Maruti Vendor System Audit Checklist

MSIL Audit Checklist:

MSIL Audit checklist is a 19-points checklist that is used to do system audits at Tier 2 vendors. There are 19 clauses in this checklist. There are 5 critical clauses in this check sheet. It is compulsory to pass in critical clauses. Overall 60% are required to pass this MSIL/MACE audit.

Maruti VSA Audit Checklist:

Production Preparation/New Product Development
Regulation of Initial Production Control
Change Management
Standard Management
Education and Training
Quality Audit and Process verification
Supplier Control
Handling abnormality in quality
5S Management
Equipment and Inspection Equipment Management
Implementation of Standard
Product Management
Handling Management
Critical Parts Management
Adequate Testing Facility
Process audit
Scale and top management bandwidth
Safety
Legal Compliance and Environment

Critical Clauses in VSA Audit:

List of 5 critical clauses in the VSA audit for Tier 2 vendors:

Change Management
Education and Training
Handling abnormality in Quality
Equipment and Inspection Equipment Management
Safety

List of 5 critical clauses in the VSA audit for Tier 1 vendors:

Change Management
Education and Training
Handling abnormality in Quality
Equipment and Inspection Equipment Management
Supplier Control

VSA Audit Checklist, MSIL Audit Checklist

Clause 1: Production Preparation/ New Product Development

S.No	Check Point
1	Do you define the procedure for Product development including the following? -scope of parts, responsibility of each department, control contents/items?
2	Do you implement follow-up to control the schedule and progress of production preparation items? Incl top management
3	Do you consider the following items and implement corrective and preventive action to the processes and standards before regular production? -Troubles in the past; -Defect items expected; -Defect items unable to capture at customer; -Defect items difficult to repair.
4	Do you prevent defects by quality-improving activities of cross-functional teams to evaluate quality performance?

Procedure for New Product Development (Production Preparation/APQP)

Clause 2: Initial Production Control

S.No	Check Points
1	Do you define the following items related to initial production control by standards? -controlled parts; -controlled items; -inspection method, -initial production control period, a person who announces the start/end of initial production control and the finish condition.
2	How do you define items that require special control during initial production control? Do you set stricter inspection methods than ordinary inspection?
3	Do you control process capability and defect rate (For visual defects) during initial production control?

Procedure for Initial Production Control (Initial Flow Control)

Clause 3: Change Management

S.No	Check Points
1	Do you define unexpected change (unusual) and planned change clearly?
2	Do you define procedure (rules applied from sharing information to result confirmation) at change occurrence?
3	Do you record product quality check results to ensure traceability? Incl retroactive checks
4	Do you define and control the initial part?
5	Do you control initial parts separately and make quality records about them? (Both internal and outsourced processes are included)

Procedure for Change Management

Clause 4: Standard Management

S.No	Check Points
1	Do you make and review process control standards, Inspection specifications and Operation instructions for all products that are shipped to SMC / MSIL / Tier 1?
2	Do you have the consistency to keep process control standards, inspection specifications, operation inspection and parameter chart?

Procedure for Standard Management

Clause 5: Education and Training

S.No	Check Points
1	Do you clarify the department in charge of promoting quality education and implementing education based on the annual plan? Are records of education kept?
2	Do you define and implement the skill evaluation of the operator to determine whether the operator can work without surveillance? (e.g. acceptable level/evaluation frequency/evaluation method)
3	Do you periodically monitor the skills of certified operators and follow up to improve their skills?

Learn about the Education and Training procedure and Process of the Poison Test

Clause 6: Quality Audit and Process Verification

S. NO	Check Points
1	Do you conduct quality audits to identify issues and properly improve them?
2	Do you confirm consistency between the actual operation and the standard?
3	Do you confirm if countermeasures are taken properly to prevent the recurrence of quality failure?

Procedure for Internal Audit

Clause No. 7: Supplier Control

S.No	Check Points
1	Do you define criteria to certify new suppliers and implement them?

Procedure for the Supplier Selection and Development Process

Clause No. 8: Handling Abnormality in Quality

S.No	Check Points
1	Do you clearly define what an abnormal situation and make operators know the definition?
2	Do you clarify and standardize the handling rules/routes for customer claims, in-process failure and supplier failure?
3	Do you reflect corrective action to improve process control and review of standards?
4	Do you prevent the recurrence of issues by analyzing the cause of occurring defects based on process investigation results such as 5-why analysis?
5	Do you reflect corrective action to improve of process control and review of standards?
6	After corrective action, do you conduct an on-site check-up and evaluate the effectiveness? And horizontal deployment.

Procedure for Handling Abnormalities in Quality.

Clause No. 9: 5S Management

S.No	Check Points
1	Do you keep store material, work-in-process, finished products, inventory and containers at appropriate storage protected from dust, rust, scratches, deformation and rainwater?
2	Do you control material, work-in-process and finished products by designated location, volume and standard using visual control?
3	Do you implement inspection or critical operation under a properly controlled environment luminance /temperature/humidity/vibration/noise/work table etc.)?
4	Do you keep the condition of production equipment, jigs and tools properly?
5	Do you keep the condition of inspection equipment properly to ensure accuracy?

Procedure for 5S Management.

Clause No. 10: Equipment and Inspection Equipment Management

S.No	Check Points
01	Do you conduct daily/regular checks of production equipment, dies and jigs? Are records of maintenance kept?
02	Do you confirm regularly the function of Pokayoke, automated stop and alarm? Are records of maintenance kept?
03	Do you standardize the frequency of polishing and replacement for consumable tools (blade/electrode/rub stone, etc.)?
04	Do you regularly calibrate inspection equipment and put the expiration date on them?
05	Do you control the deterioration (expiration date) of boundary samples for objective judgments such as appearance inspection?

Procedure for Machine Maintenance and Calibration

Clause No. 11: Implementation of Standard

S.No	Check Points
01	Do you use easy expressions (visualizer, onomatopoeia etc.) for operation instructions? So that the operator can easily understand the process and critical points.
02	Do you keep operation instructions in an accessible place and post important quality points and critical operation points in a place where operators can see them easily?
03	Do you regularly monitor that each operator operates according to the operation instructions?
04	Is it possible to judge OK/NG specifically by each check sheet (of daily equipment check, quality control report, etc.) you use?

Clause No. 12: Product Management

S.No	Check Points
01	Do you keep FIFO (first-in first-out) of finished products and work-in-progress (material, reserve parts? By using an identification tag or lot indication?
02	Do you control production history by product lot numbers? -production date; -production volume; -shipping date
03	Do you control the identification of similar parts separately?
04	Do you control the identification of non-conforming parts and parts on hold? Do you store them separately?
05	Regarding repaired non-conforming parts and parts on hold to re-use, do you define responsibility to implement? Are repair records kept?

Clause No. 13: Handling Management

S.No	Check Points
01	Do you make arrangements with customers about the packing style & transportation system to prevent damage during the handling of finished products & perform accordingly?
02	Do you have a system to maintain Bins /Trolleys in Good Condition?

Clause No. 14: Critical Parts Management

S. No	Check Points
01	Do you have Special checks/Inspections for the Maru A parameters of the Maru A part available?
02	Do you have the Identification of the Maru A Process/Operator on the Shop Floor?
03	Do you keep the repair history when repairing & using Maru A items?

Procedure for Product Safety. (Maru A Parts)

Clause No. 15: Adequate Testing Facility

S. NO	Check Points
01	Does the supplier have all the Testing Equipment/Rigs required as per the drawing requirements?
02	Does the Supplier have trained manpower to operate these inspection and testing instruments?
03	Does the Supplier have trained manpower to operate these inspection and testing instruments?

Clause No. 16: Process Audit

S. No	Check Points
01	Conduct a process audit as per the process control standard (Control Plan)
02	Closure of all the observations.

Clause No. 17: Scale and Top Management Bandwidth

S.No	Check Points
01	Do you have an adequate organization structure and defined roles/ responsibilities for key areas such as Plant Head, Quality, Production, Safety and Maintenance?
02	How frequently Top management visit the shop floor? How frequently does Top Management monitor key performance KPI (Performance at the customer end, in-house quality, productivity, maintenance, safety etc.)?
03	Plant Sales Turnover for the auditee plant. Group Turnover
04	PAT/Sales ( Profit After Tax / Sale)
05	D/E ratio ( Debt / Equity Ratio)
06	ROCE ( Return on Capital Employed)

Note: Clause No. 17 has been revised to the New EHS requirement

Clause No. 18: Safety

S.No	Check Points
01	Is the shop floor temperature, noise level and air quality (fumes) ok? Is the layout and escape route on the shop floor OK? Is Rest Area/Toilets Available? Is area/machine sufficient enough to allow easy movement of machines and tools?
02	Are Safety Standards made (as per process requirement) and taught to all operators? Are PPEs available as per the standards or not?
03	Machine Safety system (Door sensors etc.) available or not? Is Safety in material movement and tools ensured or not?
04	Are safety standards followed on the shop floor as per the procedure? Are usage of PPES adhered and monitored (by a supervisor/senior) on the shop floor? Accident reporting mechanism is defined? Countermeasures against accidents taken and periodic verification being done?
05	Audit conducted by a reputed 3rd party on MSIL defined check sheet?

Note: Clause No. 18 has been revised to the New EHS Requirement

Clause No. 19: Legal Compliance and Environment

S.No	Check Points
01	Consent to operate (Valid as on date) available or not?
02	Enrolment of all employees for ESI & PF
03	Are different types of wastes identified on the shop floor and standards/ Procedures made? Is Segregation done at the source for different types of waste? Storage and disposal being done as per consent and periodic confirmation at the disposal stage?