- Rev 4 Date 10.05.2013 -

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1

Revision Index

Revision

no

Change description Date

0 Initial release 30.12.2008

1 Part identification guidelines for traceability

included

25.07.2009

2 Flow chart for Forward & Reverse traceability

of supplier parts included

Supplier process change control added

30.10.2009

3 Company name WABCO-TVS has been

changed to WABCO INDIA LIMITED (WIN)

15.09.2011

4 Safety and significant characteristics CpK

report submission by Suppliers in Supplier

web portal added.

10.05.2013

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Preface

WABCO INDIA LIMITED (WIN) being involved in developing, manufacturing and

selling products for heavy / light commercial vehicles and utility vehicles such as

braking system, vacuum brake valves and electronic braking system, the quality

of which plays a vital role in terms of vehicles safety. WIN has evolved the Safety

strategy and striving to achieve excellence in Product Safety. It is being ensured

that the various processes involved in the manufacture of the products comply

with Product Safety Management requirements. It is also essential that the

same has to be extended to Suppliers supplying various components being fitted

into the assembly. The purpose of this manual is to define the Product Safety

management requirements which will be useful to suppliers in implementing.

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CONTENTS

Page no

1. Objective 4

2. Scope 4

3. Product Safety Management Overview 4

4. Safety , Significant characteristics 5

5. General awareness Training 7

6. Process design for Zero defect 7

7. Process Machine capability 7

8. Machine maintenance 7

9. Customer application 8

10. Control of Tools, dies , fixtures 8

11. Visual management identification 9

12. Control plan 9

13. Measurement system Analysis 10

14. Management of nonconformities 10

15. Control of rework 11

16. Material traceability 11

17. Identification of safety component suppliers 18

18. Deployment for Tier n suppliers 18

19. Control of changes 18

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20. Manufacturing at Tier 2 suppliers 19

1.0 Objective of this Manual:

To spell out the various requirements of Product Safety Management through

this manual so that the suppliers understands and become aware of the

requirements, implement the same in their manufacturing process ensuring

defect free supplies which forms a part of the Safe Product

2.0 Scope:

This is applicable to all Direct material Suppliers

3.0 Product Safety Management:

The term Product Safety Management refers to the set of activities which the

supplier shall implement at their end which will ensure end customer

expectations such as

- Quality of the product and Service Zero rejection at customer end

- Safety of the truck / vehicle

- Zero downtime to accomplish JIT deliveries

- Immediate response at an issue

- Durability and high residual value

Thus, a truck / vehicle could not lost the control or afford unscheduled stops for a

reason of a defective component supplied by a supplier

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4.0 Safety, Significant Characteristics:

WIN identifies Safety significant characteristics during system, component, and

process design. The logic of identifying safety characteristic and significant

characteristic is as shown below in the flowchart

4.1 Safety Product characteristics Definition

Even that can lead injury at people

Definition of Safety Characteristics by

customer

Definition of Significant Characteristics by

customer

Characteristics with requirements from legal

regulations

System FMEADesign FMEA

Identified and

marked as Safety Characteristic

Identified and marked as Significant

Characteristic

Characteristics

with S=10 or Vehicle breakdown

Characteristics with S=9,8,7or no fit on vehicle

or noticeable defect with immediate need for repair

Yes

Yes

No

Results of tests

and simulations

No

No marking

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Risk of injury

Can affect the product safety or legal consideration

4.2 Significant product characteristics Definition

Characteristic that is important for customer

Can affect customer satisfaction

Loose of principles functions of the device

Breakdown, repairing, ability of the product, stability

A sample of the drawing shown Safety product characteristics and significant

product characteristics is shown below

- Safety product characteristics

- Significant product characteristics

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It is essential that suppliers shall maintain a master list of Safety significant

characteristics.

5.0 General awareness Training:

WIN conducts periodical training program on product safety. Suppliers shall

nominate persons and get trained. They in-turn can train their in-house

employees, new recruits and temporary trainees in their own organization. The

training programs are conducted to develop and maintain the knowledge on

product safety and liability. It is also the responsibility of the supplier to train Tier

n suppliers so that they are well aware of product safety requirements

6.0 Process design for Zero defect:

The supplier shall design and carryout processes which will ensure Zero defect.

The supplier shall also maintain all safety significant characteristics and

processes under control

- Cpk meets or exceed Cpk target (>1,67)

- Design and process poka yoke

- Auto-detection systems combined with containment of defective

products

The supplier shall not alter any process without prior approval obtained from

WABCO INDIA

7.0 Process and machine capability

Supplier shall ensure that Statistical process control techniques are being used in

the safety machines, workstations to constantly check the process capability. The

stability of the process parameter shall be demonstrated through SPC charts and

shall be monitored.

Supplier shall upload every months and , Critical and Major

Characteristics CpK report in www.wabcoindiaportal.com (supplier web portal) on

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or before 5th of following month. CpK report submission status will appear in

WABCO in-coming inspection GRN tag, and the parts will be accepted only if

CpK report is received on time.

8.0 Machine maintenance:

The machines which are used for manufacturing safety products shall have high

equipment efficiency in order to avoid any substitution. It is essential that the

machine and equipments related to product safety operations are highlighted in

the maintenance plan. There should be delay on maintenance operations for

safety critical related equipments. The maintenance people are well trained in

product safety and related specific instructions

9.0 Customer application:

Supplier shall ensure that the components manufactured are being handled safe.

Necessary protective arrangements / dedicated containers / packaging shall be

ensured at the appropriate level to avoid any damages on safety significant

characteristics. The supplier shall ensure the above throughout the supply chain.

For example a threaded component manufactured by a supplier transferred to

heat treatment and surface protection operation has to be protected against

thread damage which is a customer end fitting shall be handled safe by providing

appropriate in-house dedicated containers , covered with protection sleeve

during the transit and dispatch

Raw material Supplier

Supplier A

Tier 2 Supplier Heat treatment

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10.0 Control of Tools, Dies and Fixtures:

The supplier shall have a system of monitoring tool life, periodical Inspection and

calibration of Jigs and fixtures used in the manufacturing of safety products.

11.0 Visual Management Identification:

There shall be a specific identification on Product safety for dedicated

manufacturing or workstations, Safety characteristics on manufacturing

documentation. Product safety workstations and manufacturing documentation

are audited periodically and updated regularly based on the experience

Tier 3 Supplier Surface protection

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12.0 Control Plan:

The supplier shall ensure that control plans are defined and suitable for all safety

characteristics. The controls plans shall be audited periodically (once in 6

months) and updated regularly according to the experience. In case of any

change in the process, the supplier shall submit updated control plan and get

prior approval from WIN without which any change would not come into effect.

The supplier shall also produce the control plan documents to WIN auditors

during the PPAP audit

13.0 Measurement System Analysis:

The supplier shall establish a process to evaluate the reproducibility and the

repeatability of each measurement done on safety characteristics. R&R

measurem