Quality Assurance - ter

1 Quality Supplier ManualSupplier Quality Improvement ManualEffective date : May 16th, 2014 Tokai Eastern Rubber (Thailand), Section09-May-1409-May-1409-May-14 Issued ByChecked ByApproved ByQuality Assurance Quality Assurance Quality Assurance Quality Assurance Quality Assurance Revision 13 Quality Assurance Quality Assurance Quality Assurance Quality Assurance Part 1: System Management1. Incoming Inspection12. Control of Nonconforming Products33. Special Approval Request (SAR)84. Product Identification and Traceability95. Lot Control106. Quality Assurence Items in Supplier Monthly Evaluation Standard117. Process change Requirement 12 Part 2: System Improvement1. Critical Process Supplier Annual Follow up NG major/minor case Audit (CAR/PCAR follow up)162. Supplier Improvement Supplier Self Improvement Activity (SSIA) Supplier Quality Control Circle Supplier' s Full Lay-out Inspection Activity20 Appendix Quality Information (QI) A-1 Promptly Corrective Action Request (PCAR) A-2 Corrective Action Request (CAR) A-3 Defect Improvement Request (DIR) A-4 Special Approval Request (SAR) B-1 Special Approval Tag B-2 Supplier Quality Monthly Evaluation ReportB-3 Supplier Critical Process Audit Check sheetC-1 to C-4 Supplier Welding Process Audit Check sheetC-5 to C-8 Full Lay-out Inspection Data Format D-1 to D-2 Process Change NoticeE-1 to E-2 ContentsQuality Assurance Supplier Manual 13 13 13 13 13 13 13 13 13 13 13 13 Part 1 : System Management1.

2 Incoming Inspection Objective : To ensure the Quality of material are meet to TER's specification or standard. Supplier responsibility :1. Supplier have to send parts according to submit inspection data follow TER's Supplier inspection data must cover all points that was shown on inspection standard because some data will be determined by TER as the based 1 : TER Material Receiving Inspection StandardPage 1 of 20 Quality Assurance Supplier Manual 13 Supplier Group Production StageQuality Level Criteria Classification Require to Supplier - Submit inspection data every batch when deliver material to TER .- Attach "Special Tag" every boxes and identify "Initial Stage"Current StageNormal Group N/A- Submit inspection data every batch when deliver material to TER .Initial StageNormal Group N/A- Submit COA every lot when deliver to TER Current StageNormal Group N/A- Submit COA every lot when deliver to TER - Submit inspection data 10 lots when deliver part to TER- Attach Special tag every boxes and identify Initial stage for 10 lots- Submit Inspection data, Mill sheet, Characteristics test result and all data to TER for 1 time/month by E-mail only.

3 (All parts which deliver to TER in each month)- Stamp QA PASSED on delivery tag every boxes (TER barcode tag)- Attach Special tag every boxes and identify Quality confirmation for 10 lots- Confirm part and submit inspection data 10 lots continue in 1st month, Paper sheet Confirm part and submit inspection data 1 time/month for 2 months later, E-mail Consider NG recurrence of this part GroupNew modelECIPCN"Zero claim"More than 3 Compound Initial StageChemical Initial StageInitial Group"Zero claim"Less than or equal to3 months.(TER found NG Major Case)Defect Group Normal Group Current StageMetalPlasticAluminumRubber PartSponge3. According to TER Material Receiving Inspection Standard. Supplier have to attach indication tag of each stage to TER. As Initial Stage : Initial 10 lots of mass productionDelivery Tag : Supplier have to stamp QA Passed / QA Passed on delivery Tag: Supplier have to attach special tag every boxes and write a line on "Initial stage" Current Normal Group : Usual of mass production Delivery Tag : Supplier have to stamp QA Passed / QA Passed on delivery 2 of 20 Quality Assurance Supplier Manual 13 Defect Group : 10 lots after have Tag : Supplier have to stamp QA Passed / QA Passed on delivery Tag: Supplier have to attach special tag every boxes and write a line on " Quality confirmation" In case of supplier did not send inspection data follow TER requirement.

4 TER going to deduct supplier monthly evaluation score. 5. In case of supplier did not attach indication card follow TER requirement and/or indication card was incorrect. TER going to deduct supplier monthly evaluation score. 2. Control of Nonconforming Product Objective : To determine supplier responsibility for control and make corrective action in nonconforming (NC) products. Definition of NC : NC product means the products that their specifications do not meet with either engineering drawing or related standards. TER separated NC into 2 groups referring to their signification affects. As follow:Major NC : NC which affect part functional and/or affect TER's fit/form NC : NC which do not affect part functionalPage 3 of 20 Quality Assurance Supplier Manual 13 13 Table 2 : NC major cases Supplier responsibility in case of NC found at TER case of NC found at TER (Incoming or In-process), QA/TER and supplier have to do the procedure as shown in Figure 1.

5 Brief steps are also described as below:QA/TER will issue QI* and inform to supplier by telephone, Fax or e-mail.* ( Quality Information, See appendix A-1) case of NG Minor case, supplier will issue PCAR** and submit to TER** (Promptly Corrective Action Request, See appendix A-2) case of NG Major case Supplier will issue CAR** and submit to TER** (Corrective Action Request, See appendix A-3) If supplier need to report corrective action, please implement according to DIR** flow as shown in Figure 2. **(Defect Improvement Request : DIR, See appendix A-4).4. Suppliers much reply PCAR or CAR to QA/TER within 7 working days for each case. (Oversea / Import suppliers are allowed to send within 4 weeks)5. TER will deduct supplier monthly evaluation score (Referring to supplier monthly evaluation standard) when issued CAR/PCAR and suppliers do not reply PCAR or CAR to TER on : If supplier has Quality claim from TER for 3 months continuously, TER will request supplier to do Quality Residence Entrance activity (QRE activity) for guarantee part's Quality before send through to production line.

6 Supplier clinic of defect improvement request : Supplier can review evaluation result beforeQA/TER summary monthly evaluation and send to supplier. Supplier must quickly action afterreceived Quality information from QA/TER, and must present DIR report to QA at TER by yourself.(DIR , supplier must finished within 7 working day only). monthly evaluation review : If DIR accepted by QA/TER , result ofQ-Monthly Evaluation is reviewed by excluding NG case which accepted and period of DIR, show in Figure 4 of 20 Quality Assurance Supplier Manual 13 AV/SP/PI partsMetal PartsPH PartsWrong MaterialOver/Under cureAdhesive NGSqueezing NGFlat surface NGPress fit in NGLeak liquidAssembly NGWrong MaterialHeat Treatment NGWelding NGCaulking NGAssembly NGWrong MaterialOver/Under cureAdhesive NGInsertion over or shortTensile strength NGCaulking NG Supplier responsibility related to PCAR, CAR items :1.

7 Detail of Complain/Occurrence situation : Supplier shall check all products in their stock to ensure that no NC repeatedly out to TER. Supplier must manage their NC by scrap, rework, etc. Supplier shall mark the re-inspection products (Marking place will be allowed by TER) and make any certification as information. Root cause :Supplier shall analyze root cause in cause of product NC and delivery NC. Corrective action : Supplier shall correct the problems at root cause and supplier shall review inspection standard in order to ensure that all problems can be Preventive Action : Supplier shall realize that the preventive action will be contained: (A) Criteria for maintenance and inspection machine before machine break out. (B) Use of error-proofing method or POKAYOKE as inspection 5 of 20 Quality Assurance Supplier Manual Page 6 of 20 Figure 1 Flow of NC found in TERQ uality Assurance Supplier Manual QA issue Quality Information (QI) and record related data QA/TER and Supplier do activity that support production smooth continually as sorting material in production line/TER stock QA/TER inform to supplier for do activity that make sure NC will not send to TER recur and recheck part in supplier stock, add 100% inspection etc.

8 QA Supervisor and Manager judge level of NC Supplier issue PCAR Supplier investigate root cause, do corrective action and reply to QA/TER within 7 working days QA/TER follow up PCAR PCAR closing Supplier issue CAR Supplier investigate root cause, do corrective preventive action and impact to similar product/process Supplier reply CAR to QA/TER and explain CAR at TER within 7 working days QA/TER follow up CAR at supplier process (If necessary) CAR closing Major Minor Accept Not accept Accept Not accept Inform to TER for improvement (DIR) Show in Figure 2 Page 7 of 20 Figure 2 Flow of Defect Improvement Request (DIR) Quality Assurance Supplier Manual 3. Special Approval Request (SAR) Objective : SAR will be issue in case of NC which TER accepts. Scope : As SAR is the temporary authorization to delivery/use a specific quantity of part which does not keep on the standards.

9 Special approval request (SAR) will be approving only in case NC product not affects the following items. - Marketability of TER's Quality image - Safety, function, performance, durability (Evidence must be available) SAR must be limited to a specific part number, quantity or time period and it will not be considered to be a permanance change from design drawing. Supplier responsibility for SAR :1. The supplier must complete SAR form (See in appendix B-1) and submit together with NC sample to The supplier must identify all discrepant parts or material and store them in the location which parts can be prevented shipping parts mistake QA/TER and/or Tech will analyze parts and All discrepant part lots must be identified by special tag. (See appendix B-2) Some marks/tag will be described in SAR Tag: Supplier have to attach special tag every boxes and write a line on "SAR" slot.

10 5. All discrepant part lots must be shipped on only the dates specified in SAR form. Flow and period of SAR approve chart, show in Figure 8 of 20 Quality Assurance Supplier Manual 13 Samai Supoj JT-528 010414 Metal Scrached 1234/45678 4. Product Identification and Traceability Objective : To determine supplier responsibility in lot identification for traceability in case of NC Definition of product identification and traceability :1. Identification is a method to define some important information for fast action and high accuracy of problem analysis. This will be very useful to scope the problem occurred in the same lots. It also helps guarantee of product Quality before shipping to Traceability means traceable in all processes which is related to raw material including raw material types, process parameter, inspection and testing. This will be also useful in analysis and reduce scope to find NC cases.