Audit Date : 03.03.

2023
Check Sheet for Significant Production Trial Run ( SPTR ) Audit - 1st / 2nd / 3rd / 4th
Sup. Self Audit Date : 03/03/2023 SPTR Score : 83.04 No of Agreed Actions : Closed : Pending : % Of Closure :
1 st Audit : Date : SPTR Score : No of Agreed Actions : Closed : Pending : % Of Closure :
2nd Audit : Date : SPTR Score : No of Agreed Actions : Closed : Pending : % Of Closure :
3rd Audit : Date : SPTR Score : No of Agreed Actions : Closed : Pending : % Of Closure :
Supplier : IPEC India PVT Ltd
Part no : TVSIPPC750 Part name : CHARGER Model(S) : ECN Ref :
SAP SGRN Ref No : SGRN Date : . SGRN Type * : Alt Source / CQ ECR / VE ECR .
Capacity Assessment :
a) Working Hours / Shift : 8 Hours b) No of Lines / Cells : 1 c) Capacity / Cell :
Total working Shifts : Overall Capacity / Day : No of Operators / CellNo
: of Inspectors : 2
Die No(s) / Tool No (s) :
Approved Tier 2 Supplier(S) - CSCC List : Enclosed & Sign off Made : Yes / No / Not-Applicable
Audit Observations*
# Check points Remarks
N/A 0 1 2
A) Process Robustness Score ( Refer Sheet 1) 2
B) Process Adherence .
Is the gauges/instruments/ Fixtures / Processes Parameter indicators ( Like Pressure
gauges , Temp Controller , Timers , Weighing Scales Etc.) are calibrated & certified 2 Instrument calibration list available
B1 with NABL accreditation traceability ?

2 Available
B2 Is first off approval system is followed
2 Poke yoke list available
B3 Check Poka Yoke - Audit Check list available / followed .
B4 Check the process layout is made as per PFD 2 As per PFD process sequence is defined
Check the operator deployment is made covering all processes As per process requirement manpower
2
B5 (Total no. of operators planned vs actual) planned
Check the operators are trained in the process Yes, Trained operator depolyed in
2
B6 indivudual process
Is receiving inspection facilities installed (gauges/instruments/ equipment's etc.)
2 Incoming quality stage inspection available
B7
Check the Certified operators were deployed in Special Process
2 Skilled operator deployed
B8 (Heat treatment/Plating/painting/welding/assembly/PDI/Final inspection/CMM/MPI
Is attribute MSA system followed for both defect and defectives (For Final inspector
certification) mainly on visual Parameters Inspection. 2 MSA Attribute Study to be carried Out
B9

2 Done
B10 Is periodic in - process followed by operator/inspector(3nos/shift min)

2 Yes available
B11 Is fixture/Jigs/Tools/Mold/Die calibration available /followed ?
Is fixture/Jigs /Too/Mold/Die maintained system followed including spare for fixture 2 Yes available
B12 child parts?

Check the updated operation standard / Work instruction in local language is

2 Available
available for all operation
B13

Is Quality alert system followed for communication to operators(customer complaints) 2 Avaialble

B14
B15 Is any Process / S.Assy / Child Parts offloaded to Tier 2 as against Original PFD NA
Is TVSM designed gauges used for incoming & Final inspection(Fabrication/Plastic
NA
B16 parts)
B17 Is Gauge R&R study done (attribute &variables) 2 Study done
Is MSA study done for instruments(Linearity/bias/R&R) as per MSA AIAG - 4th Edition
Study done
B18 Manual ? 2
B19 Is 3 gauge system(line/calibration/stock) followed including spare for gauge 2 Yes available
B20 Is all Tier 2 Parts - PPAP approved & PSW Signed off by Supplier ? 1 PPAP Audit under process
Is a Process Qualification has been completed ? ( Qualification of Process / Operator
Process qualified as per Control plan, PFD,
/ Equipment for the input Material and the target output ) and accordingly FMEA / 2
WI
Control Plan / Operation Standards have been updated >
B21

Is the Supplier implemented and maintaining process for Software Quality assurance
which includes development process , using prioritization based on risk and potential 2 Available EOL testing software
impact to the customer and self assessment on Software development retained ?
B22
C) Product Adherence .
C1 Check the raw material is procured as per CSCC 2 Yes
C2 Check the planned gauges are available for inspection, gauge inspection report 2 Yes, Available
C3 Check the test facility is available for performance parameters 2 Available EOL testing
C4 Is child part meet critical parameters (5nos verification) 2 Yes, Sampling plan availble

Classification: Public SPTR audit CS (2) revision 4 dated 22.04.2019

 Yes, Available
C 5 Check critical parameters of assembly (5nos) is meeting the requirements 2
C 6 Check the final product is taken care for fitment related in the fixture itself 2 Yes, Available
C 7 Is EJO fitment feedback points were corrected by the Supplier 2 Yes, Available
Check whether all the Drawing - Safety / Fitment Parameters ( Critical / Major ) were SPC conducting for torque values
C8 given for SPC / Poka Yoke Controls / FAG or EOL Testing - 100% 2

Audit Observations*
# Check points
N/A 0 1 2 Remarks
D) Standards Adherence
Is latest TVS-M drawing available for the final product & Child Parts
Yes , Available
D 1 ( For Prop . Design Parts - TVS-M Approved drawing shall available ? ) 2
D 2 Is supplier drawing is approved for mass production (For Prop Design )? 2 Yes
D 3 Whether DFMEA meets its objectives?(For Prop Design ) NA

Whether actions for all the points identified in the previous reviews have been
D 4 effectively completed (All recommended actions identified in DFMEA - Prop. Design ) NA
D 6 Is all the relevant Test Standards ( TSES ) available for the part ? 2 Available

Are there any changes in the design records which are yet to be incorporated in the
D 7 original design records? NA
Is PSW contains data on the following - Drawing No / Latest Rev No / Weight
Calculations for 10 Pieces average with 4 decimals value of KG / Run @ Rate / If Under process PPAP to be Submitted
D8 Conditional Approval - Period / Quantity with Action plan for improvement . 1
E) Documents Adherence For sign off
Is Process Flow Diagram available with 6M Conditions ( Man , Machine , Method ,
Material , Material Handling & Mother Nature ( Dust Level/Noise Level/Illumination, Available
E 1 Fume Extractors Etc. - As Applicable ) 2

Whether actions for all the points identified in the previous reviews have been Available
E 2 effectively completed (including all recommended actions identified in PFMEA)? 2
Is Control plan available with 6M Conditions ( Man , Machine , Method , Material ,
Material Handling & Mother Nature ( Dust Level/Noise Level/Illumination, Fume Available
E 3 Extractors Etc. - As Applicable ) and should be inline with PFMEA 2
E 4 Is BOM available & CSCC-Component supply chain chart as per BOM (Tier 2) 2 BOM Available
AOI/MOI(Agreement of inspection/Method of inspection ) & Appearance Approval for Available and need to be updated and to be
E 5 selected Part & Limit Samples Sign off made including periodic re-validation ? 1 signedoff

Available
E 6 AOT(Agreement of Testing) 2
Layout inspection covering all Material , dimensions and Characteristics , Functional /
Reliability & Durability testing including Notes points in drawing / TSES & Found Yes all points covered
E 7 meeting the requirements 2
E 8 Packaging standard 2 Available
PPAP Audit done and PSW sign off need to
E 9 PSW Signed off 1 be done
E 10 Check the previous problems observed during sample approval stage are corrected NA
PPAP Audit done and PSW sign off need to
E 11 Is PPAP / PSW signed by Tier 1 Supplier for all Tier 2 Supplier Parts -available 2 be done
For Special process ( Powder Coating / Painting / Heat treatment / Ni Cr Plating /
E 12 Alloy Plating Etc. ) whether only TVS-M approved suppliers ( Directed By ) followed NA
Is Raw material procurement is linked with TVS-M approved Suppliers (
E 13 Directed by ) & covers under group buying concept NA
F) Capacity Assessment :
PPAP Audit done and PSW sign off need to
F 1 Check line production Capacity available as per PSW run @ rate 1 be done
F 2 Is current Capacity is adequate to meet current TVS-M Production volume ? 2 Yes
F 3 Is capacity available for Raw material /Tier 2 / Special process? 2 Yes available
F 4 Is required man power deployed to meet the required volume 2 Yes
F 5 Is layout(Single piece flow) is adequate to meet required capacity 2 yes
G) SPC Adherence
G 1 Monitor X bar R chart for critical parameters at periodical interval (Measurable) 2 Yes Measureable
Select Minimum 33nos at random and evaluate Ppk for critical parameters to
meet Target Cpk ( Linear Parameter : Safety : 2.0 Critical : 1.66 Major : 1.33 Done
G 2 & Geometry Parameters : 1.0 ) 2

G 3 Is online Updation which is interlink with TVS-M SAP website is followed . NA

Classification: Public SPTR audit CS (2) revision 4 dated 22.04.2019

 Is target Cpk is not achieved - 100% inspection is adhered as M2 action and Cpk Achieved
G4 M3 action for achieving the Target Cpk 2
H) Handling and Packaging Adherence
H1 Is packing standard available 2 Yes available
H2 Is required bin/trolley available for required volume(including in-house storage 2 Yes available
H3 Is trolley/bin maintenance check sheet available on individual trolley/bin 2 Yes available
H4 Check the dedicated bin / trolley is made for subcontracted processes 2 Yes available

Audit Observations*
# Check points
N/A 0 1 2 Remarks
Check whether Target PPM levels is achieved during SPTR trials . Done
I1 As per Part "Q" rating System 2
Check whether the internal rework / rejections levels are adequate to meet
Available
I2 TVS-M Part "Q" rating targets 2
J Responsiveness
J1 Is Supplier promptly response on TVS-M requirements 2 Yes
J2 Is Supplier adhere to the commitments / Target dates 2 Yes
J3 Is Supplier having positive attitude towards continual improvements . 2 Yes
J4 Is Supplier team provides transparency / support during the audit . 2 Yes
J5 Is supplier having regular updates / provide feedback on the committed actions . 2 Yes
* NA - Not Applicable . 0-System not available 1 - System available & Partially followed 2- System available & Followed fully

Audit Status :

Weighted Actual
Individual Average Max App Points
Description Weightage # Score Score Points (X) (Y) A
Process 100.00 100.00
Robustness 30 A 62.50 25.00 48 30 J B
80.0062.50
Score
Process
Adherence .
20 B 52.78 15.00 36 19 60.00 52.78
Product 40.00
15 C 83.33 14.00 12 10 100.00
Adherence . I C
83.33
Standards 20.00
5 D 83.33 4.00 12 10
Adherence
Documents 0.00
5 E 90.00 4.00 20 18
Adherence
Capacity
5 F 83.33 4.17 6 5
Adherence H75.00 D
83.33
SPC
5 G 62.50 3.13 8 5
Adherence
Handling and
Packaging 5 H 75.00 3.75 8 6 62.50
Final G E
Inspection 5 I 100.00 5.00 2 2 90.00
Adherence 83.33
Responsiven F
5 J 100.00 5.00 10 10
ess
Overall
SPTR Score
100.00 83.04
Average :
A~J
Remarks / Observations :

Note : Shade - Marked Check points are the mandatory check points - Supplier shall to provide action plan if the Score is >2 and PSW will be
approved only after verifying the effectiveness of the actions implemented

On Supplier Site Sign off

TVS-M : Supplier
Name : Name : Pradeep Kumar
Sign Sign

Classification: Public SPTR audit CS (2) revision 4 dated 22.04.2019