qms awareness

Welcome to the Family of

IFB AUTOMOTIVE PRIVATE LIMITED

IFB Automotive Private Limited

Induction Program on

QUALITY MANAGEMENT SYSTEM


Today's induction program includes the following topics:1. Definition of Quality Management System

2. Quality Management Systems of IFBAPL

3. Quality Systems at IFBAPL

4. ISO and ISO 9001:2000 Standard

5. ISO/TS 16949:2002

- Evolution of ISO/TS 16949:2002

- ISO/TS 16949:2002 – Clauses- Requirements in brief

6. Q1

- Introduction to Q1

- Q1 Requirements: What it talks about

7. Introduction to MMOG/LE

8. ISO 14001:2004 Standard

- Introduction to ISO 14001:2004

- ISO 14001:2004 Clauses in brief

9. Our Policies

10. Quality credentials


Definition of Quality Management System


What is Quality Management System (QMS)?

QMS is a system in an Organization which performs the

activities related to production & supply of product that

meets customer requirements, applicable statutory and

regulatory requirements and to enhance customer

satisfaction

Quality Management System (QMS)



Quality Management System at IFBAPL

IFBAPL has five units, one each in Bangalore, Gurgaon, Chennai, Uttarakhand and Pune.

It has four divisions namely Seating Division, Door Division, Motor Division and Latch Division.

The product range includes Seating Mechanisms, Window Regulator Mechanisms, Automotive Motors and Latch Mechanisms for 4-wheelers and Transmission parts for 2-wheelers.

Quality Management System of IFB Automotive Private Limited covers all the units, all the divisions and all the products. It comprises of Quality Systems and Environmental Management Systems.

It is controlled by Bangalore Unit. Bangalore Unit is responsible for the preparation, approval and issue of all the manuals, procedures and forms.

Quality Management System at IFBAPLIFB Automotive Private Limited

IFBPAL-Bangalore and IFBAPL-Chennai are certified for ISO/TS

16949:2002 and ISO 14001:2004. They have achieved Q1 Certification

by Ford India Limited which qualifies them as a global supplier for

Ford Motor Company.

IFBAPL-Bangalore is also in the process of 5 Star system

implementation which is a requirement of Hyundai Motors India

Limited.

IFBAPL-Gurgaon is certified for ISO/TS 16949:2002.

IFBAPL-Uttarakhand and IFBAPL-Pune are new units and they do

not have any kind of certifications.

Mr. R Vijendran is the Management Representative of the Company.

Quality Management System at IFBAPL


Quality Systems at IFBAPL

We have an apex level Quality System Manual in which we have

documented our system. All the requirements of the ISO/TS

16949:2002 standard have been addressed in it.

We have a Quality System Procedures Manual in which we have

described mandatory procedures as per TS 16949:2002 requirement.

This is a second level document.

Next level documents are divisional manuals for different functions

such as Product design, Process Development, Operations, Quality

Assurance, Marketing, Vendor Development, SCM/SQA, Human

Resources, and divisional manuals for Chennai Operation and

Gurgaon Operation. In these we have documented procedures required

to carry out various activities.



Level 1: Quality System Manual

Level 2: Quality System Procedures

Level 3: Divisional Procedures

Level 4: Forms & Formats

Documentation Structure at IFBAPL


One of the main features of ISO/TS 16949:2002 is Process Approach.

Process is an activity or sequence of activities which adds some value

to the inputs and gives the output.

This principle we have applied in our QMS


INPUT OUTPUTPROCESS

FEED BACK & IMPROVEMENT


Quality is the basic requirement of any product.

IFB APL is always committed to Quality of its products and

customer satisfaction.

We have a defined Quality Policy on the basis of which we are

working.

To assure the customer the quality of our product, IFBAPL,

Bangalore has a third party certified Quality Systems in

accordance with automotive Standards ISO/TS 16949:2002.

Our QMS is certified by TUV SUD South Asia Private Limited

initially in 2004.

We have been recertified in 2007.

Quality Systems at IFBAPLIFB Automotive Private Limited

The validity of the certification is 3 years. Once in a year

surveillance audits are carried out by the certifying body.

To ensure effective implementation of the QMS, we conduct

Internal Quality Audits on TS 16949:2002. All the functions are

audited once in three months. Trained Internal Quality auditors

will conduct the audits, report any non conformances and the

auditees will take appropriate actions to close the non

conformances.


To ensure the quality, quantity, timeliness of the product we supply

to our customer we are using tools such as

Advanced Product Quality Planning

Production Part Approval Process

Failure Modes and Effects Analysis

Measurement System Analysis

Statistical Process Control.


ISO and ISO 9001:2000 Standard


Background:

ISO (International Organization for Standardization) is responsible for bringing out international standards on various subjects like Quality Assurance, Environment, Health & Safety, Software etc. It has published about 17000 standards till now.

ISO has brought out one Standards series on Quality Assurance &

Management which is known as ISO 9000 series.

These standards were first released in 1987.These were reviewed and

released again in 1994.

These were further reviewed and revised in 2000 and are known as ISO

9000:2000 Series. These are the valid standards at present.

One more revision is under progress which will be released by December

2008.

ISO 9000 SERIES STANDARDSIFB Automotive Private Limited

In this series there are three standards:

ISO 9000:2000 Quality Management Systems – Fundamentals & Vocabulary

ISO 9001:2000 Quality Management Systems – Requirements

ISO 9004:2000 Quality Management Systems – Guidelines for Performance

Improvements.

In this series only ISO 9001:2000 Quality Management Systems – Requirements is intended for certification. Other two are for guidelines purpose only.

• Any type of organization (product or service oriented) can undergo this type of certification.

• E.g. Manufacturing, processing, banking, educational, hospital etc.

• Process Approach to all activities and Continual Improvement are the two

important features of ISO 9001:2000 standards.

ISO 9000:2000 SERIES STANDARDSIFB Automotive Private Limited

The ISO 9001:2000 is based on eight Quality management principles:

customer focused organizations

Leadership

Involvement of people

Process Approach

System approach to management

continual improvement

Factual approach to decision making

Mutually beneficial supplier relationships

ISO 9001:2000 STANDARDSIFB Automotive Private Limited

The ISO 9001:2000 has 8 Clauses:

1. Scope

2. Normative Reference

3. Terms and Definitions

4. Quality Management System

5. Management Responsibility

6. Resource Management

7. Product Realization

8. Measurement, Analysis and Improvement

ISO 9001:2000 ClausesIFB Automotive Private Limited

ISO/TS 16949:2002

Evolution of ISO/TS 16949:2002 Standards


ISO/TS 16949:2002 STANDARDS

ISO/TS 16949:2002 is an international standard and

“Technical Specification” containing requirements for

establishing and maintaining a Quality Management System

for the design and development, production and, when

relevant, installation and service of automobile-related

products.

It is based on ISO 9001:2000 and has additional requirements

for automotive industries.


ISO/TS 16949 is based on four automotive standards in

addition to ISO 9001:2000 they are :

VDA 6.1 (GERMANY)

QS 9000 (USA)

AVSQ`94 (ITALY)

EAQF`94 (FRANCE)



TS16949:2002 was formulated by International Automotive Task

Force (IATF) and Japan Automobile Manufacturers

Association (JAMA) with support from Technical Committee

ISO/TC 176 on Quality Management and Quality Assurance.

Automotive majors DaimlerChrysler AG, Ford Motor Company

and General Motors Corporation played a very important role

in bringing out these standards.



The following 5 core tools must be used unless otherwise

specified by the customer for the effective implementation of

TS 16949:2002

APQP (Advanced Product Quality Planning)

PPAP (Production Part Approval Process)

FMEA (Failure Modes and Effects Analysis)

MSA (Measurement System Analysis)

SPC (Statistical Process Control)



Management Responsibility

Product Realization

Measurement,analysis & improvement

Resource management

Customers

Continual improvement of the Quality Management system

RequirementsProduct

Output

Customers

Satisfaction

Input

Model of Process Based Quality management SystemPDCA Cycle

Value-adding activities

Information flow


The goal of Technical Specification is fundamental

Quality System that provides continuous

improvement, emphasizes defect prevention and

the reduction of waste in the supply chain.




ISO/TS 16949:2002 – Clauses

Requirements in brief


ISO/TS 16949:2002 Standard requirements are basically

ISO 9001:2000 and additional requirements for

automotive industries

The ISO/TS 16949:2002 has 8 Clauses:

1. Scope

2. Normative Reference






8. Measurement, Analysis and Improvement

ISO/TS 16949:2002 ClausesIFB Automotive Private Limited

1. Scope

Scope of Quality Management System of the Organisation

Products

Exclusions if any (Non applicability)

2. Normative reference

Reference to ISO 9000:2000 Quality Management Systems –

Fundamentals & Vocabulary


3. Terms and definitions (special terms used in automotive industry)

Continual improvement

Control plan

Error proofing

Laboratory

Manufacturing

Outsourcing

Predictive maintenance

Premium freight

Special characteristics



4.1 General Requirements

Establish, document, implement and maintain a Quality Management System

Identification of all necessary processes

Determination of sequence and interaction of these processes

Criteria & methods to ensure the operation and control is effective

Availability of resources and information

Monitoring, measurement and analysis

Actions necessary to improve them


4.2 Documentation Requirements

Quality Manual

Procedures

Quality policy

Quality objectives

Document control (approval, review, update & issue)

Engineering specifications, their change control

Record control (identification, storage, protection, retrieval, disposition)

Record retention



Communicating importance of meeting customer, statutory and regulatory requirements

Establishing quality policy and quality objectives

Ensure resources are provided

Customer focus

Define & communicate Responsibility & Authority

Appointment of Management Representative

Appointment of customer representative

Management review



Provision of necessary resources

Human Resources -

Competency, awareness, On-job-training

Employee motivation and empowerment

Infrastructure -

Plant, facility & equipment planning, contingency plans

Work environment -

safety & cleanliness



7.1 Planning of Product realization

Advanced Product Quality planning (APQP)

7.2 Customer related processes

Determination and review of requirements of the product

Manufacturing feasibility commitment

7.3 Design & Development

Product design and development

Design FMEA, drawings, specifications


Process design & development

Process flow chart, Process FMEA, Control plan, Work instructions

Design & Development review

Design & development verification

Design & development validation -

Prototype programme

Process qualification

Production part approval process (PPAP)

Design & development changes


7.4 Purchasing

Identification, selection, assessment and approval of Suppliers

Customer approved sources

Purchasing information like product requirements, QMS requirements

Supplier scheduling

Verification of purchased product

Incoming inspection

Supplier monitoring

Supplier audits and Supplier development


7.5 Production & Service Provision

Availability of Machineries and equipment

Availability of Gages & instruments

Drawings

Control plans

Work instructions

Set up approval

Preventive & predictive maintenance

Production tooling – identification, change management

Perishable tool life monitoring


Production planning and control

Validation and revalidation of production processes

Identification and traceability

Customer property

Preservation of product – Handling, Storage & inventory and Delivery of products

7.6 Control of monitoring & measuring devices

Calibration, Status identification, Traceability to national/ international standards

Measurement System Analysis

Internal Laboratory & External Laboratory requirements


8. Measurement, analysis and improvement

Monitoring & measurement of customer satisfaction

Monitoring & Measurement of QMS –

Internal Quality audits – plan, nonconformance, horizontal deployment, Internal auditor qualification

Manufacturing process audit

Product audit

Monitoring & measurement of processes – process capability study


Monitoring and measurement of product -

Process quality, Layout inspection, Functional testing

Appearance items

Control of nonconforming product -

Identification, actions

Positive recall system

Control of reworked product

Deviation and customer waiver


Analysis of data/information -

customer satisfaction

conformance to product requirements, trends of processes

suppliers

Improvement -

Continual improvement

Manufacturing process improvement

Corrective actions

Problem solving, Error proofing, Horizontal deployment

Rejection / Warranty Analysis

Preventive actions


ISO 14001:2004 STANDARDS

INTRODUCTION


Why we need to have an environmental management System?

Global Environmental Issues:

• Global warming• Acid Rain• Ozone Depletion• Desertification• Deforestation• Depletion of water

ENVIRONMENTAL MANAGEMENT SYSTEM


Global warming

Causes & source:

• Greenhouse gases trap the Sun’s heat which causes the increase in atmospheric temperature.

• Greenhouse gases are Carbon Dioxide, Methane, CFCs, Nitrous Oxide

• These are produced when we burn fossil fuels like oils, coal, etc.



Global warming

Effects:• Disturbed pattern of rain & snowfalls• Ecosystem gets affected• As oceans get warm glaciers melt and sea level raises

Solutions:• Use of cleaner production technologies• Improve efficiency of fossil-based energy production & in energy

use• Promote renewable energy production technologies• Increase in reforestation



Acid rain

Causes & source:

• Release of sulphur oxides & nitrogen oxides during combustion of fuels.

Effects:• Acidity of water increases causing ecological changes affecting fish &

plants• Acid rain also causes dissolution of toxic heavy metals which are then

released into soil & water

Solutions:• Technological innovations to reduce oxides of sulphur & nitrogen



Ozone depletion

Ozone layer strongly absorbs ultraviolet rays from Sunlight

Causes & source:

• Release of chlorine from Chlorofluorocarbons, volcanoes etc

Effects:• Allows UV rays reach earth thereby affecting humans, other

organisms and ecosystems

Solutions:• Stop use of CFCs



Desertification

Degradation of land.

Causes & source:

• Population & Human exploitation of land

Effects:• Water, air and soil pollution, loss of biodiversity• Loss of productive land leading to reduced production of food grains

Solutions:• Development and application of acceptable land use practices



Deforestation

Causes & source:

• Use of wood for fuel, furniture, construction of houses, paper• Felling trees for expansion of agricultural land

Effects:• Loss of habitat, biodiversity, soil degradation, reduced rains

Solutions:• Re-plantation• Better management of forest & agricultural land



Depletion of water

97% of total water on earth is in oceans3% is fresh water

70% of freshwater is ice30% in lakes, rivers, ground water

Use of water: 69% of water used for irrigation23% used for industrial purpose8% for domestic/municipal purpose

Release of chemicals and drainage water is main reason for water pollution



The reason for all environmental problems is Industrialisation.

We use power, water, fuels, oils, metals like copper, iron Aluminium, grease etc. We carry out various chemical processes like plating.

Consumption of power results in increased usage of water, coal etc.

Use of fuels like diesel, coal release various harmful Emissions.

Mining of ores and fuels also leads to desertification.Chemical industries generate hazardous waste.



So any activity we carry out will have a direct or indirect effect on the environment.

For example:• We use various metals, grease, fuel, oils which results in depletion of natural resources.• There are chances of oil, grease and fuel contaminating water, soil etc.• Use of fuel in DG leads to smoke generation.• Uncontrolled Use of paper leads more demand on trees in paper

industries.• We use plastics which are non-biodegradable.• We use ACs, refrigerators which could be CFC based.• Improper use of water



So in order to reduce control the impacts of these activities

governments all over the world are imposing stringent

requirements. This has resulted in bringing out an international

standard. The aim of this standard is to have a uniform system for

implementing and assessing the environmental management

system.

The International Organization for Standardization formed one

Technical Committee TC 207 which brought out this ISO 14001

standard. The first edition was released in 1996. The second edition

was released in 2004. The second edition is similar to ISO

9001:2000 in structure.



ISO 14001:2004 STANDARDS

CLAUSES


4 Clauses in ISO 14001:2004 Standards

1. Scope

2. Normative References


4. Environmental Management System Requirements

4.1 General Requirements

4.2 Environmental Policy

4.3 Planning

4.3.1 Environmental Aspects

4.3.2 Legal and other Requirements

4.3.3 Objectives and, Targets and programmes

4.4 Implementation and Operation

4.4.1 Resources, Roles, Responsibilities & Authority

4.4.2 Competence, Training, Awareness

ENVIRONMENTAL MANAGEMENT SYSTEMIFB Automotive Private Limited

4.4.3 Communication

4.4.4 Documentation

4.4.5 Control of Documents

4.4.6 Operational control

4.4.7 Emergency Preparedness and Response

4.5 Checking

4.5.1 Monitoring & measurement

4.5.2 Evaluation of compliance

4.5.3 Nonconformity, corrective action and preventive

action

4.5.4 Control of Records

4.5.5 Internal Audits

4.6 Management Review



As per this system we have to list all the activities which are called

aspects. Then we need to determine their impact on the

Environment. Significance of these impacts, our actions &

controls to reduce the impact have to be identified and

implemented. This is called Aspect & Impact Study. Based on these

significant aspects and EMS Policy we need to frame EMS

objectives and identify Environmental Management Programmes

(EMP) to achieve the objectives.



So, in order to manage its activities in a better way and as a

commitment towards protection of Environment, IFBAPL has

implemented Environmental Management System in accordance

with ISO 14001:2004 Standards.

TUV SUD South Asia has certified our EMS.

Our EMS has been initially certified in the year 2004.

We have been recertified in 2007.

This certification is valid for 3 years. Surveillance audits are held

once in a year.

Internal Audits on ISO 14001:2004 are held once in four months.



Level 1: Environmental System Manual

Level 2: EMS Procedures

Level 3: Work Instructions,

Aspect/Impact Study

Level 4: Forms & Formats

Documentation Structure at IFBAPL




OUR POLICIES

QOUR QUALITY POLICY

• To visualize customer needs and provide satisfaction through prompt

supply of value added quality goods and services continuously.

• To achieve and sustain excellence in performance through use of

appropriate technology, cost efficient operations and team work of all

associates.

• To have a World Class Human Resources through training and

motivating them for higher aspirations and also maintain safe working

environment.


We at IFB APL supplying Automotive systems are committed to protect the Environment and prevent pollution by:

1. Optimum utilisation of natural Resources and energy.

2. Adhering to statutory and applicable legal requirements.

3. Awareness on EMS to employees and associates.

4. Monitoring and continual improvement of environmental aspects.

OUR ENVIRONMENTAL POLICY


OUR MATERIAL POLICY

To visualize customer needs and provide

satisfaction through prompt supply of products

To continuously improve the delivery

performance through use of appropriate

technique / service, cost effective operations

and team work of all associates.

To maintain safe work environment



QUALITY CREDENTIALS

QUALITY CREDENTIALS

ISO 90001998

2000QS 9000

ISO/TS16949, ISO14001, HMIL-100 PPM 2004

Our Quality Journey

Continues ……….

FORD - Q12006

ISO/TS 16949 & ISO 14001

Recertification 2007


QUALITY CREDENTIALS

Our Chairman receiving the 100 PPM Certification from the Managing Director of HMI

Q1 Certificate


ISO/TS 16949:2002 ISO 14001:2004

QUALITY CREDENTIALS


qms awareness

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internal quality audits

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