TAB I.4 - QUALITY ASSURANCE PLAN - cdn.mbta.com

1 RFP No. CAP 27-10 New Orange and Red Line Vehicles Massachusetts Bay Transportation Authority TAB - QUALITY ASSURANCE plan A. The Offeror is to provide an outline of the QUALITY System Manual and Project QUALITY plan requirements stipulated in T and T of the Technical Provisions within Part B of its proposal. The outline should include details of approach, organization, sample procedures, sample documentation, and feedback mechanisms for all phases of the program (design, manufacture, final assembly, test/commissioning, warranty). PART 1: QUALITY SYSTEM MANUAL OUTLINE T his o utline describes the organization and contents of Hyundai Rotem s QUALITY System Manual (QSM). The complete QSM provides all process details, which are summarized in this outline. Hyundai Rotem s QUALITY System conforms to ANSI/ISO/ASQ 9001-2008. 1. QUALITY Policy All emp lo yees of Hyundai Rotem s hall maintain high QUALITY awareness, with the goal of continuous improvement.

2 All managers and supervisors have res p o ns ib ility to continuously promote QUALITY awareness fo r all employees. 2. QSM P urpose The QSM provides a time-tested framework for guiding management review, design and document control, production, equipment procurement, subcontractor management , customer satisfaction, corrective and preventive action, and process improvement on all projects. The QSM provides standard work processes to assure staff across all functional groups understand their responsibilities, and understand how to hand off information to other functional groups, while maintaining compliance with customer requirements, company standards, and statutory regulations. Hyundai Rotem s QSM is to be applied on stages of all projects, inc lud ing: d es ign, material s up p ly, p ro d uc tio n, F irs t Artic le Ins p ec tio n, d elivery, testing/commissioning and warranty.

3 3. QA/QC Organization The Hyundai Rotem QA/QC organization and main res p o ns ib ilities are described in Figure 1. TAB Page 1 of 20 ASSURANCE RFP No. CAP 27-10 New Orange and Red Line Vehicles Massachusetts Bay Transportation Authority Figure 1 QA/QC Team Organi zati on and Responsi bi l i ti es Testing, Commissioning & DLPTeam (DMRC Depots, Delhi)(Mr. BK Kim) Functional tests of Vehicles Static & Dynamic test of train Commissioning test at Main-LineAdvanced QC Team(Mr. Youm, General management )Advanced EQC Team(Mr. You, General management )CS Team(Mr. Son, General management ) QUALITY Planning Team(Mr. Kim, General Manager) QUALITY management Division(Mr. Kyung, QM General Director) QUALITY ASSURANCE Director(Mr. Chae) QUALITY ASSURANCE Team(Mr. Kim, General management ) QUALITY Control Team(Mr. Cho, General management )Testing & Commissioning(Chang-Won Factory)System Assurnce duringwarranty periodCarbody & Bogie QCOutfitting QC Company-wide QUALITY Planning management of Company QUALITY System QUALITY Audit (Subsupply) General management of dvanced QUALITY control Feed-back & Improvement of Past Projects QUALITY Issues QUALITY Approval of First Article QUALITY Improvement at Initial Production Stage of Vehicle EQC.

4 QC for Electronic/ Electrical Equipment QUALITY management Representative the project Drafting & control of QAP QUALITY Audit After sales service(A/S) during warranty period Reception/feedback/action for Employer s QUALITY feedback Analysis of field QUALITY QUALITY control of purchased/subcontracted products(Receiving inspection/verification, Source Inspection) Subcontractor QUALITY analysis & control QUALITY Control of Car Body and Bogie In-process Employer inspection QC of Subcontracted parts for Carbody and Bogie QUALITY Control of fitting (final assembling) QUALITY Control of completed vehicle and train QUALITY Control of painting In-process Employer inspection Car History Book of Manufacturing Functional tests of Vehicles Static & Dynamic test of train Pre-delivery inspection ( Function Test part) Car History Book of Test & CommissioningPart QCAdvanced QUALITY Director(Mr. Choi) TAB Page 2 of 20 ASSURANCE RFP No.

5 CAP 27-10 New Orange and Red Line Vehicles Massachusetts Bay Transportation Authority 4. management Review management review of QUALITY procedures & processes, imp lementatio n, and improvement occurs at several levels within Hyundai Rotem. The overall planning of the company QUALITY processes, documentation, and direction is provided by the QUALITY Planning Team. The Advanced QUALITY Team looks at improvements of the QUALITY System based on feedback fro m all p ro jec ts and production processes, including mechanical, electrical and software issues. The QUALITY ASSURANCE Director has overall management of the QUALITY ASSURANCE Team, the Q uality Control Team, and the Co mmis s io ning & S ervic e Team. Each team manages a specific area of QUALITY , and the feedback from all areas is continuously reviewed to improve the design, procurement, production, s ervic e, and training processes.

6 5. Design Control Design Concept Development The Design team defines the scope and targets for each design and development activity. For the vehicle design, a Vehicle Design Document (VDD) and Vehicle Interface Control Document (VICD) are created. The VDD describes the overall features and performance of the vehicle based on the performance requirements, customer specifications, industry standards and statutory/regulatory requirements related to the product. The VICD describes all the mechanical, electrical and software/control interfaces for the overall vehicle, married pair, train and all of the vehicle subsystems. From the VICD, an Interface Control Document (ICD) is created for each of the vehicle subsystems that d efine all of the interfaces for the specific subsystem. Within the VDD, VICD and ICDs, the Design Team identifies relevant QUALITY requirements to ensure the overall QUALITY is achieved through the manufacturing and assembly processes.

7 As the design progresses from conceptual design, preliminary design to final design, the VDD, VICD and ICDs are updated based on feedback from the customer, subcontractors, production, and Design Team to address all issues of the design, including performance, fit and functionality, ergonomics, safety, reliability, maintainability, and q uality. Feedback is also received from testing and field service activities from the current project and also from previous projects where longer term data, es p ec ially relating to reliab ility and q uality, is available. All design documents, including the definition of relevant standards, contractual requirements, catalogue data, component specifications and all engineering calculations and analyses are maintained in the permanent project file through the Document Control system. Design Reviews At appropriate stages of design, documented internal design reviews are planned and conducted.

8 Participants at each design review include representatives of all functions concerned with the design features being reviewed, as well as other specialist personnel, and subcontractor representatives as required. Records of all d es ign reviews are maintained as design review meeting minutes and action items. F o rmal d es ign reviews will b e c o nd uc ted with the s imilar personnel as above and customer personnel. The formal design reviews will inc lud e: 1. Conceptual design review (CDR); 2. P reliminary d es ign review (PDR); TAB Page 3 of 20 ASSURANCE RFP No. CAP 27-10 New Orange and Red Line Vehicles Massachusetts Bay Transportation Authority 3. F inal d es ign review (FDR). Formal records of these meetings and the design decisions and ac tio n items will b e d is trib uted to all parties, and maintained in the permanent projec t file. Design Verification At appropriate stages of design, design verification is performed through analysis, test and measurement as appropriate.

9 In addition to conducting design reviews, design verification may als o inc lud e ac tivities s uc h as: 1) perfo rming alternative c alc ulatio ns ; 2) comparing the new design with a similar proven design, if available; 3) c o mp leting testing, mock-ups and prototype samples. F inal des ign valid atio n is performed to ensure that the product conforms to defined user needs and/or requirements. The design of the vehicle/train is valid ated through the testing and commissioning on the revenue service line of the customer under actual service operation conditions. Design Changes All design changes and modifications are id entified , d ocumented, reviewed and approved by authorized personnel before their implementation. If, during or after Pilot Train testing and commissioning, design changes, including software, are deemed necessary, Hyundai R o tem will submit such changes for customer approval and internal approval through an Engineering Change Notification (ECN).

10 All supporting info rmatio n will be provided, including reason for change, updated drawings and other documentation, modification plan and schedule, impacted production vehicles, detailed Field Modification Instructions (FMI) as appropriate, parts required, and any other data required to allow the Authority to fully evaluate any proposed design change. 6. Document Control Documentation relating to the requirements of each contract and the QUALITY system are subject to review and approval by authorized personnel prior to issue. Such documentation shall include, but not be limited to the QUALITY management plan (QMP), Inspection and Test plan (ITP), P ro jec t Q uality S ys tem Procedures, Work Instructions, Procedures, Specifications, Drawings, Inspection/Test Reports. Access to this documentation is availab le for all work-s ite lo c atio ns . Obsolete documents are disposed of, o r c learly id entified as obsolete, or stored in a separate location identified for obsolete data.