SUPPLIER QUALITY ASSURANCE

MANUAL - CV

Version 3.0 (Revised on 14-March-2023)

©Copyright 2017 Tata Motors Ltd.
This material belongs to Tata Motors Ltd. and is of confidential nature. Reproduction, circulation or distribution of this
material in part or whole in any form without permission is prohibited.
Owner:
P&SC – PMT Process

This book is property of Tata Motors. All rights reserved. No part of this book may be reproduced in any form or by any electronic
or mechanical means, including information storage and retrieval systems, without permission in writing from the copyright
owners.

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 TABLE OF CONTENTS
AMENDMENT RECORD SHEET 3
1. TATA MOTORS POLICIES 4
1.1. MISSION, VISION AND VALUES 4
1.2. QUALITY POLICY 5
1.3. ENVIRONMENT POLICY 6
1.4. ENVIRONMENTAL PROCUREMENT POLICY 7
1.5. SAFETY AND HEALTH POLICY 8
2. HOW TO USE THIS MANUAL 9
2.1. DOCUMENT ACCESS 9
2.2. AIAG DOCUMENTS 9
2.3. SUPPLIER FEEDBACK 9
3. INTRODUCTION 10
3.1. PURPOSE 10
3.2. SCOPE 10
3.3. RESPONSIBILITY 10
3.4. RECORDS 10
3.5. GENERAL REQUIREMENTS 10
3.5.1. Quality Requirements 10
3.5.2. Applicable Statutory and Regulatory Requirements 11
3.5.3. Product Safety 11
3.5.4. Laboratory Requirements 11
3.5.5. Specific Requirements 11
3.5.6. Tata Code of Conduct & Supplier code of conduct 11
4. TATA MOTORS’S PROCESS OF SUPPLIER QUALITY 12
4.1. ADVANCE QUALITY 12
4.1.1. Potential Supplier Assessment (PSA) 12
4.1.2. Sourcing Decision 15
4.1.3. Advanced Product Quality Planning 16
4.1.4. Pre-Production Meeting 18
4.1.5. Quality Management System- APQP Quality Requirements 20
4.1.6. Production Part Approval Process-PPAP 20
4.1.7. Run at Rate 28
4.1.8. Early Production Containment 34
4.2. CURRENT QUALITY 38
4.2.1. Continual Improvement 38
4.2.2. Continual Improvement Requirements 39
4.2.3. SQ Process & Measures 41
4.2.4. Level I – Controlled Shipment (CS I) 50
4.2.5. Level II – Controlled Shipping (CS II) 53
4.2.6. Performance Monitoring 55
4.2.7. Improvement Meeting 56
4.2.8. Re-Sourcing 58
5. CUSTOMER SPECIFIC REQUIREMENTS 59
6. APPLICABLE DOCUMENTS 63
7. GLOSSARY OF TERMS 64

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 SUPPLIER QUALITY ASSURANCE MANUAL - CV

Amendment Record Sheet

Rev./Effective
Reference Page Rev Nature of change / reason
Date

All sections & Pro- X Manual updated with existing

All 2.2 10.01.2020
Procedures practice and processes.
1). Run@Rate details defined.
2). PPAP 3 steps explained.
All sections & 3). Customer Specific Requirements
All 3.0 14.03.2023
Procedures added as a part of manual.
4). Updated with current practices and
processes.

3
1. TATA MOTORS POLICIES

1.1. Mission, Vision and Values

4
1.2. Quality Policy

5
1.3. Environment Policy

6
1.4. Environmental Procurement Policy

7
1.5. Safety and Health Policy

8
2. HOW TO USE THIS MANUAL
The purpose of this document is to communicate to all the stakeholders of P&SQ including
Suppliers about the requirements of Tata Motors to ensure the quality of supplied parts.
The Tata Motors Supplier Quality Manual is organized into two sections:
 Advance Quality
 Current Quality

All our Supplier related transactions are through SAP, single server environment across all
the plants of Tata Motors in India.
Suppliers have been provided access through our intranet services called SRM. This is
compatible with SAP and suppliers can view Purchase Order details, schedules, status of their
quality acceptance of supplies, payments etc. along with other initiatives like quarterly
feedback on Supplier rating, rejection, warranty information and Tata Motors Standards
required by them at their premises.

2.1. Document Access

Tata Motors SQ-Manual form references are available in this manual and can be obtained
from the Tata Motors SRM portal. The latest valid version of this Supplier Quality Manual is
posted on the Tata Motors SRM portal. (https://srm.inservices.tatamotors.com/irj/portal).

To access the manual, log on to the SRM portal using your Admin ID (Vendor code) and
password. After logging on, go to the “Supplier Manual” folder using the following path:
Home > Documents > Tata Motors > Message > Supplier Quality > Supplier Manual.

2.2. AIAG Documents

All AIAG specific documents referenced can be ordered from www.AIAG.org.

2.3. Supplier Feedbacks

Feedback concerning this document is welcome. Should you have any improvement
suggestion about this document, please send an e-mail to the following address:
sqms@tatamotors.com.

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3. INTRODUCTION
The Tata Motors Supplier Quality Manual has been developed for suppliers to understand the
requirements of Tata Motors regarding quality management systems and ensure quality of
supplied parts.

3.1. Purpose
The Tata Motors Supplier Quality Manual has been developed to assist suppliers understand
the expectations of Tata Motors regarding quality management systems and meet the terms
of Tata Motors purchase agreement, engineering drawings and specifications.
This Supplier Manual defines the processes and requirements for:
 Process Standardization across all Tata Motors locations for Supplier Quality
 Follow of Benchmark Best Practices
 Cultivation of World Class Quality in Supplier Outputs
 Supplier Performance Measurement Parameters
 New Business

3.2. Scope
This process, under SQA Manual, is an integral part of the Supplier Quality Improvement
Process. It applies equally to all suppliers and affiliated organizations that supply parts,
materials, equipment, for production, pre-production, and/or services to the customer.

3.3. Responsibility
Suppliers shall utilize the latest revision of this Quality Manual and seek clarification from their
Tata Motors contact when necessary for items that are not identified or completely clear in the
manual. Tata Motors will continually improve and revise the contents of this manual.

3.4. Records
Suppliers shall maintain records of all required documents of this manual and shall be made
available to Tata Motors Supplier Quality Engineer upon request.

3.5. General Requirements

Tata Motors quality requirements stated in this document are general in nature. Quality
requirements for specific parts are specified in product specifications and order documents.

3.5.1. Quality Requirements

Supplier Partner’s to Tata Motors supplying auto parts meant for OE and SPD requirements
are expected to be IATF 16949: 2016 QMS Certification. Second and third tier are expected
to be certified to minimum ISO 9001-2015 with an aim to comply with IATF 16949: 2016 QMS
requirements. Tata Motors will carry out periodic assessment / audit of supplier’s Quality
Systems and manufacturing processes. Supplier is expected to carry out improvements in
time bound manner as identified during such audits. Supplier is expected to proactively take
suitable actions to make systems robust enough to ensure that non-conforming parts are
prevented from escaping supplier’s premises.

Supplier shall inform Tata Motors about changes in their QMS registration status, such as new
certificate, suspension, revocation or switchover to another certification body. Tata Motors
expects its Tier 1 suppliers to manage the quality of their supplier base. Tier 1 suppliers should
also ensure that their supplier base meets Tata Motors requirements.

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3.5.2. Applicable Statutory and Regulatory Requirements
Tata Motors demands the supplier to be in compliance with all applicable statutory and
regulatory requirements to products and processes. Adherence to statutory and regulatory
requirements, including but not limited to,
- Consent to operate or Establish as applicable,
- Factory license
- Fire NOC Certificate
- Stability certificate
- Form V ( As applicable ),

3.5.3. Product Safety

Tata Motors manufactures products for performance and safety in vehicles. It is of utmost
importance that our products are reliable in their applications. Product safety must therefore
be the highest priority throughout the complete supply chain.

3.5.4. Laboratory Requirements

 Supplier's laboratory shall comply with the requirement of the IATF 16949: 2016 &
Capability to perform these services correctly, traceable to the relevant process
standard. Laboratory and measurements reports shall comply with the requirement of
the IATF 16949: 2016.
In particular, laboratory and measurement reports shall include:
 The identity and location of the laboratory used
 The reference to the test methods used
 Any deviation of the test method shall be noted
 Measurement results
 All necessary materials and process traceability information on the tested components
or samples

3.5.5. Specific Requirements

In many cases, this manual will not sufficiently describe all of the specific requirements of Tata
Motors. The Tata Motors specific requirements shall be identified during the Advanced Product
Quality Planning (APQP) activities. If there are any questions regarding these specific
requirements, the supplier shall contact the respective Purchasing / Supplier Quality
Department of Tata Motors.

Product-specific requirements may include but not be limited to the following:

 Special characteristics
 Testing
 Special handling

3.5.6. Tata Code of Conduct & Supplier code of conduct

The supplier shall implement Tata Code of Conduct (TCOC) & Supplier Code of Conduct
(SCOC) requirements at supplier's operations and is applicable to all his dealings relevant to
his relationship with Tata Motors. Supplier as a business partner of Tata Motors shall not only
subscribe to Tata Motors policy but also support, promote and propagate them in all possible
manners.

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4. TATA MOTORS PROCESS OF SUPPLIER QUALITY

4.1 Advance Quality

The Advance Quality defines TML’s common product quality planning requirements that are
necessary to develop and implement a robust development process for a product.
It is intended as a standard to provide the Supplier Quality Engineer and the Supplier a
common platform from which to proceed with all steps of Product Development.

4.1.1 Potential Supplier Assessment (PSA)

Purpose
Potential Suppliers assessment is done for new suppliers based on the assessment criteria
established through MSA (Manufacturing Site Assessment) and their technical proposals are
assessed to ascertain that all information with respect to TML’s requirements are understood,
and the supplier is capable of manufacturing parts as per Tata Motors requirements.
Scope
This step is applicable to all Suppliers of production parts, raw materials, service parts, and
sourced products.
Activities
The PSA is part of Tata Motors supplier approval process and has the following tasks:
 Potential Supplier Assessment for all new potential suppliers
 Technical Review
Process
This step formally starts off APQP process with program review and identification of key
strategies in the Purchasing Process. A set of requirement including technical specification
and business information (from the concerned stakeholders) is prepared to ensure that all
information necessary to receive equivalent bids is present.

Potential Suppliers are identified and tabled into the Sourcing council Phase-I. The suppliers
are assessed either on the Past Performance or Initial Supplier Assessment.

Potential Supplier Assessment is conducted in following conditions (Ref. MSA Guidelines)

 For a New Supplier / For a New location (Relocation)
 For a New Process / Technology with Existing Supplier

Suppliers, who qualify the MSA (Manufacturing Site Assessment) or have approved Supplier
Performance in Supplier Performance Indicator are eligible to receive RFQ. On submission of
RFQ, the Technical Reviews are evaluated to ensure suppliers are technically capable of
producing parts as per parameters set by Tata Motors.

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Process Flow

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Manufacturing Site Assessment

Description
Assessment of potential new suppliers, identified in the Sourcing Council Phase-1, based on
the assessment criteria established in MSA process. Key focus in this activity is on evaluation
of risks associated with:
1. Company Management & Financials
2. Technology
3. Program Management.
4. Purchasing & SCM
5. Process Control & analysis
6. Customer Support.

A risk assessment score from manufacturing site assessment shall be given to the supplier:
1. With more than 80% score: supplier is considered as capable.
2. Between 70% and 80% score: the supplier is considered as conditionally capable.
3. Less than 70%: The supplier considered as non-capable.

*Sourcing council can override the above on case to case business decisions with
necessary approval as per MSA Guidelines.

Timeline
Prior to Sourcing Decision
Output
Supplier Capability i.e. MSA Completion for the Supplier’s Manufacturing site with detailed risk
assessment.

Inputs
Input Source
List of Potential Suppliers Buyer / ERC
Supplier Profiles Purchase Buyer

Methodology
 The SQE receives a request to conduct MSA from the Purchasing Buyer/ ERC.
 The SQE sends intimation to the supplier to conduct self-assessment.
 After receiving self-assessment, SQE proceeds towards MSA.
 Audit of suppliers are being done as per ‘Manufacturing site assessment’ (MSA)
program and format. Please refer Manufacturing Site Assessment (MSA)
latest guidelines and format on SRM portal.
 The supplier supports the SQE in conducting the MSA by providing all
documents/necessary support in a timely manner.

MSA format: TML PSC-SQ-MSA-7.1

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4.1.2 Sourcing Decision
Purpose:
Sourcing decision is conducted to finalize the supplier so that the supplier gets on-boarded
and is engaged in part development and timely start of supplies.

Scope:
Direct Materials

Activities:
Sourcing decision is part of Sourcing Council.
Technical Signoff
Description
This activity reviews the technical proposal of the supplier to validate that all the requirements
from TML have been understood and the supplier has a plan and is capable to produce parts
meeting Tata Motors Requirements. The Technical Feasibility study is a pre-requisite for any
commercial negotiation and approval at the Sourcing Council.

Output
Identification of capable suppliers

Inputs
Input Source
Technical Documents Design Engineer
Quality SOR (May Include Part Specific SOR) SQE
List of Directed Buys Buyer
Carryover Part List (PMXU) Design Engineer
Required Quality Information Supplier

Methodology
Supplier Responsibilities:
Suppliers must review information in the SOR and produce information as requested by the
Tata Motors SQE:
 Adherence to Tata Motors Quality Requirements, including but not limited to:
– Adherence to IATF 16949:2016 / other QMS.
– Adherence to requirements mentioned in AIAG documents
– Production Support Requirements
– Continuous Quality Improvement Plan
 Preliminary Timing Charts
– Highlight concerns related to tooling, gages & fixtures, and/or testing that may
impact PPAP.
– Detailed list of (proposed) changes to the manufacturing facility, including
Greenfield and brownfield plans.
– Optimized and dedicated resource deployment to successfully complete the
APQP project; including competency mapping and training requisite to
complete the tasks.
 Suppliers should have Preliminary process flow diagrams, PFMEA and Control Plan.

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  Capability Studies on similar parts (Commodity) and tolerances:
– Error Proofing systems, MSA studies, SPC, EPS mechanisms and their record
keeping is included.
– Plan to meet warranty targets (Review open PRRs, existing warranty action
plans and data on similar parts/aggregates)
 Present process and resource plan for evaluation and management of sub-
contracted/tiered suppliers.
 Respond to the assessment and observations and where applicable identifying
countermeasures to be taken.
 Provide evidence of product experience or technical expertise relevant to the new
product.

4.1.3 Advanced Product Quality Planning

Purpose:
APQP is a structured method of defining and establishing the steps necessary to assure that
a product satisfies the customer (Tata Motors). The goal of APQP is to facilitate
communication with all stakeholders to assure that all required steps are completed on time.
Some of the benefits of APQP are:
 To direct resources to satisfy the customer requirements.
 To promote early identification of required changes
 To avoid late changes
 To provide a quality product on time

Scope:
All new parts under development

Activities:
APQP enlists 3 core activities within the step, namely:
 APQP Project Plan
 APQP Timing Chart
 APQP Kick Off Check sheet

Inputs:
Input Source
APQP Status SQE
Part development status monitoring
Detailed Timings for tooling, facilities, gages Supplier/SQE
Project Timing Requirements LOB
Open Issues SQE/Supplier/Design Engineer (COC)
Sub-Contract Management (Supplier Tiers / Supplier/Buyer
Directed Buy)

Output
 APQP Open Issues List
 Updated APQP Timing Chart

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Process
The APQP project plan is developed in accordance with the recommendation of AIAG APQP
manual, listing the various activities in line with Tata Motors NPI Gen3 DR Gates /Milestones.
The type of Product, complexity and project expectations are considered in selecting the timing
elements that are planned and charted. Each event has a “start” & “completion” date along
with the actual point of progress recorded. APQP process is then formally kicked off (APQP
Kick-Off) for the various projects.
 The reviews are conducted by Tata Motors for all parts under development. Supplier
must update all information pertaining to Product Quality and Timing to the concerned
SQE.
Note:
 The timing chart is developed in accordance with principles of Critical Path Method
(CPM), Gantt chart, and is driven by the principles of simultaneous engineering
performed by product and manufacturing engineering activities working concurrently.
 Each project plan will be different depending on the project program and the part.
 The APQP Timing chart will be continually referenced and reviewed throughout the
Product Development Cycle.
 APQP project planning facilitates communication between the supplier and customer
(Tata Motors) to clarify the customer requirements that translate into more detailed
specifications.
 Suppliers prepare component specific timing chart in line with the APQP Project Plan
(Master Timing Chart) considering development along the entire supply chain
(including Sub Contractor Development).

Supplier Responsibilities
 Create an APQP Timing Chart to track tasks and review regularly
 Suppliers should use APQP as a tool to support process development:
– To develop and execute an APQP Plan for flawless product launch.
 Launch of new components intended for regular production.
 Development of new manufacturing processes
 Significant changes to existing products or process
– Regularly update the progress of product development based on their APQP plan
and share the same with Tata Motors.
 Suppliers are required to adhere to APQP Timing Chart.
– Create an APQP Open Issues and monitor the same throughout the program.
 Utilize APQP Open Issues list to capture all issues requiring action.
– Update timing chart as timing changes occur and communicate any changes,
concerns and issues to SQE.
 Develop recovery plans for issues impacting quality and timing and drive
the plan to maintain program timing
 Any timing changes by the Tata Motors have to be adequately
communicated downstream.
– Sub-component (tier II) milestones shall be pulled ahead of the Supplier’s
assembly milestones to protect Tata Motors program timings.

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4.1.4 Pre-Production Meeting
Purpose
Pre-Production Meeting is a review mechanism to track the progress of all APQP Tasks in the
APQP Project Plan and APQP Timing Chart.

Scope
All activities covered under the APQP process.

Activities
Pre-Production Meeting marks the start of activities which are conducted periodically
throughout the APQP cycle to evaluate progress of various activities in a structured manner.
Tata Motors SQE will be scheduling these Gate Reviews with Supplier.

Process
 SQ Gate Reviews are conducted prior, preferably 1-2 weeks, to Project DR Gate
Reviews.
 Pre-Production Meeting entails the first Gate Review (GR1) should be completed
within 4 weeks after the release of PO.
– Subsequent Gate Reviews are aligned with the vehicle built for each
component.
 Completion of all activities as mentioned in the APQP Gate Review Chart, ensures
qualification to next level, else the progress takes a step back to a prior level.

4.1.4.1 Gate Reviews

Description
Gate Reviews are done to ensure that all tasks in the APQP project plan due at a particular
Gate are completed.

Timeline
Completed prior, preferably 1-2 weeks, to Project DR Gate Reviews.

Output
 Updated APQP Open Issues List with Escalation Red Alerts (if any)
 Progress of Project – Completed documents of all required activities
 Gate Clearance Status
 PPAP approval as per program milestone.
Inputs:
Input Source
Program timing for key events Buyer/ Program Manager
Detailed Program Timing Supplier / SQE
APQP Open Issues List Supplier / SQE
APQP Timing Chart Supplier / SQE

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Methodology
Supplier Responsibilities
 Ensure completion of required activities as per APQP plan at various gates.
 Supplier should ensure his readiness for audit by Tata Motors prior to any gate review.
 Review the completion status of actions required for compliance to SQ SOR and Part
Specific SOR, Lessons learned.
 Ensure lessons learned are captured adequately in the FMEAs or Control Plans.
 Validate capability studies and risk reduction plans to satisfy Tata Motors design
specifications and quality requirements.
 Validate capacity/plan vs. capacity required by Tata Motors.
 Identify and communicate key issues in adhering to the APQP timing chart to Tata
Motors management.
 Co-ordinate the gate reviews after APQP kick-off. For Supplier monitored parts, the
supplier must conduct the APQP Gate reviews and periodically report the same to Tata
Motors SQE.
 Complete the gate reviews with sub-contractors (Tier II to Tata Motors), prior to Tata
Motors gate reviews as per project plan to protect Tata Motors project timing. Inform
Tata Motors SQE, in case of any discrepancy or non-conformation.

 Protect Tata Motors program timing and objectives by adhering to the APQP charts.
– In case of deviation, prepare comprehensive recovery plans and submit the
same to Tata Motors SQE.
– Track all open APQP issues and report any concerns to Tata Motors SQE,
immediately.

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4.1.5 Quality Management system - APQP Quality Requirements
Purpose
Quality Management system helps us to Achieve & Exceed the global benchmark levels to
manufacture and deliver the Highest Quality Products
Quality is built into the process
 Built-in-quality (BIQ) is made the DNA of the Organization
 People are involved and strive for Quality Excellence
 Prompt Actions are taken for all abnormalities
Scope
Quality Management system applies to all Suppliers collaborating and/or engaged in business
with Tata Motors. This is also evaluated during MSA audit at supplier.

Timeline
 During APQP & sustenance.

Output
 Quality management system helps us to Achieve & Exceed the global benchmark
levels to manufacture and deliver the Highest Quality Products

4.1.6 Production Part Approval Process-PPAP

4.1.6.1 Production Part Approval Process

Description
The Production Part Approval Process (PPAP) demonstrates that the manufacturing process
used to produce parts for the Tata Motors is fully developed, thoroughly tested, and capable
of serial production of parts conforming to the technical specifications. For the PPAP (as for
the APQP) Tata Motors follows the AIAG requirements, using the requirements applicable for
trucks and heavy equipment.
Sample parts and the supporting documentation are submitted to show evidence that:
 The design records and specifications have been properly understood and met
 The manufacturing process has the capability to produce conforming parts in the actual
production environment
 The manufacturing process has the capacity to support production quantities at a
consistent quality level

Suppliers shall ensure that the PPAP document and sample submissions are in accordance
with the requirements of the Automotive Industry Action Group (AIAG) PPAP Manual.
Additional guidelines and a copy of the Part Submission Warrant (PSW) template are available
on the Supplier Portal.
Tata Motors requires its suppliers to follow the Customer Notification and Submission
requirements as specified in the AIAG PPAP Manual that includes but is not limited to:
 Introduction of new components
 Changes to an existing part
 Drawing or specification changes
 Corrections to a prior discrepancy

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 Supplier process change
 Material changes or substitutions
 Changes of sub-tier suppliers

Process Flow Diagram

Description
Process Flow Diagram provides a logical pictorial representation of the process flow that can
be used as the foundation for PFMEA’s, control plans, work station layouts, etc.

Timeline
Initial chart–prior to sourcing, reviewed at Gate 2 and Gate 3, and completed in PPAP.

Output
Process Flow Chart (depicting Sub component system)
Inputs:
Necessary Inputs: Source:
Information on each step of Manufacturing Process Supplier
Part Specific Quality & Process SOR (If applicable) SQ

Methodology
Supplier Responsibility
 Create a preliminary process flow chart using a similar process as part of response to
TML’s requirement.
 Define a production flow chart once product design is released.
 Document all items in the flow chart with the respective nomenclature (store, move,
inspect, correct, etc.)
 Ensure the process flow chart is linked to the PFMEA and control plan
 Update flow chart to reflect actual production process.
 Communicate any changes on an ongoing-basis to SQE.

4.1.6.2 Design Review

Description
The purpose of Design Review is to ensure that the Product Design is adequately defined to
enable construction of tools and gages. The Supplier shall have the design record for the part,
including design records for sub-components.

Timeline
As per APQP Project Plan

Output
 Defined and measurable Classification of Characteristics (CTQ)
 Appearance, performance and material testing specifications
 Geometric Dimensioning & Tolerance (GD&T)

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Inputs
Necessary Inputs: Source of Input:
SOR ERC
Appearance specifications PAT-PQ Engineer (ERC)
Performance and material specifications PAT Engineer (ERC)
Production Assembly Documents if available Simultaneous Engineer
Bill of Material (BOM) Bill of Material (BOM)

Methodology
Supplier Responsibility
 Confirm the manufacturing process can achieve the specified tolerances on a
sustained basis.
 Any recommendations / improvements to the design record are documented and
submitted to Tata Motors for approval.
 Communicate any concerns related to the CTQ cascade Designators or GD&T
scheme and the manufacturability of the part. Document any open issues on the
APQP Open Issues List
 Develop an understanding of the engineering change process with the Tata Motors
ERC Engineer. Refer Design Review Check sheet1 and address any open action
item.
 Note: Where the design record is in electronic format, e.g., CAD/CAM, the Supplier
shall produce a hard copy.

4.1.6.3 Design Failure Mode and Effects Analysis (DFMEA)

Description
Design Failure Mode and Effects Analysis is an activity to assess and prioritize the risk of
failure of a product design component, subsystem, or system in achieving product
performance, reliability, or safety goals and to develop mitigation plans.
The purpose of DFMEA is to predict the potential failure of the product design, evaluate the
effects of those failures, and then identify actions to reduce the risk before the design is
released to manufacturing.

Timeline
Initiated before or at design concept

Output
DFMEA document and cascade DFMEA to sub-component level DFMEA.
Inputs:
Necessary Inputs: Source:
Requirements as stated in SOR COC-ERC
Design intent COC-ERC
Vehicle Requirements ERC
Manufacturing/Assembly requirements ERC
Lessons Learned /Part-Specific Quality & Process SOR SQE
CTQ Cascade Templates (if already identified) FMQ

22
Methodology
Supplier Responsibilities:
 The supplier needs to create and submit the DFMEA if it is design responsible.
 The DFMEA document should be maintained throughout the life of the product and
updated and revised prior to any engineering changes. Changes in part level DFMEA
should be communicated to Tata Motors for updating system level DFMEA.
 Supplier must address and identify all Tata Motors special characteristics as given in
TS11413 standard.
 The DFMEA shall be ranked based on AIAG guidelines for Severity, Occurrence and
Detection Ratings.
 The DFMEA shall be reviewed by the COC and the SQE shall support in conducting
the reviews before drawing release.

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4.1.6.4 Process Failure Mode and Effects Analysis (PFMEA)
Description
A PFMEA is used to identify potential weak areas in the manufacturing and assembling
process. Cross-functional teams should be organized to study each step of the process for
possible failure modes, effects of failures, and potential causes. Countermeasures must be
provided for failure modes as per requirements in AIAG FMEA Manual.

Timeline
Starting at APQP Kick-Off Meeting and complete by PPAP.

Outputs
 PFMEA
 Risk Reduction /Action Plan Summary

Inputs
Necessary Inputs: Source of Input:
DFMEA ERC/Supplier Design Engineer
Lessons Learned/ Parts Specific Quality/ Supplier/ SQE
Process SOR
Process Flow Chart Supplier
Warranty Data SQE
PRRs on Similar Parts Supplier/ SQE
Supplier Performance Report Supplier/ SQE
Supplier’s Manufacturing Process Capability on Supplier
similar parts
Error Proofing Techniques Supplier/ SQE

Methodology
Supplier Responsibilities:
 Review and update PFMEA each time a design change is made or a Process change
is implemented. All potential areas for failure are included in the PFMEA and
appropriate corrective actions are planned and implemented.
o Note: A PFMEA should not consider product design changes to compensate
the process deficiencies.
 Prepare PFMEA with inputs and participation from cross functional team.
 Adhere to PFMEA Risk reduction/AP Summary , including the categorization of risk,
establishment of a top ten list, development of recommended actions, and update to
Tata Motors SQE on demand.
 Drive simple and inexpensive mistake / error proof devices into the process to help
prevent and detect errors.
 Ensure that all failure modes and related severity numbers from DFMEA are listed in
the corresponding PFMEA.
 Ensure that the current process controls and results of recommended actions on the
PFMEA are listed on the control plan.
 Ensure that the PFMEA has a link with the manufacturing process flow chart and the
control plan.
 If the process, material or manufacturing location changes, revise the PFMEA and re-
evaluate the impact on severity, occurrence, and detection ratings.

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  Ensure that subcontractors’ PFMEAs are developed and risk reduction action plan are
implemented.

4.1.6.5 Tooling and Equipment Review

Description
The task ensures that the manufacturing process is designed to the latest engineering change
level (e.g. NR, A, B, C etc.) and certified to produce quality parts at rated production rates as
per Tata Motors specifications.

Timeline
Starting at Tooling Kick off Meeting till PPAP approval

Outputs
Process capable Tooling and Equipment delivered on time as per APQP Project Plan.

Inputs:
Necessary Inputs: Source of Input:
Approved GD&T, CTQ Cascade Design Engineer
Designators and CAD Data
Part-Specific Quality & Process SOR SQE
Quoted Tool Capacity Buyer
Process Capability Requirements SQE/Supplier
Timing Requirements Buyer/SQE/Supplier
Capacity Requirements Buyer
Error Proofing Supplier
Functional Test Requirements Tata Motors Validation Engineer
(IDT/ODT)/ Supplier

Methodology
Supplier Responsibilities:
 The supplier should review and inform Tata Motors about any changes in the original
project timing.
 The supplier must participate in Tata Motors design reviews to incorporate Tata Motors
requirements and special characteristics in the tooling or equipment.
 Design, build and obtain certification of and validation of tooling and equipment as per
latest CAD data.
 Participate in design reviews with Tata Motors and ensure GD&T, CTQ Cascade
requirements are included in the tooling, equipment and functional test design. Also
ensure tooling and equipment will produce parts consistently to meet process
capability requirements.
 The supplier should inform Tata Motors about any design and process changes
regarding any new or modified tools, rearrangement of existing tooling or equipment,
any product or process changes impacting fit, form, function, performance and
durability of saleable product, any test/inspection methods and any new facilities.
 Prior to tools being grained, dimensional verification is required by Tata Motors and
Grain Approval to be signed off.

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4.1.6.6 Gauge Development and Approval
Description
To design, build and certify gages according to latest GD&T release.

Timeline
To be completed by PPAP Approval

Outputs
Approved Gauge Prior to PPAP.

Inputs:
Necessary Inputs: Source of Input:
Part CAD Data Design Engineer
CTQ Cascade Designators Design Engineer
Gauge Design & Build Approval Gauge Engineer
Timing Requirements Buyer/SQE/Supplier

Methodology
Supplier Responsibility
 Identify gauge requirement as per CTQ cascade mentioned on drawing.
 Review timing to ensure compliance and inform Tata Motors SQE about any changes
from original project timing, any design and process changes, any new part math data
and/or GD&T changes, any test/inspection methods that include gages, any new
facilities that would house the gages.
 Participate in design reviews, ensure GD&T scheme is released and relevant CTQ
cascade parameters are incorporated into final gage design.
 Design, build, certify gage dimensionally (including a third party certification), perform
complete AIAG MSA (GR&R and Bias study) and meet all requirements as per Tata
Motors fixture standards.
 The supplier shall conduct and document Gage R&R studies upon receipt of new or
repaired measuring equipment.

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4.1.6.7 Control Plan
Description
 It defines the method to be used to control all CTQ Cascade for parts being built for
vehicle builds, power train, and service applications to ensure customer requirements.
 It is to be developed in line with the control plan format referenced in the AIAG APQP
Manual.
 For Product safety requirement refer IATF 16949: clause 4.4.1.2.

Timeline
Starts with Initial draft at APQP Kick Off, supplier shall update parallel PFMEA changes prior
to PPAP.

Output
 Control Plan
 Individual Process Control Charts for all CTQ cascades (FMASOW)

Inputs:
Necessary Inputs: Source of Input:
DFMEA/PFMEA COC/ Supplier
Lessons Learned, Part Specific Quality & Process SOR Supplier/ SQE
Process Flow Chart Supplier
Warranty Data SQE
PRR on similar parts SQE
Supplier Performance Report SQE
Supplier’s Manufacturing Process Capability on similar parts Supplier
Error Proofing Techniques Supplier/ SQE

Methodology
Supplier Responsibilities:
 Supplier should maintain the control plan throughout the life of the product.
 The control plan must be approved by a cross functional team at supplier’s end. It may
be reviewed by Tata Motors depending upon the component.
 The supplier must identify and address all Tata Motors special characteristics on the
control plan.
 The supplier should communicate any changes in control plan to Tata Motors
 The supplier should conduct frequent audits to check the implementation of controls in
the control plan.

PPAP Monitoring

Part development progress is monitored at three stages for confirming readiness at following
milestone.

27
First Sample Submission -PIST PPAP
Closure of IRMR from supplier side considered as PIST PPAP, Customer touch points & performance
parameters are verified. Inspection report generated with supplier sign off. Note: PIST acceptance
guideline is100 % score for bought parts & 80 % for frame assembly

Final samples submission -PIPC PPAP

These parts are made from off tool off process as per agreed PFD. Process capability for CTQ
parameters to be initiated on production intended tool/process. Process capability study & Inspection
report (IR) to be submitted by supplier.
PPAP process improvement actions initiated after process visit.

Production Trial Run

The supplier should perform production readiness reviews and trials internally prior to the start of
production for a minimum of two hours for all purchased parts or as required by Tata Motors. The
production trial run must meet overall efficiency, scrap, and downtime targets.
Production trial run will ensure that process controls, machine checklists, cycle times, work standards,
inspection standards, capacity, downtime, consumable tooling, spare parts, SPC capabilities,
changeover procedures and instructions, subcomponent PPAP approvals and inspections, gauging,
corrective actions for downtime, scrap & efficiency, and packaging requirements are in place. The
supplier must resolve all non-conformances found during PTR prior to start of production. The supplier
will coordinate with Tata Motors to allow to witness the subject trials if requested by Tata Motors.

Production Run Quantity

The production trial run shall be conducted at the production site, using production tooling, Production
gauging, production process, production material and production operators
It is important that the adequate quantities of the parts to be manufactured during this run to confirm
the quality capability of production at the rate prior to full production

Truck Industry (Low Volume) Passenger Car

Significant Production run Minimum 30 Nos Minimum 300 consecutive
quantity parts or one day (8 Hrs.) production parts

4.1.7 Run at Rate

Run at Rate (R@R) is an activity to verify that the supplier’s actual manufacturing process, functioning
under normal conditions, is able to produce components meeting Tata Motors requirements mentioned
in SOR.
Scope
All new parts require a Run @ Rate, unless exempted by the supplier quality engineer and approved
by the Supplier Quality Head.
Exemptions –
a. One time PO requirement
b. Low volume - like defense, tenders, aggregates
c. Low volume (Monthly requirement < 300)

Calculation of Lean Capacity Required (LCR) at Supplier end

LCR = Daily Requirement = (SOP+1 Year) SOR Volume/No of working days

Working days –
Considering 6 working days and 12 planned holidays = 365-53-12 =300 days

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E.G.

SOR volume (SOP+1 year)

Year 1 2 3 4 5
Volume 10000 12000 15000 10000 8000

LCR = 12000/300
= 40 Nos / Day

Duration of R@R study

The number of components to be produced during the Run @ Rate should be sufficient to
demonstrate manufacturing process capability and should be predetermined by the supplier
and Supplier Quality Engineer. Factors such as product complexity, shelf life, storage, cost
and single shift vs. multiple shift operations are taken into consideration in determining the
length of the Run @ Rate.

Supplier should demonstrate R@R for minimum 4Hrs or Max 2 shifts (8Hrs) of the
customer's daily production requirement. R&R of bare minimum of 30 nos. to be ensured in
line with minimum 4 Hrs.

Subcontractor Process/Product
Subcontractor’s' abilities to meet the customer's quality and capacity requirements must be
confirmed by the supplier prior to the Run @ Rate being conducted at the supplier's facility.
Verification of the subcontractor’s manufacturing processes should be done through a Run @
Rate or similar process conducted by the supplier.

Corrective Actions
If the results of the actual manufacturing process do not meet TML requirements corrective
action must be taken to correct any non-conformances.
 Non-conformances -If non-conformances occurred during the Run @ Rate which were not
identified previously by the normal control plan, a corrective action plan needs to be put in
place (i.e., error proofing or a change in the control plan) and documented in the PFMEA
and/or process flow diagram.

Approval
Upon completion of the Run @ Rate, the worksheets must be reviewed for completeness and
a decision made whether or not to approve the review. The Run @ Rate can have one of the
results: pass or fail.
A. Pass
Pass indicates that all Run @ Rate requirements were met. The supplier demonstrated the
capability to produce parts that meet TML’s on-going quality requirements at LCR.
B. Fail
Fail indicates a serious non-conformance exists that requires significant action by the supplier
to correct, such as quality systems are not in place and serious non-conformances exist or
supplier fails to meet Volume Requirements. An additional Run @ Rate will be required.
Once the Corrective Action plan is completed, SQ Engineer will schedule the new Run @ Rate
to verify the successful implementation of the corrective action plan.

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Process Flow

Supplier Responsibility
 Develop a R@R plan and provide to the SQE
 Complete the Capacity Workbook (Manufacturing Flow Diagram, Shared Capacity
Sheet(s), and Manufacturing System Capacity Estimate) and submit to the SQE.
 The capacity analysis must show satisfactory results prior to ordering tooling and
equipment.
 Ensure understanding of the R@R “PASS” performance metrics.
 Conduct preliminary R@Rs and/or simulations prior to the planned R@R to confirm
readiness. The PPAP run of parts will be one of the trial runs.
 Complete verification for all subcontractors, and submit prior to the R@R.
 Completely fill the R@R Hourly Count Sheet during the R@R for both the final
operation and the constraint operation (>85% utilization).
 For constraint operation identify bottleneck sub-operations and plan actions
accordingly.
 Completely fill the Capacity Workbook for all R@Rs and forward to the SQE

References
 Run @ Rate Check Sheet : TML PSC-SQ-R@R-20.1

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Documentation requirements
The supplier shall submit the items and/or records specified in the level identified below:

Requirement Level1 Level2 Level3 Level 4 Level 5

PSW PSW PSW PSW & other PSW samples
&AAR IRMR Sample & requirements all supporting
only Sample All as demanded documents
supporting by TML reviewed at
documents Supplier’s
location
Design Record
- for proprietary parts R R R * R
- for all other parts R S S * R
Engineering Change R S S * R
Documents
Customer Engineering approval R R S * R
DFMEA R R S * R
Process Flow Diagrams R R S * R
PFMEA R R S * R
Control Plan R R S * R
MSA Studies R R S * R
Dimensional Results R S S * R
Material, Performance and Test R S S * R
Initial Process Studies R R S * R
Qualified Lab Documentation R S S * R
Appearance Approval Report S S S * R
Sample Product R S S * R
Master Sample R R R * R
Checking aids R R R * R
Records of compliance R R S * R
Part submission warrant S S S S R
Bulk Materials Checklist S S S S R

Legend
S – Supplier shall submit to Tata Motors and retain a copy of records or documentation items at
appropriate location
R – Supplier shall retain at appropriate locations and make readily available to Tata Motors upon
request.
* – Supplier shall retain at appropriate locations, and submit to Tata Motors upon request. Tata Motors
will determine what is needed for submission.
The supplier shall submit the items and/or records specified in the level identified below:

Submission to Tata Motors: - Levels of Evidence2

2 As per AIAG PPAP Manual

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Methodology
PPAP activities (DFMEA, PFMEA, MSA studies etc.) are conducted concurrently, as per the
APQP timing charts. Evaluation of the significant production run is done after all issues
identified in EPC station are resolved.
 For Production parts, product for PPAP shall be taken from a significant Production
Run. A significant production run is of at least 8 hours of continuous production or a
production quantity of at least 300 consecutive parts, unless otherwise specified and
approved by Tata Motors SQE.
– For bulk materials, supplier shall refer to AIAG PPAP Manual, Appendix F.
– For tires, unless otherwise specified by Tata Motors SQE, size of significant
production run is 30 tyres. PPAP is derived from 8 hours of tyre curing from the
approved production process as specified in the control plan.
– For parts developed for commercial vehicles (Truck Industry), guidelines as
referenced in Appendix H of AIAG PPAP Manual, are applicable, unless
otherwise stated by Tata Motors SQE.
– This production is conducted at the production site, at the production rate, using
the production tooling, process, materials and operators. Parts from each
production line e.g., duplicate assembly line and/or work cell, each position of
a multiple cavity die, tool or pattern, shall be measured and representative parts
tested.
 The supplier is responsible for obtaining the latest revision of the AIAG Manuals and
forms. The supplier shall submit by default a “Level 3” PPAP package, unless
otherwise specified by Tata Motors SQE. All parts that are supplier designed require
“Level 5” PPAP package, unless otherwise specified.
 Any changes to the 4M’s shall be duly notified to the authorized Tata Motors
representative. After the change has been approved by Tata Motors SQE, the supplier
must re-submit the PPAP documents unless otherwise specified.
 Supplier shall maintain all records at his end regardless of submission levels for the
length of time that the part is active plus one calendar year.

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4.1.7.1 Lessons Learned
Description
The purpose is to maximize the knowledge gained from previous programs and not revisit the
same quality or design issues.

Timeline
Throughout new part development

Output
 DFMEA & PFMEA and other PPAP Documents updated with Lessons Learned
 Part-Specific SOR for key commodities updated with Lessons Learned throughout the
APQP process.

Inputs:
Necessary Inputs: Source of Input:
Existing Lessons Learned for same commodity SQE
Engineering Knowledge for commodities COC
Process knowledge for same commodity SQE

Supplier Responsibility
 Lessons Learned Update
– Review solutions to issues identified in the Kick-off meeting and new items
added to the list in various builds till launch.
– As solutions are identified, DFMEA, PFMEA, Flow Chart, and Control Plan are
reviewed and updated.
 Contribute with additional lessons learned based on knowledge of the commodity.
 Adhere to the Part-Specific SOR.
 Place a formal process to update FMEA and control plans based on Lessons Learned.

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4.1.8 Early Production Containment
Purpose
The purpose of EPC is to:
 Validate the supplier’s production control plan
 Protect Tata Motors assembly and manufacturing centres and service part
warehouses from quality non-conformances
 Document the supplier's efforts to verify control of its processes during start-up,
acceleration and after revisions to the manufacturing process.
 Ensure that any quality issues that may arise are quickly identified, contained, and
corrected at the supplier's location
 Increase involvement and visibility of supplier’s top management

Scope
EPC station is to be established for all parts that require PPAP approval from Tata Motors.

Timeline
EPC is an activity conducted at supplier’s location:
 EPC will start from first off tool sample to meet Product and Process Validation Phase
 Containment until agreed exit criteria is achieved.

Output
 EPC Control Plan audit (TML PSC-SQ-EPC-21.1)
 Defect free parts

Inputs
Necessary Inputs: Source of Input:
Production Control Plan Supplier
Order Requirement Tata Motors - SCM

34
Process Flow

Methodology
Supplier Responsibility
Supplier should demonstrate compliance to requirements mentioned in SQ-SOR for EPC but
not limited to the following:
A. Establish a validation process that contains the following elements:
i. Identify and train staff that ensures the development and implementation of the
verification process.

35
 ii. Implement EPC with entry date, exit criteria, and exit date as defined by Tata
Motors SQE.
iii. Establish EPC containment stations, which must be off-line, separate, and
independent check from the normal manufacturing process and located at end of
process. Additional, or when increased effectiveness, in process containment
stations can be utilized, permission from approved Tata Motors SQE must be
sought and the same documented.
iv. Identify additional inspections, testing, and dimensional checks required at the
EPC station based on Critical to Quality Characteristics (CTQs), critical
measurement points, high risk and/or issues identified during product and process
development.
v. Establish a reaction plan for each and every defect.
vi. Implement an audit process of the EPC station utilizing Layered Process Audit
Methodology3, including site leadership, to ensure conformance to the Pre-Launch
Control Plan.
vii. Include subcontractor (Tier 2) in the validation process.
viii. Submit data to Tata Motors for all CTQ, and critical measurement points.

B. Plan Development of a significantly enhanced Pre-Launch Control Plan, consisting of

additional controls, inspections, audits, and testing to ensure the conformance and
capability of the manufacturing process. The plan needs to consider:-
i. Increased frequency/sample size as stated in the Production Control Plan.
ii. Verification of packaging and label requirements – including service and accessory
part requirements.
iii. Verification of the effectiveness of error proofing.
iv. Immediate implementation of containment and irreversible corrective action when
non-conformances are discovered in the EPC containment area or at the receiving
location.

C. Documentation: Document the Pre-Launch Control Plan using the Control Plan format
referenced in the AIAG Advanced Product Quality Planning and Control Plan
Reference Manual. (Note:-The Pre-Launch Control Plan is not a substitute for the
Production Control Plan but, is an addition to the Production Control Plan and is used
to validate it.)
i. Document additional inspections, functional testing, and dimensional inspections
required at the EPC containment station or at process work stations on the Control
Plan Special Characteristics form referenced in the AIAG APQP Manual –
Supplement K and reference said document in the Pre-launch Control Plan as a
specific operation.
ii. Document inspection work instruction in a standardized format for the EPC
containment station to ensure standardized work.
iii. Document evidence of execution and validation of the control plan utilizing the I-
chart or other format agreed upon by Tata Motors. The data must be readily
available for review by the SQE.
iv. Document problem solving for both internal and Tata Motors quality concerns
utilizing customer acceptable format; including problem description, root cause,
irreversible corrective action with break points and update FMEAs and Control
Plans as appropriate.

D. Identification: To identify lots shipped with EPC gates, supplier must attach to each
shipping label a green circular, sticker, signed by the supplier’s staff person
accountable to ensure proper implementation of EPC.

3 Refer AIAG CQI-8 Layered Process Audit

36
Exit Criteria
Supplier will be eligible to exit EPC after validating the effectiveness of Process Control Plan
and meeting the criteria listed below. If the supplier is unable to meet the exit criteria or the
supplier’s EPC plan continues to identify non-conformances.
The supplier shall continue the necessary containment measures to insulate Tata Motors
manufacturing location until the quality concerns have been resolved to the satisfaction of both
the supplier and Tata Motors, and the supplier’s Production Control Plan is validated.
The exit criteria are as mentioned below:
 Ship required quantity as specified by the Tata Motors for the EPC period without any
issues identified at either the EPC gate or Tata Motors. For a Supplier to exit from the
EPC firewall, the manufacturing process should be error free for 21 consecutive days
after observation of the problem, subject to minimum 3 months of a firewall stationed
installed at the supplier end.
 If EPC plan continues to identify non-conformances, the EPC plan shall be kept in
place until process controls and capabilities have proven effective and the Production
Control Plan is validated.

Consequences of shipping non-conforming material

 Failure to execute EPC may result in Controlled Shipping Level 2 and other possible
consequences.
 Shipment of non-conforming material may result in Controlled Shipping Level 2.

37
4.2 Current Quality

The Current Quality defines the common processes used across all locations to protect Tata
Motors manufacturing/assembly plants and to drive systemic improvement to the supply base.

4.2.1. Continual Improvement

Purpose
Continual Improvement has been included in SQ-First Manual to promote the culture of PDCA
at supplier manufacturing locations. Continual improvement:-
 Defines the supplier’s responsibility in developing and sustaining a manufacturing and
its allied processes that continuously improves the product and related manufacturing
processes throughout the product/part lifecycle.
 Reduces variation and ensures process stability and capability over time (after a part
has satisfactorily completed PPAP), with emphasis on zero defects.

Scope
Continual Improvement applies to all suppliers of Tata Motors and is applicable even when
Tata Motors has not requested data and/or product characteristics have not been called out
in the design record.

Basic Requirements
All suppliers are required to have quality systems in place that ensures parts shipped to the
Tata Motors meet specification. Suppliers are also expected to have a system to:-
 Properly identify the root cause of non-conformities
 Capture and horizontally deploy lessons learned
 Prevent recurrence of non-conformances across their operations.
Additionally, all suppliers shall have processes in place to capture:
 Voice of the Customer (VOC):- (These measures reflect quality performance as seen by
the Tata Motors)
– Compliance with SQA Manual - Suppliers are required to have a process in place
that appropriately responds to PRRs on a timely basis.
– Defective parts shipped to Tata Motors - This measure represents the number of
non-conforming parts shipped to the Tata Motors and is expressed in parts per
million (PPM). Those suppliers that ship to our assembly and manufacturing plants
via a sub-assembler and/or sequencer must also monitor any defective product
found at either the sub-assembler and/or sequencer. Field and warranty issues are
also considered.
 Voice of the Process (These measures reflect quality performance as seen in the
supplier’s facility/process)
– Measure First Time Quality - First time quality (FTQ) is a measure of a process’
ability to make quality parts without scrap or rework. Reducing and controlling the
variation in the input variables presents an opportunity for continual improvement.
FTQ should be measured at the following locations:
- End of line FTQ (minimum requirement)
- Quality Gates
Quality Gates include the following elements:
- Alarm limits established (e.g. 1 defect/hour) to drive immediate containment
upstream in the process
- A Pareto of failure modes for a specific timeframe
- FTQ trend chart (I-Chart format recommended)

38
 Further, suppliers must have adequate checks in the control plans to maintain and
improve the process capability of CTQs designated by Tata Motors.
– Process performance on CTQ’s - Variation on key product characteristics and
product quality characteristics (CTQs) reflects the variation in the process and is a
result of a supplier's ability to control the input variables of a process.
 Effective Problem Solving (EPS), Root Cause Analysis, and Corrective Action
Implementation with Verification –
– Suppliers are required to have an EPS4 process in place to identify the root
cause on a timely basis, and implement and validate the corrective actions. A
3*5 why analysis is required. Verification and validation of root cause and
corrective action should demonstrate the ability to turn the problem on and off.

4.2.2. Continual Improvement Requirements

Suppliers must have an organized and integrated approach for continual improvement that
drives reduction of risk and variation associated with manufacturing and supporting processes.
The continual improvement process must be documented and institutionalized, actively
supported by the supplier’s leadership teams and include of the following elements:
 Variation reduction on CTQ. Suppliers are required to have an on-going process to
reduce variation on characteristics identified as CTQs.

 Risk reduction process. Suppliers are required to have a formal and documented Risk
reduction process which includes:
– A cross functional team that meets regularly and updates FMEA and Control Plans
– Collection of external and internal data relative to rejects (scrap and rework)
– Incorporation of internal data (FTQ, scrap, etc.) and external data (PRR, etc.) into
the FMEA and validation that assigned SOD numbers are reasonable and accurate
– A defined strategy for on-going efforts for risk reduction (SOD approach)
– Identification and implementation of action plans with timing and accountability

 Lessons Learned process. Suppliers are required to have a documented and effective
process in place to drive lessons learned into current and future application of FMEAs and
Control Plans.

 Focus on Prediction and Prevention of potential failures. The supplier’s efforts must
ultimately be focused on prediction and prevention of potential failures and failure modes.
Supplier’s quality system should:
– Validate and Evaluate Error-Proofing to ensure it is capable of preventing defects.
– Ensure CTQs are audited/monitored and correlated.
– Maintain the process under statistical process control
– Remove special causes of variation.
– Reduce variation of common causes – improve the process.
– Following change requests ensure that existing process and engineering controls
are still effective and confirm process stability.

Update Documentation
The supplier must update and revise the FMEA, Control Plan, and Standardized Work.
 Internal data should drive at least quarterly updates.
 External data should drive at least monthly.

4 Refer AIAG CQI 10 – Effective Problem Solving

39
Verification of a suppliers' continual improvement process by Tata Motors
Suppliers will maintain documentation supporting the continual improvement activities
conducted on their facilities. Tata Motors may review a supplier's continual improvement
efforts periodically. Suppliers are expected to document, maintain and display the following at
a minimum:
 First Time Quality Trend Chart ( I Charts)
 PRR Analysis Summary
 Horizontal Deployment
 Revised FMEAs
 Revised Operator Standardized Work Instructions
 Revised Process Control Plan
 Risk Reduction Summary

References:
AIAG Manuals for Process Control Plans, Statistical Process Control, and Production Part
Approval

40
4.2.3. SQ Process & Measures
Purpose
To produce a product quality plan which will support development of a product or service that
will satisfy the customer. This section defines the process, roles, responsibilities and
requirements of:
 Problem Reporting and Resolution (PRR)
 Controlled Shipping
 New Business Hold
 Supplier Measurements
– PRRs
– Parts Per Million (PPM)
– Incidents of Controlled Shipping
– Major Disruptions
– New Business Hold
 Process control and Analysis pillar of MSA
 Shutdown/Startup Activity
Scope
This process is to be used for all pre-production, production, service and accessory part
requirements.

Problem Reporting and Resolution (PRR)

Description
A “Problem Resolution Report” (or “PRR”) is a record issued in a Tata Motors standard format
to:
 Quantify and describe the problems encountered by the Customer
 Define the magnitude of the problem
 Identify the Supplier Code
 Identify the part number, if applicable
 Identify key contacts’ name and phone numbers
 Identify the phase of vehicle build (production, development)
 Quantify and request reimbursement for costs incurred due to problems encountered
 Define status and material disposition
 Record corrective action plan
 Record timing of updates to FMEAs and control plans
 Identify how the solution will be institutionalized across the Supplier’s facility
 Identify where the defect was found
 Identify tier 2 suppliers, if applicable

PRR’s may be issued to address the following:

 Part or material nonconformance through the life of the part or material
 Packaging nonconformance (i.e. labelling issues)
 Issues and concerns with the shipping of production parts or material to the customer
 Issues and concerns related to the quality of service as described in the service
contract
 Supplier responsible engineering design issues
 Procedural or process non-conformity i.e., failure to communicate in a timely fashion,
failure to comply to procedures, failure to meet deadlines
 New Business Hold

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Inputs:
Input Source
Specific Non-Conformance Details SQE/Manufacturing/Tata Motors
Quality teams/ Program
Management Teams/ Supplier
Corrective and Containment action plans Supplier
Lessons Learned SQE / Supplier

Methodology
Types of PRR are listed below:
Supplier-Initiated PRR
 The issuing location may categorize a PRR as “Supplier-Initiated” if the supplier
notified the customer of a possible nonconformance prior to customers identifying the
problem on their own.
 If the part has not entered or affected the customer’s production process, and the part
has not impacted the workstation, no PRR is required.
 If the suspect material has entered the customer’s normal material flow to the
production operator, the PRR should be classified as “Supplier Initiated”.
Implications of Supplier-Initiated PRR’s
Costs incurred by the customer (e.g. segregating, rework) may be charged to the supplier.

Customer-Initiated PRR
Types of Customer-Initiated PRR’s
1) Quality
A Quality PRR should be issued when the customer has verified that a nonconformance was
caused by the supplier. Non-conformances that may result in a Quality PRR include, but are
not limited to, discrepancies or problems with:
 Appearance
 Dimensions
 Welds
 Finish, i.e. burrs or flash
 Contamination
 Coating
 Part or Container labeling issues affecting the part identification
 Laboratory and metallurgy specifications
 Machining
 Functions

2) Customer Satisfaction
A Customer Satisfaction PRR is issued when Tata Motors has verified that nonconformity,
excluding pricing and/or other commercial issues, was the result of a supplier’s action or
inaction.

NOTE: A Customer Satisfaction PRR can be issued to a supplying location with or without
reference to a part number
Nonconformance’s that can result in a Customer Satisfaction PRR include, but are not limited
to failures regarding:

42
  Communication requirements for data or information
 Lack of responsiveness, timeliness, or deadline issues (e.g. APQP Program
Management)
 Procedural requirements
 Failure to honor promised corrective action

3) Engineering
Engineering PRR’s may be issued to design responsible suppliers to document design related
concerns.

4) Indirect
An Indirect PRR may be issued to document a supplier responsible problem caused by a non-
production supplier (tooling, equipment repair parts, capital equipment, etc.) at the customer
plant. This would include scheduled work activities that cannot be completed due to the
supplier’s failure to meet prior delivery commitments.

5) Packaging
A Packaging PRR is issued when Tata Motors has verified that the supplier caused a
packaging non-conformance, which could result in part damage or affect the salability of the
part.

Non-conformances that may result in a Packaging PRR include, but are not limited to:
 Part or material was inadequately secured in the container
 Container was inadequately secured in the transport vehicle
 Container design, ergonomic interface, and/or fabrication was inadequate
 Container that has been damaged by improper handling
 Mixed pallets built incorrectly
 Labeling issues that do not affect part identification

The different types of packaging PRR are:

 Container Design/function
 Part Damage
 Design

a. Container Function (Product Packaging):

A Container Function (Product Packaging) PRR may be issued when the container
(Packaging) does not function properly. These types of issues do not result in part
damage.

b. Part Damage:
A Part Damage PRR may be issued when there are part quality concerns resulting
from the container. These types of issues will ultimately result in part damage. Non-
conformances in this category that may result in a PRR, but are not limited to:
 Jumbled parts
 Scratches on parts
 Warped / Deformed parts / Broken parts

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 c. Ergonomics:
An Ergonomic PRR may be issued when it has been verified that ergonomic stressors
exist on a container. Examples of non-conformances in this category that may result
in a PRR include, but are not limited to:
 Excessive reach required to load/unload the container
 Excessive forces required to open/close the container
 Sharp edges

d. Fabrication of Material Handling Equipment:

A Fabrication PRR may be raised if it has been verified that the fabrication of container
is not proper. These types of issues may or may not result in part damage. Examples
of non-conformances in this category that may result in a PRR include, but are not
limited to:
 Container not fit for use
 Swing arms not closing properly
 Part interference issues (dunnage locations)
 Sharp edges
 Non-compliance to specifications

e. Design of Packaging:
A Design PRR is issued if the container was not designed properly. These types of
issues may or may not result in part damage. Examples of non-conformances in this
category that may result in a PRR include, but are not limited to:
 Issues with build prints
 Insufficient container close offs.

f. Container Delivery
Delivery/ Logistics Failure:
 A delivery / logistics failure PRR should be issued when a fabricator or dunnage
supplier misses a milestone and delivers late or when they cause excess
transportation costs (dry run).

6) New Business Hold

The customer will issue a New Business Hold PRR to document the supplier being placed on
New Business Hold.
 No response to Customer Satisfaction PRR
 Repeat issues despite escalation
 TCOC issues
 No QMS Certification/ Plan not available

Placing a supplier on New Business Hold

Suppliers with ongoing quality problems or suppliers without IATF 16949:2016 certification
may be placed on New Business Hold (NBH). The process to place a supplier on NBH is as
follows:
 SQE sends a notification to Commodity Purchase Buyer informing them that a New
Business Hold request is being initiated and their support is requested.

44
  SQE submits NBH report to Commodity Purchase Buyer to schedule a review with
supplier
 Buyer and SQE review the improvement expectations with the supplier.

Removing a supplier from New Business Hold

Once a supplier has met the defined exit criteria, the process to remove a supplier from NBH
is as follows:
 SQE monitors supplier’s progress to ensure exit criteria are being met.
 SQ Manager sends a notification to Commodity Purchase Buyer to advise them that a
New Business Hold removal is being initiated.
 SQE will close the NBH PRR in the SRM portal.

7) Shipping
A Shipping PRR should be issued when the customer has verified that a shipping or
scheduling-related nonconformity was caused by the supplier.

Non conformances that may result in a Shipping PRR include, but are not limited to:
 Noncompliance to schedule requirements
 Documentation noncompliance, i.e. missing or inaccurate shipping documents
 Nonconformity, or nonconformance caused by transportation carrier
 Nonconformity, or nonconformance caused by Logistical Service Provider
 Electronic communication issues or problems
 Premium shipment issues, i.e. prepayment, coordination, excessive use
8) Program Management
A Program Management PRR may be issued by Tata Motors P&SC only, for nonconformance
during launch phase that does not result in part damage or does not affect the salability of the
part. Non-conformances that may result in a Program Management PRR include, but are not
limited to the following:
 Failure to meet program timing
 Repeated engineering issues
 Data submission issues
 Non-responsiveness or lack of cooperation

Supplier Responsibilities
Acknowledgement
The supplier shall acknowledge the PRR by an email reply and initiate initial response
(containment) within 24 hours.

Initial Response (Time – 1 Working Day)

Supplier response must contain the following:
 Immediate containment actions to prevent further shipments of nonconforming parts
or material. Containment shall include data collection and analysis.
 Initiate rework or segregation as an immediate containment at the Tata Motors plant
location.
 Disposition of the nonconforming parts at all Tata Motors locations, warehouses and
Stocks-in-transit.

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Problem Solving
The supplier shall promptly complete appropriate problem solving activities as per PRR
process explained in the SRM portal.

Final Response
The supplier shall provide a final response within 15 days of issuance of the PRR. The final
response shall include at a minimum:
 Containment and preventive actions taken and evaluations/success of the results
thereof
 Root cause of the problem, including methods used to identify the root cause.
 How the solution is to be institutionalized with respect to other similar processes and
products. ”Horizontal Deployment” HD shall be used to document and implement
corrective action across similar processes. Supplier shall update HD tracking status to
SQE on regular basis as applicable, in order to avoid recurrence or repeat concerns.
 Dates when revised process Failure Mode and Effects Analysis (FMEA) and Control
Plan (PCP), will be available for customer review.
 Identification of the responsible tier 2 supplier, if applicable. This does not absolve the
tier 1 supplier of any responsibility
Note: Suppliers will be measured on the timeliness of their final response. If an adequate
response cannot be completed within 15 days, the supplier must notify the customer. Failure
to respond, without prior notification, may result in a Customer Satisfaction PRR.

Controlled Shipping
For details refer to the section on CS1 and CS2.

Supplier Measurements
This section defines the supplier measurements used by Tata Motors to monitor supplier
quality performance. These measures are used in Quality Performance Reports to help guide
future business decisions, and help direct resources to the appropriate areas that require
additional focus.

Major Disruption
Major Disruptions are tracked by the issuance of PRR’s. Major Disruption categories include:
Premium Transportation, Downtime, Plant Disruption, Stock out and Field Action. Premium
Transportation disruptions relate to transportation failures, while Field Action disruptions relate
to significant Warranty issues. Plant Disruption, Stock out and Downtime PRR’s are produced
for quality related issues.
 A problem that affects multiple plants is considered one Major Disruption.
 A problem that could be classified as more than one type of Major Disruption shall be
issued under one PRR with one type of Major Disruption.

Parts Per Million (PPM)

PPM for a supplier code is calculated monthly using the following formula:
1. Total all the “actual quantity nonconforming” for all part numbers for that location
2. Divide by total receipts for that location
3. Multiply by 1,000,000.

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Incidents of Controlled Shipping
On a weekly basis, the customer tracks and reports the number of incidents of Controlled
Shipping Levels 1 and 2 for each supplier manufacturing location.

PRR Measures
On a weekly basis, the customer tracks the number of PRR’s for each supplier manufacturing
location to determine which suppliers require additional focus.

On a monthly basis, the customer tracks the PRR “Time to Implementation.” This measure
represents the time from PRR origination to the time when the supplier completes the PRR
response.

On a monthly basis, the customer tracks the PRR “Time to Closure.” This measure represents
the time from when the supplier completes the PRR response to the time when the customer
approves the PRR response.

New Business Hold

The customer tracks and reports all supplier manufacturing locations unable to quote new
business due to quality performance and/or lack of IATF16949:2016 certification.

4.2.3.1. MSA- Process Control and Analysis Pillar

Purpose
The purpose of the Process Control and Analysis is to ensure that the supplier is following,
updating, and maintaining the PPAP required documents (PFA, FMEAs, and Control Plans)
and, executing the Process Control Plan, while executing continual improvement.

Timeline
Valid throughout the line of the product.
Audit to be conducted-
a. If the supplier performance deteriorates over a period of 4 months
b. Upon expiry of audit cycle i.e. 3years
c. Random audit as deemed necessary by TML

Output
MSA Summary with updated Pillar 5

Inputs
Input Source
PRR Analysis Summary IT Systems
Supplier’s Internal Data Analysis Supplier Supplier
Process Flow Diagram (PFD) Supplier
FMEAs Supplier / SQE

47
Methodology
Criteria for Application:
 Review the supplier’s manufacturing process during any onsite visit
 Investigate a potential nonconformance
 Understand the supplier’s process
 Verify corrective action implementation and updated documentation for a quality issue

Supplier Responsibility
 Extend full support for the MSA audit.
 Implement any immediate containment/addition process controls as directed.
 Develop, document, and provide action plan with appropriate detail, timing, ownership,
etc.
 Implements action plan on a timely basis.

4.2.3.2. Shutdown / Startup Activity (SD/SU)

Purpose
This activity is specifically focused around standardized set of activities to be enacted during
extended shut down periods and subsequent startups to ensure zero major disruptions caused
by a supplier’s shut down and subsequent restart of operations.
E.g. includes elimination and/or restart of a production shift or an extended weekend.

Timeline
Throughout the line of the product

Output
Shutdown / Startup Activity Audit form.

Inputs
Input Source
Shutdown/Start-up Audit Form IT Systems
High Risk Supplier Supplier Performance Reports/SQE

Methodology
Criteria for Application:
 Extended shutdown periods
 Selected high-risk suppliers
Planning Phase
SQE Activity
 Identify key criteria for selecting targeted suppliers for the SD/SU Audit activity.
Suggested criteria may include:
– Spills, downtime, and emerging issues during a specified period
– CS2 activity for a specified period
– Number of CS2’s over 90 days
– High PPM or discrepant parts for a specified period
– Warranty or Customer Satisfaction spikes for a specified period

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 – Previous evidence of poor startup
 Identify the suppliers based on the criteria mentioned above

Do:
Supplier Activity
 Performs a self-assessment of their shutdown/startup readiness using the SD/SU audit
 Completes the SD/SU audit form and return to the assigned SQE with appropriate
supporting documentation/evidence
 Develop an action plan to resolve any issues identified in the self-assessment and
implement containment and/or corrective actions. Sends the action plan to the
assigned SQE.
SQE Activity
 Reviews the supplier’s self-assessment on the shutdown/startup audit form
 Evaluate and update the supplier’s status on a master tracking list
o In case of lack of satisfactory response, the SQE does an onsite review at the
supplier location to resolve any issues and review the supplier’s action plans.
o Places the supplier into EPC or CS2 until all open issues are resolved.

Check/Act
SQE Activity
Review the supplier’s progress in resolving open issues and in implementing the action plan

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4.2.4. Level I – Controlled Shipment (CS I)
Purpose
Level 1 - Controlled Shipment is a demand by Tata Motors that a supplier puts in place an
inspection process at the supplying location to sort parts/products for a specific issue. CS 1
helps to:-
Implement a root-cause and effective problem solving process (EPS), while isolating Tata
Motors manufacturing plant from the receipt of nonconforming parts/material.
Note: - This inspection, enforced by Tata Motors SQE, is in addition to normal controls.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products with
below listed issues may fall under the purview of CS 1.
 Repeat and/or non-conforming PRRs
 Delayed closure of PRRs
 Severity of the problem
 Internal/External Supplier Data
 Major Disruptions
 Field Issues (Warranty, JD Power etc.)
Note: The above mentioned reasons are not exhaustive and the final say rests with the Tata
Motors SQE.

Inputs:
Input Source
Problem Reporting & Resolution (PRR) Mfg./QA/SQE
Request for entry into CS 1 Mfg./QA/SQE

Timeline
Suppliers may be placed in CS1, as per several criteria defined in the scope of the step. An
exit criterion for the supplier is mentioned in the methodology section of this activity.

Output
 Certified Material to the Customer facility.
 I-Chart to demonstrate product quality conformance. (Nonconforming vs. quantity
checked)
 Additional process controls to prevent future occurrences.
 Documented and verified Corrective Action.
 Revised PCPs, PFMEA, Standardized work instructions as required.
 Controlled Shipping Level I entry letter from TML SQE
 Corrective Action Report from Supplier
 Controlled Shipping Level 1 Exit Letter from TML SQE

Methodology
Supplier Responsibilities:
Assessment
 Tata Motors manufacturing or Tata Motors Quality makes a request for CS1,
referencing the details as mentioned in the scope of the step.

50
  SQE reviews the request documentation to ensure it complies with the criteria for
application of CS1, and if applicable places the supplier in CS1.

Entry and Implementation

 Understand the nonconformance and revert with necessary escalation/action plan.
 Establish a separate CS 1 area at the manufacturing location
 Notify additional Tata Motors facilities that use the same part, inform them of the
nonconformance, and provide containment activities as necessary.
 Track breakpoints of nonconforming material. (Purge the supply chain of suspect
material, i.e. at Tata Motors facility, Stock in transit and all storage locations /
warehouses.)
 Mark individual parts, material, and containers, with CS 1 tags, to identify parts CS1
certified to be used in Tata Motors assembly/operations
 Provide a proper layout and instruction documents, space and tooling to perform
Controlled Shipping - Level 1.
 Commence segregation activities and display the results in a public and visible
location.
 The supplier, simultaneously, implements an Effective Problem Solving Process
(EPS), and isolates Tata Motors from the receipt of nonconforming parts/material.
 Review the results obtained at the additional, redundant station to measure the efficacy
of the additional process and corrective actions taken to eliminate the specific non-
conformance.

Performance Measurement
 Perform a redundant inspection of all suspected non-conforming products as per the
agreed upon process, and ensure defect free parts/material are delivered.
 Determine and demonstrate the root cause to the SQE
 PRR report to be filled and submitted to the SQE for validation.
 Develop, implement and validate the permanent corrective and/or preventive actions,
along with improved process controls
 Conduct a daily management meeting at the segregation location to review the results,
ensure the corrective actions taken are effective, and plan required changes.
 Update all applicable documentation, (i.e. Control Plan, PFMEA, Process Flow
Diagram, and Standardized work Instruction Sheets etc.)
 Document containment data in I-chart format.
 Communicate the action plan, inspection status, and results of problem resolution
activities to Tata Motors SQE.
Note: - If the PRR raised is for dimensional issue involving a CTQ characteristic, the supplier
shall revert to the inspection frequency defined in the EPC plan for a period of 30 production
days or until capability is re-established, as directed by Tata Motors SQE.

Exit
 Meet the defined exit criteria.
 Provide supporting documentation on performance and corrective actions to the
appropriate Tata Motors SQE.

CS Established Zone Guidelines (Common for CS 1 and CS 2)

CS Established Zone must follow a basic rigorous process that insulates the customer
assembly plant from the receipt of nonconforming parts and material:

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  CS established inspection zone must be highly visible and properly lighted, equipped,
etc.
 CS established inspection zone must have well defined efficient material flow including
clearly identified areas for incoming and outgoing parts/material.
 Repairs will not be done in the CS established inspection zone.
 CS established inspection zones must be independent of the supplier production
process, unless not feasible.
o Approval of the Tata Motors SQE must be sought for the same.
 CS visual display bulletins must prominently display non-conformances, measures,
action plan and status, and results of the containment activity.
 Charts must be updated on a daily basis and reviewed by Supplier’s Quality Head.
 Inspection officers/operators must have standardized job instructions, quality
standards, boundary samples, tools, and equipment, etc. in a visible location.
o Operators must be properly trained.
 Preventive maintenance must be employed if required.

CS Visual Bulletins (Common for both CS 1 and CS 2)

CS Visual Bulletin boards should display the following:
 Boundary samples, technical specifications, drawings, etc.
 Nonconformance descriptions and resolution action plans (including the CS entry
letter, PRR etc.)
- PFD, Process Control Plan elucidating the location of the non-conformance.
- Trend charts and SPC charts, if applicable (I-Chart)
 Operator instructions, inspector instructions and training records.
 Inspection Control Plan, Inspection Flow Diagram, and Inspection FMEA (CS2 only).

Exit criteria (Applicable to CS 1 and CS 2)

The following details are a pre-requisite in any exit criteria:
 Measurable elements specific and relevant to the non-conformance issues
 Documentation demonstrating effectiveness of corrective actions taken
 Exit criteria must remain constant for each nonconformance
Default exit criteria
Default criteria will be used in absence of any exit criteria, as defined below:
 20 working days from date of implementation of corrective action, of data from the CS
Established zones
 The data should represent that the normal production controls are effective to contain
and prevent the non-conformances
 Documentation validating the root cause
 Documentation validating the implemented corrective action
 Copies of all documentation revised and updated as required (control plan, FMEAs,
process flow diagram, operator’s instructions, etc.)

References
 CS Entry and Exit Letter through mail

52
4.2.5. Level II – Controlled Shipping (CS II)
Purpose
Level II - Controlled Shipment is a requirement by Tata Motors that supplier put in place a 3rd
party redundant inspection process to sort for a specific non-conformance, while maintaining
Level 1 Controlled Shipment and implementing a root-cause problem solving process.
- The third party is selected by the supplier, approved by Tata Motors, and paid for by the
supplier. Suppliers may select the third party from an approved listing of Third Party
Suppliers maintained by Tata Motors.

Scope
A CS2 may be raised due to any of the following parameters:
 Repeat PRRs
 Severity of the problem
 Internal / external Supplier data
 Major Disruptions
 Ineffective Level 1 Controlled Shipment
 Field issues (Warranty, JD Power etc...)

Timeline
Suppliers may be placed in CS 2, as per several criteria defined in the scope of the step. An
exit criterion for the supplier is mentioned in the methodology section of this activity.

Activities
 Certified Material (with CS 1 tag) to the Tata Motors facility.
 Problem solving capability to establish root cause.
– I-Chart to demonstrate product quality conformance. (nonconforming vs.
quantity checked)
– Documented and verified Corrective Action.
– Additional process controls to prevent future occurrences.
– Revised PCPs, PFMEA, Standardized work instructions as required.

Description
Controlled Shipping Level II (CS 2) is a Tata Motors mandate to the supplier to put in place a
3rd party, redundant, inspection process to segregate a specific non-conformance, while
maintaining Controlled Shipping Level 1,and implementing a root-cause problem solving
process.
The 3rd party or a Tata Motors representative may perform assessment audits.
Note: - The 3rd party is selected by the supplier, approved by Tata Motors, and paid by the
supplier.

Methodology
Supplier Responsibility
Assessment
Refer the CS 1 phase for the same.

53
Entry and Implementation
 Supplier contacts a Controlled Shipping 3rd party provider and issues a purchase order
for Controlled Shipping Level 2 activities within 24 hours of receiving the CS2
letter/PRR. SQE should receive a copy of the same when appropriate.
 Supplier performs a redundant inspection of all suspect nonconforming products per
the agreed upon process to ensure defect free parts (CS1). CS1 is a separate and
independent inspection process from CS2
 Supplier notifies additional Tata Motors facilities that use the same part of the
nonconformance, and provides containment activities as necessary.
 The 3rd Party Provider performs an additional redundant inspection of all suspect non-
conforming products per the agreed upon process to ensure defect free parts are
delivered to Tata Motors.
 Supplier submits irreversible corrective action plans to the IATF 16949:2016 registrar
for review and/or assessment and authorizes IATF 16949:2016 registrar to submit the
review and/or assessment findings to Tata Motors.

Performance Measurement
Refer to CS1 Activity for the same.

Exit
Refer to CS1 Activity for the same

54
4.2.6. Performance Monitoring
Purpose
 Enable suppliers to assess their performance.
 Award suppliers with best-in-class performance.
 Identify suppliers with poor performance for re-sourcing decisions.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products.

Timeline
Every quarter for all suppliers (Individual Supplier Location and Cumulative Supplier
Performance) supplying to Tata Motors Manufacturing Locations.

Inputs:
Input Source
PRR Analysis Summary IT System
PPM Report IT System
Program Mgmt. Issues SQE
Plant Disruptions IT-Systems, PPC/ Supply Chain Manager/
SQE
Discrepant Part Systems – IT/ Production Manager/ SQE

Output
 Timely release of Supplier Performance Indicator
o PPM; PRR; Discrepant Parts; Major Disruptions
 PRR Measures – Weekly/Monthly
o Time To Close; No. of PRR; Time to Implement
 New Business Hold Cases

Process
The supplier is rated on certain parameters5 and his Quality Performance Reports are
generated. Similarly the sourcing metrics are generated classifying the supplier as approved
or low performing supplier. These reports will be available to the supplier via the SRM portal
and updated every quarter.
These measures are used to:
 Report the sourcing metrics and Quality Performance Reports
 Direct future business decisions6
 Direct resources to the appropriate areas that requires additional focus.

5 Reference the Quality Performance Reports for further details

6 Step 1 : Potential Supplier Assessment

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4.2.7. Improvement Meeting
Purpose
This step describes the formal meetings between Supplier’s Leadership Teams and Tata
Motors Leadership teams to review the Supplier’s quality performance and actions for driving
improvement.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products.

Activities
 This task describes 3 types of meetings, each with specific drivers, which engages
leadership involvement to improve supplier performance.
– Supplier Performance Review.
– Supplier Quality Improvement Meeting.
– Plant Disruption Review Meeting.
 Top Focus is used to improve the quality performance of the supplier by utilizing audits,
analysing data and driving systemic changes in manufacturing and quality systems at
supplier’s manufacturing locations.

4.2.7.1. Top Focus

Description
Top Focus is a process engaging the leadership teams to improve the quality performance of
the supplier via systemic changes (audits, data mining etc…) in the supplier’s manufacturing
and quality systems. Supplier’s Management is accountable for each action plan and impact
of failure of each target is identified in a step down chart.

Criteria for Application:

 Poor performing suppliers
 Negative impact on multiple Tata Motors Assembly due to either of the following:
o Major disruptions
o High PPM
o High PRRs
o Impact on DRR/DRL
 Continual improvement activity for strategic suppliers

Timeline
Complete Product Life-cycle

Output
 MSA Pillar-5- Process Control Analysis

56
Inputs
Input Source
Supplier Performance Reports IT Systems
PRR Summary IT Systems
Data Analysis Supplier

Methodology
Phase 0: Plan / Assess
SQE Activities
 Identifies potential systemic issues and present the same to the supplier’s quality
manager/director.
 Conducts a Process Control Plan Audit (preferred in the assessment phase.)

Phase 1: Do
Supplier Activities
 Commit resources and participates in Quality Workshop (as requested).
 Performs a detailed analysis of the Supplier Performance Reports, including but not
limited to analysis of the defect sources (manufacturing process or product line), the
failure modes, the failure systemic root causes.
 Develop a Quality Improvement Plan, which includes specific quality action plans and
initiatives to address the issues identified in the Pareto analyses performed above.
 Track implementation of the initiatives and resulting quality improvements.

Phase 2: Check
SQE Activities
 SQE tracks the supplier’s progress with regular on site shop floor reviews, as required.
 Supplier provides an update of the action plans a minimum of once a month.
o Frequency may change as determined by the Tata Motors SQE.
 Update the PPM Glide path and recent monthly audits.
 Escalate the consequences as stated on the PPM Glide path if targets are not met.

Phase 3: Exit
 Supplier has met all exit requirements as stated: -
o Improvement in PRRs, PPM as per Targets defined
o No major downtime (>2hrs) within the last 6-month period
o Improvement is the result of specific identifiable improvements and sustained
over a period of time.
 SQE verifies effectiveness of corrective actions.
 Once the exit request has been approved, SQE notifies the supplier and issues the
exit notification letter/mail.

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4.2.8. Re-Sourcing
Purpose
Re-Sourcing step is included in SQ-First Process manual to protect and mitigate risk to Tata
Motors from engaging in business with poorly performing suppliers.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products with poor
performance in parameters including, but not limited to, Quality, Quantity and Business Quotes
of the part shipped. Supplier’s prior performance will not be considered in case of continuous
non-conformance with Tata Motors expected standards.

Input
Input Source
APQP Open Issues List SQE
Bid List Purchase Buyer
Supplier Performance Report SQE
PRR Summary SQE
PPM Glide Path SQE
Warranty Data SQE
Supplier Action Plan Supplier

Process Flow

Methodology
Suppliers with continuous quality problems may be placed on New Business Hold (NBH) or
Tata Motors may proceed to resourcing if the following criteria are met:
 Repeat of major disruptions: downtime, part shortage, tool/process change etc.
 Lack of IATF 16949:2016 certification (unless waived by buyer)
 Continuous Poor performance
 Unresolved and Repetitive Customer Satisfaction PRR’s

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5 CUSTOMER SPECIFIC REQUIREMENTS:
1. Specifications & drawings-
Supplier must acknowledge the drawing revision level on SRM portal. Where drawings
are not available or revisions are mismatching, supplier shall take up with concerned
buyer/SQE to obtain correct the drawing. Wherever drawing specifies
National/International Standard, Supplier shall maintain the latest copy of the same
unless pertinent issue is specified. Latest drawing can be reviewed & downloaded from
SRM portal provided valid PO for same is released to supplier.

2. Conformance to specification-
Supplier shall ensure maintaining all parameters of parts as per latest drawing, being
supplied to Tata Motors. In case of any deviations prior approval to be taken before
shipment from concern SQE.

3. Product Audit & Layout inspection-

Supplier to conduct product audit at appropriate stages of production & delivery.
Supplier shall carry out layout inspection of products and inform the result to TML once in
a year. In case of nonconformity, supplier shall work on the 4M to meet the specifications.

4. Warranty Analysis-
Supplier to attend the warranty analysis meeting as per schedule.

5. Raw material-
Raw material/ Std. Parts (Fasteners/washer/etc.) shall be procured from approved sources
only. This shall not absolve supplier of the responsibility to meet the specified quality
requirement. The supplier should ensure that the Raw material conforms to the TML
Quality Standard and also get it cross checked from NABL approved laboratories.

6. Type test-
Supplier shall carry out type test for the products of their own design and inform the
verification result to TML every 6 months.

7. Inspection gauges/fixtures/instruments-
Supplier shall be responsible to maintain gauges, inspection Fixtures and instruments
used in a valid state of calibration and shall carryout preventive maintenance of production
tooling such as dies, jigs and fixtures at frequent intervals. Calibration work at specified
interval shall be carried out from calibration laboratories, who have traceability to National
Standards.

8. Reworked & Repaired Products-

Supplier shall obtain TML approval before commencing rework & repair of parts.

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9. Special process Requirement-
Heat treatment, plating and surface treatment, Supplier shall, Display documented work
instruction & Carry out process qualifications. The process shall be carried out by the
qualified operator and shall continuously monitor and control process parameter to ensure
that specified requirements are met. Maintain Training record of operators & approved
process qualification reports for future reference. Whenever there are changes in process
control parameters, Supplier shall again carry out process qualification & validation.
Supplier shall ensure similar controls on sub-contractor when the item is off- loaded with
prior information and agreed by TML.

Supplier shall follow the list of approved sources (Tier-II) for special process like Plating,
Painting, Powder coating, Heat treatment etc. In-case approved supplier is not available
near supplier location, the Tier-II supplier to be approved by SQ with support of SME.

10. Incoming parts

Supplier shall exercise appropriate controls for off loaded / bought out items & any change
by the tier-2 or vendor will be validated before introduction. Even though part is off loaded,
parts quality & quantity is primary responsibility of supplier.

11. Product liability:

Supplier shall sign off mutually agreed warranty procedure made for supplier designed
products and in case of TML designed parts, supplier shall be liable for any manufacturing
defects if observed during the course of usage / product life. Also the supplier will be liable
for the consequential defects due to part manufacturing defects.

12. Quality concerns:

Supplier shall inform TML in case of any serious process lapse at his end resulting in non
-conforming parts being supplied to TML. In this case the supplier will also bear the cost
of Field Analysis Cost (FAC) or any other rework/ rectification at TML or in the field.

13. Logistics/ packing:

Supplier shall to ship / transport production parts as per TML approved logistics/ packaging
only.

14. Third party inspection:

Tata motors may deploy 3rd party for inspection & segregation of parts to protect non
confirming parts issued to assembly line. In Case of 3rd Party Deployment at TML, the cost
of such deployment will be debited to supplier.

15. Supplier SPOC:

Supplier shall declare SPOC for TML to the concerned SQE. In case of any changes,
Supplier will communicate immediately in writing. Updation of contact details on yearly
basis regardless of any changes.

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16. Supplier visits:
TML will have the right to verify the products, processes and quality systems audit at
Vendor’s / Sub-contractor’s premises / Sources. Such verifications shall not absolve
supplier of the responsibility to meet the specified quality requirement.

17. Homologation:
Suppliers supplying parts related to homologation should extend the validity of certification
on a continuous basis through certifying agencies like ARAI/ BIS/VRDE etc. as applicable.
If there is likely to be any break in certification, it needs to be proactively informed to TML.

18. IMDS, POP & Conflict of Minerals:

International Material Data System (IMDS): Supplier shall upload the Material data on
IMDS site with client code provided by TML as applicable. This is mandatory for all new
parts developed after Jan’2018.
Conflict of Minerals Declaration: Supplier shall provide information about the usage of 3TG
materials (i.e. Tin, Tungsten, Tantalum and Gold) in the components supplied during
calendar year.
Supplier shall declare every year (before 30 April) for the material used during previous
calendar year.
Declarations on use of Persistent Organic Pollutants (POPs) as per Stockholm
Convention: Supplier shall declare presence of listed POP in the parts supplied to TML.
Link is provided on SRM portal for declaration of POP.
**For any requirement that cannot be met or is not feasible waiver to be obtained from
TML SQ or SQMS department
**Suppliers should use latest AIAG manuals for respective core tool implementation.

19. Supplier Performance Indicator:

Supplier shall review and monitor Supplier Performance Indicator in SRM portal
every month and take actions accordingly.

20. Record Retention:

Production part approvals, Tooling Records, Product & process design records,
Purchase Orders or contracts and amendments shall be retained for the length of
time that the product is active for production and service requirements, plus one
year. (Ref. IATF 16949:2016 record requirements)

21. Traceability:
Supplier should have a robust system to ensure the traceability of the component
from the raw material stage till final dispatch.

22. Tooling Identification:

Supplier shall identify tooling with visual Metal label / Tag / Engraving as agreed
during tooling development with TML. Identification of tooling to include minimum
TML asset number, Tooling PO, PO date, Part number, Part description, Project,

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date of tool made, Tool life, Tool Material. Tooling identification shall be ensured
by Supplier for entire tool life.

23. Tooling Maintenance:

Supplier shall maintain history cards and do maintenance of tooling such as Dies,
Molds, Jigs, Fixture either provided by TML or Supplier made. Supplier are
responsible to maintain the tooling’s in right conditions and intimate SQE in case
loss or damage. Supplier must intimate SQE/ Purchase well in advance for cases
of tool life over.

24. CTQ Parameters Capability:

Suppliers shall maintain the capability index of the critical characteristics provided
in drawing or agreed during SOR / PPAP. Supplier to inform TML about symbol
used for special characteristics apart from customer specified symbol. Suppliers
are responsible to plan and execute the requirements to meet the above index
throughout the product life time & keep the records.

25. CTQ Parameters reports:

Suppliers of identified parts related to Emission and safety should share the
reports of all CTQ parameters on quarterly basis with SQE.

26. 4M Change requirements:

Supplier shall inform TML if there is any change in Methods / Processes / Tooling
or change of premises of its manufacturing facilities (4M Changes). Supplier shall
obtain prior permission from TML for any changes in product/ process / sub-
contractor and shall keep TML posted. The changes will be validated and
approved by TML through PPAP route. (PPAP portal >Request for PPAP >4M
change intimation)

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6 APPLICABLE DOCUMENTS

Document
Supplier Quality Statement of
Requirements
APQP Project Plan (Illustrative)
APQP Kick Off Meeting Checklist
APQP Open Issues list tracking
Tier II Supplier Management
Process Flow Diagram
DFMEA Format
DFMEA Check Sheet
Design review Check Sheet
Tooling/Equipment Review Check Sheet
Checking Fixture Design Check List
PFMEA Format
PFMEA Check Sheet
Risk Reduction Summary
Control Plan
I Charts

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7 GLOSSARY OF TERMS

4M Material, Machine, Man, Method

AAR Appearance Approval Report
AIAG Automotive Industries Action Group, an organization formed by
General Motors, Ford and Daimler-Chrysler to develop common
standards and expectations for automotive suppliers.
APQP Advanced Product Quality Planning
BOM Bill of Materials
Cpk Capability Index for a stabile process
CSCS Classification of Special characteristics and symbols
DFMEA Design Failure Modes and Effects Analysis. It is used to identify the
potential failure modes of a part, associated with the design, and
establish a priority system for design improvements.
DVP Design Validation Plan
FMASOW Failure Mode Avoidance Statement of Work
FMQ Forward Model Quality
Gage R&R Gage Repeatability and Reproducibility
GD&T Geometric Dimensioning & Tolerance
IPTV Incidents per Thousand Vehicles
KCC Key Control Characteristics. It is a process characteristic where
variation can affect the final part and/or the performance of the part.
APQP Kick-Off The first APQP supplier program review.
Meeting
MSA Measurement Systems Analysis
MSA Manufacturing Site Assessment
NBH New Business Hold
NPI New Product Introduction
OEM Original Equipment Manufacturer
PFMEA Process Failure Modes and Effects Analysis. It is used to identify
potential failure modes associated with the manufacturing and
assembly process.
PO Purchase Order
PPAP Production Part Approval Process
Ppk Performance index for a stable process
PPM Parts per Million
PRR Problem Reporting & Resolution
PSA Potential Supplier Assessment
QTC Quoted Tool Capacity
R@R Run at Rate
RFQ Request for Quotation
RPN Risk Priority Number related to FMEA development
SOR Statement of Requirements
SPC Statistical Process Control
SQ Supplier Quality
SQE Supplier Quality Engineer

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