Quality Assurance -

process
In-coming Inspection. Product Audit Supplier Audit.
•Samples are randomly picked up from every •Audit carried out on a Yearly basis. •Audit carried out as per yearly plan
lot as per ANSI/ASQC Z1.4 •Audit is carried out at all stages of •PPAP audit
•A sampling inspection is carried out to production and delivery. •QMS audit
check for Visual, Dimensional, Functional •Verify conformity to all requirements, •Supplier assessment audit
and Assembly condition. such as product dimensions, functionality,
•Conformance of material to all BOM packaging and labeling
specifications is verified.
Customer Complaint
Layout Inspection •Handling of Customer Complaint
In-process Inspection. •Inspection is carried out on a Yearly •Resolution thru 8D approach
•Inspection is carried out as per defined basis.
frequency in control plan. •Complete measurement of all product
•Product undergoes visual, dimensional and dimensions as shown on the design Customer Returns
functional checks for process related defects. records is carried out. •Handling of Customer Returns
•Concept of First Off inspection for critical •Root cause analysis for failure
operations are also covered •Rework & return back to customer
Shipment Audit
Outgoing Inspection. • Shipment audit is carried out as per COQ / COPQ
•As per the sampling plan ANSI/ASQC Z1.4, monthly plan FR/QE/200
•Monitoring COQ & COPQ for automotive
samples are picked up for outgoing • Min one product is covered for each
and non-automotive products
inspection. customer.
•Outgoing Product undergoes visual, • Shipment audit requirements are
dimensional, electrical and fitment checks. verified as per check sheet FR/QE/201
•Product is inspected as per IPC-A-610 rev H PV / SPC / MSA
Dock Audit •First article inspection for new products.

CQI Audit • Material Insp. Is carried out on six •SPC monitoring for SC
• MSA attribute / Gauge R&R study
• Special Process – Soldering is consider for monthly basis for FG material based on
ageing report. •ICT / AOI / EOL / SMT line validations
CQI audit.
Quality Assurance -
process
In-coming Inspection In-process Inspection Final Inspection
Incoming Inspection as per the appropriate Sampling Size & frequency as defined in
sampling plan – ANSI / ASQ Z1.4 Lot submitted by Production
Control Plan

Verify the components / PCBs / Custom Parts Verify the process output as per the Final Inspection as per the appropriate
as per Approved BOM specification defined in Control plan sampling plan – ANSI / ASQ Z1.4

Rejected Rejected
Observations Observations are
Observations are recoded in recorded in
are recoded in inprocess Raise RAR / Outgoing
Feedback Inspection
incomong Inspection demand CA
to supplier Format?
Inspection Format? from Production
Format?

Accepted Accepted

Accepted
Lot given to the production Clear the quantity in SAP
SCAN QR Code - DEAL Traceability

Robust Execution of QA Process

 Quality Control plans Apply OK/QA accepted stamp
Apply OK/QA accepted stamp
on the material packet  MSA & Gauge R&R Study on the batch card
 Set-up validation
 SPC Analysis
 Product specific OJT
Quantity handed over to Finished
Clear the quantity in SAP  One point Lesson good Stores for packing
 Trained operators in IPC 610
Return material to the stores.
Incoming Sampling Plan : Customised Parts, eBom Parts, PCB, Fasteners and Consumables
Quality Assurance - process

elaborate approach to ensure repeatability

• Competency in Quality Core Tools (FMEA, MSA, SPC, APQP/
PPAP, Risk Assessment)
• Robust Execution of process through
 Control plans
 Process Audits
 Set-up validation
 SPC Analysis
 Product specific training (visual tools)
 Workmen training on IPC 610 E
• Structured approach to defects elimination
 In-process checks, EOLs, dock audits
 Gauge R&R and Calibration
 One-point lessons/ Visual controls
 Focused containment actions
• System level improvements through internal audits, quality circles,
supplier assessment, G8D
• Annual customer feedback surveys