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MUSASHI SOUTH CAROLINA AMENDMENTS

DOC NO:MSC-QM1

Issued by: Ralph Sulser

Edition: 01

TS Manual Amendment Record

CLAUSE CHANGE

7/30/03 1 5- Mgmt. Resp. Updated for organization changes RSS

7/6/04 2 5- Mgmt. Resp. Updated for organization changes RSS9/13/04 1 Forward Distribution list revised to post on "S" RSS


5/3/05 1 1-Scope Revised scope statement, & expanded RSS

7.3 Product design exclusion detail


of responsibilities

REVISION DATE

REVISIONNUMBER

APPROVED BY



MUSASHI SOUTH CAROLINA INTRODUCTIONPage 4 of 70

DOC NO.:MSC-QM1SECTION#: 00


Edition : 01

SECTION NO. TITLE

0 0 5

0.1

0.2

0.3

0.4

-Manual Revision, Updating & Amendment Procedu 0.5

0.6 -0.7 1

1 Scope 1 0 1

1.1

1.2

3 Terms and Definitions 3 0 1

4 Quality Management System 4 0 3

- General Requirement 4.1

4.24.2.1

4.2.2

4.2.3

4.2.4

+May not be part of the "Uncontrolled Copy”

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

SECTION NO. TITLE

5 Management Responsibility 5 7

- Management Commitment 5.1

- Customer Focus 5.2

- Quality Policy 5.3

5.4

5.4.1

5.4.2

5.5

5.5.1

5.5.2

5.5.3

5.6

5.6.15.6.2

5.6.3

6 Resource Management 6 0 2

6.1

6.2

6.2.1

6.2.2

6.3

6.4

CL.REF.

REVISIONNO.

NO. OFPAGES

Introduction

- Table of Contents

- Foreword

- Structure of the Manual

- Manual Issue Procedure

- Company Profile

- Distribution List +

- General

- Application (Exclusions, if any)

- Documentation requirement- General

- Quality Manual

- Control of Documents

- Control of Records

CL.REF.

REVISIONNO.

NO. OFPAGES

3 Updated positionsresp. 3/01/05

- Planning

- Quality Objectives

- Quality Management System Planning

- Responsibility, Authority & Communication

- Responsibility & Authority of Managers

- Management Representative

- Internal Communication

- Management Review

- General- Review Inputs

- Review Outputs

- Provision of Resources

- Human Resources

- General

- Competence, Awareness & Training

- Infrastructure

- Working Environment






Edition : 01

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






Edition : 01

SECTION NO. TITLE

0 7

7 Product Realization 7

- Planning of Product Realization 7.1

- Customer Related Processes 7.2

7.2.1

7.2.2

7.2.37.3

7.4

7.4.1

7.4.2

7.4.3

7.5

7.5.1

7.5.2

production and service provision

7.5.3

7.5.4

7.5.5

7.6

7.6.1

7.6.27.6.3

7.6.3.1

SECTION NO. TITLE

8 8 0 3

8.1

8.2

8.2.1

8.2.2

8.2.3

8.2.4

8.3

8.4

8.5

8.5.1

8.5.2

8.5.3

9 Section 2- Customer Specific requirements 1

10 Amendment Record 1

Annex 0 4

Annex Organization Chart 0 1

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

CL.REF.

REVISIONNO.

NO. OFPAGES

- Determination of requirements related to the produc

-Review of Requirements related to the product

-

Customer Communication- Design & Development

- Purchasing

- Purchasing Process

- Purchasing Information

- Verification of Purchased Product

- Production & Service Provision

- Control of production and service provision

*Validation of processes for

- Identification & Traceability

- Customer Property

- Preservation of product

-Control of Monitoring and Measuring Devices

- Measurement system analysis

- Calibration/verification records- Laboratory requirements

- Internal Laboratory

CL.REF.

REVISIONNO.

NO. OFPAGES

Measurement, Analysis andImprovement

- General

- Monitoring & Measurement

- Customer Satisfaction

- Internal Audit

- Monitoring & Measurement of Processes

- Monitoring & Measurement of Products

- Control of Non-conforming Product

- Analysis of Data

- Improvement

- Continual Improvement

- Corrective Action

- Preventive Action

Product Process Flow Chart , Process ApproachCharts






Edition : 01

Introduction

0.2 FOREWORD

0.3

0.4 MANUAL ISSUE PROCEDURE

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

revisions.


This Quality Manual describes the Quality Management System – Requirements adopted by Musashi South Carolina.The Manual lists the Procedures and measures stipulated for ensuring the quality of products manufactured by this unit.

The Quality Management System has been formulated on the basis of ISO/TS 16949:2002(E) for MSC. This Sectiontitled "Introduction" explains the Structure, Issue and Updating procedure of the Quality System Manual. This Manualand the information incorporated herein are the property of Musashi South Carolina. It must not be reproduced in wholeor in part or otherwise disclosed without prior consent in writing from MSC.

STRUCTURE OF THE MANUAL

This Quality Manual is structured as shown in the content pages of the Manual. Different sections are arrangedsequentialy as per clause number of ISO/TS 16949:2002(E) and ISO 9001: 2000 (herein after called QMS Standard).The main clause number of QMS Standard has also been indicated along with title of each Section. For all Sections,relevant sub-clause numbers under the main clause of QMS Standard have been indicated in the text. Quality SystemManual pages are numbered serially with page number indication. All pages of the Master Copy of each Section of the

manual contain electronic signature(s) of the Issuing and Approving Authority of the manual. The current revisionnumbers and edition numbers on each page is also indicated. Revision no. ”0” has been given to first issue of theSection. This master manual is available in English Language only, and copies may be available in Japanese if required

The TS16949 Coordinator/Management Representative is authorized by the Quality Control Manager, and the Presidentto carry out the activities of preparing, issuing, maintaining and updating of this Quality System Manual.

The distribution of the Manual and the amendment(s) are con-trolled and the TS16949 Coordinator/ ManagementRepresentative carries out this activity.

The Master Copy contains the electronic signature of the approving and issuing authority in original. The Master files arein the controlled in the TS16949 Coordinator’s computer files, with restricted access. Printed Controlled Copies are redstamped "Controlled Document" on the first page. Uncontrolled copies issued to designated individual s (as per distribution list) are legibly photocopied from the Master Copy.

Additional copies of the Manual, required by external agencies, if any, are issued by the TS16949Coordinator/Management Representative and such copies of the Manual issued are not stamped in red. This indicates thatthe copies are not controlled by virtue of the non-red stamp due to the copy process. These uncon-trolled copies do notcome under the control of the document amen-dment procedure, and are used for reference only, and are not used withinthe Company.

The TS16949 Coordinator / Management Representative maintains a record of the distribu-tion list of the Quality SystemManual. This list is used as reference for updating of the respective controlled copies.






Edition : 01

0.5 MANUAL REVISION, UPDATING AND AMENDMENT PROCEDURE

The TS16949 Coordinator/Management Representative retains one copy of the

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

0.6 COMPANY PROFILE

In 1938, Musashi Seimitsu Industry Co. LTD, Toyohashi, Japan started its first

Manufacturing operation in Musashino City, Tokyo. Business flourished and

they soon became a major supplier of precision automotive components worldwide.

Musashi Seimitsu has grown to include facilities in the United States, Thailand,

United Kingdom, Brazil, Indonesia and Canada.


The TS16949 Coordinator/ Management Representative in consultation with the related departments reviews the QualitySystem Manual periodically. No revision is implemented unless it has been approved by the Senior Manager QualityControl, then formally issued.

Each revision is introduced formally by the TS16949Coordinator/ Management Represen-tative by issue of revisedsection(s) for each of the copies as per the Distribution List.

When revisions take place, the revisions are indicated by the revision number in each of the revised sections and recordedin the Amendment Sheet (Refer Amendment Sheet) supplied with the controlled copies of the Manual. If there are morethan 20 revisions, the complete manual is revised to the next edition number.

The insertion of the additional/amended sections and the removal of the old sections in the individual controlled copiesas per the distribution list of the Manual are the responsibility of the person holding the individual copy. All old sectionsso removed are crossed with an inscription of the marking "OBSOLETE" and returned to the TS16949 Coordinator/Management Representative who ensures that the same are destroyed.

Musashi South Carolina, Inc. was established on October 25th, 1999, and started production in 2001. The 120,000 squarefoot main plant and 10,000 square foot assembly plant were built on 40.4 acres of land near Bennettsville, SouthCarolina. MSC produces ATV gears and assemblies and automotive differential gears.

MSC is dedicated to the Team Philosophy. Teamwork is essential, and open communication is the cornerstone of all our processes.

MSC's production areas are supported by several departments, including General Administration, Human Resources,Purchasing, Engineering, E/H/S, Quality Control, Maintenance and Tool and Die.

QUALITY, CUSTOMER FOCUS, AND CUSTOMER SATISFACTION is a way of life at Musashi South Carolina.Our products are sold in the international automotive and ATV markets. Musashi products have an established reputationin the world market for excellence in quality, and customer focus.

Musashi continually upgrades technology and customer focus for quality, to optimize product performance, superior ininternational world-class quality expectations.






Edition : 01

DISTRIBUTION LIST

(Distributed uncontrolled copy by electronic e-mail)

Posted on the "shared" computer file

TS16949 Coordinator (Printed Controlled copy)


Master Copy



MUSASHI SOUTH CAROLINA SCOPE

DOC NO.:MSC-QM1


Edition: 01

1 SCOPE

1.1 General

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

Application

1.2

The following ISO/TS16949:2002 requirement is not applicable to MSC QMS, and therefore excluded from our scope:

MSC does not have product design responsibility. All products are manufactured to customer drawings.

MSC has adopted Technical Specification, ISO/TS 16949:2002(E) and Visteon Customer Specific Requirements, which

specifies the requirements for a Quality Management System in order to:

a) Demonstrate ability to consistently provide product(s) that meet(s) customers’ standards, and applicable regulatory

requirements, and

b) Enhance customer satisfaction through the effective application of the system, including the processes for continualimprovement of the system and the assurance of conformity to customer and applicable regulatory requirements.

The established system is applicable to the activities of the company plant located at One Musashi Drive,Bennettsville, SC. The scope of implementation of this standard is as given below:

Clause 7.3 activities related to Product Design and Development.



MUSASHI SOUTH CAROLINA SCOPE

DOC NO.:MSC-QM1


Edition: 01




MUSASHI SOUTH CAROLINA TERMS and DEFINITIONS12 of 70

DOC NO.:-QM1SECTION#:3


Edition: 01

3.0 TERMS, DEFINITION & ABBREVIATIONS

3.1OrganizatiMusashi South Carolina (MSC)

Supplier: Organizations supplying the materials, parts and /or services to MSC

Customer: The Customer /end user who buys the MSC products. It is also used for Internal

Customers

3.2

QMS Quality Management System NC Non-conformance

OPI Operator Process Instructions FMEA Failure Mode Effect AnalysisT/L Team Leaders PPAP Production Part Approval Process

PC Production Control APQP Advanced Product Quality Planning

MT Maintenance PH Purchasing

PC Production Control PD Production

MGT Management CP Control Plan

SP Standard procedure CAR Corrective Action Request

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

Terms and definitions:

Abbreviations:



MUSASHI SOUTH CAROLINA TERMS and DEFINITIONS13 of 70

DOC NO.:-QM1SECTION#:3


Edition: 01




MUSASHI SOUTH CAROLINAQUALITY MANAGEMENT SYSTEM

Page 14 of 70DOC NO.:MSC-QM1

SECTION#: 4

Issued by: Ralph Sulser Approved by: Keith Shepard

Edition: 01Date: 04/02/03

Rev. 0

4.1 General Requirements

MSC has therefore:

These processes are managed by MSC in accordance with the requirements of the QMS Standard.


4.0 Quality Management System

The MSC has established, documented, and implemented a Quality Management System. The company maintains andcontinually improves the effectiveness of our QMS in accordance with the requirements of ISO/TS 16949:2002

a) identified the processes needed for the quality management system, and their application throughout MSC, except for the exclusion as mentioned at Section 1.0 (Refer 1.2), The outsource processes, if any, that affect product conformity withrequirements, have also been identified. Apart from their identification, the Company has also identified the controls over their processes in order to ensure product conformity.

b) determined the sequence and interaction of these processes (QC-PM-001 &001b) , and a typical bevelgear Process Flow Diagram(s) shown in each part’s PPAP/QAV booklet. (located in the front of manual)

c) determined the criteria and the methods needed to ensure that both the operation and control of these processes are effective. This has been done while planning for the processes. (Refer Section 7.1).d) ensured the availability of resources and information necessary to support the operation and monitoring of these processes (Refer Section 6 & 7.1). These have been determined and verified at the time of planning the processes.

e) decided to monitor, measure and analyze the above identified processes (Refer Section 8), and

f) implemented actions necessary to achieve the planned results and deciding, the continual improvement of these processes.

4.1.1 MSC assures control over any outsourced processes and responsibility of same conforming to all customer requirements.





SECTION#: 4



Rev. 0

4.2 Documentation Requirements

The Quality Management System documentation of the MSC includes:

a) Documented statement of Quality Policy and Quality Objectives, (Refer Section 5.3 & 5.4.1 of this Manual)

b) Quality System Manual,

The Company has developed document structure as given below:

Level 1- Quality System Manual

Level 2- Standard Procedures

Level 3 -Operator Process Instructions

Work Instructions

Process Flow Diagrams

Drawings / Specifications

Level 4- Checksheets, Charts, Forms, Tags

4.2.1 General

c) Documented procedures wherever required by ISO/TS 16949:2002 and where the absence of these procedures can affect the quality of the product.

d) Applicable documents needed by the Company to ensure the effective planning, operation and control of its processes, and

e) Quality Records specified by this standard required for demonstrating the objective evidence of havingcarried out the activity.

MSC has established procedures to conform with those specified in the Standard and identified as

“Documented Procedures”. These have been established, documented, implemented and maintained. While planning for the processes, apart from the required procedures, other procedures and guidelines / work instructions have also been identified based on the type of the activity, complexity of the processes and theexisting competence of the personnel.





SECTION#: 4



Rev. 0


The controls defined in the procedure include the methods:

and implementation of all customers engineering standards/specifications and

changes. Timely review shall not exceed two working weeks.

A record will be maintained of the date each change is implemented, and corresponding document changes

Procedure No.: QC SP 003 -Document Control

4.2.2 Quality Manual

MSC has established and maintains a Quality Manual that includes the applicable Scope of the QualityManagement System (Refer Section 1.1). Procedures established have been referenced in the relevant Sections.

Wherever no procedures are required, the required methodology as adopted and implemented to meet therequirement of the standard have been explained in the Manual itself. The interaction between the processes(QC-PM-001) of the Quality Management System have also been described in the Manual and byincluding the Process Flow Diagram(s) of the product(s) processed by the Company.

4.2.3 Control of Documents

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

a) To approve documents for adequacy prior to issue, from designated approving authorities,

b) To review and update, as necessary, as a part of improvement of the management systems and re-approvethe documents after modifications by the designated approving authorities,

c) To ensure that changes and the current revision status of documents are identified through establishingdistribution and maintaining revision / issue number.

d) To ensure that relevant versions of applicable documents are available at the points of use.

e) To ensure that documents, while distributing and use, remain legible and are readily identifiable by their document numbers, revision status and/or titles,

f) To ensure that documents of external origin like customer drawings, international / other national standards areidentified and updated periodically and their distribution controlled.

g) To prevent the unintended use of obsolete documents by eliminating same and substituting with revised version, andto apply suitable identification to them if they are retained for any legal / reference purposes.

4.2.3.1 A system has been established and maintained to assure timely review distribution

4.2.4 Control of Quality Records

While planning for the processes (Refer Section No. 7.1), the MSC has determined, established and maintainedapplicable “Quality Records” which provide evidence of conformity to requirements [including regulatory andcustomer requirements] and of the effective operation of the Quality Management System. These qualityrecords serve as the objective evidence and are part of the Quality Management Systems. Quality records aremaintained in such a manner that these remain legible, readily identifiable and retrievable.

MSC has established a documented procedure which defines the controls needed for identification, storage, protection, retrieval, retention time, and disposition of records.

4.2.4.1 Records retention controls shall satisfy regulatory, and customer requirements if these differ from MSC





SECTION#: 4



Rev. 0


company policies. Procedure No.: QC SP 004 - Control of Records



MUSASHI SOUTH CAROLINAMANAGEMENT RESPONSIBILITY

Page 18 of 70

DOC. NO.;MSC-QM1SECTION #: 5



Rev. 4

5.2 Customer Focus

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

MGT SP 001 Contract Review (Product Requirement Review)

QC SP 023 APQP (Planning for product realization)

QC-SP-007 Failure Mode And Effect Analysis

5.3 Quality Policy

The Management of the company has defined the quality policy ensuring that the quality policy


5.0 Management Responsibility

5.1 Management Commitment

The MSC management is committed to the development and implementation of the quality management systemand continually improve its effectiveness by:

a) Communicating to all employees of the company: the importance of meeting customer as well

as statutory and regulatory requirements through regular training programs, display of documentsand departmental meetings, communication meetings, and manag

b) Establishing the quality policy based on the improvement objectives,

c) Ensuring that quality objectives are established,

d) Conducting regular management reviews, and

e) Ensuring the availability of resources for improvements when required.

f) Product realization process and support processes are reviewed for their effectiveness and efficiency

The Top Management of MSC ensures that customer requirements are determined and fulfilled with the aim of enhancingcustomer satisfaction. While reviewing the requirements, the implied needs and expectation of the customer are alsoidentified. These are conveyed to the respective functions for ensuring that they are met. As a part of Management Review

(Refer 5.6 below), a focus is made for communicating the customer requirements to all functions and ensuring productconformance.

a) is appropriate to the purpose and organizational goals of the company,

b) includes a commitment to comply with requirements and continually improve the effectiveness of the qualitymanagement system,

c) provides a framework for establishing and reviewing quality objectives,

d) is communicated to all employees of the company and is understood at all levels in the company,

e) is periodically reviewed for continuing suitability.




Page 19 of 70




Rev. 4

QUALITY POLICY

Dated: 03/20/2003 S. Okubo President

customer satisfaction. Current plant organizational charts are on file in H.R.


The Policy of the company has been displayed at strategic locations and also distributed to all employees. Periodic TrainingPrograms are held for understanding by all the functions through out the organization. Quality Policy distribution anddisplay records are maintained.

The policy of Musashi South Carolina is to achieve total customer satisfaction by delivering products and providing servicesthat meet or exceed customer quality requirements and expectations. Deliver on time, and at the most competitive prices indomestic and export market for our entire product range.

It is implied that all people at all levels in our organization be committed to comply with requirements and continuallyimprove the effectiveness of the Quality Management System and their performance. Ultimate goal of working towardsachieving zero defects. Necessary measures are also taken towards product safety, and environmental needs to minimize potential risks to employees, and subsequent end users.

Our mission is to make Musashi South Carolina a synonym for a world-class organization excelling in gear, and gear assembly manufacturing.

MSC Senior Management, Department Managers, Assistant Managers, and area Team Leaders shall ensure that this policyis understood, implemented and maintained by all personnel in their respective division / department / section.

“MSC will continually strive to produce quality products that meetor exceed customer expectations, cost competitiveness, and timelydeliveries – QCD (Quality, Cost, Delivery) – through exercise of continual improvement, employee support, and customer communication.”

Process interactions of achieving product realization are described on QC-PM-001. Outlined below aretypical duties, and inputs of the department management to focus on objectives, and




Page 20 of 70




Rev. 4

5.4 Planning5.4.1 Quality objectives

Quality objectives address customer expectations and achievement goals within a defined time period.

5.4.2 Quality management system planning

Top management ensures that

5.5 Responsibility, authority and communication

5.5.1 Responsibility and authority

Top management ensures that the responsibilities and authorities are defined and communicated within the organization.

Top management ensures that quality objectives, including those needed to meet requirements for product [see 7.1 a)] areestablished at relevant functions and levels within the organization. The quality objectives are measurable and consistent

with the quality policy.

Top management defines quality objectives and measurements that are included in the business plan and used to deploy thequality policy.

a) the planning of the quality management system is carried out in order to meet the requirements given in 4.1, as well asthe quality objectives, and

b) the integrity of the quality management system is maintained when changes to the quality management system are planned and implemented.

1. President - Musashi South Carolina• The senior most executive at the plant and designated as President, and has responsibility for the entire operation..

• Approves customer and supplier contract review actives.

• Approves the company's policies and gives directions for managing the objectives, and company activities.

• Approves the MSC's quality policy and objectives.

• Responsible for providing essential resources and personnel for implementation of the quality policy, and quality

management system.

• Responsible for effective implementation of the quality management system.

• Through leadership and actions, the President creates an environment where people are fully involved, and in which a

QMS can operate effectively.• Reviews customer scorecards for Visteon, and other customers, on their web sites

• Chairman of the Management Review Committee.

2. Senior Manager Engineering/Maintenance

• Overall responsibility for planning, coordinating & managing activities related to functions of Manufacturing

Engineering, Maintenance, Projects.

• Preventive/Predictive Maintenance, Tool/Die, Mechanical, Electrical, Compressor, pump house and LPG and all utilities

• Manages, and coordinates any modifications to be carried out in the existing operations or enhancing the efficiency of

the plant.

• Responsible for building the required competency level in the employees reporting to him.

• Assisted by Manufacturing Engr. Mgr, Maint. Manager.• Authorized for approval of production processes in the plant.

• Authorized for taking corrective & preventive action in case of deviations in the operations.

• Authorized to “STOP PRODUCTION” if systems are not being implemented.

• Developing facilities, processes and equipment, and contingency plans.

• Supporting QMS activities including regulatory requirement if any, for the products.

• Reports to the Plant President.




Page 21 of 70




Rev. 4





Page 22 of 70




Rev. 4

Responsible for quality systems, procedures, and instructions for the plant


3. Senior Manager – Quality Control

• Monitoring the Process for outputs.

• Providing Test Status on In-coming, In-process and Finished Products

• Documenting trends in quality and current quality levels.

•

Controlling of non-conforming products.• Authorized for dispositioning deviations on Non-conforming products for use at next stages.

• Authorized for release of finished product.

• Obtaining waivers from customer on non-conforming finished products.

• Developing and implementation of plans for customer complaint resolution.

• Assessment of Preliminary (Ppk) and on going process capabilities (Cpk).

• Preparing details for Production Part Approval Process.

• Inspection and testing at incoming, in process and final stages

• Controlling the procedures for In-coming, In-process and Final Inspection Stages

• Calibration of all identified inspection, measuring and test equipment.

• Authorized for providing inspection and test status on all products.

• Identifying and implementing statistical technical techniques for process and product.

• Verifying the effectiveness of corrective and preventing actions.

• Issuing and maintaining originals and withdrawal of obsolete APQP documents, process standards, drawing anddocuments of external origin.

• Production Part Approval Process (PPAP&PSW) and liaison with customers for same

• Establishing, and maintaining customer communication channels.

• Monitoring and Measuring Customer Satisfaction metrics.

• Representing the needs of the customer in internal functions in addressing the ISO/TS 16949 requirements.

• Assisted by Quality Control Mgr. QC, QC Technicians, QC Associates, TS16949 Coordinator

• Reviews and maintains scorecards for Visteon, and other customers, weekly on their web sites

• Designated as Customer Representative to ensure customer requirement are met, and contact for quality issues.

· Representing the needs of the customer in internal functions addressing the product realization planning (APQP) for

ISO/TS 16949 requirements (e.g. selection of special characteristics, setting quality parameters.

• Develops manufacturing process design quality controls including Process Flow Diagram, FMEAs, Control Plans andProcess Standards, and Inspection Standards.

• Authorized to “STOP PRODUCTION” if systems are not being implemented.

• Reports to the Plant President




Page 23 of 70




Rev. 4


4. Senior Manager Production/Production Control/New Sales• Overall responsibility for planning, coordinating & managing activities related to functions of Production

• Purchasing of manufacturing materials, and supplier monitoring.

• Production scheduling of all products

• Control of customer-supplied products, and packaging

•

Receiving, storage and issue of products, and packaging.• Reviewing, approving and maintaining effectiveness of the procedures for the above activities.

• Disposal of scrap, and waste.

• Ensuring 100% on time delivery to customer.

• Inventory management of purchased products, WIP and finished product.

• Checking adequacy of FIFO.

• Supplier performance tracking

• Supporting QMS requirements related to these functional areas.

• Assisted by Production Control Manager, and Coordinators.

• Reviews customer scorecards for Visteon, and other customers, on their web sites

• Preparing and submitting the quotation offer to customers.

• Receipt of order / dispatch schedules from customer.

• Review of customer’s order for correctness.• Resolving any differences between the inquires and potential orders.

• Communicating customer’s requirement to concerned personnel in the company.

• Interaction with Customer for product development and all contract review activities

• Also responsible for EHS, ISO14001 and assisted by the EHS Administrator

• Assisted by Managers, and Assistant Managers for Forging, Lathing, Heat Treat/Assembly, for these activities.

• Guiding and supporting QMS activities including regulatory requirement if any, for the products.

• Reviews customer scorecards for Visteon, and other customer rating systems

• Authorized for approval of production processes in the plant.

• Authorized for taking corrective & preventive action in case of deviations in the operations.

• Authorized to “STOP PRODUCTION” in his area, if systems are not being implemented.

• Reports to the Plant President

5. Accounting Manager• Overall responsibility for all accounting, finance, and supplies purchasing functions in the plant.

• Assists in guiding and supporting QMS related activities in those functions such as purchased supplies, tooling, and

stores.

• Assisted by the, Assistant Manager of Accounting, and the Assistant Manager Purchasing/Buyer, Accounting

Coordinator, and IT Administrator for these activities.


6. Manager– Human Resources• Responsible for coordinating with departmental heads to obtain staffing.

• Determine the training needs related to managers, staff, associates, temporaries, probationers, and trainees.

• Identifies, and implements training, and employee motivation needs.

• Also responsible for public affairs, and industrial relations to enhance productivity.• Assisted by the H.R. Assistant, and Payroll Coordinator.





Page 24 of 70




Rev. 4

Identification of training needs for building a team of internal quality auditors

5.5.1.1 Responsibility and authority of managers

Personnel responsible for product quality have the authority to stop production to correct quality problems.

5.5.2 Management representative

d) liaison with external parties on matters relating to the quality management system.


7. MSI Engineering- Japan

• Reviewing, recommending and providing guideance for effectiveness of the procedures on Product requirement

Review – Manufacturing Process Designing and Development; Plant Facilities and Equipments Provisioning,

• Developing guidelines of new products planning.• Reviewing customer engineering specifications and standards.

8. President - Sales and Marketing-Musashi North America, Detroit, MI• Receipt of Inquiries from the customers, review, and passes thyrough to Musashi South Carolina

• Coordinating with MSI, MSC President for planning future business

• Assists in assessments of customer satisfaction.

• Reports to President Musahi North America

9. Management Representative ( Ref. 5.5.2 )

The Management of the company has appointed the TS16949 Coordinator , as Management Representative, who,irrespective of other responsibilities, has the responsibility and authority that includes:

Management Representative (MR) / TS16949 Coordinator, Quality Controlare responsible for

• Establishing, implementing and maintaining quantity system in accordance with ISO/TS 16949:2002 (E)

• Reporting the performance of the Quality System for Management Review, which forms the basis for

improvement of Quality System.

• Liaison with internal and external parties on matters relating to Quality System.

• Ensuring timely management review of the Quality System.

• Organizing Audit Summary Report, and summary of the Preventive Actions for Management Review.

• Approving and ensuring effectiveness of procedures on Document Control, Quality Management SystemAuditing and Records Control.

• Preparation and issue of Quality System, and Procedures Manuals

• Maintaining original documents and their master lists and issue of Quality System Manual, all Quality System

Procedures, all work instructions, and samples of all formats

Managers with responsibility and authority for corrective action are promptly informed of products or processes that do notconform to requirements.

Production operations across all shifts are staffed with personnel in charge of, or delegated responsibility for, ensuring product quality.

Top management has appointed the TS16949 Coordinator-Quality Control who, irrespective of other responsibilities, hasthe responsibility and authority that includes:

a) ensuring that processes needed for the quality management system are established, implemented and maintained,

b) reporting to top management on the performance of the quality management system and any need for improvement, and

c) ensuring the promotion of awareness of customer requirements throughout the organization.




Page 25 of 70




Rev. 4

5.5.3 Internal communication

5.6 Management review5.6.1 General

5.6.1.1 Quality Management System Performance-Input

5.6.2.1 Additional Review Inputs

a) Management analysis of actual and potential field failures, and their impact on quality, safety, or the environment.

5.6.3 Review output

Procedure No. QC SP 001 – Management Review

Management Review Form: QC-F-MR418


5.5.2.1 The Sr. Manager-Quality Control has been designated as Customer Representative to assure customer requirementsare addred within MSC. Visteron will be notified of any changes to customer rep., or senior mgmt.

The Management of the MSC ensures that appropriate communication processes are established within the company andthat communication takes place regarding the effectiveness of the quality management system, and actions to be taken onnon-conformances encountered in the activities including customer communication.

Top Management of MSC reviews the company’s quality management system, at planned intervals to ensure its continuingsuitability, adequacy and effectiveness. The Quality Management System of the company is reviewed by the ManagementReview Team that comprises all Managers of Departments under the Chairmanship of the President.

The review includes assessing opportunities for improvement and the need for changes to the quality management system,including the quality policy and quality objectives. Management Representative maintains records of management reviews.

- All requirements of the quality management system, performance, and trends for continual improvement.

- Monitoring quality objectives

- Regular reporting and evaluation of cost of poor quality- Evidence of achieving: quality objective specified in the business plan

- Evidence of customer satisfaction with products supplied

5.6.1 Review input

The input to management review in the form of Agenda for Management Review Team meeting includes information for the period under review on sections of applicable QMS STANDARDS. However, more focus is placed on the following:

a) Business Plan/Quality objectives

b) Cost of poor quality

c) Customer satisfaction, feedback, (Customer perceptions & Complaints)

d) Analysis of actual and potential field failures and their impact on quality, safety or the environment

e) Follow-up actions from previous management reviews,

f) Results of internal/external audits including the trends,

g) Process performance and product conformity,h) Status of preventive and corrective actions,

i) Planned changes that may affect the quality management system, and

j) Recommendations for improvement especially for product / process characteristics,

k) Status and results of Quality objectives and Quality Improvement Programs,

l) Performance of Suppliers, e.a., monthly ratings for quality, and delivery

b) Measurements at specified stages of design and development will be defined, analyzed, and reported with summaryresults. Items such as quality risks, costs, lead times, critical paths, and others as appropriate.

The minutes of the management review meeting are recorded and maintained for a specified period. The output from themanagement review in the form of minutes of meeting and action plans include any decisions and actions related to:

a) Improvement of the effectiveness of the quality management system and its processes,

b) Improvement of product related to customer requirements, and

c) Resource needs support



MUSASHI SOUTH CAROLINARESOURCE MANAGEMENT

Page 26 of 70

DOC NO.: MSC-QM1SECTION#: 6


Approved by: Keith Shepard


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6 Resource Management

6.1 Provision of Resources

6.2 Human Resources

6.2.1 General

For process design responsible personnel this includes competence on design tools and techniques

MSC determines and provides the resources, such as competent personnel, proper working environment and adequateinfrastructure needed to implement and maintain the Quality Management System and continually improve its effectiveness.

Equipment and instruments needed for work and verification are identified, procured. Procedures are issued to ensure thatthese are fit for use in carrying out work and verification activities.

Department Managers identify the resources required for implementing, performing and verification activities related toMSC’s quality management systems. These are further examined, reviewed and provided as and when required to enhancecustomer satisfaction by meeting customer requirements. These resources are identified at the time of planning for productrealization and periodically reviewed ( Refer Section No. 7.1). Necessary identified resources are planned and provided tomeet the requirements.

MSC has identified the competence level required for the personnel carrying out the activities in different areas of operations and production departments. The “Job Description (Profiles) for all functions have been defined on the basis of requirements related to appropriate education, training, skills and experience for the specific jobs. Hence the personnel performing such work, which affects product quality, are assigned the tasks on the basis of defined competence. The jobdescriptions are also used for identifying the training needs of the personnel to ensure they are competent to do their assigned activities.

6.2.2 Competence, Awareness and Training

MSC has established a documented procedure for Training. Through this procedure, the training needs of personnel areidentified to ensure competence for carrying out their activities. The controls exercised for making the personnel competentare:

a) To determine the required minimum competence for the personnel performing work affecting product quality in termsof criticality of the process through defined “Job Description (Profiles) (Refer Section 6.2.1 above),

a) To provide structured / unstructured training (i.e. technical college courses, on job training / coaching under thesupervision of their seniors) to the identified personnel to satisfy and meet their training needs. On the job training is provided to all the personnel including temporary/contract personnel whenever there is any new or modified job/processaffecting product quality is incorporated. During this training, associates are informed of the consequences to the customer of non-conformity to quality requirements.

b) To evaluate, after a defined period, the effectiveness of the structured / unstructured training provided, toward progress

in their achievements:

c) To ensure that the MSC associates are fully aware of the relevance and the importance of their activities includingtheir involvement and contribution to the achievement for the identified quality objectives.

d) To maintain records of education, training, skills and experience of all associates as quality records. These records alsohelp in determining the need for multi-skill training requirements, if any. (Refer to Skill Maps for each department)

f) A documented procedure has been established and maintained for employee motivation and empowerment for achievingquality objectives, continual improvement and promote innovation. A process is in place to ensure that personnel are awareof the relevance and importance of their activities and contribution in achieving quality objectives.

Procedure: HR SP 001 Training




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Infrastructure

As per the identified requirements, MSC provides the infrastructure needed to achieve conformity to product requirements.

Procedure: QC SP 024 Contingency Plan

MT-SP-001

6.4 Work Environment

MSC determines and manages the required work environment needed to achieve conformity

to product requirements as per documented process. At the time of planning for Product Realization

wherever required, reviewed upgrading. The following applicable work environment factors

6.4.1 Personnel safety to achieve product quality

6.4.2 Cleanliness of premises

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

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

HR SP 002 Resource Management

6.3

MSC identifies and determines, with a multidisciplinary approach, the required infrastructure at the time of Planning for Product Realization (Refer Section No. 7.1). The infrastructure considered during planning includes:

a) adequate buildings for storage, processing, inspections b) adequate workspace for working and house keeping, processing and storage

c) required associated utilities like power, compressors, water supply, fuel supply, utilities etc.;

d) required process equipment / machinery (both hardware and software) which can meet needs for converting the inputsinto required outputs at relevant stages of processing, and can meet the customer requirements.

e) supporting services, such as transport for movement within and outside of MSC and required means of communication.

f) Plant layout is developed in such a way so that it optimizes material travel; handling and value added use of floor space, and facilitates a synchronous flow of material. A system is in place to evaluate and monitor the effectiveness of existing operation.

g) A contingency plan is prepared and followed in all manufacturing departments to ensure supply of products in theevent of emergency such as utility interruptions, labor shortage, key equipment failure and field returns.

MSC has also established a documented procedure, and preventative maintenance schedule matrix for maintaining the aboveinfrastructure by conducting preventive, condition monitoring and break-down maintenance in order to ensure continuingsuitability. The data related to maintenance is analyzed and maintenance objectives are established for continualimprovements.

- Procedure for Preventative Maintenance(update-CG)

( Refer Section No. 7.1), the requirements of Work Environment are considered and examined and

are considered at the time of planning:

• Temperature, humidity, vibration, air quality, noise, lighting, as appropriate to the nature of the work being performed.

Product safety and means to minimize potential risks to employees, and customers are addressed by MSC, especially in thedesign and development process and in manufacturing process activities.

• Human factors such as ergonomics (space required for effective working), and need for the use of personal protective

equipment (PPE).




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The work conditions and environment are continually improved for meeting the product requirements. These requirementsare met by providing the adequate facilities and conducting regular maintenance for their upkeep.



MUSASHI SOUTH CAROLINA PRODUCT REALIZATIONPage 29 of 70





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7.0 Product Realization

7.1.1 Customer requirements and references or differences to the specified technical specifications are included in the planning.

Procedure No. MGT-SP-001 Contract Review

Procedure No. QC SP 023 Advanced Product Quality Planning

7.2 Customer Related Processes

7.2.1 Determination of Requirements Related to Product

The organization has established a documented procedure to determine:

customer and statutory and regulatory requirements;

characteristics;

7.2.1.1 Customer designated special characteristics are identified for conformance according to

customer requirements of the designation, documented and controlled

7.2.2 Review of Requirements Related to Product

7.1 Planning of Product Realization

MSC uses a multi-disciplinary approach for Planning for the products realization [using advance product quality process].While Planning for product realization, it is ensured that the requirements of the other processes of the Quality ManagementSystem (see 4.1) are consistent with the anticipated requirements.

Product and process regulatory requirements are also given due consideration during the development and preparation of relevant Process Control Documents. The resources, infrastructure, work environment and competency of required personnel are identified.

The following are considered, as appropriate, at the time of development, updating / modification for improvement in the existing process:

a) identified quality objectives and requirements for the product; [7.1.2 Acceptance criteria are defined by the company, and approved by the customer if required. The acceptance level for attribute data sampling is always zero defects.]

b) the need to establish processes, documents, and provide resources specific to meet the requirements of the product;

c) required verification, validation, monitoring, inspection and test activities specific to the products processed at relevant stages of processes and the criteria for the product acceptance; Acceptance criteria for attribute data sampling is zero defects.

d) 7.1.3 Confidentiality of customer contracted product/projects and related product information.

e) records needed to provide objective evidence that the realization processes and resulting product fulfill requirements.

The business risks, the FMEAs (failure modes), their current status (i.e. Severity, Occurrence, Detection criteria) are studied and therequired controls are identified. If upgrades are required for improvements, then action plans are initiated.

The output of this planning in the form of a Control Plan, FMEA, Operator Process Instructions, or process control standards (PCS),quality inspection plans are made and provided at the relevant stages of processing for implementation.

7.1.4 A system is in place to control and react to changes that impact product realization. Assessment, verification, validation is done for the changes including the changes by the supplier.

- requirements related to product including those specified by the customer, not stated by the

- conformity to customer requirements for designation, documentation, and control of special

- review of requirements related to product prior to supply and resolving any differences;

- amendments of relevant documents if product requirements are changed;

- investigating, conforming and documenting the manufacturing feasibility of the proposed product

- determining and implementing effective arrangements with the customer; and

- ability to communicate necessary information in customer specified language and format

MSC reviews the requirements related to the product. This review is conducted via a check list prior to the organization's commitment tosupply products to the customer and ensures that:

a) Product requirements including delivery schedules, packing requirements are clearly defined. Where the customer provides nodocumented requirements, the customer requirements are confirmed before acceptance by: phone calls, e-mails, meetings, letters.








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Records of the results of the review and actions arising from the review as quality records are also maintained.

Procedure No. MGT-SP-001 Contract Review

Procedure No. QC SP 023 APQP

b) Contract or order requirements differing from those previously expressed are resolved, and

c) MSC has the ability to meet the defined requirements.

d) Manufacturing feasibility including risk analysis is investigated, confirmed and documented before contracting.

e) In case any formal review of the contract is not applicable, prior authorization from the customer is obtained before proceedingwith the contract.

If any amendments to product requirements are received from the customer, MSC ensures that these are reviewed for ability to supply,and the relevant documents are amended accordingly. The modified documents are conveyed to relevant functions for making themaware of the changed requirements for immediate compliance.

7.2.3 Customer communication

MSC has determined and assigned responsibilities for implementing effective arrangements for communicating with customers inrelation to:

a) Product information through customer visits, meetings, letters, e-mails, and web site.

b) Inquiries, contracts or order handling, including amendments, and

c) Customer feedback, including resolving customer complaints. Such feedbacks from customer are reviewed and analyzed for rootcause of the problems through problem solving techniques. The decisions taken for corrective and preventive actions including further improvements in the products / processes.

d) Where required by the customer, necessary information including data is communicated to customers in their specified languageand format. (web sites, e-mail, electronic data exchange)

Procedure No. MGT SP 001 - Procedure for Contract Review

QC SP 019 - Corrective Action (Includes Customer complaint response)

QC SP 011 - Procedure for internal & External Customer Satisfaction

7.3.2 Design and Development Planning

MSC only manufactures products from customer provided designs and specifications, and therefore performs only manufacturing process design and development activities in conjunction with Planning for product Realization.

Upon receiving a Letter of Intent (LOI) or Purchase Order (PO) from the customer the organization develops a process design anddevelopment plan defining the development stages design review, verification and validation requirements and responsibilities /authorities for design and development.

7.3.2.1 The organization uses cross-functional teams for manufacturing process design and development. The team carries out feasibilitystudies, prepares process flow diagrams, PFMEA, (process failure mode and effective analysis), develops Control Plans and identifiesspecial characteristics for products giving due care to product safety, utilizing appropriate mistake proofing methodologies with effortson defect prevention rather than detection and, creating internal awareness on safety considerations.

7.3.2.2 The design and development inputs are then identified, documented and reviewed based on product and customer requirementsand experience from previous developments.

Control Plans are developed at the system, sub system and component levels for the products supplied at the different phases via

Prototype, Pre-launch and Production as appropriate including listing all controls used for process control.

7.3.2.3 Manufacturing design outputs consist of process control guidelines, i.e., FMEAs, Control Plans, Process Standards and Operator Process Instructions. These are marked with the customer’s special characteristics symbols, if specified by the customer on thedrawings/documents supplied.

All production processes, which directly affect the quality of products, are considered during quality planning. Control Plans arereviewed and updated if the product or process changes, or becomes in-capable / unstable. Inspection methods, and frequencies are alsorevised if necessary.

Process approval acceptance criteria data for quality, reliability, maintainability and measurability results of error-proofing activities.Methods of rapid detection and feed back of manufacturing process non conformities are defined, as appropriate as an output, of the








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-identification of need for submission / preparation of PPAP-decision on submission level

-Preparation of Part Submission Warrant and submitting a copy of PPAP document / sample to customer, as appropriate

-Maintaining original PPAP documents / records

-Maintaining master sample (s)

-Incorporating changes required by customer in the documents and processes

Purchasing

PH-SP- 002 Approved Supplier List

7.4.2 Purchasing information

Quality management system requirements.

design and development activity in the form of procedures, work instructions or process standards.

Programs of design and development is monitored at defined stages / frequency, analyzed and reported with summary results in themanagement reviews.

7.3.6.3 A procedure has also been established for production part approval process (PPAP) addressing the following activities asapplicable:

Part approval process is used for suppliers. The system ensures that the engineering changes are properly validated. Review, verificationand validation of the newly designed and developed manufacturing process is carried out at sample / prototype, production part approvaland pre-launch stages of production respectively. Developed product is reviewed at sample / prototype stage, verified and validated after production part approval. Records of results of reviews, verification and validation of manufacturing process design and developmentactivities are maintained.

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

7.47.4.1 Purchasing process

MSC has established a documented procedure to ensure that purchased products conform to specify purchase requirements [includingconformity to applicable regulatory requirements]. The type and extent of control applied to the supplier and the purchased productdepends upon the effect of the purchased product on subsequent product realization or the finished / final product. The Companyevaluates and selects suppliers based on their ability to supply product in accordance with the Company’s requirements [where specified by the customer, purchasing is done from customer approved sources only unless waived by the customer.

Criteria for selection, evaluation and periodical re-evaluation have been established [monitoring of the supplier is done usingdocumented process which considers the indicators like quality, delivery schedule performance, premium freight, field return and specialstatus, customer notification]. Records of the results of evaluations and any necessary actions arising from the evaluation at company or supplier end are maintained.

MGT-SP- 001 Contract Review (Sr. Manager Production Control and President)

PH-QP- 4.6 Purchasing – Materials/Components (Production Control Manager)

MSC has established criteria for detailing adequate “Purchasing Information” in the Purchase Documents (in hard copies / through e-mails) for the products to be procured. The product and supplier details are described in Purchase Documents or e-mails, including whereapplicable:

a) Requirements for approval of product, procedures, processes, and equipment,

b) Requirements for qualification of personnel, and

The authorized Production Control Manager or Purchasing Manager reviews the purchase information to ensure the adequacy of specified purchase requirements prior to their communication or issue to the suppliers.

MGT-SP- 001 Contract Review (Sr. Manager Production Control and President)

PH-QP-4.6 Purchasing-Materials/Components (Production Control Manager)

PH- SP- 005 – Purchasing Indirect Materials, Tooling, Supplies (Purchasing Manager)








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(Rec.Insp.)

Procedure No. QC SP 014 Receiving Inspection-Bar Stock

Work Instruction PD-WI-017 Receiving Steel Bars

Work Instruction PD-WI-HF-109 Receiving and inspection of ATV Billets

Production and service provision7.5.1 Control of Production and Service Provision

Equipment, tooling and gages not likely to be used for a considerable time are packaged and preserved per a checklist.

A system has been established to assure minimum stocks of replacement parts for all key manufacturing equipment.

Maintenance objectives are developed in the beginning of financial year which are evaluated and improved at planned intervals.

A goal has been established for quality management system development of suppliers That goal is eventual supplier conformity with

ISO/TS 16949-2002. As a first phase suppliers are encougred to pursue and obtain third party certification to ISO 9001-2000 and finallyto ISO/TS16949-2002 if applicable.

7.4.3 Verification of Purchased Product

a) MSC has established a documented procedure for implementing the Inspection / Testing or Verification of the products, asnecessary, for ensuring that purchased products meet the specified purchase requirements. The company ensures that through this procedure for receiving inspection and testing, all material at incoming stage are inspected, tested/verified for conformance to thespecified requirements.

b) During verification of purchase product one of the methods as given below are followed:

- Receipt and evaluation of statistical data

- Receiving inspection and testing on the basis of sampling

- Assessment of supplier by customer or third party supported through acceptable product quality record.

- Test Report from accredited laboratory.

- Other methodology as advised by the customer .

c) If contractually agreed, the company also allows its customers or their representatives to verify that the purchased materials atsupplier end for ensuring materials conformance to specified requirements. When it is proposed to verify the purchased product at thesupplier's premises by either customer or company’s representatives, the verification arrangements and the method of product release arespecified in the purchase order or its attachments.

7.5

Servicing, and Appearance Items are not currently a contractual part of Musashi South Carolina customer requirements, and not part of MSC’s current manufacturing operations. If in the future these become a requirement, we will address them in accordance with the

applicable specification, and/or standards.

Production is controlled by way of preparing and implementing Operator Process Instructions, Work Instructions, Check Sheets, and X bar & R Charts. Suitable equipment, and monitoring and measuring devices are provided and maintained. Release and delivery activitiesare implemented.

MSI Engineering Departments during Manufacturing Process Designing and Development process prepares initial FMEAs, ControlPlans, and Operator process Instructions. These are then modified to reflect MSC actual conditions.

7.5.1.1 Controls Plans are developed at the system, subsystem, component and / or material level for the product supplied, for differentstages of process development i.e. prototype pre-launch and production, from the process FMEA output.

Control Plans are reviewed and updated when any change occurs effecting product, manufacturing process, measurement, logistics,supply source or FMEA.

7.5.1.2 The manufacturing departments carry out production based on the Operator Process Instructions and prepare any additional work instructions necessary, and checklists for employee responsible for the operation of process including set up personnel, which are

accessible for use at the work station.7.5.1.3 First piece set up is approved, before allowing mass production by authorized person during each job change of each operation.

7.5.1.4 Detailed checklists developed for each process equipment are used for preventive maintenance and predictive maintenance as per the maintenance plans developed yearly and reviewed monthly.

7.5.1.5 A system for maintenance of production tooling has been established including maintenance personnel storage and recovery,








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Note: Printed documents are not controlled copies-check master computer files for latest revisionsRelated procedures/Instructions:

Shear Operations PD-WI- SH-101

Hot Forging Press Start Up PD-WI- HF- 102 &103

Hot Forging Press Die Change PD-WI-HF-105

Heat Treatment PD-WI-HT-100

Shot Blast-Billets and Forged Gears PD-WI-FSB-101

Handling, Storage, Packing, Preservation

Customer Supplied Parts and Packaging PH SP 001

Final Inspection & Packing of Visteon Gears PD-WI-HT-109

Before starting mass production, validation of processes, equipment and personnel is performed.

Procedure No. QC-SP-009 PSW/PPAP

setup, tool change program for perishable tools; tool and tool design modification, documentation, tool identification and tool status.

7.5.1.6 The production scheduling is customer order/ forecast driven and supplies are made just in time based on customer schedules/releases and electronic dispatch instructions (EDI).

7.5.1.7 Customer feedback from service or field performance concerns is transmitted to the company via web customer web site, e-mail,and phone calls.

7.5.1.8 MSC currently does not have any service agreements with customers. If in the future Service Provisions become a requirement,we would develop a procedure to incorporate those requirements

PC SP 001

7.5.2 Validation of Processes for Production

A system has been established and maintained for revalidation of the processes. Validation is performed by determining CPks at run rateon customer designated characteristics, and records are maintained. The validation process is defined by the customer, or PPAP for specific criteria for review and approval, equipment approval, personnel qualification, methods / procedures, records requirements andrevalidation.

7.5.3 Identification and Traceability

The Company has established a system for product identification and traceability, which requires that products be identifiable to theapplicable specifications, as appropriate. Incoming materials, WIP, and finished packaging are identified by a lot tag giving details of part lot numbers, part name, and part number. Identification of all products at different stages of activity in the plant is maintained fromthe beginning billet shear operation through finished product to final packaging operation to the customer for all products.

Work In-Process is also identifiable and traceable by part number lot tags. The products lot traceability is also identified through the datadocumented on the each part’s check sheets. These sheets become quality records at each operation, and are traceable to date of production operations, inspection/testing / packing. The traceability lot tags are assigned at each operation and logged in and out, and isalso provided on packaged products sent to the customers.

The inspection and test status of items are identified through lot identification tags, inspection records, designated staging/storage areasand placards, as applicable. The identification, inspection and test status of incoming items are identified based on supplier’s tags/labels,and certificate of conformance and / or the inspection and tests performed. These are then stored at designated locations. Separate areashave been identified and marked for incoming materials, and non-conforming items.

Procedure No. QC SP 015 Product Identification & Traceability

Procedure No. QC SP 005 Lot Control

7.5.4 Customer Property

MSC takes due care with customer property while under the MSC’s control, or being used by the MSC. MSC may receive products,samples, drawings and packaging from the customers. A documented procedure identifies, verifies, protects and safeguards thecustomer property provided for use or incorporation into the product. If any customer property is lost, damaged or otherwise found to beunsuitable during verification for further use, it is reported to the customer and the necessary records are maintained.








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Procedure No. PH SP 001 Customer Supplied Parts and Packaging


Every employee is responsible for safe handling of the products at various stages of processing.

PC SP 001 Handling, Storage, Packing, Preservation

PC WI 002 Production Planning

Provisions to safeguard the calibrated equipment from adjustments and setting are also made as and where applicable.

The calibration is carried out under controlled conditions as detailed in the relevant procedures.

7.5.5 Preservation of Product

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

Handling, storage and transportation of products is to be controlled to prevent damage, deterioration or loss. When necessary, for particular items, special instructions are issued and monitoring is carried out to check satisfactory implementation. The appropriatehandling of products is followed to avoid any deterioration of quality of product while in transit.

7.5.5.1 Appropriate storage areas are provided for materials and products for protection, and to prevent damage and deterioration of the product quality, including suitable preservation wherever necessary. The condition of the products in stock is assessed at appropriateintervals.

All raw materials are issued on First In-First Out basis. An inventory management system is also used to optimize inventory turns. Work instructions have been established for inventory management. FIFO is utilized for issuing and using stock. Obsolete products are treatedas non-conforming.

A system for packing, packaging, marking, considering customer packaging standard and labeling / marking requirements have also been established.

PC WI 010 Monthly Inventory Corrections in the AS400

PC WI 011 Process Count Inventory Adjustment

7.6 Control of monitoring and measuring devices

The range of measurements and required accuracies are determined by the gage control technician. Measuring devices, including testsoftware if necessary, used for conforming product quality, are selected based the capability of meeting the necessary accuracy and precision. This ensures that the measurement uncertainty is known and is consistent with the required measurement capability.

The measuring devices that can affect products are identified and calibrated / verified / adjusted / readjusted at prescribed intervals,against measurement standards traceable to national / international measurement standards.

Where no such standards exist, the basis used for calibration is recorded. If applicable, test software and test hardware used for inspection purposes are checked at prescribed intervals to assess their capability to verify the acceptability of product.

Master list and calibration records containing necessary details are maintained in a controlled computer "Master file" by the QC GageCalibration Technician, for all such devices. They are identified with a suitable indication through use of an engraved code number, a

label, or color coded mark indicating the calibration status, and due dates for re-calibration.

Persons using the calibrated equipment are trained to handle, store and preserve them appropriately to prevent damage and maintain theaccuracy and fitness for use.

Any measuring devices that fail during operation, are suspect, known to be outside its designated criteria or show evidence of physicaldama e affectin accurac are removed from the location of use and isolated b the Ga e Control Technician. Validit of ins ection and








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test results of parts checked with measuring devices found to be out of calibration is assessed as applicable. If it has been determined thatsuspect material has been shipped, MSC will recall that material from transit, or notify customer if already delivered.

7.6.1 Measurement System Analysis is carried out for each type of measuring and test equipment, referred in the control plan, usingappropriate statistical techniques. The analytical methods and acceptance criteria used conform to those in customer reference MSAmanual.

7.6.2 Records of calibration / verification of all measuring devices include: equipment identification, measurement standard used for calibration, revisions following engineering changes, any out of specification reading as received for calibration with their assessment of

impact, statement of conformance to specification after calibration and notification to customer if suspect material or product may have been shipped are maintained as defined in the relevant procedure.








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QC SP 017 Gage Control

QC SP 026 Gage Calibration Scope

QC SP 008 Internal Laboratory Scope

PD-HT-703&705SM Laboratory System –Skill Maps

7.6.3.1 MSC has an established system and procedure for the internal laboratory with a defined scope, which includes the capability to perform the required inspection, test and calibration services.

The technical requirements for compliance by the laboratory include: adequacy of the laboratory procedures, qualification of thelaboratory personnel conducting test, testing of commodities and capability to perform these test correctly, traceable to relevant processstandard (e.g. ASTM) and review of related records.

7.6.3.2 External laboratories selected for inspection, test or calibration purposes are based on capability to perform the requiredinspection/ test / calibration, and its accreditation of ISO / IEC 17025 or national equivalent or its acceptability to customer.

Computer Software, when used in the monitoring and measurement of specified requirements, are validated at the time of installationand records are maintained. The ability of computer software to satisfy the intended application is confirmed. As and when such softwareis updated, the same are again re-validated and the results are re-confirmed. Such software is re-confirmed at specified frequency asreferred in the documented procedure.

Procedure Nos.








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MUSASHI SOUTH CAROLINAMEASUREMENT, ANALYSIS, IMPROVEMENT


SECTION#: 8




Rev. 0

Related Procedures

QC SP 006 Control Plans

QC SP 007 FMEA

HR SP 001 Human Resource – Training

QC SP 013 Statistical Process Control

Customer satisfaction and expectations are evaluated on both perceptive as well as performance measures.

Audit frequency is appropriately increased when internal / external non-conformances or customer complaints occur.

Corrective actions are taken as appropriate when planned results are not achieved.

8. Measurement, analysis and improvement

8.1 General

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

8.1.1 Appropriate statistical techniques are determined during manufacturing process design and included in control plan.

8.1.2 Training on basic statistical concepts, such as variation, control (stability) process validity and over adjustment is acompetency requirement throughout the organization.

8.2 Monitoring and measurement

8.2.1- A procedure has been established for evaluation of customer satisfaction, expectations and applications of measures toenhance customer satisfaction.

Information on customer performance measures are obtained from our customers’ electronic web site postings of supplier rating systems. These measures include quality, delivery, and systems. Sr.Mgr.QC or Asst.Mgr. QC monitors weekly.Theinformation on perceptive measures are developed by the organization for additional customer feedback, such as phonecalls, e-mail, sales communications, related to customer perceptive/performance measures.

Countermeasures are developed and monitored for any unsatisfactory areas identified from the customer ratings, andcustomer satisfaction expectations.

The customer satisfaction ratings are monitored, and maintained continually and evaluated for performance of the productrealization process. Customer web site information is updated monthly for key scoring criteria.

8.2.2- The organization has a procedure for performing internal audits at planned intervals to determine if the qualitymanagement system conforms to the planned arrangements and is effectively implemented, covering all qualitymanagement related process, activities and shifts.

Specific checklists are developed for the audits. Corrective actions are taken on the non-conformance observed, in meetingthe planned results, during the audits. The audits also aim at determining the effectiveness of the manufacturing process, and products.

8.2.3 Performance monitoring measures are decided for the quality management system processes. Processes performanceon each measure is measured by the concerned process owner, and measured as: Percents /$ /PPM / DPM and results presented in Management Review Meetings.

8.2.3.1 Process capability of each new process is studied and verified during production part approval process (PPAP).Control plans are reviewed and revised for additional control needed, if any, based on the PPAP results. PPAP results aredocumented.

The output of the manufacturing process design and development process is in the form of Operator Process Instructions.OPIs define inspection, standards, frequencies, and methods, and other instructions to provide necessary information asmeans of production measurement, test and maintenance instructions. Also includes objectives for manufacturing processcapability, validity, maintainability and availability as well as acceptance criteria.

Process control procedures established within the organization ensures maintaining manufacturing capability or performanceas specified by the customer part approval process requirement by following the manufacturing process design anddevelopment process output documents such as process / inspection / packaging standards and other work instructions.Significant process events are noted on the control charts and inspection records maintained for controlling the





SECTION#: 8




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Related procedures

QC SP 023 APQP

QC SP 017&026 Gage Control, and Gage Calibration Scope

QC SP 016 Control of Non Conforming ProductQC SP 018 Internal Quality Auditing

QC SP 011 Customer Satisfaction

QC SP 001 Management Review

PD SP 001 Process Control

QC SP 016

manufacturing process.

Appropriate reaction plans in the Control of Non-Conforming Product, and Corrective Action Procedures have beendeveloped and are followed for characteristics that are either unstable or non-capable.

The reaction plans include containment, and segregation of product, 100% inspection, and root cause analysis asappropriate. Corrective actions plans are developed and implemented to assure that the process become stable and capable.The plans are reviewed and approved by the customer, if required.

8.2.4 Operator Process Instructions, check sheets, and X bar & R charts have been established for monitoring and measuringthe characteristics of the product to verify that product requirements have been met.

Product releases for delivery to customer do not proceed until all the planned operations, inspections and tests have beensatisfactorily completed, unless approved otherwise by a relevant authority or via customer communications.

The O.P.I.s also includes product audit and layout inspections of products at appropriate stages of production and delivery,and at frequency defined for each product.

Currently MSC does not have any customer requirements for “appearance items”. In the event this becomes a futurerequirement the necessary controls, including appropriate lighting, master samples and qualifications of personnel, will bedefined.

8.3 Control of nonconforming product

A procedure for control of nonconforming products has been established, defining a system for identification, control,evaluation, documentation, disposition, containment, segregation (where practicable), rework / repair and prevention of unintended use of nonconforming / suspect products at various stages during manufacturing.

According to this procedure nonconforming products are reviewed by authorized personnel for action required to eliminatecause, determine rework, acceptance without repair by waiver (through deviation from customer, if and where necessary), or

for the rejection / scrap. Reworked / repaired products are re-inspected according to the original specified requirements.Products with unidentified or suspect status are classified as nonconforming.

Nonconforming / suspect material is placed in designated color-coded product bins at operations, and the products in the bins containing then are visually identified.

Rework instructions are established, accessible and utilized by appropriate personnel in their work area. Reworked parts arere-inspected prior to release. Nonconforming products are quantified, analyzed and a prioritized reduction plan instituted asnecessary.

Currently MSC does not have service, or aftermarket provisions required by customers. In the event service applications arerequired, products with visible nonconformances detected will not be reworked without prior approval of customers.

Prior written customer approval is obtained whenever the product or process, that affects the final product, is different fromthat approved in Production Part Approval Process (PPAP). (Ref. Also SCR-Supplier Change Request)

Quantity/time criteria for this approval is maintained. The system ensures that the product / process conforms to original or superceding specifications on expiration of this approval. Material shipped after customer approval is appropriatelyidentified.

When non-conforming product is detected after delivery or use has started, necessary actions, including customer notification appropriate to the effect, or potential effect, of the non-conformance is taken. Records pertaining to control of nonconforming products are maintained as per relevant procedures.

8.3.1 Related Procedures

Control of Non Conforming Product





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The trends are compared with progress towards overall business objective, and appropriate benchmarks.

QC SP 001 Management Review

Non-conformances observed and reported by customer if any, are responded to in manner prescribed by the customer.

The effectiveness of the corrective action is verified from the quality of subsequent product processes, or internal audits.

Records of results of corrective and preventive actions including analysis of customer returned products are maintained.

Documented procedures established for corrective and preventive action are as follows.

QC SP 019 Corrective Action

QC SP 020 Preventive Action

QC-SP 021 Continual Improvement

8.4 Analysis of Data

The organization prepares and maintains trends in quality, productivity, delivery, cost, safety and other performancemeasures. This demonstrates the suitability and effectiveness of the quality management system. The data is used toevaluate / identify opportunities for continual improvement of the effectiveness / performance of the quality managementsystem. This includes data relating to customer satisfaction, conformance to product requirements, characteristics and trendsof processes and product and suppliers.

Key customer related trends are determined and action plans prepared and prioritized for prompt solutions to customer related problems. The trends are presented in the Management Review Meeting, where they are reviewed along with actions plans if necessary.

8.4.1 Related procedure

8.5 Improvement

A procedure has been established defining a method for controlling the process for continual improvement, and for continually improving the effectiveness of the quality management system and the performance of the organization.

The continual improvement process also focuses on control, reduction of variation in product characteristics, andmanufacturing parameters. This occurs once manufacturing processes are capable and stable and product characteristics are predictable and meet customer requirements.

All customer complaints, customer returned products, reports of product non-conformances identified during the process areanalyzed, using disciplined problem solving methods; causes relating to product, process and quality systems areestablished; and countermeasures are taken to eliminate the causes.

Wherever applicable the successfully implemented corrective actions and controls are applied to other similar processes and products to prevent possible non-conformances.

Mistake proofing methods are used as part of corrective and preventive action process, appropriate to the magnitude of the problem.

Trends in non-conformances observed in internal quality audits, incoming material, production process, final inspection,customer complaint, delivery performance, process capability, vendor delivery performance, customer satisfaction index,etc. are analyzed to determining potential non conformances and preventive action taken to prevent their occurrences.

Effectiveness of the preventive action is reviewed. Changes in quality system / processes are documented and summary of the preventive action taken are submitted for Management Review.

8.5.1 Related procedures





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Section 2: Customer Specific Requirements

MSC will adhere to its customer specific requirements in relation to TS16949:2002, or other standards as necessary.

See Visteon Customer Specific requirements. Currently, we do not have any other business with the companies who haverequirements in Section 2. In the future, should business with customers be realized that have these requirements, MSC willfulfill their specific requirements.



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MUSASHI SOUTH CAROLINA

PROCESS INTERACTIONVISTEON BEVEL GEARS

OPERATIONS

Quallity Decisions INPUT

Intructions/Methods

Work Instruction Steels bars from

Accept approved supplier Non-conformance

yes

no -------------------------->

Operator Process Shear cut steel bars

Instruction into billets

yes

no ---------------------------> Process Owners Customer Oriented P

President (Key Processes)

Deliver to shot blast Plant Manager RFQ Process

Sr. Production Manager Customer P.O. requir

Operator Process Shot blast removes Managers: (APQP)

Instruction rust and scale Forging/Sizing Design Process

Lathing Product/Process Valid

Deliver to Hot Forging Heat Treat & FI (PPAP)

Operator Process Forge billetts into gears Team Leaders Mass ProductionInstruction Associates Delivery

yes Feedback

no ---------------------------> Management Oriente

Business Planning

Resource Planning

Management Review

Operator Process Gears enter directly inline Continous improveme

Instruction Anneal forged gears Analysis of Data

Corrective/ Preventive

Customer satisfaction

yes Product/process perfo

no --------------------------> Internal audit

Deliver to shot blast

Operator Process Shot blast cleans residue

Instruction

Deliver to Sizing

Operator Process Trims & Sizes

Instruction preliminary dimensions

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

Deliver to Lathing staging area

Operator Process CNC precision lathe,Instruction dimensions

yes

no -------------------------->

Operator Process During lathing operations: SORT REWORK

Instruction Broach, champher, burnish REJECT/S

ACCEPT ACCEPT

Place gears on racks RETURN TO MANUF. DISPOSE

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

Deliver to Heat Treat Dept.

Operator Process Degrease lathing lubricants

Instruction

Identify Lot #s, and route thru

Heat Treat furnaces

Operator Process Caborize, harden cycles

Instruction Time & temp

APQP:Feasibility, Control PlaFMEA, Process DesigProcess Validation(CP

PPAP

Start Bevel Gear Manufacturing

Receive Steel

Cut Billets

Shot BlastBillets

Hot Forge

Normalizing /Annealing

Shot Blast

C.O.A.

Inspect-checksheet

Inspect-checksheet

Inspect-checksheet,+ X&R

Sizing

Inspect-checksheet, +X&R

Lathing

Inspect-checksheet, +X&R

Broach/Champher/

Burnish

Inspect-checksheet, +

X&R

Degrease

Heat Treat

Non-Conforming HOLD Tag, Log BookHOLD AREAReview for Disposition by QC



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xternal & Internal Process Inputs to Musashi South Carolina ProcessQC-Flow

Rev. 2

Material/Components Inputs

Customer

Designated

Raw Steel /Supplied Honda(Assy.)

Material Parts/Pkg. Parts& Pkg.

Musashi South Carolina

C u s t o m e r s

Customer Process Planning Process Production Process

Musashi Review Team

North America President - Tooling Communicate Review

Sales Office Sr. Mgr. PC/Sales/Proj. - Engineering Facility & Equipment Controls

Detroit, MI Sr. Mgr. Prod./Engrg./Maint. - Maintenance

RFQ Info-Pass thru Sr. Mgr. QC Machine

Customer Contact Contracts Review

Liaison RFQ Feasibility Review

Inputs Order Info Delivery Reqmnts. Product PPAP Monitor Monitor

Business decisions - Refine controls CPks Analysis Analysis

Feedback - Instructions OPIs

- Training Meas. Equip.

Continual Improvement Communicate

APQP FMEAs Control Plans Process Info Parts

Musashi - Japan (MSI) Inputs of Information and Parts

Develops preliminary draft plans input for each new product

MSC takes ownership upon receipt and finalizes to conform to MSC processes

May supply finished, or W.I.P. Parts

PlanProcess

DefinesProcesses

EstablishCapability

Data AnalysisReview

Customer Approval

LaunchProduct

MassProduction

Ship onTime



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