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Hcil SQM Rev04

The Supplier Quality Manual (SQM) outlines the quality assurance processes and requirements for suppliers of Honda Cars India Ltd. (HCIL) to ensure high-quality parts delivery. It includes sections on safety parts, regulatory compliance, quality evaluations, and various stages of production management. The manual emphasizes confidentiality, compliance with HCIL guidelines, and the importance of continuous improvement in quality assurance activities.

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isha kaushal

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0% found this document useful (0 votes)

103 views193 pages

Hcil SQM Rev04

Uploaded by

isha kaushal

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 193

Supplier Quality Manual

8th June’ 2015

4 G-IPP, Layout Inspection added &

Align with Global Honda Guidelines 08-06-15 M. ISHII RAKESH KAPIL

Honda Siel Cars replaced with

3 Honda Cars India, Delivery Quality
evaluation revised 22-10-13 T. OKADA S. SACHDEVA D. JAWA

2 Align with Global Honda Guidelines 16-07-12 T. OKADA S. SACHDEVA D. JAWA

System for all activities aligned as

1 per HCIL common / QC dept.
procedure 12-06-01 H. SAKAMOTO S. SACHDEVA P.NAUTIYAL

0 Initial Issue 23-09-97 N.NAKANISHI M.KHATTAR P.NAUTIYAL

REV REVISIED APPROVED REVIEWED PREPARED

No. DESCRIPTION ON BY BY BY

Honda Cars India Ltd.

Page 1 of 193
Supplier Quality Manual

Table of Contents

No. Content Page No.

1 Preface 4

1-1 1-1 Structure of SQM 5

1-2 1-2 Production Process Image 6
1-3 1-3 SQM Overview 7-11
2 General

2-1 Important Safety Parts 12-14

2-2 Regulatory Compliance Certification 15-16
2-3 Designation of Quality Representative 17-20
2-4 Sub-Supplier Quality Assurance 21-23
2-5 Control of HCIL-Owned Property 24-25
2-6 Control of Supply Parts 26-30
2-7 Supplier Quality Evaluation 31

2-7-1 Delivery Quality Evaluation 32-33

2-7-2 Supplier Quality Audit 34-37
2-8 Contaminants Control 38-43
2-9 Control of Quality Records 44
3 Pre-Production Stage

3-1 Stage Management 45-51

3-2 Process Design 52-53
3-2-1 Process Quality Control Table 54-62
3-3 Delivery Packaging 63-67
3-4 Countermeasure at Pre-production Stage 68
3-5 Quality Standards

3-5-1 Inspection Criteria for Parts 69-75

3-5-2 Preparation of Limit Samples 76-79
3-5-3 Grain and Color Adjustment 80-81
3-6 Control of Monitoring and Measuring Devices 82-83
3-7 Operation Control Documents 84-88
3-8 Parts Delivery 89
3-9 Transition to Mass Production 90-92

3-9-1 Validity Testing 93-97

Honda Cars India Ltd.

Page 2 of 193
Supplier Quality Manual

Table of Contents

4 Mass Production Stage

4-1 Initial Mass Production Quality Control 98-99

4-2 Mass Production Quality Control 100-102
4-3 Identification and Traceability 103-111
4-4 Change Point Control 112-125
4-5 Corrective Action Report 126-130
4-5-1 Delivery Quality Problem 131-136
4-5-2 Market Quality Problem 137-139
4-6 Specification Change 140-141
4-6-1 Countermeasure Request Form 142-148
5 Reference

5-1 Process Capability 149-156

5-2 Error Proofing 157-158
5-3 Control Chart 159-170
5-4 Principals for Problem Solving 171-175
5-5 Process FMEA 176-184
5-6 Layout Inspection 185
6 Supplement

6-1 Glossary of Terms and Definitions 186-191

6-2 Master List 192-193

Honda Cars India Ltd.

Page 3 of 193
Supplier Quality Manual

1. Preface

1. Preface
Purpose: This manual is referred to as Supplier Quality Manual (herein after referred to as SQM) and
is supplemental to the “General Agreement for Purchase of Parts”, to establish a process of providing
high quality that satisfies and exceeds the expectations of HCIL product users.

Scope: SQM is applied to all parts ordered by Honda Cars India Ltd. (herein after referred to as
HCIL) under the General Agreement for Purchase of Parts. The scope of SQM includes all quality
assurance activities performed by suppliers to ensure the appropriate quality of delivered parts.
However, where the application of SQM is not practical, exemption may be accepted by specifying
operations to which the SQM is not applicable and reasons for the exclusion.

Roles of SQM: This manual is a part of the “Quality control manual” set forth in the “General
Agreement for Purchase of Parts” entered into and concluded between HCIL and suppliers, and
designed with a view to provide supplemental information in order for parts and suppliers quality
assurance activities to confirm to the respective provisions of the “General Agreement for Purchase
of Parts”. Suppliers are required to comply with each of the requirements specified in the “General
Agreement for Purchase of Parts” with SQM as guidance on practice of quality assurance.

Confidentiality: HCIL and suppliers agree to take the same care to preserve the confidentiality of
each other's confidential information and will not disclose such information to any third party without
the prior permission of the other party.
This SQM is copyrighted by HCIL. All printed or downloaded contents of SQM via online by suppliers
are maintained and stored in a safe and controlled manner. Suppliers may make photocopies of
sections and pages of SQM for the purpose of training use or as reference, however please exercise
proper custody and control in a manner that such downloads and printouts are constantly updated to
the latest.
SQM contains confidential and proprietary information of HCIL, and as a general rule, it will not be
disclosed to any individual or organization other than those who are suppliers without prior written
approval of HCIL. However, if it required to perform operations and tasks, such as dissemination to
second and sub-suppliers, the information may be shared under the sole responsibility of the
disclosing suppler by identifying the person responsible for the control and by exercising appropriate
discretion and confidentiality of the information.

Revision: HCIL may revise or update SQM as necessary. HCIL shall notify suppliers of such revision
or update of SQM, and it takes effect after a grace period specified at the time of notification of the
revision or update.
Suppliers may request HCIL for disclosure of obsolete versions of SQM.

Revision proposal: We would appreciate if you could forward your comments or suggestions for
improvement to SQM, please contact:

Honda Cars India Ltd., New model Planning & Control Department, QD Division

Honda Cars India Ltd.

Page 4 of 193
1-1 Structure of SQM
2-1 Important Safety Parts
3-1 Stage Management

2-2 Regulatory Compliance Certification

3-2 Process Design - 1 Process Quality Control Table

2-3 Designation of Quality Representative

3-3 Delivery Packaging

2-4 Sub-Supplier Quality Assurance

3-4 C/M at Pre-Production Stage - 1 Inspection Criteria for Parts

2-5 Control of HSCI-Owned Property

3-5 Quality Standards - 2 Preparation of Limit Samples

2-6 Control of Supply Parts

3-6 Control of Monitoring & Measuring

General
1 Delivery Quality Evaluation - 3 Grain and Color Adjustment
Devices
2-7 Supplier Quality Evaluation
3-7 Operation Control Documents

Pre- Production Stage

2 Supplier Quality Audit
2-8 Contaminants Control
3-8 Parts Delivery

2-9 Control of Quality Records

Page 5 of 193
3-9 Transition to Mass Production - 1 Validity Testing

Honda Cars India Ltd.

5-1 Process Capability 4-1 Early Mass Production Quality Control

5-2 Error Proofing 4-2 Mass Production Quality Control

5-3 Control Chart 4-3 Identification and Traceability

Referance
5-4 5 Principles for Problem Solving 4-4 Change Point Control
- 1 Delivery Quality Problem

5-5 Process FMEA 4-5 Corrective Action Report

- 2 Market Quality Problem
Mass Production Stage

4-6 Specification Change - 1 Countermeasure Request Form

Supplier Quality Manual
1-2 Production Process Image
Prototype Stage Pre-Production Stage Mass Production Stage
Final
Protype Protype MPDWG  MP Go  Determine capability
Timing DWG
D Hin Ryo
MP
Kaku Kaku Kaku

Stage II III IV V VI

3-1 Stage Management

3-2 Process Design - 1 Process Quality Control Table

4-1 Early Mass Production Quality Control

3-3 Delivery Packaging

4-2 Mass Production Quality Control

3-4 C/M at Preproduction Stage

4-3 Identification and Traceability

3-5 Qty Std -1Inspection Criterion for Parts

-2 Preparation of limit Samples 4-4 Chnge Point Control

3-6 Control of Monitoring and Measuring Equipment

4-5 Corrective Action Report

Page 6 of 193
3-7 Operation Control Documents - 1 Delivery Quality Problem

Honda Cars India Ltd.

3-8 Parts Delivery

2 General
2-1 Important Safety Parts

1 Overview
1) HCIL specifies important safety parts with drawings (specifications included).
2) Suppliers recognize “important safety parts” designated by HCIL, become familiar with the
definition of HS, HA, and HB, and control them as critical items.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.

No. Term Definition

1 Important Safety Parts Important safety parts set forth in HES A 3050.
2 Important Quality Characteristics Important quality characteristics set forth in HES A 3051

3 Requirements
The supplier shall confirm special characteristics, which are specifically selected from important
safety parts and important quality characteristics , and exercise control in accordance with
section 3.2.

3.1 Review of specification

The supplier shall confirm important safety parts and important quality characteristics ,
designated by HCIL in accordance with respective drawings (specifications included).Part rank
varies by product type, such as automobile, or other product. The same parts with identical
function may be given different designation depending on the product type. If providing the same
parts for different products, the supplier shall confirm the designation for each product.

3.2 Implementation of special control

The supplier shall implement a thorough for important safety parts and important quality
characteristics , the supplier shall implement a thorough maintenance and control of quality
characteristics as follows in addition to regular quality assurance activities.

3.2.1 Process Control for Important Safety Parts (refer to SQM 3-2 Process Design and SQM
3-2-1 Process Quality Control Table ).
The supplier shall place marks specified by HCIL (HS, HA or HB) on the process quality
control table. The supplier shall include all quality characteristics related to important safety
parts in the process quality control table, and control processes related to the HCIL-
designated important quality characteristics (Q) by designating them as key items.
3.2.2 Dissemination of Important Quality Characteristics (refer to SQM 3-2-1 Process Quality
Control Table and SQM 3-7 Operation Control Documents).
The supplier shall identify process control documents including process quality control table,
operation control documents, etc., with the HCIL’s symbol or the supplier’s equivalent
symbol or notation. The supplier shall identify those process steps that affect special
characteristics , and raise associates’ awareness of quality.
3.2.3 Lot Control (refer to SQM 4-3 Identification and Traceability)
The supplier shall practice lot control for important safety parts and maintain records in a
manner that manufacturing history and release history correspond to the identification of
lots. With this procedure, the supplier shall excise control that the scope of affected lots is
identified and kept to a minimum in the event of non-conformity.

Honda Cars India Ltd.

Page 12 of 193
Supplier Quality Manual

2-1 Important Safety Parts

3.2.4 Assurance of process capability

The supplier shall perform verification of process capability to confirm if important quality
characteristics of important safety parts are controllable by manufacturing conditions.
For the verification of process capability, a set of data with a sample size of n=100 or more
is advisable. A minimum of 30 data sets should be used (however, if the quality
characteristics requires destructive inspection, or can be assured by molds, then this
may not apply) and at least one of the following requirements must be satisfied.
a) Cpk ≧1.33 or P＜0.01 is observed
b) If the process capability does not satisfy the condition above (a), conduct 100 percent
inspection, and take appropriate actions in order for the process to gain the same level of
assurance.
Note: For a single specification limit case, Cp control shall apply.
※Besides important safety parts’ important quality characteristics（）,refer to SQM
5-1 process function to carry out process function verification.
Refer to the following requirements for the timing and handling of the verification.
SQM 2-4 Sub-supplier quality assurance
SQM 3-1 Stage Control
SQM 3-2 Process Design
SQM 3-9 Transition to Mass Production
SQM 4-1 Early Mass Production Quality Control
3.2.5 Control of Repair Parts (refer to SQM 4-5-1 Delivery Quality Problem)
The quality assurance representative of the supplier or the quality representative of the
facility shall approve repairs of important quality characteristics of important safety
parts. The supplier shall conduct a100 percent inspection of repaired parts, and maintain
records identifying the lot.
3.2.6 Operator Training
The supplier shall provide training to its personnel on the process which involves important
safety parts and important quality characteristics , and subsequently assign personnel
who possess sufficient knowledge and skills of the respective process.
3.2.7 Use of Sub-Suppliers (refer to SQM 2-4 Sub-Supplier Quality Assurance)
The supplier shall, if using its sub-suppliers with respect to important safety parts, assume
responsibility for and exercise control of sub-suppliers in a manner that ensures
requirements described in this manual are thoroughly implemented at the supplier’s
responsibility.

4 Key Points
1) When providing support on important safety parts to companies related, ensure that the supplier’s
know how is adequately transferred.
2) Wherever possible, check multiple times for assembly processes that could contribute to serious
malfunctions (e.g. Cotter pin insertion, etc.).
3) Check if recurrence prevention measures are in place for both hardware and software for work
involves important safety parts (e.g. bolt fastening for critical part installation).

5 Reference Materials
1) SQM 2-4 Sub-Supplier Quality Assurance
2) SQM 3-1 Stage Control
3) SQM 3-2 Process Design
4) SQM 3-2-1 Process Quality Control Table
5) SQM 3-7 Operations Control Documents
6) SQM 3-9 Transition to Mass Production
7) SQM 4-1 Early Mass Production Quality Control
Honda Cars India Ltd.
Page 13 of 193
Supplier Quality Manual

2-1 Important Safety Parts

8) SQM 4-3 Identification and Traceability

9) SQM 4-5-1 Delivery Quality Problem
10) SQM 5-1 Process Capability
11) SQM 6-1 Glossary of Terms and Definitions.
12) HES A 3050 “Designation for Important Safety Parts”
13) HES A 3051 “Designation for Important Quality Characteristics”.

Honda Cars India Ltd.

Page 14 of 193
Supplier Quality Manual

2-2 Regulatory Compliance Certification

1 Overview
1) HCIL shall specify laws and regulations that suppliers must comply with in a manner that all parts
constituting a product meet the respective regulatory requirements.
2) The suppliers shall ensure that the products fully comply with any applicable laws and regulations
as requested by HCIL.

2 Definition
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.
No. Term Definition
A course of action by the quality assurance representative, facility
Declaration of
quality representative, or responsible person who was appointed
compliance with
1 and entrusted by the quality assurance person of a supplier to
regulatory
verify that the specifications of parts designed by the supplier
requirements.
comply with regulatory requirements.

3 Requirements
The supplier shall assure that all parts coming into HCIL conform to requirements that define the
structure, function, and performance of parts with respect to safety and environment.
For chemical substances, the supplier shall, on its own responsibilities, assure compliance with
requirements from HCIL and with the regulatory requirements for chemical substances if designated.

3.1 Compliance with Regulatory Requirements

3.1.1 Confirmation of Application
The supplier shall validate regulatory requirements to be applied with drawings
(specifications included).
In addition to the information provided by HCIL, collect all regulatory information about
safety and environment for the parts from government agencies, affiliated companies
overseas and external organizations concerned, and validate compliance of parts coming
into HCIL with respective regulations.
3.1.2 Dissemination of regulatory requirements
The supplier shall confirm regulatory requirements for parts and for sub-suppliers who supply
parts to the supplier, if necessary, inform the respective suppliers of such regulatory
requirements, etc.
3.1.3 Promotion of Regulatory Compliance
The supplier shall determine appropriate responses to regulatory information applicable to
parts, and implement necessary measures as follows to ensure compliance with regulatory
requirements.
1) Assure regulatory compliance of parts designed and developed by its own and obtain
regulatory approval of such parts (present or submit an acquisition plan for regulatory
approval, if HCIL requests).
2) Declare compliance with regulations (present or submit a compliance report and
certification, if HCIL requests).
3) Communicate with HCIL any information about changes resulted from a decision that
there would be an effect on the acquisition plan, compliance report, or certificate that had
already been acquired.
4) Improve manufacturing methods, inspection methods and quality control systems.
5) Install facilities and inspection equipment.

Honda Cars India Ltd.

Page 15 of 193
Supplier Quality Manual

2-2 Regulatory Compliance Certification

3.1.4 Verification of Management for Regulatory Compliance

The suppliers shall verify its management of the compliance of parts with regulatory
requirements, and confirm that all regulatory requirements are met. Maintain records in a
manner that the result of verification is retrievable upon request by HCIL.

3.2 Compliance with Chemical Substance Regulations

The supplier shall assure compliance of designated parts with respective regulations of chemical
substances, including parts to be bought from sub-suppliers, in accordance with HCIL Chemical
Substance Control Standard (NH mark definition document and HR mark specification document).
The compliance with respective regulations of chemical substances indicates that the parts being
delivered satisfy prescribed values. This applies to all parts to be installed in vehicles, including
labels, inks, bundled bags, etc.
3.2.1 Confirmation of Directions for Chemical Substances
Verify applicable chemical substances in accordance with drawings (specifications
included) and “HCIL Chemical Substance Control Standard” issued by HCIL.
Chemical Substance Information Display on Drawing.
Automobile: accords with HES A 3060 “Drawing indication method of hazardous substance
measures”.
3.2.2 Control of Chemical Substances
Promote elimination, alternation or reduction of chemical substances in accordance with
“HCIL Chemical Substance Control Standard”.
As for the creation of Process Quality Control Table, include content rates of chemical
substances as control items (refer to SQM 3-2-1 Process Quality Control Table).
(Example) Control item: content rate of Cadmium
Allowable limit: 0.01wt% or less
Check method: Fluorescent x-ray device, etc.
Check frequency: every start of IPP
Data format: inspection check sheet
Frequency of data submission: at delivery of IPP
3.2.3 Verification of Compliance with Chemical Substance Regulations
The supplier shall confirm that chemical substances contained in parts are less than
allowable limits. Present or submit inspection check sheet upon request by HCIL.
4 Control of Records
No. Type of Record. Retention Period.
Verification Result of regulatory compliance
1 15 Years.
management.

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions
2) Honda Chemical Substance Management Standard
3) Indication Methods Conforming to Honda Chemical Substance Management Standard
(automobiles).
4) Honda Chemical Substances/Recycle Data Collection Operation Manual

Honda Cars India Ltd.

Page 16 of 193
Supplier Quality Manual

2-3 Designation of Quality Representative

1 Overview
1) Supplier shall inform HCIL a supplier’s quality contact of matters relating to the quality (Quality
Assurance Representative and Facility Quality Representative).
2) The supplier shall register its quality contact to HCIL in order for communication with HCIL
about quality to be effective.

2 Definitions
The definitions of terms used in this manual are described in SQM 6-1 Glossary of Terms and
Definitions.

3 Requirements
The supplier shall designate contacts for quality assurance to manage quality related operations with
HCIL to facilitate thorough communication with HCIL.

3.1 Designation of Quality Contact

The supplier shall designate qualified personnel to act as a contact to HCIL for the following
duties in accordance with roles and tasks.
3.1.1 Quality Assurance Representative (executive officer level)
The supplier’s person responsible for implementation of company-wide quality assurance
activities.
Assume responsibility for the following as the representative for the supplier’s quality.
1) Attends seminars on quality for suppliers organized by HCIL.
2) Follows if HCIL requests a corporate-level quality improvement.
3) Receives SQM issued by HCIL and deploy its requirements throughout the company.
4) Represents the supplier and participates in regular audits (QAV-1) for supplier quality by
HCIL.
5) Serves as the contact person to HCIL for a corporate-level communication or when HCIL
makes corporate-level requests to the suppler.
3.1.2 Facility Quality Representative (head of a factory or general manager level officials)
A supplier’s personnel who is appointed per facility and responsible for quality assurance
activities at own facility. Entrusted by the quality assurance representative and is
responsible for deploying the latest version of SQM issued by HCIL and putting it into
practice at all departments concerned of the facility.

3.2 Designation of Quality Contact

3.2.1 Initial Registration
The supplier shall submit to HCIL the form “Quality Assurance Representative Notification
Form” as described in Designation of Quality Representative Notification form.
3.2.2 Change of Contact Person or Information on the “Quality Assurance Representative
Notification Form.”
In the event of a contact person change or a change to the information provided on “Quality
Assurance Representative Notification Form”, the supplier shall immediately inform HCIL of
the change, make necessary changes to the “Quality Assurance Representative
Notification Form”, and reports to HCIL in the form of electronic data file.

4 Reference Materials
1) Glossary of Terms and Definitions

Honda Cars India Ltd.

Page 17 of 193
Supplier Quality Manual

2-3 Designation of Quality Representative

5 Flow Chart

Supplier HCIL
Contact

Purchasing
Establish relationships with Cost
Initial Registration

new suppliers
General Agreement Purchasing
Designate Quality Assurance
for Purchase of Parts Cost
Representative & Facility Quality
Representative
SQM QD-New
Quality Assurance Model
Representative Planning &
Notification Form
Control

QD-New
Register Quality Assurance
If there are changes

Representitive & Facility Quality Model

Representitive Planning &
Control

If any changes needed

Honda Cars India Ltd.

Page 18 of 193
Supplier Quality Manual

2-3 Designation of Quality Representative

6 Forms
6.1 Quality Assurance Representative Notification Form (Blank)
Date:
Honda Cars India Limited
QD New Model Planning & Control CODE Company Name:
Prepared By:

Quality Assurance Representative E-Mail:

Notification Form

Reason for reporting

Quality Assurance Mgr
As of _____/_____/ Facility Qlty Mgr .Qlty Assurance System
New registration
Information update

Quality Assurance Rep.

Incumbent New
Address/Phone/FAX/E-mail address
Name Title Name Title

Phone: Fax:
E-mail:

Facility Quality Rep.

Facility Name Title Address/ Phone /FAX/E-Mail address A B C D E F

O O

Quality Assurance System

Honda Cars India Ltd.

Page 19 of 193
Supplier Quality Manual

2-3 Designation of Quality Representative

6.2 Quality Assurance Representative Notification Form (Entry Procedure)

Date: Jan 2.2012
* Enter the date of filling in. Use the eastern calendar
Honda Cars India Limited
QD New Model Planning & Control CODE Company Name:
Enter your company's reg. no.  9 9 9 9 Prepared By: Name, dept/job title

Quality Assurance Representative E-Mail: * Enter the mail address of the person filling

Notification Form out this form

Reason for reporting * Please put a circle (O) in the appropriate box.
O Quality Assurance Mgr
As of DD/MM/YYYY Facility Qlty Mgr .Qlty Assurance System
New registration Check this if there is no change to the information and
Information update only the date of issuance is changed

Quality Assurance Rep.

Incumbent New
Address/Phone/FAX/E-mail address
Name Title Name Title
Gen. Manager,
Executive
XYZ Dept of Quality ABC Phone: Fax:
Director
Assurance E-mail: * Enter yo ur email address. If yo u do n't have o ne, write "No ne"

Facility Quality Rep.

Plant-1
Plant-2
Plant-3
Plant-4
Plant-5
Plant-6
Address/ Phone /FAX/E-Mail address
Facility Name Title Circle appropriate
facilitydelivery.
Plant O
Plant1 DEF Head Fill in the blanks even
if"Quality Assurance
rep" doubles as
Plant O O
Mention in detail, the address, phone, Facility Quality rep".
Plant-2 GHI Head fax and e-mail of the Quality Put a circle in the
Assurance Representative column of the
Plant O destination of
Plant-3 JKL Head delivery.

Plant O O
Plant-4 MNO Head

Plant O
Plant-5 PQR Head

Quality Assurance System

DEF Qlty Div. ACD, Mgr

Plant-1
Qlty Div. ABD, Mgr

GHI Engg Div. ADE, Mgr

Plant-2 Prod Div. BAC, Mgr

Qlty Div. BCG, Mgr

Quality JKL
Assurance rep Prod Div. BHF, Mgr
Plant-3
Qlty Div. CKL, Mgr
ABC MNO
Prod Div. CAX, Mgr
Executive Director Plant-4
Qlty Div. CVB, Mgr
PQR
Prod Div. DHY, Mgr
Plant-5

Honda Cars India Ltd.

Page 20 of 193
Supplier Quality Manual

2-4 Sub-Supplier Quality Assurance

1 Overview
1) HCIL shall identify and outline the scope of activities of sub-suppliers for which a supplier
assume sole responsibility.
2) The supplier shall establish basic requirements for quality assurance of purchased parts and
outsourced processes in order for the quality of parts to be properly controlled by its sub-
suppliers.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.
No. Term Definition
All component parts and materials that a supplier procures from its
1 Purchased parts sub-suppliers in order to produce products to be delivered to HCIL.
Supplier A first tier supplier to HCIL who receives orders for parts directly
2 from HCIL.
(tier 1 supplier )
A service provider whom a supplier purchases parts from and
Sub-Supplier outsource services to such as fabrication, testing, etc., and including
3 those who beyond the first service provider, it is collectively referred
( tier 2 and beyond)
to as sub-suppliers.

3 Requirements
The supplier shall exercise control over sub-suppliers on its own responsibly in order for the
requirements set by HCIL to be thoroughly followed.
Supply parts provided by HCIL are controlled in accordance with SQM 2-6 Control of Supply Parts.
3.1 Selection of and Contracting with Sub-Suppliers
The supplier shall establish criteria for selecting sub-suppliers, perform evaluation, and enter into
a contract with sub-suppliers.
The suppler shall also create and maintain a list of such sub-suppliers with whom the suppler has
entered into a contract.
3.2 Quality Audit
3.2.1. The supplier shall perform quality audits of sub-suppliers on a regular basis or as needed,
confirm their quality performance and evaluate and/or re-evaluate them.
3.2.2. The supplier is required to be prepared in a manner that HCIL can participate in a quality
audit of sub-suppliers if so requested by HCIL ( refer to SQM 2-7 Supplier Quality
Evaluation).
3.2.3. The supplier is required to maintain audit results in a manner that can be presented or
submitted to HCIL upon request.
3.2.4. The supplier shall discuss with HCIL if any restrictions apply to 3.2.2 and 3.2.3 above for
reasons of confidentiality and nondisclosure agreement.
3.3 Important Safety Parts
The supplier shall, if using sub-suppliers with respect to important safety parts, assume
responsibility for and exercise control of sub-suppliers in a manner that ensures requirements
described in this manual are thoroughly implemented at the supplier’s responsibility ( refer to
SQM 2-1 Important Safety Parts).
3.4 Regulatory Compliance Certification
In the case where a secondary supplier is involved in required regulations, the supplier ensures
each important matter indicated in SQM 2-2 Regulatory Compliance Certification is implemented
properly, and controls the sub-supplier at their own responsibility.

Honda Cars India Ltd.

Page 21 of 193
Supplier Quality Manual

2-4 Sub-Supplier Quality Assurance

3.5 Process Design

If critical items are processed by a sub-supplier, the supplier shall be responsible for managing
the sub-supplier in a manner that ensures all requirements in this manual are thoroughly
implemented ( refer toSQM 3-2 Process Design).
3.6 Process Quality Control Table
The supplier shall specify a process in Process Quality Control Table if such process which
controls important quality characteristic specified by HCIL is to be outsourced to a sub-supplier.
The supplier shall clearly specify a process to be outsourced to sub-suppliers in the supplier’s
Process Quality Control Table, or as required by HCIL, present or submit the Process Quality
Control Table of the sub-supplier’s to HCIL.
However, if outsourcing all or part of production or fabrication processes, the outsourced
processes shall be treated as part of the supplier’s processes and controlled in a manner
following SQM. ( refer to 3-2-1 Process Quality Control Table )
3.7 Parts Inspection Criteria
If inspection items specified in the Inspection Criteria are performed by sub-suppliers, the
supplier shall collect the inspection results from such sub-suppliers and provide HCIL with the
results ( refer to SQM 3-5-1 Parts Inspection Criteria).
3.8 Early Mass Production Quality Control
The supplier shall direct and control necessary sub-suppliers of component parts to perform
Quality control of the same degree as set forth in this manual at the early stage of mass
production ( refer to SQM 4-1 Early Mass Production Quality Control).
3.9 Identification and Traceability
To ensure traceability, the supplier shall assure that sub-suppliers employ the same degree of
control for manufacturing history ( refer to SQM 4-3 Identification and Traceability).
3.10 Change Point Control
The supplier shall direct and control sub-suppliers and ensure IPP control of the same level as
This manual requires for the component parts processed by sub-suppliers ( refer to SQM 4-4
Change Point Control).
3.11 Correction and Improvement
The supplier shall review own sub-suppliers with respect to feedback on nonconformity
attributable to them and subsequent corrective actions taken, including quality nonconformity
found at HCIL or in the market and problem found upon delivery, etc., and carry out a thorough
prevention of recurrence and passing through of the problem. The supplier shall receive a report
from the sub-supplier, confirm the effect on parts and, if necessary, takes an action in
accordance with SQM 4-5 Corrective Action Report, if nonconformity found at a sub-supplier is
deemed to have an effect on the supplier’s parts.
3.12 Direct Delivery to HCIL
The supplier shall, if delivering parts directly to HCIL (including any location designated by HCIL)
from sub-suppliers without going through the supplier, clarify verification processes and control
items using control plans such as process quality control sheet, etc. in a manner that the final
part quality can be verified.
3.13 Evaluation of Purchased Parts
Supplier shall establish testing methods and acceptance criteria, etc., for quality evaluation of
purchased parts (including limit samples or master samples as required), and implement
receiving inspection, etc. accordingly.

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2-4 Sub-Supplier Quality Assurance

3.14 Confirmation of Pre-production Status

The supplier shall confirm, in order for its manufacturing plan for parts not to be affected by
changes made to a sub-supplier’s plan, the progress of production preparation, etc.( refer to
SQM 3-9 Transition to Mass Production) including the following points as a minimum.
1) Control plans such as Process Quality Control Table and operation standards are established
and controlled in the sub-suppliers’ manufacturing processes (refer to SQM 3-2-1 Process
Quality Control Table and SQM 3-7 Operation Control Documents).
2) Parts that are manufactured by the sub-supplier meet the requirements of applicable
drawings, specifications, etc. (refer to SQM 3-2-1 Process Quality Control Table and SQM 3-
9-1 Validity Testing).
3) The sub-supplier’s manufacturing processes are assessed including process capability.
( refer to SQM 5-1 Process Capability).
4) Productivity of production facilities and accuracy of measuring equipment, etc., are
maintained and required production capacity is assured (refer to SQM 3-9 Transition to Mass
Production)
4 Control of Records
No. Type of Record Retention Period

1 Sub-suppliers List Update to latest version

2 Audit records of sub-suppliers ( or tier 2suppliers) 10 years
3 Analysis Record [Analysis Report] 10 years
15 years after the issue date of
4 Process quality control table
a discontinuation order

5 Receiving inspection data 15 years

6 Results of pre-production status confirmation 5 years

7 Results of validation testing 5 years

5 Reference Materials
1) SQM 2-1 Important Safety Parts
2) SQM 2-2 Regulatory Compliance Certification
3) SQM 2-6 Control of Supply Parts
4) SQM 2-7-2 Supplier Quality Audit
5) SQM 3-2 Process Design
6) SQM 3-2-1 Process Quality Control Table
7) SQM 3-5-1 Parts Inspection Criteria
8) SQM 3-7 Operation Control Documents
9) SQM 3-9 Transition to Mass Production
10) SQM 3-9-1 Validity Testing
11) SQM 4-1 Early Mass Production Quality Control
12) SQM 4-3 Identification and Traceability
13) SQM 4-4 Change Point Control
14) SQM 4-5 Corrective Action Report
15) SQM 5-1 Process Capability
16) SQM 6-1 Glossary of Terms and Definitions

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2-5 Control of HCIL-Owned Property

1 Overview
1) HCIL shall, where necessary, lend suppliers machines, dies, jigs and tools, etc. necessary to
manufacture parts.
2) The supplier shall take over the control method of HCIL to properly control machines, dies, jigs
and tools, etc., necessary to manufacture parts.

2 Definition
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.
No. Term Definition
When necessary, after consulting with the supplier, HCIL
1 HCIL-owned property will lend machines, dies, tools and jigs, etc. needed to
manufacture parts, etc.

3 Requirement
3.1 HCIL-owned Property
3.1.1 Identification
The supplier shall identify HCIL owned properties in a manner that allows the items to be
visually explicit and permanently identifiable as lent items.
3.1.2 Maintenance
The supplier shall, when using lent items, perform maintenance and control its records in
accordance with the procedure provided by HCIL to ensure proper quality. If no procedure
is provided by HCIL, the supplier may establish its own procedures to maintain lent items. If
lent items are not used for a long period of time, the supplier shall properly store and
prevent deterioration in accuracy, functions, etc. of the items. Perform additional
preoperational inspections to verify there are no problems with the condition of lent items
when operations resume.
3.2 Use of Lent Items
The supplier shall comply with instructions for use of lent items provided by HCIL, if any. Unless
otherwise deemed necessary by HCIL, the supplier may not use lent items for any purpose other
than the purpose for which it was originally intended, or may not alienate, sublease or mortgage
such lent items to the third party.
3.3 Actions for Abnormal Conditions
The supplier shall, in the event that lent items are lost or damaged, or found not suitable for use,
report to HCIL, determine a course of action after consultation with HCIL, and control records.

3.4 Return of Lent Items

The supplier shall, if HCIL so requests, return lent items to HCIL on the date, time and place
specified by HCIL.

3.5 Records
The supplier shall, if HCIL requires, control quality records related to lent items by following
instructions provided by HCIL.
If no instructions are provided by HCIL, the supplier may establish its own procedures and
maintain records accordingly.

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2-5 Control of HCIL-Owned Property

4 Control of Records

No. Type of Record Retention Period

1 Maintenance records of HCIL-owned properties 15 years
Records of actions for abnormal conditions of HCIL-
2 owned properties 15 years

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

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2-6 Control of Supply Parts

1 Overview
1) When HCIL provides component parts to a supplier on consignment, HCIL shall control quality of
the supply parts by clarifying roles and responsibilities of supply parts users, supply parts
suppliers, and HCIL.
2) The supply parts user shall assure the quality of parts of own in accordance with the roles and
responsibilities defined by HCIL.
3) The supply parts supplier shall assure supply parts in accordance with the roles and
responsibilities defined by HCIL.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.
No. Term Definition
Component parts provided to a supplier by HCIL to manufacture parts to be
delivered to HCIL. This applies when HCIL purchases a part from a supplier
1 Supply Parts
(supply parts supplier) and/or manufactures a part, which is provided to
another supplier (user) for a fee to manufacture parts delivered to HCIL.
A supplier who uses supply parts as components in the manufacture of parts
2 Supply Part User
to HCIL.
Supply Part A company which has a direct contract with HCIL, and provides supply parts
3
Supplier to another company designated by HCIL.
Composite Quality A quality characteristic that will be demonstrated or explicated by a
4
Characteristics combination of supply parts and manufacturing parts.
Total Quality
5 Quality characteristics of the final products completed by a supply part user.
Characteristics

3 Requirements
3.1 Responsibilities
The major responsibilities of supply part user, supply part supplier & SCI are described in the following :
1) Perform receiving inspection (consult with HCIL for details).
2) Request a supply parts supplier for analysis and measures if a problem with supply parts
Supply
is found.
parts user
3) Assure overall quality characteristic of complete parts.
4) Request HCIL for a coordination meeting set forth in section 3.2 as necessary.
1) Assure quality characteristics of parts of own manufacture.
2) Disclose information to its user and HCIL when necessary to control the quality of supply
Supply
parts.
parts
3) Perform analysis and measures against a problem with supply parts requested by a
supplier
supply part user (supply part user may perform process verification as necessary)
4) Request HCIL for a coordination meeting set forth in section 3.2 as necessary.

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2-6 Control of Supply Parts

1) Organize a coordination meeting with supply part users and supply part suppliers to
build consensus on the responsibility for quality assurance of parts with composite quality
characteristics.
2) Assure quality characteristics of supply parts manufactured by HCIL.
HCIL
3) Disclose information to supply parts users and supply parts suppliers when necessary
to control the quality of supply arts.
4) Request supply parts supplier to conduct analysis and measures if any problems with
supply parts are found after delivery to HCIL.

3.2 Agreement on the burden of quality assurance of parts with composite quality characteristics.

3.2.1 The supply parts user and supply parts supplier shall, if so requested by HCIL, take part in
coordination meeting to discuss the burden of quality assurance of parts with composite
quality characteristics to reach agreement for items necessary to control these parts. The
items necessary for the control shall include the following at a minimum.
1) Delivery packaging for supply parts
2) Handling of supply parts
3) The burden of quality assurance of parts with composite quality characteristics.
4) Handling of nonconforming parts.
5) The supply part supplier shall document and control records of the coordination
meeting, if so requested by HCIL.
3.2.2 The supply part user and supply part supplier shall, if necessary to amend the agreement
reached at a coordination meeting, immediately report to HCIL.

4 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

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2-6 Control of Supply Parts

5 Flowchart
Pre-Production Stage
Supply Part Supplier Supply Part User HCIL

M/L decided

Supply NO
part
Normal
Yes business flow

Notice to suppliers

Confirmation Confirmation

Request coordination Request coordination meeting

Decision of holding coordination

Coordination meeting notice

Coordination meeting to build consensus on the responsibility for quality assurance of parts
Production Preparation Stage

Pass
Sample event part production Acceptance

<<Improvement instruction>>
Fail

CM promotion

Prior information on IPP

Event part production

Pass Sample
Event part release Pass
Acceptance event part Acceptance
production

Fail <<Improvement
CM instruction>> Fail
promotion

Event part production

Pass
Event part release Acceptance

<<Improvement
instruction>> Fail

Event product

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2-6 Control of Supply Parts

Mass Production Stage

Supply Part Supplier Supply Part User HCIL

Request coordination meeting Request coordination meeting

Decision making of holding
coordination meeting

Coordination meeting notice

Coordination meeting to build consensus on the responsibility for quality assurance of parts

MP part production

Pass
MP part release Acceptance

<<Improvement
instruction>> Fail Fail
Judgment on
Honda's

<<Improvement
instruction>> Required

CM promotion
MP part production
Production Stage

Acceptance Pass
MP part release
inspection

Pass
CM promotion CM detail Fail

Modified part production

Initial Product
Control [IPP] Pass
Modified part release IPP after quality Acceptance
improvement

Fail

Modified part production Initial Product

Control [IPP] Pass
IPP after quality Acceptance
improvement
Modified part release
Fail

MP product

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2-6 Control of Supply Parts

Specification Change
Supply Part Supplier Supply Part User HCIL

Instruction of specification change

Keep track of specification Keep track of specification

changes changes

Decision of holding
Request coordination meeting Request coordination meeting
coordination meeting (if
required)

Coordination meeting notice

Coordination meeting to build consensus on the responsibility for quality assurance of parts

Pass
IPP processing / production Conformity

<<Improvement Fail
Implement CM instruction>>

Prior information on IPP

Event part production
Initial Product
Control [IPP] Pass
IPP release Acceptance
IPP af ter
specif ication <<Submit
information>> Judgment
<<CM request>> Fail on
HCIL's
intervention
CM promotion

Require
Production Stage

IPP-installed part production

Initial Product
Control [IPP]

Part release IPP af ter Acceptanc

specif ication
change
Fail Pass

CM detail report Pass

CM detail

Fail

Modified part production

Initial Product
Control [IPP]
Modified part release Pass
Acceptance
IPP af ter
specif ication
change

Fail

MP part production
Initial Product
Control [IPP] Pass
MP part release IPP af ter Acceptanc
specif ication
change

Fail

MP part production

Fail
Final

Pass

Finished product release

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2-7 Supplier Quality Evaluation

1 Overview

1) HCIL shall communicate the purpose and viewpoints of quality assessment to suppliers.
2) The supplier shall become familiar with requirements of HCIL and take appropriate actions.

2 Definitions
The definitions of terms used in this manual are contained in SQM 6-1 Glossary of Terms and
Definitions.

3 Requirements
The supplier evaluation shall be for the following assessment items as a basis for the ability to supply
parts in accordance with requirements established by HCIL.
The results of the evaluation may be used by HCIL for determining maker layout.
The supplier shall sustain and improve the quality of parts to be delivered to HCIL while monitoring
conformity to the requirements and consistently achieving targets for quality and delivery timing.
3.1 Assessment items
1) Market quality evaluation
2) Parts Quality Evaluation
3) Cost evaluation (quantity, timing)
4) Delivery evaluation (quantity, timing)

3.2 Assessment viewpoints

The following are HCIL’s viewpoints for each assessment item.
Assessment Item View Point
Market Claim Rate
Transition in Market Claim
Market quality evaluation
Transition of amount per Market Claim.
Quality
Occurrence & Transition of serious quality problems
Delivery Quality
Parts Quality Evaluation
Quality System
Achievability of cost reduction targets
Cost Purchasing Evaluation
Occurrence of cost reduction targets

Delivery Delivery Irregularity

3.3 Corrective Action Request

The supplier shall, if so requested by HCIL for improvement based on the result of quality
evaluation, implement appropriate measures.
If deemed necessary, HCIL shall conduct an audit, such as Quality Assurance Visit, for
quality improvement purposes.

4 Reference Materials
1) SQM 2-7-1 Delivery Quality Evaluation
2) SQM 2-7-2 Supplier Quality Assurance Visit
3) SQM 6-1 Glossary of Terms and Definitions
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2-7-1 Delivery Quality Evaluation

1 Overview
1) HCIL shall inform suppliers of the results of delivery quality performance (including supply parts).
2) The supplier shall monitor the results of performance, verify attainment of the target, and
continuously improve the delivery quality.

2 Definitions
The definitions of terms used in this manual are contained in SQM 6-1 Glossary of Terms and
Definitions.
No. Term Definition
Global Quality Index is total of index allocated each defective /
reworked part based on its problem Rank & Quantity Index.
1 Global Quality Index
Global Quality Index is zero for suppliers who have not supplied any
rejection in a particular month.
Worst supplier rank is the position of supplier based on their Global
quality index amongst the Suppliers who have supplied any rejection
2 Worst Supplier Rank during a month.
No rank is given to suppliers who have not supplied any rejection in
a particular month
3 Requirements
3.1 The supplier shall be evaluated for quality, delivery & Market failure by HCIL each month.
3.1.1 Quality rating
a) Rating of worst suppliers shall be done as per Global quality index e.g. highest Global
quality index shall be worst supplier rank no 1.
b) In case of two or more suppliers have same Global quality index, their rating shall be
same.
c) Data of all suppliers shall be maintained by HCIL-QD New Model Planning & Control.
Global Quality index is based upon the following :
A) Problem Rank Index - Rank of the problem i.e. Rank A, Rank B, Rank C.
Index is taken as given in table below :
Problem Rank Index
Problem Rank Index
Rank A 100
Rank B 20
Rank C 4

B) Quantity Index - Quantity rejected/reworked

Quantity Index
NG/Rework Qty Index
1 2
2~9 10
10~ 99 50
100 or More 70

Global Quality Index= Rank index + Quantity index

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2-7-1 Delivery Quality Evaluation

3.1.2 The supplier shall be evaluated for delivery quality by HCIL each month. The results
are classified into 6 evaluation levels.
3.1.2.1 Delivery quality evaluation criteria
Level 1 2 3 4 5 6
Delivery Below 6 Between Between Between Between Above
quality points 6-18 18-30 30-60 60-90 90
performance points points points points points
score

3.1.3 Delivery Rating

Delivery irregularity ranking of suppliers shall be done on the basis of PPM of delivery
irregularity. The supplier having same PPM level shall be graded the same rank and the
subsequent ranking shall be based on serial order.
 Method of calculation
Delivery PPM = Quantity date variance X 10,000.
3.1.4 Market failure
Market Quality department calculate warranty claim data and send to QD- New Model
Planning & Control Department.
QD- New Model Planning & Control Department send warranty cost/car data along with
detail Market failure sheet to all the suppliers.
 Method of calculation
Warranty Cost/Car = Total claim cost/Total No. of cars under warranty
3.2 Performance review
The supplier shall include the results of delivery quality evaluation provided by HCIL as an input
to the management review. Top management of the supplier shall review the performance results
and continually improve quality.
The results of delivery quality evaluation are compiled on a fiscal monthly basis and issued as
“Quality & Delivery data” and “Delivery Warranty claim summary Report”. HCIL shall send the
results to the supplier’s Quality Assurance Representative via the president of the supplier.
4 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

5 Flow Chart

Supplier HCIL
Contact

Send supplier delivery quality

evaluation results

Supplier QD - New Model

Delivery Quality Planning & Control
President/quality assurance Performance Delivery Quality
representative review results Report Ranking Report

Carry out continuous

quality improvement

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2-7-2 Supplier Quality Audit

1 Overview
1. HCIL shall conduct quality audits of suppliers’ sites.
2. The supplier shall participate in the quality audit and take appropriate actions with respect to the
findings identified.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.
No. Term Definition
Supplier in-house A member who was selected by a supplier from its own employees
1
visitor and leads assessment during a Quality assurance Visit.
A section of HCIL, which acts as a planning center for the Quality
2 Lead section of HCIL Assurance Visit and issues individual audit plans to notify
suppliers of the audit

3 Category of Audit
3.1 The supplier shall receive a supplier’s quality audit conducted by HCIL.
There are two types of audits: a regular audit and an occasional audit of suppliers’ quality
conducted by HCIL.
No. Types of Audit Detail
Quality audit carried out to review the quality system of a supplier and to
verify the status of implementation of the quality system (also called
1 Regular Audit
Quality Assurance Visit-1” or “QAV-1”).
This also includes verifying the suppliers’ audit results through documents.
Of those which correspond to the following criteria, a supplier’s quality
audit which will be conducted when deemed necessary by HCIL (also
referred to as QAV-2), and this will be performed by specifying the scope
of confirmation and verification in accordance with the purpose of the audit.
Occasional
2 1) At occurrence of serious problem which is attributable to the supplier
Audit
2) When a new manufacturing process is used for the production of new
models or new derivatives, etc.
3) When establishing new business relationships with new suppliers.
4) Others

3.2 Regular audit

3.2.1 Supplier Subject to Regular Audit
A supplier subject to regular audit shall be selected from among those with whom HCIL has
entered into the General Agreement for Purchase of Parts and on the basis of the following.
1) Suppliers produce important safety parts
2) Other suppliers for which HCIL deems a quality audit is necessary.
3.2.2 Frequency of audit
The frequency of regular audits shall be at least once every two years in principle. However,
it may be changed in accordance with the discretion of HCIL taking into consideration the
supplier’s status for quality.
3.2.3 Supplier in-house visitor
The supplier shall select suppler in-house visitors from its own employees and have them
participate in a regular audit.

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2-7-2 Supplier Quality Audit

3.2.4 Scope of Audit

The scope of audit shall include all aspects of the quality system. The review points shall
including the following.
1) Quality policy and organization
2) Quality system
3) Specification and design control
4) Control of documents and records
5) Control of suppliers
6) Control of component parts
7) Control of manufacturing processes
8) Control of manufacturing facilities
9) Final inspection and reliability testing
10) Control of monitoring and measuring devices
11) Control of nonconforming products and concession parts
12) Internal quality audit
13) Quality training
14) Compliance to the SQM requirements: review through the assessment of above 1-13
areas.
3.2.5 Countermeasure and Promotion
The supplier shall, based on audit report issued by HCIL, formulate an improvement plan
and submit to HCIL by the date specified. HCIL may request changes to the
implementation plan where necessary.
3.2.6 Quality meeting
The supplier shall, attend a quality conference upon request from HCIL, receive evaluation
reports on the implementation, and verify effectiveness of the results of the measures.
3.3 Occasional audit
3.3.1 Supplier Subject to Occasional Audit
A supplier subject to occasional audit shall be selected from all suppliers with whom HCIL
has entered into the General Agreement for Purchase of Parts.
3.3.2 Scope of Audit
The scope of the audit shall be determined by HCIL in accordance with the purpose of the
audit.
3.3.3 Countermeasure and promotion
The supplier shall, based on the audit report issued by HCIL, formulate an improvement
plan, obtain approval from the quality assurance representative or the quality
representative of the facility, and submit to HCIL by the date specified.
HCIL may request a change to the implementation plan where necessary.
3.3.4 Confirmation of countermeasure completion and documentation of results.
The supplier shall, upon request from HCIL, verify completion of the countermeasure taken
and record results of verifications made.
4 Control of Records
No. Type of Record Retention Period

1 Records of Regular Audit 10 years

2 Records of Occasional Audit 5 years

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

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2-7-2 Supplier Quality Audit

6 Flowchart
6.1 Regular Audit (QAV-1)
Supplier HCIL
Contact

Issue annual regular QD - New Model

audit schedule Planning & Control
Inform the
Confirm month of an
audit
<Audit implemented
by supplier>
Send implementation plan Audit
Prepare for audit
per audit Lead Sec

Carry out regular audit, review audit findings, and issue audit report Auditor

Plan countermeasure Issue audit report Audit

(provisional) Lead Sec

Implement Implement
and take countermeasure
measures

Quality meeting (review implementation schedule, details of C/M, etc.) Auditor

Update countermeasure plan

Implementation of
countermeasure

Qlty Assurance Rep to Record Improvement

approve countermeasure progress Audit
Lead Sec.

Audit
Submit audit report Approval
Lead Sec.

Audit
Audit Report Lead Sec.
Formal issue
Audit report retention/ Summary
maintenance of record
QAV-1
report

Reflect on the next annual QD - New Model

schedule Planning & Control

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2-7-2 Supplier Quality Audit

6.2 Occasional Audit (QAV-2)

Supplier HCIL
Contact

Draw up audit schedule Audit

Define audit scope. Lead sec.

Prepare for audit Notify detailed audit Audit

schedule Lead sec.

Auditor
Carry out occasional audit, review audit findings, and issue audit report

Audit
Plan countermeasure Issue audit report (provisional)
Lead sec.

Audit
Qlty Assurance Rep to
Receive audit report Lead sec.
approve countermeasure

Implement countermeasure

Auditor
Confirm completion of countermeasure and record results

Audit Report
approval / formal issue Audit
Lead sec.
Receive the QAV-2
duplicate
Retrun duplicate

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2-8 Contaminants Control

1 Overview
1) HCIL shall define the requirements to properly exercise the control of contaminants.
2) The supplier shall define control items, points, etc. for parts subject to contaminants control and
maintain satisfactory condition conforming to contaminants control criteria.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of Terms and
Definitions for other terms.

No. Term Definition

1 Contaminants Foreign matter such as grain, grit, chip, burr, dirt, dust, etc.

Component parts constituting an automatic speed change

Automatic mechanism, such as AT (automatic transmission), CVT
2
transmission, etc. (continuously variable transmission), 4WD (4-wheel drive), MCU
(moment control unit), etc., and parts assembled to them.
A ranking of contaminants control parts such as automatic
3 Cleanliness rank transmission, etc. in the order of influence of contamination on
the function of the automatic transmission, etc.
A ranking of contaminants control parts, which are not included
4 Control priority ranking in the definition of automatic transmission, etc., by safety,
function and performance.

3 Requirements
3.1 Key control parts
3.1.1 Of those parts such as automatic transmission, etc., the ones subject to intensive control of
contaminants shall be the parts whose cleanliness ranks and contaminant mass criteria are
specified on the drawing in accordance with HES (Honda Engineering Standards).
However, parts that are not specified on the drawing but are set forth in “Contaminants
Control Parts (automatic transmission, etc.)” shall also be included.
3.1.2 Of those parts not included in the definition of automatic transmission, etc., the ones
subject to intensive control of contaminants shall be the parts set forth in “Contaminants
Control Parts (other than automatic transmission, etc.)”.
3.1.3 Cleanliness rank of each critical control part such as automatic transmission, etc. shall be
as follows.
Cleanness
Description
Rank
Control circuit parts whose failure, such as valve locks failure by contact with
A
contaminants, causes to lose function and quality of drive train.

Parts having contact with hydraulic fluid excluding control circuit parts whose
B failure, such as valve lock by contact with contaminants, causes to lose function
and quality of drive train

Parts not included in rank A nor B which can contaminate parts in rank A or B
C
indirectly by contact with contaminants.

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2-8 Contaminants Control

3.1.4 Management priority ranks classified by key control parts not included in automatic
transmissions, etc. shall be as follows.
Management importance rank Description
Parts which may seriously injure basic functions (run, turn, stop,
A
etc.) of products by contaminants.
Parts which may affect basic functions (run, turn, stop, etc.) of
B
products by contaminants.

3.2 Contaminants control

3.2.1 The supplier shall appoint a section and person responsible for control items, control
points, etc. shown in the table below to maintain parts subject to contaminants control in a
manner satisfactory to contaminant requirements until delivered to HCIL.

No. Control Item Control Pint

1 Placing of cleanness ranking and contaminant mass criteria in
1 Design of parts accordance with HES A3054 “DESIGNATION FOR CLEANLINESS OF
AUTOMATIC TRANSMISSION”.
1 Verification
Automatic transmission, Other than automatic
Verification of etc transmission, etc.
cleanliness ranks ・Drawing
2
and management Cleaness rank
・Section 6 this manua
importance ranks
Management priority
・Section 7 this manual.
Rank
1. Define items subject to contaminants control items during
Setting of
processing and transportation.
3 contaminants
2. Arrange preventives against contaminants mix-up.
control plans
3. Reflect contaminants control items in the standard documents.
Setting up of
1. Define packaging specifications and delivery packaging with
4 Delivery
preventive measures for contaminants mix-ups.
Packaging.
1. Cleaning control of processing facilities, jig & fixture, and work
Processing of supplies
5
parts 2. Control of working conditions in the process of cleaning parts
3. Cleanliness control of circulating oil from QA device to parts
1. Setting up of inspection method and feedback of inspection results
Inspection of 2. Agreement on contaminants control with supplier
6
contaminants 3. Instruction for improvement of suppliers’ contaminants control
activities
1. Implementation of preventive measures for keeping contaminants
from entering release/delivery parts
7 Release/ delivery
2. Agreement on contaminants control with outside contractors for
transportation
Verification of
8 delivery 1. Feedback of delivery package verification
package

9 Storage of parts 1. Ensure prevention of contaminants in the storage parts

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2-8 Contaminants Control

3.3 Inspection of Parts Such As Automatic Transmission, etc.

3.3.1 The basic method for inspection of contaminants on parts such as automatic
transmission, etc. shall be sampling inspection.

3.3.2 The sampling inspection shall start from normal inspection and the severity of
inspection shall be adjusted as follows.
Reduced
Normal inspection Tightened inspection
inspection

Start sampling inspection

Acceptance(three
consecutive times) Improvement

Failed 5 times in total Sorting

Acceptance (three
consecutive times)
Rejection
(one time) Discontinue sampling
inspection

Rejection
(one time)

3.3.3 The inspection frequency for each inspection severity category shall be as follows.
Severity of inspection Reduced inspection Normal inspection Tightened inspection
Frequency of inspection Once a month Once every two Weeks Once a week

3.3.4 Collect inspection samples in accordance with the following part mass category (if
other than a whole number, shall be rounded).
The part mass shall be the values indicated on drawings.
Classification
11 to 100g 10 to 500g 501 to 1000g More than 1001g
by part mass Less than 10g
Sample size 10 5 5 3 3

3.3.5 The criteria for inspection of contaminants shall be as follows.

1) Part mass criteria (allowable maximum mass (mg) of contaminants per part) Unit:
mg

1001g
Cleanliness 10g or less 11 to 100g 10 to 500g 501 to 1000g
rank and more
A 0.5 or less. 0.7 or less. 1.0 or less. 1.1 or less. 1.3 or less.
B 0.7 or less. 1.0 or less. 1.4 or less. 1.6 or less. 1.8 or less.
C 1.4 or less. 2.0 or less. 2.8 or less. 3.2 or less. 3.6 or less.

2) The size of contaminants shall be 0.4mm max. as the target value.

3.3.6 Contaminant inspection method
1) Calculate the size of contaminant mass per inspection sample by measuring total
mass of contaminants collected by filtering the cleaning agent used for the
inspection

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2-8 Contaminants Control

sample in accordance with part mass category through a filter paper with nominal
filtration rating of 1μm or so.
2) Measure the size of contaminants by observing sampled contaminants using
magnifying lenses and microscopes, etc.

3.4 Inspection of parts other than automatic transmission.

3.4.1 The basic method for inspection of contaminants on parts other than automatic
transmission, etc. shall be sampling inspection.
3.4.2 The sampling inspection shall start from normal inspection, and severity of
inspection shall be adjusted in accordance with section 3.3.2 .
3.4.3 The frequency of inspection for each inspection category of severity shall be in
accordance with section 3.3.3.
3.4.4 The inspection sample shall be picked up for each inspection category as follows.
Severity of inspection Reduced inspection Normal inspection Tightened inspection
Number of samples 2 3 3

3.4.5 The criteria for contaminant inspection shall be as follows.

Management priority rank Criteria

A No contaminants of 0.2 mm or larger in size shall be found.

Quantity of contaminants of about 0.2 mm shall be six or less,
B and also no contaminants of 0.2mm or larger in size shall be
found.

3.4.6 Contaminant Inspection Method

1) Filter the cleaning agent through filter paper per inspection sample unit, and
using magnifying lenses and microscopes, measure the size and quantity, etc.
of sampled contaminants.
2) Only if the size and quantity of contaminants of parts satisfy the judgment
criteria, the parts shall be deemed acceptable
3.5 Control of Inspection Records, etc.
3.5.1 Collected contaminants and inspection records of the collected contaminants shall
be controlled in a manner that allows the supplier to present the contaminants or
records to HCIL whenever so requested by HCIL.

4 Control of Records

No. Type of Record Retention Period

1 Collected Contaminants 1 year

2 Contaminant Inspection Records 5 years

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions
2) HES A3054 “Designation for Cleanliness of Automatic Transmission”.

Honda Cars India Ltd.

Page 41 of 193
Category of Cleanliness rank
Mechanism
A B C
AT TC case COMP Regulator valve body ASSY Baffle plate COMP C3gear Shift rail screw set Suction pipe Pick up ASSY Transmission hanger
Transmission case Governor ASSY Breather pipe M4 gear Servo detent ASSY Oil cooler (including trailer Drive transfer gear Torque converter cover
R side cover COMP Servo body ASSY Breather cap C4gear Control shaft COMP traction kit) Differential ASSY Change cover
Clutch ASSY Linear solenoid ASSY Transfer case Counter reverse gear Manual valve pin ATF gauge COMP Hypoid pinion Transmission under
Feed pipe COMP Accum. piston Transfer side cover Reverse idle shaft holder Manual valve roller Oil level pipe COMP Hypoid ring gear guard
Main shaft COMP L/C body ASSY T case packing COMP Change shaft COMP ATF filter bolt Final driven gear Speed meter gear holder
Counter shaft COMP Secondary body ASSY R side cover packing Reverse idle gear Servo detent sleeve COMP Oil hose pipe COMP Throttle adjust bolt plate
Secondary shaft Secondary filter Oil guide cover Reverse gear selector P/BRK Joint bolt COMP Extension shaft Throttle cable COMP
Shift rail Second accum. body ASSY Oil guide plate Selector hub P/BRK spring Joint bolt Control lever
Oil pump gear MOD body ASSY LOW gear Speed meter gear ASSY P/BRK stopper Bypass body Control wire holder
ATF strainer Shift solenoid ASSY Counter LOW gear Speed meter gear holder Parking pole spring Bypass body cover Throttle control lever
TRQ/CONV ASSY L/C solenoid ASSY One-way clutch ASSY Gear holder seal P/BRK pole Throttle valve shaft COMP Position sensor ASSY
Main valve body ASSY Oil pressure sensor Parking gear Speed meter gear COMP Parking shaft Throttle cam stopper Meter cable clip
Separate plate Stator shaft COMP M2gear Companion flange COMP Cooler hose Throttle cable stay Oil pipe clip COMP
Shift valve cover Reverse shift fork Transmission magnet Accum. cover
Servo detent base COMP Accum. spring

ＣＶＴ Fly wheel case Manual valve body pipe Oil pan RVS return spring COMP Secondary drive gear Parking brake pole Pitot pipe stay Transmission hanger
Transmission case COMP Differential cover RVS brake plate ASSY Parking pole SPG ATF gauge COMP Control wire stay
COMP Input shaft COMP Intermediate plate ASSY RVS brake disc Planetary gear COMP Detent spring ASSY Oil hose pipe COMP B
R side cover ASSY Oil pump ASSY Pulley cover plate COMP RVS brake disc spring Sun gear O/P drive sprocket Pick up ASSY
Forward clutch ASSY ATF Filter COMP A RVS brake end plate Ring gear COMP O/P drive chain Final driven gear
RVS brake piston Valve body ASSY FW case packing Oil path pipe holder Drive sprocket hub Pitot pipe Oil pipe clip COMP
Start clutch ASSY Manual valve body ASSY I/M plate packing COMP Control lever Pitot LUB pipe Cotter retainer
Feed pipe Manual separate plate R over packing LUB pipe Control shaft COMP Pitot flange Circlip retainer
Oil path pipe COMP Linear solenoid ASSY Oil pan packing Secondary gear shaft P/BRK rod holder

４ＷＤ Pump body ASSY ATF strainer Rear differential magnet TCD case Oil pump pin Pinion shaft Transfer driven bevel gear Breather tube joint
Clutch piston D ring COMP Hypoid gear Back-up ring Transfer shaft Differential clutch ASSY Breather tube clamp

Page 42 of 193
Companion flange Pinion spacer Pinion gear SET Driven transfer gear Oil pump drive shaft Breather tube ASSY
Differential ASSY Piston spring Differential case Transfer drive bevel gear Transfer case Breather tube
Differential carrier SET Transfer side cover

Honda Cars India Ltd.

2-8 Contaminants Control

ＭＣＵ R/L clutch case COMP Regulator valve R side cover Center shaft Planetary ASSY Clutch disc Special bolt Under cover
L side cover ASSY Oil pump driven gear R side cover packing R/L clutch case packing L central gear Clutch plate Oil pump gear cover MCU sub-harness
Solenoid valve body Oil pump drive gear Breather cover packing Solenoid body packing R central joint COMP Clutch return spring Oil hose pipe COMP Harness clamp stay
Solenoid separate Clutch piston Extension tube COMP Breather cover COMP R central gear Spring guide plate Sub-harness stay
plate ATF strainer COMP Extension shaft Valve cap plate C central gear Clutch end plate Breather tube ASSY
Linear solenoid ASSY Regulator valve spring
Shift solenoid ASSY Regulator valve cap
Oil pressure sensor
Oil TEMP sensor

Common Seal ring Cooler hose Thrust washer Needle bearing Washer Spring washer
parts Drive shaft Distance collar Thrust needle bearing Shim Drain plug bolt
Half shaft Snap ring Oil seal Snap ring Plug washer
Flange bolt Ball bearing Collar Dowel pin Differential pinion thrust
O ring Ball radial bearing Roller Hex nut washer
Cotter Taper bearing circlip Flange nut Spring pin
Radiator (AT oil cooler)
Supplier Quality Manual
Supplier Quality Manual

2-8 Contaminants Control

7 Contaminants Control Parts ( other than automatic transmission)

Management
importance A B
rank
 Brake system  Driving channel system
・Brake master cylinder ・Water pump COMP
・Brake hose (pipe) ・Radiator ASSY
・Caliper ASSY ・Water hose
・Brake System ・Reserve tank
・Brake Fluid ・Cooling water circuit
component
 Fuel system
・Carburetor ASSY  Lubrication system
・Fuel Filter ・Oil pump ASSY
・Fuel strainer COMP ・Manual transmission ASSY
・Fuel injector COMP ・Crank shaft COMP
・Fuel feed pipe COMP ・Cylinder head
・Cylinder block
・ Piston
Part group ・ Engine Component

 Functional system
・Front fork
・Front damper
・Completed system function
part with rotating/sliding function

 EM control system
・ECU
・Catalytic Converter
・Secondary Air System
・ Air Cleaner Assembly
 Fuel system
・Fuel tank
・Fuel pump

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Page 43 of 193
Supplier Quality Manual

2-9 Control of Quality Records

1 Overview
1) HCIL shall identify quality records which HCIL may require suppliers for presentation.
2) The supplier shall retain quality records, when so designated in SQM in accordance with
requirements established by HCIL.
2 Definitions
The definitions of terms used in this manual are contained in SQM 6-1 Glossary of Terms and
Definitions.
No. Term Definition
The act of organizing frequently-used documents in a manner
1 Storage
that allows fast retrieval during daily business operations.
The act of preserving less-frequently-used documents
(including electronic medium) in a location such as archive and
2 Retention
stockroom outside the worksite in a manner that allows prompt
retrieval when needed.

3 Requirements
3.1 Storage and retention of quality records
3.1.1 The supplier shall, if maintain quality records on electronic media, make the records
available for HCIL to view with a support from the supplier associates upon request
from HCIL.
3.1.2 The supplier shall give consideration for retention and storage means in order for
the records not to become illegible due to deterioration of the media or changes in
the environment for use.
3.2 Retention Period
The supplier shall, for the period of time specified in the “Control of Records” section in
respective SQM articles, ensure retention and/or storage of quality records concerned.
The retention period shall be the duration from the day of establishing or receiving to the
day of disposition of the records.
3.3 Presentation or submission of quality records
3.3.1 The supplier shall, in response to a request from HCIL, present or submit quality
records to HCIL. HCIL may request submission of relevant quality records on
electronic media.
3.3.2 The supplier shall, if so requested by HCIL for presentation or submission of stored
quality records, provide information in regard to the time needed until presenting or
submitting the records..
3.4 Disposition of records
The supplier shall, for quality records that have reached their retention period, dispose
them after rendering the contents illegible.

4 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

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Supplier Quality Manual

3-1 Stage Management

3 Pre-Production Stage

3-1 Stage Management

1 Overview
1) HCIL shall designate key control parts, and verify production preparation activities of a
supplier for the key control parts.
2) The supplier shall plan production preparation activities to be linked to the pre-production
schedule of HCIL. Items to complete at each stage of Pre-production shall be defined in
order for the supplier to thoroughly implement the planned activities.
2 Definition
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No Term Definition
A management method that controls supplier activities on a step-by-
step basis. The processes of pre-production and mass production
are divided into 6 stages from stage I to stage VI. Main activity to be
completed at each stage is described below.
Stage I : Obtain product requirements from HCIL (Stage I will be
omitted hereafter since this stage consists of activities prior to the
Stage Pre-production).
1
Management Stage II : Formulate a manufacture management plan.
Stage III : Promote activities required based on the manufacture
management plan.
Stage IV: Verify quality maturation status.
Stage V : Confirm the prospect of transition to mass production and
declare completion of production preparation.
Stage VI : Mass production.
Manufacturing
A Control plan to monitor progress of the activities specified in the
2 Control
Stage Management.
Plan
3 Requirements
The supplier shall formulate a manufacturing Control Plan that includes control items
designated in “Control Items and Objectives” at a minimum, and implement activities to
achieve objectives set forth for each stage for respective control items.
3.1 The supplier shall formulate a manufacturing Control Plan in conjunction with respective
stages below.
(Design & Mass Production
Honda Pre-production Stage
Development Stage) Stage
Supplier Pre-production Stage Mass Production Stage

Timing
Prototype Drg Prototype Drg M/P Dwg.

No. Control Item Outline
Stage II Stage III Stage IV Stage V Stage VI
15 Process quality An action plan for the process quality • Decide process • Verify processes • Address
control table control table. sequence in line with the concerns from
(process system process quality the previous
diagram) control table. stage.
• Formulate the • Production and
process quality delivery in line
with HCIL’s
production plan.
16 Approval mark Application for part approval and approval • Confirm • Manage planned • Evaluate • Gain part • Practice quality
mark display. regulatory and actual products approval. control in line with
requirements. outputs. (conformity with • Display an SQM 4-1 Early
• Understand the • Agree on drawings). approval mark on Mass Production
scope of subject approval mark the parts. Quality Control
parts. identification • Submit an and SQM 4-2
• Draw up a plan methods. approval Mass Production
for gaining • Part approval certificate and Quality Control
approval. application. test reports to
HCIL.

17 Material identification Material identifiation for the recycling of • Understand the • Agree • Evaluate
materials of parts. scope of subject identification products

Page 49 of 193
parts. methods. (conformity with
drawings

Honda Cars India Ltd.

including
specifications.
Supplier Quality Manual
3-1 Stage Management
Stage/Category Pre-Production Stage Production Stage
No. Control Item
Outline Stage II Stage III Stage IV Stage V Stage VI
18 Management of Plan to ensure compliance of products • Confirm • Confirm • Carry out • Present or • Address
compliance with laws with laws and regulations. restrictions. conformity of inspection to submit inspection concerns from
and regulations. • Understand the purchased ensure results. the previous
scope of subject materials. compliance with stage.
parts/materials. laws and • Production and
• Draw up a plan regulations. delivery in line
to ensure with HCIL’s
compliance. production plan.
• Practice quality
control in line with
19 Mass Production Confirm transition of production to mass • Mass SQM 4-1 Early
Transition production.. Production Mass Production
Declaration Transition Quality Contro
Declaration and SQM 4-2
Mass Production
.

Page 50 of 193
Honda Cars India Ltd.
Supplier Quality Manual
Supplier Quality Manual

3-1 Stage Management

4 Control of Records

No. Type of Record Retention Period

1 Manufacturing control plan 5 years

5 Reference Materials
1) SQM 2-2 Regulatory Compliance Certification
2) SQM 3-2-1 Process Quality Control Table
3) SQM 3-5-3 Grain and Color Adjustment
4) SQM 3-9 Transition to Mass Production
5) SQM 3-9-1 Validity Testing
6) SQM 4-1 Initial Mass Production Quality Control
7) SQM 4-2 Mass Production Quality Control
8) SQM 6-1 Glossary of Terms and Definitions

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Supplier Quality Manual

3-2 Process Design

1 Overview
1) HCIL shall define the requirements for suppliers to design a process.
2) The supplier shall clarify requirements for designing a process, and maintain the
manufacturing process at an appropriate quality level.

2 Definitions
The definitions of terms used in this manual are contained in SQM 6-1 Glossary of Terms and
Definitions

No. Term Definition

A general term for market action, which includes recall, improvement
1 Recall, etc.
campaign, service campaign and extended warranty.
An act of implementing improvement measures by submitting a notice to
the competent authorities in accordance with Paragraph 3 of Article 63
(Report, etc. of Corrective Action) of Road Vehicles Act (Law No.185 of
2 Recall
1951).
This includes the implementation of equivalent actions in foreign
countries in accordance with the laws and regulations of those countries.
An action taken by Honda to implement improvement measures by
submitting a notice to the competent authorities in accordance with
Improvement
3 Article 9 (Improvement Campaign) of Circular Notice "Handling
campaign
Procedure for Notification, etc. of Recall" (Jishin No.1530 of December
1, 1994, hereinafter referred to as "Circular Notice").
An act of implementing improvement measures by submitting a notice to
Service
4 the competent authorities in accordance with Article 10 (Implementation
campaign
of Service Campaign) of Circular Notice.
Extended An act of extending the warranty period, submitting a notice to the
5
warranty competent authorities, and implement improvement measures.

3 Requirements
3.1 Process Control Item Setting
3.1.1 The supplier shall, to ascertain quality requirements through the drawing
(specifications included) and maintain appropriate quality, set control items in
consideration of the following when designing manufacturing processes (refer to
SQM 5-2 Error Proofing and SQM 5-5 Process FMEA).
1) Part design input requirements
2) Required production capacity and process capability
3) Capability and accuracy of production equipment
4) Capability and accuracy of measuring equipment
5) Experience from past process designs
6) Past problems attributed to process designs
7) Possible problems predicted by Process FMEA and/or other means.
8) Incorporation of error proof measures as necessary
9) Necessary inspection and testing
3.1.2 The supplier shall classify defined control items into quality characteristics items and
process control items, and establish control methods respectively.
3.1.3 The supplier shall create a process quality control table based on the results of
paragraph 3.1.1 and 3.1.2 above in accordance with SQM 3-2-1 Process Quality
Control
Table.

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Supplier Quality Manual

3-2 Process Design

3.2 Designation and Control of Critical Items

3.2.1 The supplier shall designate control items that meet any of the following conditions
as critical items.
1) Items that may cause problems which may be difficult to detect in the
subsequent processes, if one occurs.
2) Items to which a market action was applied.
3) Items marked “Q” on part drawing.
4) Quality control items set forth in Inspection Criteria etc. issued by HCIL.
5) Other items for which a special agreement with respect to quality was made
between HCIL and the supplier.
3.2.2 The supplier shall control critical items with consideration to the following
requirements.
1) Identify critical items on process quality control table, operation standard, etc.
2) Submit data of periodic inspections or testing, if so required by HCIL.
3) Assign personnel who are trained with the knowledge of the relevant processes.
4) Assess the process capability in accordance with SQM 5-1 Process Capability ,
if so required by HCIL.
5) If applicable, apply contaminants control in accordance with SQM 2-8
Contaminants Control.
3.2.3 If critical items are processed by a sub-supplier, the supplier shall be responsible
for managing the sub-supplier in a manner that all requirements in this manual are
thoroughly implemented ( refer to SQM 2-1 Important Safety Parts, SQM 2-4
Sub-Supplier Quality Assurance & SQM 3-2-1 Process Quality Control Table )

3.3 Work environment

3.3.1 The supplier shall, if deemed necessary in accordance with quality characteristics
and control items of parts, manage work environment with consideration to the
following conditions.
1) Dust-proof room designed to prevent contaminants from entering inside.
2) Temperature controlled room to maintain precision of measuring instruments.
3) Quiet environment suitable for auditory testing.
4) Illumination condition for visual inspection process.
5) Antistatic facility.
6) Others
3.3.2 The supplier shall address product safety and means to minimize potential risks to
employees (e.g. protection mat for falling parts, necessary protectors, etc.).
3.4 Result review
3.4.1 The supplier shall put the process into operation in accordance with the process
quality control table, operation standard, etc. The Quality Assurance
Representative, Facility Quality Representative or appointed deputy shall review
the results of process design. The record of the review results shall be kept
retrievable when so requested by HCIL.
3.4.2 The supplier shall maintain documents used for designing processes, and utilize
them in the investigation, analysis, and measures when a problem occurs, as well
as in the development of the next model.

4 Reference Materials
1) SQM 2-1 Important Safety Parts
2) SQM 2-4 Sub-Supplier Quality Assurance
3) SQM 3-2-1 Process Quality Control Table
4) SQM 5-1 Process Capability
5) SQM 5-2 Error Proofing
6) SQM 5-5 Process FMEA
7) SQM 6-1 Glossary of Terms and Definitions

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Supplier Quality Manual

3-2-1 Process Quality Control Table

1 Overview
1) HCIL shall define contents and provide operation procedure for process quality control
table.
2) The supplier shall control and maintain the process quality control table and use for the
following purposes.
a) Management of control items for in-process quality assurance.
b) Monitoring of process control conditions.
c) Accumulation and conveyance of skills and technology, etc.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Term Definition
Quality Property and performance subject to quality evaluation, and
1
Characteristics standards and criteria to control them.
Control items for the set up condition and its standards and/or
Production
2 criteria necessary to ensure quality required for respective
Conditions
manufacturing processes.

3 Requirements
3.1 Preparation criteria
The supplier shall design manufacturing processes, conduct process FMEA, etc., and
draw up process quality control table in accordance with drawings, specifications, etc.
issued by HCIL and/or those draw up by the supplier and verified by HCIL.
3.2 Subject Parts and Processes
3.2.1 Process Quality Control Table shall be made for all parts ordered by HCIL. For the
parts with the same or similar process sequence, quality characteristics, production
condition, etc., a representative process quality control table may be accepted with
the attachment of “Process Quality Control Table (Appendix) List of Applied Parts“
The differences between process sequence, quality characteristics and production
conditions of similar parts shall also be clearly entered appending to the process
quality control table of the representative parts.
3.2.2 Regardless of the preceding section, the supplier may exclude standardized parts
that comply with standards such as ISO (International Organization for
Standardization), JIS (Japanese Industrial Standards), and HES (Honda
Engineering Standards) from the subject parts for the process quality control table.
However, if so requested by HCIL, the supplier shall follow the direction and
provide the process quality control table for review.
3.2.3 The supplier shall include all processes from the receiving of materials and
component parts to the shipping of finished product to HCIL (or to the supply parts
user) in the process quality control table. Process quality control table shall be
made per delivery package (per delivery package to the receiving party if shipped
as supply parts).
3.2.4 The supplier shall, in the event of employing an outsourced process after receiving
component parts, encompass all processes from the release to the delivery of parts
from outsourced service providers in the process quality control table.
3.3 Submission Procedure
3.3.1 The supplier shall be notified by HCIL of the scope of process quality control table
to be submitted to HCIL.
However, if excluded from such submission, the supplier shall manage process
quality control table in a manner that is readily available for HCIL to view if so
requested by HCIL.

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3-2-1 Process Quality Control Table

3.3.2 The supplier shall, with approval of its Quality Assurance Representative or the
Facility Quality Representatives submit the original of the process quality control
table to HCIL by the date specified.
3.3.3 The supplier shall if there are any changes made to the contents of the process
quality control table submitted to HCIL, revise and resubmit the process quality
control table to HCIL immediately. Related processes, i.e. change point control,
shall be completed in accordance with SQM 4-4 Change Point Control , etc.
3.3.4 The supplier shall submit a process quality control table using the forms below.
1) “Process Quality Control Table (I)- Form 1”
2) “Process Quality Control Table (II)- Form 2”
3) “Process Quality (Appendix)- Form 3”
(Used when issuing as a representative for multiple parts.)
3.3.4.1 The supplier may choose to use its format in lieu of “Process Quality
Control Table (I)” and “Process Quality Control Table (II)” on the condition
that HCIL confirms all items set forth in those forms are covered in the
supplier’s format.
3.3.4.2 The supplier shall, if a note was added referring other documents e.g. “XX
standards, etc.” in the quality characteristics field and the production
conditions field control the cited documents in a manner that is readily
available for HCIL to view.
3.3.4.3 The supplier shall, if HCIL requests submission of a process quality control
table made by sub-suppliers, submit that of the Quality Assurance
Representative or the Facility Quality Representative approved.
3.4 Process Quality Control Table Entries
The suppler shall follow the direction provided in the entry procedure and make
appropriate entries with required information in “Process Quality Control Table (I)” and
“Process Quality Control Table (II)”.
3.5 Use of Process Quality Control Table
The supplier shall put the process quality control table into practice in accordance with
“Process Quality Control Table Operation Flowchart”.
3.6 The supplier shall, if the need for a new process quality control table arises due to the
launch of production at a new plant or in a new line after new model start-up, report to
HCIL in advance, and proceed according to the directions, such as prior presentation of
parts, submission of a new process quality control table on the specified date, etc.
4 Key points
1) Conduct process FMEA and define control items required as manufacturing standards.
2) Perform casting parts pressure leakage testing with the parts for which the final
fabrication was completed.
3) Choose cleaning agent taking into consideration chemical reactions with substances used
subsequently, such as rust inhibitor, lubricant, etc.
4) In the event of confirming the status of reflection of the requirements in the process
quality control table, cross check the requirements for products with drawings
(specifications included)

5 Control of Records

No. Type of Record Retention Period

15 years after the issue of discontinuation
1 Process Quality Control Table
order.

6 Reference Materials
1) SQM 4-4 Change Point Control.
2) SQM 6-1 Glossary of Terms and Definitions.

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Supplier Quality Manual

3-2-1 Process Quality Control Table

6 Flowchart “Process Quality Control Table Operation Flowchart”
Supplier HCIL
Contact

Process design Drawings QD-New model

- Process FMEA
- Problem containment system Receipt
- Error proofing

Create Process
Quality Control Table
(I) and (II)

Review Process Establish and issue

Pre-Production Stage

Quality Control Table inspection Criteria

QD-New model

Process verification with Issuance of "Notice for

Process Quality Control Table Submission of Process Quality
Control Table " QD-New model

- Reflect process FMEA review

- Review instructions from HSCI
- Drawing change details
Create "Process Request submission of
Quality Control Process Quality Control
Table Receipt QD-New model
Table
Issuance Report"

Submit by due date

Approve

(Not required to submitt)

Verify Process
Review Process NG Quality
Quality Control Table QD-New model
Control Table

Process Quality
Store Process Receipt Control Table
MPQ
Quality Control submission request
Table originals

A need for revision of Process

Quality Control Table is
identified
Production Stage

Review Process
Quality Control Table

- When submission is required by HCIL

- When PQCT is revised
Approval
(Not required to submitt)
NG Verify Process
Quality MPQ
Control Table
Return the original
after verification
OK

Honda Cars India Ltd.

Page 56 of 193
DESIGN ISSUING COMPANY [SUPPLIER] CONFIRMATION DEPARTMENT
MODEL
RANK HONDA CARS INDIA LIMITED
APPR. BY CHK BY ISSUE BY APPR. BY CHK BY REC. BY
PART NO.

PARTNAME

Process diagram (Attach the A3-sized sheet for more space, if necessary.)
COMPONENT PARTS SOURCING LIST
SOURCE
S.NO. PART NO. PART NAME SUPPLIER NAME
PURCHASE INHOUSE

Page 57 of 193
Honda Cars India Ltd.
3-2-1 Process Quality Control Table

FLOW CHART SYMBOLS [ COMBINATIONS OF SYMBOLS CAN BE USED TO SHOW MULTIPLE OPERATION PROCESSES ]
PROCESSING QUANTITY INSPECTION CROSSING LINES WITH NO INTERSECTION OPERATION ZONE

TRANSFER QUALITY INSPECTION MULTIPLE OPERATION -- MAINLY PROCESSING PLUS QUALITY CHECK
INITIAL ISSUE
ISSUED B Y CHECKED B Y A P P ROVED B Y CHECK BY APPR. BY
STORAGE PROCESS FLOW MULTIPLE OPERATION -- MAINLY QUALITY CHECK PLUS COUNTING ISSUE DATE CONTENTS OF REVISION
Supplier Quality Manual

ISSUING DEPARTMENT [SUPPLIER] CONFIRMATION DEPT.

FORMAT NO: HSQF QC 0029/ OCT'13 PAGE 1/2
DESIGN ISSUING COMPANY [SUPPLIER] CONFIRMATION DEPARTMENT
MODEL 2
1 RANK 5 7 HONDA CARS INDIA LIMITED
APPR. BY CHK BY ISSUE BY APPR. BY CHK BY REC. BY
PART NO.
3
6 8
PARTNAME
4
9. Process diagram (Attach the A3-sized sheet for more space, if necessary.)
COMPONENT PARTS SOURCING LIST
1 Enter the model name (enter the name of the representative model if there are more than one). SOURCE
S.NO. PART NO. PART NAME SUPPLIER NAME
2a. Circle design rank (From Drawing). PURCHASE INHOUSE
3 Enter the part name shown in the drawing. Enter first three digits for the type number. If there are multiple part classification no. or type no., one of the following may be taken for parts that process sequence,
10 11 11 12 13
quality characteristics, production conditions, etc. are the same or similar
1. Include in the same field.
2 Prepare and attach a Process Quality Control Table (Appendix). List of Applied Parts. Write "see List of Application (appendix)for part numbers" in the part number column.
4 Enter the part name shown in the drawing.
5 Enter the name of the supplier and the responsible section.
6 Signatue or seal of the supplier 's representative. Be reminded that all signatures and seals affixed at the time of establishment will remain and
quality assurance representative or facility quality be printed out by the preparing section,if computers are used to revise the content of this document.
7 For Honda use only. Circle the facility that received this form.
8 For Honda use only. Enter the name of the section that received and checked this form. Enter the signature or seal of the Manager, (or
signature of person responsible for receipt of this form). Be remainded that all signatures and seals given at the time if establishment will
remain on this form and be printed out by the preparing section,if computers are used to revise the content of this document.
9 Draw the process diagram from receipt of component parts to processing and shipment.
1 Enter the process name in ( ), if it is performed at the supplier.
2 Attach an additional form or an A3 size sheet if more space is needed.
3 Other types of sheets can be attached if appropriate.
4 Follow procedures below for lot control parts.
a) Place a . To the left of appropriate process drawing code for lot formation process. Lot forming process' is "a process of forming and
identifying a manufacturing lot according to the priority of quality characteristics, process layout,equipment,process capability,etc to
track and control manufacturing records of parts".
b) For the process marked.- write designed 'lot formation criteria and designated lot size' and " name of recording forms" in a square box to
the right of the process name (see below the reference)
* Set'lot formation criteria' within the range in which a product was or was considered to be produced
under equal conditions. For example, by material charge,process setup change,or processing machine ,etc.
* Set up a lot size based on a set production quantify per day in the process design calculated with the set product quantity
for amortization, and the aforementioned lot formation criteria (actual lot size may vary according to production plan).
* For 'names of recording forms'. Fill in the names of forms in which the lot formation and lot sizes are recorded.
5 In case that symbols other than indicated in the process drawing symbol column are used, add such symbols
and explanations in the margin.

Page 58 of 193
10 Enter the serial number. For parts with the Process Quality Control Table.circle the serial number that applies.
11 Enter the part number and the part name shown in the drawing and the first three digits for type number. Be reminded to use the part number
from Honda (Honda 's part number).

Honda Cars India Ltd.

12 Cross out 'RCVD' for received parts in Component Order List field with a diagonal line. Circle the applicable item; "SUB" for supplied by Honda
or MFG for self- supplied parts.
13 Enter the name of the designated sub - supplier if this is 'SUP' or the supplier name if 'MFG'.
3-2-1 Process Quality Control Table

14 Enter the establishment data in the western calendar, if revising the form for reasons other than a new establishment, transcribe the
establishment data of previous versions.
15 Enter "establishment".
16 Fill in a serial number each time revision is made. In the event that a new form is created or revision column is rewritten due to short of revision
filed, the revision number is to be the sequential to the last version. Implement identification to prevent misuse of previous versions, and
exercise control over and maintain previous versions in a manner that they are easily when needed.
17 Enter the data of revision in the western calendar.
18 Write a summary of the revision, In case that the original or form format is to be renewed by the revision, write "original rewritten due to XX"
(insert reasons).
19 In the latest revision, sign or seal the names of supplier's quality assurance representative or facility quality representative. Be reminded that all
signatures and seals affixed to previous versions will remain and be printed out by the preparing section,if computers are used to revise the
content of this document.
20 For Honda use only. In the latest revision,in principle,sign or seal the names of the manager or equivalent of the checked section
at Honda. Be remained that all signatures and seals affixed to previous versions will remain and be printed out by the preparing section, if
computers are used to revise the content of this document.

FLOW CHART SYMBOLS [ COMBINATIONS OF SYMBOLS CAN BE USED TO SHOW MULTIPLE OPERATION PROCESSES ]

PROCESSING QUANTITY INSPECTION CROSSING LINES WITH NO INTERSECTION OPERATION ZONE

16 17 18 19 20
Supplier Quality Manual

14
TRANSFER QUALITY INSPECTION MULTIPLE OPERATION -- MAINLY PROCESSING PLUS QUALITY CHECK
INITIAL ISSUE
ISSUED B Y CHECKED B Y A P P ROVED B Y CHECK BY APPR. BY
STORAGE PROCESS FLOW MULTIPLE OPERATION -- MAINLY QUALITY CHECK PLUS COUNTING ISSUE DATE CONTENTS OF REVISION
ISSUING DEPARTMENT [SUPPLIER] CONFIRMATION DEPT.
FORMAT NO: HSQF QC 0029/Oct'13 PAGE 1/2
Supplier Quality Manual

3-2-1 Process Quality Control Table

Process Quality Control Table (I)
Basic Drawing Symbol
Number Process Symbol Symbol Description Remarks
Component Name
Process where shapes
or natures of raw
1 Process Processing materials, materials,
parts or products
are transformed.
Process where positions Diameter of the conveyance
of raw materials, symbol is 1/2 - 1/3 of that of
materials, parts or the processing symbol.
2 Conveyance Conveyance products are can be used instead of
changed. ○.However, this symbol
does not show the direction
of conveyance.
Process where raw
materials, materials,
3 Storage
parts or products are
systematically stored.
Stagnation
State where raw
materials, materials,
4 Retention
parts or products
are behind the schedule.
Process where volume
or quantity of raw
materials, materials,
Quantity parts or products are
5
Inspection measured to compare
the results with
standards and to learn
the difference.
Process where quality
Inspection
characteristics of raw
materials, materials,
parts or products are
Quality tested to compare the
6
Inspection results with standards
and to judge ACCEPT or
NOT ACCEPT for lots, or
GOOD or NOT GOOD
for parts.
Supplementary Drawing Symbol
Symbol
Number Symbol Description Remarks
Name
Order relations of component
1 Streamline processes.

Control classification in
2 Classification process sequence.

Omission of part of process

sequence.
3 Omission

Combined Symbol
When functions or states of two component processes exist in one component process, those
component process symbols can be combined. In such case, "main" component process
symbol should be placed outside and "sub" component process symbol inside. As for the
conveyance symbol when combined, the symbol to be used is .
Combined Symbol Description
Perform quantity inspection as well as quality
inspection primarily conducted.

Perform quality inspection as well as quantity

inspection primarily conducted.
Perform quantity inspection as well as
processing primarily conducted.

Perform conveyance as well as processing

primarily conducted.

Honda Cars India Ltd.

Page 59 of 193
PAGE : /

PROCESS NO. FAILURE MODE CRITICAL ITEM PRODUCTION CONDITION CONTROL

PROCESS NAME CRITICAL ITEM QUALITY CHARACTERISTICS DATA [ EQUIPMENT, DIE, FAIL SAFE DEVICE, OIL PRESSURE, VOLTAGE, TEMPERATURE, etc. ]
EQUIPMENT FILING CONTROL CONTROL
NO. CONTROL ITEM STD. VALUE CHK BY CHECK METHOD FREQUENCY DATA TYPE FREQ. ITEM VALUE CHK BY CHECK METHOD FREQUENCY DATA TYPE ILLUSTRATION

Page 60 of 193
Honda Cars India Ltd.
3-2-1 Process Quality Control Table

< CLASSIFICATION OF FINISHED VEHICLE ( M/C) FAILURE MODE > 1 : FIRE 2 : DOES NOT STOP 3 : DOES NOT RUN 4 : DOES NOT TURN 5 : ELECTRIC SHOCK 6 : LEGAL REQUIREMENT 7 : APPEARANCE, COMMERCIAL VALUE
FORMAT NO: HSQF QC 0029/OCT'13 PAGE 2/2
Supplier Quality Manual
/

PROCESS NO. 1 FAILURE MODE CRITICAL ITEM PRODUCTION CONDITION CONTROL

2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
4

1 Enter in correspondence with operation number in process system diagram. If it is an aoutsourcing process, 13 Circle a control item, which has direct influence to the classification number selected
circle in manufacturing order number. in the failure mode column (3)for completed unit.
2 enter the name of the process or facilities. If it is an outsourced process, enter the supplier's name with 14 Enter a control item (e.g. temperature, eccentricity, speed, machining allowance, etc. )
parentheses. for maintaining specification limits specified in the characteristics field.
3 Perform FMEA etc., and enter int this column the applicable no. from" Failure Mode Classificatiion" 15 Enter the standard value and units of measure for the parameter selected in the
for complete unit at the bottom margin of this form. The preparing section and Honda coordinate and control item column. Use SI units as a rule. When using a conventional unit at the
build consensus on the failure mode classification, if necessary. same time, put it in parentheses ( ).
4 On items that affects complete vehicle failure mode classification, place a circle if applicable to any of the 16 Enter the job title of the person in charge of controlling of control items.
following. 17 Enter the check method of the control value, or the name of control equipment.
18 Enter the frequency of checking control value.
The preparing section and Honda perform adjustments of circled items as necessary. Control conditions
be set in a way that the circled items are assured in applicable processes 100% , in regard to quality Example : once/hr, per work resumption, once/shift, etc.
characteristocs and manufacturing condition control. ("per work resumption" means every resumption of work which
2) Item that experienced any recall in the past. has been put on hold or stopped due to setup, operational break, etc.)
3) Item that has "Q" mark in the part drawing.
4) Quality control item (item grade A) listed in HONDA'S Parts Inspection Criteria, etc. 19 Enter the name of the form to control the control value.
5) Item that made a quality agreement with HONDA. (E.g. check sheet, check list, daily report, record sheet, etc. )
20 Provide schematic drawing of a specific area of part to process,
5 Enter a sequence number for each process. delivery destination, etc., as necessary.

Page 61 of 193
6 Enter a quality control item. (E.g. apprearance, diameter,surface roughness,hardness,weight etc.)
7 Enter reference values or specification limits and a unit (If it can't be quantified, enter limits or samples, etc.)

Honda Cars India Ltd.

Use SI units as a rule. When using a conventional unit at the same time, put it in parentheses( ).
8 Enter the job title of the person in charge of control items. (E.g. PIC of inspection, operator, etc. )
9 Enter the inspection method or name of inspection equipment for specification limit.
10 Enter the frequency of checking control items.
3-2-1 Process Quality Control Table

Example : n=10/lot, n=5/day, 100% inspection, n=3/at start up, n=3/resumption

("per work resumption" means every resumption of work which has been put
on hold or stopped due to setup, operational break, etc. )

Take a lot - size change into consideration, when setting the frequency of checking in units of lot, day, etc.
11 Enter the name of control record forms for specification limits. (E.g. check sheet, inspection check sheet, etc. )
12 Enter the frequency of data submisssion to HONDA.
Supplier Quality Manual

3-2-1 Process Quality Control Table

8.11 Process Quality Control Table (appendix) (Form - 5)

(Form - 5)
Process Quality Control Table (appendix)
Created by
List of Applied Parts

Revision
No. Part Number Part Name Remarks
code

Original to be retained until. / (year/month)

This appendix is to be attached on top of Process Quality Control Table (I) whe there are tow or more
parts that the table is required to be applied to.

Honda Cars India Ltd.

Page 62 of 193
Supplier Quality Manual

3-3 Delivery Packaging

1 Overview
1) HCIL shall examine and agree the proposed packaging style for delivery of parts.
2) The supplier shall determine and obtain agreement from HCIL on packaging style for
delivery of parts, and preserve the conformity of product during handling, delivery, and
storage from the time of shipment from the supplier to the time of use by HCIL.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Term Definition

A state of parts in a container or on a cart to be shipped

1 Delivery packaging
out from a supplier to a manufacturing plant of HCIL.
3 Requirements
3.1 Delivery Packaging Preparation
3.1.1 Selection of Subject Parts
The supplier shall, in order to put forward a proposal on delivery packaging to HCIL,
select subject parts that fall into the following categories.
1) Parts that require attention to delivery packaging to maintain quality.
2) Parts that require attention to delivery method and delivery packaging due to
their shape, weight, etc.
3) Parts that require special protection and security against theft or for
confidentiality.
4) Other parts required by HCIL.

3.1.2 Arrangement of delivery packaging

The supplier shall, with consideration to the following items, make an arrangement
for delivery packaging.
1) Damage to parts (breakage, scratch, deform, tear, loose, detached, stain)
2) Deterioration of parts (swell, rust, discoloration, color fading, hardening,
softening).
3) Collapse or protrusion of parts.
4) Interference (between parts, parts and container, etc.)
5) Shock protection (protection material, dunnage, partition)
6) Identification (display location, clarity: misuse prevention, display of lot and
content information, etc., first-in, first-out.)
7) Environment such as water, heat, air, light, dust, foreign particles, etc.
8) Synchronization with HCIL’s production line.
9) Transfer of parts at the supplier’s site (consideration to size and weight limits
for the lift, elevator, conveyer, etc.)
10) Workability (easiness in taking out, weight, easiness in holding, miss assembly
prevention)
11) Environnent protection (reuse, recycle, returnable)
12) Personnel safety (projection, pinching, etc.)
13) Efficiency of loading and transportation of parts.
14) Prevention of past problems from recurring.
15) Regulations and policies with respect to containers of parts and products.

Honda Cars India Ltd.

Page 63 of 193
Supplier Quality Manual

3-3 Delivery Packaging

3.1.3 Delivery Packaging Specification

3.1.3.1 The supplier shall, in reference to “Delivery Packaging Specification Form”,
prepare a “ Delivery Packaging Specification Form” or create an equivalent
form, and submit to HCIL.
3.1.3.2 The supplier shall, if any instruction is given by HCIL in regard to the
“Delivery Packaging Specification Form” follow the instruction.
3.1.4 Delivery Packaging Verification Meeting
3.1.4.1 The supplier shall, if so requested by HCIL, build a container or cart sample
in accordance with the “Delivery Packaging Specification” and participate in
a delivery packaging verification meeting.
3.1.4.2 The supplier shall, for issues raised at a delivery packaging verification
meeting, carry out measures and revise the “Delivery Packaging
Specification Form “by the date specified by HCIL.
3.1.5 Production of Containers and Carts
The supplier shall accommodate a container or cart in accordance with “Delivery
Packaging Specification Form”.
3.2 Improvement of Delivery Packaging During Mass Production
The supplier shall, if the need of improvement of delivery packaging arises, create a new
“Delivery Packing Style Specification Form”, submit to HCIL, and make such
improvements in delivery packaging. However, no new “Delivery Packaging Specification
Form” is required if such improvements are not related to the matters agreed upon with
HCIL in the previously issued “Delivery Packaging Specification Form”.
3.3 Control of Returnable Containers and Carts
The supplier shall define inspection methods including procedures, frequency, subject
items, etc. to control containers and carts that are used repeatedly.
4 Key Point
1) Containers and carts shall be identified with the name of the owner i.e. company name
5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

Honda Cars India Ltd.

Page 64 of 193
Supplier Quality Manual

3-3 Delivery Packaging

-- Flow Chart

Supplier HCIL
Contact

Determine parts requiring a delivery packaging

specification to be made taking into consideration
the following:
- quality maintenance
- limitations of shape, weight, carry-in
method, etc.
- theftproof, confidentiality protection
- requirement from Honda
- improvement of existing delivery packaging.
- others

Review packaging style for parts

Pre-Production Stage

Select
Create and submit Delivery
Delivery Packaging
Specification Form
Prototype
production
Need Delivery No
procedures
Produce container/cart Packaging Parts Logistics
prototypes Verification Control/ QD
meeting ?
Delivery

Hold a Delivery Packaging Verification Yes

meeting.
(verify part protection, workability, etc.)

Not Passed Passed

Parts Logistics
Carry out measures against Resubmit Control/ QD
Approve the Delivery
problems pointed out. Revise and Packaging Specification Form Delivery/
resubmit Delivery Packaging Respective Shop
Specification Form
Delivery Packaging
Specification Form

Produce containers and carts

Mass Production Stage

Inspect and use containers and

carts

Honda Cars India Ltd.

Page 65 of 193
3-3 Delivery Packaging

HCIL PACKING STANDARD FOR BOPs PLANT

PART No. 1 PART NAME 2 VENDOR 3

PHOTOGRAPH / SKETCH PACKING DETAILS

4 BIN 5 CARTON 14 TROLLEY 23

PCS PER BIN PCS PER BOX PCS PER TROLLEY

6 15 24

BIN COLOR BOXES PER CARTON TROLLEY COLOR

7 16 25

BIN SIZE CARTON SIZE TROLLEY SIZE

8 17 26

BIN WEIGHT CARTON WEIGHT TROLLEY WEIGHT

9 18 27

WRAPPING MATERIAL WRAPPING MATERIAL WRAPPING MATERIAL

Page 66 of 193
3-3 Delivery Packaging

10 19 28

Honda Cars India Ltd.

COVERING MATERIAL COVERING MATERIAL COVERING MATERIAL

11 20 29

RETURNABLE/NON-RETURN RETURNABLE/NON-RETURN RETURNABLE/NON-RETURN

12 21 30

IDENTIFICATION ON BIN IDENTIFICATION ON CARTON IDENTIFICATION ON TROLLEY

13 22 31

1 2 3 COMMENTS :-
QD P.L.C. CONCERN DEPT ACCEPTED
33 34
SIGN 32
NOT ACCEPTED
Supplier Quality Manual

NAME
* Packing sample should be submitted to M.S. at the time of approval
Supplier Quality Manual

3-3 Delivery Packaging

‘1.2 Delivery Packaging Specification Form (entry procedure)

No. Entry procedure No. Entry procedure

1 Enter part number 18 Enter Carton Weight ( in KG)

2 Enter part name 19 Enter wrapping material

3 Enter vendor name 20 Mention covering material

Mention Returnable / Non returnable

Attach the photograph sketch of 21
4 status
the container currently used
22 Mention the Identification on carton

Packaging details in terms of bins,

23 Tick mark if trolley is used
cartons or trolley

5 Tick mark if bin is used 24 Enter trolley color

Pieces per bin (Numeric Enter trolley size( in length X breath X
6 25
Quantity) height )

7 Mention bin color 26 Enter trolley color

Enter bin size (in length X

8 27 Enter trolley weight
breadth X height)
9 Enter bin Weight (in KG) 28 Enter wrapping material

10 Enter wrapping material 29 Enter covering material

Mention Returnable / Non returnable

11 Enter covering material 30
status
Mention Returnable / Non
12 31 Mention the Identification on carton
returnable status
Take approval from the authorized
13 Mention the Identification on bin 32
sections

14 Tick mark if carton is used

Clarify Accepted/Not accepted status by
33
ticking in the appropriate box
15 Enter pieces pre box

16 Enter boxes per carton 34 Enter comments if necessary

Enter carton size ( in length X

17
breadth X Weight )

Honda Cars India Ltd.

Page 67 of 193
Supplier Quality Manual

3-4 Countermeasure at Pre-production Stage

1 Overview
1) HCIL shall require suppliers of problem parts, which were found in the pre-production
stage and its cause was considered attributable to the supplier, to conduct analysis and
take countermeasure against the cause.
2) The supplier shall conduct analysis and take countermeasure for the cause of the
problem in accordance with a request from HCIL and report the results to HCIL. For
problems in the pre-production stage, it is important that measures for the problem be
preferentially implemented and results be evaluated for effectiveness by the
subsequent pre-production trial event.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Term Definition
A drawing of parts drawn and issued by a supplier, which HCIL
had outsourced the design, development, and manufacturing to,
Supplier
1 in accordance with the basic requirements of preliminary
drawing
specifications provided by HCIL, or a “parts supplier’s drawing”
which referred to as a supplier’s drawing.
3 Requirements
The supplier shall, if a problem with parts delivered from the supplier is found at HCIL
during the pre-production stage, and if the supplier is so informed by HCIL, promptly take
measures that include prevention of problem recurrence.
3.1 The supplier shall undertake analysis of problem parts, investigate the cause of the
problem, and report to HCIL’s new model section.
3.2 If the cause of the problem is attributable to the supplier’s drawings, etc., the supplier
shall issue a “Countermeasure Request [Countermeasure Request Form]“ in
accordance with SQM 4-6-1 Countermeasure Request Form and request necessary
changes to drawings, etc. to HCIL (QD-New model).
3.3 If the cause of the problem is attributable to the suppliers’ manufacturing processes, the
supplier shall seek improvement in manufacturing processes following consultation with
HCIL (QD-New model). If so requested by HCIL, the supplier shall report to HCIL (QD-
New model) the result of the improvement using ”Analysis Record [Analysis Report]” in
SQM 4-5 Corrective Action Report or equivalent forms.

4 Control of Records
No. Type of Record Retention Period

1 Analysis Record [Analysis Report] or equivalent form 10 years

Countermeasure Request [Countermeasure

2 5 years
Request Form]

5 Reference Materials
1) SQM 4-5 Corrective Action Report.
2) SQM 4-6-1 Countermeasure Request Form.
3) SQM 6-1 Glossary of Terms and Definitions.

Honda Cars India Ltd.

Page 68 of 193
Supplier Quality Manual

3-5-1 Parts Inspection Criteria

3-5 Quality Standards

3-5-1 Parts Inspection Criteria
1 Overview
1) HCIL shall issue Parts Inspection Criteria to suppliers to verify quality characteristics of
parts to which verification is mandated by laws and regulations.
2) The supplier shall report inspection results with respect to the quality characteristics of
parts specified in Parts Inspection Criteria.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Term Definition
Parts Inspection Criteria [System/Device and Parts], which set forth
1 Inspection acceptance criteria to be applied to inspection of individual
Criteria constituent parts of a product.
3 Requirements
3.1 Receipt of Parts Inspection Criteria
The supplier who received Parts Inspection Criteria from HCIL shall review requirements
for inspection and reflect them in Process Quality Control Table, etc.
3.1.1 Matters Specified in Parts Inspection Criteria
Major matters specified in Parts Inspection Criteria shall be as follows.
1) Part number/ part name
2) Inspection item
3) Item importance
4) Quality judgment criteria
5) Inspection method
6) Inspection plan (HCIL’s inspection plan and frequency)
7) Data format
8) Inspection section (HCIL’s section to which the result is submitted)
3.1.1.1 Severity ranking
HCIL shall assign an item importance to each inspection item, which
indicates the degree of severity of respective quality characteristics.
Definition of item importance and its criteria are as follows.
Item
Definition
Importance
Conditions which are judged to pose a serious threat to human
lives such as the following when a problem with the structure,
equipment, or function of the product occurs.
1) Condition that disables vehicle operations (drive, steer, or stop)
A
2) Condition that associated with electrification, burn, or injury.
3) Condition that associated with fire.
4) Condition that associated with pollution.
5) Condition that disables protection of vehicle occupants

Conditions other than described in A and that cause significant

B loss of function or merchantability as the product when
a problem with the performance, function, or structure of parts occur.

C Conditions that do not comply with either A or B above.

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Page 69 of 193
Supplier Quality Manual

3-5-1 Parts Inspection Criteria

3.2 Inspection
3.2.1 Reflection in Process Quality Control Table
The supplier shall confirm that quality characteristics and inspection frequency
specified in Inspection Criteria are included in process quality control table, and
reflect the frequency of data submission to HCIL in process quality control table.
3.2.2 Implementation of Inspection
The supplier shall implement inspections in accordance with process quality control
table.
3.2.3 Record of Inspection Results
The results of inspection shall be recorded and stored in the Inspection Check
Sheet, etc.
3.2.4 Sub-Supplier Management
If inspection items specified in Inspection Criteria are performed by sub-suppliers,
the supplier shall collect the inspection results from such sub-suppliers and provide
HCIL with the results.
3.2.5 Submission of Inspection Check Sheet
1 The supplier shall submit the inspection results to HCIL at the frequency
specified. The inspection results provided by sub-suppliers shall be included
in the Inspection Check Sheet, etc. to be submitted to HCIL.
2 HCIL Purchase shall provide Inspection Result List (standard) of each part to
supplier before Dankaku Event & can be revised before Mass Production
where ever required.
3 Supplier shall perform inspection of all parts before delivering to HCIL to
ensure that parts meet all requirement as prescribed in the drawing and on
inspection result List (Standard).
4 It is required to submit inspection report for each supply during Development.
5 It is required to submit inspection report for each part on Monthly basis in
regular Mass Production for both DOL & NON DOL parts.
6 Inspection Items of Inspection Result list are kept in same sequence while
entering actual Observations in Monthly reports for both DOL & NON DOL
parts.
7 Each inspection report format bears drawing / part No. and Part name.
(Before using the format it is required to match both the items ).
8 Minimum 5 No. or 1 No./cavity inspection report is required or as specified in
PQCT. * Inspection report shall be accompanied with identified parts
( inspected parts )for the first supply of every manufacturing lot / batch.
* Inspection report shall bear the Lot / Batch No.
* If subsequent supplies are made of same previous Lot/Batch, then suppliers are
required to submit only photocopy of the inspection report already submitted to
HCIL along with the first supply, identifying Lot / batch No.
9.These inspection standard may be revised or updated as & when required by
HCIL – MPQ.
3.2.6 Inspection report other than standard items :
HCIL - MPQ may ask for the following as & when required
a) Performance test data
b) Material test data
c) Sub suppliers data (sub suppliers / raw material supplier )
d) Some specified parameters already mentioned in the drawing but not covered
in the standard format.

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Page 70 of 193
Supplier Quality Manual

3-5-1 Parts Inspection Criteria

e) In process inspection data already indicated in PQCT.

The above information can be provided in the blank standard format.
f) Supplier has to submit Layout Inspection Report at least once per Year as per
agreed schedule with MPQ.
Note : Lot No. and batch No. are used to identify the production lot. Distinction
made between the two for better understanding is as under :-
Lot No. : Applicable to HS, HA etc. parts already identified and mutually agreed
between HCIL & supplier to have traceability
Batch No. : Supplier's own system for distinguishing one production lot with
other..

4 Control of Records

No. Type of Record Retention Period

Record of inspection results (Inspection Check
1 15 years
Sheet, etc. for submission)

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

6 Flowchart

Supplier HCIL

Contact

Parts Inspection Criteria

formulate, revise/issue
QD- New Model
Part Insp.
Verify or
Criteria
MPQ

Inspection setting
Process quality control table
Prepare operation control
doc.

Perform inspection

Submit inspection results Verify and maintain records

MPQ
inspection
report, etc.

Honda Cars India Ltd.

Page 71 of 193
Supplier Quality Manual

3-5-1 Parts Inspection Criteria

SUPPLIER…………………………………………….
23 DATE………………………………………
24
DESTINA TION
8 Inspection result list (Standard)
Part No Purpose 5 Approval seal 6
1
Parts name Periodic inspection Special inspection(analysis of defects)
2
Lot No Lot size Inspection of initial product Request of measurement
3 4
9
Reasons 7
Unit µ mm
Sample
No Inspection items Method
Standard 1 2 3 4 5 6 7 8 9 10
10 11 12 13 22

Investigation 14 15 Judgement
Acceptable
Rejectable

16 17 New 18 19 20 21 25
No Date Articles Prep by Chk by App by D/C No.

HSQF QC 0017/JUN'11

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3-5-1 Parts Inspection Criteria

Guidelines
S. No. Description
1 Part number
2 Part name
3 Manufacturing lot number
4 Lot size
5 Encircle the applicable purpose of inspection.
6 Approval from supplier
7 Write latest D.C. no if not given in the revision table
8 Deleted not to be filled
9 Encircle the applicable unit of measurement
10 Serial number
11 Inspection parameter
12 Inspection method/instrument name
13 Standard value/sample
14 Special remark of inspection about the part
15 Encircle applicable judgment
16 Revision number
17 Revision date
18 Revision article
19 Revision prepared by
20 Revision checked by
21 Revision approved by
22 Observed value against standard value
23 Supplier name
24 Date of inspection by supplier
25 Design Change Number

Honda Cars India Ltd.

Page 73 of 193
SUPPLIER NAME: PAGE:
(CHARACTERISTICS AS PER LATEST INSPECTION RESULT LIST (STANDARD)
INSPECTION RESULT LIST - DOL PARTS
PART NAME PART NO. MODEL COLOUR ISSUE DATE MONTH

S.N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

6
7

8
3-5-1

10
11

12
13

Page 74 of 193
14

Honda Cars India Ltd.

17
18
Parts Inspection Criteria

LOT NO.

QTY.

F IN A L
S T A T US

INSP. BY
REMARKS (SUPPLIER) CHECKED : REMARKS (HCIL) CHECKED :
SUPPLIER HCIL
APPROVED : APPROVED :
* LAST MONTH REPORT TO BE SUBMITTED ON 5th OF NEXT MONTH
MIN
HSQF QC 0005/OCT'13 MAX
Supplier Quality Manual
MONTHLY INSPECTION RESULT LIST
SUPPLIER NAME:
(CHARACTERISTICS AS PER LATEST INSPECTION RESULT LIST (STANDARD)
PART NAME PART NO. MODEL COLOUR ISSUE DATE MONTH

DATE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
S.N.
1
2
3

4
5
6

7
8
3-5-1

9
10
11
12
13
14
15

Page 75 of 193
Honda Cars India Ltd.
Parts Inspection Criteria

QTY.

F IN A L
S T A T US

INSP. BY
REMARKS (SUPPLIER) CHECKED : REMARKS (HCIL) CHECKED :
SUPPLIER HCIL
APPROVED : APPROVED :
* LAST MONTH REPORT TO BE SUBMITTED ON 5st OF NEXT MONTH
MIN
HSQF QC 0092/ OCT'13 MAX
Supplier Quality Manual
Supplier Quality Manual

3-5-2 Preparation of Limit Samples

1 Overview
1) HCIL shall, if a supplier produces limit samples of parts for which acceptability is
determined by visual inspection, etc., examine and approve such samples.
2) The supplier shall control limit samples approved by HCIL, and judge the acceptability of
manufactured parts for quality.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Term Definition
A sample of parts which demonstrates quality limits for
1 Limit sample
conformance or nonconformance.
.
3 Requirements
3.1 Preparation of Limit Samples
3.1.1 The supplier shall, if it is difficult to quantitatively define or explain the
characteristics required for parts, produce limit samples at the direction of HCIL or
at its discretion.
3.1.2 The supplier shall, if necessary, identify areas showing the limits by circling with a
line or marking with an arrow, and clearly identify the limit sample by attaching a
tag, etc.
3.1.3 The supplier shall produce limit samples prior to the transition to mass production
stage (refer to SQM 3-9 Transition to Mass Production).
3.1.4 The supplier shall produce limit samples for posting at the site, based on the limit
sample agreed upon with HCIL if necessary. HCIL may require a duplicate sample
for its possession.
3.2 Limit Sample Control Forms
3.2.1 The supplier shall create a limit sample control form in accordance with the example
provided in following pages, however, the format may be changed depending on
the type, size or shape of the limit sample.
The following items shall be included in the control form at a minimum.
1) Date of production of the limit sample
2) Control number
3) Inspection items (scratch, color, roughness, unevenness, wrinkle, shape, etc.)
4) Applicable part number or part name
5) Effective period (Time-dependent change of limit samples shall be taken into
consideration when establishing an effective period.)
6) Signature field
3.2.2 The supplier shall issue a limit sample control form per limit sample, include the
signature of the person responsible, and submit the form to HCIL with the limit
sample.
3.3 Consensus on Limit Sample
3.3.1 The supplier shall build consensus on limit samples with HCIL prior to the transition
to mass production (refer to SQM 3-9 Transition to Mass Production). No parts,
which are to be examined with limit samples, shall be released until consensus is
achieved with HCIL.
3.3.2 The supplier shall, if a limit sample produced by HCIL is provided, adopt the limit
sample. However, the supplier may discuss the level of limit sample with HCIL as
necessary.

Honda Cars India Ltd.

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3-5-2 Preparation of Limit Samples

3.4 Maintenance and control of limit samples

3.4.1 The supplier shall retain limit samples considering damage, deterioration, etc.
3.4.2 The supplier shall, if duplicates of the limit sample are made, number the duplicates
and control with a ledger.
3.4.3 The supplier shall review and revise limit samples and their effective periods. Where
changes are made, the suppliers shall rebuild a consensus on the subject matter
with HCIL.
3.4.4 The supplier shall periodically verify that limit samples are retained in the same
condition as agreed with HCIL
4 Control of Records
No. Type of Record Retention Period

Until a production closing order for the

1 Limit sample control forms
production is issued.

Until a closing order for the production is

2 Limit sample duplicate ledger
issued.

5 Reference Materials
1) SQM 3-9 Transition to Mass Production
2) SQM 6-1 Glossary of Terms and Definitions

Honda Cars India Ltd.

Page 77 of 193
Supplier Quality Manual

3-5-2 Preparation of Limit Samples

6 Flowchart

Supplier HCIL

Contact

Issue instructions for preparing

Supplier's decision QD-New Model
limit sample

Prepare a limit sample

Pre-Production stage

Pre. Limit
sample control
forms
OK
Agreed
NG
QD-New Model
Approved

Duplicate a sample for

displaying limits

Duplicate ledger

Put in use, maintenance

Create new, revise or update/

.. extend the effective period
criteria change ,etc.
renew /extend limit samples
Revise
Control

OK
Mass Production stage

Agreed

NG
Approved MPQ

Duplicate a sample for

display of limits

Page 82 of 193
Supplier Quality Manual

3-6 Control of Monitoring and Measuring Devices

3.3 Check, Inspection and Calibration

3.3.1 The supplier shall establish a schedule for regular check, regular inspection, and
calibration to ensure precision, function, and accuracy of equipment, perform
checks and regular inspections and calibrations of equipment accordingly, and
maintain records.
3.3.2 The supplier shall establish a schedule for regular check, regular inspection, and
calibration to ensure precision, function, and accuracy of equipment, perform
checks and regular inspections and calibrations of equipment accordingly, and
maintain records.
3.3.3 The supplier shall identify equipment to enable the calibration status to be
determined.
3.4 Reaction Plan to Abnormal Conditions
3.4.1 The supplier shall, if any abnormality is found in the equipment, stop immediately
use of the equipment and take remedial measures.
3.4.2 The supplier shall, if any repairs are made to the equipment, recalibrate prior to
resume use of the equipment as necessary.
3.4.3 The supplier shall, when equipment is found not to conform to requirements,
evaluate effect to parts, safety and pollution prevention, and if applicable, request
related sections to take appropriate actions.
3.4.4 Records of the nature of the abnormality and any subsequent actions taken shall be
maintained.

4 Key point
1) Determine the frequency of checks and calibrations based on previous records, data,
etc.
2) If there are more than two units of the same type of equipment and normally one unit is
reserved as a spare, check the setting, etc. at the time of use when using a spare unit.
3) Equipment shall be safeguarded from adjustments that would invalidate the
measurement result.
4) Criteria for judging the adequacy of equipment shall be approved by qualified personnel.
5) If wears or changes due to aging affect the validity of measurement, draw up plans for
checks and repairs of consumable parts (area) in view of the frequency of use, duration
of life, cycle of replacement, etc.
6) In case of any abnormality or nonconformity to requirements is found during use, check,
or calibration of equipment, stop immediately use of the equipment, and verify conformity
of parts previously measured by the equipment.

5 Control of Records
No. Type of Record Retention Period
1 Routine maintenance records 1 year
Periodical check and calibration
2 15 years
records
3 Repair records 15 years after abolishment

6 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions
2) JIS Z 8103
3) JIS B 0155

Honda Cars India Ltd.

Page 83 of 193
Supplier Quality Manual

3-7 Operation Control Documents

1 Overview
1) HCIL shall provide suppliers with requirements of operation control documents, which the
suppliers make available to their operators, in order for the suppliers’ manufacturing
processes to be in a controlled state.
2) The supplier shall formulate operation control documents in accordance with
requirements prescribed by HCIL, provide to its operators and utilize for training.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Terms Definition
1 Operation A generic term for documents to provide operators with directions for
control work sequences, set-up condition, etc. in order for each of the
documents fabrication, assembly, inspection, equipment maintenance,
transportation, and administrative processing, etc. to be controlled per
process, product, operation, etc. Documents such as operation
standards, condition control tables, specifications, signs or displays
showing photographs or illustrations to caution, and check/inspection
standards for inspecting equipment are included.
2 Operation A set of documents that describe requirements and procedures to be
standard followed such as illustrations of work, work sequences, jigs and tools,
quality characteristics and standards, operation key points, inspection
methods, parts to be used, facilities, actions to be taken when
abnormality occurs, and other cautions (it is referred to as “ work
instruction” in ISO/TS”).

Page 86 of 193
Supplier Quality Manual

3-7 Operation Control Documents

4 Control of Records

No. Type of Record Retention Period

1 Validity test plans/actual results 5 years

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

Honda Cars India Ltd.

Page 93 of 193
Supplier Quality Manual

3-9-1 Validity Testing

6 Flowchart
Supplier HCIL
Contact

Drawings, etc. QD- New Model

Verify contents

Submit
Draw up test plan Verify test plan
Production Preparation Stage

Need to
change the test Specification
Yes change.
No

Test

Result
Not Good
Good

Summarize test results

Submit QD- New Model

Approve test results Check test results

Maintain records

Honda Cars India Ltd.

Page 94 of 193
3-9-1 Validity Testing
7 Forms
7.1 Validity Testing Plan/Actual Performance Table (blank)

Prepared section ( supplier name ) Prepared section ( supplier name ) Validity Test Plan/Actual
PerfomanceTable
Rev no. Date Natuere of the change Supplier Honda
Plan Actual Plan Actual M odelcode Honda event schedule
Approved by Prepared by Approved by Prepared by Approved by Prepared by Approved by Prepared by Part number
Part name
Design change number

Part origin

Plan Actual
No Test item Scheduled Scheduled Date started Date completed
Test plan
Criteria Test condition n Test period Test result n Judgement
start date completion date (start) (actual)

Page 95 of 193
3-9-1 Validity Testing

Honda Cars India Ltd.

Supplier Quality Manual
3-9-1 Validity Testing
7.2 Validity Testing Plan/Actual Performance Table (Entry procedure 1/2)

Prepared section ( supplier name ) Prepared section ( supplier name ) Validity Test Plan/Actual 8

1 2
PerfomanceTable
Rev no. Date Natuere of the change Supplier Honda
Plan Actual Plan Actual M odelcode 3 Honda event schedule
Approved by Prepared by Approved by Prepared by Approved by Prepared by Approved by Prepared by Part number 4
Part name 5
Design change number 6 9
Part origin

Plan Actual
No Test item Scheduled Scheduled Date started Date completed
Test plan
Criteria Test condition n Test period Test result n Judgement
start date completion date (start) (actual)

10 11 12 13 14 15 16 17 18 19 20 21 22

Page 96 of 193
3-9-1 Validity Testing

Honda Cars India Ltd.

Supplier Quality Manual
Supplier Quality Manual

3-9-1 Validity Testing

7.3 Validity Testing Plan/Actual Performance Table (entry procedure 2)

No. Item (section) Instruction
Enter company name and supplier code.
Supplier
1 Enter signature of the person in charge of and the person
signature
prepared the test plan and results. Enter the date of signature.
HCIL enters the applicable section name.
2 HCIL signature
HCIL signs and enters the date of test plan and results received.
3 Model code Enter the code of a model in which the part is used.
4 Part number Enter HCIL’s part number.
5 Part name Enter HCIL’s part name.
Design change Enter HCIL’s design change number used in the part subject to
6
No. the test.
Enter the origin of part subject to the test (trial or mass
7 Part origin
production).
8 Revision Enter revision history.
HCIL event
9 Enter timing for production and other events of HCIL.
schedule
10 Test item Enter the item subject to the test.
11 Criteria Enter criteria for the test.
Standards, measuring equipment, environments, etc., of the
12 Test condition
test.
13 n Enter the number of samples planned per test item.
14 Test period Enter the time period required for the test.
Scheduled start
15 Enter the scheduled date of the start of the test.
date
Scheduled
16 Enter the scheduled date of completion of the test.
Completion date
17 Date started Actual date of the test started.
18 Date completed Actual date of the test completed.
Enter the result of the test.
Enter the minimum and maximum values measured for
quantitative tests.
19 Test result
For qualitative tests, enter results described in accordance with
the expressions used in the column of limit values of respective
tests.
20 n Enter the number of samples used per test item.
21 Judgment Enter either accepted or rejected based on test results.
22 Test schedule Enter the anticipated schedule per test item.
Note Origin of items to
If necessary, test results lie between upper and lower limits.
1 be tested

Note 1. This applies only to parts designated by HCIL. The format in which results (data) are
presented is under the supplier’s control, however, it should be easily understandable.

Honda Cars India Ltd.

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Supplier Quality Manual

4-1 Initial Mass Production Quality Control

4 Mass Production Stage

4-1 Initial Mass Production Quality Control
1 Overview
1) HCIL shall provide a verification method for process capability and mass productivity,
which HCIL requires suppliers during Initial stage of mass production.
2) The supplier shall perform verifications of process capability and mass productivity in
accordance with requirements prescribed by HCIL during the Initial stage of mass
production. The verification results shall be presented to HCIL if so requested.

Page 101 of 193
Supplier Quality Manual

4-2 Mass Production Quality Control

4 Control of Records
No Type of Record Retention Period
Monitoring data of manufacturing conditions of
1 3 years
production facilities which affect quality.
2 Training record 15 years

5 Reference Materials

Page 105 of 193
Supplier Quality Manual

4-3 Identification and Traceability

6 Flowchart
Identification and Traceability

Supplier HCIL

Contact

Specify Important Safety Parts

QD - New Model

Drawing
Pre-Production stage

Select lot-control-specified parts

QD - New Model
Lot-Control-
Specified Parts
Notice
Decision of lot control standard items
1) Lot forming unit
2) Lot forming process and key process
3) FIFO control.
4) Lot number display method.
5) Recording of lot control.

Lot Number Display Verify display contents

Details QD - New Model
or

Record of Mass Production

Manufacture parts
manufacturing Quality
Carry out lot control
history
Mass Production stage

Carry-in Manufacturing/
Assembly

Record of
manufacturing
history

Honda Cars India Ltd.

Page 106 of 193
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4-3 Identification and Traceability

7 Forms
7.1 Lot-Control-Specified parts notice (blank)

Lot Control [Specified Parts] Honda Cars India Limited (Name of Facility)

Issue Date: / / (YYYY/MM/DD)

To:

Lot-Control-Specified Parts Notice

The following parts have been designated as lot-control-specified parts in addition to important safety
parts ( HS, HA and HB of important safety part rank) indicated in the title field of the drawing.

Critical
No. Model Part Number Part Name
Process

(Note) 1. Upon receiving this notice, clarify the lot control method for parts subject to lot control
in [Lot Number Display Details] or the like.
2. Maintain [Lot Number Display Details] in a manner that it can be submitted if so requested.
3. When displaying a lot mark on each part (if there is no specification on the drawing), consult with
for display method.
4. Parts are should be controlled on a "first-in first-out" basis.

Honda Cars India Ltd.

Page 107 of 193
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4-3 Identification and Traceability

7.2 Lot Number Display Details (blank)

LOT NO DISPLAY DETAILS

PART NO
SUPPLIER NAME
PART NAME

IMPORTANT PROCESS
SELECT PROCESS

STRUCTURE OF LOT NO

LOCATION OF LOT NO.IDENTIFICATION

LOT NO. IDENTIFICATION METHOD

ILLUSTRATION OF PARTS LOT CONTROL

PART NO. CHANGE APPROVAL [SAME LOT NO DETAILS REMAIN APPLICABLE]

Date of Issue D/C No. New Part No. Prep By Check By App By
Honda Cars India Limited

Rev.No Date of Issue Change Contents Prep By CheckBy App By Prep By CheckBy App By
Lot No. Details Approval Supplier Honda Cars India Ltd
HSQF CM 0069/OCT'12

Honda Cars India Ltd.

Page 108 of 193
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4-3 Identification and Traceability

7.3 Lot Number Display Details ( entry procedure )

LOT NO DISPLAY DETAILS

PART NO 1
SUPPLIER NAME
PART NAME 2 3

4
IMPORTANT PROCESS
SELECT PROCESS

STRUCTURE OF LOT NO 5

6
LOCATION OF LOT NO.IDENTIFICATION

7
LOT NO. IDENTIFICATION METHOD

ILLUSTRATION OF PARTS LOT CONTROL

PART NO. CHANGE APPROVAL [SAME LOT NO DETAILS REMAIN APPLICABLE]

12 13 14
11

Date of Issue D/C No. New Part No. Prep By Check By App By
Honda Cars India Limited

9 9c 10

9a 9b

Rev.No Date of Issue Change Contents Prep By CheckBy App By Prep By CheckBy App By
Lot No. Details Approval Supplier Honda Cars India Ltd
HSQF CM 0069/OCT'12

Honda Cars India Ltd.

Page 109 of 193
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4-3 Identification and Traceability

Lot Number Display Details (entry procedure)

Reference No. Explanation
1 Part no : Part no as per HCIL drawing
2 Part name : Part name as per HCIL drawing
3 Supplier name : Name of Supplier
4 Important process : In parts manufacturing important process shall be indicated.
5 Structure of Lot no: Structure of Lot no to be shown (i.e. how the lot no will be
displayed, for example date, month & year of manufacturing etc.).
6 Location of Lot no: Location i.e. at which place on the part the Lot no shall be
displayed.
7 Method of identification : Method of identifying the Lot I.e. brief meaning of Lot
no structure.
8 Illustration : Illustration of part showing specific location of Lot no
9 To be filled by supplier
9a Date of issue : Date on which Lot control method is issued from supplier.
9b Change Contents : Details of changes made
9c Person in-charge : In-charge - Supplier, finalizing Lot no identification method.
10 To be filled by HCIL : Approval of Group Officer, In-charge & HOD –NM/MPQ
11 Date of Issue Date of Revision for lot control Display sheet
12 D/C No. Updated Design Change Number of part
13 Part No. Part No. as per Latest HCIL Drawing
14 To be filled by supplier In-charge - Supplier, finalizing Lot no identification
method.

Honda Cars India Ltd.

Page 110 of 193
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4-3 Identification and Traceability

Lot Number Display Details (entry example)

LOT NO DISPLAY DETAILS

PART NO
９００１８－Ｓ００－００００ SUPPLIER NAME
PART NAME ＢＯＬＴ, ＦＬＧ

ENTER LOT FROMING PROCESS AND CIRCLE KEY PROCESS

IMPORTANT PROCESS Material-Cold Working - HeatTraeatment - Galvanizing Release/ inspection

STRUCTURE OF LOT NO ０７０４０４
PROCESS
SELECT

LOCATION OF LOT NO.IDENTIFICATION

On the side of the container.

LOT NO. IDENTIFICATION METHOD Labeling

ILLUSTRATION OF PARTS LOT CONTROL

? Material
① Lot structure : numbering per coil.
② Lot number : 070402A ( reads April 2, '07, steel type: A)
③ Lot control record: record material records in conjunction
with the material lot number.
? Cold working
① Lot structure : total no. of parts processed per day.
② Lot number : 070403A ( reads April 3, 2007)
③ Lot control record: record material lot number in conjunction with total
number of cold-working processes.
? Heat Treatment
① Lot structure : total no. of parts processed per cold working lot.
② Lot number : 070404A ( reads April 4, 2007)
③ Lot control record: record in conjunction with cold-working lot, heat
treatment lot and total of heat treated parts.
? Plating
① Lot structure : total no. of parts plated per heat treatment lot.
② Lot number : 07/04/05 ( reads April 5, 2007)
③ Lot control record: record in conjunction with heat treatment lot, plating lot
and total of plated parts.
? Plating
① Lot structure : inspection lot per plating lot.
② Lot number : 07/04/05 (reads April 5, 2007)
③ Lot control record: record in conjunction with plating lot, inspection lot,
release lot, no. of inspected parts and no. of released parts.

Date of Issue D/C No. New Part No. Prep By Check By App By
Honda Cars India Limited

3.4 Mass Production and Release

3.4.1 The supplier shall start mass production of IPP which has been approved for
Mass production while controlling and following supplier procedures.
3.4.2 The supplier shall comply with the FIFO order and release IPP accordingly.
3.4.3 The supplier shall issue IPP tag for the self-controlled IPP requiring IPP
presentation. The initial lot released shall be identified with the IPP tag and
submitted to HCIL along with the inspection data.
3.4.4 If there are more than one delivery locations, IPP tag shall be attached to each
initial lot released for each of the locations. In the case where an IPP lot is divided
and delivered in multiple containers, attach a supplemental IPP tag to each
container. Handling of supplemental IPP tags may be consulted with HCIL (material
service section) in advance.
3.4.5 If the same IPP is used for multiple parts, i.e. assembled into parts of multiple types
or variations, the supplier may consult with HCIL (Parts quality section) for use of
IPP tags.
3.5 Process Control
3.5.1 The supplier shall monitor the process of IPP after transition to mass production for
a period of one month, as a rule, focusing on the conformity of quality. Length of the
monitoring period may be adjusted at the discretion of the quality assurance
representative or facility quality representative of the supplier.
3.5.2 The supplier shall, in the case where there are any specified items from HCIL on the
control after application to mass production, implement such items.
3.6 Sub-Supplier Control
The supplier shall direct and control its sub-suppliers and ensure IPP control of the same
level as this manual requires for the component parts processed by sub-suppliers.
3.7 Controlling IPP of Supply Parts
3.7.1 The supply parts supplier shall provide supplier parts users of information about IPP
prior to transition to mass production.
3.7.2 The supplier shall, if receiving supply parts with IPP tag attached, ensure
traceability of the IPP and re-attach IPP tag to the initial lot released to HCIL
containing the IPP of supply parts.
3.7.3 The supplier shall, when dividing the IPP lot of supply parts to use for multiple types
or variations of parts, issue and attach a new IPP tag for each initial lot released to
HCIL containing the supply parts IPP.

4 Key point
1) Confirm quality of parts before and after the change, if an unexpected change occurs.
2) In the process of communicating specification change IPP, do not omit or abbreviate
digits of part number in order to prevent miscommunication.
3) When adopting a new material for coated parts, verify its durability, adhesion, etc. by
coating tests.
4) In the event of transferring production, provide the party to which the production is
transferred with necessary information to carry on the same quality control items specified
in standards.

5 Control of Records
No. Type of Record Retention Period
1 Self-Controlled IPP Communication Form One year
2 Record of change points 15 years
3 IPP control IPP 15 years
4 Inspection data attached to IPP 15 years

6 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

Honda Cars India Ltd.

Page 114 of 193
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4-4 Change Point Control

7 Examples of IPP
No. Classification Item Description
1 Specification Specification ・Change to new specification.
change IPP change
・Non-interchangeable specification change is made
・Interchangeable specification change is made.
2 Quality Quality ・Quality improvement is made on the request of the MPQ or market quality
Improvement IPP improvement
section
Self-controlled New supplier
IPP ・Addition of a new supplier (including supplier’s plant expansion).
・Supplier change (including supplier manufacturing facilities).
・Change of destination of delivery.
・Change in manufacturing process from in-house to outsourced, or vise versa.
Material ・Material supplier change
change
・Change of material such as HM-supplied material to self-procured material is
made and vice versa.
・Change of material not related to a specification change
(including rust preventive oil, lubricant , etc.).
Change in ・Change in method of casting or forging.
process
conditions or ・ Change in sintering conditions (process, temperature, time , etc.).
methods ・Change in heat treatment conditions (temperature, time, heating method,
cooling method, etc.)
・Change in molding conditions for rubber and synthetic resin.
・Change in welding conditions.
・Change in cutting conditions.
・Change in machining datum or setting method.
・Change in plating, buffing or coating conditions.
・Change assembly conditions.
Process ・Consolidate, abolish or change in process sequence.
sequence
change ・Change in process from temporary to permanent, or vice versa.
Machining ・Modify or repair of the machine.
process
change ・A new machine is used.
・Machine is relocated.
Jig and tool ・Change in master sample for parts fabrication.
change
・New or modified jigs and tools.
Die/mold change ・Modification or renewal of dies/molds.
Inspection ・New or modified checking fixture or inspection equipment.
method
Change ・Change in measuring instruments or measuring criteria.
Operator ・When a change in operator of critical process, which is particularly
change (*)
designated as a process requiring IPP control Whenever operator change is
made, occurs.
Change in
delivery
method or ・Change in delivery and packaging methods and containers.
delivery
packaging
Operator change: Items require IPP control. Advance notice to HCIL may not be required.

Honda Cars India Ltd.

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4-4 Change Point Control

8 Flowchart
8.1 Change Point Control
S.no Input ACTIVITY TIME Responsibility Output

Training to new operator Head Mfg./ Head Q.A Training Format No

Update Skill Matrix Head Mfg./ Head Q.A Skill Matrix Format
1 (A) Man Power Change
Install Extra Check Head Mfg./ Head Q.A Inspection Report Format

Lot approval. Head Q.A Inspection Report Format

Any major Man power change/ New
1 (B)
parts/Capacity up
2 Material : Any unusual process
Any change required in items
as mentioned in Input. observed in line /
1) Specification change

2) Source change Stop Line/production and Concern Deptt. Supervisor

Inform to concerned
3) Shelf life expire
supervisor
Machine/Jigs/Fixture/Tooling-
3 Change Point Request
(Inspection/production) Prepare Change point
1) Machine/Jigs/Fixture/Tooling- request with Hold the parts and provide
improvement action Concern Deptt. Supervisor Action Plan formet
(Inspection/production)change separate identification
plan
2) Process parameter change

3) Machine/Jigs/Fixture/Tooling
No
repair/Modified PLANT HEAD
Approval Reject the Idea/lot
4 Location :

1) Shifting with in plant/New plant Yes

2) Shifting within sister concern
Prior Information to
HCIL (PUR & MPQ) for Advance Approval Format
shifting To/ From sub supplier Head Q.A
advance approval (HCIL Specific)
Sub supplier change

Advance Approval Format

5 Method Approval Reject the Idea Head Mfg./ Head Q.A
NO (HCIL Specific)
1) Manufacturing method/Inspection
OK
method change-addition/deletion/altretion

2) Manufacturing sequence change

Advance
3) Inspection Qty/Freq change
information or prior
make a trial lot & infromation from
check process respective Deptt
Reject the material and
6 qualification and should reach to Head Mfg./ Head Q.A Test report / Insp. Report
Any repair /rework on part other than prepare new proposal
follow approval NO HCIL before 7days
mentioned in PQCT condtion of implimentation
and in case of
urgent situation

Send parts/ data HCIL as Head Mfg./ Head Q.A IPP Tag
per agreed with HCIL-MPQ
Test report / Insp. Report

Approval NG Reject the remaining Head Q.A Rejection tag / Scrap Note
from HCIL material
IPP Tag / Comunication
through mail / phone
OK

PQCT / OPS / Insp. Std /

Update relavant Head Q.A
documents like PQCT / Etc.
OPS / Insp. Std / Etc if
required and submit to
HCIL

Mass production by following

approval condition (aditional Head Q.A IPP Tag
checks etc)
Inspection results/test report

Record lot detail with change

point detail Head Q.A Change point record formet

Send parts to HCIL with IPP

Head Mfg./ Head Q.A IPP Tag
tag.

Honda Cars India Ltd.

Page 116 of 193
Supplier Quality Manual

4-4 Change Point Control

8.2 Specification change IPP
Supplier HCIL

Contact

Specification change notice.

( notify whether or not a Prior QD-Delivery
Confirmation is required)
Keep track of changes to the Application
specification Change
Instruction

Correction

IPP fabrication,assembly & Inspection Prior confirmation is required

Issue IPP
tag
Prior Confirmation NG
Create Inspection
not required Transition to
Check Sheet M/P
Mass Production
Pre-Production stage

Quality
OK
NG
Judge transition
to MP IPP tag
judged OK

OK Verify IPP
tag

Mass Production
Issue IPP
tag

Attach to the product

Incoming （enter the applicable
Release Inspection VIN No. in IPP tag.）

Mass Production
Control IPP tag Control IPP tag Quality

Honda Cars India Ltd.

Page 117 of 193
Supplier Quality Manual

4-4 Change Point Control

8.3 Quality improvement IPP

Supplier HCIL

Contact

Mass
Quality problem occurred
Production
Quality Quality
Analysis and C/M for improvement
problem request

Correction

IPP fabrication and assembly Response to C/M

NG
Confirm reply and
contents of C/M Mass
Production
Quality Improvement IPP

Quality
Transition to NG
OK
MP

Issue IPP
tag

Create
Inspection
check sheet

Attach to the product

（enter the applicable
Release
VIN No. in IPP tag.）
Mass
Production
Control IPP tag Control IPP tag Quality

Honda Cars India Ltd.

Page 118 of 193
Supplier Quality Manual

4-4 Change Point Control

8.4 Self-Controlled IPP

Honda Cars India Ltd.

Page 119 of 193
To: ____________________________ Advance Notice of Initial production Parts Company/Section Name:________________________________________
Issued On QA Rep Confimration PIC
Part No Planned
Part Name Sudden
Affect Quality Characteristics
Part Characteristic Yes/No Change Items Change Details Reason for Change
Yes/No Affected
Important Quality
Characteristics
Part Inspection Criteria

Others

change
Part Approval

New Supplier
Jig, tool change
Tooling Change

Machine change
packaging change
Transport, delivery

Process Series Change

Chemical Substance

Inspection Method Change

Process condition/ method

Others

HCIL response Supplier Evaluation Results

Schedule Schedule
Assessment Items Evaluation Details Production Delivery

Date
Date Date

Completed

Scheduled Date
9.1 Advance Notice of Initial production Part (Form)

Process Function
Mass production critical
monitoring items after
Validity Test

Page 120 of 193

transition to mass
4-4 Change Point Control

production

Honda Cars India Ltd.

Process FMEA
(Prevention), (Outflow
Prevention),(Past Trouble
Verification) Date Confirmation Submitter Receipt

IPP Measurement

Control No: HCIL Confirmation

・ Process Quality Control Table
・ Operation Control Standards Department Name Department Name
・ Revision/Establishment
・ Operator Training Practice

Homologation Date Confirmation Submitter Receipt Date Confirmation Submitter Receipt

Supplier Quality Manual

Others
HSQF CM0067/JUN'15 Original to be retained untill:
3
To: ____________________________ Advance Notice of Initial production Parts 2
Company/Section Name:________________________________________
Issued On QA Rep Confimration PIC
Part No 6 Planned 1 4
Part Name Sudden
Affect Quality Characteristics
Part Characteristic Yes/No Change Items Change Details Reason for Change
Yes/No Affected
Important Quality
Characteristics
Part Inspection Criteria
10 11 12

Others

change
Part Approval 7 8

New Supplier
Jig, tool change
Tooling Change

Machine change
packaging change
Transport, delivery

Process Series Change

Chemical Substance

Inspection Method Change

Process condition/ method

Others 9
HCIL response Supplier Evaluation Results
Schedule Schedule
Assessment Items Evaluation Details Production Delivery

Date
20
Date Date

Completed

Scheduled Date
Process Function 15 16
Mass production critical
4-4 Change Point

monitoring items after

Page 121 of 193

Validity Test transition to mass

Honda Cars India Ltd.

production

Process FMEA
(Prevention), (Outflow
9.2 Advance Notice of Initial production Parts Form (Entry Procedure)

Prevention),(Past Trouble
Verification) Date Confirmation Submitter Receipt

13 14 19 17
IPP Measurement 21 22

Control No: HCIL Confirmation

・ Process Quality Control Table
・ Operation Control Standards Department Name Department Name
・ Revision/Establishment 23
・ Operator Training Practice

Homologation Date Confirmation Submitter Receipt Date Confirmation Submitter Receipt

Supplier Quality Manual

Others
HSQF CM0067/JUN'15 Original to be retained untill:
To: Honda Cars India Ltd., GNU Factory. MPQ Department
Advance Notice of Initial production Parts Company/Section Name:JNCC Quality Assurance Division Inspection Department
Issued On QA Rep Confimration PIC
Part No 42100－TF0－0030 Planned O
2015/Feb/15 Endo Sato Nishida
Part Name BEAM ASSY, RR AXLE Sudden
Affect Quality Characteristics
Part Characteristic Yes/No Change Items Change Details Reason for Change
Yes/No Affected
Important Quality Welding Process (Inc.) JNCC→JEC (Inc.) welding process transfer of ・welding quality
Yes No
Characteristics control due to process ・parts accuracy
reorganization ・parts strength
Part Inspection Criteria No
① ①

Welding Wire KC－28→KM－50S change due to relocation of line ・welding wire

Others
chemicals

change
Part Approval No

New Supplier
Jig, tool change
Tooling Change

Machine change
packaging change
②Shielding Gas CO2→Gas Blending Ar：CO2＝8：2 ②Change due to relocation of line

Transport, delivery
deterioration

Process Series Change

Chemical Substance Yes No
③New Welding Jig ③launching new jigs due to jig

Inspection Method Change

Process condition/ method

④ ④

Others O O O O

HCIL response Supplier Evaluation Results

Schedule Schedule
Assessment Items Evaluation Details Production Delivery

Date
Date Date

Completed

Scheduled Date
・Requirement quality characteristics /Evaluation
-Process capabilities investigation (n=30) requirement results.
Process Function quality w hole entry 15-Apr 15-May Standards have no difference in quality for goods

15-Mar
15-Mar
-Macro examination （n=5） by SX8 SPEC before and after changes, and the process function
Mass production critical is satisfied at the same time. Maintenance of each
monitoring items after report type and training is complete, and no
Validity Test Unit endurance tester （n=1）vibration endurance
transition to mass

Page 122 of 193

problems are judged regarding mass production

15-Apr
15-Apr
4-4 Change Point Control

production flow.

Honda Cars India Ltd.

9.3 Advance Notice of Initial production Parts Form (Example)

・Welding macro
Process FMEA inspection frequency once
(Prevention), (Outflow Process FMEA implementation of changing point a w eek （regular
Prevention),(Past Trouble entry frequency once a month）

15-Mar
15-Mar
Verification) ・Parts precision
Date Confirmation Submitter Receipt
measurement three
coordinate measuring
IPP Measurement ・Part accuracy （n=5） machine continuously 21-Apr-15 Endo Sato Nishida

15-Apr
15-Apr
n=1/day （regular
frequency testing device HCIL Confirmation
・ Process Quality Control Table ・ Process quality control table / process flow chart / start n=1/day ）
Control No:
・ Operation Control Standards arrangement sequence of components ・Factory person in Department Name Department Name
・ Revision/Establishment ・Operation standard establishment / training charge
15-Mar
15-Mar

・ Operator Training Practice ・Production conditions control chart revision on site rounds 1 time/day

Not Require (Judgement by New Model-Homologation

Homologation Section HCIL)
Date Confirmation Submitter Receipt Date Confirmation Submitter Receipt
Supplier Quality Manual

Others ・confirmation and revision of IMDS registration data

15-Mar
15-Mar

HSQF CM0067/JUN'15 Original to be retained untill:

Supplier Quality Manual

4-4 Change Point Control

9.4 Advance Notice of Initial production Parts Form (Entry Method)
No. Item Entry Method Entered By
1 Issuance Enter date of issue.
Company/ Section Enter company name and section name.
2
Name
To: Enter the receiving quality section and applicable Honda
3
factory for parts delivery.
Submitter/Confirmation/ The submitter, confirmer, quality assurance representative or
4 Quality Assurance facility quality representative add their signature or seal.
Representative
Planned/ Sudden For change details, in the case of planned change points, put
5 [○] in the ''plan'' column, and in the case of sudden change
points, put [○] in the ''sudden'' column.
Part Number/ Part Name Enter in ''change items'' the applicable part number/ part
name in change items. In addition, if there are multiple parts,
6 enter the part number/ part name of a representative part,
and attach on a separate paper the part numbers/part names
of all parts received at the applicable facility.
Yes/No Regarding each part characteristic of changed parts, in
7 applicable cases mark ''Y,'' and in un-applicable cases mark
''N.''
Affect Yes/No Regarding each part characteristic of changed parts, in
8
affected cases mark ''Y,'' and in unaffected cases mark ''N.''
Change Item Enter ''○'' for applicable change items. In addition, if the
Supplier
9 change items are not applicable, enter ''○'' in other, and in
the change content column enter those details.
10 Change Details Insert concrete details regarding change items.
11 Reason for Change Enter the reasons for changes regarding the change details.
Quality Characteristics Enter the quality characteristics that will be affected by the
12
Affected change
Evaluation Details Enter determined evaluation items/evaluation content
regarding quality characteristics affected by change
13 items/change details.
Furthermore, the supplier may attach a separate sheet if
information will not fit on the form.
Schedule Date Enter the schedule date for completing the evaluation
14
details.
Scheduled Enter the scheduled date for beginning mass
15
Production Date production.
Schedule Delivery Date Enter the scheduled date for delivery of the requested parts
16 to the applicable facility.
Mass Production Enter the predominant items for inspection after transition to
Important mass production.
17 Monitoring Items after (general rule 1 month)
Transition to Mass
Production
18 HCIL Response Column for HCIL Use Leave Blank HCIL
19 Completed Date. Enter the date the evaluation details were completed
Supplier Evaluation Enter decision after transition to mass production and
20
Results completion evaluation results.
YYYY/MM/DD Enter the date of the decision for transition to mass
21 Supplier
production.
Submitter/Confirmation/ The submitter, confirmer, quality assurance representative or
22 Quality Assurance facility quality representative add their signature or seal.
Representative
23 HCIL Confirmation Column for HCIL Use Leave Blank HCIL
※Before reporting, enter No. 1-17. When reporting evaluation results, enter 19-22.

Honda Cars India Ltd.

Page 123 of 193
Supplier Quality Manual

4-4 Change Point Control

9.5 IPP Control Format〔IPP〕

C IR C L E A P P L IC A B L E N O .
1 .IN IT IA L P R O D U C T IO N P A R T S
O F S P EC . C H A N G E
2 .Q U A L IT Y IM P R O V E M E N T A C T V IT Y
3 .V O L U N T A R Y IN IT IA L P A R T S C O N T R O L
01
(1 . A D V A N C E Q U A L IT Y C O N F IR M A T IO N )
TO B E C O M P LETED B Y SU P P LIER EXC EP T W H ER E IN D IC A TED IN B O LD LIN ES (2 . S U B M IT A C T U A L IN IT IA L P A R T S )

C O N TRO L N O . 02
INITIAL PRODUCTION PARTS
D ATE O F ISSU E 03
W H ER E "A " A N D "B " A R E C O M M O N ,S T R IK E O U T "A "

A
SU PPLIER O F D EPARTM EN T ISSU IN G PERSO N ISSU IN G D ATE Q U AN TITY LO T N O .

04 05 06 07 08
B
FIRST SU PPLIER PERSO N ISSU IN G D ATE Q U AN TITY LO T N O .

PART N O . - 09

PART N AM E - 10
H O W C H AN G ED
SPEC N O TIC E N O . - 11 12

1 SPEC C H A N G E 6 M A C H IN E C H A N G E
13
2 N EW SU PPLIER 7 JIG /TO O L C H A N G E
3 M A TER IA L C H A N G E 8 D IE/M O U LD C H A N G E

4 M A N U FA C TU R IN G M ETH O D C H A N G E 9 IN SPEC TIO N M ETH O D C H A N G E

5 M A N U FA C TU R IN G PR O C ESS O R D ER C H A N G E 10 TR A N SPO R TA TIO N M ETH O D /TYPE O F PA C KIN G C H A N G E
C IR C LE A P P LIC A B LE N O .

D ELIVER IN ITIAL PRO D U C TIO N PARTS W ITH IN SPEC TIO N RESU LT SH EET
1) SH EET 1 M U ST B E KEPT B Y SU PPLIER O R D EPARTM EN T ISSU IN G
2) SH EET 2 3 4 M U ST B E PASSED TO N EXT PRO C ESS W ITH SIG N ATU RE O F RESPO N SIB LE PERSO N FO R PRO C ESS

SIG N ATU RE O F RESPO N SIB LE PERSO N PRO D U C TIO N LIN E

1 2 3 SU PPLY JU D G EM EN T
FO U R TH SU PPLIER D A TE TH IR D SU PPLIER D A TE SEC O N D SU PPLIER D A TE
PASS - FAIL
14

4 FIR ST SU PPLIER D A TE 5 H O N D A / R EC EIPT D A TE 6 H O N D A / IN SP.D A TE

18
15 16 17

6 Forms
If using both “Rejection Countermeasure Request” or “HTR” and “Analysis Record [Analysis
Report]”, enter the date and number, etc., in order for the “Analysis Record [Analysis Report]”
referred to by the “Rejection Countermeasure Request” or “HTR” and “Analysis Record to be
identifiable.
6.1 n countermeasure request sheet

PROBLEM COUNTERMEASURE DEPT./SUPPLIER DATE: 04

02 A
A P

T
P

R
HCIL
CONTROL T IN-CHARGE O

03
V
DEPARTMENT
05
A

NO 01 N L

A P P ROV E D B Y CHE CK E D B Y M A DE B Y
RANK PROBLEM AREA (Part name + Problem) QTY

06 07 08 11 10 09

OCCURANCE DATE
12 LOCATION
13 PROBLEM (CONTENT,ILLUSTRATION)
FRAME MODEL
14
FRAME NUMBER
15 22
ENGINE MODEL
16
ENGINE NUMBER
17
MISSION NUMBER 18
MISSION TYPE 19 MT AT
DEPT.
20 TEL. NO

CONTACT PERSON
21
DATE REQUIRED: 23
SUBMIT TO:
24

ANALYSIS AND CAUSE COUNTERMEASURE

M ANAGER'S EVELUATION 26
Prepare OPS (New)

Revise OPS (Old)

No need

27
Manager's Sign/ Dat e
Date Verified: 31
C/M STSTUS (MIDDLE,FINISHED) 28 DECISION 32
APPROVED BY CHECKED BY MADE BY Good
C/M BREAKPOINTS Satisfactory
29
DATE F.NO./ E.NO.PROD.LOT.NO. Not Satisfactory

33 34
COUNTERMEASURE APPROVAL DATE
R E M A R KS :
APPROVED BY CONFIRMED BY CHECKED BY
35

HSQF QC 0011/OCT'13

Honda Cars India Ltd.

Page 127 of 193
Supplier Quality Manual

4-5 Corrective Action Report

GUIDELINES FOR PROBLEM COUNTERMEASURE REQUEST

S.NO. PURPOSE/CONTENTS
1 CONTROL NO OF PCR
2 NAME OF DEPT./SUPPLIER TO WHICH PCR IS RAISED
3 INCHARGE OF DEPT/SUPPLIER TO WHICH PCR IS RAISED
4 DATE ON WHICH PCR IS RAISED
5 DEPARTMENT OF HCIL WHICH HAS RAISED PCR
6 RANK OF PROBLEM
7 PROBLEM DETAILS & PART NUMBER
8 NG QTY
9 SIGN OF PREPARING AUTHORITY
10 SIGN OF CHECKING AUTHORITY
11 SIGN OF APPROVING AUTHORITY
12 DATE WHEN PROBLEM OCCURRED
13 LOCATION/ STAGE AT WHICH PROBLEM OCCURRED
14 FRAME, MODEL (E1, E2 etc0
15 FRAME NO OF CAR HAVING PROBLEM
16 ENGINE MODEL (1.3, 1.5, VTEC & AT etc)
17 ENGINE NO HAVING PROBLEM
18 MISSION NO HAVING PROBLEM
19 MISSION TYPE MT OR AT
20 SUPPLIER CONTACT DEPT. & PHONE NO
21 SUPPLIER RESPONSIBLE PERSON
22 PROBLEM DETAILS WITH PICTURE, IF REQUIRED
23 T.D.C. FOR COUNTERMEASURE
24 HCIL-MPQ CONTACT PERSON
25 ANALYSIS OF PROBLEM & CAUSE OF PROBLEM IN DETAIL
26 TICK WHETHER
- NEW OPS IS REQUIRED
- REVISION OF OLD OPS IS REQUIRED
- NO OPS/ CHANGE IN OPS IS REQUIRED
27 SIGN/ DATE OF SUPPLIERS RESPONSIBLE DEPT HEAD
28 CIRCLE C/M STATUS ALREADY COMPLETED OR IN PROGRESS
29 APPROVAL OF ANALYSIS & CAUSE BY SUPPLIERS RESPONSIBLE
DEPT HEAD
30 C/M TO PREVENT OCCURRENCE OF PROBLEM
31 C/M VERIFICATION DATE BY HSCI-PQ
32 DECISION OF PQ ON C/M CONTENTS
TICK WHETHER
- GOOD
- SATISFACTORY
- NOT SATISFACTORY
33 DATE WHEN C/M IS APPLICABLE
34 CUT OFF FRAME/ ENGINE NO.
35 REMARKS RELATED TO C/M TAKEN BY HSCI
36 APPROVAL OF C/M

Honda Cars India Ltd.

Page 128 of 193
HCIL-MPQ
CONTROL NO. - HCIL - MPQ REPORT TO APPROVED BY APPROVED BY
5 PRINCIPLES FOR SECTION OR SUPPLIER NAM E
BE
PROBLEM PROBLEM SOLVING ISSUED BY
DATE APPROVED CHECKED BY PREPARED BY MADE TO
WORKSHEET
DATE

Part check results, factor analysis, quality condition

PROBLEM DEFINITION Symptom, content of Who,What,When,Where. PROBLEM DEFINITION(GRASPING THE FACTS)
1-A complaint frequency… Why, How, How many. 1-B of current part / process

1)WRITE HERE THE DESPATCH DETAIL OF THE PROBLEM LOT 5) IDENTIFY ACTUAL CAUSE IN THE PROCESS FLOW CHART
PART NO :- SHOW IN THE PROCESS FLOW CHART WHERE THE PROBLEM
PART NAME :- DESPATCHED TO HCIL. IDENTIFY THE PROBLEM LOT. ACTUALLYHAPPENED & HOW IT BYPASSED THE EXISTING
MODEL :- SUPPLIER DATE DATE DATE DATE DATE CHECKING PARAMETERS.
SUPPLIER :- LOT QTY
PROBLEM :- DESPATCH TO UNIT 2
DATE :- RECVING AT UNIT 2
HOW IT HAPPEN :- DESP TO HCIL
HOW IT BECAME :-
HOW MANY :- (MENTION FRAME/ ENGINE NO. ALSO)
WHERE :-

2)EXTERNAL OVERVIEW OF THE SITUATION.

(TABLE 1.) PLACE LOT QTY SEG QTY REJ QTY IDENTIFICATION
PLACE LOT QTY SEG QTY REJ QTY STATUS
HCIL AF LINE

W/H
3)SHOW ANALYSIS OF THE NG PART
WRITE QTY:

OK: COMPARE SPEC VS ACTUAL & FINAL RESULT.

NG: PARAMETER SPEC OBSD RESULT
NOTE:MATCH QTY OF TABLE 1 & TABLE 2.

6)CONFIRM THRU SIMULATION TRIAL FOR THE OUTFLOW CAUSE

IDENTIFIED.
4)THE PROBLEM WHICH HAS OCCURRED ,CAN IT OCCUR IN ANY OTHER CAR IN
AF/VQ/CBU/MARKET.
2-A
IDENTIFY ROOT CAUSE ( QUESTION AND ANSWER ) From Fishbone Chart Question and answer analysis
2-B IDENTIFY ROOT CAUS E problem and occurrence process
duplication test

Page 129 of 193

Honda Cars India Ltd.
4-5 Corrective Action Report

Content of c/m prediction of HOROZONTAL DEPLOYMENT

4 CONFIRM COUNTERMEAS URE(S ) Actual effects 5
3 CORRECTIVE COUNTERMEAS URE (S ) effects, potential problem analysis.

NO FURT HER OCCURRENCES

Supplier Quality Manual

FOLLOW-
UP DATE

HSQF CM 0062/OCT'13
HSCI-PQ
X X - Y Y - Z Z 5 PRINCIPLES FOR HSCI - PQ REPORT TO
CONTROL NO. -
SECTION OR SUPPLIER NAME BE APPROVED BY APPROVED BY
PROBLEM PROBLEM ISSUED BY MADE TO
DATE PREPARED BY CHECKED BY APPROVED BY
SOLVING
DATE
WRITE THE ACTUAL PROBLEM REPORTED. WORKSHEET
Part check results, factor analysis, quality condition of
1-A PROBLEM DEFINITION Symptom, content of Who,What,When,Where. PROBLEM DEFINITION(GRASPING THE FACTS)
1-B current part / process
complaint frequency… Why, How, How many.
1)WRITE HERE THE DESPATCH DETAIL OF THE PROBLEM LOT 5) IDENTIFY ACTUAL CAUSE IN THE PROCESS FLOW CHART
PART NO.: WRITE HSCI PART NO. WRITE HOW MANY PARTS WERE MADE & WHEN & IN HOW MUCH QTY THESE WERE SHOW IN THE PROCESS FLOW CHART WHERE THE PROBLEM
PART NAME: WRITE NAME OF PART DESPATCHED TO HSCI. IDENTIFY THE PROBLEM LOT. (SEE A TYPICAL EXAMPLE)TABLE 2 ACTUALLYHAPPENED & HOW IT BYPASSED THE EXISTING
SUPPLIER: SUPPLIER DATE DATE DATE DATE DATE CHECKING PARAMETERS.
PROBLEM: WRITE ACTUAL PROBLEM REPORTED IN THE VEHICLE LOT QTY 520
DATE: DESPATCH TO UNIT 2 520 CHECK WHY IT OUTFLOWED.CRITICAL POINTS OF OUTFLOW TO BE
HOW IT HAPPEN: WRITE HOW THE PROBLEM WAS ACTUALLY OBSERVED IN VQ/AF/INCOMING RECVING AT UNIT 2 520 SEARCHED.
HOW IT BECAME :WRITE THE IMMIDIATE CAUSE OF THE PROBLEM WHICH IS EVIDENT VISUALLY/BY DESP TO HSCI 220 300 METHOD OF FINDING THE CAUSE:
MEASUREMENT LOT HAVING PROBLEM PART TO BE SEGREGATED.TAKE JUDGEMENT FOR WITHDRAWL -IN WHICH PROCESS IT HAS OCCURRED
HOW MANY: WRITE QTY & BATCH CODE OF THAT LOT IF REQD.WRITE THE ACTUALS IF WITHDRAWL DONE. -HOW THAT PROCESS IS CONTROLLED
WHERE: WRITE STAGE AT WHICH THE PROBLEM WAS REPORTED. WRITE THE MEASURE TAKEN FOR CARS FROM WHERE THE WITHDRAWL IS NOT POSSIBLE. -WHY IT OUTFLOWED WITH EXISTING CONTROL METHOD
WRITE THE REASON WHY THE LOT OTHER THAN THE TROUBLE ONE IS TO BE USED. -HOW IS THE RULE TO PREVENT OUTFLOW & CAN RULE BE
FOLLOWED
NOW WRITE THE OK /NG STATUS OF THE PART AT LINE & WARE HOUSE 2)EXTERNAL OVERVIEW OF THE SITUATION. -WAS THERE ANY PROBLEM WITH THE USUAL WORKING METHOD.
WRITE LOT DEATIL AT SUPPLIER END & CONFIRMATION RESULT OF ALL PARTS CHECKED.
(TABLE 1.) PLACE LOT QTY SEG QTY REJ QTY IDENTIFICATION DO THE CRITICAL POINT ANALYSIS FOR THE PROBLEM OCCURRED
PLACE LOT QTY SEG QTY REJ QTY STATUS SEARCH METHOD FOR CRITICAL POINTS & RAISE ALL THE CRITICAL POINTS
HSCI AF LINE MENTION WHERTHER ANY WITHDRAWL FROM LINE WAS REQD LIKE MAN,MACHINE,TIME,CONVEYOR METHOD,RAW MATERIAL,CONTROL
W/H MACHINE ,RULE ETC.(I.e. MAKE CAUSE & EFFECT)

3)SHOW ANALYSIS OF THE NG PART .ATTACH RANK TO THE CRITICAL POINTS CONNECTING TO PROBLEM.
WRITE QTY: SHOW DIMENSIONAL ANALYSIS/PERFORMANCE REPORT STRIKE OUT THE CRITICAL POINTS WHICH ARE TAKEN CARE AT ACTUAL WORK
OK: COMPARE SPEC VS ACTUAL & FINAL RESULT. PLACE.FOR REMAINING CRITICAL POINTS JUSTIFY THEM BY DOING THE
NG: PARAMETER SPEC OBSD RESULT SIMULATION TEST.
NOTE:MATCH QTY OF TABLE 1 & TABLE 2.

CONCLUDE THE PROBLEM AREA IN THE PART & SHOW PHOTOGRAPH IF REQD 6)CONFIRM THRU SIMULATION TRIAL FOR THE OUTFLOW CAUSE
IDENTIFIED.
4) THE PROBLEM WHICH HAS OCCURRED ,CAN IT OCCUR IN ANY OTHER CAR IN METHOD OF UNDERSTANDING THE FACTS.:
AF/VQ/CBU/MARKET.CONFIRM THE RESULT THROUGH SIMULATION TRIAL ALL THE REPLIES YOU GET FOR INVESTIGATION POINTS TO BE WRITTEN IN
IF IT CAN HAPPEN THEN DEFINE CLEARLY WHAT THE MEASURE WILL BE TAKEN & HOW. MEMOS & THEN ARRANGED IN PROPER ORDER.
CORRECTIVE COUNTERMEASURE (S) Question and answer analysis
2-A IDENTIFY ROOT CAUSE ( QUESTION AND ANSWER ) From Fishbone Chart 2B IDENTIFY ROOT CAUSE problem and occurrence process
duplication test

WHY WHY WHY WHY -WRITE THE MECHANISM OF OCCURRED PROBLEM(I.e. OCCURRENCE ROUTE CAUSE)
WHY
(IF WE DO THE SIMULATION TEST WE WILL UNDERSTAND THE MECHANISM)
-DONOT WRITE THE MECHANISM OF VEHICLE PROBLEM .WRITE THE SIMULATION TEST RESULT.
WRITE THE CAUSE OF OCCURRENCE
-WRITE ROUTE CAUSE OF PROBLEM IN PART.DONOT WRITE VEHICLE PROBLEM CAUSE.

Page 130 of 193

DO WHY-WHY ANALYSIS DO IT TILL ROOT CAUSE
-WRITE WHY THE CAUSE EXISTED .(IF THERE IS ONLY ONE CAUSE.)

WRITE ACTUAL

Honda Cars India Ltd.

-OUTFLOW CAUSE:
PROBLEM WRITE THE CAUSE FOR TROUBLE OUTFLOW.
REPORTED (THERE IS ONLY ONE CAUSE)

WRITE THE CAUSE OF OUTFLOW

DO WHY-WHY ANALYSIS DO IT TILL ROOT CAUSE

4-6 Corrective Action Report

Content of c/m prediction of effects, 4

3 CORRECTIVE COUNTERMEASURES potential problem analysis. CONFIRM COUNTERMEASURE(S) Actual effects 5

RESP TDC
NO FURTHER OCCURRENCES
COUNTERMEASURE FOR OCCURENCE CAUSE: CONFIRM THE C/M TAKEN & WRITE THE RESULTS OF EFFECTIVENESS AFTER
THE C/M IMPLEMENTATION DATE.
-TAKE COUNTERMEASURE FOR THE FINAL ITEM OF WHY WHY ANALYSIS. IDENTIFY THE PROCESSES IN WHICH THE SIMILAR
(COUNTERMEASURE CONTENT IS ONLY ONE.) TYPE OF C/M CAN BE IMPLEMENTED TO AVOID ANY
-IF CAUSE COULDN'T BE SQUEESED THEN THERE ARE MORE COUNTERMEASURES FURTHER OCCURENCES.
-IN CASE IT IS TAKING LONGTIME FOR PERM C/M THEN TAKE TEMP C/M.
-IMPLEMENT IT BY MAKING A PLAN.
-C/M FOR OUTFLOW CAUSE:

-TAKE C/M FOR THE FINAL ITEM/OUTCOME OF WHY-WHY ANALYSIS

(WHEN C/M CONTENT IS ONLY ONE)
-IF CAUSE COULDN'T BE SQUEESED THEN THERE ARE MORE COUNTERMEASURES
-IN CASE IT IS TAKING LONGTIME FOR PERM C/M THEN TAKE TEMP C/M.

NOTE:
-MUST ADD C/M DATE
APPLIED LOT TO BE WRITTEN.
Supplier Quality Manual

FOLLOW-UP
DATE

Honda Cars India Ltd.

Page 133 of 193
Supplier Quality Manual

4-5-1 Delivery Quality Problem

7 Flowchart

Supplier HCIL
Contact

Discovery of Discovery of
problem parts problem parts.
Preliminary analysis Mass
Production
Quality
Issue
Investigate if problem Countermeasure
parts w ere shipped out Request
to the destination. or 5 Why
NO

YES
Take
measures to
the parts Notify
Verify
delivery destinations

Analyze causes and

take measures.
Handling of problem Mass
parts Production
Quality
Dispose Identify parts
parts to be
Return

Modify
Mass Production Stage

Inspect

NG Mass
Judge Production
Quality
Put back into
manufacturing
process
OK

Concession

Mass
NG Production
Judge
NG or OK Quality

Put back into OK

manufacturing
process

Reply to
Countermeasure Verify
Request, or 5 Why

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4-5-1 Delivery Quality Problem

8 Forms
8.1 Deviation Note for Parts (Blank format)

Honda Cars India Ltd.

DEVIATION FORM
CONTROL NO : DATE :
1 2

PART NO : 3 PART NAME : 4

PREP BY CHKD BY HCIL (QD)
SUPPLIER : 5
6 7

PROBLEM DETAILS (ILLUSTRATION):

QTY :
9
REASON FOR DEVIATION : COUNTERMEASURE (TEMP./PERMANENT):

11
10

APPROVAL ROUTE :
DEPTT NAME JUDGEMENT COMMENTS APPRV BY

12 13 14 15

DATE OF APPLICATION………………….. 16
18 19
VIN No/EIN No:………………………….. 17 SIGN SIGN

HSQF QC 0060/OCT’13

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Deviation Note for Parts ( Entry procedure)

No. Entry procedure

1 Enter Control No. (To be given by HCIL)

2 Deviation From Raising date
3 Enter part number
4 Enter part name
5 Enter Supplier or department name
6 Enter Signature of the requesting person (Supplier)
7 Enter Signature of responsible person of the Purchasing
8 Enter type of problem
9 Enter requested quantity
10 Enter the reason for deviation
11 Enter the temporary & permanent countermeasures
12 Enter the approval route (To be given by HCIL)
13 Enter the final judgment ( OK/ NG ) by concerned department
14 Enter the comment by Concerned department
15 Signature of the responsible person of the concerned department
16 Enter date of application
17 Enter VIN/EIN number
18 Verification Signature of the Section Head of MPQ
19 Authorization by Dept Head of MPQ

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4-5-2 Market Quality Problem

1 Overview
1) HCIL shall, where problem occurs in the market after products are sold, and where the
problem is deemed attributable to the supplier from which the concerned parts were
purchased, request the supplier to perform analysis of the problem and to take preventive
measures against recurrence.
2) The supplier shall analyze market problems required by HCIL, and if it is attributable to its
own conduct, take measures to prevent the problem from recurring.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Terms Definition
A part that was recovered from a marketed product as a
1 Call-in part possible problem part and collected from the market by HCIL
for analysis of causes.
3 Requirements
3.1 Analysis and Measures of Market Quality Problem
3.1.1 The supplier shall, if HCIL issues “Market Quality Information [Analysis /
Countermeasure Request], analyze the details of the problem in compliance with
the request, and take measures if the cause is attributable to its conduct.
3.1.2 The supplier shall respond to HCIL by submitting an “Analysis Record [Analysis
Report]” with photographs, data, etc. attached by the date specified on “Market
Quality Information [Analysis / Countermeasure Request]
(refer to SQM 4-5 Corrective Action Report for the use of [Analysis /
Countermeasure Request]) .
3.1.3 The supplier shall, if response due date cannot be met, issue an interim report
including reasons for the delay.
3.1.4 The supplier shall obtain call-in parts and related information from HCIL for
improvement of part quality and reliability. The supplier shall be aware of how its
parts affect customers of HCIL products, and perform analysis of problems in a
positive manner.
3.2 Monitoring of Market Quality Information
3.2.1 The supplier shall review, monitor, and analyze market quality information via
electronic data distributed by HCIL, and continuously seek to reduce market quality
problems.
3.2.2 The supplier may request HCIL for additional call-in parts, if the need for further
investigation arises from a result of its own autonomous analysis on market quality
information. However, HCIL may confer with the supplier for reimbursement of
transportation costs, etc. incurred due to recovery of the parts.
3.2.3 The supplier shall report the results of investigation, analysis, etc. to HCIL’, if
received call-in parts from HCIL.
3.2.4 The supplier shall keep the recovered parts provided by HCIL under control.
Consideration shall be given to the storage place to maintain confidentiality.
4 Key point
1) When identifying the subject parts at the time of nonconformity occurrence, all
manufacturing lots including ones shipped to overseas facilities shall be included in the
scope.

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4-5-2 Market Quality Problem

5 Control of Records
No Type of Record Retention Period
1 Supporting data to Analysis Record [Analysis 10 years
Report]

6 Reference Materials
1) SQM 4-5 Corrective Action Report
2) SQM 6-1 Glossary of Terms and Definitions

7 Flowchart
7.1 Flowchart for treating market quality information.

Supplier HCIL

Contact

Monitor and analyze market Obtain market quality

quality information information and actual parts Market
Primary analysis Quality

Request collection of
Collection
problem parts.

Request supplier to provide

Obtain market quality
analysis and contermeasure Mass
information and actual parts
Mass Production Stage

Market Quality production

Information Quality
[Analysis/Countermeasure
Request]
Analysis, C/M and reccurence
prevention.
Verify accuracy of parts
Verify processes.
reproduction test
countermeasure
Recurrence prevention, etc.

Mass
Report results Verify results production
Analysis Record Quality
[Analysis Report]

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4-5-2 Market Quality Problem

7.2 Flowchart for scope identification when nonconformity occurs.

Supplier HCIL

Contact

-Information
-Problem description
-Part name
-Part number
- Vehicle identification number Market Quality
-Date of production

-Verify production history

-Check shipping records
-Examine change points, etc.
in the manufacturing process.
Mass Production Stage

-Determine production volume

-Investigate sub-suppliers, etc.

-Identify the scope of the problem

-Including those that were shipped
out to other Honda facilities
overseas.

Notify the scope and destination of

problem parts. Market Quality
Identify the scope

Take
countermeasure
Market Quality

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4-6 Specification Change

1 Overview
1) HCIL shall provide requirements to ensure a smooth implementation of the specification
change issued by HCIL to suppliers.
2) The supplier shall establish procedures to process specification changes to parts in
accordance with the requirements of HCIL.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No Term Definition
A change to the entry in the field for notating
1 Specification change changes to component parts in the product drawing
or specification change notice.

3 Requirements
3.1 The supplier shall respond to HCIL by the date specified, if HCIL requests a survey for
specification change by issuing a specification change questionnaire or by other means.
3.2 The supplier shall implement the following when HCIL issues a specification change
notice.
3.2.1 Review concerned drawings (specifications, etc. included) by using electronic data
processing system or other methods. The drawings (specifications, etc. included),
may be provided along with the specification change notice.
3.2.2 The supplier shall, when received a specification change notice, review details of
the change, examine the following items, and respond to HCIL by the date
specified.
1) Application timing
2) Compensation for tooling
3) Compensation for parts
4) Changes in cost
5) Remarks and others
3.2.3 If prior confirmation is required in the specification change instruction, follow the
procedure set forth in SQM 4-4 Change Point Control for the confirmation.
3.2.4 If the need arises to change Process FMEA, process quality control table, operation
standard, etc. along with the specification change, implement such changes.
3.2.5 Comply with SQM 4-4 Change Point Control for IPP control as a result of
specification change.
3.2.6 If the need arises to change the application timing stated in specification change
notice, immediately inform HCIL of new timing of application.

4 Key point
1) The order of specification change shall be controlled by the order in which the changes
were applied. The supplier shall verify the revision level when using drawings.
5 Control of Records

No. Type of Record

Retention Period
1 Initial Product Control [Initial Production Part] 15 years
2 Inspection data attached to IPP 15 years

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4-6 Specification Change

6 Reference Materials
1) SQM 4-4 Change Point Control
2) SQM 6-1 Glossary of Terms and Definitions

7 Flowchart to be followed when a specification change is directed by HCIL.

Supplier HCIL

Contact

Investigate Issue Specification QD- Delivery

Change Questionnaire
Return by the date
specified
Fill in the
questionnaire

Issue Specification QD- Delivery

Change Notice

Verify drawings, etc.

Return within 5
business days.
Mass Production Stage

Complete
Specification Change
Receive
Notice QD- Delivery
When application timing
notified was changed
Receive
QD- Delivery

Revise process quality

control table, operation
standard, etc.

Apply specification
change

Control change points

(IPP control)

See (SQM 4-4 Change Point Control)

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4-6-1 Countermeasure Request Form

1 Overview
1) HCIL shall provide suppers with procedure for requesting a specification change.
2) The supplier shall request HCIL for a specification change while identifying the need for
specification change.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No Term Definition
An action to be taken by a supplier to request HCIL for a
Countermeasure change to the drawings (specifications, etc., included) by
1
request using “Countermeasure Request [Countermeasure Request
Form]”.

3 Requirements
3.1 The supplier shall make a countermeasure request to HCIL for a specification change of
parts by submitting a “Countermeasure Request [Countermeasure Request Form].
The supplier shall review the following items before making a countermeasure request
and clearly define the need for the specification change by providing the related data
attached.
1) Purpose of the countermeasure request (e.g. quality improvement, workability
improvement, cost reduction, etc.)
2) Evidence for the validity of the countermeasure request (e.g. prove that the root
cause of a problem is attributable to the specification).
3) History of previous countermeasure requests of the same kind (e.g. if a duplicate
request exists, investigate the reason for the request not being processed).
4) Effectiveness of a countermeasure request (e.g. if a specification change is effective
to solve problem and if the change will not cause secondary problems).
5) Cost performance (e.g. if the benefits will justify increased costs for parts)
3.2 The supplier shall submit “Countermeasure Request [Countermeasure Request Form] “to
HCIL’s purchasing-cost or procurement section.
Countermeasure requests shall be submitted prior to establishing permanent tooling at
the production preparation stage, however, in cases where one of the following conditions
applies, submission of a countermeasure request on a case-by-case basis will be
accepted.
1) Countermeasure request for regulatory or safety noncompliance issues.
2) Countermeasure request which may result in an increase in production capability, a
significant increase in workability or quality, or a significant reduction in costs, etc.
3) Countermeasure request which is not for current parts, but is expected to apply in the
future.
3.3 The supplier shall receive a decision from HCIL for the proposed” Countermeasure
Request [Countermeasure Request Form] “.
4 Control of Records
No. Type of Record Retention Period
Countermeasure Request
1 5 years
[Countermeasure Request Form]
Supporting data to Countermeasure
2 5 years
Request [Countermeasure Request Form]

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

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4-6-1 Countermeasure Request Form

6 Forms
6.1 Countermeasure Request Form (blank)
対策要求｢対策要求票」重要度 PRIORITY 発行DATE :
試作・量産・立上 PROTOTYPE .
COUNTERMEASURE REQUEST MASSPRODUCTION. START UP 推進No
1/1
FORM A.B.C CTRL
NO.
認証
申請区(REQUEST ＤＥＰＴ．) TEL NO. : 購買ＣＰ資材ＰＵＲ品管ＱＣＤＥ部門ＳＳ設計ＤＥＳ。Ｄ部門ＨG
CERTF
DATE: . . . . . . . . . . . . . .
責任者責任者担当者責任者責任者責任者責任者最終責任者責任者最終責任者
RESP. RESP. CHARGE RESP. RESP. RESP. RESP. ＦＩＮＡＬＲＥＳＰ RESP. ＦＩＮＡＬＲＥＳＰ

イベントカテゴリー：部品名

機種MODEL:
EVENT: ＣＡＴＥＧＯＲＹ P. NAME
部番
標題TITLE:
DWG. NO.

目的：ＣＯＤＥ原因ＣＯＤＥ仕向地通知NO

PURPOSE ＮＯ. ＣＡＵＳＥＮo.: VARIATION:
-
REVIS No.:
- -
内容
DESCRIPTION :

対策案
項目 OLD NEW 差DIFFERENCE
PROPOSED COUNTERMEASURE :

COST 変動DIFFE.

WT 変動DIFFE. - - -
新規追加投資
INVESTMENT￥ - - -
損失 LOSS (DIE REP.) - - -
OVERHEAD

型改修日程確認CHECK
-
DIE MODIFICATION
SCHEDULE

品管部門 QCＤ、（課)ＳＥＣＴ

ＳＰＲ

ＨＳ

回答部門記入欄 COLUMN OF REPLYING DEPT. OK NG RETURN HOLD

部門名担当予定日
DEPT CHARGE EXPECTED DATE:

通知NO.
REVISION NO.

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4-6-1 Countermeasure Request Form

6.2 Countermeasure request form (entry procedure)

対策要求｢対策要求票」重要度 PRIORITY 発行DATE : 5
試作・量産・立上 PROTOTYPE .
COUNTERMEASURE REQUEST MASSPRODUCTION. START UP 推進No
1/1
FORM A.B.C CTRL
NO.
認証
申請区(REQUEST ＤＥＰＴ．) TEL NO. : 6 -b 購買ＣＰ資材ＰＵＲ品管ＱＣＤ
CERTF
Ｅ部門ＳＳ設計ＤＥＳ。Ｄ部門ＨG

DATE: 6 -c . . . . . . . . . . . . . .
6 -a 責任者責任者担当者責任者責任者責任者責任者最終責任者責任者最終責任者
RESP. RESP. CHARGE RESP. RESP. RESP. RESP. ＦＩＮＡＬＲＥＳＰ RESP. ＦＩＮＡＬＲＥＳＰ

6 -d 6 -e

イベントカテゴリー：部品名

機種MODEL: 9 -a EVENT:
10 -a ＣＡＴＥＧＯＲＹ
10 -b P. NAME
11 -a
部番
標題TITLE: 9 -b DWG. NO. 11 -b
目的：ＣＯＤＥ原因ＣＯＤＥ仕向地通知NO
12 13 -
14 - 15 -
PURPOSE ＮＯ. ＣＡＵＳＥＮo.: VARIATION: REVIS No.:
内容
DESCRIPTION :

対策案
項目 OLD NEW 差DIFFERENCE
PROPOSED COUNTERMEASURE :

COST 変動DIFFE.
18 -a

WT 変動DIFFE. - 18 -b -
17 新規追加投資
INVESTMENT￥ - 18 -c -
損失 LOSS (DIE REP.) - 18 -d -
管理費 OVERHEAD
［千/＄/£］
18 -e

型改修日程確認CHECK
18 -f
-
DIE MODIFICATION
SCHEDULE

品管部門 QCＤ、（課)ＳＥＣＴ

ＳＰＲ

ＨＳ

回答部門記入欄 COLUMN OF REPLYING DEPT. OK NG RETURN HOLD

部門名担当予定日
DEPT CHARGE EXPECTED DATE:

通知NO.
REVISION NO.

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4-6-1 Countermeasure Request Form

Countermeasure request form (entry procedure)

6.2.1 Issuing of Countermeasure Request Form

6.2.1.1 Submit one page for one case
In cases where there are numerous part numbers (parts and models, etc.), a list may be
attached on a separate sheet.
6.2.1.2 Requirements for Issuing Countermeasure Request Form
Note1) If entry is unnecessary, or the subject is non-applicable, write a forward slash in the
entry field.
Note2）The ‘’P S M’’ in the ‘’entered by’’ column indicate that entry is necessary in the P, S,
and M periods respectively. (prototype, start-up, mass production)
Note3) When applying from an electronic processing system, etc., the standard's content will
be changed to match the format.
No. Item Description
①～④ For HCIL use only (no number is provided in entry procedure 1/6).
⑤ Page Enter the total number of pages as the denominator.
⑥ Request ⑥-a Request dept: enter the company name, plant name and
department section name.
⑥-b. Phone number: enter the phone number.
⑥-c Date: Enter the date (month, date, and year) on which the
responsible person signed.
⑩-Enter other dates in the same manner.
Ref) date (Arabic numerals), month (English) and year ( last
2
digits of the year in the western calendar)
⑥-d Responsible person (left): if not applicable, cross out with a
diagonal line.
Responsible person (center): enter the name of the person
responsible for the entry of data into this form.
⑥-e Person prepared (right) : person who prepared this form.
⑦、⑧ For Honda use only (no number is provided in entry procedure
1/6).
⑨ Model ⑨-a Enter the code of a model subject to countermeasure
(code).
Enter the part type number provided in the “DWG No.”
section (part number or drawing number) in the drawing title
block.
In cases where multiple model names do not fit in the entry
section, enter the information in the description column or
attach on a separate sheet.

Enter the part number provided in the DWG No. in the

drawing title block or part category number of the drawing
number.

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4-6-1 Countermeasure Request Form

Countermeasure request form (Entry procedure)

No. Item Description
⑨ Title ⑨-b Explain details of the request briefly with part name,
expected
outcomes (target),etc. (example: heat resistance of XX,
interference prevention for XX, etc.)
⑩ Event ⑩-a Enter the event if there is one that resulted in a request and
it is necessary to specify.
However, if the event is unknown or the necessity of entry
is not certain, consult HCIL before making an entry. If the
entry of event is needed, cross out this section with a
diagonal line.
Category ⑩-b Enter the category of subject parts. Consult HCIL if
information to be included in this section is unknown before
making an entry. E.g.: B-F21
⑪ Part Name ⑪-a Enter the name of the subject parts.
Enter the information provided in the NAME section (part
name or drawing name) in the drawing title block.

Enter the part name or drawing name in the latest drawing

in full.
Part Number ⑪-b Enter the number of the subject part or drawing.
or Drawing If applicable, enter the information provided in the DWG.No.
Number section (part number or drawing number) in the drawing title
block.

※ Enter part name or drawing name in the latest drawing

in full.
※Do not enter the prototype part number during mass
production countermeasure requests or the facility
preparation part number.
※If a countermeasure request is made for multiple parts, all
part numbers or drawing numbers of own production that
may be affected are included in the part number section or
in a separate sheet.
※If more than two countermeasure requests are made for
a part, prepare a countermeasure request form for each
case

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4-6-1 Countermeasure Request Form

Countermeasure request form (Entry procedure)

No. Item Description

⑫ Code No. Enter the applicable purpose code number (refer to the following
table).
No. Purpose of CM Request
1 Quality (except no. 2 through no. 5).
2 Improve durab lity (strength, weather resistance, heat
resistance, low-temperature res stance)
3 Eliminate interference and secure clearance (except wiring or
piping).
4 Improve wiring and piping.
5 Improve anticorrosive quality.
6 Improve marketable value ( except no.7)
7 Reduce vibration and noise, and improve steering stability and
ride quality.
8 Improve maintainability.
9 Increase productivity (process ability, workability)
10 Facilitate common use and consolidation.
11 Carry out VA and reduce cost.
12 Maker/supplier layout.
13 Facilitate procurement.
14 Simplify parts control.
15 Comply with criteria, standards, or regulations.
16 Response to patent issues.
17 Correct errors in bill of material and drawing, and put them
(except 18) in order.
18 Rationalize drawing formation.
19 Release finished drawing.
20 Address problem for in-use vehicle.
21 Meet special procurement demand.
22 Add specification (including knock-down parts).
23 Others (no responsible section).
⑬ CODE No. Enter the cause code that is most appropriate (refer to the following
Cause code table).
no. No. Reasons for Countermeasure Request
1 Release of drawings for remaining items.
2 Error on drawing.
3 Error in bill of material.
4 Imperfect design (layout, interference, requirement)
5 Insufficient adjustment by test .
6 Poor communication among HG sections concerned.
7 Improvement of assemble-ability and process-ability that are
verifiable only in the mass production line (request from
production line, manufacturer, etc.).
8 Insufficient study by plant, EG or manufacturer. (insufficient
adjustment among sections in charge of actual operation).
9 Unexpected external factor.(Influence of other companies, top
management direction, specification change request from
sales section.
10 Event.(VA, lightweight contest, electro deposition verification,
wiring verification, maintainability verification, noise
verification, etc.)

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4-6-1 Countermeasure Request Form

Countermeasure request form (Entry procedure)

No. Item Description
⑬ CODE No. No. Reasons for Countermeasure Request
Cause code 11 Market quality information, etc.
no. 12 Others.
⑭ Variation Cross out with a diagonal line.
⑮ Revis. no. Enter the final notice number of the part (base part) subject to
countermeasure request.
If applicable, enter the part type number provided in the “DWG No.”
section (part number or drawing number) in the drawing title block.

Enter the final notice number of the revision record.

⑯ Description Describe the phenomenon (request contents) clearly and concisely.
Where possible, illustrate the phenomenon.
If data, etc., are available, attach them (detailed as much as
possible).
※ Suppliers to describe HCIL locations to which they deliver parts
(including overseas), because parts subject to countermeasure may
be used in multiple HCIL products as part of parts.
⑰ Proposed Describe proposed countermeasure against phenomenon clearly
C/M and concisely. Where possible, illustrate the phenomenon.
If data, etc., are available, attach them (detailed as much as
possible).
Regarding countermeasures, when it is necessary to coordinate
verification with the related HCIL sections, a prior request is
necessary. Also, when coordination with related HG occurs, the HG
representative‘s full name and HG to which he/she belongs is filled
in.
⑱ Effects of Calculates the amount if the countermeasure is applied and enters
C/M the amount.
OLD: cost before countermeasure. New: cost after countermeasure.
Diff: difference between OLD and NEW.
⑱-a Cost difference-calculate the cost incurred by the requesting
section.
⑱-b WT difference – the requesting section calculates the
difference in weight.
⑱-c New investment – calculate the cost needed by the
requesting section.
⑱-d Loss – calculate the cost incurred in die modification,
disposition, etc. due to countermeasure.
⑱-e For HCIL use only ( no entry required)
⑱-f Die modification schedule – enter schedule of die
modification.
Check For HCIL use only (no entry required).
Note: cross out fields that will not be affected and no entries to be
made with a diagonal line.

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5-1 Process Capability

5 Reference
5-1 Process Capability

1 Overview
This manual is to provide basic concepts and points to consider for evaluating process
capability to prove that a manufacturing process has the ability to consistently achieve
intended quality levels, and for taking actions to the outcome of such evaluation.
2 Definitions
The definitions of terms used in this manual are as follows. Refer to (SQM 6-1 Glossary of
Terms and Definitions) for other terms.
No. Terms Definition
Process The ability to achieve quality requirements of a process in a controlled
1
capability state.
A quantified measure of process capability, and “a value calculated by
Process dividing the specification range by 6σ for a certain characteristic”
2 capability ”Process in a controlled state” in the definition above for process capability
Index means that the characteristic value is normally distributed, and this forms
the basis of the process capability index.
One of the numeric values which correspond to the distribution of
Standard
3 statistical values and random variables, and expressed by σ.
deviation
6 σ represents the value of σ (standard deviation) multiplied by six times.
50 %
Setting up of inspection standard tolerance at 50 percent of the
4 Tolerance
tolerance specified on drawings.
limit band

3 Requirements
3.1 Concept of Process Capability
Process capability is the ability of a stable process to achieve the required quality, and
which is expressed by X±3σ representing the distribution range of dispersion of product
quality produced by a standardized process.

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5-1 Process Capability

3.2 Process Capability Index.

Process capability index is expressed as Cp (an index used when the center (=
average) of the distribution of data plotted at the median between the upper and lower
limits) or Cpk (used when the mean is displaced from the center between the upper and
lower limits).
The “k” in Cpk stands for “Katarori” in Japanese language for shift or offset.
3.2.1 Process Capability Index (Cp)
Compare the deviation range 6σwith the product specification range and
determine the ability of a process to manufacture products meeting required
specifications.
Cp＝ specification range / 6σ (if a single specification limit, Cp＝｜specification
limit － mean｜/3σ).

1) If Cp ≧ 1.00, the process capability is not considered adequate, however

almost no nonconforming products will be produced.
(99.7% or more products are within the specification range): perform a
thorough process control and maintain it in a controlled state). if Cp becomes
close to 1, there will be a possibility that nonconforming products will occur,
so take appropriate actions as necessary.
2) If Cp ≧ 1.33, the process capability is considered adequate.
(99.99 % or more products are within the specification range): this is an ideal
state so maintain.
3.2.2 Process Capability Index (Cpk)
Even if Cp ≧ 1, nonconformity can occur if the mean value is displaced from the
center of the specification limits. Use Cpk process capability index for judgment,
which takes deviation into consideration.
Take appropriate action for the mean value to be the center of the specification
limits
if the mean is shifted from the center.

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5-1 Process Capability

3.3 Calculation of Process Capability Index

The followings are examples of calculation of process capability.
Relationship bet/ distribution
Classification Formula Calculation Example
and specification limits
Both-sided specification limits

Cpk
Single-sided specification limits

Upper
limit
(SU)

Lower limit
(SL)

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5-1 Process Capability

 Bad example of the mean :

Although distribution range
is
within product specification
limits, the mean value is
shifted and a deviation is
generated.
The degree of deviation is
large and nonconformity
may

If Cpk＝NG, even if Cp＝OK,

nonconformity my not be
contained and dispatched to
the market.

 Bad example of distribution :

Although the mean is in the

center of the product
specification limits, the
distribution range is largely
exceeding the upper and
lower limits.
Nonconformity is very likely
to occur.

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5-1 Process Capability

3.4 Process Capability Judgment and Measures

Following examples demonstrate the determination process capabilities by the process
capability based on the process capability index and subsequent responses.
Relationship bet. Estimated
distribution & Cpk Judgment Measures percent
specifications defective

Inspection method: 100 %

inspection or sampling
Process
inspection. 0.06/
capability
Cpk ≧ Slight increase in product 100000
is more
1.67 dispersion is of no concern. units or
than
Consider simplification of less
sufficient.
control, reduction of costs,
etc.

0.06
Inspection method: 100%
Process /100000
1.67 ＞ inspection or sampling
capability to
Cpk inspection.
is 6.3
≧ 1.33 sufficient.
This is the ideal state, so it
/100000
is maintained.
units

Inspection method:
Sampling tests are
completed and no
nonconformity is found, or a
procedure is employed to
6.3
take retroactive action for
Process /100000
1.33 ＞ the possible nonconforming
capability to
Cpk product lot before
is not 2.6
≧ 1.00 sufficient.
dispatching from the
/1000
supplier.
units
Process improvement is
required until a Cpk of 1.33
is achieved.
Maintain the process in a
controlled state.

Inspection method:
determine whether or not 2.6/
Process the lack of process 1,000
1.00 ＞
capability capability is due to a to
Cpk
is displacement of the median 45.6/
≧ 0.67 insufficient. or dispersion. 1000
Investigate and take units
measures.

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5-1 Process Capability

3.5 Key Points for process capability

3.5.1 Correct sampling: points to estimate the characteristics of the general population
are as follows.
1) Random sampling = do not use data collected only under the same conditions.
2) Measurement accuracy= calculate to one more decimal place than the
specification value.
3) Avoidance of factors causing problems = obtain data from the condition in
which problem factors do not exist.
4) Clarify the definition of the lot and comprehend lot-to-lot dispersion. Check at
least 3 lots and determine the acceptance by increasing n.
3.5.2 Interpretation and Judgment of Data
3.5.2.1 Confirm data distribution and its shape (on a normal distribution)
If multiple tooling are used, verify data for each die or mold. For fabrication
method previously employed, comparison with actual performance may
also be effective to check the degree of dispersion and median.
If it is not a normal distribution, change variables.
3.5.2.2 Check dispersion from the median with Cpk.
3.5.2.3 Use sufficient quantity of n. If n is small, it is important to take into account
that the reliability of data may be reduced when making the judgment
(increase or adjust the number of n, if it is very close to 1.33).
3.5.3 Condition Setting with Allowance
When determining process capability based on data analysis, judgment shall be
made taking into consideration the preceding sections 3.5.2.1 and 3.5.2.2. Where
conditions affecting results are under control, it can be said that a process has an
acceptable process capability if manufacturing output is confimed to be within the
specification range even if conditions are slightly deviate from the upper and lower
limits.
Condition setting with appropriate allowance backed by data is important.

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5-1 Process Capability

3.6 Evaluation at the Production Preparation Stage

3.6.1 Concept of 50 Percent Tolerance Band
At pre-production stage in which n is limited, in order to assure process capability
during mass production by such small size of n, the population shall be aimed to
come closer to the center of the specification limits.
If deviations close to the upper and/or lower limit are found in the evaluation of
measurements with such small n, it is more likely for deviations to go beyond the
specification at mass production stage. In such cases, die/mold change, etc. will
become necessary during mass production.
When ensuring initial quality as part of production preparation activities, evaluate
dispersion in the specification range set at 50 percent of the specification limits
shown on drawings.

3.6.2 Judgment Criteria

All measured values shall be within one half of the tolerance given on the drawing.
This may not be mandatory if it is proved that the specifications will be satisfied for
mass production.
Note: the requirements above are in effect for pre-production stage where n is
insufficient. In mass production stage, process capability shall be evaluated with
Cpk based on n of sufficient size, and necessary improvement actions shall be
taken accordingly.
It is intended for the mean to be closer to the center of specification limits in the
Initial stage of production. Reduction of tolerance itself shall not be the purpose of
employing the 50 percent tolerance band. As long as the original drawing tolerance
is met, products beyond the 50 percent tolerance shall be considered conforming.
3.6.3 Measures Against Out-Of-Specification
3.6.3.1 When employing judgment criteria set forth in the preceding section 3.6.2
and if deviations out of the tolerance range (50 percent of tolerance on
drawing) are found, continue on measuring in mass production, and
determine the process capability(Cpk) based on data with n=125 or more.
3.6.3.2 Criteria for judging process capability using data size n=125 or more and
subsequent measures shall be in accordance with section 3.4.

4 Control of Records
No. Type of Record Retention Period
1 Records of process capability study 5 years after study
5 Reference Materials
SQM 6-1 Glossary of Terms and Definitions

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5-1 Process Capability

6 Operation flow

Determine product specifications Note ： quality is built

into a product through
(drawings, specifications included ) a process.
Process can achieve
optimum performance
only under a controlled
Clarify important quality characteristics of parts.
state

Set process parameters for part characteristics to control.

Make the process to be in a controlled state.

Calculate Cpk

5-3 Control Chart

3.3 Representative Control Charts

3.3.1 X – R chart
X – R chart is mainly used to monitor changes in mean values (between-group
variation: dispersion between groups), and R- charts is to monitor changes in the
dispersion of values (within-group variation: dispersion within a group). X-chart and
R-chart are frequently used in combination.
X -R chart Defect
Specification
limit
Control limit problem
(UCL) Take action here
CL

Control limit
(LCL)
Specification limit

3.3.2 Preparation of
3.3.2.1 Collection of Data
Collect as much data as possible about the characteristics which provide
important information of the process. Ensure that collected data is comparatively
new, is applicable to the process in the future, and have a clear record.
3.3.2.2 Grouping
Group data based on data history, and sort by lot sequence and sampling
measurement sequence etc.. The number of data in one group (the sample
size) is generally expressed by n, and the number of groups, by k.
3.3.2.3 Datasheet
Create a datasheet with consideration of section 3.3.2.1 and 3.3.2.2. and
enter data. No specific style of form is designated.
3.3.2.4 Calculation of Mean Value
Calculate the mean, round to one more decimal place that the measured
value. Find the mean value ( ) per group.

X1+X2+X3+X4+…………+Xn
X = n

3.3.2.5 Calculation of Range

Find the range (R) per group. R is used to indicate dispersion within a
group and is a difference between the maximum and the minimum values
within a group. R, X max ,X min.

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5-3 Control Chart

X
3.3.2.6 Calculation of Grand Mean ( )

Add X of all groups and divide by the number of groups, K.

X1+X2+X3+X4+…………+Xk
X = k
Calculate the mean to two more decimal places than the measured value.
(Do not round off since it will be used in later calculations.)

3.3.2.7 Calculation of Range Mean Value

Add all the R values of each group and divide by k
R1+R2+R3+R4+…………+Rk
R = k
Calculate the mean to one more decimal place than the measured value.
(Do not round off since it will be used in later calculations.)

3.3.2.8 Calculation of Control Limits

X control chart
Control Limit Line Coefficient
Centerline : CL = X
n A2 D4
Upper control limit line :
2 1.88 3.267
UCL = X + A2 . R
3 1.023 2.575
Lower control limit line :
4 0.729 2.282
LCL = X - A2 . R
5 0.577 2.115
R chart
Centerline : CL = R
Upper control limit line : UCL = D4R
Lower control limit line : LCL ignored when n is equal to or smaller than 6.

3.3.2.9 Entry of Control Lines

Set scale on the control chart so that the spacing between the upper and lower
control lines will be about 20 to 30 mm and enter CL, UCL and LCL on the chart.
Draw center line (CL) by solid line and draw limit lines by broken lines in the case
of data analysis or dashed-dotted lines in the case of process control.
Centerline

: solid line
Limit analysis : broken line
line process control: : dashed-dotted line

In case the control chart for analysis is extended for application to process
control, the line is changed from broken line to dashed-dotted line. Also enter CL,
UCL, LCL and each value near the lines.

3.3.2.10 Plotting
For plotting normally, “●” is used for X and “x” is used for R. Plots outside of the
control limits (including those on the limits) should be so marked as to facilitate
identification. (e.g. ” ◎” or in red, etc.)

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5-3 Control Chart

3.3.2.11 Points to Remember

In general, set control limits based on the dispersion of data when preparing a
control chart.
In some cases control limits are set at the upper specification limit and the
lower specification limit with an optimistic view of no nonconformance being
expected. However if control limits are set at the specification limits, the chart
will not allow
detection of possible abnormality and it is a misuse of the chart. Count the
dispersion of data in setting control limits (action lines) on a chart when using
specification limit. Use the chart to prevent problems from occurring by taking
precautions when dispersion is observed in the red zone.
3.3.3 p Chart
P chart does not require a fixed sample size. P chart is used in control of the process
in which percent defective can be expressed in percentage. For instance, when
finished- or semi-finished goods of 100 sheets, 100 units or n in general are
inspected for quality, 5 (r or np in general) out of 100 of products are found to be
non-conforming, therefore the percent defective P is 5/100, .05 or 5%. The percent
non defective may also be used.
3.3.4 Preparation of p control chart
3.3.4.1 Data Collection
Collect data of inspection results with number of units inspected (n) and
number of units rejected (np). Minimum of 20 sets of data shall be collected.
Data shall be collected and recorded with respect to each lot, machine, date,
time, etc.
3.3.4.2 Grouping
Form a group with the collected data. The size of a group n should not be too
large or too small since groups with many p=0 points are not appropriate.
3.3.4.3 Determination of Percent defective
Fill in a datasheet with the group number, n, np, etc., and calculate a percent
defective for each group (p).
no. of rejects np
p = =
size of a group n
Multiply by 100 for percentage.
3.3.4.4 Determination of Average Percent defective
total of rejects np
p = =
total of units inspected n
note that this is not the mean value of the percent defective p of each group.

1. Calculation and Entry of Control Limits.

Centerline : CL＝p

Upper control line :

Lower control line ：

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5-3 Control Chart

3.3.4.6 Control Chart Preparation

3.3.4.7 Points to Remember
If the sample size n varies among groups, center line will remain the
same, but control limits shall be calculated for each group and a limit
value be applied for each point.
Thus, limit lines on the control chart may be uneven, and control range
becomes smaller as n becomes larger. If n is larger than 500, use a
stratification approach since the control range becomes exceptionally
small.
3.4 Reading of Control Charts
In order to understand the condition of processes i.e., acceptable, marginal or critical, it is
necessary to read trends in data points appeared on control chart. The purpose is to take
actions proactively when abnormality is observed in control chart.
3.4.1 The criteria for judging process conditions, whether or not a process is in a
controlled state (or stable state), are as follows. It is advisable that evaluations be
made on the basis of at least 25 plotted points.
3.4.1.1 No plotted points outside control limits; no out-of-control points. However a
process is considered as being in a controlled state if the following cases
apply. when 25 consecutive points are within the limits. One point or less
out of 35 consecutive points lies outside the limits. (And, this one point
exhibits no particular abnormality.)
1) Two points or less out of 100 consecutive points lie outside the limits.
(and, these two points exhibit no particular abnormality.)
2) No bias in sequence, trends, cycles, etc. in the order of plotted points.
3.4.2 Data Point Exceeds Control limits

out of control Circle the point

Control Limit

Control Limit
out of control

The points outside control limit lines are referred to as being “control-out” or “out of
control”. Reasons for points being control-out are as follows.
(1) Due to a random cause resulting in the point lies outside the limit lines, or
(2) An abnormality has occurred in the process and resulted in the point being
outside the control limit lines.
Phenomenon described in (1) above may occur with a probability of three times in
1000 plots. If control-out occurs, take action on the premise that 2) above is most
likely to have occurred and probe the cause of abnormality.

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5-3 Control Chart

3.4.3 Run of Data Points

Circle the point

Control Limit

Control Limit
A series of points appear consecutively on one side of the centerline (median line,
to be precise, may be substituted by the centerline) is called a run. The length of a
run is the number of consecutive points to one side of the centerline.
A run with seven or more points is judged as indicating control-out state.

3.4.4 Data points show a cycle

Control Limit

When data points show a cyclic pattern of always declines on Mondays, there must
be a reason.
Investigation into the cause of cycles peculiar to the process is very useful in terms
of process analysis. Although these cycles are not easy to identify, it is ideal to
analyze them with experiences and engineering knowledge over a long period of
time and develop control methods well matched to the rhythm (cycle).
It is necessary to discern the cause of the cycle and carefully evaluate the process
condition to determine whether or not a process is in a controlled state.

Control Limit
10 out of 11 consecutive points are on one side of CL.
If one of the following conditions appear on one side of the centerline (median line
to
be precise), the process is judged as out of control controlled state.
1) 10 or more points out of 11 consecutive points
2) 12 or more point out of 14 consecutive points
3) 14 or more point out of 17 consecutive points, or
4) 16 or more point out of 20 consecutive points.

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5-3 Control Chart

3.4.9 Few Points Along the Centerline

Control Limit

Under normal circumstances, a large number of points should be near the

centerline if the sample follows a single normal distribution. Accordingly, the chart
above shows an abnormality.
This is often found when plotting data on the chart with sample groups taken from
each of two machines with different process average. It is necessary to stratify the
sample groups and draw control chart for each machine.

3.4.10 Points Close to the Control Limit Lines.

Control Limit

Evaluate as control-out in the following cases when points are near the control limit
lines, beyond the line two third of the distance from the center line to the control
limit lines.
1) 2 out of 3 consecutive points
2) 3 out of 7 consecutive points
3) 4 out of 10 consecutive points
The above conditions shall be judged abnormal since probability of the process
being beyond ±2σ range from the centerline is approximately 5 percent.

4 Control of Records

No. Type of Record Retention Period

1 X – R control chart 5 years after creation

2 p control chart 5 years after creation

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

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5-3 Control Chart

6 Operation flowchart

Process output

・Collect samples to form 25 groups of size

4 or 5.
Evaluate w/ control ・Calculate the center line and control limit
chart lines.
・Plot and check data on a control chart.

・Identifiable cause exists

・Data points are outside ・Plotted points are randomly dispersed
the control limits. Process not in a Process in a statistically from the centerline.
・Run, trend, cycle, etc. statistically controlled controlles state. ・Points are inside the CL
exist. ・No run, trend, or cycle.
・Process is stable and predictable.

Eliminate identifiable Evaluate process ・Estimate σ

causes capability ・Find Cpk

Cpk<1
1≦Cpk<1.33 Cpk≧1.33

Need improvement Study if improvement is Maintain status

100 % inspetion necessary / Sampling inspection quo (monitoring)

Make improvement

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Page 168 of 193
HCIL STATISTICAL PROCESS CONTROL CHART
PART NAME : OPERATION: USL : SUB GROUP SIZE: MONTH :

PART No. : PARAMETER: LSL : SAMPLING FREQUENCY: INSTRUMENT :

7-1

Average Chart (X Bar Chart) X=Avg X = UCL = X+A2R = LCL = X-A2R=

USL -
7 Examples of Forms
:

CL -

LSL -

Range Chart (R Chart) R = Avg R= UCL=D4R= LCL = D2R

Page 169 of 193

0.05
5-3 Control Chart

Honda Cars India Ltd.

0.04

0.03

CL
0.02

0.01

DATE
SHIFT / TIME

X1
X2
X3
X4
X5
Sum
Supplier Quality Manual

AVG X

RANGE R

Operator sign

Line-incharge sign
5-3 Control Chart
7-2 P control Chart

Part Number Part Name

- - 〔 P Chart 〕 Date: YY/MM/DD

(%)
Description

Date

Item Total
No.
of units
5-3 Control Chart

Page 170 of 193

Honda Cars India Ltd.
Number processed

Number of defective units

Defect rate （％）

Notes
Be sure to provide the following information.
1. Causes and measures taken if points
had been found lying outside the control limits.
2. Specify changes if there is a change to
the contents of a control chart.
3. Any changes to operation standards, or
to other major items which require changes
Supplier Quality Manual

Original to be retained until YY/MM/DD

Supplier Quality Manual

5-4 5 Principals for Problem Solving

1 Overview
This manual provides the concept of “5 Principles for Problem Solving”, which is used by
suppliers to investigate and eliminate the root cause of nonconformity of parts and of quality
management system.

Page 173 of 193
5-4 5 Principals for Problem Solving

3.3 Why-why Analysis Method

Root Cause/Task
Start from the problem symptom. Sort out and
systematize relevant factors until the root cause is 1-1-1-1-1
revealed. Why does 1-1-1-1 occur ?
5th “Why” A

1-1-1-1 1-1-1-1-2
4th “Why”
Why does 1-1-1 occur ? B
1-1-1
3rd “Why” 1-1-1-2-1
1-1-1-2
Why does 1-1 occur ?
Why does 1-1-1-2 occur ?
2nd “Why” C
1-1
1-1-2-1
(Tangible cause)
1-1-2-2-1
1st “Why”
Why does 1-1-2 occur ?
1-1-2
D
1
1-1-2-2 1-1-2-2-2

(Cause of Occurrence)
1-2-1-1 1-2-1-1-1 E
Why does 1-2-1 occur ? Why does 1-2-1-1 occur ?
1-2 1-2-1

(Intangible cause) 1-2-1-2 1-2-1-2-1

F
Why does 1-2-1-2 occur ?

2-1-1-1 2-1-1-1-1
2-1-1 G

Page 174 of 193

2-1-1-2 2-1-1-2-1
2-1

Honda Cars India Ltd.

2 2-1-2 H
2-1-2-1 2-2-1-1-1
(Cause of Outflow)

2-2 2-2-1 2-2-1-1 2-2-1-1-2

3 3-1

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5-5 Process FMEA

Criteria for ranking shall be established in reference to the table provided below.
Justification for the evaluation criteria shall be provided as required in section 3.3.24. The
ranking is often expressed on a scale of 0 to 10. Other measurement scales such as 1-4
scale (linear scale: 1, 2, 3, and 4, or exponential scale: 1, 2, 3, 4, 8, etc.) are also
acceptable, as long as the employed scale is effective for evaluation and severity is well-
expressed.

Ranking Severity Ranking on a 1-10 Scale (example)

 Failure mode of parts that impairs the safety of HCIL products
10 and leads to a fatal accident and/or involves a violation of
Extremely regulatory requirements (without predictability)
Severe  Failure mode of parts that impairs the safety of HCIL products
9 and leads to a fatal accident and/or a violation of regulatory
requirements (with predictability).
 Failure mode of parts that causes loss or deficiency of primary
8 performance, function, or structure of HCIL products.
 Failure mode that leads to a serious accident.
 Failure mode of parts that may cause loss or deficiency of
7 primary performance, function, or structure of HCIL products.
Severe
 Failure mode that may lead to a serious accident.
 Failure mode of parts that may but may not necessarily cause
6 loss or deficiency of performance, function, or structure of HCIL
products.
 Affected HCIL products are usable or operable but at a
5
reduced level of performance or function.
 Lead to multitudes of warranty claims against HCIL products
4 with respect to fit and finish, appearance, noise in use or
Moderate operation, feeling, etc.
 Lead to warranty claims against HCIL products with respect to
3 fit and finish, appearance, noise and feeling in use or
operation, etc.
 Lead to complaints against fit and finish, appearance, noise
2 Mild and feeling when in use or operation, etc. Defect noticed by
limited users.
1  No discernible effect or effect can be ignored.

Ranking Severity Ranking on a 1-10 Scale (example)

Failure mode of parts that impairs (or may impair) the safety of Honda
4 products, which leads to a fatal accident and/or involves a violation of
regulatory requirements.
Failure mode of parts that impairs the safety of Honda products and
3 leads to a fatal accident and/or involves a violation of regulatory
requirements (without predictability).
Failure mode of parts that reduce (or may reduce) performance level of
Honda products. Honda products are usable and operable but at a
2
reduced level of performance or function with respect to fit and finish,
appearance, noise and feeling in use or operation, etc.
1 No discernible effect or effect can be ignored.

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5-5 Process FMEA

3.3.15 Cause of the failure mode

List every possible cause assignable to every potential failure mode (conditions for
process malfunction or parts nonconformity to occur and mechanisms of problem
causes to be developed).
3.3.16 Occurrence (O)
Enter the probability of occurrence of the failure mode set forth in section 3.3.15. in
numerical values. The higher the value is, the higher the certainty is. The probability
of occurrence is the likelihood of a failure occurring, not the failure mode, severity, or
probability of detection.
Criteria for ranking shall be established in reference to the table provided below.
Justification for evaluation criteria shall be provided as required in section 3.3.24.
Ranking criteria shall preferably be quantitative and supported by statistical evidence.
If it is not practical to use Cpk or percent defective as a statistical basis, use
alternative scales such as quantitative scale or time based scale for lot, batch, etc., to
set the ranking criteria.
The ranking is often expressed on a scale of 0 to 10. Other measurement scales such
as a 1-4 scale (linear scale: 1, 2, 3, and 4, or exponential scale: 1, 2, 3, 4, 8, etc.) are
also acceptable if the employed scale is effective for evaluation and probability of
occurrence is well-expressed.

Occurrence Evaluation Criteria on a 1-10 Scale (example)

on a 1-10 Scale (example)
Ranking
Percent defective
Cpk P (%)
(estimate)
10 < 0.33 ≥ 32 1/2 or more
Continual
9 Frequent ≥ 0.33 < 32 1/3 or less
8 ≥ 0.50 < 13 1/8 or less
7 ≥ 0.67 <5 1/20 or less
6 ≥ 0.83 < 1.2 1/80 or less
5 ≥ 1.00 < 0.3 1/400 or less
4 ≥ 1.17 < 0.05 1/2,000 or less
3 ≥ 1.33 < 0.01 1/15,000 or less
Rare
2 Almost ≥ 1.50 < 0.0007 1/150,000 or less
absent

1 ≥ 1.67 < 0.00006 1/1,500,000 or less

Low
Remote

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Ranking Occurrence Evaluation Criteria on a 1-10 Scale (example)

10 Continual More than once a day

Frequent Frequently occur
9 Once every 3 to 4 days
8 Once a week
High incidence rate
7 Once a month
6 Once every 3 months
Moderate incidence rate
5 Semi annually
4 Annually
Low Low incidence rate
3 Remote Once every 1 to 3 years
2 Once every 3 to 5 years
Almost never occurs Less than once every 5
1
years

Ranking Criteria for Occurrence on a 1-4 Scale (example)

It occurs consistently or frequently. With high probability,
4
High probability, or consistent or frequent occurrence.
3 Moderate probability, or occasional occurrence.
2 Low probability, or little occurrence
1 Very little occurrence

3.3.17 Current Process Control

Describe methods of process control, testing, and inspection that are currently in practice
for the purpose of preventing or detecting the failure mode and cause and mechanism of
the failure mode. Such methods include QA devices, error proofing or inspection
processes, preventive maintenance of machines and tools, and the use of statistical
process control techniques such as control charts, etc.,
Improvement of process control will work favorably for the improvement of rate and
possibility of detection.
(e.g. improvement in the rankings of occurrence probability and detection possibility by
use of QA devices, event probability by implementing preventive maintenance or
detection possibility by the use of control charts, etc.) .
3.3.18 Detection Possibility D
Enter the probability of detection of a failure mode occurred by the method provided in
section 3.3.17 on a 1 to 10 scale. The higher the value in the ranking, the more difficult it
is to detect a failure mode.
Since detection possibility is the likelihood of detection on the premises that a failure
mode has occurred, occurrence probability has no effect on the detection possibility.
The detection probability describes the probability of a process control to detect failure
when all parts in process might have a failure mode. Monitoring of delivery quality
performance and market warranty claim (containment confirmation) is effectual for the
verification of failure mode delectability.
Criteria for ranking shall be established in reference to the table provided below.
Justification for the evaluation criteria shall be provided as required in section 4.3.24.
Prospect of detecting the failure mode before delivery to HCIL shall determine the
ranking. Factors such as difficulty level of visual check, tightness of inspection level
including method, frequency, etc. shall be considered.

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5-5 Process FMEA

The ranking is often expressed on a scale of 0 to 10. Other measurement scale such as
a 1-4 scale (linear scale: 1, 2, 3, and 4, or exponential scale: 1, 2, 3, 4, 8, etc.) is also
acceptable as long as the employed scale is effective for evaluation and detestability is
well-expressed.
Ranking Detection Evaluation Criteria: 1-10 Scale (example)
Impossible  Failure cannot be detected before delivery to HCIL.
10 (very difficult)  No process controls available to detect failure.
 Failure is likely to be flowed out to HCIL.
9
 Process controls currently in place cannot detect failure.
 Extremely difficult to be detected failure before shipping.
8
 Process control currently in place will probably not detect failure.
 Failure is detectable by periodic sampling inspection.
 Difficult to detect failure by current process control.
7  Failure can be detected by periodic sampling inspection.
 Process controls currently in place have poor chance of detection
of failure.
 Failure can be detected by regularly conducted sampling
6 Moderate inspection.
chance of  Process controls currently in place may overlook failure.
detection  Failure can be detected by 100% final inspection.
5  Process controls currently in place may detect failure. (e.g. trends
monitored using statistical process control, etc.)
 Failure can be detected in the subsequent process.
 Process controls currently in place can detect failure. (e.g. trends
4
monitored using statistical process control in addition to the 100%
inspection, etc.)
 Failure can be detected in the subsequent process.
 Process controls currently in place can detect failure (monitor
3
trends by using statistical process control in addition to 100%
inspection, etc.).
Certain  Failure can be detected within the process.
2 ( easy)  Process control such as QA devices, etc. is in place for 100%
inspection with automatic error detection feature.
 Can be detected within the process. Detection is easy and no
attention is required.
1  Process control system such as QA device, etc. is in place for
100% inspection with automatic error detection and removal
features.

Ranking Criteria for Occurrence on a 1-4 Scale (example)

4 Not detectable

3 Less likely to be detected or overlooked).

2 Likely to be detected.

1 Almost certain to be detected.

Honda Cars India Ltd.

Page 181 of 193
Supplier Quality Manual

5-5 Process FMEA

3.3.19 Risk Priority Number RPN

Enter the value obtained by multiplying severity (S), occurrence (O), and detection
(D) ranking numbers together.
[ Risk priority number (RPN) = Severity (S)× Occurrence (O)× Detection (D) ]
The RPN is for the risk evaluation, which is to rank order of concerns in the
process. Risk of failure modes shall be evaluated in consideration of three aspects,
severity, occurrence, detection, and priority of corrective actions shall be
determined accordingly.
The RPN is a quantitative measure, which determines the priority for corrective
actions to be taken to a failure mode. The higher the RPN, the higher the priority for
corrective action, since more attention to the particular manufacturing process of
the product is required Criteria of prioritizing corrective actions based on RPN shall
be established in reference to the table provided below.
Justification for the evaluation criteria shall be provided as required in section
4.3.24.

Ranking RPN Evaluation Criteria : 1-10 Scale (example)

RPN = S×O×D RPN Measures
1000 Top priority • Top priority.
436 ~ 1000
• Immediate measures required.
• High priority.
130 ~ 435
• Implement measures.
• Moderate priority.
• Monitor the occurrence of a failure
27 ~ 129 mode and implement measures
accordingly.
• Low priority.
8 ~ 26 • Implement measures where time and
1 Least resources allow.
priority • Accept as a remaining risk.
1 ~ 7 • No further measures required.

Ranking RPN Evaluation Criteria : 1-4 Scale (example)

RPN = S×O×D RPN Measures
12 ~ 64 12 or more • (Immediate) measures required.
• Monitor the occurrence of a failure mode and
6 ~ 9 6 or more
implement measures accordingly
1 to 4 6 or less • No further measures required.

3.3.20 Action Plan and Target Implementation Date

Enter action plan and target date of completion for the anticipated failure mode.
Implement an action plan for failure mode by priority. Higher the risk priority
number (RPN) is, sooner the measures shall be taken.
Measures such as inspection, etc., may be employed as interim. Permanent
measures including changes to design and/or manufacturing process shall be
implemented in order for the root cause of a failure mode to be eliminated.
If RPNs are the same, prioritize the one of greater severity, and contemplate to
reduce the rate of occurrence by taking measures.

Honda Cars India Ltd.

Page 182 of 193
Supplier Quality Manual

5-5 Process FMEA

3.3.21 Action Taken
Record measures that have been implemented such as control method
change, installation of inspection equipment, etc.
If follow-up activities were conducted in addition to the original plan, keep a
record of such activities as well. Especially, if any changes were made to
design as part of measures, process FMEA shall be implemented continuously.
The FMEA is a living document and should always reflect the latest design
level as well as the latest relevant actions.
3.3.22 Effective Date of Measure and Responsible Person
Enter target completion date for measures and person in charge of the
measures.
3.3.23 Verification of Actions Taken
Reassess the severity (S), occurrence (O), detection (D) and risk priority
number (PRN) rankings of each failure mode after having implemented the
planned actions.
Examine if further analysis and countermeasure is necessary. In order to
validate that further measures for remaining risks are not necessary where
measures are deemed to be completed or will not be implemented, evaluation
criteria shall be established as and when required.
3.3.24 Criteria
Define evaluation criteria for each of the risk evaluation aspects, such as
severity (S), occurrence (O), detection (D), and risk priority number (PRN), and
the tolerance level for risks remaining.

4 Control of Records

No. Type of Record Retention Period

5 years after the issue of discontinuation

1 Process FMEA worksheet
order.

5 Reference Materials
1) SQM 6-1 Glossary of Terms and Definitions

Honda Cars India Ltd.

Page 183 of 193
6 Forms 5-5 Process FMEA
6.1 Process FMEA worksheet

Process FMEA Worksheet For Honda use only Revision No. Description of revision Date of date est./revision Approved by Confirmed by Prepared by

Model/Type/Model Year Process FMEA control no 00 Establishment

Honda part no. Supplier part number

Honda part name Supplier part name Process FMEA was carried out by (dept or person)

Supplier name Supplier code

Supplier address (factory location)

Process FMEA was carried out by (dept or person)

Identification if parts are of Honda specified parts, enter a code (HS, HA, Q, NH, HR, etc.) .

Completion confirmation with consideration given to acceptance level of residual risks, confirm completion of a Process FMEA (no further measures required), and enter the name of the person confirmed and the date of confirmation.

Scope of risk evaluation Risk evaluation Countermeasure ( risk minimizing activities) Verification of C/M (re-evaluate risks)

Influence if a failure mode occurs

Occurren
Function of the Seriou Current process control Detection Risk C/M C/M Occurrence Detection Risk
Failure Identifyc Cause of failure mode ce C/M carried out PIC of Seriousness Completion
No. Process name process sness method probability priority Proposed C/M date application rate probability priority no.
mode To To Honda ation (Occurrence mechanism) rate (including follow-ups) CM (S) confirmation
(what does this (S) (prevention/detection of (D) RPN (target) date (O) (D) (RPN)
parts/components products (O)

Page 184 of 193

Honda Cars India Ltd.
5-5 Process FMEA

Seriousness (S) Occurrence (O) Detection probability (D) Risk priority number (RPN) RPN = S×O×D
Rank Evaluation criteria Rank Evaluation criteria Rank Evaluation criteria RPN Response
10 10 10
9 9 9
8 8 8
7 7 7
6 6 6
5 5 5
4 4 4
3 3 3
2 2 2
Supplier Quality Manual

1 1 1
Supplier Quality Manual

5-6 Layout Inspection

1 Overview
This manual explains method to ensure that a complete measurement of all parts dimension
is done at certain frequent intervals to assure product conformity to the specification & to
achieve customer satisfaction.

2 Definitions
The definitions of terms used in this manual are as follows. Refer to SQM 6-1 Glossary of
Terms and Definitions for other terms.
No. Terms Definition
Layout Layout inspection is the complete measurement of all part dimensions
1
Inspection shown in the customer drawing.

3 Requirements
3.1 Concept of Layout Inspection
Supplier shall plan complete measurement of all part dimensions shown in the customer
drawing
even if not expressly required by customer; this plan shall fulfill following requirements:
-Complete dimensional controls every year (Unless otherwise agreed by customer).
-Keep records for inspection & submit to customer if requested.
3.2 Scope of Layout Inspection
Layout Inspection shall be done for all products supplied to customer.
3.3 Process
Following activity to be perform .
1) Prepare an annual plan for carrying out the layout inspection with customer
specific requirements in consideration.
2) The plan should cover all the products supplied by the organization.
3) Check and include if there are any specific customer requirements.
4) Use a sample size of ONE unless specified by the customer.
5) If there is a significant change in manufacturing process like change in process
flow, machines, or revision of process control parameters, carry out layout
inspection to approve the process
6) Draw sample parts as required at random from the lot (packed and ready for
dispatch) for layout inspection
7) Measure all the product dimensions mention in drawing.
8) Retain the sample as master sample till further layout inspection.
9) Records the results & Initiate Corrective Action plan on the observed non
conformity.

4 Control of Records

No. Type of Record Retention Period

Honda Cars India Ltd.

Page 190 of 193
Supplier Quality Manual

6-1 Glossary of Terms and Definitions

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