Maruti Vendor System Audit Checklist

MSIL Audit Checklist:

Ensuring quality and consistency in supplier systems is critical for every automotive manufacturer, but it holds particular importance for leaders like Maruti Suzuki India Ltd. (MSIL). The Maruti Vendor System Audit Checklist, also known as the Vendor System Assessment (VSA) or MACE Audit, serves as a comprehensive evaluation tool designed for Tier-2 vendors. With its structured 19-point framework, it helps auditors assess vital areas such as production preparation, initial production control, change management, standards implementation, and safety compliance.

In this blog post, we’ll explore how this checklist not only guides suppliers in aligning with Maruti’s rigorous quality expectations but also facilitates continuous improvement within their own operations. We’ll break down its key components and reveal why mastering this checklist isn’t just about passing an audit—it’s about ensuring top-tier performance and unlocking growth opportunities.

Maruti VSA Audit Checklist:

  1. Production Preparation/New Product Development
  2. Regulation of Initial Production Control
  3. Change Management
  4. Standard Management
  5. Education and Training
  6. Quality Audit and Process Verification
  7. Supplier Control
  8. Handling abnormality in quality
  9. 5S Management
  10. Equipment and Inspection Equipment Management
  11. Implementation of Standard
  12. Product Management
  13. Handling Management
  14. Critical Parts Management
  15. Adequate Testing Facility
  16. Process audit
  17. Scale and top management bandwidth (Financial Data of the Company)
  18. Safety (Safety (Working Conditions, Human & Machine Safety, Fire Safety)
  19. Top Management Bandwidth and HR Practices (Legal Compliance and Environment)

Critical Clauses in VSA Audit:

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

  1. Change Management
  2. Education and Training
  3. Handling abnormality in Quality
  4. Equipment and Inspection Equipment Management
  5. Safety

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

  1. Change Management
  2. Education and Training
  3. Handling abnormality in Quality
  4. Equipment and Inspection Equipment Management
  5. Supplier Control
VSA Audit Checklist, MSIL Audit Checklist
VSA Audit Checklist, MSIL Audit Checklist

Clause 1: Production Preparation/ New Product Development

S.NoCheck Point
1Do you define the procedure for Product development including the following? -scope of parts, responsibility of each department, control contents/items?
2Do you implement follow-up to control the schedule and progress of production preparation items? Incl top management
3Do 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 the customer; -Defect items difficult to repair.
4Do 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.NoCheck Points
1Do 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.
2How do you define items that require special control during initial production control? Do you set stricter inspection methods than ordinary inspection?
3Do 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.NoCheck Points
1Do you define unexpected change (unusual) and planned change clearly?
2Do you define procedure (rules applied from sharing information to result confirmation) at change occurrence?
3Do you record product quality check results to ensure traceability? Incl retroactive checks
4Do you define and control the initial part?
5Do 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.NoCheck Points
1Do you make and review process control standards, Inspection specifications and Operation instructions for all products that are shipped to SMC / MSIL / Tier 1?
2Do 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.NoCheck Points
1Do you clarify the department in charge of promoting quality education and implementing education based on the annual plan? Are records of education kept?
2Do 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)
3Do 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. NOCheck Points
1Do you conduct quality audits to identify issues and properly improve them?
2Do you confirm consistency between the actual operation and the standard?
3Do you confirm if that countermeasures are taken properly to prevent the recurrence of quality failure?

Procedure for Internal Audit

Clause No. 7: Supplier Control

S.NoCheck Points
1Do 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.NoCheck Points
1Do you clearly define what an abnormal situation and make operators know the definition?
2Do you clarify and standardize the handling rules/routes for customer claims, in-process failure and supplier failure?
3Do you reflect on corrective action to improve process control and review of standards?
4Do you prevent the recurrence of issues by analyzing the cause of occurring defects based on process investigation results, such as 5-why analysis?
5Do you reflect corrective action to improve of process control and review of standards?
6After 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.NoCheck Points
1Do you keep store material, work-in-process, finished products, inventory and containers at appropriate storage protected from dust, rust, scratches, deformation and rainwater?
2Do you control material, work-in-process and finished products by designated location, volume and standard using visual control?
3Do you implement inspection or critical operation under a properly controlled environment luminance /temperature/humidity/vibration/noise/work table etc.)?
4Do you keep the condition of production equipment, jigs and tools properly?
5Do you keep the condition of inspection equipment properly to ensure accuracy?

Procedure for 5S Management.

Clause No. 10: Equipment and Inspection Equipment Management

S.NoCheck Points
01Do you conduct daily/regular checks of production equipment, dies and jigs? Are records of maintenance kept?
02Do you confirm regularly the function of Pokayoke, automated stop and alarm? Are records of maintenance kept?
03Do you standardize the frequency of polishing and replacement for consumable tools (blade/electrode/rub stone, etc.)?
04Do you regularly calibrate inspection equipment and put the expiration date on them?
05Do 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.NoCheck Points
01Do you use easy expressions (visualizer, onomatopoeia etc.) for operation instructions? So that the operator can easily understand the process and critical points.
02Do 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?
03Do you regularly monitor that each operator operates according to the operation instructions?
04Is 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.NoCheck Points
01Do 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?
02Do you control production history by product lot numbers? -production date; -production volume; -shipping date
03Do you control the identification of similar parts separately?
04Do you control the identification of non-conforming parts and parts on hold? Do you store them separately?
05Regarding 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.NoCheck Points
01Do you make arrangements with customers about the packing style & transportation system to prevent damage during the handling of finished products & perform accordingly?
02Do you have a system to maintain Bins /Trolleys in Good Condition?

Clause No. 14: Critical Parts Management

S. NoCheck Points
01Do you have Special checks/Inspections for the Maru A parameters of the Maru A part available?
02Do you have the Identification of the Maru A Process/Operator on the Shop Floor?
03Do 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. NOCheck Points
01Does the supplier have all the testing equipment and rigs required as per the drawing specifications?
02Does the Supplier have trained manpower to operate these inspection and testing instruments?
03Does the Supplier have trained manpower to operate these inspection and testing instruments?

Clause No. 16: Process Audit

S. NoCheck Points
01Conduct a process audit as per the process control standard (Control Plan)
02Closure of all the observations.

Clause No. 17: Scale and Top Management Bandwidth

S.NoCheck Points
01Do you have an adequate organizational structure and defined roles/ responsibilities for key areas such as Plant Head, Quality, Production, Safety and Maintenance?
02How frequently does 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.)?
03Plant Sales Turnover for the auditee plant. Group Turnover
04PAT/Sales ( Profit After Tax / Sale)
05D/E ratio ( Debt / Equity Ratio)
06ROCE ( Return on Capital Employed)

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

Clause No. 18: Safety

S.NoCheck Points
01Is the shop floor temperature, noise level and air quality (fumes) ok? Is the layout and escape route on the shop floor OK? Are Rest areas/ Toilets Available? Is area/machine sufficient enough to allow easy movement of machines and tools?
02Are Safety Standards made (as per process requirement) and taught to all operators? Are PPEs available as per the standards or not?
03Machine Safety system (Door sensors etc.) available or not? Is Safety in material movement and tools ensured or not?
04Are 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?
05Audit 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.NoCheck Points
01Consent to operate (Valid as on date) available or not?
02Enrolment of all employees for ESI & PF
03Are 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?

New EHS Requirements redefined by MSIL / MACE

17. Financial data of the company

18. Safety (Working Conditions, Human & Machine Safety, Fire Safety)

19. Top Management Bandwidth and HR Practices:

EHS requirements for Tier 2 Vendors in detail:

New EHS Requirements by MSIL / MACE

Frequently Asked Questions (FAQs) on Maruti Vendor System Audit Checklist

What is the Maruti Vendor System Audit (MACE Audit)?

The Maruti Vendor System Audit, also known as MACE Audit or Vendor System Assessment (VSA), is a structured evaluation of supplier systems by Maruti Suzuki India Ltd. It covers 19 key areas as discussed earlier in the post.

Why is the Maruti Vendor Audit important?

This audit ensures that suppliers consistently meet Maruti Suzuki’s quality, safety, and delivery requirements. Passing the audit not only helps suppliers maintain business with Maruti but also improves their internal processes and competitiveness.

How many clauses are there in the MACE Audit checklist?

The audit checklist has 19 clauses that cover all critical aspects like management responsibility, production preparation, calibration, safety, delivery performance, and continual improvement.

Who conducts the Maruti Vendor System Audit?

The audit is typically conducted by Maruti Suzuki’s Supplier Quality Assurance (SQA) team or the Maruti Center for Excellence (MACE) Team.

How can suppliers prepare for the Maruti Vendor Audit?

Suppliers should:

  • Implement a strong Quality Management System (QMS) aligned with IATF 16949.
  • Ensure documentation and records are up to date.
  • Train employees on process and safety requirements.
  • Strengthen process controls and traceability systems.
  • Focus on continual improvement initiatives.

What happens if a supplier fails the MACE Audit?

If a supplier does not meet the required score, they may receive a Corrective Action Request (CAR). Continuous poor performance may impact future business with Maruti Suzuki.

Is the Maruti Vendor System Audit linked to IATF 16949?

Yes, many requirements of the MACE Audit are aligned with IATF 16949 standards. Suppliers certified to IATF 16949 have a stronger foundation to perform well in this audit.

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