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QUALITY MANUALISO/TS 16949: 2002

TGCopy No. Issued To Copy Status

Current issue status

Turbo Gears India Pvt. LimitedB2/3, MIDC, Ranjangaon, Pune District 412210, India. Phone: +91 2138 661600 Fax: +91 2138 661631 Website: www.gear-world.com

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ISO/TS 16949: 2002 QUALITY MANUALSl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Document No. QMSM/01 QMSM/02 QMSM/03 QMSM/04 QMSM/05 QMSM/06 QMSM/07 QMSM/08 QMSM/09 QMSM/10 QMSM/11 QMSM/12 QMSM/13

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Content Sheet

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Clause No. 4.2.2 5.3 5.4.1 5.5.1 4.2.2 4.0 5.0 6.0 7.0 8.0 -

Document Description Content Sheet List of abbreviations Company Profile Scope and exclusions for QMS Quality Policy Quality Objectives Organization Structure

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Number of page(s) 01 02 01 01 01 03 01 02 03 04 02 09 06 02 07

TGQMSM/14 QMSM/15 Prepared by M.R.

14 15

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LSequence and Interaction between processes - Generic diagram Quality Management System Requirement Management Responsibility Resource Management Product Realization Measurement, Analysis and Improvement List Of Processes Clause wise process mapping

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Reviewed & Approved by C.O.O.

ISO/TS 16949: 2002 QUALITY MANUALSl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Abbreviation APQP B/D CA CAR CFT CP FMEA HOD HT I/C IATF

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List of abbreviations

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Abbreviation description Advanced Product Quality Planning Break Down Corrective action Corrective action report Cross Functional Team Control Plan Failure Mode and Effect analysis Head of department Heat Treatment In-charge

TGIQA Internal Quality Audit M/C Machine MGT Management MMD MNT Maintenance MOM MR Minutes of Meeting Management Representative MRM Management Review Meeting MSA Measurement System Analysis NABL NC NCR OEE Non-Conformance Non-Conformance Report Overall Equipment Efficiency

International Automotive Task Force

Monitoring and Measuring Devices

National Accredited Board for Inspection and Calibration Laboratory

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ISO/TS 16949: 2002 QUALITY MANUALSl. No. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 Abbreviation OEM PA PAR PDCA PFD PM PO PPAP PPM QA QMSM R&A R/M

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List of abbreviations

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Abbreviation description Original Equipment Manufacturer Preventive Action Preventive Action report Plan-Do-Check-Act Process Flow Diagram Preventive Maintenance Purchase Order Production Part Approval Process Parts Per Million

Quality Assurance

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TGResponsibilities & Authorities Raw Material RPN WI Risk Priority Number Work Instruction TGL Turbo Gears India Private Limited Prepared by M.R.

Quality Management System Manual

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ISO/TS 16949: 2002 QUALITY MANUAL Company Profile

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Turbo Gears is a part of the Italian multinational group Carraro, headquartered in Italy. All the plants specializing in manufacturing gear components and subassemblies have been merged into a new vertical called GearWorld. GearWorld has plants in Italy, North America, South America, China and India. Turbo Gears India Pvt. Ltd. specializes in the production of high technology gears and subassemblies and was started in Dec 2005. Besides supplying to the Carraro group plants, it also caters to the component requirements of major OEMs worldwide. The products go to customers in Agricultural, Construction equipment, Automotive, Industrial equipment and other specialized sectors. Some of the key customers are: Force Man Trucks, Cummins, Caterpillar, Turner, Waukesha Engines Dresser, Transform, Ingersoll Rand, JKM Daerim and Dynamatics Technology. Since inception of the plant, focus has been on introduction of new processes and technologies for gear manufacturing. Starting with conventional gear processes, the company soon established gear-grinding technology as a key growth driver for superior quality gears. The company has also invested into new technologies like gas-Nitriding, heavy duty broaching and Hobbing used in high-end applications. The plant is ISO 9000-2001 certified and has applied for the ISO-TS 16949 in 2008. Total Quality Management is the driving force behind implementation of these initiatives. Gears for wind energy sector is a new growth initiative.

The plant has a total investment of 150 crores. With strength of approx. 350 employees in 2008, the plant is expected to achieve a turnover around Rs. 130 crores.

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ISO/TS 16949: 2002 QUALITY MANUAL Scope & Exclusions for Quality Management System

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Scope: Manufacturing and Supply of Transmission Gears & Shafts. Scope of the elements / clauses of ISO / TS 16949: 2002 to Manufacture and Supply of Transmission Gears & Shafts have been defined in following chapters of this quality management system. Chapter No. QMSM/09 QMSM/10 QMSM/11 QMSM/12 QMSM/13 Chapter Description Quality Management System - Requirements Management Responsibility Resource Management Product Realization Measurement, Analysis and Improvement

Exclusions: The following exclusions have been considered for TGLs QMS. Sr. 1. 2. Clause No. 7.3.2.1 7.3.3.1 Clause Description Product Design Input

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TGProduct Design Output Prepared by M.R.

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Justification for exclusion.

All Design / Drawings are provided by the customer. TGL is designing only manufacturing processes and manufactures the products as per customer requirement.

ISO/TS 16949: 2002 QUALITY MANUAL Quality Policy

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Quality is the backbone of all product & services offered by TGL in line with Carraro Group philosophy. We will strive to achieve market leadership in our field of manufacturing & supply of premium quality gear components, & subassemblies for off highway, automotive, globally.

through development of robust processes of manufacturing, introduction of advanced technologies and implementation of effective Quality Management System leading to profitable growth of the company.

We will build a strong capable team with emphasis on continual knowledge assimilation & skill enhancement.

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We will continually improve satisfaction of all stakeholders

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industrial and other applications, catering to customers

Shashank Jauhri Chief Operating Officer

ISO/TS 16949: 2002 QUALITY MANUALSr. Function

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Quality Objectives

Rev. No./Date Page No.

Process Management review

Objective / Process measures ----Business Plan Achievement --------Repetitive NC Audit Plan Vs Actual COPQ

U/M ----% --------Nos. % %

Target 2008 ----100% --------Zero 100% ------------30% 75% 75% 3,000 ----5 4,500 Zero 100% 100%

1

Top Management Business planning Control of documents Control of Records Internal audit

Control of NC product Corrective action

Preventive action

TGHandling of enquiries Sales Customer satisfaction & analysis Monitoring of customer satisfaction based on objective data. Incoming Inspection Set up approval Final inspection QA Handling of customer complaints Control of MMD (Calibration) Layout inspection

Continual improvement

L------------Hit Ratio Customer satisfaction level (Survey) Customer satisfaction Index (Objective Data) Supplier Rejection ----Customer complaints (max.) / Month Customer Rejection (max.) / Month Repetitive complaints Calibration Plan Vs Actual Plan Vs Actual

2.

MR

------------% % %

3.

PPM ----Nos. PPM Nos. % %

4.

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ISO/TS 16949: 2002 QUALITY MANUALSr. Function

Document No. Issue No./Date

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Quality Objectives

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Process Product audit

Objective / Process measures Plan Vs Actual Plan Vs Actual Plan Vs Actual Supplier Performance Inventory Sales

U/M % % % % Turns Rs.

Target 2008 1