SUPPLIER QUALITY MANUAL

Version 1.0
©Copyright 2014 Tata Motors Ltd.
This document belongs to Tata Motors Ltd. and is of confidential nature. Reproduction, circulation or distribution of this
document in part or whole in any form without permission is prohibited.
 TABLE OF CONTENTS
1. FOREWORD 1
2. TATA MOTORS POLICIES 2
2.1. Mission, Vision and Values 2
2.2. Quality Policy 3
2.3. Environment Policy 4
2.4. Safety and Health Policy 5
3. HOW TO USE THIS MANUAL 6
3.1. Document Access 6
3.2. AIAG Documents 6
3.3. Supplier Feedback 6
4. INTRODUCTION 7
4.1. Purpose 7
4.2. Scope 7
4.3. Responsibility 7
4.4. Records 7
4.5. General Requirements 7
4.5.1. Quality Requirements 7
4.5.2. Applicable Statutory and Regulatory Requirements 8
4.5.3. Product Safety 8
4.5.4. Laboratory Requirements 8
4.5.5. Specific Requirements 8
4.5.6. Tata Code of Conduct 8
5. TATA MOTORS PROCESS OF SUPPLIER QUALITY 9
5.1. Advance Quality 10
5.1.1. Potential Supplier Assessment 10
5.1.2. Sourcing Decision 14
5.1.3. Advanced Product Quality Planning 16
5.1.4. Pre-Production Meeting 18
5.1.5. World Class Supplier Quality 20
5.1.6. Production Part Approval Process-PPAP 21
5.1.7. Run at Rate 31
5.1.8. Early Production Containment 33
5.2. Current Quality 35
5.2.1. Continuous Improvement 35
5.2.2. Quality Workshop 36
5.2.3. SQ Process & Measures 37
5.2.4. Level I – Controlled Shipping (CS I) 40
5.2.5. Level II – Controlled Shipping (CS II) 41
5.2.6. Performance Monitoring 42
5.2.7. Improvement Meeting 43
5.2.8. Re-Sourcing 44
6. APPLICABLE DOCUMENTS 45
7. GLOSSARY OF TERMS 46
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1. FOREWORD

We at Tata Motors have built our governance model on the principle of ACES –
Accountability, Customer & Product Focus, Excellence and Speed. The major focus, in
future, for our suppliers will be on quality of parts delivered to Tata Motors and customer,
robust manufacturing processes and comprehensive adherence to the APQP process
leading to WORLD CLASS QUALITY. To facilitate Supplier Engagement effectively we have
upgraded our existing 16 Step Supplier Quality Process and have prepared this common
Supplier Quality Manual.
Going forward we need to focus on: Flawless Product Launches & Continual Quality
Improvement. To address these objectives in a holistic manner we will deploy the 16 Step
Supplier Quality Process for New Part Development. The first 8 steps are the Advance
Quality phase. The objective of Advance Quality is to achieve robust product development.
Each of these steps shall be further cascaded into individual tasks. Steps 9 through 16 are
the Current Quality phase. The objective of Current Quality is to reduce variability and
improve process stability. We have internally trained all the Supplier Quality Engineers on
this process. This process will now become a way of life for our end to end Supplier
Management.
The Advanced Product Quality Planning process defines the steps that are necessary to
ensure that the PRODUCT and PROCESS meet Tata Motors requirement. Adherence to
APQP is required for all new parts. Suppliers Top Management support is critical to the
Success of APQP process. Establishing robust Quality Management Systems as well as
Product and Process Validations are equally critical to the Success of APQP process. We
are sure that you as an Automotive Supplier must be aware of these tools and processes
and many of you would already be practicing these.
Together we have to overcome many challenges. Suppliers have a vital role in reducing the
warranty failure rate, warranty costs and incoming PPM. Thus, suppliers have a key role to
play in improving our current position and overall Customer Satisfaction. This needs to be
addressed on topmost priority to enable us to achieve better results. We have to do it right,
first time and every time. We need to be mindful of our speed of responses. Innovation will
be the Key to our Sustainability & we at Tata Motors have a firm belief that “Together We
Can Do It”.
We look forward to your support in implementing these requirements and partnering with us
in our journey towards Process Excellence.

Warm Regards
Dilip Huddar
Head - Supplier Quality

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2. TATA MOTORS POLICIES

2.1. Mission, Vision and Values

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2.2. Quality Policy

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2.3. Environment Policy

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2.4. Safety and Health Policy

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3. HOW TO USE THIS MANUAL

The objective of this document is to communicate to our suppliers the Tata Motors
requirements to ensure the quality of supplied parts.
The Tata Motors Supplier Quality Manual is organized into two sections:
 Advance Quality
 Current Quality
Each Section in the manual is divided into 8 Steps. Each step contains certain activities,
which include the following details:

Activity Supplier Flow

Description Output References
Name Responsibility Chart

All our Supplier related transactions are through SAP, single server environment across all
the plants of Tata Motors in India.
Suppliers have been provided access through our intranet services called SRM. This is
compatible with SAP and suppliers can view Purchase Order details, schedules, status of
their quality acceptance of supplies, payments etc. along with other initiatives like quarterly
feedback on Supplier rating, rejection, warranty information and Tata Motors Standards
required by them at their premises.

The latest valid version of this Supplier Quality Manual is posted on the Tata Motors SRM
portal. [Link]
To access the manual, log on to the SRM portal using your Admin ID (Vendor code) and
password. After logging on, go to the “Supplier Manual” folder using the following path: Home
> Documents > Tatamotors > Message > SupplierQuality > Supplier Manual

3.1. Document Access

Tata Motors SQ Pro-X formats references are available in this manual and can be obtained
from the Tata Motors SRM portal.

3.2. AIAG Documents

All AIAG specific documents referenced can be ordered from [Link].

3.3. Supplier Feedback

Feedback concerning this document is welcomed. Should you have any improvement
suggestion about this document, please send an e-mail to the following address:
sqms@[Link]

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4. INTRODUCTION
The Tata Motors Supplier Quality Manual has been developed to document the quality
requirements with the following objectives:
 Ensure flawless new part development
 Assure that quality tools are utilized by suppliers in the development of and revisions
to their products, processes, and services
 Provide a framework for sustaining and improving the quality of supplier products,
processes, and services

4.1. Purpose
The purpose of this document is to communicate to our suppliers the expectations of Tata
Motors and meet quality management systems requirements.

4.2. Scope
This document covers the details of Tata Motors Supplier Quality Process. Tata Motors has
developed 16 Step Supplier Quality Process, under Process Excellence Initiative (Pro-X).
This process is applicable equally to all suppliers and affiliated organizations that supply
parts, materials for production, pre-production, and/or services to the customer.

4.3. Responsibility
Suppliers shall utilize the latest revision of this Quality Manual and seek clarification from
their Tata Motors contact when necessary for items that are not identified or completely clear
in the manual. Tata Motors will continually improve and revise the contents of this manual.

4.4. Records
Suppliers shall maintain records of all required documents of this manual and shall be made
available to Tata Motors Supplier Quality Engineer upon request.

4.5. General Requirements

Tata Motors quality requirements stated in this document are general in nature. Quality
requirements for specific parts are specified in product specifications and order documents.

4.5.1. Quality Requirements

Suppliers to Tata Motors supplying auto parts meant for OE and SPD requirements are
expected to be ISO TS 16949 QMS certified. Second and third tier are expected to be
certified to minimum ISO 9001-2000 with an aim to comply with TS16949 QMS
requirements. Tata Motors will carry out periodic assessment / audit of supplier’s Quality
Systems and manufacturing processes. Supplier is expected to carry out improvements in
time bound manner as identified during such audits. Supplier is expected to proactively take
suitable actions to make systems robust enough to ensure that non-conforming parts are
prevented from escaping supplier’s premises.

Supplier shall inform Tata Motors about changes in their QMS registration status, such as
new certificate, suspension, revocation or switchover to another certification body. Tata

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Motors expects its Tier 1 suppliers to manage the quality of their supplier base. Tier 1
suppliers should also ensure that their supplier base meets Tata Motors requirements.

4.5.2. Applicable Statutory and Regulatory Requirements

Tata Motors demands the supplier to be in compliance with all applicable statutory and
regulatory requirements.

4.5.3. Product Safety

Tata Motors manufactures products for performance and safety in vehicles. It is of utmost
importance that our products are reliable in their applications. Product safety must therefore
be the highest priority throughout the complete supply chain.

4.5.4. Laboratory Requirements

Supplier's laboratory shall comply with the requirement of the chapter 7.6 of the TS 16949.
Laboratory and measurement reports shall comply with the requirement of the TS 16949,
chapter 4.2.4. In particular, laboratory and measurement reports shall include:
 The identity and location of the laboratory used
 The reference to the test methods used
 Any deviation of the test method shall be noted
 Measurement results
 All necessary materials and process traceability information on the tested
components or samples

4.5.5. Specific Requirements

In many cases, this manual will not sufficiently describe all of the specific requirements of
Tata Motors. The Tata Motors specific requirements shall be identified during the Advanced
Product Quality Planning (APQP) activities. If there are any questions regarding these
specific requirements, the supplier shall contact the respective Purchasing / Supplier Quality
Department of Tata Motors.

Product-specific requirements may include but not be limited to the following:

 Special characteristics
 Testing
 Special handling

Customer-specific requirements may include but not be limited to the following:

 Quality management systems
 Process techniques and process controls
 Identification and processing of critical parts and features
 Certification

4.5.6. Tata Code of Conduct

The supplier shall implement Tata Code of Conduct (TCOC) requirements at supplier's
operations and is applicable to all his dealings relevant to his relationship with Tata Motors.
Supplier as a business partner of Tata Motors shall not only subscribe to Tata Motors policy
but also support, promote and propagate them in all possible manners.

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5. TATA MOTORS PROCESS OF SUPPLIER QUALITY

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5.1. Advance Quality

The Advance Quality defines TML’s common product quality planning requirements that are
necessary to develop and implement a robust development process for a product.
It is intended as a standard to provide the Supplier Quality Engineer and the Supplier a
common platform from which to proceed with all steps of Product Development.

5.1.1. Potential Supplier Assessment

Purpose
Potential Suppliers are identified in Key Stakeholder meetings, assessment is done for new
suppliers based on the assessment criteria and their technical proposals are assessed to
ascertain that all information in RFQ package is understood, and the supplier is capable of
manufacturing parts as per Tata Motors requirements.

Scope
This step is applicable to all Suppliers of production parts, raw materials, service parts, and
sourced products.

Activities
The PSA is part of Tata Motors supplier approval process and has the following tasks:
 Key Stakeholder Meeting
 PSA
 Technical Review

Process
This step formally starts off APQP process with program review and identification of key
strategies in the Purchasing Process, through the Key Stakeholder Meeting. A
comprehensive RFQ package based on SOR (from the concerned stakeholders) is prepared
to ensure that all information necessary to receive equivalent bids is present.

Potential Suppliers are identified and tabled into the Preliminary Bid List. The suppliers are
assessed either on the Past Performance or Initial Supplier Assessment.

Potential Supplier Assessment is carried out in following conditions:

 For a New Supplier / For a New location
 For a new process / technology with Existing Supplier

Suppliers who pass the PSA (Potential Supplier Assessment) or have approved Supplier
Performance in Integrated Supplier Rating (Source-able Category) are eligible to receive
RFQ. On submission of RFQ response, the Technical Reviews are evaluated to ensure
suppliers are technically capable of producing parts as per parameters set by Tata Motors.
Suppliers who have passed the Technical review and who have cleared the risk assessment
(Step 2) are eligible to receive new business, depending on the acceptance of their bids by
the purchase officer.

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Process Flow
INPUTS:-

1. Indent for New

Key Stakeholder
Part SOR
Meeting
2. ECN

3. Alternate
Source

4. Project Details
Preliminary Bid
List

Potential Supplier
Exit Fail Supplier Rating Poor Exit
Assessment (PSA)

RFQ RFQ
Package Package

Pass Approved
Technical Review

[Link]. Key Stakeholders Meeting (KSM)

Description
The purpose of KSM is to introduce and establish key internal stakeholders’ ownership in the
APQP process and ensure that the RFQ package contains all information needed to receive
comparable quotes. KSM is conducted for every new part to be developed across any
platform/project and results in a well-documented RFQ package containing SOR inputs
(from various agencies viz. ERC, Supplier Quality, Purchase, SCM, etc.) to be released to
eligible potential suppliers identified in the preliminary bid list.

Timeline
Prior to Sourcing decision, before PSA

Output
Timely release of RFQ package with appropriate supporting documents

Process
The buyer invites the key internal stakeholders and conducts the KSM meeting as per the
agenda (This meeting is conducted for reviewing the potential bidders list and contents of
the SOR).

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[Link]. Potential Supplier Assessment (PSA)

Description
Assessment of potential new suppliers, identified in the preliminary bid list, based on the
assessment criteria. Key focus in this activity is on evaluation of risks associated with:
 Quality
 Production
 Design and Development
 Financial Capability
 Service
Based on the risk assessment score, the supplier’s eligibility for sourcing will be decided.

Timeline
Prior to Sourcing Decision, before Technical Review

Output
Risk assessment Status – Pass or Fail

Process
 The SQE receives the potential bid list from the buyer.
 In case, the Supplier has active business, the SQE reviews the Supplier Rating to
verify that supplier meets the required criteria before proceeding towards Technical
Review.
 If the supplier is not engaged in active business, the SQE proceeds towards PSA.
 The supplier supports the SQE in conducting the PSA by providing all
documents/necessary support in a timely manner.
 If the supplier has achieved satisfactory Score in each of the 5 parameters, the
supplier is qualified for technical review.

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[Link]. Technical Review

Description
This activity reviews the technical proposal of the supplier to validate that all the
requirements mentioned in the RFQ package have been understood and the supplier has a
plan and is capable to produce parts meeting Tata Motors Standards. The Technical Review
is a pre-requisite for any commercial negotiation and approval at the Sourcing Table

Timing
Prior to Sourcing Decision

Output
Identification of capable suppliers

Supplier Responsibilities:
Suppliers must review information in the SOR and produce upon information as requested
by the Tata Motors SQE:
 Adherence to Tata Motors Quality Requirements, including but not limited to:
– Adherence to ISO/TS 16949 Systems.
– Adherence to requirements mentioned in AIAG documents
– WCSQ Requirements
– Production Support Requirements
– Continuous Quality Improvement
 Preliminary Timing Charts
– Highlight concerns related to tooling, gages & fixtures, and/or testing that may
impact PPAP.
– Detailed list of (proposed) changes to the manufacturing facility, including
Greenfield and brownfield plans.
– Optimized and dedicated resource deployment to successfully complete the
APQP project; including competency mapping and training requisite to
complete the tasks.
 Suppliers should have Preliminary process flow diagrams, PFMEA and Control Plan.
– The suppliers must specifically list down all information that is material,
including but not limited to special assembly techniques, test methods
(including EOL testing, functional and compliance testing), and containment
procedures deployed.
 Capability Studies on similar parts (Commodity) and tolerances:
– Error Proofing systems, MSA studies, SPC, EPS mechanisms and their
record keeping is included.
– Plan to meet warranty targets (Review open PRRs, existing warranty action
plans and data on similar parts/aggregates)
 Present process and resource plan for evaluation and management of sub-
contracted/tiered suppliers.
 Respond to the assessment and observations and where applicable identifying
countermeasures to be taken.
 Provide evidence of product experience or technical expertise relevant to the new
product.

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5.1.2. Sourcing Decision

Purpose:
Evaluate the sourcing eligibility of the supplier based on the TRSO and risk criteria. The
score band in the risk criteria serves as a guideline to determine if APQP is Supplier
Monitored or Customer Monitored.

Scope:
All parts under development

Activities:
Risk Assessment

Process
To receive new business, the supplier’s manufacturing location must be aepproved on the
Tata Motors Preliminary Bid List for Quality in the specific commodity
Suppliers clearing the Technical Review and qualifying the risk evaluation criteria will be
eligible for consideration in the sourcing process.

[Link]. Risk Assessment

Description
The overall risk assessment score decides if APQP project plans proceed with Customer
monitored (Tata Motors) or Supplier monitored APQP.
Note: Further Risk Assessment can be done during any stage of APQP Project Plan, and the
decision to change APQP Risk Assessment Status can be taken by SQE in consultation with
SQ Head.

Timing
Prior to Sourcing Decision (Sourcing Recommendation Table)

Output
Completed APQP Supplier Assessment

Supplier Responsibilities:
Provide necessary information and support audit requests.

APQP Activity Responsibility Matrix:

The following matrix describes the responsibility differences between “Customer-Monitored”
and “Supplier-Monitored” APQP. Suppliers are responsible for carrying out all the “R”
activities shown in the supplier column of the matrix, whether or not their parts are
designated as customer or supplier monitored APQP. If a part is designated as customer-
monitored APQP, Tata Motors SQE will monitor and approve the APQP activities.

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APQP Activity (Illustrative) Tata motors Supplier Monitored

Monitored APQP APQP
Supplier Tata Supplier Tata
Motors motors
1 PSA S R S R
2 Technical Reviews S R S R
3 Sourcing Decisions N/A R N/A R
4 Pre-Production Meeting
a) Kick Off Meeting S R S R
b) Remaining Gate Review R A R I
5 World Class Supplier Quality R A R A
6 DFMEA
a) Supplier Responsible R S R I
b) Build To Print Parts S R A I
7 Tool & equipment review R A R I
8 Gage Review & Approval R A R A
9 Control Plan R I R I
10 PFMEA R I R I
11 PPAP R A R A
12 Run @ Rate R A R I
13 Lessons Learned R I R I

Legend
R – Responsible; A – Approve; S – Support; I – Inform
Note: Unless otherwise specified, APQP will be supplier monitored.

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5.1.3. Advanced Product Quality Planning

Purpose:
APQP is a structured method of defining and establishing the steps necessary to assure that
a product satisfies the customer (Tata Motors). The goal of APQP is to facilitate
communication with all stakeholders to assure that all required steps are completed on time.
Some of the benefits of APQP are:
 To direct resources to satisfy the customer requirements.
 To promote early identification of required changes
 To avoid late changes
 To provide a quality product on time

Scope:
All new parts under development

Activities:
APQP enlists 3 core activities within the step, namely:
 APQP Project Plan
 APQP Timing Chart
 APQP Kick Off Check sheet1

Output
 APQP Open Issues List
 Updated APQP Timing Chart

Process
The APQP project plan is developed in accordance with the recommendation of AIAG APQP
manual, listing the various activities in line with Tata Motors NPI DR Gates /Milestones. The
type of Product, complexity and project expectations are considered in selecting the timing
elements that are planned and charted. Each event has a “start” & “completion” date along
with the actual point of progress recorded. APQP process is then formally kicked off (APQP
Kick Off) for the various projects.
 The reviews are conducted by Tata Motors for all parts that are designated as
Customer monitored APQP during Step 2.
 For supplier monitored APQP parts, the supplier reviews and updates the timing
charts and Open issue lists throughout the APQP Process. Supplier must update all
information pertaining to Product Quality and Timing to the concerned SQE.
Note:
 The timing chart is developed in accordance with principles of Critical Path Method
(CPM), Gantt chart, and is driven by the principles of simultaneous engineering
performed by product and manufacturing engineering activities working concurrently.
 Each project plan will be different depending on the project program and the part.
 The APQP Timing chart will be continually referenced and reviewed throughout the
Product Development Cycle.
 APQP project planning facilitates communication between the supplier and customer
(Tata Motors) to clarify requirements that translate into more detailed specifications.

1
APQP_KickOff.pdf

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 Suppliers prepare component specific timing chart in line with the APQP Project Plan
(Master Timing Chart) considering development along the entire supply chain
(including Sub Contractor Development).

Supplier Responsibilities
 Create an APQP Timing Chart or equivalent and track tasks to completion in line with
chart.
 Suppliers should use APQP as a tool to support process development2:
– To develop and execute an APQP Plan for flawless product launch.
 Launch of new components intended for regular production.
 Development of new manufacturing processes
 Significant changes to existing products or process
– Regularly update the progress of product development based on their APQP
plan and share the same with customer (Tata Motors) teams.
 Suppliers are required to adhere to APQP Timing Chart.
– Create an APQP Open Issues and monitor the same throughout the program.
 Utilize APQP Open Issues list to capture all issues requiring action.
– Update timing chart as timing changes occur and communicate any changes,
concerns and issues to SQE.
 Develop recovery plans for issues impacting quality and timing and
drive the plan to maintain program timing
 Any timing changes by the customer (Tata Motors) have to be
adequately communicated downstream.
– Sub-component (tier II) milestones shall be pulled ahead of the Supplier’s
assembly milestones to protect Tata Motors program timings.

Chart
Prototype Pilot / Pre-Launch Launch /
Planning Production
AIAG APQP Product Design and Development
PHASES Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
PO+4w eek Alpha Build Beta build PO/PP PL SOP
GR-1

GR-2

GR-3

GR-4

Gate Sourcing
# APQP Task Reviews Activities

1 PSA GR-1 o------o o

2 Technical Reviews GR-1 o------o o

Risk Assessment / Update Risk
3 Sourcing GR-1,3 TR o o o
Timing Charts / Initial-TR
4 Open Issues GR-1,2,3,4 o o o o o o o o o o o o o o o o o o o o o o o o o o o o
WCSQ WCSQ Audit - GAP Analysis WCSQ Audit - compliance
5 GR-1,,3,
Initial -TR Prototype Production
6 Flow Chart GR-1,2,4 o o o o o o
DFMEA Update RPN
7 DFMEA GR-1,2,4 o o o o o o o
Plan Before SR Freez Execute Complete
8 DVP GR 2,3,4
KCDS Workshop GD&T
9 Design Reviews GR-2,3 o o o o
Gauge, Tooling and Prod Concept-TR Gage Concept Approval Gage Design Approval Gage Approval/R&R, Tool Completion
10 Equipment Reviews GR-1,2,3,4 o o o o o
Initial-TR Prototype / RPN Baseline Production / RPN RPN Reduction
11 PFMEA GR-1,2,3,4 o o o o o o o o
Initial-TR Prototype EPC & Production
12 Control Plan GR-1,2,3,4 o o o o o o o
Early Production Initial-TR Plan Execute Exit (Platform Discretion)
13 Containment GR-3,4 o o o o

14 PPAP GR-4 o o
Plan Capacity Analysis Capacity Analysis Conduct Run@Rate
15 Run @ Rate GR-1,2,3,4 o o o o o o o

16 Lessons Learned GR-1,2,3,4 o o o o o o

2
Refer AIAG APQP Manual

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5.1.4. Pre-Production Meeting

Purpose
Pre-Production Meeting is a review mechanism to track the progress of all APQP Tasks in
the APQP Project Plan and APQP Timing Chart.

Scope
All activities covered under the APQP process.

Activities
Pre-Production Meeting marks the start of activities which are conducted periodically
throughout the APQP cycle to evaluate progress of various activities in a structured manner.
Tata Motors SQE will be scheduling these Gate Reviews with Supplier.

Process
 SQ Gate Reviews are conducted prior, preferably 1-2 weeks, to Project DR Gate
Reviews.
 Pre-Production Meeting entails the first Gate Review (GR1) should be completed
within 4 weeks after the release of PO.
– Subsequent Gate Reviews are aligned with the vehicle built for each
component.
 Completion of all activities as mentioned in the APQP Gate Review Chart, ensures
qualification to next level, else the progress takes a step back to a prior level.

[Link]. Gate Reviews

Description
Gate Reviews are done to ensure that all tasks in the APQP project plan due at a particular
Gate are completed.

Timeline
Completed prior, preferably 1-2 weeks, to Project DR Gate Reviews.

Output
 Updated APQP Open Issues List
 Progress of Project – Completed documents of all required activities
 Gate Clearance Status
 100 % Interim Saleable along with minimum 75 % Fully Approved PPAP Status at
time of pilot production.
 100% WCSQ compliance before PPAP approval.
– WCSQ compliance will be considered as a pre-requisite for fully approved
PSW.
 Minimum 90% Run @ Rate at SSF (Start of System Fill)

Supplier Responsibilities
 Ensure completion of required activities as per APQP plan at various gates.

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 Review the completion status of actions required for compliance to SQ SOR3 and
Part Specific SOR, Lessons learned.
 Ensure lessons learned are captured adequately in the FMEAs or Control Plans.
 Validate capability studies and RPN reduction plans to satisfy Tata Motors design
specifications and quality requirements.
 Validate capacity/plan vs. capacity required by Tata Motors.
 Identify and communicate key issues in adhering to the APQP timing chart to Tata
Motors management.
 Co-ordinate the gate reviews after APQP kick-off. For Supplier monitored parts, the
supplier must conduct the APQP Gate reviews and periodically report the same to
Tata Motors SQE.
 Complete the gate reviews with sub-contractors (Tier II to Tata Motors), at least 6
weeks prior to Tata Motors gate reviews to protect Tata Motors project timing. Inform
Tata Motors SQE, in case of any discrepancy or non-conformation.
 Protect Tata Motors program timing and objectives by adhering to the APQP charts.
– In case of deviation, prepare comprehensive recovery plans and submit the
same to Tata Motors SQE.
– Track all open APQP issues and report any concerns to Tata Motors SQE,
immediately.

Chart

3
Refer SQ_SOR.pdf

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5.1.5. World Class Supplier Quality

Purpose
WCSQ helps us to Achieve & Exceed the global benchmark levels to manufacture and
deliver the Highest Quality Products to our Customers. WCSQ ensures
 Quality is built into the process
 Built-in-quality (BIQ) is made the DNA of the Organization
 People are involved and strive for Quality Excellence
 Prompt Actions are taken for all abnormalities

Scope
WCSQ applies to all Suppliers partnering and/or engaged in business with Tata Motors.

Timeline
 Gate 1 (Gap Analysis)
 Gate 4 (Compliance, before PPAP)

Output
 Action Plan for WCSQ compliance – Gate Review 1
 Full Compliance with WCSQ audit – Gate Review 4

Activity
The activity has the following 10 key elements
1. Quick Response Teams
a. Quick Response Process
b. Problem Solving
c. Lessons Learned
2. Control of Non-Conforming Product
3. Quality Gate
4. Standardized Operations
5. Standardized Operator Training
6. Error Proofing
7. Layered Process Audits
8. RPN Risk Reduction (Reverse FMEA)
9. Contamination Control
10. Supply Chain Management

Supplier Responsibilities
 At the WCSQ Gap Analysis audit, provide action plans with appropriate detail, timing,
ownership, etc.
 Implement and verify effectiveness of all the action plan items before Supplier Gate
Review 4.
 Keep the customer (Tata Motors) updated regarding implementation status and any
issues or concerns with implementation.
Note: WCSQ compliance is a compulsory requirement to qualify the eligibility criteria to
receive new business.

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5.1.6. Production Part Approval Process-PPAP

Purpose
PPAP’s purpose is to provide the evidence that all Tata Motors engineering design record
and specification requirements are properly understood by the Supplier and that the
manufacturing process at the Supplier has the potential to produce the product meeting
these requirements consistently during an actual production run at the quoted production
rate.

Scope
 Applies to all supplier sites supplying Production parts, service parts, production
materials or bulk materials.
o For bulk materials, refer to the Bulk Materials Checklist4.
 Suppliers supplying standard catalogue parts (e.g. Bolts, nuts etc.) shall comply with
PPAP, unless otherwise specified by the authorized Tata Motors SQE.

PPAP Requirements5
 Design Record
 Authorized Engineering Changes
 Customer Engineering Approval
 Design FMEA
 Process Flow Diagrams
 Process FMEA
 Control Plan
 MSA Studies
 Dimensional Results
 Records of Material/Performance Test Results
 Initial Process Studies
 Qualified Laboratory Documentation
 Appearance Approval Report
 Sample Production Parts
 Master Sample
 Checking Aids
 Customer Specific Requirements
 Part Submission Warrant (PSW)

[Link]. Process Flow Diagram

Description
Process Flow Diagram6 provides a logical pictorial representation of the process flow that
can be used as the foundation for PFMEA’s, control plans, work station layouts, etc.

Timeline
Initial chart–prior to sourcing, reviewed at Gate 2 and Gate 3, and completed in PPAP.

Output
Process Flow Chart (depicting Sub component system)
4
AIAG PPAP Manual, Appendix F
5
Refer AIAG PPAP Manual, Section 2 – PPAP Process Requirements
6
Refer [Link]

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Supplier Responsibility
 Create a preliminary process flow chart using a similar process as part of response to
RFQ package requirement.
 Define a production flow chart once product design is released.
 Document all items in the flow chart with the respective nomenclature (store, move,
inspect, correct, etc.)
 Ensure the process flow chart is linked to the PFMEA and control plan
 Update flow chart to reflect actual production process.
 Communicate any changes on an ongoing-basis to SQE.

[Link]. Design Review

Description
The purpose of Design Review is to ensure that the Product Design is adequately defined to
enable construction of tools and gages. The Supplier shall have the design record for the
part, including design records for sub-components.

Timeline
As per APQP Project Plan

Output
 Defined and measurable Classification of Characteristics (CTQ)
 Appearance, performance and material testing specifications
 Geometric Dimensioning & Tolerancing (GD&T)

Supplier Responsibility
 Confirm the manufacturing process can achieve the specified tolerances on a
sustained basis.
 Any recommendations / improvements to the design record are documented and
submitted to Tata Motors for approval.
 Communicate any concerns related to the CTQ cascade Designators or GD&T
scheme and the manufacturability of the part. Document any open issues on the
APQP Open Issues List
 Develop an understanding of the engineering change process with the Tata Motors
ERC Engineer. Refer Design Review Check sheet7 and address any open action
item.
 Note: Where the design record is in electronic format, e.g., CAD/CAM, the Supplier
shall produce a hard copy.

7
Refer Design_Review_Chk.xlsx

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[Link]. Design Failure Mode and Effects Analysis (DFMEA)

Description
Design Failure Mode and Effects Analysis is an activity to assess and prioritize the risk of
failure of a product design component, subsystem, or system in achieving product
performance, reliability, or safety goals and to develop mitigation plans.
The purpose of DFMEA is to predict the potential failure of the product design, evaluate the
effects of those failures, and then identify actions to reduce the risk before the design is
released to manufacturing.
Timeline
Initiated before or at design concept

Output
DFMEA document8 and cascade DFMEA to sub-component level DFMEA.

Supplier Responsibilities:
 The supplier needs to create and submit the DFMEA if it is design responsible.
 The DFMEA document should be maintained throughout the life of the product and
updated and revised prior to any engineering changes. Changes in part level DFMEA
should be communicated to Tata Motors for updating system level DFMEA.
 Supplier must address and identify all Tata Motors special characteristics as given in
TS11413 standard.
 The DFMEA shall be ranked based on AIAG guidelines for Severity, Occurrence and
Detection Ratings.

[Link]. Process Failure Mode and Effects Analysis (PFMEA)

Description
A PFMEA is used to identify potential weak areas in the manufacturing and assembling
process. Cross-functional teams should be organized to study each step of the process for
possible failure modes, effects of failures, and potential causes. Countermeasures must be
provided for failure modes as per requirements in AIAG FMEA Manual.

Timeline
Starting at APQP Kick-Off Meeting and complete by PPAP.

Outputs
 PFMEA9
 RPN Reduction Summary

Supplier Responsibilities:
 Review and update PFMEA each time a design change is made or a Process change
is implemented. All potential areas for failure are included in the PFMEA and
appropriate corrective actions are planned and implemented.

8
Refer [Link]
9
Refer [Link]

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o Note: A PFMEA should not consider product design changes to compensate

the process deficiencies.
 Prepare PFMEA with inputs and participation from cross functional team.
 Adhere to PFMEA RPN Reduction Summary10, including the categorization of risk,
establishment of a top ten list, development of recommended actions, and update to
Tata Motors SQE on demand.
 Drive simple and inexpensive mistake / error proof devices into the process to help
prevent and detect errors.
 Ensure that all failure modes and related severity numbers from DFMEA are listed in
the corresponding PFMEA.
 Ensure that the current process controls and results of recommended actions on the
PFMEA are listed on the control plan.
 Ensure that the PFMEA has a link with the manufacturing process flow chart and the
control plan.
 If the process, material or manufacturing location changes, revise the PFMEA and re-
evaluate the impact on severity, occurrence, and detection ratings.
 Ensure that subcontractors’ PFMEAs are developed and RPN reduction action plan
are implemented.

[Link]. Tooling and Equipment Review

Description
The task ensures that the manufacturing process is designed to the latest engineering
change level (e.g. NR, A, B, C etc.) and certified to produce quality parts at rated production
rates as per Tata Motors specifications.

Timeline
Starting at Tooling Kick off Meeting till PPAP approval

Outputs
Process capable Tooling and Equipment delivered on time as per APQP Project Plan.

Supplier Responsibilities:
 The supplier should review and inform Tata Motors about any changes in the original
project timing.
 The supplier must participate in Tata Motors design reviews to incorporate Tata
Motors requirements and special characteristics in the tooling or equipment.
 Design, build and obtain certification of and validation of tooling and equipment as
per latest CAD data.
 Participate in design reviews with Tata Motors and ensure GD&T, CTQ Cascade
requirements are included in the tooling, equipment and functional test design. Also
ensure tooling and equipment will produce parts consistently to meet process
capability requirements.
 The supplier should inform Tata Motors about any design and process changes
regarding any new or modified tools, rearrangement of existing tooling or equipment,
any product or process changes impacting fit, form, function, performance and
durability of saleable product, any test/inspection methods and any new facilities.
 Prior to tools being grained, dimensional verification is required by Tata Motors and
Grain Approval to be signed off.
10
Refer RPN_Red_Sum.xlsx

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 Ensure PFMEA has been comprehended and incorporated into tooling and
equipment design.

[Link]. Gage Development and Approval

Description
To design, build and certify gages according to latest GD&T release.

Timeline
To be completed by PPAP Approval

Outputs
Approved Gage Prior to PPAP.

Supplier Responsibility
 Identify gage requirement as per CTQ cascade mentioned on drawing.
 Review timing to ensure compliance and inform Tata Motors SQE about any changes
from original project timing, any design and process changes, any new part math
data and/or GD&T changes, any test/inspection methods that include gages, any
new facilities that would house the gages.
 Participate in design reviews, ensure GD&T scheme is released and relevant CTQ
cascade parameters are incorporated into final gage design.
 Design, build, certify gage dimensionally (including a third party certification), perform
complete AIAG MSA (GR&R and Bias study) and meet all requirements as per Tata
Motors fixture standards.
 The supplier shall conduct and document Gage R&R studies upon receipt of new or
repaired measuring equipment.

[Link]. Control Plan

Description
 It defines the method to be used to control all CTQ Cascade for parts being built for
vehicle builds, power train, and service applications to ensure customer
requirements.
 It is to be developed in line with the control plan format referenced in the AIAG APQP
Manual.

Timeline
Starts with Initial draft at APQP Kick Off, supplier shall update parallel PFMEA changes
prior to PPAP.

Output
 Control Plan11
 Individual Process Control Charts for all CTQ cascades (FMASOW)

11
Refer Control_Plan.xlsx

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Supplier Responsibilities:
 Incorporate necessary inputs from PFD, PFMEA, Lessons learned, warranty data,
PRRs on similar parts and manufacturing process capability on similar parts.
 Supplier should maintain the control plan throughout the life of the product.
 The control plan must be approved by a cross functional team at supplier’s end. It
may be reviewed by Tata Motors depending upon the component.
 The supplier must identify and address all Tata Motors special characteristics on the
control plan.
 The supplier should communicate any changes in control plan to Tata Motors
 The supplier should conduct frequent audits to check the implementation of controls
in the control plan.

[Link]. Production Part Approval Process

Description
The details of various PPAP activities as prescribed in the AIAG PPAP manual are
mentioned. Please refer to AIAG PPAP Manual, latest edition for further details.

Timeline
As per APQP timing Chart

Output
Completed PPAP documents, PSW

When PPAP is required?

 New Part
 Engineering Change(s)
 Tooling: Transfer, replacement, refurbishment or additional tooling
 Correction of discrepancy
 Tooling inactive > one year
 Change of optional construction or material
 Sub-supplier or material source change
 Change in part processing
 Parts produced at new or additional location

Submission Levels
The supplier shall submit the items and/or records specified in the level identified below:

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•PSW only and AAR, if applicable submitted to TML.

Level 1

•PSW with product samples and dimension results submitted to TML.

Level 2

•PSW with product samples and complete supporting data.

Level 3

•PSW and other requirements as defined by the TML.

Level 4

•PSW with product samples and complete supporting data reviewed at the
Level 5 supplier’s location.

Submission to Tata Motors: - Levels of Evidence12

Requirement Level 1 Level 2 Level 3 Level 4 Level 5
Design Record
- for proprietary parts R R R * R
- for all other parts R S S * R
Engineering Change Documents R S S * R
Customer Engineering approval R R S * R
DFMEA R R S * R
Process Flow Diagrams R R S * R
PFMEA R R S * R
Control Plan R R S * R
MSA Studies R R S * R
Dimensional Results R S S * R
Material, Performance and Test R S S * R
Initial Process Studies R R S * R
Qualified Lab Documentation R S S * R
Appearance Approval Report S S S * R
Sample Product R S S * R
Master Sample R R R * R
Checking aids R R R * R
Records of compliance R R S * R
Part submission warrant S S S S R
Bulk Materials Checklist S S S S R

Legend
S – Supplier shall submit to Tata Motors and retain a copy of records or documentation
items at appropriate location
R – Supplier shall retain at appropriate locations and make readily available to Tata Motors
upon request.
* – Supplier shall retain at appropriate locations, and submit to Tata Motors upon request.
Tata Motors will determine what is needed for submission.

PPAP Approval Status

12
As per AIAG PPAP Manual

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Full Approval
 PSW signed off as approved and all open issues are closed13.
 For Bulk Materials, supplier shall use the Bulk Materials Approval Form, AIAG PPAP
Manual, Appendix F.
 For tires and Commercial Vehicles (truck industry), suppliers shall refer the AIAG
PPAP Manual, Appendix G and H respectively.

Interim Saleable
 Permits shipment of parts for a given time or quantity, whichever is less.
 Interim approval is granted when the supplier has prepared and submitted an
approved action plan to the Tata Motors SQE and is valid till POPP batch.
 If the PPAP is not re-submitted within the time frame of Interim Saleable status
(unless otherwise specified by the Tata Motors SQE), PPAP is rejected.
– If the PPAP submission date is extended beyond the time frame, approval
from SQ Head and Design Engineering Head shall be taken.

Interim Non Saleable

 PPAP submission does not account for all defined Tata Motors requirements.
– If the requirements are related to Product safety and/or statutory
requirements this status is invalid and PPAP stands rejected.
 Supplier must submit corrective action plans to meet Tata Motors requirements
 Interim Non Saleable PPAP is valid for only alpha and beta build.
– Note: - Parts should be dimensionally known parts

Reject
 PPAP submission does not meet Tata Motors defined requirements based on the
production lot and/or accompanying documentation.
 Document submission and/or process correction is required.
 Parts will not be shipped before submission of approved/Interim Saleable PPAP.

Process
PPAP activities (DFMEA, PFMEA, MSA studies etc.) are conducted concurrently, as per the
APQP timing charts. Evaluation of the significant production run is done after all issues
identified in EPC station (Step 8) are resolved.
 For Production parts, product for PPAP shall be taken from a significant Production
Run. A significant production run is of at least 8 hours of continuous production or a
production quantity of at least 300 consecutive parts, unless otherwise specified and
approved by Tata Motors SQE.
– For bulk materials, supplier shall refer to AIAG PPAP Manual, Appendix F.
– For tires, unless otherwise specified by Tata Motors SQE, size of significant
production run is 30 tires. PPAP is derived from 8 hours of tire curing from the
approved production process as specified in the control plan.
– For parts developed for commercial vehicles (Truck Industry), guidelines as
referenced in Appendix H of AIAG PPAP Manual, are applicable, unless
otherwise stated by Tata Motors SQE.
– This production is conducted at the production site, at the production rate,
using the production tooling, process, materials and operators. Parts from
each production line e.g., duplicate assembly line and/or work cell, each
13
Refer APQP_OpenIssues.xlsx

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position of a multiple cavity die, tool or pattern, shall be measured and

representative parts tested.
 The supplier is responsible for obtaining the latest revision of the AIAG Manuals and
forms. The supplier shall submit by default a “Level 3” PPAP package, unless
otherwise specified by Tata Motors SQE. All parts that are supplier designed require
“Level 5” PPAP package, unless otherwise specified.
 Any changes to the 4M’s shall be duly notified to the authorized Tata Motors
representative. After the change has been approved by Tata Motors SQE, the
supplier must re-submit the PPAP documents unless otherwise specified.
 Supplier shall maintain all records at his end regardless of submission levels for the
length of time that the part is active plus one calendar year.

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[Link]. Lessons Learned

Description
The purpose is to maximize the knowledge gained from previous programs and not revisit
the same quality or design issues.

Timeline
Throughout new part development

Output
 DFMEA & PFMEA and other PPAP Documents updated with Lessons Learned
 Part-Specific SOR for key commodities updated with Lessons Learned throughout
the APQP process.

Supplier Responsibility
 Lessons Learned Update
– Review solutions to issues identified in the Kick-off meeting and new items
added to the list in various builds till launch.
– As solutions are identified, DFMEA, PFMEA, Flow Chart, and Control Plan
are reviewed and updated.
 Contribute with additional lessons learned based on knowledge of the commodity.
 Adhere to the updated SOR.
 Place a formal process to update FMEA and control plans based on Lessons
Learned.

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5.1.7. Run at Rate

Purpose
Run at Rate (R@R) is an activity to verify that the supplier’s actual manufacturing process,
functioning under normal conditions, is able to produce components meeting Tata Motors
requirements and matching the Quoted Tool capacity as mentioned in Purchase order.

Scope
All Suppliers of production parts, service parts, and sourced products that have PPAP
submission status as “saleable” or “fully approved”.

Timeline
 Upon PPAP approved Status.
 8 weeks prior to start of production.

Output
• Completed R@R Capacity Workbook and R@R for each part
• Supplier meets Daily Contract Capacity

Process
R@R is carried out once the PPAP has been submitted as mentioned in scope above. The
SQE verifies that Tata Motors Lean Capacity Requirement14< = Quoted Tool Capacity15

Supplier Responsibility
 Develop a R@R plan and provide to the SQE at the Gate 1 APQP Kick-Off meeting.
 Complete the Capacity Workbook (Manufacturing Flow Diagram, Shared Capacity
Sheet(s), and Manufacturing System Capacity Estimate) and submit to the SQE prior
to the Gate 3 APQP Review.
 The capacity analysis must show satisfactory results prior to ordering tooling and
equipment.
 Ensure understanding of the R@R “PASS” performance metrics.
 Conduct preliminary R@Rs and/or simulations prior to the planned R@R to confirm
readiness. The PPAP run of parts will be one of the trial runs.
 Complete verification for all subcontractors, and submit prior to the R@R.
 Completely fill the R@R Hourly Count Sheet during the R@R for both the final
operation and the constraint operation.
 Completely fill the Capacity Workbook for all R@Rs and forward to the SQE

14
Daily Production Requirement
15
QTC as mentioned in the Tata Motors Purchase Order

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Process Flow
Escalate any
Missing PO
information

GR 3 Meeting and
Is Run @ Rate
Yes R@R Kick off Meeting escalate any missing
Required
supplier information

No Supplier completes
PFD, Shared
Capacity Sheets.
Exemption
from SQ Head

Status:-
Exempt Supplier
TML or Supplier Conducts
TML
monitored APQP Prior R@R

Supplier

Supplier conducts Fill the Hourly Supplier conducts

R@R in presence of Sheet R@R in presence of
SQE SQE

Supplier completes Supplier completes

Capacity Workbook Capacity Workbook
& sends it to SQE. & sends it to SQE.

R@R
R@R Status?? Pass
Complete

Fail

Supplier updates
APQP Open Issues
List.

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5.1.8. Early Production Containment

Purpose
The purpose of EPC is to:
 Validate the supplier’s production control plan
 Protect Tata Motors assembly and manufacturing centres and service part
warehouses from quality non-conformances
 Ensure that any quality issues that may arise are quickly identified, contained, and
corrected at the supplier's location

Scope
EPC station is to be established for all parts that require PPAP approval from Tata Motors.

Timeline
EPC will start from first off tool sample to meet Product and Process Validation Phase

Output
 EPC Control Plan audit

Supplier Responsibilities:
Supplier should demonstrate compliance to requirements mentioned in SQ-SOR for EPC but
not limited to the following:
 Implement EPC with entry date, exit criteria, and exit date as defined by Tata Motors
SQE.
 Establish EPC containment stations, which must be off-line, separate, and
independent check from the normal manufacturing process and located at end of
process.
 Verification of the effectiveness of error proofing.
 Immediate implementation of containment and irreversible corrective action when
non-conformances are discovered in the EPC containment area or at the receiving
location.

Exit Criteria
For a Supplier to exit from the EPC firewall, the manufacturing process should be error free
for 21 consecutive days after observation of the problem, subject to minimum 3 months of a
firewall stationed installed at the supplier end.

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Process Flow

New Part / Change

in Existing part

No EPC
Is PPAP Required No
Required

Yes

Verify Supplier has used

PFMEA to determine
necessary controls

Implement additional
Supplier develops EPC
checking provisions. Inform
plan
Tata Motors SQE

Timeline : minimum 3
months after SOP

Correct any Non-

Conformances found by Tata
Motors manufacturing sites

No

Has the Supplier

achieved the Exit
Criteria ?

Yes

EPC Exit

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5.2. Current Quality

The Current Quality defines the standardized work around common processes used across
all locations to protect Tata Motors manufacturing/assembly plants and to drive systemic
improvement to the supply base.

5.2.1. Continuous Improvement

Purpose
Continuous Improvement has been included in the Pro-X 16 Step SQ Process to promote
the culture of PDCA at supplier manufacturing locations. Continuous improvement:
 Defines the supplier’s responsibility in developing and sustaining a manufacturing
process that continuously improves the product and related manufacturing processes
throughout the product/part lifecycle.
 Reduces variation and ensures process stability and capability over time (after a part
has satisfactorily completed PPAP), with emphasis on zero defects.

Scope
Continuous Improvement applies to all suppliers of Tata Motors and is applicable even when
Tata Motors has not requested data and/or product characteristics have not been called out
in the design record.

Supplier Responsibility:
All suppliers are required to have quality systems in place that ensures parts shipped to Tata
Motors meet specification. Suppliers are also expected to have a system to:
 Properly identify the root cause of non-conformities
 Prevent recurrence of non-conformances across their operations.
 Effective Problem Solving (EPS) process in place to identify the root cause on a
timely basis, and implement and validate the corrective actions.
 Lessons Learned process: Suppliers are required to have a documented and
effective process in place to drive lessons learned into current and future application
of FMEAs and Control Plans.

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5.2.2. Quality Workshop

Purpose
 Quality Workshop is a 2 day workshop conducted to facilitate the development and
implementation of 10 basic WCSQ strategies
 Quality Workshop ensures that benchmarked practices are standardized across all
suppliers.

Scope
 Proactive – All Suppliers of legacy parts; Enhance supplier’s QMS.
 Reactive – Exit Criteria for all Controlled Shipping Process / Top Focus

Process
 WCSQ is a 2 day workshop that develops and facilitates implementation of 10 basic
strategies of WCSQ16.
 A WCSQ Audit will be conducted by the Tata Motors SQE to gage need for Quality
Workshop.
 Supplier provides detailed time bound action plan to the Tata Motors SQE
highlighting the updates on a weekly basis.

16
Refer Step 5 of Pro-X SQ 16 Step Process

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5.2.3. SQ Process & Measures

Purpose
To produce a product quality plan which will support development of a product or service
that will satisfy the customer. This section defines the process, roles, responsibilities and
requirements of:
 Problem Reporting and Resolution (PRR)
 Controlled Shipping
 New Business Hold
 Supplier Measurements
– Parts Per Million (PPM)
– Major Disruptions
 Process control plan audit

Scope
This process is to be used for all pre-production, production, service and accessory part
requirements.

[Link]. Problem Reporting and Resolution (PRR)

Description
A “Problem Resolution Report” (or “PRR”) is a record issued to address the following:
 Part or material nonconformance through the life of the part or material
 Packaging nonconformance
 Issues and concerns with the shipping of production parts
 Supplier responsible warranty and engineering design issues
 Procedural or process non-conformity
 New Business Hold

Types of PRR are listed below:

i. Quality
A Quality PRR should be issued when the customer has verified that a nonconformance was
caused by the supplier resulting in part quality issues.

ii. Customer Satisfaction

A Customer Satisfaction PRR is issued when Tata Motors has verified that nonconformity,
excluding pricing and/or other commercial issues, was the result of a supplier’s action or
inaction.

iii. Engineering
Engineering PRR’s may be issued to design responsible suppliers to document design
related concerns.

iv. Indirect
An Indirect PRR may be issued to document a supplier responsible problem caused by a
non-production supplier (tooling, equipment repair parts, capital equipment, etc.) at the
customer plant. This would include scheduled work activities that cannot be completed due
to the supplier’s failure to meet prior delivery commitments.

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v. Packaging
A Packaging PRR is issued when Tata Motors has verified that the supplier caused a
packaging non-conformance, which could result in part damage or affect the sale-ability of
the part.

vi. New Business Hold

The customer will issue a New Business Hold PRR to document the supplier being placed
on New Business Hold.

vii. Shipping
A Shipping PRR should be issued when the customer has verified that a shipping or
scheduling-related nonconformity was caused by the supplier.

viii. Program Management

A Program Management PRR may be issued by Tata Motors P&SC only, for
nonconformance during launch phase that does not result in part damage or does not affect
the sale-ability of the part.

Supplier Responsibilities
Acknowledgement
The supplier shall acknowledge the PRR by an email reply and initiate initial response
(containment) within 24 hours.

Initial Response (Time – 24 Working Hours)

Supplier response must contain the following:
 Immediate containment actions to prevent further shipments of nonconforming parts
or material.
 Initiate rework or segregation as an immediate containment at the Tata Motors plant
location.
 Removal of the nonconforming parts across the entire supply chain.

Final Response
The supplier shall provide a final response within applicable number of days as mentioned in
SRM PRR portal. The final response shall include at a minimum:
 Containment and preventive actions taken and evaluations/success of the results
thereof
 Root cause of the problem, including methods used to identify the root cause.

[Link]. Controlled Shipping

For details refer to the section on CS1 and CS2.

[Link]. New Business Hold

Suppliers with continuous poor Supplier Rating or suppliers without TS16949 certification
may be placed on New Business Hold (NBH).

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[Link]. Supplier Measurements

This section defines the supplier measurements used by Tata Motors to monitor supplier
quality performance. These measures are used in Quality Performance Reports to help
guide future business decisions, and help direct resources to the appropriate areas that
require additional focus.

Major Disruption
Major Disruptions are tracked by the issuance of PRR’s.
 A problem that affects multiple plants is considered one Major Disruption.
 A problem that could be classified as more than one type of Major Disruption shall be
issued under one PRR with one type of Major Disruption.

Parts Per Million (PPM)

PPM is impacted when both of the following conditions exist:
 Quality PRR is written with quantity discrepant and
 There are receipts for referenced part and supplier code within the previous twelve
months.

PPM for a supplier code is calculated monthly using the following formula:
1. Total all the “actual quantity nonconforming” for all part numbers for that location
2. Divide by total receipts for that location
3. Multiply by 1,000,000.

[Link]. Process Control Plan Audits

Purpose
The purpose of the Process Control Plan Audit is to ensure that the supplier is following,
updating, and maintaining the PPAP required documents (PFA, FMEAs, and Control Plans)
and, executing the PCP, while executing continuous improvement.

Timeline
Throughout the line of the product

Output
PCPA Audit Summary

Supplier Responsibility
 Extend full support for the PCPA audit.
 Implement any immediate containment/addition process controls as directed.
 Develop, document, and provide action plan with appropriate detail, timing,
ownership, etc.
 Implements action plan on a timely basis.

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5.2.4. Level I – Controlled Shipping (CS I)

Purpose
Level 1 - Controlled Shipping is a demand by Tata Motors that a supplier put in place an
inspection process at the supplying location to sort parts/products for a specific issue. CS 1
helps to implement a root-cause and effective problem solving process (EPS), while isolating
Tata Motors manufacturing plant from the receipt of nonconforming parts/material.
Note: This inspection, enforced by Tata Motors SQE, is in addition to normal controls.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products with
below listed issues may fall under the purview of CS 1.
 Repeat and/or non-conforming PRRs
 Severity of the problem
 Field Issues (Warranty, JD Power etc.)
Note: The above mentioned reasons are not exhaustive and the final decision will be taken
by Tata Motors.

Timeline
Suppliers may be placed in CS1, as per several criteria defined in the scope of the step

Output
 Certified Material to the Customer facility.
 Additional process controls to prevent future occurrences.
 Corrective Action Report from Supplier

Supplier Responsibilities:
 Establish a separate CS 1 area at the manufacturing location
 Notify additional Tata Motors facilities that use the same part, inform them of the
nonconformance, and provide containment activities as necessary.
 Mark individual parts, material, and containers, with CS 1 tags, to identify parts CS1
certified to be used in Tata Motors assembly/operations
 The supplier, simultaneously, implements an Effective Problem Solving Process
(EPS), and isolates Tata Motors from the receipt of nonconforming parts/material.
 Perform a redundant inspection of all suspected non-conforming products as per the
agreed upon process, and ensure defect free parts/material are delivered.
 Develop, implement and validate the permanent corrective and/or preventive actions,
along with improved process controls
 Meet the defined exit criteria as mentioned in the SRM portal.

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5.2.5. Level II – Controlled Shipping (CS II)

Purpose
Level II - Controlled Shipping is a demand by Tata Motors that supplier put in place a 3rd
party redundant inspection process to sort for a specific non-conformance, while maintaining
Level 1 Controlled Shipping and implementing a root-cause problem solving process.
 Suppliers shall select the third party from an approved listing of Third Party Suppliers
maintained by Tata Motors.

Scope
A CS2 may be raised due to any of the following parameters:
 Repeat PRRs
 Severity of the problem
 Ineffective Level 1 Controlled Shipping
 Field issues (Warranty, JD Power etc.)

Timeline
Suppliers may be placed in CS 2, as per several criteria defined in the scope of the step

Activities
 Certified Material (with CS 1 tag) to the Tata Motors facility.
 Problem solving capability to establish root cause.
– Documented and verified Corrective Action.
– Additional process controls to prevent future occurrences.

Supplier Responsibility
 Supplier contacts a Controlled Shipping 3rd party provider.
o SQE should receive a copy of the same when appropriate.
 Supplier performs a redundant inspection of all suspect nonconforming products as
per the agreed upon process to ensure defect free parts (CS1). CS1 is a separate
and independent inspection process from CS2
 The 3rd Party Provider performs an additional redundant inspection of all suspect
non-conforming products as per the agreed upon process to ensure defect free parts
are delivered to Tata Motors.

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5.2.6. Performance Monitoring

Purpose
 Enable suppliers to assess their performance.
 Award suppliers with best-in-class performance.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products.

Timeline
Every quarter for all suppliers

Output
Timely release of Supplier Performance rating

Process
The supplier is rated on certain parameters and his Quality Performance Reports are
generated. Similarly the sourcing metrics are generated classifying the supplier as approved
or low performing supplier. These reports will be available to the supplier via the SRM portal
and updated every quarter.

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5.2.7. Improvement Meeting

Purpose
This step describes the formal meetings between Supplier’s Leadership Teams and Tata
Motors Leadership teams to review the Supplier’s quality performance and actions for driving
improvement.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products.

Activities
Top Focus

[Link]. Top Focus

Description
Top Focus is a process engaging the leadership teams to improve the quality performance
of the supplier via systemic changes in the supplier’s manufacturing and quality systems.
Supplier’s Management is accountable for each action plan and impact of failure of each
target.

Timeline
Complete Product Life-cycle

Output
 Process Control Plan Audit (PCPA)
 Step Down Chart

Supplier Responsibilities
 Commit resources and participates in Quality Workshop (as requested).
 Performs a detailed analysis of the Supplier Performance Reports
 Develop a Quality Improvement Plan
 Track implementation of the initiatives and resulting quality improvements.

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5.2.8. Re-Sourcing
Purpose
Re-Sourcing step is included in Pro-X 16 Step SQ Process to protect and mitigate risk to
Tata Motors from engaging in business with poorly performing suppliers.

Scope
All Suppliers of production parts, raw materials, service parts, and sourced products with
poor performance

Process Flow

Resourcing /
Exit

No
New
Business
D/E Supplier Quality PRR Improvements
Hold
Yes

Eligible for Good Parts Performance

Supply Award! Supplied Monitoring

Process
Suppliers with continuous quality problems may be placed on New Business Hold (NBH) or
Tata Motors may proceed to resourcing if the following criteria are met:
 Repeat of major disruptions: downtime, part shortage, tool/process change etc.
 Lack of ISO/TS16949 certification
 Continuous Poor performance
 Continuous Customer Satisfaction PRR’s

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6. APPLICABLE DOCUMENTS

Document File name on SRM

Supplier Quality Statement of
SQ_SOR.pdf
Requirements
APQP Kick Off Meeting Checklist APQP_KickOff.pdf
APQP Open Issues list tracking APQP_OpenIssues.xlsx
Tier II Supplier Management TierII_Mgmt.xlsx
Process Flow Diagram [Link]
DFMEA Format [Link]
DFMEA Check Sheet DFMEA_Chk.xlsx
Design review Check Sheet Design_Rev_Chk.xlsx
PFMEA Format [Link]
PFMEA Check Sheet PFMEA_Chk.xlsx
RPN Reduction Summary RPN_Red_Sum.xlsx
Control Plan Control_Plan.xlsx

Document path:
Log on to [Link] using your Admin ID (Vendor Code) and password.
Go to the “Documents” folder using the following path: Home > Documents > Tatamotors > Message
> SupplierQuality > Supplier Manual

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7. GLOSSARY OF TERMS

4M Material, Machine, Man, Method

AAR Appearance Approval Report
AIAG Automotive Industries Action Group, an organization formed by
General Motors, Ford and Daimler-Chrysler to develop common
standards and expectations for automotive suppliers.
APQP Advanced Product Quality Planning
BOM Bill of Materials
Cpk Capability Index for a stabile process
CSCS Classification of Special characteristics and symbols
DFMEA Design Failure Modes and Effects Analysis. It is used to identify the
potential failure modes of a part, associated with the design, and
establish a priority system for design improvements.
DRR Direct run rate
DRL Direct run loss
DVP Design Validation Plan
EPC Early Production Containment
FMASOW Failure Mode Avoidance Statement of Work
FMQ Forward Model Quality
Gage R&R Gage Repeatability and Reproducibility
GD&T Geometric Dimensioning & Tolerance
IPTV Incidents per Thousand Vehicles
KCC Key Control Characteristics. It is a process characteristic where
variation can affect the final part and/or the performance of the part.
Kick-Off Meeting The first APQP supplier program review.
MSA Measurement Systems Analysis
NBH New Business Hold
NPI New Product Introduction
OEM Original Equipment Manufacturer
PCP Process Control Plan
PFMEA Process Failure Modes and Effects Analysis. It is used to identify
potential failure modes associated with the manufacturing and
assembly process.
PO Purchase Order
PPAP Production Part Approval Process
Ppk Performance index for a stable process
PPM Parts per Million
PRR Problem Reporting & Resolution
PSA Potential Supplier Assessment
R@R Run at Rate
RFQ Request for Quotation
RPN Risk Priority Number related to FMEA development
SOR Statement of Requirements
SPC Statistical Process Control
SQ Supplier Quality
SQE Supplier Quality Engineer
SQMS Supplier Quality Management Systems
WCQ World class quality
WCSQ World class supplier quality

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