Maruti Vendor System Audit Checklist

MSIL Audit Checklist:

MSIL Audit checklist is a 19-point sheet that is used to do system audits at Tier 2 vendors. There are 19 clauses in this checksheet. 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.

  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
  18. Safety
  19. Legal Compliance and Environment

Critical clauses in VSA Audit:

List of 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 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
VSA 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 customer; -Defect items difficult to repair.
4Do you prevent defects by quality-improving activities of cross-function teams to evaluate quality performance?

Clause 2: Initial Production Control

S.NoCheck Point
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, -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 during initial production 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)

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 consistency to keep process control standards, inspection specifications, operation inspection and parameter chart?

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 revel/evaluation frequency/evaluation method)
3Do you periodically monitor the skills of certificated operators and follow up to improve their skills?

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 actual operation and standard?
3Do you confirm if countermeasures are taken properly to prevent the reoccurrence of quality failure?

Clause No 7: Supplier Control

S.NoCheck Points
1Do you define criteria to certify new suppliers and implement them?

Clause No 8: Handling Abnormality in Quality

S.NoCheck Points
1Do you define clearly what is 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 have criteria to estimate the scope of a suspected lot for an abnormal situation? When an abnormal situation occurs, do you trace a suspected lot based on the criteria?
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. (

Clause No 9: 5S Management

S.NoCheck Points
1Do you keep store material, work-in-process, finished products, inventory and containers at appropriate storage prevented from dust, rust, scratch, deformation and rainwater?
2Do you control material, work-in-process and finished product 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?

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 calibrate regularly 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?

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 on an accessible place and post important quality points and critical operation points on a place where operators can see it 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 first-in first-out of finished products and work-in-process (material, reserve parts? by using an identification tag or lot indication?
02Do you control follows 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-confirming 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 are available?
02Do you have the Identification of Maru A Process/Operator on the Shop Floor?
03Do you keep the repair history when repairing & using Maru A items?

Clause No 15: Adequate Testing Facility

S. NOCheck Points
01Does the supplier has all inspection instruments required as per drawing requirements
02Does the supplier has all Testing Equipment/Rigs required as per drawing requirements
03Does the Supplier has trained manpower to operate these inspection and testing instruments?

Clause No 16: Process Audit

S. NoCheck Points
01Conduct process audit as per process control standard
02Closure of all the observations

Clause No 17: Scale and Top Management Bandwidth

S.NoCheck Points
01Do you have adequate organization structure and defined roles/ responsibilities for key areas such as Plant Head, Quality, Production and Maintenance?
02How frequently Top management visit the shop floor? How frequently Top Management monitor key performances (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)

Clause No 18: Safety

S.NoCheck Points
01Is 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.
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 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?

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?

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