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CHAPTER 03

PAK SUZUKI MOTOR CO. LTD.

STARTING DEVELOPMENT OF PARTS

Preparation of Vendor Selection

Specification meeting

Prepare LAR Publication

LAR Publication

Deletion Notice Publication

Activities of TE (Tender Enquiry) publication

LP Publication

Cope with LAR need

Development of Proto Model & Mass Production (LOI issuance, Tooling

Development, OTS approval)

Development of Proto Model & Mass Production (Process Verification,

Pilot, Trial & Regular supply)

Parts Selection

LP Reply

LP Reply

NG Entrust


LAR approved

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SUPPLIER QUALITY ASSURANCE MANUAL 14

Doc. # QAD-MAN-01 Rev: 00, Feb - 2011

3.1 PARTS SELECTION

3.1.1

3.1.2

3.1.3

3.1.4

3.2 PREPARATION OF VENDOR SELECTION

3.2.1

3.2.2

3.2.3

3.2.4

·

·

·

·

·

·

Parts Localization Department & Technical Management Department is jointly responsible for the selection of parts for Localization.

Selection of parts for localization based on Cost Saving through SRO Cases, A-Max Parts, Commonality, SMC recommended parts etc. Selection of parts also based on Availability of manufacturing Facility, Material, availability of Testing Facility etc.

Technical Management Department is responsible to prepare selected part list for Approval.

Selection of parts finalized with the consent of all concern Department. / Division, QAD, SCM at approval stage.

Parts Localization Department proposed vendor for selected parts localization after study the nature of Parts, Drawing, Material, Testing requirement etc.

Technical Management Department compile data base for vendor capability / testing facilities.

Technical Management Department arranges the Drawings of Parts & other standards required for vendor selection.

Local Parts Purchasing (SCM) arranges the meeting for vendor selection after receiving of selected parts list from TMD Selection of vendor based on:

Development Performance Data

Supliability status

Quality (PPM) status

Manufacturing / Testing Capability

Organizational Structure

Financial Position etc.

Selection of vendor finalized with the consent of all concern Department / Division (R&D, SCM, QAD)

3. STARTING DEVELOPMENT OF PARTS

PAK SUZUKI MOTOR CO. LTD.STARTING DEVELOPMENT OF PARTS



3.2.5

3.2.6

3.3 R&D DIVISION ACTIVITIES FOR TE PUBLICATION

3.3.1

3.3.2

3.4 SPECIFICATION MEETING

3.4.1

3.4.2

3.4.3

·

·

·

·

·

·

·

After selection SCM gets approval of selected vendor list from management.

Technical Management Department prepare the Master Development Schedule of selected parts for localization with consent of Parts Localization Department.

Technical Management Department issues the Drawing , Samples & other Data to Local Parts Purchasing & Parts Localization Department for issuance of Tender Enquiry to vendor & preparation of Specification meeting respectively.

Technical Management Department monitors & updates the record of Tender Enquiry.

PLD Concern Development Engineer start preparation of specification meeting with vendor (Study of Drawing, Standards , Test Details etc) as per specification meeting schedule after issuance of Tender Enquiry to vendor from Local Parts Purchasing (SCM).

Technical Management Department prepares specification meeting schedule & coordinate with vendor & concern staff of PLD, LPP and PID for arrangement of meeting.

Parts Localization Department Concern Development Engineer conduct specification meeting with vendor, points discussed in specification meeting includes:

Parts manufacturing Process & Capacity.

Tests Requirement.

Material Specification.

Tooling Detail.

Quality Documents requirement (PSIS, WI).

Development time.

Packing and handling of parts etc.

Besides this participants of specification meeting also verify the fitment of part at actual place(Gamba) if required.

Minutes of specification meeting noted and copy of meeting minutes also given to vendor for record and reference.




3.4.4

3.5 LP PUBLICATION

3.5.1

3.5.2

3.5.3

3.5.4

3.6 PREPARE LAR PUBLICATION

3.6.1

3.6.2

3.6.3

3.7 COPE WITH LAR NEEDS

3.7.1

3.7.2

The participants of specification meeting are the concern development engineer PID, LPP & vendor.

Parts Localization Department concern development engineer prepares the LP (Localization Plan) document of selected parts for localization and after getting approval from management hand it over to Technical Management Department.

.

Technical Management Department dispatched the LP to SMC through I-BOM.

Technical Management Department receives the LP reply, LAR (Localization Approval Request) requirements from SMC through NET/ I-BOM and hand over to PLD for working.

SMC replies that LP as “Entrust" (approved for localization) or "NG" (not approved for localization) or LAR requirement (need samples, data or drawing) for approval for localization.

Parts Localization Department concern development engineer in case of LAR requirement, study the LAR requirement in detail, Test requirements, Data requirements, Samples etc.

The same LAR requirement sends to concern vendor for fulfillment / study.

In case of any ambiguity in LAR data requirement, development engineer raises query to SMC for clarification / detail.

After detail study of LAR requirements, concern development engineer discussed the LAR requirements with concern vendor to confirm the possibility of required Data, Test and Procedure.

In case of some data/ test not possible, counter action also discussed and concern development engineer informs to PSMCL management & query to SMC raises for advise if needed.




3.7.3

3.8 DEVELOPMENT OF PROTO MODEL AND MASS PRODUCTION

3.8.1

3.8.2

3.8.3

3.8.4

3.8.5

3.8.6

3.8.7

3.8.8

3.8.9

A schedule is prepare to fulfill the LAR requirements

After LOI, the vendor in consultation with concern development engineer makes the detail development schedule.

Concern development engineer guides the vendor in the development of Tooling, Processes, Testing and Inspection.

Concern development engineer monitor the related activities for timely development of components according to the plan through review meetings & visits to vendor premises.

Departmental & divisional Heads review the progress of under development parts with concern engineer / sectional heads.

In case of CNG parts development, CNG planning and designing section of TMD is responsible to plan, execute, monitor, record the CNG development related activities.SMC provides support / guidance where required. As per mutual decision of SMC and PSMCL, CNG planning & Design section makes arrangement for endurance testing of respective product.

Technical Management Department concern person prepare the attaching part order and after necessary approval hand it over to Import Parts Purchasing (SCM) for arrangement.

Vendor submits initial sample (OTS) approximately 3 or 5 samples together with self inspection report / test reports, material certificate & fixture etc. after examination by development engineer these samples are sent to PID for detail inspection .

Part Inspection Department (PID) is responsible for the inspection of the part and preparation of the inspection report. Concern development engineer is responsible for coordination between PID and vendor to get the improvements done according to inspection report.

After approval of initial (OTS) sample, process verification is done at vendor site by concern PID engineer along with PLD engineer before pilot lot. Pilot lot (FPP) for approximately 15 vehicles is taken from the vendor by development engineer and submitted to PID through Travel Card. If pilot lot is “OK” from PID, Pilot lot is handed over to MHD Department for issuance on line. Concern development engineer monitor the consumption of pilot lot, fitment




is verified for performance check. All observations from concerned shop of plant are recorded on the Travel Card. After approval of pilot lot PID intimates to LPP Department through PLD to issue order for trial lot for approximately 30 vehicles. Trial lot is also passed through the same process as pilot lot along with the Travel Card.

After approval of Trial lot, PID intimates Local Parts Purchasing Department through Parts Localization Department to issue regular schedule of certain quantity necessary for consumption before sending deletion notice.

Concern development engineer responsible to ensure follow-up for timely issuance of Pilot / Trial & Mass production schedule from concern department.

Technical Management department responsible to ensure arrangement of CKD attaching parts on time, matching with Pilot/ Trial or Regular supplies.

Parts Localization Department concern engineer prepare the LAR publication documents and arranges the entire LAR requirement (Data, Sample, Dimensional inspection reports, Test reports & other data).

In case of sample to be dispatched to SMC, concern engineer arranges the packing of part and after security check hand over the part to Import part purchasing (SCM) along with Gate Pass & Export Document.

After necessary approval from management LAR requirements, Data handed over to Technical Management Department to dispatch to SMC through NET / I-BOM.

Based on the parts approved for deletion after successfully consumption of regular supplies, Technical Management Department prepares the Deletion Notice.

After necessary approval from management Deletion Notice (KDCR) is sent to SMC on monthly basis to delete the parts.

After confirmation from I-BOM, TMD forward the information of Deletion Notice to Divisional Head of Finance, QAD, SCM, Production & Departmental Head of spare Parts & MHD for intimation.

3.8.10

3.8.11

3.8.12

3.9 LAR PUBLICATION

3.9.1

3.9.2

3.9.3

3.10 DELETION NOTICE PUBLICATION

3.10.1

3.10.2

3.10.3




STARTING DEVELOPMENT OF PARTS PAK SUZUKI MOTOR CO. LTD.






LOCALIZING APPROVAL REQUEST [LAR]Company Code Date

Planned

Planned

PIC

Supplier Name Code No. 120

Collaborator

Modification for SMC DWG

Comment:

PIC Checked Approved CE

NE

Date : / /

Reference; JAPAN Supplier

NO YES

Checked

Checked

Checked

Approved

Approved

Approved

Resident

Resident

CE

NE

Company Name

Model

Part Name

BRACKET COMP. FRT. MOUNTING, R

DWG ECN No.

NE

NE

PUR Comment

Expected Change Timing MARCH, 2012

Cost Saving Merit WRT

KD/ 1st/ 2nd/ 3rd/ p c

Part No. Spec DWG No.

Block No. LAR No. Re-issue

PAK SUZUKI MOTOR CO., LIMITED

A

Overseas Plant

Comment

Evaluation Test & PlaceActual Car Test

Parts Test

no

no

need

need

Attached DWG

Data

Approve

Pending - Request

NE

Comment

NE comment

Circulation : Overseas Plant NE Pur NE Designer CE NE Overseas Plant

Sheet No. 4070 (NE) NE Designer CE NE Overseas Plant

Reject

DWG

OthersData Sample ( pcs)

Date : / /

Sample ( pcs)

Others

Date : / /

Date : / /

ECN No.

Note; when send the above materials with attached this form

Place Suzuki Local

SMC Designer Comment ( )

SMC Designer CommentEntrustLARDWGDataSample ( pcs)Others

1

2

LP

LAR

STARTING DEVELOPMENT OF PARTS PAK SUZUKI MOTOR CO. LTD.

