------------
(Managing Director)
(Vice President - Works)

Revision-02
TOOLS / DIES / MOULD STATUS
DATED :
LIST OF TOOLS/ REQMT. AVAILABILITY @ PROCUREMENT PLAN
S.N. LIFE VALIDATION SCHEDULE
DIES / MOULD @ VOL/DAY VOL / DAY @ VOL / DAY
NOTE :- LEAD TIME FOR PROCUREMENT / MFG. FOR TOOLS / DIES / MOULDS.
Page 105 of 148

CRITICAL PROCESSES / WORK STATION CONTROL
Revision-02
DATED :
TRAINED MANPOWER NAME OF PERSONS IN

NAME OF DEPLOYED
S.NO. CRITICAL PROCESSES SPARE POOL
TRAINED MANPOWER
REQD. AVAIL. TRG..PLAN (WITH MULTISKILLING)
Page 106 of 148

Revision-02
JIGS & FIXTURES STATUS
DATED :
LIST OF JIGS/FIXTURES REQMT. AVAILABILITY @ PROCUREMENT PLAN
S.N. LIFE VALIDATION SCHEDULE
(INCLIDING SPARES) @______VOL/DAY _____VOL / DAY @____VOL / DAY
NOTE :- LEAD TIME FOR PROCUREMENT / MFG. FOR TOOLS / DIES / MOULDS.
Page 107 of 148

Page 109 of 122Revisi
SUPPLIERS 4M PREPAREDNESS EVALUATION

EVALUATION Supplier's Name-
REQUIREMENTS
CRITERIA OBSERVATIONS OF GEMBA VISIT ON LEVEL
TARGET
TOTAL MARKS 100 DATE : JUDGEMENT 100 DATE
MAN 25 25
# IS QA HEAD AVAILABLE ?
# HAS EXPERIENCE IN SIMILAR INDUSTRY?
QUALITY CUSTODIAN # IS ROLE / RESPONSIBILITY CLEARLY DEFINED?
6 6
# HAS AUTHORITY ON PROCESS / F.I CONTROLS?
# IS TOTAL REQUIREMENT FOR VOLUMES DEFINED?

STATUS OF RECRUITMENT OF # IS REQMT. GRADED INTO SKILLED / SEMI SKILLED ?
# IS SPARE POOL REQMT. IDENTIFIED IN LINE WITH ATTRITION RATE ?
4 4
WORKMEN
# CHECK ACTUAL AVAILABILTY ( PLAN vs ACTUAL ).
# IS TOTAL REQUIREMENT OF ENGGRS , SUPERVISORS DEFINED?

STATUS OF RECRUITMENT OF # IS REQMT. IDENTIFIED FUNCTIONWISE ( MANF. , QA , MAINT. ETC ?
# ARE ROLES , RESPONSIBILITY , AUTHORITY CLEARLY DEFINED ?
4 4
STAFF
# CHECK ACTUAL AVAILABILTY ( PLAN vs ACTUAL ).
# ARE STATIONWISE / PROCESS WISE TRAINING MODULES AVAILABLE ?

# CHECK TRAINING MODULES' ADEQUACY W.R.T CTQs OF PRODUCT / PROCESS.
TRAINING WORKMEN / STAFF # ARE CLASS ROOM TRAINING PROGRAMS CONDUCTED ?
4 4
# IS MINIMUM TRAINING DEFINED/ PROVIDED BEFORE DEPLOYMENT AT WORK STATION ?
# IS ON JOB TRAINING PROVIDED ?

ON JOB TRAINING THROUGH # ARE CYCLE TIMES MONITORED FOR OPERATORS DURING OJT ?
# IS REJN. RATE / ESCAPE RATE MONITORED OPTRWISE DURING OJT?
7 7
PRODUCTION (WORKMEN)
# ARE ACTIONS TAKEN TO MEET BENCHMARK CYCLETIME & RTY ?
MACHINE / EQUIPMENT 10 10
# IS PLAN AVAILABLE FOR PROCUREMENT OF MACHINERY CONSIDERING VOLUMES ?
STATUS OF PROCUREMENT # IS ACCEPTANCE CRITERIA AVAILABLE FOR NEW MACHINE APPROVAL ?
# CHECK AVAILABILITY STATUS ( PLAN vs ACTUAL ) .
5 5
OF M/Cs & EQUIPMENT
# CHECK MACHINE APPROVAL REPORT (SAMPLE ) .
# ARE MACHINES INSTALLED AS PER TIMING PLAN & FINAL LAYOUT ?

INSTALLATION OF MACHINES # ARE MACHINE TRIALS CONDUCTED ?
# CHECK MACHINE CAPABILITY & MACHINE APPROVAL REPORTS ( SAMPLE ) .
5 5
/ EQUIPMENT
METHOD 55 55
PROCESS
31 31
ESTABLISHMENT
INITIAL PROCESS CAPABILITY # ARE INITIAL PROCESS CAPABILITY STUDIES CONDUCTED USING M.P 4M CONDITIONS ?
# CHECK INITIAL PROCESS CAPABILITY REPORTS .
STUDY OF NEW EQUIPMENT / # DO THESE REPORTS MEET THE ACCEPTANCE CRITERIA ( Cpk > 1.33 ) ? 4 4
PROCESS QUALIFICATION # CHECK PROCESS QUALIFICATION REPORTS FOR SPECIAL PROCESSES .
# IS PRE PRODUCTION PQCS PREPARED ?

PRE PRODUCTION PQCS # HAVE THE RESULTS OF TRIAL / PROCESS QUALIFICATION / INITIAL CAPABILITY REPORTS
INCORPORATED INTO PQCS ?
4 4
(PPAP) DOCUMENTS
# HAVE WORK STANDARDS & SOPs BEEN MADE IN LINE WITH PQCS ?
# IS A LAYOUT PLAN AVAILABLE CONSIDERING VOLUME REQUIREMENTS ( SCOPE FOR

FINALIZED LAYOUT OF LINE
FUTURE EXPANSION ) ? 4 4
AS PER M.P. CONDITION # ARE THE LINES / MACHINES INSTALLED AS PER FINAL LAYOUT ?
TRIALS OF NEW EQUIPMENT 8 8
# HAVE NECESSARY FOCUS BEEN GIVEN FOR AUTOMATION IN SELECTION OF

EQUIPMENT?
TECHNOLOGICAL # HAVE THE EQUIPMENT WITH NEWER TECHNOLOGY BEEN SELECTED ? 7 7
UPGRADATION # DOES THE TECHNOLOGY REDUCE OR ELIMINATE MANUAL INTERVENTION ?
# ARE MISTAKE PROOFING MEASURES INCORPORATED IN THE MANUFACTURING ,
INSPECTION EQUIPMENTS ?
# IS THE REQUIREMENT OF MATERIAL HANDLING EQUIPMENT ( TROLLEYS , BINS )
MATERIAL HANDLING / IDENTIFIED IN LINE WITH VOLUME REQUIREMENTS ?
# ARE THE INHOUSE HANDLING METHODS APPROPRIATE ( REDUCE HANDLING & DO NOT
TRANSPORTATION EFFECT QUALITY) ?
4 4
EQUIPMENT # ARE THE EQUIPMENT USED FOR FINAL DESPATCH APPROVED BY CUSTOMER ?
# CHECK AVAILABLITY ( PLAN vs ACTUAL ) STATUS .
JIGS / FIXTURES / DIES 12 12

# IS THE REQUIREMENT OF JIGS / FIXTURES IDENTIFIED IN LINE WITH VOLUME
REQUIREMENTS ?
STATUS OF PROCUREMENT
# IS THERE A PROCUREMENT PLAN AVAILABLE FOR THE SAME ? 3 3
OF JIGS / FIXTURES / DIES # IS THE ORDERING DONE KEEPING IN VIEW THE LEAD TIMES OF PROCUREMENT ?
# CHECK AVAILABILITY STATUS ( PLAN vs ACTUAL ) .
# ARE THE CHECK POINTS FOR JIGS / FIXTURES AVAILABLE ?

INSPECTION OF JIGS /
# ARE THE JIGS / FIXTURES INSPECTED AS PER CHECK POINTS BEFORE ISSUE TO LINE ? 3 3
FIXTURES / DIES # CHECK JIGS / FIXTURES ' INSPN. REPORTS ( SAMPLE ) .
# ARE TRIALS OF JIGS , FIXTURES , DIES CONDUCTED BEFORE USE FOR MASS
TRIALS OF JIGS / FIXTURES / PRODUCTION ?
# ARE THE TRIALS REPORTS JOINTLY APPROVED BY USER & THE MAKER / APPROVER (
3 3
DIES
TOOL ROOM ) ?
# HAVE THE TRIAL RESULTS BEEN VERIFIED AND APPROVED ?

VERIFICATION OF TRIAL # DO THE TRIAL RESULTS MEET THE ACCEPTANCE CRITERIA ( Cpk >1.33 OR EQUIVALENT )
?
3 3
RESULTS
# CHECK THE TRIAL REPORTS & APPROVAL REPORTS ( SAMPLE )
INSPECTION OF
12 12
INSTRUMENT / GAUGES
PROCUREMENT & # IS THE REQUIREMENT OF INSTRUMENTS & GAUGES IDENTIFIED IN LINE WITH VOLUME
INSTALLATION OF REQUIREMENTS ? 4 4
INSTRUMENTS / GAUGES # CHECK AVAILABILITY STATUS ( PLAN vs ACTUAL ) .
# ARE THE FIRST CALIBRATION REPORTS AVAILABLE ?

GAUGE CALIBRATION # IS THERE A CALIBRATION PLAN AVAILABLE FOR THE SAME ? 4 4
# CHECK CALIBRATION STATUS ( PLAN vs ACTUAL ) .
INSPECTION FACILITY AT # IS THE REQUIREMENT OF INSPECTION EQUIPMENT IDENTIFIED ?

NEW PLANT LOCATION (FOR # IS THE RAW MATERIAL & LAB TEST FACILITY IDENTIFIED ? 4 4
BOP'S) # CHECK AVAILABILITY STATUS ( SAMPLE ) .
MATERIAL 10 10
# ARE THE SELF INSPECTION REPORTS BY PART SUPPLIER AVAILABLE ?

PROCUREMENT OF BOP
# ARE INSPECTION STANDARDS & PLAN AVAILABLE FOR BOP PART INSPECTION ? 5 5
PARTS (TIER-2 SUPPLIERS) # CHECK FOR INSPECTION STATUS OF BOP PARTS ( SAMPLE ) .
# ARE THE RAW MATERIAL TEST REPORTS AVAILABLE ?

RAW MATERIAL TEST # IS THERE A PLAN AVAILABLE FOR VERIFICATION OF RAW MATERIAL AT SUPPLIER / III
PARTY ?
5 5
REPORTS
# CHECK FOR INSPECTION REPORTS ( SAMPLE ) .

SUPPLIERS 4M PREPAREDNESS EVALUATION (EXISTING SUPPLIERS)
Supplier's Name- Part Name:-
EVALUATION CRITERIA No. of Shifts - @ Hrs, No of Lines:- LEVEL
OVERALL TARGET
TOTAL MARKS DATE : RATING 0 DATE
MAN 25 ATTRIBUTES RATING OBSERVATIONS OF GEMBA VISIT ON 0
# IS QA HEAD AVAILABLE & HAS EXPERIENCE IN SIMILAR INDUSTRY ?
# IS THE QUALITY ORGANIZATION STRUCTURE REQUIRED VS AVAILABLE DEFINED?
QUALITY CUSTODIAN & TEAM 6 # IS THE QUALITY TEAM SUFFICIENT & COMPETENT ENOUGH TO ENSURE QUALITY?
# IS ROLE / RESPONSIBILITY CLEARLY DEFINED?
# HAS AUTHORITY ON PROCESS / F.I CONTROLS?
# IS TOTAL WORKMAN REQUIREMENT FOR DESIRED VOLUMES DEFINED & GRADED IN TO

SKILLED / SEMI SKILLED?
# IS SPARE POOL REQMT. IDENTIFIED IN LINE WITH ATTRITION RATE & ABSENTEEISM?
STATUS OF WORKMEN 4 CHECK ACTUAL AVAILABILITY STATUS ( PLAN vs. ACTUAL )?
# IS THE SKILL MATRIX AVAILABLE FOR WORKMAN ?
# IS THE DEPLOYMENT OF OPERATORS ENSURED AS PER SKILL MATRIX ?
# IS TOTAL REQUIREMENT OF ENGGRS , SUPERVISORS DEFINED & IDENTIFIED FUNCTION

WISE ( MFG. , QA , MAINT. ETC)? CHECK ACTUAL AVAILABILITY ( PLAN vs. ACTUAL ).
STAFF ADEQUACY 4 # IS THE CUSTOMER REPRESENTATIVE AVAILABLE? 0
# ARE ROLES , RESPONSIBILITY , AUTHORITY CLEARLY DEFINED ?
# IS THE VERSATILITY CHART AVAILABLE FOR STAFF ?
# ARE STATION WISE / PROCESS WISE TRAINING MODULES AVAILABLE ?

# CHECK TRAINING MODULES' ADEQUACY W.R.T CTQs OF PRODUCT / PROCESS.
# ARE CLASS ROOM TRAINING PROGRAMS CONDUCTED ?
TRAINING WORKMEN / STAFF 4 # IS MINIMUM TRAINING DEFINED/ PROVIDED BEFORE DEPLOYMENT AT WORK STATION ?
0
#IS THERE ANY REFRESHER TRAINING PROVIDED? NEW TECHNOLOGY, SKILL UP
GRADATION).
# IS ON JOB TRAINING MODULE AVAILABLE AND TRAINING PROVIDED ?
# ARE THE QUALITY CHARACTERISTICS ADDED IN OJT TRAINING MODULE ?
ON JOB TRAINING THROUGH # ARE CYCLE TIMES MONITORED FOR OPERATORS DURING / AFTER OJT ?
7 # IS REJN. RATE / ESCAPE RATE MONITORED OPTRWISE DURING / AFTER OJT?
0
PRODUCTION (WORKMEN)
# ARE ACTIONS TAKEN TO MEET BENCHMARK CYCLE TIME & RTY ?
MACHINE / EQUIPMENT 10 0
# IS THE PLAN AVAILABLE FOR PROCUREMENT OF MACHINERY CONSIDERING RAMP UP /

CONTINGENCIES ?
AVAILABILITY STATUS OF M/Cs & # IS THE MACHINE REQUIREMENT CALCULATED CONSIDERING OPERATION CYCLE TIME ?
5 # ARE THE MACHINES INSTALLED AGAINST THE DESIRED VOLUMES CONSIDERING 6 DAYS
0
EQUIPMENT
PRODUCTION ( @8 /10/12 HRS /SHIFT ).?CHECK AVAILABILITY STATUS (REQUIRED vs.
ACTUAL ) .
# ARE THE MACHINES DAILY MAINTENANCE ,PREVENTIVE MAINTENANCE SCHEDULE

AVAILABLE, ADEQUATE AND ADHERED TO ?
MAINTENACE STATUS OF MACHINES /
5 # ARE THE MACHINE BREAKDOWNS RECORDED AND ANALYSIS DONE ? 0
EQUIPMENT # IS PLAN AVAILABLE FOR REPLENISHMENT OF OLD MACHINES?
# IS THERE ANY PLAN FOR TECHNOLOGY UP GRADATION ?
METHOD 55 0
PROCESS ESTABLISHMENT 31 0
# ARE PROCESS CAPABILITY STUDIES CONDUCTED UNDER MASS PRODUCTION 4M

CONDITIONS AT DEFINED FREQUENCY ?( CHECK PROCESS CAPABILITY REPORTS ).
# DO THESE REPORTS MEET THE ACCEPTANCE CRITERIA ( Cpk>1.67 ) ?
PROCESS CAPABILITY STUDY / # CHECK PROCESS QUALIFICATION REPORTS FOR SPECIAL PROCESSES LIKE HEAT
4 TREATMENT / PLATING / CASTING ETC.
0
PROCESS QUALIFICATION
# ARE THE MISTAKE PROOFING DONE THROUGH POKE YOKE AND POKE YOKE
VERIFICATION DONE?
# IS THE REJECTION AND REWORK DATA RECORDED AND ANALYZED?
# IS THE MASS PRODUCTION PQCS AVAILABLE & CYCLE TIME ADDED IN TO PQCS ?
# IS THE PQCS CONTAIN REFERENCES OF APPLIED SOP'S ,WORK STANDARDS ,M/C CHECK
MASS PRODUCTION PQCS 4 SHEET & CALIBRATION CHECK SHEETS & PROCESS REVALIDATION FREQUENCY ? 0
#ARE THE CTQ'S & CTP'S (PROCESS) IDENTIFIED IN PQCS.
# ARE THE AMENDMENTS INCORPORATED IN PQCS AS PER IPPT CONDITION .
# IS A LAYOUT PLAN AVAILABLE CONSIDERING VOLUME REQUIREMENTS ( SCOPE FOR

FUTURE EXPANSION ) ?
FINALIZED LAYOUT OF LINE AS PER
4 # ARE THE LINES / MACHINES INSTALLED AS PER FINAL LAYOUT ? 0
M.P. CONDITION # IS THE LAYOUT IS ADEQUATELY DEFINED TO HAVE BETTER MATERIAL FLOW FORM ONE
STATION TO OTHER AND ONE SHOP TO OTHER SHOP?
# IS THE PROBLEM SOLVING METHODOLOGY USED FOR TROUBLE SHOOTING?

#IS THE IMPROVEMENT PLAN AVAILABLE ?
QUALITY SYSTEM 8 # ARE THE FINAL INSPECTION / PDI CONTROLS IDENTIFIED AND ADHERED TO? 0
ARE THE LAYOUT INSPECTION PERFORMANCE TEST & ENDURANCE TESTING PLAN
AVAILABLE AND ADHERED TO?
#ARE THE NEW EQUIPMENTS TRIALS CONDUCTED & ACCEPTANCE CRITERIA DEFINED.?
# ARE THE NEW MACHINE / EQUIPMENT UPGRADED CONSIDERING OLD M/C PROBLEMS
TECHNOLOGICAL UPGRADATION 7 AND UPGRADED FOR AUTOMATION AND NEW TECHNOLOGY? 0
# DOES THE TECHNOLOGY REDUCE OR ELIMINATE MANUAL INTERVENTION ?
# ARE MISTAKE PROOFING MEASURES INCORPORATED IN THE MACHINES?
# IS THE REQUIREMENT OF MATERIAL HANDLING EQUIPMENT ( TROLLEYS , BINS )

IDENTIFIED IN LINE WITH VOLUME REQUIREMENTS & ADHERED TO ?
# ARE THE IN-HOUSE HANDLING METHODS APPROPRIATE ( MIN. HANDLING & DO NOT
MATERIAL HANDLING /
4 EFFECT QUALITY) ? 0
TRANSPORTATION EQUIPMENT # ARE THE EQUIPMENT USED FOR FINAL DISPATCH ARE IN CONSENSUS WITH HMCL?
# IS THERE ANY MAINTENANCE SYSTEM FOR TROLLEYS / BINS AVAILABLE ,ADEQUATE &
ADHERED TO ?.
JIGS / FIXTURES / DIES 12 0

# IS THE REQUIREMENT OF JIGS / FIXTURES / DIES / RECEIVER GAUGES IDENTIFIED IN
LINE WITH VOLUME REQUIREMENTS INCLUDING CONTINGENCY& ORDERING DONE
STATUS OF PROCUREMENT OF JIGS / KEEPING IN VIEW THE LEAD TIMES OF PROCUREMENT ?
3 # IS THERE A PROCUREMENT PLAN AVAILABLE FOR THE SAME ?
0
FIXTURES / DIES / RECEIVER GAUGES
# ARE THE REQUIREMENT OF PERISHABLES DEFINED AND IN LINE WITH THE
REQUIREMENT?
# ARE THE CHECK POINTS & DESIGN FOR JIGS / FIXTURES / DIES / RECEIVER GAUGES
INSPECTION OF JIGS / FIXTURES / AVAILABLE ?
3 # ARE THE JIGS / FIXTURES INSPECTED AS PER CHECK POINTS BEFORE ISSUE TO LINE ?
0
DIES / RECEIVER GAUGES
CHECK JIGS / FIXTURES ' INSPN. REPORTS ( SAMPLE ) .
# ARE TRIALS OF JIGS , FIXTURES , DIES CONDUCTED BEFORE USE FOR MASS
TRIALS OF JIGS / FIXTURES / DIES / PRODUCTION ?
3 # ARE THE TRIALS REPORTS JOINTLY APPROVED BY USER & THE MAKER / APPROVER (
0
RECEIVER GAUGES
TOOL ROOM / THIRD PARTY MANUFACTURER ) ?
# ARE THE JIGS / FIXTURES / DIES / RECEIVER GAUGES DAILY MAINTENANCE

,PREVENTIVE MAINTENANCE SCHEDULE AVAILABLE AND ADHERED TO ?
# ARE THE JIGS / FIXTURES / DIES / RECEIVER GAUGES BREAKDOWNS RECORDED AND
MAINTENANCE OF JIGS / FIXTURES /
3 ANALYSIS DONE ? 0
DIES / RECEIVER GAUGES # IS THE PLAN AVAILABLE AND ADHERED FOR REPLENISHMENT OF JIGS / FIXTURES / DIES
/ RECEIVER GAUGES?
# IS THE BOP MATERIAL PACKING & HANDLING METHOD IDENTIFIED AND ADHERED TO?
INSPECTION OF INSTRUMENT /
12 0
GAUGES
PROCUREMENT & INSTALLATION OF # IS THE REQUIREMENT OF INSTRUMENTS & GAUGES IDENTIFIED & ADEQUATE IN LINE
4 WITH VOLUME REQUIREMENTS ?CHECK AVAILABILITY STATUS ( PLAN vs. ACTUAL ) .
0
INSTRUMENTS / GAUGES
# ARE THE FIRST CALIBRATION REPORTS AVAILABLE ?
# IS THERE A CALIBRATION PLAN AVAILABLE FOR THE SAME ?CHECK CALIBRATION
GAUGE CALIBRATION 4 STATUS ( PLAN vs. ACTUAL ) .
0
# IS THE MSA AND RR STUDY CONDUCTED ?
# IS THE REQUIREMENT OF INSPECTION EQUIPMENT IDENTIFIED ?

LAB TESTING FACILITY 4 # IS THE RAW MATERIAL & LAB TEST FACILITY IDENTIFIED,ADEQUATEAND ADHERED TO ? 0
CHECK AVAILABILITY STATUS ( SAMPLE ) .
MATERIAL 10 0
# ARE THE PQCS,INSP. STANDARD & INSP. PLAN OF BOP PARTS AVAILABLE & ADHERED?
CHECK FOR INSPECTION STATUS OF BOP PARTS ( SAMPLE ).
# ARE THE SELF INSPECTION REPORTS OF PART SUPPLIER AVAILABLE ?
# IS THE REWORK / REJECTION DATA OF BOP PARTS AVAILABLE AND ANALYZED?
TIER-2 SUPPLIERS CONTROLS 5 # ARE THE VENDOR RATING CALCULATED AND IMPROVEMENT PLAN AVAILABLE?
0
# ARE THE PACKING OF FINISHED PART IS ADEQUATELY DEFINED TO AVOID AND
MISHANDLING DEFECTS?.
# IS THE BOP'S MATERIAL STORAGE AND INVENTORY NORMS IDENTIFIED
# ARE THE RAW MATERIAL TEST REPORTS AVAILABLE ?

RAW MATERIAL TEST REPORTS 5 # IS THERE A PLAN AVAILABLE FOR VERIFICATION OF RAW MATERIAL AT SUPPLIER / III 0
PARTY ?CHECK FOR INSPECTION REPORTS ( SAMPLE ) .
Rating :- *OEE = Availability * Performance * Quality
Available & Adhered o (Full Marks) (Availability % = NOT / NAT * 100,Performance % = IOT / NOT * 100,Quality = (IOT – LOT) / IOT * 100 )
Partially Available or Partially Adhered D ( 50 % Marks ) 1. NAT = Net Available Time (Scheduled ProductionTime – Planned Down Time)
Not Availabe / Not Adhered X (Zero Marks ) 2. NOT = Net Operating Time (Net Available Time – Unplanned Down Time)
3. IOT = Ideal Operating Time (Time to Produce All Parts at Rate)
4. LOT = Lost Operating Time Due to Production of Scrap or Non-Saleable Product.

ANNEXURE NO 11
AESTHETIC QUALITY
MANUAL

AESTHETIC QUALITY MANUAL
CONTENTS
1. PREFACE
2. SCOPE
3. GENERAL REQUIREMENTS
4. AESTHETIC APPEARANCE CLASS
5. PART WISE ILLUSTRATIONS
6. DEFECTWISE ACCEPTANCE CRITERIA
7. HMCL QUALITY INDEX ( HQI )
8. EQUIPMENTS FOR AESTHETIC EVALUATION

PREFACE
Hero MotoCorp has been the market leader in two-wheeler industry in India right from the
beginning of the company. Over the years Hero MotoCorp products have been able to make a special
place in the hearts of millions of Indians. No wonder Hero MotoCorp is the world’s largest
manufacturer of two-wheelers for almost a decade now.
The success of our products depends crucially on its appearance and visual appeal. Especially in this
age of increased customer’s expectations this has become one of the most important criteria to sell
the product in market. It has become essential for all our employees as well as the suppliers to
produce the vehicles within our present aesthetic standards.
This aesthetic quality manual is an initiative the direction of making a compilation of expectations of
acceptable aesthetic quality at Hero MotoCorp. By acceptable quality, here we mean the level of
quality which represents a realistic balance between customer’s expectation, the capabilities at Hero
MotoCorp and our suppliers manufacturing processes and being cost-effective. While it is important
to recognize that our standards represent today’s conditions, we must do continuous improvements
in this direction. We also recognize that as our technology and technology of our suppliers, we must
ove our quality expectations.
Absence of specific aesthetic requirement standards and their subjectivity has always been a
problem for Hero MotoCorp and it’s suppliers in terms of un-necessary rejections and stoppage of
lines.
We hope this manual will replace much of this subjectivity with objectivity based on specific
requirements.

GENERAL REQUIREMENTS
Un-like any other vehicle, motorcycle is a kind of vehicle where most of its parts are exposed and it
has the largest number of parts which are visible, making the aesthetic quality most important part of
manufacturing/ designing.
Both Hero MotoCorp and the supplier should be involved in setting the aesthetic standard of a part.
All standards must be properly documented to ensure consistency with respect to expectations. The
criteria used to make an aesthetic quality standard will be discussed later in this manual.
It is important to note that aesthetic requirements may change during the product life-cycle with the
changes in expectations arising due to any reasons.
In general making an aesthetic standard has main steps:-
1. Defining aesthetic class based on parts location in motorcycle/scooter.

2. Defining appearance grade based on surface finish.
3. Defining expectations to standards based on specific parts characteristics.
Different aesthetic classes and appearance grades will be explained in detail later in this manual.
TEMPORARY DEVIATIONS
At times it may be required to review the aesthetic standard of an existing part. The process should
remain same as it was a newly developed part. The criteria adopted remain consistent as well as the
specific steps required to set the standard. We may also find it necessary to issue a deviation to the
aesthetic standard on a temporary condition that exists with that part. Temporary conditions are
ed as not representative of the process or the individual part in long run.
It is responsibility of the inspector / engineer at that time to consult with the aesthetic quality in
charge to determine whether a deviation may be issued.
All temporary deviations issued must be accompanied by time-bound corrective action plan.
PART SPECIFIC AESTHETIC REQUIREMENTS
Every part purchased or produced at Hero MotoCorp has specific issues that are relevant to that
specific part, like part design, tooling design or material. During aesthetic standard development
these issues should be addressed considering the customer’s expectations, technology limitations
and cost. After considering all of these, part specific issues against the base criteria the aesthetic
standard of the particular part should be finalized.
Generally such requirements are mentioned in the respective parts drawings of HMCL.

INSPECTION GUIDELEINES
Again in order to the replace subjectivity of quality inspection with objectivity based on specific
requirements, following guidelines should be followed both by our suppliers as well as HMCL.
TRAINING
Persons doing the visual inspection must be properly qualified. This should include review of the
types of discrepancies that can occur and actual inspection of parts under the guidance of
experienced person. Persons inspecting the parts should be familiar with the following:-
• How and where the parts will be used

• What areas are exposed to customer’s vision or are hidden by mating parts.
• Type of discrepancies that can occur to that part.
• Procedures for rejecting parts including segregation of parts and procedures for evaluation and
disposition.
New persons may tend to both not consider certain type of discrepancies as well as to over inspect
parts. They may strive for better appearance and reject parts that are marginally acceptable. It is
important that employees be monitored for consistency in applying standards and inspection
methods. Immediate feedback is required to calibrate the persons for consistent application of the
standard. It is important that periodic audits of the entire process are conducted.
VIEWING PROCEDURE
Parts should be viewed as zoned. In other words, the viewing process should have minimal effect on
whether a part meets the aesthetic standard or not. There should be minimum reliance on viewing
procedure.
LIGHTING
Proper lighting conditions must be present within the area where inspection occurs. This will
facilitate the inspection process and help ensure that parts are properly measured against the
aesthetic standard. This will also help maintaining the objectivity of the inspection process.
LIMIT SAMPLES
Limit samples of the part can be utilized to convey the aesthetic and appearance class of that
particular part. Picture can be used as templates in case the parts are bulky. Samples must be
maintained at both the supplier and HMCL to minimize inconsistencies in the application of
aesthetic standard. Physical samples must be protected from dirt or damage and shall be reviewed
periodically to ensure that they represent current process capabilities. These physical samples can be
useful for training and for solving discrepancies. They should be made available to inspectors at all
times.

MATERIAL HANDLING
Material handling of finished surfaces is essentially important. Improper handling of parts can
damage the surface finish so packaging, transportation, trolley design, protective padding etc must
be agreed upon and these procedures followed to ensure surfaces are not degraded.
CONFINEMENT OF POTENTIAL NON-CONFORMING PARTS
Parts suspected to be not conforming to aesthetic standards must be confined in an area separate
from acceptable parts. These parts should be properly labeled to prevent them from entering the
normal flow of acceptable material. Written procedures should define how rejected material will be
reviewed and dispositioned. Rejected material must not be allowed to accumulate and information
gathered should be used as feedback for process improvement.
DOCUMENTATION AND ANALYSIS OF NON-CONFORMANCE
Suppliers/ in-house shop must actively be involved in the use of preventive/corrective action.
Aesthetic discrepancies found should be documented and maintained to aid in the continuous
improvement process. The records must contain sufficient information and details to allow for
identification of the major issues and provide for the determination of root cause of those issues. The
documentation may also be used to determine process capabilities and future aesthetic requirements
for that part as well as others that utilize the same production process.

SCOPE
The aesthetic quality manual covers the basic parts of the two-wheelers manufactured at Hero
MotoCorp Ltd , in which the whole part or it’s portion has decorative value. The decorative value is
broadly divided in two classes as explained below :-
1. BASIC CLASS: The basic class is the fundamental appearance class according to which
critical portions of a part are assessed and specific appearance class of an entire part varies
depending on the sum of the importance of the individual portions of the part.
2. APPEARANCE CLASS: It is for the decorative value of the portion of the part depending
upon part design and fitment.

AESTHETIC APPEARANCE CLASS
Depending upon the importance of decorative value, the parts or it’s portion are designated by the
appearance class ‘sa’ to ‘c’.
Following table illustrates the appearance class:-
CLASS DESCRIPTION
sa Those portions which are clearly visible after

assembly and require and extremely high
appearance value.
a Those portions which are clearly visible after

assembly and require high appearance value
b Those portions which are clearly visible after

assembly but have appearance value requirements
slightly lower than grade ‘a’
c Those portions which are not clearly visible or are of

low appearance value requirements.
Appearance class is explained by following examples of the important parts:-
FUEL TANK

SIDE COVER

FRONT FENDER
PIPE STRG HANDLE

PARTS ILLUSTRATION:
Following is the pictorial illustration of various motorcycle parts as assembled:-
SIDE
COVER FUEL TANK
RR CUSHION
PEDAL
COVER BRAKE
MUFFLER MUFFLER
COMP
EXHAUST MAIN FR WHEEL FR FORK
STAND FENDER ASSY ASSY

SIDE
COVER
SEAT
RR FENDER
PANEL BRAKE
CRANK PEDAL
CASE GEAR CHAIN CASE SARI GUARD
COVER CHANGE COVERS
'L'

SPEEDOMETER RR VIEW MIRRORS
SWITCH ASSY
TOP BRIDGE
HANDLE
GRIP HANDLE
HANDLE
HOLDERS
CAP FUEL TANK
FRONT/ENGINE
GUARD

RR GRIP/
COWL CENTRE
CARRIER
RR WINKER
TAIL LAMP
NUMBER PLATE

LEVER HANDEL
WINKER FR
WIND SCREEN
FR COWL/VISOR
HEAD LAMP

Part list for basic appearance class:-

‘sa
1. Fuel tank
2. Fuel tank lid
3. Side covers ( left and right )
4. Grip RR
5. Carrier RR
6. Handle
7. Fr Fender
8. Fr cowl ( visor )
‘a
1. Bolt fr fork
2. Fr fork bottom case
3. Fr fork pipe
4. Speedometer
5. Nut strg stem
6. Top bridge
7. Muffler comp exhaust
8. Handle holder upper
9. Switch assy
10. Handle lever
11. Master cylinder assy
12. Winkers
13. RR fender
14. Crank case cover ( right ,left & RR )
15. Cylinder head side cover
16. Cylinder head cover
‘b
1. Tail light bracket
2. Tail light base
3. Rear view mirror
4. Rear cushion upper cover
5. RR cushion metal
6. RR cushion spring

7. Fr fender stay
8. Frame body
9. Head light stay
10. Horn
11. Chain case
12. Swing arm
13. Steering stem
14. Caliper assy
15. Caliper holder
16. Brake disc
17. Wheel hubs
18. Brake panel
19. Wheel rim
20. Engine hanger plate
21. Tool box
22. Battery box
23. Pillion step bar
24. Pillion step bar bracket
25. Cylinder
26. Cylinder head
27. Carburetor
28. Crank case R& L
‘c
1. Muffler stay
2. Exhaust pipe joint
3. Kick starter arm
4. Drive chain adjuster
5. Brake pedal
6. Gear change pedal
7. Brake arm
8. Spoke
9. Brake rod
10. Main stand
11. Side stand
12. Stand spring (side and main)

DEFECTWISE
ACCEPTANCE CRITERIA

DEFECTWISE ACCEPTANCE CRITERIA OF PAINTED PARTS
DEFECT CLASS
sa a b c
Color Difference Visually equivalent to master
Shall not be Shall not be Shall not be
Uneven color visible from visible from visible from
0.5m under 0.5m under 1m under Allowed if
1000lux 500 lox. 500 lux not
unsightly
Variation in Within +3%
gloss Shall not be
conspicuous
Uneven color Not allowed
Blushing
Not allowed
Clouding
Cracks
Flaking
Not allowed
Exposed
surfaces
Dents
Allowed of not
Scratches
unsightly
Not allowed
Bubbles
Blisters Allowed if
Craters not
unsightly
Pinholes
Runs Not Allowed Not Allowed Allowed if

except inconspicuous not
Drips
ones at bent areas conspicuous
Sports Shall not Shall not Shall not be visible Allowed if not
be visible be visible from 1m under 500 lux conspicuous
Bleeding from 0.5m from 0.5m
Stains under under
1000 lux 500 lux
Seeding

Wrinkles Shall not Shall not Shall not be Allowed if

Smoothness be visible be visible visible from not
(irregularity) 1m under conspicuous
from from
Orange peels 300 lux
0.5m 0.5m Shall not be
Flaws on
metal surface under under Visible from
Deformation 500 lux 300 lux 2m under
Filing marks 300 lux
Dust 2 max 4 max 6 max
particles, dia:
<0.3mm
Dia : 0.3~0.5mm 2 max 4 max
Not
Dia : 0.5~1.0mm Not 2 max
Allowed
Allowed
Dia : 1.0~1.5mm 1 max
Not Allowed
Dia : > 1.5mm Not Allowed
Fibrous dust Shall not be At minimum At

Length : <3mm minimum intervals
intervals of 100mm
of 25mm
conspicuous
Length : 3~5 mm Shall not be conspicuous At minimum
intervals of 30 mm
Length : 5 mm Shall not be conspicuous
Notes:
1. When color difference meter is used, reference value shall be : color difference <1.5
2. For semi-matte coating, grade ‘a’ shall not be specified as a rule, but grade ‘b’ or lower
grades shall be specified.
3. For matte coating, grade ‘b’ or lower grades shall be specified.
4. The number of dust particles and fibrous dust shall be the numbers within an area of
300mm².
5. Fibrous dust shall be less than 0.3mm in width.
6. The appearance criteria may be replaced with master samples / limit samples and
supplementary requirements may be added if required. The details of supplementary
requirements shall be agreed upon by purchaser and supplier concerned.
7. Dust particles and fibrous particles will be checked from a visual distance of 0.5m under
1000 lux as a rule.

ACCEPTANCE CRITERIA FOR PLATED PARTS
SCOPE: All parts with following type of electroplating:-
1. Nickel-Chrome
2. Hard ( porous ) chrome
3. Zinc
4. Copper
5. Tin
Depending upon the decorative value / appearance grade as specified in the respective part drawing
and grade for example:-
MF Cr3- a appearance grade ‘a’
Appearance test method
This test is conducted by giving illumination of approx 300 lux on the surface of the specimen with
black back ground using standard light ‘D 65’. Approximately 50 cm apart from the specimen and
with a natural posture check the specimen visually (with normal eyesight), for the following:-
exposure of base materials, blisters, peeling, pinholes, pits, rough surface, stain, spots, burnt
deposits, dull deposits, wrinkles, uneven surface, polishing marks, deformation due to polishing,
flaws on base metal, hammer marks, scratches, mottle gloss etc. However polishing marks,
scratches mottle and gloss may be checked visually as required, from the distance of approx 25cm,
against the limit sample which is agreed upon mutually.

APPEARANCE CRITERIA FOR ASSESSMENT IN PLATED PARTS
DEFECT sa a b c d
Separation Not Not Not Not Not
Allowed Allowed Allowed Allowed Allowed
Blistering
Pin holes
Exposed metal Allowed except
surface specified portions
Exposed Allowed
nickel except
or specified
copper portions
Pitting Should Should Even Even conspicuous
not be not be conspic defects are
Rough surface easily conspi uous acceptable
Stains identif cuous defects
iable are
Spots acceptable
Bronzing
Buring
Blushing
Wrinking
Uneven Surface
Should
Polishing marks not be
excessive
Deformation Should
due to not be
polishing conspic
uous
Flaws of Metal Should
surface not be
conspic
uous
Dents
Scratches
Uneven Color

Gloss Should Should Should Allowed if Some even gloss is

be be not be not accepted
uniform uniform conspicu excessive
ously
uneven
Deformed Should Should Should Allowed if Should not be

Metal surface not be not be not be not conspicuous
conspi conspi conspi excessive
cuous cuous cuous
Chalk marks Not Not Not Not Allowed
allowed allowed allowed allowed
NOTES:
1. The appearance criteria may be replaced by the relevant limit samples or supplementary
requirements may be added if mutually agreed.
2. Color chromatic treated surfaces may have interference fringes.
3. The standards for limit samples for scratches, dents and flaws over 3cm² area selected from the
plated surface in critical areas shall conform to following table.

Flaw sa a b
Flaw on Maximum of one flaw Maximum of 2 flaw Maximum of 2 flaw
metal surface per 3cm2: maximum more than 1 mm but more than 1 mm but
length 1 mm less than 4mm per less than 4mm per
3cm 3cm
2 2
Dents Maximum of one dent Maximum of 2 dent Maximum of 2 flaw

per 3cm2: maximum more than 0.5mm more than 1 mm but
diameter 0.5 mm per diameter per less than 4mm per
3cm2 3cm2 3cm2
Scratches Maximum of one Maximum of one Maximum of two

scratch less than scratch more than scratches more than
3mm in length and 3mm but less than 3mm but less than
0.05 mm per 5mm in length but 10mm per 3cm :
2
3cm2 not more than minimum space of

0.05mm in width 20mm maximum
per 3cm width 0.1mm
2

HQI

HQI stands for Hero MotoCorp Quality Index.
It is objective and quantified analysis of quality of the vehicle as supplied to a

customer. It is a methodology to evaluate quality level of Hero MotoCorp
vehicles on a scale of 1~10 on the following aspects by well trained auditors:-
1 Finish of:-
-Painted Sheet metal parts.
-Painted ABS parts.
-Plated Parts.
-Unpainted Plastic Parts.
-Rubber parts.
-ADC Parts.
2. Fits & Gaps.
3. Wiring & Routings.
4. Functional.
5. Performance.
-Frame Drivability.
-Engine Drivability.
-Mode F.E.
The objective of HQI system is to get a rating of the produced vehicles (model
wise) to enhance the Fits, Finish, Functional & Performance level of Hero
MotoCorp Products to stay ahead in global competitive environment.

Following graph illustrates the interpretation of the ratings observed in the HQI audit:-

Evaluation Criteria-HQI
Though HQI considers various aspects for rating the quality of a vehicle, aesthetic is one of the most
important criteria.
The various criteria used for giving the aesthetic rating of the vehicle parts are attached in the
subsequent table.

EVALUATION CRITERIA OF RATING FOR HQI ( APPEARANCE ) - 1 & 2

S.NO. TYPE OF NATURE OF GRADE / CLASS AREA
COMP. DEFECTS A+ RATING CRITERIA A&B RATING CRITERIA C RATING CRITERIA
Scratches Scratches a) Scratch of 1mm & one Scratches a) Scratch of 1mm & one Minor Scratch a) Scratch of 1mm & one
shall not no. then the rating is 6.5 shall not be no. then the rating is 6.5 allowed ( if not no. then the rating is 6.5
be visible b) Scratches of 1mm & 2 visible from b) Scratches of 1mm & 2 penetrated to b) Scratches of 1mm & 2
from 0.5m. no's then the rating is 6.0 0.75m. no's then the rating is 6.0 bare metal ) no's then the rating is 6.0
c) 1.5 to 2.0 mm scratch & c) 1.5 to 2.0 mm scratch & c) 1.5 to 2.0 mm scratch &
1 no. the rating is 6.0 1 no. the rating is 6.0 1 no. the rating is 6.0
d) 1mm length & 3 Scratches, d) 1mm length & 3 d) 1mm length & 3
then the rating 5.5 Scratches, then the rating 5.5 Scratches, then the rating 5.5
e) 1.5 ~ 2.0 mm & 2 e) 1.5 ~ 2.0 mm & 2 scratches e) 1.5 ~ 2.0 mm & 2 scratches
scratches then the rating is 5.5 then the rating is 5.5 then the rating is 5.5
f) 1mm & 4 scratches then f) 1mm & 4 scratches then f) 1mm & 4 scratches then
the rating is 5.0 the rating is 5.0 the rating is 5.0
g) 1.5 ~ 2.0 mm & 3 g) 1.5 ~ 2.0 mm & 3
g) 1.5 ~ 2.0 mm & 3
scratches, the rating is 5. scratches, the rating is 5.
scratches, the rating is 5.
Spot Marks Spot a) Spot Marks of 1mm & Spot marks a) Spot Marks of 1mm & Minor Spot a) Spot Marks of 1mm &
Marks one no. then the rating is 6.5 shall not be one no. then the rating is 6.5 Marks allowed one no. then the rating is 6.5
shall not b) Spot Marks of 1mm & 2 no's visible from b) Spot Marks of 1mm & 2 b) Spot Marks of 1mm & 2 no's
be visible then the rating is 6.0 0.75m. no's then the rating is 6.0 then the rating is 6.0
from 0.5m. c) 1.5 to 2.0 mm spot c) 1.5 to 2.0 mm spot marks c) 1.5 to 2.0 mm spot marks
marks & 1 no. the rating is 6.0 & 1 no. the rating is 6.0 & 1 no. the rating is 6.0
d) 1mm length & 3 Spot d) 1mm length & 3 Spot d) 1mm length & 3 Spot
marks, then the rating 5.5 marks, then the rating 5.5 marks, then the rating 5.5
e) 1.5 ~ 2.0 mm & 2 spot e) 1.5 ~ 2.0 mm & 2 spot
e) 1.5 ~ 2.0 mm & 2 spot
marks then the rating is 5.5 marks then the rating is 5.5
marks then the rating is 5.5
f) 1mm & 4 spot marks then f) 1mm & 4 spot marks then
f) 1mm & 4 spot marks
the rating is 5.0 the rating is 5.0
then the rating is 5.0
g) 1.5 ~ 2.0 mm & 3 spot g) 1.5 ~ 2.0 mm & 3 spot
g) 1.5 ~ 2.0 mm & 3 spot
marks, the rating is 5. marks, the rating is 5.
marks, the rating is 5.
Orange Defects a) Defects under 300 Lux Defects shall a) Defects under 300 Lux Minor defects a) Defects under 300 Lux
Peel ./ shall not Level are not visible then not be visible Level are not visible then allowed Level are not visible then
Paint be visible the rating is 7.0 from 0.75m. the rating is 7.0 the rating is 7.0
Roughness from 0.5m. b) Defects under 300 Lux b) Defects under 300 Lux b) Defects under 300 Lux
( Dry & Level are visible in the area Level are visible in the area Level are visible in the area
Flow )
of 1mm2 then the rating is 6.5 of 1mm2 then the rating is 6.5 of 1mm2 then the rating is 6.5
c) Defects under 300 Lux c) Defects under 300 Lux c) Defects under 300 Lux
Level are visible in the Level are visible in the area Level are visible in the area
area of 2mm2 then the of 2mm2 then the rating is 6.0 of 2mm2 then the rating is 6.0
rating is 6.0 d) Defects under 300 Lux d) Defects under 300 Lux
d) Defects under 300 Lux Level are visible in the area Level are visible in the area
Level are visible in the of 3mm2 then the rating is 5.5 of 3mm2 then the rating is 5.5
area of 3mm2 then the e) Defects under 300 Lux
e) Defects under 300 Lux
rating is 5.5
PLASTIC Level are visible in the area Level are visible in the area
1
PARTS e) Defects under 300 Lux
Level are visible in the area of of 4mm2 then the rating is 5.0 of 4mm2 then the rating is 5.0
of 4mm2 then the rating is 5.0
Dust Dust a) Dust of 1mm & one no. Dust a) Dust of 1mm & one no. Minor dust a) Dust of 1mm & one no.
Particles particles then the rating is 6.5 particles then the rating is 6.5 allowed then the rating is 6.5
shall not b) Dust of 1mm & 2 no's shall not be b) Dust of 1mm & 2 no's b) Dust of 1mm & 2 no's
be visible then the rating is 6.0 visible from then the rating is 6.0 then the rating is 6.0
from 0.5m. c) 1.5 to 2.0 mm dust & 1 0.75m. c) 1.5 to 2.0 mm dust & 1 c) 1.5 to 2.0 mm dust & 1
no. the rating is 6.0 no. the rating is 6.0 no. the rating is 6.0
d) 1mm length & 3 dust, d) 1mm length & 3 dust, d) 1mm length & 3 dust,
then the rating 5.5 then the rating 5.5 then the rating 5.5
e) 1.5 ~ 2.0 mm & 2 dust e) 1.5 ~ 2.0 mm & 2 dust e) 1.5 ~ 2.0 mm & 2 dust
then the rating is 5.5 then the rating is 5.5 then the rating is 5.5
f) 1mm & 4 dust then the f) 1mm & 4 dust then the f) 1mm & 4 dust then the
rating is 5.0 rating is 5.0 rating is 5.0
g) 1.5 ~ 2.0 mm & 3 dust, g) 1.5 ~ 2.0 mm & 3 dust, g) 1.5 ~ 2.0 mm & 3 dust,
the rating is 5. the rating is 5. the rating is 5.
Paint
Shrinkage
Paint Shall not a) If not visible at a Shall not be a) If not visible at a distance Minor a) If not visible at a distance
Mismatch be visible distance of 0.5 m than the visible at a of 0.5 m than the rating is Mismatch of 0.5 m than the rating is
at a rating is more than 6 distance of more than 6 allowed more than 6
distance of b) If visible from the 0.75m b) If visible from the b) If visible from the
0.5m distance of 0.5 m than the distance of 0.5 m than the distance of 0.5 m than the
rating is less than 5. rating is less than 5. rating is less than 5.
c) If the rating is between 5~ 6 c) If the rating is between 5 ~ 6 c) If the rating is between 5 ~ 6
( with conditional ( with conditional ( with conditional
acceptance & acceptance & management acceptance & management
management discretion ). discretion ). discretion ).
Air Air Bubles a) Air Bubble of 1mm & Air Bubles a) Air Bubble of 1mm & one Minor Air a) Air Bubble of 1mm & one
Bubbles in shall not one no. then the rating is 6.5 shall not be no. then the rating is 6.5 Bubbles no. then the rating is 6.5
Stripes be visible b) Air Bubble of 1mm & 2 no's visible from b) Air Bubble of 1mm & 2 allowed b) Air Bubble of 1mm & 2
from 0.5m. then the rating is 6.0 0.5m. no's then the rating is 6.0 no's then the rating is 6.0
c) 1.5 to 2.0 mm Air c) 1.5 to 2.0 mm Air Bubble c) 1.5 to 2.0 mm Air Bubble
Bubble & 1 no. the rating is 6.0 & 1 no. the rating is 6.0 & 1 no. the rating is 6.0
d) 1mm length & 3 Air d) 1mm length & 3 Air d) 1mm length & 3 Air
Bubbles, then the rating 5.5 Bubbles, then the rating 5.5 Bubbles, then the rating 5.5
e) 1.5 ~ 2.0 mm & 2 Air e) 1.5 ~ 2.0 mm & 2 Air e) 1.5 ~ 2.0 mm & 2 Air
Bubbles then the rating is 5.5 Bubbles then the rating is 5.5 Bubbles then the rating is 5.5
f) 1mm & 4 Air Bubbles then f) 1mm & 4 Air Bubbles then f) 1mm & 4 Air Bubbles then
g) 1.5 ~ 2.0 mm & 3 Air g) 1.5 ~ 2.0 mm & 3 Air g) 1.5 ~ 2.0 mm & 3 Air
Bubbles, the rating is 5. Bubbles, the rating is 5. Bubbles, the rating is 5.


S.NO. TYPE OF NATURE OF GRADE / CLASS AREA
COMP. DEFECTS A+ RATING CRITERIA A&B RATING CRITERIA C RATING CRITERIA
Pin / Blow Pin / Blow a) Pin / Blow holes of 1mm & one Pin / Blow a) Pin / Blow holes of 1mm & one Minor Pin / Blow a) Pin / Blow holes of 1mm & one
Holes Holes shall no. then the rating is 6.5 Holes shall not no. then the rating is 6.5 holes no. then the rating is 6.5
not be visible b) Pin / Blow Holes of 1mm & 2 be visible from b) Pin / Blow Holes of 1mm & 2 b) Pin / Blow Holes of 1mm & 2
from 0.5m. no's then the rating is 6.0 0.75m. no's then the rating is 6.0 no's then the rating is 6.0
c) 1.5 to 2.0 mm Pin / Blow Holes c) 1.5 to 2.0 mm Pin / Blow Holes c) 1.5 to 2.0 mm Pin / Blow Holes &
& 1 no. the rating is 6.0 & 1 no. the rating is 6.0 1 no. the rating is 6.0
d) 1mm length & 3 Pin / Blow d) 1mm length & 3 Pin / Blow d) 1mm length & 3 Pin / Blow
Holes, then the rating 5.5 Holes, then the rating 5.5 Holes, then the rating 5.5
e) 1.5 ~ 2.0 mm & 2 Pin / Blow e) 1.5 ~ 2.0 mm & 2 Pin / Blow e) 1.5 ~ 2.0 mm & 2 Pin / Blow
Holes then the rating is 5.5 Holes then the rating is 5.5 Holes then the rating is 5.5
f) 1mm & 4 Pin / Blow Holes then f) 1mm & 4 Pin / Blow Holes then f) 1mm & 4 Pin / Blow Holes then
g) 1.5 ~ 2.0 mm & 3 Pin / Blow g) 1.5 ~ 2.0 mm & 3 Pin / Blow g) 1.5 ~ 2.0 mm & 3 Pin / Blow
Holes, the rating is 5. Holes, the rating is 5. Holes, the rating is 5.
Paint a) If not visible at a distance of a) If not visible at a distance of 0.5 a) If not visible at a distance of 0.5
Mismatch 0.5 m than the rating is more than 6 m than the rating is more than 6 m than the rating is more than 6
b) If visible from the distance of b) If visible from the distance of b) If visible from the distance of 0.5
0.5 m than the rating is less than 0.5 m than the rating is less than 5 m than the rating is less than 5
Shall not be 5 ( Subject to Severity ). Shall not be ( Subject to Severity ). (Subject to Severity ).
visible at a c) If the rating is between 5 ~ 6 visible at a c) If the rating is between 5 ~ 6 c) If the rating is between 5 ~ 6
distance of ( with conditional acceptance & distance of (with conditional acceptance & Minor Mismatch (with conditional acceptance &
0.5m management discretion). 0.75m management discretion ). allowed management discretion ).
a) No Brazing then the rating is 7 a) No Brazing then the rating is 7 a) No Brazing then the rating is 7
b) 10% ~12% Brazing on the b) 10% ~12% Brazing on the area b) 10% ~12% Brazing on the area
area with Good Finish then the with Good Finish then the Rating with Good Finish then the Rating is
Brazing on
Rating is 6.0. Brazing on MFF is 6.0. Brazing on MFF 6.0.
MFF Area
Area shall not be Area shall not be c) 12% ~ 25% Area then the Rating
METAL shall not be c) 12% ~ 25% Area then the c) 12% ~ 25% Area then the
2 present present
PARTS present Rating is 5.5 Rating is 5.5 is 5.5
d) 25% ~ 35% area, then the d) 25% ~ 35% area, then the d) 25% ~ 35% area, then the
Rating is 5.0 Rating is 5.0 Rating is 5.0
e) 35% ~ 40% area, then the e) 35% ~ 40% area, then the e) 35% ~ 40% area, then the
Brazing on the Rating is 4.5 Rating is 4.5 Rating is 4.5
MFF Area f) > 40%, then the Rating is 4.0 f) > 40%, then the Rating is 4.0 f) > 40%, then the Rating is 4.0
Brazing on a) No Brazing observed then the a) No Brazing observed then the a) No Brazing observed then the
Brazing on Seam Brazing on Seam
Seam Area Rating is 7.0. Rating is 7.0. Rating is 7.0.
Area shall not be Area shall not be
Brazing on the shall not be b) In case Brazing observed then b) In case Brazing observed then b) In case Brazing observed then
present present
Seam Area present the Rating is 4.0 the Rating is 4.0 the Rating is 4.0
a) No Dent then the Rating is 7.0. a) No Dent then the Rating is 7.0. a) No Dent then the Rating is 7.0.
b) 2mm Dent, then the Rating is 6.0 b) 2mm Dent, then the Rating is 6.0 b) 2mm Dent, then the Rating is 6.0
No Dents shall c) 4mm ~ 5mm Dent, then the Rating No Dents shall c) 4mm ~ 5mm Dent, then the Rating No Dents shall be c) 4mm ~ 5mm Dent, then the Rating is
be Visible is 5.5 be Visible is 5.5 Visible 5.5
d) 7mm ~8mm Dent, then the Rating is d) 7mm ~8mm Dent, then the Rating is 5.0 d) 7 mm~8mm Dent, then the Rating is 5.0
5.0 e) 8mm ~ 10mm Dent, then the Rating e) 8mm ~ 10mm Dent, then the Rating
Dents on Fuel e) 8mm ~ 10mm Dent, then the Rating is 4.5 is 4.5 is 4.5
Tank f) > 10mm, then the Rating is 4.0 f) > 10mm, then the Rating is 4.0 f) > 10mm, then the Rating is 4.0
No Spatters No Spatters shall No Spatters shall be

shall be Visible be Visible Visible
a) No Spatters, then the Rating is 7.0 a) No Spatters, then the Rating is 7.0 a) No Spatters, then the Rating is 7.0
b) One Spatter, then the Rating is 6.5 b) One Spatter, then the Rating is 6.5 b) One Spatter, then the Rating is 6.5
c) 2 Spatters, then the Rating is 6.0 c) 2 Spatters, then the Rating is 6.0 c) 2 Spatters, then the Rating is 6.0
Welding d) 3 Spatters, then the Rating is 5.0 d) 3 Spatters, then the Rating is 5.0 d) 3 Spatters, then the Rating is 5.0
Spatters on the e) 4 Spatters, then the Rating is 4.5 e) 4 Spatters, then the Rating is 4.5 e) 4 Spatters, then the Rating is 4.5
Frame Body f) > 4 Spatters, then the Rating is 4.0 f) > 4 Spatters, then the Rating is 4.0 f) > 4 Spatters, then the Rating is 4.0


S.NO TYPE OF NATURE OF GRADE / CLASS AREA
. COMP. DEFECTS A+ RATING CRITERIA A&B RATING CRITERIA C RATING CRITERIA
Dents / Scratches a) Scratch of 1mm & one no. then Scratches shall a) Scratch of 1mm & one no. then Minor Scratch a) Scratch of 1mm & one no. then
Scratches shall not be the rating is 6.5 not be visible the rating is 6.5 allowed ( if not the rating is 6.5
visible from b) Scratches of 1mm & 2 no's from 0.75m. b) Scratches of 1mm & 2 no's then penetrated to bare b) Scratches of 1mm & 2 no's then the
0.5m. then the rating is 6.0 the rating is 6.0 metal ) rating is 6.0
c) 1.5 to 2.0 mm scratch & 1 no. c) 1.5 to 2.0 mm scratch & 1 no. c) 1.5 to 2.0 mm scratch & 1 no. the
the rating is 6.0 the rating is 6.0 rating is 6.0
d) 1mm length & 3 Scratches, d) 1mm length & 3 Scratches, then d) 1mm length & 3 Scratches, then
then the rating 5.5 the rating 5.5 the rating 5.5
e) 1.5 ~ 2.0 mm & 2 scratches e) 1.5 ~ 2.0 mm & 2 scratches e) 1.5 ~ 2.0 mm & 2 scratches then
then the rating is 5.5 then the rating is 5.5 the rating is 5.5 f) 1mm
f) 1mm & 4 scratches then the f) 1mm & 4 scratches then the & 4 scratches then the rating is 5.0
rating is 5.0 rating is 5.0 g) 1.5 ~ 2.0 mm & 3 scratches, the
g) 1.5 ~ 2.0 mm & 3 scratches, g) 1.5 ~ 2.0 mm & 3 scratches, the rating is 5.
the rating is 5. rating is 5.
Air Bubbles in Air Bubles a) Air Bubble of 1mm & one no. Air Bubles shall a) Air Bubble of 1mm & one no. Minor Air Bubbles a) Air Bubble of 1mm & one no.
Stripes shall not be then the rating is 6.5 not be visible then the rating is 6.5 allowed then the rating is 6.5
visible from b) Air Bubble of 1mm & 2 no's from 0.5m. b) Air Bubble of 1mm & 2 no's b) Air Bubble of 1mm & 2 no's then
0.5m. then the rating is 6.0 then the rating is 6.0 the rating is 6.0
c) 1.5 to 2.0 mm Air Bubble & 1 c) 1.5 to 2.0 mm Air Bubble & 1 c) 1.5 to 2.0 mm Air Bubble & 1 no.
no. the rating is 6.0 no. the rating is 6.0 the rating is 6.0
d) 1mm length & 3 Air Bubbles, d) 1mm length & 3 Air Bubbles, d) 1mm length & 3 Air Bubbles, then
then the rating 5.5 then the rating 5.5 the rating 5.5
e) 1.5 ~ 2.0 mm & 2 Air Bubbles e) 1.5 ~ 2.0 mm & 2 Air Bubbles e) 1.5 ~ 2.0 mm & 2 Air Bubbles
f) 1mm & 4 Air Bubbles then the f) 1mm & 4 Air Bubbles then the f) 1mm & 4 Air Bubbles then the
g) 1.5 ~ 2.0 mm & 3 Air Bubbles, g) 1.5 ~ 2.0 mm & 3 Air Bubbles, g) 1.5 ~ 2.0 mm & 3 Air Bubbles,
Spot Marks Spot Marks a) Spot Marks of 1mm & one no. Spot marks a) Spot Marks of 1mm & one no. Minor Spot Marks a) Spot Marks of 1mm & one no.
shall not be then the rating is 6.5 shall not be then the rating is 6.5 allowed then the rating is 6.5
visible from b) Spot Marks of 1mm & 2 no's visible from b) Spot Marks of 1mm & 2 no's b) Spot Marks of 1mm & 2 no's
0.5m. then the rating is 6.0 0.75m. then the rating is 6.0 then the rating is 6.0
c) 1.5 to 2.0 mm spot marks & 1 c) 1.5 to 2.0 mm spot marks & 1 c) 1.5 to 2.0 mm spot marks & 1 no.
no. the rating is 6.0 no. the rating is 6.0 the rating is 6.0
d) 1mm length & 3 Spot marks, d) 1mm length & 3 Spot marks, d) 1mm length & 3 Spot marks, then
then the rating 5.5 then the rating 5.5 the rating 5.5
e) 1.5 ~ 2.0 mm & 2 spot marks e) 1.5 ~ 2.0 mm & 2 spot marks e) 1.5 ~ 2.0 mm & 2 spot marks
f) 1mm & 4 spot marks then the f) 1mm & 4 spot marks then the f) 1mm & 4 spot marks then the rating
rating is 5.0 rating is 5.0 is 5.0
g) 1.5 ~ 2.0 mm & 3 spot marks, g) 1.5 ~ 2.0 mm & 3 spot marks, g) 1.5 ~ 2.0 mm & 3 spot marks,
METAL
2 Orange Peel / Defects shall a) Defects under 300 Lux Level Defects shall a) Defects under 300 Lux Level Minor defects
PARTS
Roughness not be visible are not visible then the rating is not be visible are not visible then the rating is allowed a) Defects under 300 Lux Level are
from 0.5m. 7.0 from 0.75m. 7.0 not visible then the rating is 7.0
b) Defects under 300 Lux Level b) Defects under 300 Lux Level b) Defects under 300 Lux Level are
2 2 2
are visible in the area of 1mm are visible in the area of 1mm visible in the area of 1mm then the
then the rating is 6.5 then the rating is 6.5 rating is 6.5
c) Defects under 300 Lux Level c) Defects under 300 Lux Level c) Defects under 300 Lux Level are
2 2 2
d) Defects under 300 Lux Level d) Defects under 300 Lux Level d) Defects under 300 Lux Level are
2 2 2
e) Defects under 300 Lux Level e) Defects under 300 Lux Level e) Defects under 300 Lux Level are
2 2 2
Dust Particles Dust particles a) Dust of 1mm & one no. then Dust particles a) Dust of 1mm & one no. then the Minor dust allowed a) Dust of 1mm & one no. then the
shall not be the rating is 6.5 shall not be rating is 6.5 rating is 6.5
visible from b) Dust of 1mm & 2 no's then the visible from b) Dust of 1mm & 2 no's then the b) Dust of 1mm & 2 no's then the
0.5m. rating is 6.0 0.75m. rating is 6.0 rating is 6.0
c) 1.5 to 2.0 mm dust & 1 no. the c) 1.5 to 2.0 mm dust & 1 no. the c) 1.5 to 2.0 mm dust & 1 no. the
d) 1mm length & 3 dust, then the d) 1mm length & 3 dust, then the d) 1mm length & 3 dust, then the
rating 5.5 rating 5.5 rating 5.5
e) 1.5 ~ 2.0 mm & 2 dust then the e) 1.5 ~ 2.0 mm & 2 dust then the e) 1.5 ~ 2.0 mm & 2 dust then the
f) 1mm & 4 dust then the rating is f) 1mm & 4 dust then the rating is f) 1mm & 4 dust then the rating is
5.0 5.0 5.0
g) 1.5 ~ 2.0 mm & 3 dust, the g) 1.5 ~ 2.0 mm & 3 dust, the g) 1.5 ~ 2.0 mm & 3 dust, the rating
rating is 5. rating is 5. is 5.
Seam Welding
/ Burrs
a) No Burr then the rating is 7 a) No Burr then the rating is 7 a) No Burr then the rating is 7
b) 2mm ~ 4 mm Burr on the b) 2mm ~ 4 mm Burr on the area b) 2mm ~ 4 mm Burr on the area
area then the Rating is 6.0. then the Rating is 6.0. then the Rating is 6.0.
Burr on Seam c) 4mm~5mm Burr on the area Burr on Seam c) 4mm~5mm Burr on the area c) 4mm~5mm Burr on the area
Burr on Seam Area
Area shall not then the Rating is 5.5 Area shall not be then the Rating is 5.5 then the Rating is 5.5
shall not be present
be present d) 7mm ~ 8mm Burr on the area, present d) 7mm ~ 8mm Burr on the area, d) 7mm ~ 8mm Burr on the area,
then the Rating is 5.0 then the Rating is 5.0 then the Rating is 5.0
e) 8mm ~ 10mm Burr on the e) 8mm ~ 10mm Burr on the area, e) 8mm ~ 10mm Burr on the area,
area, then the Rating is 4.5 then the Rating is 4.5 then the Rating is 4.5
f) > 10 mm Burr on the area then f) > 10 mm Burr on the area then f) > 10 mm Burr on the area then
the Rating is 4.0 the Rating is 4.0 the Rating is 4.0

AESTHETIC QUALITY
MEASUREMENT TOOLS

Tough aesthetic quality measurement is a visual checking process in which the human eye is the tool,
but to quantify the aesthetic quality level for certain criteria and to compare with standards,
following tools/instruments can be used for measuring the aesthetic quality of the parts:-
• Limit samples – for comparison
• Aesthetic quality manual – for reference
• Std shade panel – for comparison
• Glossmeter – for checking gloss level degree
• Colorscan – for quantification of shade/color and quantified measurement of shade

difference.
• Color matching cabinet - for shade inspection in different lights
• DOI meter – for checking the orange-peel effect of paint film.
• DFT meter – for checking paint film thickness.
• Roughness tester - for checking substrate finish.

ANNEXURE 16
SOP FOR FIXTURE MANUFACTURING & MAINTENANCE

REF ANNEXURE A
REF ANNEXURE B

GUIDE LINES FOR FIXTURE DESIGN AND MAINTENANCE

ANNEX : A
FIXTURE DESIGN CRITICAL FOCUS POINTS
A MENTION RAW MATERIAL FOR ALL THE PARTS.

B MENTION HARDNESS OF ALL THE WEARABLE PARTS.
C WEARABLE PARTS SHOULD BE DESIGNED FOR EASY REMOVAL AND HAVE AN ACCURACY IN REFITTING.
D DOWEL SIZE AND BOLT SIZE SHOULD BE FREEZE ACCORDING TO THE LOAD AND EFFORT TO BE MADE
FOR STANDARDISATION.
E EXTERNAL DOWELING CAN BE DESIGNED WHERE THE CHANCES OF DISTORTION IS VERY HIGH
F CLAMPING PRESSURE SHOULD BE MENTIONED FOR ALL THE CLAMPS (PNEUMATIC AND TOGGLE CLAMPS).
G PNEUMATIC CLAMPS SHOULD BE PREFERRED THEN MANUAL CLAMPS
H PROVIDE THE LIST OF FAST WEARABLE PARTS SEPARATELY
I DESIGN STANDARD PACKING'S FOR BLOCKS.
J MENTION THE LIFE OF FIXTURE, BLOCKS, PINS FOR EASY SPARE PLANNING ( FOR WEARABLE PARTS)
K USE STANDARD PIN AND BUSH SIZES FOR EASY REPLACEMENT AND TO MAINTAIN LESS INVENTORY OF
SPARES e.g. MAKE ALL THE PINS AND BUSHES OF DIA 10 MM AND KEEP FREE LENGTH AND MAKE THE
LOCATION POINT DIA AS AND WHEN REQUIRED
L PROVIDE THE POCKETS IN FIXTURE FOR EASY CLEANING
M USE COPPER PIPE TO AVOID AIR LEAKAGES.
N MENTION THE MAXIMUM AND MIN SIZE( WEAR LIMIT) OF THE BLOCK FOR TAKING THE REPLACEMENT
DECISION.
O MENTION ALL THE POKA YOKA. SEPARATELY FOR REGULAR MONITORING.
P AIR BOOSTER TO BE PROVIDED WHERE EVER REQUIRED.
Q USE COPPER PLATES ON THE BASE PLATE TO AVOID SPATTERS STICKING.
R REVALIDATION FREQUENCY SHOULD BE MENTIONED ON DRAWING.
S FIXTURE REMOVAL AND RELOADING TIME SHOULD BE SHORT.
T BASED ON PAST EXPERIENCE AND HISTORY, DISTORTION TO BE CONSIDERED IN THE DESIGN OR
PROVISON OF ADJUSTEMNT DURING TRIALS TO BE KEPT IN DESIGN FOR THOSES POINTS ( e.g OUTER
DOWEL, STD PACKING IN THE BLOCKS etc.)
U MENTION THE STRENGTH AND SIZE OF MAGNET BUTTONS.
FIXTURE MANUFACTURING CRITICAL FOCUS POINTS
A MANUFACTURING LOCATION SHOULD HAVE THE COMPLETE INSPECTION FACILITY FOR CHECKING THE
ASSEMBLED FIXTURE.
B ENSURE ALL THE FIXTURE BLOCKS SHOULD BE OK AS PER DRG.
C ALL BASE PLATES AND PROFILE BLOCKS SHOULD BE MANUFACTURED AT VMC/JIG BORING.
D PROPER HEAT TREATMENT AS PER THE DRG TO BE ENSURED FOR ALL THE PARTS

GUIDE LINES FOR FIXTURE DESIGN AND MAINTENANCE

ANNEX : A
FIXTURE TRIALS CRITICAL FOCUS POINTS
A INSPECT THE FIXTURE IN ASSEMBLED CONDITION.
B TAKE OK CHILD PARTS FOR TRIAL.
C TACK WELD THE COMPONENT IN THE WELD FIX AND TAKE OUT THE SAME TO CROSS CHECK THE OUT PUT
OF FIXTURE, PART SHOULD BE PERFECTLY OK AS PER THE DRG AS THERE IS NO WELD DISTORTION IN
THIS CONDITION. IF PART IS OK FOLLOW POINT 'E' ELSE FOLLOW POINT 'D'.
D ANALYSE THE DIM OF FIXTURE IF THE PART IS FOUND NG AND CORRECT THE SAME.
E DO THE DESIRED WELDING AS PER THE WORK STANDARD IN THE FIXTURE AS PER WORK STANDARD AND
CHECK THE RESULTS
F IF RESULTS ARE OK, CONTINUE THE TRIALS, IF RESULTS NG THEN ANALYSE
THE BEHAVIOUR OF DISTORTION
G STUDY THE WELDING SEQUENCE AND PROCESS PARAMETERS AND FREEZE THE WELDING SEQUENCE
WHERE THE DISTORTION IS MINIMUM
H IF STILL THERE IS DISTORTION THEN ADJUST THE BLOCKS TO ELIMINATE THE EFFECT OF DISTORTION.
I MAKE THE FINAL REPORT OF FIXTURE AFTER THE RESULTS ARE ACHIEVED
J IMPLEMENT THE CHANGES DONE ABOVE IN THE FIXTURE DRG
L MAKE THE GAUGE AS PER THE SET DISTORTION WHERE EVER REQUIRED FOR EASY INSPECTION OF PART
DRG REVIEW
UPDATE WHEN EVER ANY CHANGE IS DONE IN THE FIXTURE FOR IMPROVEMENT AND GIVE THE COPY TO ALL
CONCERNED AND DESTROY THE OLD DRG AT ALL LOCATIONS
PRODUCTION FOCUS POINTS

USE ONLY OK BOP PARTS
A PRODUCTION PERSON SHOULD NOT MODIFY OR CORRECT THE FIXTURE IF THE RESULTS ARE NOT OK, HE MUST STOP
B THE PRODUCTION AND CALL THE AUTHORISED PERSON OF FIXTURE MAINTAINACE TO CHECK AND CORRECT THE SAME.
C HAMMERING THE PART IN THE FIXTURE FOR PROPER SITTING OF PART IS NOT PERMITTED, ( IF REQUIRED DO
TAPPING OF PART WITH PLASTIC HAMMER ( MALLET))
D ENSURE FIXTURE IS CALIBRATED AS PER THE DESIGN FREQUENCY AND HAVE VISUAL CONTROL OF THE SAME.
E IF OUT PUT FIXTURE IS NOT OK, CROSSCHECK THE COMPLETE PROCESS AS PER THE PQCS, AND WORKSTD.
F HAVE VISUAL STOCK CONTROL OF WEARABLE PARTS.
E FOP TO BE DONE FOR THE ALL THE PARTS

GENERAL CHECK SHEET FOR FIXTURE DESIGN AND MAINTENANCE

ANNEX B
DAILY MAINTAINACE RESP: PRODUCTION ( OPERATOR)
S .NO PARAMETERS INSP METHOD SPEC FREQUENCY
A SPATTER REMOVAL FROM FIXTURE MANUAL NO SPATTERS EVERY SHIFT
B CHECK ALL THE POKA YOKA VISUAL/OPERATE ALL POKA YOKA IN PLACE EVERY SHIFT
C BLOCK TIGHTNESS MANUAL/FEEL NO LOOSE ONCE /DAY
D AIR LEAKAGE FEEL NO LEAKAGE ONCE /DAY
E MANUAL CLAMP OPERATE NO MOVEMENT OF PART AFTER CLAMPING ONCE /DAY
F INPUT AIR PRESSURE AIR GAUGE AS PER SPEC ONCE /DAY
G PNEUMATIC CLAMP OPERATE NO MOVEMENT OF PART AFTER CLAMPING ONCE /DAY
H PINS AND BUSH FEEL NO EXCESSIVE PLAY IN PIN AND BUSH ONCE /DAY
I MAGNETIC BUTTONS FEEL AVAILABLE AND PROPER CLAMPING ONCE /DAY
J EJECTORS OPERATE PART EJECTION SHOULD BE UNIFORM ONCE /DAY
K PART QUALITY MIN 2 NOS (FOP) GAUGING/INSP GAUGE /SPEC QUALIFICATION EVERY SHIFT
MAKE FIXTURE WISE CHECK SHEET AND FOLLOW
IF ANY NON CONFORMANCE IF OBSERVED TAKE CORRECTIVE ACTION BEFORE START OF PRODUCTION


SHORT TERM MAINTAINANCE ANNEX B
FREQUENCY MONTHLY ( @400 NOS/DAY, ALL SHIFTS) RESP : TOOL MAINT ENGG
S .NO PARAMETERS INSP METHOD SPEC
A CLEAN THE FIXTURE VISUAL NO SPATTERS,RUST,DUST
B CHECK ALL THE POKA YOKA ACTUAL FITMENT NO WRONG PART MFG POSSIBLE
OF PART
C BOLT TIGHTNESS OF BLOCKS RETIGHTENING MAXIMUM BY HAND TOOL W/O ANY LEVERAGE
D AIR LINES VISUAL NO SHARP BEND AND LEAKAGE
E MANUAL CLAMP MTGS RETIGHTENING MAXIMUM BY HAND TOOL W/O ANY LEVERAGE
F MANUAL CLAMP OPERATE NO MOVEMENT OF PART AFTER CLAMPING
OPERATE NO LOOSENESS OF CLAMP
G PNEUMATIC CLAMP OPERATE NO STICK MOVEMENT OF PISTON
OPERATE NO MOVEMENT OF PART AFTER CLAMPING
OPERATE CLAMP SHOULD NOT MOVE BACK WITH MANUAL AND COMPONENT LOAD
H BLOCK SIZES V/C AND HG CHECK THE SIZE OF BLOCKS
I PINS MIC CHECK THE SIZE OF PINS.*
CHECK THE GUIDING POINT OF PIN.*
J BUSH BORE GAUGE CHECK THE SIZE OF BUSH*
K PINS/BUSH FEEL NO EXCESSIVE PLAY IN PIN AND BUSH *
L MAGNETIC BUTTONS FEEL AVAILABLE AND PROPER CLAMPING
M EJECTORS OPERATE PART EJECTION SHOULD BE UNIFORM
N PART QUALITY MIN 5 NOS GAUGING/CMM GAUGE /SPEC QUALIFICATION ( IF PART IS NG THEN ANALYSE FOR BOP AND
FIXTURE BOTH) FRAME BODY SHOULD BE CHECKED ON CMM
O SPRINGS OPERATE CHECK THE SPRING FUNCTIONING BY ACTUAL PART
P BLOCKS WELDING VISUAL NO WELDING CRACKS
TAKE THE HISTORY OF PRODUCT BEFORE STARTING VALIDATION
MAKE FIXTURE WISE CHECK SHEET AND FOLLOW
IF ANY NON CONFORMANCE IS OBSERVED TAKE CORRECTIVE ACTION BEFORE START OF PRODUCTION
IF ANY BLOCK IS REWELDED OR REPLACED MAKE THE REPORT OF THE BLOCK AND REPORT AFTER ASSY OF FIXTURE.
ENTER IN TOOL HISTORY CARD

* TO REDUE THE TIME FOR FIXTURE MAINTAINANCE ENGINEER CAN ALSO PLAN TO REPLACE ALL THE PINS AND BUSHES AND CHECK THE
SAME LATER AND CAN REUSE THE OK PINS AND BUSHES IN NEXT MAINTAINANCE SHEDULE.


PREVENTIVE MAINTENANCE ANNEX B
FREQUENCY YEARLY ( @400 NOS/DAY, ALL SHIFTS) RESP : TOOL MAINT ENGG
S .NO
A TAKE THE HISTORY OF PRODUCT BEFORE STARTING VALIDATION
B CHECK THE CONDITION OF FIXTURE 15 DAYS ADVANCE AND MANUFACTURE ALL THE PARTS IN ADVANCE WHICH ARE VISUALLY WORN OUT.
C REMOVE ALL THE BLOCKS FROM FIXTURE
D CLEAN THE BASE PLATE AND ALL THE BLOCKS
E NOTE DOWN ALL THE PACKING'S REMOVED FROM FIXTURE TO ENSURE THE PROPER ASSY AFTER VALIDATION
F CHECK THE DIMENSIONAL ACCURACY OF ALL THE BLOCKS, PINS, BUSHES AND MAKE THE REPORT
G CHECK THE WELDING CONDITIONS OF ALL THE BLOCKS
H REPLACE ALL THE MAGNETIC BUTTONS
I REPLACE ALL THE INSERTS IN THE FIXTURE.
J CHECK THE PRESSURE OF PNEUMATIC CYLINDERS
K CHECK THE CLAMPING POINTS OF PNEUMATIC CLAMPS
L CHECK THE CLAMPING POINTS OF MANUAL CLAMPS
M ASSY ALL THE PARTS BACK ON THE FIXTURE
N MAKE THE DIM REPORT OF ASSEMBLED FIXTURE
O DO THE WELDING TRIALS AND CHECK THE RESULTS
P IF RESULTS ARE SATISFACTORY DO THE LINE TRIAL OF THE SAME
Q IF RESULTS OF LINE TRIAL OF HANDOVER TO PRODUCTION DEPARTMENT
R MAKE FIXTURE WISE CHECK SHEET AND FOLLOW
S IF ANY NON CONFORMANCE IS OBSERVED TAKE CORRECTIVE ACTION BEFORE START OF PRODUCTION
T FOLLOW DRG ONLY

Hero - Motocorp - Supplier - Quality - Manual Rev2

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HERO MOTOCORP LTD

Effective Date 01.0.2013

Revision-02 Page 1 of 148

I am very pleased to note that your company has prepared an enriched

Brijmohan Lall Munjal

With warm regards

As we continually strive to maintain our position as a two wheeler market leader,

Best wishes for continued future success.

Revision-02 Page 3 of 148

• Provide highest level of customer satisfaction

• Achieve excellence through teamwork

• Create enduring relations with stakeholders

Revision-02 Page 4 of 148

EXCELLENCE IN QUALITY IS THE CORE VALUE OF HERO

INNOVATION IN PRODUCTS, PROCESSES AND SERVICES.

CONTINUOUS IMPROVEMENT IN OUR TOTAL QUALITY

TEAMWORK & RESPONSIBILITY.

Revision-02 Page 5 of 148

HERO MOTOCORP IS COMMITTED TO SAFETY AND HEALTH OF

Page 6 of 122 Revision-02

Revision-02 Page 7 of 148

At Hero MotoCorp environmental protection and preservation is one of the

WE WOULD LIKE OUR VENDORS TO UNDERTAKE THE FOLLOWING ACTIONS &

Establish the environmental footprint of their operations.

Date : 5th June 2007 PAWAN MUNJAL

Revision-02 Page 8 of 148

Follow Ethical Processes & Practices

Treat Supplier as an extension of Hero MotoCorp - Operations

Be Cost Competitive , Agile , Responsive & Risk free.

Promote environment Friendly Processes & Practices

Adopt new Cost-effective Approach & Processes in line with-business

Reach to Global Supplier base for cost - ef fectiveness

Business on QCD performance

Source Technological Sensitive Parts through Associates / Ancillaries where Confidence

Extend Technical, Financial & Management support.

Revision-02 Page 9 of 148

SECTION CLAUSE AMENDMENTS DT 01.08.2013

6.11 Fixture validation System added

# IN VQR CRITERIA , NEGATIVE MARKING FOR SEGREGATION HAS BEEN ADDED

# CAPA & PDI REPORTS CAN BE UPLOADED ON SUPPLIER PORTAL NOW.

# HMCL SPECIFIC REQUIREMENT HAVE BEEN UNDERLINED IN BLUE COLOUR

# SUPPLIERS SHALL ACCESS THE PORTAL EVERY MONTH TO ENSURE

ALIGNMENT WITH HMCL SPECIFIC REQUIREMENTS .

Revision-02 Page 10 of 148

2.0 HMCL EXPECTATIONS FROM SUPPLY CHAIN PARTNERS 17 19

3.0 SUPPLIER'S INTERFACES 20 20

4.0 SUPPLIER'S MANAGEMENT RESPONSIBILITIES 21 24

5.0 NEW MODEL DEVELOPMENT SYSTEM 25 32

6.0 MASS PRODUCTION QUALITY MAINTENANCE SYSTEM 33 41

7.0 DIRECT-ON-LINE SUPPLIES 42 46

8.0 PARTS IDENTIFICATION & TRACEABILITY 48 48

9.0 PACKING STANDARDIZATION FOR OE, SPARES, EXPORTS 49 49

10.0 INITIAL PRODUCTION PART TAG SYSTEM 50 50

11.0 SUPPLIER QUALITY APPROVAL SYSTEM 51 52

Revision-02 Page 11 of 148

2.0 1 DASHBOARD PARAMETERS CALCULATION

4.2 2 MANAGEMENT REVIEWS & ITS DISCUSSION

4.13 3 BROAD ROLES , RESPONSIBILITIES &

5.0 4 NEW MODEL DEVELOPMENT SYSTEM