Supplier Quality Manual - Auto-Kabel...Public Quality Standards: Quality standards such as ISO 9000 series and IATF 16949, and environmental standards such as ISO14000 shall be complied

Confidential

This English translation is for reference purposes only and the wording in the Japanese language

prevails in case of any discrepancy.

Supplier Quality Manual

Revision date : May 1.2019

Execution date : Jun 1.2019

Confidential Supplier Quality Manual

Table of Contents

December 1, 2016

Honda Motor Co., ltd. 2/3

Table of Contents

1 Preface

1-1 Structure of SQM

1-2 Production Process Image

1-3 SQM Outline

2 General

2-1 Important Safety Parts

2-2 Regulatory Compliance Certification

2-3 Designation of Quality Representative

2-4 Sub-Supplier Quality Assurance

2-5 Control of Honda-Owned Property

2-6 Control of Supply Parts

2-7 Supplier Quality Evaluation

2-7-1 Delivery Quality Evaluation

2-7-2 Supplier Quality Audit

2-8 Contaminants Control

2-9 Control of Quality Records

3 Pre-Production Stage

3-1 Stage Management

3-2 Process Design

3-2-1 Process Quality Control Table

3-3 Delivery Packaging

3-4 Countermeasure at Pre-production Stage

3-5 Quality Standards

3-5-1 Model CP List

3-5-2 Preparation of Limit Samples

3-5-3 Grain and Color Adjustment

3-5-4 Parts Inspection

3-6 Control of Monitoring and Measuring Devices

3-7 Operation Control Documents

3-8 Delivery of Parts

3-9 Transition to Mass Production

3-9-1 Validity Testing

4 Mass Production Stage

4-1 Early Mass Production Quality Control

4-2 Mass Production Quality Control

4-3 Identification and Traceability

4-4 Change Point Control

4-5 Corrective Action Report

4-5-1 Delivery Quality Problem

4-5-2 Market Quality Problem

4-6 Specification Change

4-6-1 Countermeasure Request Form


Table of Contents

December 1, 2016


5 Reference

5-1 Process Capability

5-2 Error Proofing

5-3 Control Chart

5-4 5 Principals for Problem Solving

5-5 Process FMEA

6 Supplement

6-1 Glossary of Terms and Definitions

6-2 Honda Contacts Conversion Table

6-3 Proposal for SQM Revision

6-4 Master List


1 Preface

May 1, 2019


1 Preface

Purpose: This manual is referred to as Supplier Quality Manual (herein after referred to as SQM) and is supplemental to the “General Agreement for Purchase of Parts” and the” General Agreement for Quality Assurance, to establish a process of providing high quality that satisfies and exceeds the expectations of Honda product users.

Scope: SQM is applied to all parts ordered by Honda under the General Agreement for Purchase of Parts. The scope of SQM includes all quality assurance activities performed by suppliers to ensure the appropriate quality of delivered parts. However, where the application of SQM is not practical, exemption may be accepted by specifying operations to which the SQM is not applicable and reasons for the exclusion.

Roles of SQM: This manual is a part of the quality control manual set forth in the “General Agreement for Quality Assurance” entered into and concluded between Honda and suppliers, and designed with a view to provide supplemental information in order for parts and suppliers quality assurance activities to confirm to the respective provisions of the “General Agreement for Purchase of Parts” and the “General Agreement for Quality Assurance”. Suppliers are required to comply with each of the requirements specified in the “General Agreement for Quality Assurance” with SQM as guidance on practice of quality assurance.

Confidentiality: Honda and suppliers agree to take the same care to preserve the confidentiality of each other's confidential information and will not disclose such information to any third party without the prior permission of the other party.

SQM is copyrighted by Honda. All printed or downloaded contents of SQM via online by suppliers are maintained and stored in a safe and controlled manner. Suppliers may make photocopies of sections and pages of SQM for the purpose of training use or as reference, however please exercise proper custody and control in a manner that such downloads and printouts are constantly updated to the latest.

SQM contains confidential and proprietary information of Honda, and as a general rule, it will not be disclosed to any individual or organization other than those who are suppliers without prior written approval of Honda. However, if it required to perform operations and tasks, such as dissemination to second and sub-suppliers, the information may be shared under the sole responsibility of the disclosing suppler by identifying the person responsible for the control and by exercising appropriate discretion and confidentiality of the information.

Public Quality Standards: Quality standards such as ISO 9000 series and IATF 16949, and environmental standards such as ISO14000 shall be complied with. The suppliers who supply parts having electronic control system that covers functional safety standards shall perform development / production / quality control complying with ISO26262 Functional Safety Standard. However, third party registration to these standards by an accredited third party certification body is not required.

Please reflect the updated content into operations if the above standards is revised.

Revision: Honda may revise or update SQM as necessary. Honda notifies suppliers of such revision or update of SQM, and it takes effect after a grace period specified at the time of notification of the revision or update. Suppliers may request Honda for disclosure of obsolete versions of SQM.

Revision proposal: We would appreciate if you could forward your comments or suggestions for improvement to SQM, please complete the form attached in “SQM 6-3 SQM Revision Proposal” and contact below by IMPACT III or e-mail:

Honda Motor Co., Ltd. Purchasing Technical Division



December 1, 2016


Ge

ne

ral









-2 Supplier Quality Audit

-1 Delivery Quality Evaluation

Re

fere

nce


5-2 Error Proofing

5-3 Control Chart

5-4 5 Principles for Problem Solving


3-2 Process Design

Pre

-Pro

du

ctio

n S

tag

e



3-4 C/M at Pre-Production Stage


-2 Preparation of Limit Samples

-3 Grain and Color Adjustment

-1 Process Quality Control Table

-1 Validity Testing







Ma

ss P

rodu

ctio

n S

tag

e

-1 Countermeasure Request Form

5-5 Process FMEA


3-6 Control of Monitoring & Measuring Devices

-2 Market Quality Problem


-1 Delivery Quality Problem


-1 Model CP List

-4 Parts Inspection




December 1, 2016

Honda Motor Co., Ltd. 1/1


　MP DWG ◆ MP Go

Ⅲ Ⅳ

2-1 Important Safety Parts 2-6 Control of Supply Parts 5-1 Process Capability

2-2 Regulatory Compliance Certification 2-7 Supplier Quality Evaluation 5-2 Error Proofing

2-3 Designation of Quality Representative 　-1 Delivery Quality Evaluation 5-2 Control Chart

2-4 Sub-Supplier Quality Assurance 　-2 Supplier Quality Audit 5-4 5 Principals for Problem Solving

2-5 Control of Honda-Owned Property 2-8 Contaminants Control 5-5 Process FMEA


Prototype Stage Pre-Production Stage Mass Production Stage

Timing

Final

Prototype

DWG

Prototype

DWG

◆Determine capability

Stage Ⅱ Ⅴ Ⅵ

DKaku QC VC MP


3-2 Process Design -1 Process Quality Control Table



3-5 Qlty Std



3-4 C/M at Preproduction Stage

3-9 Transition to MP -1 Validity Testing



4-3 Identification &Traceability



-1 Delivery Quality Prolem

-2 Market Quality Problem


-1 C/M Request Form

Genera

l

Refe

rence

Supplie

r

-1 Model CP List-2 Preparation of Limit Samples-3 Grain and Color Adjustment

-4 Inspection Criteria for Parts


1-3 SQM Outline

May 1, 2019


1-3 SQM Outline

No. Document Title Overview

1 Preface Outline the purpose, scope, system, and image, etc. of production process.

2 General


1) Honda specifies important safety parts with drawings (specifications included).

2) Suppliers recognize “important safety parts” designated by Honda, become familiar with the definition of HS, HA, and HB, and control them as critical items.


1) Honda shall provide necessary information to suppliers to

assess the regulatory requirements.

2) Based on the information provided by Honda, the suppliers shall ensure all parts that compose the products fully comply with any applicable laws and regulations.

2-3 Designation of Quality Contact

1) Honda shall inform a supplier’s quality contact of matters relating to the quality (Quality Assurance Representative and Facility Quality Representative).

2) The supplier shall resister its quality contact to Honda in order for communication with Honda about quality to be effective.


1) Honda shall identify and outline the scope of activities of sub-suppliers for which a supplier assume sole responsibility.

2) The supplier shall establish basic requirements for quality assurance of purchased parts and outsourced processes in order for the quality of parts to be properly controlled by its sub-suppliers.

2-5 Control of Honda-Owned Properties

1) Honda shall, where necessary, lend suppliers machines, dies, jigs and tools, etc., necessary to manufacture parts.

2) Supplier inherits control method of Honda machines / dies / jigs and tools, etc., purchased or provided by Honda necessary to manufacture parts.


1) When Honda provides component parts to a supplier on consignment, Honda shall control quality of the supply parts by clarifying roles and responsibilities of supply parts users, supply parts suppliers, and Honda.

2) The supply parts user shall assure the quality of parts of own in accordance with the roles and responsibilities defined by Honda.

3) The supply parts supplier shall assure supply parts in accordance with the roles and responsibilities defined by Honda.


1) Honda shall communicate the purpose and viewpoints of quality assessment to suppliers.

2) The supplier shall become familiar with requirements of Honda and take appropriate actions.


1-3 SQM Outline

May 1, 2019




1) Honda shall inform suppliers of the results of delivery quality performance (including supply parts).

2) The supplier shall monitor the results of performance, verify attainment of the target, and continuously improve the delivery quality.


1) Honda shall conduct quality audits of suppliers’ sites.

2) The supplier shall participate in the quality audit and take appropriate actions with respect to the findings identified.


1) Honda shall define the requirements to properly exercise the control of contaminants.

2) The supplier shall define control items, points, etc. for parts subject to contaminants control and maintain satisfactory condition conforming to contaminants control criteria.


1) Honda shall identify quality records which Honda may require

suppliers for presentation.

2) Supplier shall create the quality records and approve the records properly in accordance with the procedures established by the supplier.

3) The supplier shall retain quality records, when so designated in SQM in accordance with requirements established by Honda.

3 Pre-production Stage


1) Honda shall designate key control parts, and verify production preparation activities of a supplier for the key control parts.

2) The supplier shall plan production preparation activities to be linked to the Pre-production schedule of Honda. Items to complete at each stage of pre-production shall be defined in order for the supplier to thoroughly implement the planned activities.

3-2 Process Design 1) Honda shall define the requirements for suppliers to design a process.

2) The supplier shall clarify requirements for designing a process, and maintain the manufacturing process at an appropriate quality level.


1) Honda shall define contents and provide operation procedure for process quality control table.

2) The supplier shall control and maintain the process quality control table and use for the following purposes.

a) Management of control items for in-process quality assurance.

b) Monitoring of process control conditions.

c) Accumulation and conveyance of skills and technology, etc.


1) Honda shall examine and agree the proposed packaging style for delivery of parts.

2) The supplier shall determine and obtain agreement from Honda on packaging style for delivery of parts, and preserve the conformity of product during handling, delivery, and storage from the time of shipment from the supplier to the time of use by Honda.


1-3 SQM Outline

May 1, 2019




1) Honda shall require suppliers of problem parts, which were found in the pre-production stage and its cause was considered attributable to the supplier, to conduct analysis and take countermeasure against the cause.

2) The supplier shall conduct analysis and take countermeasure for the cause of the problem in accordance with a request from Honda and report the results to Honda. For problems in the pre-production stage, it is important that measures for the problem be preferentially implemented and results be evaluated for effectiveness by the subsequent pre-production trial event.


3-5-1 Model CP List 1) Honda shall issue Model CP List to two-wheeled / four-wheeled suppliers to request inspections or process assurance with respect to quality characteristics of parts which inspections or process assurance is mandated by laws and regulations.

2) The two-wheeled / four-wheeled supplier shall report inspection results with respect to the quality characteristics of parts specified in Model CP List to Honda.


1) Honda shall, if a supplier produces limit samples of parts for which acceptability is determined by visual inspection, etc., examine and approve such samples.

2) The supplier shall control limit samples approved by Honda, and judge the acceptability of manufactured parts for quality.


1) Honda may coordinate and build consensus with suppliers on the specification of textures of grain and color that cannot be specified on the drawing (specifications included).

2) The supplier shall clarify requirements to be coordinated in response to a request from Honda for textures of grain and color, of parts.

3-5-4 Inspection Criteria for Parts

1) Honda shall issue Parts Inspection Criteria to suppliers to verify quality characteristics of parts to which verification is mandated by laws and regulations.

2) The supplier shall report inspection results with respect to the quality characteristics of parts specified in Parts Inspection Criteria.


1) Honda shall provide basic requirements for measuring and monitoring equipment for suppliers to use.

2) The supplier shall define installation and control methods of measuring and monitoring equipment in accordance with the requirements specified by Honda to assure the results of measuring and monitoring of parts delivered to Honda.


1) Honda shall provide suppliers with requirements of operation control documents, which the suppliers make available to their operators, in order for the suppliers’ manufacturing processes to be in a controlled state.

2) The supplier shall formulate operation control documents in accordance with requirements prescribed by Honda, provide to its operators and utilize for training.

3-8 Parts Delivery 1) Honda shall present suppliers with requirements for handling, transportation and storage, etc., of parts when delivering from suppliers to Honda.

2) The supplier shall define basic requirements for handling,


1-3 SQM Outline

May 1, 2019



transportation and storage of parts in accordance with the requirements set by Honda and preserve the conformity of product.


1) Honda shall present suppliers with evaluation items for verifying transition to mass production. Honda may attend selected suppliers’ evaluation events.

2) The supplier shall verify completion of pre-production stage and issue a Mass Production Transition Declaration, and enter into mass production stage.

3-9-1 Validity Testing 1) Honda shall, considering the level of importance, novelty, etc., select critical control parts for which suppliers are required to report results of validity testing.

2) The supplier shall draw up an implementation plan for validity testing to prove the conformity of parts to applicable drawings (specifications included), etc., and complete all testing prior to mass production startup.



1) Honda shall provide a verification method for process capability and mass productivity, which Honda requires suppliers during early stage of mass production.

2) The supplier shall perform verifications of process capability and mass productivity in accordance with requirements prescribed by Honda during the early stage of mass production. The verification results shall be presented to Honda if so requested.


1) Honda shall present suppliers with requirements to continuously maintain and improve the quality control system developed during pre-production stage, which includes change point control in the mass production stage.

2) The supplier shall, for all changes to be made to operator, manufacturing process, manufacturing method and/or parts, continuously maintain and improve the state of manufacturing process control in accordance with the method employed for the pre-production stage.


1) Honda shall provide requirements for identification and traceability control, which is to verify necessary information immediately, determine the cause and scope of parts affected, and take prompt countermeasures in the event that nonconformity occurs at a supplier’s production stage or after shipment.

2) The supplier shall identify parts in accordance with requirements prescribed by Honda, and control traceability.


1) Honda shall provide requirements to control all change points with respect to labor, manufacturing process, manufacturing method, and parts during a supplier’s production process.

2) The supplier shall maintain traceability of all change points in accordance with requirements prescribed by Honda.


1) Honda shall provide requirements for reporting of corrective action in cases where nonconformity occurs in quality of parts made by suppliers.

2) The supplier shall report corrective actions in accordance with requirements prescribed by Honda.


1) Honda shall provide requirements for the handling of delivery quality problem in the case where nonconformity is found in


1-3 SQM Outline

May 1, 2019



parts delivered from a supplier to Honda or to a delivery destination specified by Honda.

2) The supplier shall, in accordance with requirements prescribed by Honda, define procedures to eliminate nonconforming parts from Honda, and prevent nonconforming parts from being flowed out to the market.


1) Honda shall, where problem occurs in the market after products are sold, and where the problem is deemed attributable to the supplier from which the concerned parts were purchased, request the supplier to perform analysis of the problem and to take preventive measures against recurrence.

2) The supplier shall analyze market problems required by Honda, and if it is attributable to its own conduct, take measures to prevent the problem from recurring.


1) Honda shall provide requirements to ensure a smooth implementation of the specification change issued by Honda to suppliers.

2) The supplier shall establish procedures to process specification changes to parts in accordance with the requirements of Honda.


1) Honda shall provide suppers with procedure for requesting a specification change.

2) The supplier shall request Honda for a specification change while identifying the need for specification change.

5 Reference


This manual is to provide basic concepts and points to consider for evaluating process capability to prove that a manufacturing process has the ability to consistently achieve intended quality levels, and for taking actions to the outcome of such evaluation.

5-2 Error Proofing This manual is to provide points to consider when employing error proofing methods to detect abnormalities in manufacturing and inspection processes and to prevent outflow of nonconformity.

5-3 Control Chart This manual is to explain the concept of control chart and provide entry method to record data into the chart. Control chart shall be used to continually improve the quality of products and the effectiveness of quality management systems.


This manual is to provide the concept of “5 Principles for Problem Solving”, which is used by suppliers to investigate and eliminate the root cause of nonconformity of parts and of quality management system.

5-5 Process FMEA This manual explains the concept of and procedures for Process FMEA, and provides and provides entry method for the Process Design FMEA worksheet.



July 1, 2014


2 General


1 Overview

1) Honda specifies important safety parts with drawings (specifications included).

2) Suppliers recognize “important safety parts” designated by Honda, become familiar with the definition of HS, HA, and HB, and control them as critical items.

2 Definitions

The definitions of terms used in this manual are as follows. Refer to【SQM 6-1 Glossary of

Terms and Definitions 】for other terms.

No. Term Definition

1 Important safety

parts Important safety parts set forth in HES A 3050.

2 important quality characteristics

Important quality characteristics set forth in HES A 3051.

3 Requirements

The supplier shall confirm special characteristics, which are specifically selected from

important safety parts and important quality characteristics（○Q ）, and exercise control in

accordance with section 3.2.

3.1 Review of specification

The supplier shall confirm important safety parts and important quality characteristics

（○Q ）designated by Honda in accordance with respective drawings (specifications

included).

Part rank varies by product type, such as motorcycle, automobile, or power product. The same parts with identical function may be given different designation depending on the product type. If providing the same parts for different products, the supplier shall confirm the designation for each product.

3.2 Implementation of special control

The supplier shall implement a thorough for important safety parts and important quality

characteristics（○Q ）, the supplier shall implement a thorough maintenance and control of

quality characteristics as follows in addition to regular quality assurance activities.

3.2.1 Process Control for Important Safety Parts ( refer to 【SQM 3-2 Process Design】

and 【SQM 3-2-1 Process Quality Control Table 】).

The supplier shall place marks specified by Honda (HS, HA or HB) on the process quality control table.

The supplier shall include all quality characteristics related to important safety parts in the process quality control table, and control processes related to the

Honda-designated important quality characteristics（○Q ）by designating them as key

items.

3.2.2 Dissemination of Important Quality Characteristics （○Q ）(refer to【SQM 3-2-1

Process Quality Control Table】and 【SQM 3-7 Operation Control Documents】)

The supplier shall identify process control documents including process quality

control table, operation control documents, etc., with the Honda’s symbol （○Q ） or

the supplier’s equivalent symbol or notation. The supplier shall identify those

process steps that affect special characteristics（○Q ） , and raise associates’



July 1, 2014


awareness of quality.

3.2.3 Lot Control (refer to【SQM 4-3 Identification and Traceability】)

The supplier shall practice lot control for important safety parts and maintain records in a manner that manufacturing history and release history correspond to the identification of lots. With this procedure, the supplier shall excise control that the scope of affected lots is identified and kept to a minimum in the event of non-conformity.

3.2.4 Assurance of process capability

The supplier shall perform verification of process capability to confirm if important

quality characteristics （○Q ） of important safety parts are controllable by

manufacturing conditions. For the verification of process capability, a set of data with a sample size of n=100 or more is advisable. A minimum of 30 data sets should be used (however, if the quality characteristics requires destructive inspection, or can be assured by molds, then this may not apply) and at least one of the following requirements must be satisfied.

a) Cpk≧1.33 or P＜0.01 is observed

b) If the process capability does not satisfy the condition above (a), conduct 100 percent inspection, and take appropriate actions in order for the process to gain the same level of assurance.

Note: for a single specification limit case, Cp control shall apply.

※Besides important safety parts’ important quality characteristics（○Q ）,refer to

【SQM 5-1 process function】 to carry out process function verification.

Refer to the following requirements for the timing and handling of the verification.

【SQM 2-4 Sub-supplier quality assurance】

【SQM 3-1 Stage Control】

【SQM 3-2 Process Design】

【SQM 3-9 Transition to Mass Production】

【SQM 4-1 Early Mass Production Quality Control】

3.2.5 Control of Repair Parts (refer to 【SQM 4-5-1 Delivery Quality Problem】)

The quality assurance representative of the supplier or the quality representative of

the facility shall approve repairs of important quality characteristics（○Q ） of important

safety parts. The supplier shall conduct a100 percent inspection of repaired parts, and maintain records identifying the lot.

3.2.6 Operator Training

The supplier shall provide training to its personnel on the process which involves

important safety parts and important quality characteristics（○Q ）, and subsequently

assign personnel who possess sufficient knowledge and skills to the respective process.

3.2.7 Use of Sub-Suppliers (refer to【SQM 2-4 Sub-Supplier Quality Assurance】)

The supplier shall, if using its sub-suppliers with respect to important safety parts, assume responsibility for and exercise control of sub-suppliers in a manner that ensures requirements described in this manual are thoroughly implemented at the supplier’s responsibility.

4 Key Points

1) When providing support on important safety parts to companies related, ensure that the supplier’s know how is adequately transferred.

2) Wherever possible, check multiple times for assembly processes that could contribute to serious malfunctions (e.g. cotter pin insertion, etc.).

3) Check if recurrence prevention measures are in place for both hardware and software for work involves important safety parts (e.g. bolt fastening for critical part installation).



July 1, 2014


5 Reference Materials

1) SQM 2-4 Sub-Supplier Quality Assurance

2) SQM 3-1 Stage Control

3) SQM 3-2 Process Design

4) SQM 3-2-1 Process Quality Control Table

5) SQM 3-7 Operations Control Documents

6) SQM 3-9 Transition to Mass Production

7) SQM 4-1 Early Mass Production Quality Control

8) SQM 4-3 Identification and Traceability

9) SQM 4-5-1 Delivery Quality Problem

10) SQM 5-1 Process Capability

11) SQM 6-1 Glossary of Terms and Definitions

12) HES A 3050 “Designation for Important Safety Parts”

13) HES A 3051 “Designation for Important Quality Characteristics”



May 1, 2019



1 Overview

1) Honda shall provide necessary information to suppliers to assess the regulatory requirements.

2) Based on the information provided by Honda, the suppliers shall ensure all parts that

compose the products fully comply with any applicable laws and regulations .

2 Definition



No. Term Definition

1

Declaration of compliance with

regulatory requirements

A course of action by the quality assurance representative, facility quality representative, or responsible person who was appointed and entrusted by the quality assurance person of a supplier to verify that the specifications of parts designed by the supplier comply with regulatory requirements.

3 Requirements

The supplier shall assure that all parts coming into Honda conform to requirements that define the structure, function, and performance of parts with respect to safety and environment.

For chemical substances, the supplier shall, on its own responsibility, assure all parts to comply with the requirements of Honda.

3.1 Compliance with Regulatory Requirements (excluding those relating to chemical substances)

3.1.1 Confirmation of Application

The supplier shall validate regulatory requirements to be applied with drawings (specifications included).

In addition to the information provided by Honda(ex. Launching (Applying) countries),collect all regulatory information about safety and environment for the parts from government agencies, affiliated companies overseas and external organizations concerned, and validate compliance of parts coming into Honda with respective regulations.

3.1.2 Dissemination of regulatory requirements

The supplier shall confirm regulatory requirements for parts and for sub-suppliers who supply parts to the supplier, if necessary, inform the respective suppliers of such regulatory requirements, etc.

3.1.3 Promotion of Regulatory Compliance

The supplier shall determine appropriate responses to regulatory information applicable to parts, and implement necessary measures as follows to ensure compliance with regulatory requirements.

1) Assure regulatory compliance of parts designed and developed by its own and obtain regulatory approval of such parts (present or submit an acquisition plan for regulatory approval, if Honda requests).

2) Declare compliance with regulations (present or submit a compliance report and certification, if Honda requests).

3) Communicate with Honda any information about changes resulted from a decision that there would be an effect on the acquisition plan, compliance report, or certificate that had already been acquired.

4) Improve manufacturing methods, inspection methods and quality control systems.

5) Install facilities and inspection equipment.



May 1, 2019


3.1.4 Verification of Management for Regulatory Compliance

The suppliers shall verify its management of the compliance of parts with regulatory requirements, and confirm that all regulatory requirements are met. Maintain records in a manner that the result of verification is retrievable upon request by Honda.

3.2 Management of Chemical Substances (including actions for compliance with related laws and regulations).

3.2.1 Requirements for Chemical Substances

The supplier shall, based on symbols for chemical substances (NH, HR, etc.) specified on the drawing (specifications included), find the corresponding guideline provided in “Honda Chemical Substance Management Standard”.

Chemical Substance Information Display on Drawing

Automobile: accords with HES A 3060 “Indication Methods Conforming to Honda Chemical Substance Management Standard (Automobiles)”.

Motorcycle and Power Equipment: accord with HES A 3065“Indication Methods Conforming to Honda Chemical Substance Management Standard (Motorcycles and Power Products)”.

3.2.2 Control of Chemical Substances

The supplier shall refer to the most current edition of Honda Chemical Substance Management Standard provided by Honda and have knowledge of the maximum allowable concentrations of chemical substance (chemicals that fall under 3 categories of Honda chemical substance classification; P, DI, and DII) for all parts that compose a Honda product, including parts to be purchased from sub-suppliers.

For all substances specifically designated as prohibited substances, (P) under the Honda Chemical Substance Management Standard, the supplier shall assure compliance of the substance with specified standards set forth in Honda Chemical Substance Management Standard.

3.2.3 Collection and Submission of Data

Upon request by Honda, the supplier shall submit data to Honda based on “Honda Chemical Substances/Recycle Data Collection Operation Manual” provided by Honda.

Upon request from Honda with respect to submission of data on a chemical substance content rate, the supplier shall perform its own analysis of the parts being supplied to Honda and submit the result of such analysis.

4 Control of Records

No. Type of Record Retention Period

1 Verification result of regulatory

compliance management 15 years

2 Data of chemical substances/ recycling of

chemicals presented or submitted to Honda

15 years after discontinuation of production.



2) Honda Chemical Substance Management Standard

3) Indication Methods Conforming to Honda Chemical Substance Management Standard (automobiles)

4) Indication Methods Conforming to Honda Chemical Substance Management Standard (motorcycles and power products)

5) Honda Chemical Substances/Recycle Data Collection Operation Manual



March 1, 2018



1 Overview

1) Honda shall inform a supplier ’s quality contact of matters relating to the quality (Quality Assurance Representative and Facility Quality Representative).

2) The supplier shall resister its quality contact to Honda in order for communication with Honda about quality to be effective.

2 Definitions

The definitions of terms used in this manual are described in【SQM 6-1 Glossary of Terms

and Definitions】.

3 Requirements

The supplier shall designate contacts for quality assurance to manage quality related operations with Honda to facilitate thorough communication with Honda.

3.1 Designation of Quality Contact

The supplier shall designate qualified personnel to act as a contact to Honda for the following duties in accordance with roles and tasks.

3.1.1 Quality Assurance Representative (executive officer level)

The supplier’s person responsible for implementation of company-wide quality assurance activities.

Assume responsibility for the following as the representative for the supplier’s quality.

1) Attends seminars on quality for suppliers organized by Honda.

2) Follows if Honda requests a corporate-level quality improvement.

3) Receives SQM issued by Honda and deploy its requirements throughout the company.

4) Represents the supplier and participates in regular audits (QAV-1) for supplier quality by Honda.

5) Serves as the contact person to Honda for a corporate-level communication or when Honda makes corporate-level requests to the suppler.

3.1.2 Facility Quality Representative (head of a factory or general manager level officials)

A supplier’s personnel who is appointed per facility and responsible for quality assurance activities at own facility. Entrusted by the quality assurance representative and is responsible for deploying the latest version of SQM issued by Honda and putting it into practice at all departments concerned of the facility.

3.2 Designation of Quality Contact

3.2.1 Initial Registration

The supplier shall submit to Honda the form “Quality Assurance Representative Notification Form” provided in section 6 of this manual in an electronic data file.

3.2.2 Change of Contact Person or Information on the “Quality Assurance Representative Notification Form.”

In the event of a contact person change or a change to the information provided on “Quality Assurance Representative Notification Form”, the supplier shall immediately inform Honda of the change, make necessary changes to the “Quality Assurance Representative Notification Form”, and reports to Honda in the form of electronic data file.





March 1, 2018


5 Flowchart

Contact

Purchasing

Technical

Unit,

Implementati

on Division

Supplier Honda

Purchasing

CostEstablish relationships with

new suppliers

General Agreement for Purchase of Parts

General Agreement for Quality AssuranceDesignate Quality Assurance

Representative &Facility Quality Representative

Quality Assurance Representative Notif ication Form

Register Quality Assurance Representative &

Facility Quality Representative

If any changes needed

Initi

al

Regis

tratio

n

If t

here

are

changes

SQM



March 1, 2018


6 Forms

6.1 Quality Assurance Representative Notification Form (blank)

Report communication route

E-mail:

Reason for reporting

Quality Assurance Mgr

Facility Qlty Mgr ・Qlty Assurance System

New registration

Information update

Phone: Fax:

E-mail:

Facility Quality Rep. C M S K HB T

Quality Assurance System

CODE

Supplier⇒Purchasing- Cost⇒※(The management block person in

charge)⇒The Quality Improvement Dept. person in charge

Company Name:

Prepared by: Name, dept/job title

Quality Assurance Representative

Notification Form

As of　　/　　/　　　　,

Quality Assurance Rep.

Incumbent New Address/Phone/FAX/E-mail address

Name Title Name Title

C

s

s

M

s

s

S

s

s

K

s

s

Sp

are

Pa

rts

T

s

s

Facility Name Title Address/Phone/FAX/E-mail address



March 1, 2018


6.2 Quality Assurance Representative Notification Form (Entry procedure)

Report communication route

Enter your company's reg. no↑

＊Use single-width characters. E-mail:[email protected]

Reason for reporting ＊Please put a circle( ○ ) in the appropriate box.

○ Quality Assurance Mgr

Facility Qlty Mgr ・Qlty Assurance System

New registration

Information update ←

4630 Shimotakanezawa,Haga-machi,Haga-gun,Tochigi-ken 321-3393

Phone: 028-677-7014 Fax: 028-677-7050

E-mail: [email protected]

Facility Quality Rep. ※Fill in the blanks below even if no changeC M S K HB T

1500 Hirakawa, Otsu, Kikuike, Kumamoto 869-1293

Kss Phone: 096-293-1111 Fax: 096-293-8280 ○


1907 Hirata, Suzuka, Mie 513-8666

Sss Phone: 0593-78-1212 Fax: 0593-78-6379 ○ ○

E-mail:[email protected]

1-13-1 Aoihigashi, Hamamatsu, Shizuoka 433-8501

Mss Phone: 053-439-2111 Fax: 053-439-2550 ○


1-10-1 Shinsayama, Sayama, Saitama 350-1392

Css Phone: 042-953-4111 Fax: 042-953-3362 ○ ○


2900 Kamitakanezawa,Takanezawa,Tochigi 329-1224

Tss Phone: 028-687-2300 Fax: 028-687-2330 ○


Quality Assurance System

Kss

Ichiro Kumamoto, Plant Mgr

Sss

Ichiro Suzuka, Plant Mgr

Qlty Assurance Rep

Mss

Ichiro Hamamatsu, Plant Mgr

Css

Ichiro Saitama, Plant Mgr

Tss

Ichiro Tochigi, Plant Mgr

CODE Apr. 1, 2013

Supplier⇒Purchasing- Cost⇒※(The management block person in

charge)⇒The Quality Improvement Dept. person in charge

○○○○ Company Name: Honda Co.,Ltd.

Prepared by: Name, dept/job title

Jirou_Honda

※↑*Enter the email address of the person f illing out this f orm.


Notification Form

As of DD/MM/YYYY,

Check this if there is no change to the information and

only the date of issuance is changed.

Quality Assurance Rep. ↓※When there is not a change, the supplier has you fi l l out a current column, and, please make the new column a blank.

Incumbent New Address/Phone/FAX/E-mail address

Name Title Name Title

Ichiro

Honda

Gen. Manager,

Dept of Quality

Assurance

Taro

Honda

Executive

Director

C

s

s

M

s

s

Factory

Manager

S

s

s

K

s

s

Sp

are

Pa

rt

T

s

s

Facility Name Title Address/Phone/FAX/E-mail address

Ichiro

Saitama

Factory

Manager

Ichiro

Tachigi

Factory

Manager

Taro Honda,

Executive Director

Ichiro

Kumamoto

Factory

Manager

Ichiro

Suzuka

Factory

Manager

John

Hamamatsu

Fill in the blanks even if

"Quality Assurance Rep."

doubles as "Facility Qlty Rep".

Put a circle in the column of

the destination of delivery

from C.M.S.K.CS.T

Qlty Div.

Qlty Div.

Eng Qlty Div.

Welding Div.

Auto Qlty Div.

M/C Qlty Div.

Qlty Div.

Welding Div.

Qlty Div.

Eng Qlty Div.

Jiro Kumamoto, Mgr

Jiro Suzuka, Mgr

Saburo Suzuka, Mgr

Shiro Suzuka, Mgr

Jiro Hamamatsu, Mgr

Saburo Hamamatsu, Mgr

Jiro Saitama, Mgr

Saburo Saitama, Mgr

Jiro Tochigi, Mgr

Saburo Tochigi, Mgr

Attach a separate sheet if unable

to fill in here.



March 1, 2018



1 Overview

1) Honda shall identify and outline the scope of activities of sub-suppliers for which a supplier assume sole responsibility.

2) The supplier shall establish basic requirements for quality assurance of purchased parts and outsourced processes in order for the quality of parts to be properly controlled by its sub-suppliers.

2 Definitions



No. Term Definition

1 Purchased parts All component parts and materials that a supplier procures from its sub-suppliers in order to produce products to be delivered to Honda.

2 Supplier

(tier 1supplier)

A first tier supplier to Honda who receives orders for parts directly from Honda.

3

Sub-Supplier

( tier 2 and beyond)

A service provider whom a supplier purchases parts from and outsources services to such as fabrication, testing, etc., and including those who beyond the first service provider, it is collectively referred to as sub-suppliers.

3 Requirements

The supplier shall exercise control over sub-suppliers on its own responsibly in order for the requirements set by Honda to be thoroughly followed.

Supply parts provided by Honda are controlled in accordance with 【SQM 2-6 Control of

Supply Parts 】.

3.1 Selection of and Contracting with Sub-Suppliers

The supplier shall establish criteria for selecting sub-suppliers, perform evaluation, and enter into a contract with sub-suppliers.

The suppler shall also create and maintain a list of such sub-suppliers with whom the suppler has entered into a contract.

3.2 Quality Audit

3.2.1. The supplier shall perform quality audits of sub-suppliers on a regular basis or as needed, confirm their quality performance and evaluate and/or re-evaluate them.

3.2.2. The supplier is required to be prepared in a manner that Honda can participate in a

quality audit of sub-suppliers if so requested by Honda( refer to【SQM 2-7 Supplier

Quality Evaluation】).

3.2.3. The supplier is required to maintain audit results in a manner that can be presented or submitted to Honda upon request.

3.2.4. The supplier shall discuss with Honda if any restrictions apply to 3.2.2 and 3.2.3 above for reasons of confidentiality and nondisclosure agreement.

3.3 Important Safety Parts

The supplier shall, if using sub-suppliers with respect to important safety parts, assume responsibility for and exercise control of sub-suppliers in a manner that ensures requirements described in this manual are thoroughly implemented at the supplier’s

responsibility ( refer to【SQM 2-1 Important Safety Parts】).



March 1, 2018


3.4 Regulatory Compliance Certification

In the case where a secondary supplier is involved in required regulations, the supplier

ensures each important matter indicated in 【 SQM 2-2 Regulatory Compliance

Certification】 is implemented properly, and controls the sub-supplier at their own

responsibility.

3.5 Process Design

If critical items are processed by a sub-supplier, the supplier shall be responsible for managing the sub-supplier in a manner that ensures all requirements in this manual are

thoroughly implemented ( refer to【SQM 3-2 Process Design】).

3.6 Process Quality Control Table

The supplier shall specify a process in Process Quality Control Table if such process which controls important quality characteristic specified by Honda is to be outsourced to a sub-supplier.

The supplier shall clearly specify a process to be outsourced to sub-suppliers in the supplier’s Process Quality Control Table, or as required by Honda, present or submit the Process Quality Control Table of the sub-supplier’s to Honda.

However, if outsourcing all or part of production or fabrication processes, the outsourced processes shall be treated as part of the supplier’s processes and controlled in a manner

following SQM( refer to【SQM 3-2-1 Process Quality Control Table】).

3.7 Model CP List

If control items specified in the Model CP List are inspected by sub-suppliers, the supplier shall provide Honda with the inspection results of the sub-supplier (refer to

【SQM 3-5-1 Model CP List】).

3.8 Parts Inspection Criteria

If inspection items specified in the Inspection Criteria are performed by sub-suppliers, the supplier shall collect the inspection results from such sub-suppliers and provide Honda

with the results ( refer to【SQM 3-5-4 Parts Inspection Criteria】).

3.9 Early Mass Production Quality Control

The supplier shall direct and control necessary sub-suppliers of component parts to perform quality control of the same degree as set forth in this manual at the early stage of

mass production ( refer to【SQM 4-1 Early Mass Production Quality Control】).

3.10 Identification and Traceability

To ensure traceability, the supplier shall assure that sub-suppliers employ the same

degree of control for manufacturing history ( refer to【SQM 4-3 Identification and

Traceability】).

3.11 Change Point Control

The supplier shall direct and control sub-suppliers and ensure IPP control of the same level as this manual requires for the component parts processed by sub-suppliers ( refer

to【SQM 4-4 Change Point Control】).

3.12 Correction and Improvement

The supplier shall review own sub-suppliers with respect to feedback on nonconformity attributable to them and subsequent corrective actions taken, including quality nonconformity found at Honda or in the market and problem found upon delivery, etc., and carry out a thorough prevention of recurrence and passing through of the problem.

The supplier shall receive a report from the sub-supplier, confirm the effect on parts and,

if necessary, takes an action in accordance with 【SQM 4-5 Corrective Action Report】, if

nonconformity found at a sub-supplier is deemed to have an effect on the supplier’s parts.



March 1, 2018


3.13 Direct Delivery to Honda

The supplier shall, if delivering parts directly to Honda (including any location designated by Honda) from sub-suppliers without going through the supplier, clarify verification processes and control items using control plans such as process quality control sheet, etc. in a manner that the final part quality can be verified.

3.14 Evaluation of Purchased Parts

Supplier shall establish testing methods and acceptance criteria, etc., for quality evaluation of purchased parts (including limit samples or master samples as required), and implement receiving inspection, etc. accordingly.

3.15 Confirmation of Pre-production Status

The supplier shall confirm, in order for its manufacturing plan for parts not to be affected by changes made to a sub-supplier’s plan, the progress of production preparation, etc.

( refer to【SQM 3-9 Transition to Mass Production】) including the following points as a

minimum.

1) Control plans such as Process Quality Control Table and operation standards are established and controlled in the sub-suppliers’ manufacturing processes (refer to

【SQM 3-2-1 Process Quality Control Table 】and【SQM 3-7 Operation Control

Documents】).

2) Parts that are manufactured by the sub-supplier meet the requirements of applicable

drawings, specifications, etc. (refer to【SQM 3-9-1 Validity Testing】.

3) The sub-supplier’s manufacturing processes are assessed including process

capability( refer to【SQM 5-1 Process Capability】).

4) Productivity of production facilities and accuracy of measuring equipment, etc., are

maintained and required production capacity is assured (refer to 【SQM 3-9

Transition to Mass Production】).



1 Sub-suppliers List Update to the latest version

2 Audit records of sub-suppliers ( or tier 2suppliers) 20 years

3 Analysis Record [Analysis Report] 20 years

4 Process quality control table 20 years after discontinuation

of the model production

5 Receiving inspection data 20 years

6 Results of pre-production status confirmation 20 years

7 Results of validation testing 20 years



March 1, 2018



1) SQM 2-1 Important Safety Parts

2) SQM 2-2 Regulatory Compliance Certification

3) SQM 2-6 Control of Supply Parts

4) SQM 2-7-2 Supplier Quality Audit

5) SQM 3-2 Process Design


7) SQM 3-5-1 Model CP List

8) SQM 3-5-4 Parts Inspection Criteria

9) SQM 3-7 Operation Control Documents


11) SQM 3-9-1 Validity Testing



14) SQM 4-4 Change Point Control

15) SQM 4-5 Corrective Action Report





March1, 2018



1 Overview

1) Honda shall, where necessary, lend suppliers machines, dies, jigs and tools, etc., necessary to manufacture parts.

2) Supplier inherits control method of Honda machines / dies / jigs and tools, etc., purchased or provided necessary to manufacture parts.

2 Definition



No. Term Definition

1 Honda-owned

property

When necessary, after consulting with the supplier, Honda will lend machines, dies, tools and jigs, etc. needed to manufacture parts, etc.

3 Requirement

3.1 Honda-owned Property

3.1.1 Identification

The supplier shall identify Honda owned properties in a manner that allows the items to be visually explicit and permanently identifiable as lent items.

3.1.2 Maintenance

The supplier shall, when using lent items, perform maintenance and control its records in accordance with the procedure provided by Honda to ensure proper quality. If no procedure is provided by Honda, the supplier may establish its own procedures to maintain lent items. If lent items are not used for a long period of time, the supplier shall properly store and prevent deterioration in accuracy, functions, etc. of the items. Perform additional preoperational inspections to verify there are no problems with the condition of lent items when operations resume.

3.2 Use of Lent Items

The supplier shall comply with instructions for use of lent items provided by Honda, if any. Unless otherwise deemed necessary by Honda, the supplier may not use lent items for any purpose other than the purpose for which it was originally intended, or may not alienate, sublease or mortgage such lent items to the third party.

3.3 Actions for Abnormal Conditions

The supplier shall, in the event that lent items are lost or damaged, or found not suitable for use, report to Honda, determine a course of action after consultation with Honda, and control records.

3.4 Return of Lent Items

The supplier shall, if Honda so requests, return lent items to Honda on the date, time and place specified by Honda.

3.5 Records

The supplier shall, if Honda requires, control quality records related to lent items by following instructions provided by Honda.

If no instructions are provided by Honda, the supplier may establish its own procedures and maintain records accordingly.



March1, 2018




1 Maintenance records of Honda-owned

properties 20 years

2 Records of actions for abnormal conditions of

Honda-owned properties 20 years





July 1, 2014



1 Overview

1) When Honda provides component parts to a supplier on consignment, Honda shall control quality of the supply parts by clarifying roles and responsibilities of supply parts users, supply parts suppliers, and Honda.

2) The supply parts user shall assure the quality of parts of own in accordance with the roles and responsibilities defined by Honda.

3) The supply parts supplier shall assure supply parts in accordance with the roles and responsibilities defined by Honda.

2 Definitions



No. Term Definition

1 Supply Parts

Component parts provided to a supplier by Honda to manufacture parts to be delivered to Honda. This applies when Honda purchases a part from a supplier (supply parts supplier) and/or manufactures a part, which is provided to another supplier (user) for a fee to manufacture parts delivered to Honda.

2 Supply Part User A supplier who uses supply parts as components in the manufacture of parts to Honda.

3 Supply Part Supplier A company which has a direct contract with Honda, and provides supply parts to another company designated by Honda.

4 Composite Quality

Characteristics A quality characteristic that will be demonstrated or explicated by a combination of supply parts and manufacturing parts.

5 Total Quality

Characteristics Quality characteristics of the final products completed by a supply part user.



July 1, 2014


3 Requirements

3.1 Responsibilities

The major responsibilities of supply part user, supply part supplier and Honda are described in the following.

Supply parts user

1) Perform receiving inspection (consult with Honda for details).

2) Request a supply parts supplier for analysis and measures if a problem with supply parts is found.

3) Assure overall quality characteristic of complete parts.

4) Request Honda for a coordination meeting set forth in section 3.2 as necessary.

Supply parts supplier

1) Assure quality characteristics of parts of own manufacture.

2) Disclose information to its user and Honda when necessary to control the quality of supply parts.

3) Perform analysis and measures against a problem with supply parts requested by a supply part user (supply part user may perform process verification as necessary).

4) Request Honda for a coordination meeting set forth in section 3.2 as necessary.

Honda 1) Organize a coordination meeting with supply part users and supply part suppliers to build consensus on the responsibility for quality assurance of parts with composite quality characteristics.

2) Assure quality characteristics of supply parts manufactured by Honda.

3) Disclose information to supply parts users and supply parts suppliers when necessary to control the quality of supply parts.

4) Request supply parts supplier to conduct analysis and measures if any problems with supply parts are found after delivery to Honda.

3.2 Agreement on the burden of quality assurance of parts with composite quality characteristics.

3.2.1 The supply parts user and supply parts supplier shall, if so requested by Honda, take part in coordination meeting to discuss the burden of quality assurance of parts with composite quality characteristics to reach agreement for items necessary to control these parts. The items necessary for the control shall include the following at a minimum.

1) Delivery packaging for supply parts

2) Handling of supply parts

3) The burden of quality assurance of parts with composite quality characteristics.

4) Handling of nonconforming parts.

5) The supply part supplier shall document and control records of the coordination meeting, if so requested by Honda.

3.2.2 The supply part user and supply part supplier shall, if necessary to amend the agreement reached at a coordination meeting, immediately report to Honda.





July 1, 2014


5 Flowchart

Pre-Production Stage

ContactHondaSupply Part Supplier Supply Part User

New model

preparation

section

New model

preparation

section

New model

preparation

section

Pro

du

ctio

n P

rep

ara

tio

n S

tag

e

Purchasing-

cost section

Purchasing-

cost section

New model

preparation

section

New model

preparation

& other

related

section

M/L decided

Notice to suppliers

Coordination meeting to build consensus on the responsibility for quality assurance of parts (to be held if required)

Sample event part production

Event part production

<<Improvement instruction>>

CM promotion


Event part release

Event part release

Event product production

ConfirmationConfirmation

Request coordination meeting Request coordination meeting

Decision of holding coordination meeting (if required)

Coordination meeting notice

Prior information on IPP

CM promotion

Supply part

Normal business flow

No

Yes

Acceptance inspection

Fail

Pass


Sample event part production




Fail

Pass

Fail

Pass

<<Imprvement instruction>>

Fail

Pass



July 1, 2014


Mass Production Stage

Contact

Receiving

quality

sectionReceiving

quality &

other

related

section

Honda

Pro

du

ctio

n S

tag

e

Supply Part Supplier Supply Part User

Receiving

quality

section

Receiving

quality

section

Receiving

quality

section

Receiving

quality

section

CM promotion MP part production

MP part release

Modified part production

Modified part release

MP part production

MP part release

Request coordination meeting

MP part production

MP part release

MP product production

Coordination meeting to build consensus on the responsibility for quality assurance of parts (to be held if required)

CM detail report

<<Improvement request>> << Submit information >>



Decision making of holding coordination meeting



Fail Fail

PassJudgment on

Honda's intervention


CM detail confirmation


PassPassPass

Fail

FailFail

Initial Product Control [IPP]

IPP after quality improvement



IPP after quality improvement


Pass

Fail

Pass

Fail

Pass

Fail



July 1, 2014


Specification Change

Contact

Receiving

quality

section

Receiving

quality

section

Receiving

quality

section

Pro

du

ctio

n S

tag

eProcureme

nt section

Receiving

quality &

other

related

section

Receiving

quality

section

Receiving

quality

section

HondaSupply Part UserSupply Part Supplier

Instruction of specification change

Implement CM

IPP release

CM promotion

IPP-installed part production

Part release

CM detail report

Modified part release

MP part production

MP part release

Keep track of specification changes Keep track of specification changes

IPP processing / production

Conformity inspection

MP product production

Finished product release

Request coordination meeting Decision of holding coordination meeting

(if required)


Coordination meeting to build consensus on the responsibility for quality assurance of parts



IPP after specification

change

Fail


Pass

<<CM request>>

Prior information on IPP

<< Submit information >>

要<<Improvement instruction>>


Required

Fail Fail

Pass



change

Fail

Pass

Pass Pass

FailFail



change

Fail

Pass



change

Fail

Pass

Fail


Judgment on Honda's

intervention




Modified part production



Final inspection

Pass



July 1, 2014



1 Overview

1) Honda shall communicate the purpose and viewpoints of quality assessment to suppliers.

2) The supplier shall become familiar with requirements of Honda and take appropriate actions.

2 Definitions

The definitions of terms used in this manual are contained in【SQM 6-1 Glossary of Terms and

Definitions】.

3 Requirements

The supplier shall be evaluation for the following assessment items as a basis for the ability to supply parts in accordance with requirements established by Honda.

The results of the evaluation may be used by Honda for determining maker layout.

The supplier shall sustain and improve the quality of parts to be delivered to Honda while monitoring conformity to the requirements and consistently achieving targets for quality and delivery timing.

3.1 Assessment items

1) Market quality evaluation

2) Delivery quality evaluation

3) Delivery evaluation (quantity, timing)

4) Quality assurance system evaluation

The results of occasional audit may be reviewed as part of the assessment.

3.2 Assessment viewpoints

The following are Honda’s viewpoints for each assessment item.

Assessment Item Viewpoint P

rod

uct

Ind

ex

Market quality evaluation

Percentage of market warranty cost incurred

Changes in warranty claim rates

Changes in warranty claim rates

Changes in critical market quality problems

Delivery quality evaluation

( refer to 【SQM 2-7-1

Delivery Quality

Evaluation 】)

Delivery quality rating evaluation.

Changes in delivery quality rating evaluation.

Changes in delivery quality dependability rating

evaluation.

Changes in critical delivery quality problems

occurrence evaluation.

Delivery evaluation Delivery quantity and timing of mass-production parts

Syste

m In

de

x

Quality assurance system evaluation

(refer to【SQM 2-7-2

Quality Assurance Visit】)

Quality assurance system evaluation by regular quality

audit (QAV-1).

Design and development system evaluation conducted by HG for the suppliers who own R&D function.

Design and development Capability

Mass Production Capability

Activities and accomplishment in the last one year



July 1, 2014


3.3 Corrective Action Request

The supplier shall, if so requested by Honda for improvement based on the result of quality evaluation, implement appropriate measures.

If deemed necessary, Honda shall conduct an audit, such as Quality Assurance Visit, for quality improvement purposes.


1) SQM 2-7-1 Delivery Quality Evaluation

2) SQM 2-7-2 Supplier Quality Assurance Visit




March 1, 2018



1 Overview

1) Honda shall inform suppliers of the results of delivery quality performance (including supply parts).

2) The supplier shall monitor the results of performance, verify attainment of the target, and continuously improve the delivery quality.

2 Definitions


Definitions】.

3 Requirements

3.1 The supplier shall be evaluated for delivery quality by Honda each month. The results are classified into 6 evaluation levels.

3.1.1 Delivery quality evaluation criteria

Level 1 2 3 4 5 6

Delivery quality performance score

Below 6 points

Between 6-18

points

Between 18-30 points



Above 90

points

3.1.2 Rating

Rating shall be given for delivery quality performance.

3.2 Performance review

The supplier shall include the results of delivery quality evaluation provided by Honda as an input to the management review. Top management of the supplier shall review the performance results and continually improve quality.

The results of delivery quality evaluation are compiled on a fiscal monthly basis and issued as “Delivery Quality Performance Report”. Honda shall send the results to the supplier’s Quality Assurance Representative via the president of the supplier.



5 Flowchart

Contact

Purchasing,

Supplier Honda

Tecnical

Div,

Implementati

on Division

Send supplier delivery quality evaluation results

Delivery Quality Performance

Report

President/quality assurance representativereview results

Carry out continuous quality improvement



March 1, 2018



1 Overview

1) Honda shall conduct quality audits of suppliers’ sites.

2) The supplier shall participate in the quality audit and take appropriate actions with respect to the findings identified.

2 Definitions



No. Term Definition

1 Supplier

in-house visitor

A member who was selected by a supplier from its own employees and leads assessment during a Quality Assurance Visit.

2 Lead section of

Honda

A section of Honda, which acts as a planning center for the Quality Assurance Visit and issues individual audit plans to notify suppliers of the audit

3 Category of Audit

3.1 The supplier shall receive a supplier’s quality audit conducted by Honda.

There are two types of audits: a regular audit and an occasional audit of suppliers’ quality conducted by Honda.

No. Types of Audit Detail

1 Regular audit

Quality audit carried out to review the quality system of a supplier and to verify the status of implementation of the quality system (also called “Quality Assurance Visit-1” or “QAV-1”).

This also includes verifying the suppliers’ audit results through documents.

2 Occasional

audit

Of those which correspond to the following criteria, a supplier’s quality audit which will be conducted when deemed necessary by Honda (also referred to as QAV-2), and this will be performed by specifying the scope of confirmation and verification in accordance with the purpose of the audit..

1) At occurrence of serious problem which is attributable to the supplier

2) When a new manufacturing process is used for the production of new models or new derivatives, etc.

3) When establishing new business relationships with new suppliers.

4) Others

3.2 Regular audit

3.2.1 Supplier Subject to Regular Audit

A supplier subject to regular audit shall be selected from among those with whom Honda has entered into the General Agreement for Purchase of Parts and on the basis of the following.

1) Suppliers produce important safety parts

2) Other suppliers for which Honda deems a quality audit is necessary.

3.2.2 Frequency of audit

The frequency of regular audits shall be at least once every two years in principle. However, it may be changed in accordance with the discretion of Honda taking into consideration the supplier’s status for quality.



March 1, 2018


3.2.3 Supplier in-house visitor

The supplier shall select suppler in-house visitors from its own employees and have them participate in a regular audit.

3.2.4 Scope of Audit

The scope of audit shall include all aspects of the quality system. The review points shall including the following.

1) Quality policy and organization

2) Quality system

3) Specification and design control

4) Control of documents and records

5) Control of suppliers

6) Control of component parts

7) Control of manufacturing processes

8) Control of manufacturing facilities

9) Final inspection and reliability testing

10) Control of monitoring and measuring devices

11) Control of nonconforming products and concession parts

12) Internal quality audit

13) Quality training

14) Compliance to the SQM requirements: review through the assessment of above 1-13 areas.

3.2.5 Countermeasure and Promotion

The supplier shall, based on audit report issued by Honda, formulate an improvement plan and submit to Honda by the date specified. Honda may request changes to the implementation plan where necessary.

3.2.6 Quality meeting

The supplier shall, attend a quality conference upon request from Honda, receive evaluation reports on the implementation, and verify effectiveness of the results of the measures.

3.3 Occasional audit

3.3.1 Supplier Subject to Occasional Audit

A supplier subject to occasional audit shall be selected from all suppliers with whom Honda has entered into the General Agreement for Purchase of Parts.

3.3.2 Scope of Audit

The scope of the audit shall be determined by Honda in accordance with the purpose of the audit.

3.3.3 Countermeasure and promotion

The supplier shall, based on the audit report issued by Honda, formulate an improvement plan, obtain approval from the quality assurance representative or the quality representative of the facility, and submit to Honda by the date specified. Honda may request a change to the implementation plan where necessary.

3.3.4 Confirmation of countermeasure completion and documentation of results.

The supplier shall, upon request from Honda, verify completion of the countermeasure taken and record results of verifications made.





1 Records of regular audit 20 years

2 Records of occasional audit 20 years



March 1, 2018


6 Flowchart

6.1 Regular audit (QAV-1)

Contact Sec.

Pur

Audit

lead sec.

Auditing

section

Audit

lead sec.

Auditing

section

Audit

lead sec.

Audit

lead sec.

Pur

Supplier Honda

Technical

Div.

Technical

Div.

Confirm

Prepare for the auditSend implementation plan per

audit

Audit report first issue (measure request)

Prepare and plan measuresImplement measures

Issue annual regular audit schedule

inform of the month of an

audit

Amend measure scheduleImplementation of measures

Approval from the Qlty Assurance Rep.

Approval

Audit report formal issue

Summary

QAV-1report

Record retention/maintenance for audit reports

Reflect on the next annual schedule

Implement regular audit, confirm and coordinate findings, raise audit report form.

Quality meeting(confirm schedule and details of measures, discuss the direction, etc.)

<Auditimplementedby supplier>

Implementand takemeasures

Submit audit report

Improvement progress record



March 1, 2018


6.2 Occasional Audit (QAV-2)

Contact

Audit

lead sec.

Audit

lead sec.

Auditing

section

Audit

lead sec.

Audit

lead sec.

Auditing

section

Audit

lead sec.

HondaSupplier

Prepare to receive an audit

Prepare audit schedule

Define audit items

Implement occasional audit, raise audit report form.

Audit report first issue

(measure request)Prepare and plan measures

Approval from the Qlty

Assurance Rep.

Implement measures

Audit report approval/ formal

issueQAV-2

report

Send implementation plan

per audit

Receive audit report

Confirm completion of measures and record the result


2-8 Contaminants Control July 1, 2014



1 Overview

1) Honda shall define the requirements to properly exercise the control of contaminants.

2) The supplier shall define control items, points, etc. for parts subject to contaminants control and maintain satisfactory condition conforming to contaminants control criteria.

2 Definitions



No. Term Definition

1 Contaminants Foreign matter such as grain, grit, chip, burr, dirt, dust, etc.

2 Automatic

transmission, etc.

Component parts constituting an automatic speed change mechanism, such as AT (automatic transmission), CVT (continuously variable transmission), 4WD (4-wheel drive), MCU (moment control unit), etc., and parts assembled to them.

3 Cleanliness rank A ranking of contaminants control parts such as automatic transmission, etc. in the order of influence of contamination on the function of the automatic transmission, etc.

4 Control priority ranking A ranking of contaminants control parts, which are not included in the definition of automatic transmission, etc., by safety, function and performance.

3 Requirements

3.1 Key control parts

3.1.1 Of those parts such as automatic transmission, etc., the ones subject to intensive control of contaminants shall be the parts whose cleanliness ranks and contaminant mass criteria are specified on the drawing in accordance with HES (Honda Engineering Standards). However, parts that are not specified on the drawing but are set forth in section 6 “Contaminants Control Parts (automatic transmission, etc.)” shall also be included.

3.1.2 Of those parts not included in the definition of automatic transmission, etc., the ones subject to intensive control of contaminants shall be the parts set forth in section 7 “Contaminants Control Parts (other than automatic transmission, etc.)”.

3.1.3 Cleanliness rank of each critical control part such as automatic transmission, etc. shall be as follows.

Cleanness

Rank Description

A Control circuit parts whose failure, such as valve lock failure by contact

with contaminants, causes to lose function and quality of drive train.

B

Parts having contact with hydraulic fluid excluding control circuit parts

whose failure, such as valve lock by contact with contaminants, causes to

lose function and quality of drive train

C Parts not included in rank A nor B which can contaminate parts in rank A

or B indirectly by contact with contaminants.




3.1.4 Management priority ranks classified by key control parts not included in automatic transmissions, etc. shall be as follows.

Management

importance rank Description

A Parts which may seriously injure basic functions (run, turn, stop, etc.)

of products by contaminants.

B Parts which may affect basic functions (run, turn, stop, etc.) of

products by contaminants.

3.2 Contaminants control

3.2.1 The supplier shall appoint a section and person responsible for control items, control points, etc. shown in the table below to maintain parts subject to contaminants control in a manner satisfactory to contaminant requirements until delivered to Honda.

No. Control Item Control Pint

1 Design of parts 1．Placing of cleanness ranking and contaminant mass criteria in

accordance with HES A3054 “DESIGNATION FOR CLEANLINESS

OF AUTOMATIC TRANSMISSION”.

2 Verification of

cleanliness

ranks and

management

importance

ranks

1．Verification

3 Setting of

contaminants

control plans

1．Define items subject to contaminants control items during processing

and transportation.

2．Arrange preventives against contaminants mix-up.

3．Reflect contaminants control items in the standard documents.

4 Setting up of

Delivery

Packaging.

1． Define packaging specifications and delivery packaging with

preventive measures for contaminants mix-ups.

5 Processing of

parts

1．Cleaning control of processing facilities, jig & fixture, and work

supplies

2．Control of working conditions in the process of cleaning parts

3．Cleanliness control of circulating oil from QA device to parts

6 Inspection of

contaminants

1．Setting up of inspection method and feedback of inspection results

2．Agreement on contaminants control with supplier

3． Instruction for improvement of suppliers’ contaminants control

activities

Automatic transmission, etc Other than automatic

transmission, etc.

Cleanness rank ・Drawing

・Section 6 this manual

Management priority

rank

・Section 7 this manual.




7 Release/

delivery

1．Implementation of preventive measures for keeping contaminants

from entering release/delivery parts

2．Agreement on contaminants control with outside contractors for

transportation

8 Verification of

delivery

package

1．Feedback of delivery package verification

9 Storage of

parts

1．Ensure prevention of contaminants in the storage parts

3.3 Inspection of Parts Such As Automatic Transmission, etc.

3.3.1 The basic method for inspection of contaminants on parts such as automatic transmission, etc. shall be sampling inspection.

3.3.2 The sampling inspection shall start from normal inspection and the severity of inspection shall be adjusted as follows.

Reduced

inspection

Normal inspection Tightened inspection

3.3.3 The inspection frequency for each inspection severity category shall be as follows.

Severity of inspection

Reduced inspection Normal inspection Tightened inspection

Frequency of

inspection Once a month

Once every two

weeks Once a week

3.3.4 Collect inspection samples in accordance with the following part mass category (if other than a whole number, shall be rounded).

The part mass shall be the values indicated on drawings.

Classification

by part mass

Less than

10g 11～100g 101～500g 501～1000g

More than

1001g

Sample size 10 5 5 3 3

Start sampling inspection

Discontinue sampling inspection

Rejection (one time)

Improvement

Acceptance(three consecutive times)

Acceptance (three consecutive times)

Failed 5 times in total.

Sorting

Rejection (one time)




3.3.5 The criteria for inspection of contaminants shall be as follows.

1) Part mass criteria (allowable maximum mass (mg) of contaminants per part) Unit: mg

10g or less 11 to 100g 101 to 500g 501 to 1000g

1001g

and more

A 0.5 or less. 0.7 or less. 1.0 or less. 1.1 or less. 1.3 or less.

B 0.7 or less. 1.0 or less. 1.4 or less. 1.6 or less. 1.8 or less.

C 1.4 or less. 2.0 or less. 2.8 or less. 3.2 or less. 3.6 or less.

2) The size of contaminants shall be 0.4mm max. as a target value.

3.3.6 Contaminant inspection method

1) Calculate the size of contaminant mass per inspection sample by measuring total mass of contaminants collected by filtering the cleaning agent used for the inspection sample in accordance with part mass category through a filter paper with nominal filtration rating of 1μm or so.

2) Measure the size of contaminants by observing sampled contaminants using magnifying lenses and microscopes, etc.

3.4 Inspection of parts other than automatic transmission.

3.4.1 The basic method for inspection of contaminants on parts other than automatic transmission, etc. shall be sampling inspection.

3.4.2 The sampling inspection shall start from normal inspection, and severity of inspection shall be adjusted in accordance with section 3.3.2 .

3.4.3 The frequency of inspection for each inspection category of severity shall be in accordance with section 3.3.3.

3.4.4 The inspection sample shall be picked up for each inspection category as follows.

Severity of inspection Reduced

inspection

Normal

inspection

Tightened

inspection

Number of samples 2 3 3

3.4.5 The criteria for contaminant inspection shall be as follows.

Management priority

rank Criteria

A No contaminants of 0.2 mm or larger in size shall be found.

B

Quantity of contaminants of about 0.2 mm shall be six or less,

and also no contaminants of 0.2mm or larger in size shall be

found.

3.4.6 Contaminant Inspection Method

1) Filter the cleaning agent through filter paper per inspection sample unit, and using magnifying lenses and microscopes, measure the size and quantity, etc. of sampled contaminants.

2) Only if the size and quantity of contaminants of parts satisfy the judgment criteria, the parts shall be deemed acceptable

part

mass Cleanliness rank




3.5 Control of Inspection Records, etc.

3.5.1 Collected contaminants and inspection records of the collected contaminants shall be controlled in a manner that allows the supplier to present the contaminants or records to Honda whenever so requested by Honda




2) HES A3054 “Designation for Cleanliness of Automatic Transmission”.


1 Collected Contaminants 1 year

2 Contaminant Inspection Records 5 years

Confidential Supplier Quality Manual 2-8 Contaminants Control

July 1, 2014


6 Contaminants control parts (automatic transmission, etc.)

Category of Cleanliness rank

Mechanism A B C AT TC case COMP

Transmission case R side cover COMP Clutch ASSY Feed pipe COMP Main shaft COMP Counter shaft COMP Secondary shaft Shift rail Oil pump gear ATF strainer TRQ/CONV ASSY Main valve body ASSY Separate plate Shift valve cover

Regulator valve body ASSY Governor ASSY Servo body ASSY Linear solenoid ASSY Accum. piston L/C body ASSY Secondary body ASSY Secondary filter Second accum. body ASSY MOD body ASSY Shift solenoid ASSY L/C solenoid ASSY Oil pressure sensor Stator shaft COMP

Baffle plate COMP Breather pipe Breather cap Transfer case Transfer side cover T case packing R side cover packing Oil guide cover Oil guide plate LOW gear Counter LOW gear One-way clutch ASSY Parking gear M2gear C2gear

C3 gear M4 gear C4gear Counter reverse gear Reverse idle shaft holder COMP Reverse idle gear Reverse gear selector Selector hub Speed meter gear ASSY Speed meter gear holder Gear holder seal Speed meter gear COMP Companion flange COMP Reverse shift fork Servo detent base

Shift rail screw set Servo detent ASSY Control shaft COMP Manual valve pin Manual valve roller Change shaft COMP Servo detent sleeve COMP P/BRK P/BRK spring P/BRK stopper Parking pole spring P/BRK pole Parking shaft Cooler hose Transmission magnet COMP

Suction pipe Oil cooler (including trailer traction kit) ATF gauge COMP Oil level pipe COMP ATF filter bolt Oil hose pipe COMP Joint bolt COMP Joint bolt Bypass body Bypass body cover Throttle valve shaft COMP Throttle cam stopper Throttle cable stay Accum. cover Accum. spring

Pick up ASSY Drive transfer gear Differential ASSY Hypoid pinion Hypoid ring gear Final driven gear Throttle adjust bolt Extension shaft

Transmission hanger Torque converter cover Change cover Transmission under guard Speed meter gear holder plate Throttle cable COMP Control lever Control wire holder Throttle control lever Position sensor ASSY Meter cable clip Oil pipe clip COMP

ＣＶＴ

Fly wheel case Transmission case COMP R side cover ASSY Forward clutch ASSY RVS brake piston Start clutch ASSY Feed pipe Oil path pipe COMP

Manual valve body pipe COMP Input shaft COMP Oil pump ASSY ATF Filter COMP Valve body ASSY Manual valve body ASSY Manual separate plate Linear solenoid ASSY

Oil pan Differential cover Intermediate plate ASSY Pulley cover plate COMP A FW case packing I/M plate packing R over packing Oil pan packing

RVS return spring COMP RVS brake plate RVS brake disc RVS brake disc spring RVS brake end plate Oil path pipe holder COMP LUB pipe Secondary gear shaft

Secondary drive gear ASSY Planetary gear COMP Sun gear Ring gear COMP Drive sprocket hub Control lever Control shaft COMP P/BRK rod holder

Parking brake pole Parking pole SPG Detent spring ASSY O/P drive sprocket O/P drive chain Pitot pipe Pitot LUB pipe Pitot flange

Pitot pipe stay ATF gauge COMP Oil hose pipe COMP B Pick up ASSY Final driven gear Oil pipe clip COMP Cotter retainer Circlip retainer

Transmission hanger Control wire stay

４ＷＤ Pump body ASSY Clutch piston

ATF strainer D ring

Rear differential magnet COMP Companion flange Differential ASSY Differential carrier SET

TCD case Hypoid gear Pinion spacer Piston spring

Oil pump pin Back-up ring Pinion gear SET Differential case

Pinion shaft Transfer shaft Driven transfer gear Transfer drive bevel gear

Transfer driven bevel gear Differential clutch ASSY Oil pump drive shaft Transfer case Transfer side cover

Breather tube joint Breather tube clamp Breather tube ASSY Breather tube

ＭＣＵ R/L clutch case COMP L side cover ASSY Solenoid valve body Solenoid separate plate Linear solenoid ASSY Shift solenoid ASSY Oil pressure sensor Oil TEMP sensor

Regulator valve Oil pump driven gear Oil pump drive gear Clutch piston ATF strainer COMP Regulator valve spring Regulator valve cap

R side cover R side cover packing Breather cover packing Extension tube COMP Extension shaft

Center shaft R/L clutch case packing Solenoid body packing Breather cover COMP Valve cap plate

Planetary ASSY L central gear R central joint COMP R central gear C central gear

Clutch disc Clutch plate Clutch return spring Spring guide plate Clutch end plate

Special bolt Oil pump gear cover Oil hose pipe COMP

Under cover MCU sub-harness Harness clamp stay Sub-harness stay Breather tube ASSY

Common parts

Seal ring

Cooler hose Drive shaft Half shaft Flange bolt O ring Cotter

Thrust washer Distance collar Snap ring Ball bearing Ball radial bearing Taper bearing

Needle bearing Thrust needle bearing Oil seal Collar Roller circlip

Washer Shim Snap ring Dowel pin Hex nut Flange nut

Spring washer Drain plug bolt Plug washer Differential pinion thrust washer Spring pin Radiator (AT oil cooler)



July 1, 2014


7 Contaminants Control Parts ( other than automatic transmission)

Management

importance

rank

A B

Part group

Brake system

・Brake master cylinder

・ABS solenoid valve

・ABS ASSY

・Brake hose (pipe)

・Wheel cylinder

・Caliper ASSY

・Master power ASSY

・Proportioning valve ASSY

Steering system

・Steering gear BOX

・P/S pump ASSY

・Speed sensor

・Oil tank

・Feed hose

・Pipe, tube

・Oil cooler

Fuel system

・Carburetor ASSY

・Fuel feed pipe COMP

・Fuel strainer COMP

・ Circuit component filtered

through fuel filter

Driving channel system

・Water pump COMP

・Radiator ASSY

・Water hose

・Reserve tank

・Cooling water circuit component

Lubrication system

・Oil pump ASSY

・Oil pressure switch

・Manual transmission ASSY

・Crank shaft COMP

・Cylinder head

・Cylinder block

・Component with ENG

Function system

・Front fork

・Front damper

・Rear damper

・Distributor

・Completed system function part with

rotating/sliding function

EM control system

・Control BOX ASSY

・Rubber hose

・EM control circuit component

Fuel system

・Fuel tank

・Fuel pump

・Circuit component not filtered through

fuel filter



May 1, 2019



1 Overview

1) Honda shall identify quality records which Honda may require suppliers for presentation.

2) Supplier shall create the quality records and approve the records properly in

accordance with the procedures established by the supplier.

3) The supplier shall retain quality records, when so designated in SQM in accordance

with requirements established by Honda.

2 Definitions


Definitions】.

No. Term Definition

1 Storage The act of organizing frequently-used documents in a manner that allows fast retrieval during daily business operations.

2 Retention

The act of preserving less-frequently-used documents (including electronic medium) in a location such as archive and stockroom outside the worksite in a manner that allows prompt retrieval when needed.

3 Requirements

3.1 Quality records creation/approval

3.1.1 In case the quality records format is designated, the supplier shall apply the latest

format.

3.1.2 In case supplier creates quality records, the person who created the records shall

signs/seals the records.

3.1.3 In case the supplier creates the quality records, the person who was assigned by

the supplier shall signs/seals and approve the records.

3.1.4 Supplier shall store the sign/seal (including electronic) with security so that no

other person can use it.

＜Good/Bad examples＞

R&R/Authority table (“B” is “A” ‘s alternate approver)

・When “A” is out, “B” signs/seals it as “B”.…Appropriate

・When “A” is out, “B” signs/seals it as “A”. …Inappropriate

3.2 Storage and retention of quality records

3.2.1 The supplier shall, if maintain quality records on electronic media, make the records

available for Honda to view with a support from the supplier associates upon

request from Honda.

3.2.2 The supplier shall give consideration for retention and storage means in order for

the records not to become illegible due to deterioration of the media or changes in

the environment for use.

3.3 Retention Period

The supplier shall, for the period of time specified in the “Control of Records” section in respective SQM articles, ensure retention and/or storage of quality records concerned. The retention period shall be the duration from the day of establishing or receiving to the day of disposition of the records.

When retention period in SQM is revised, the revised retention period is applied to the records taken after SQM revision issuance.



May 1, 2019


3.4 Presentation or submission of quality records

3.4.1 The supplier shall, in response to a request from Honda, present or submit quality records to Honda. Honda may request submission of relevant quality records on electronic media.

3.4.2 The supplier shall, if so requested by Honda for presentation or submission of stored quality records, provide information in regard to the time needed until presenting or submitting the records.

3.5 Disposition of records

The supplier shall, for quality records that have reached their retention period, dispose them after rendering the contents illegible.



Confidential Supplier Quality Manual 3-1 Stage Management

March 1, 2018


3 Pre-Production Stage


1 Overview

1) Honda shall designate key control parts, and verify production preparation activities of a supplier for the key control parts.

2) The supplier shall plan production preparation activities to be linked to the pre-production schedule of Honda. Items to complete at each stage of Pre-production shall be defined in order for the supplier to thoroughly implement the planned activities.

2 Definition



No Term Definition

1 Stage Management

A management method that controls supplier activities on a step-by-step basis. The processes of pre-production and mass production are divided into 6 stages from stage I to stage VI. Main activity to be completed at each stage is described below.

Stage Ⅰ：Obtain product requirements from Honda (Stage I will

be omitted hereafter since this stage consists of activities prior to the Pre-production).

Stage Ⅱ：Formulate a manufacture management plan.

Stage Ⅲ ： Promote activities required based on the

manufacture management plan.

Stage Ⅳ：Verify quality maturation status.

Stage Ⅴ：Confirm the prospect of transition to mass production

and declare completion of production preparation.

Stage Ⅵ：Mass production.

2 Manufacturing Management Plan

A management plan to monitor progress of the activities specified in the Stage Management.

3 Requirements

The supplier shall formulate a manufacturing management plan that includes control items designated in Article 3.3 “Control Items and Objectives” at a minimum, and implement activities to achieve objectives set forth for each stage for respective control items.

3.1 The supplier shall formulate a manufacturing management plan in conjunction with respective stages below.

Honda (Design &

Development Stage)

Pre-production Stage Mass Production Stage

Supplier Pre-production Stage Mass Production Stage

Timing

Prototype Dwg

Prototype Dwg M/P Dwg

Event

(Honda)

Stage Ⅱ Ⅲ Ⅳ Ⅴ Ⅵ

3.2 The supplier shall monitor the progress status of control items at each stage. In case of delay in the progress, amend the manufacturing management plan and recover the delay. If there is a possibility that it may affect Honda’s production plan, the supplier shall inform Honda (new model preparation section).

Plan Tooling Quality Volume Mass production

Confirmation Confirmation Confirmation Confirmation

*********************

◆ Tooling Go


March 1, 2018


3.3 Control Items and Objectives (suppliers are to work with Honda for each product in accordance with the following as the basis)

No. Control Item Stage/Category

Outline

Pre-Production Stage Production Stage

Stage Ⅱ Stage Ⅲ Stage Ⅳ Stage Ⅴ Stage Ⅵ

1 Supplier’s production

plan.

A supplier’s production plan for the pre-

production stage drawn up in line with

Honda’s production plan.

Draw up a plan Reflect delivery

and quantity to

the plan.

Address

concerns from

the previous

stage.

Production and

delivery in line

with Honda’s

production plan.

Practice quality

control in line with

【SQM 4-1 Early

Mass Production

Quality Control】

and【SQM 4-2

Mass Production

Quality Control】

2 Tooling Plan Draw up plan for designing, manufacturing

and application of dies and molds (press,

plastic and casting and forging) adjusted

to the required level.

If there are more than two dies or molds,

draw up a plan per die or mold.

Decide quantity

of dies and

molds.

Decide

manufacturers.

Decide plans per

die or mold.

Manage planned

and actual

outputs.

Measures

against the

differences

between planned

and actual

outputs.

Trial with final

and permanent

model dies or

molds.

Product

evaluation.

Finish up final

model dies or

molds (hardening

process, etc.)

sintering

Confirm by

continues

production

3 Production facility

setup

Installation plan for facilities (new,

refurbished, etc.) necessary to secure

required quality (production capacity,

included).

Decide

production facility

concept.

Decide schedule

for facility setup.

Manage planned

and actual

outputs.

Measures

against the

differences

between planned

and actual

outputs.

Perform line trials

with permanent

facilities.

Product

evaluation.

Process

capability

verification.

Confirm by

continues

production

Check quantity.

Verify process

capability.

4 Jig/ testing device/

inspection equipment

setup (dimensions

and accuracy).

Plan to secure needed jigs/testing

devices/ inspection equipment to

guarantee required quality.

Schedule a date

to set up jigs/

testing devices/

inspection

equipment and

complete process

design.

Manage planned

and actual

outputs.

Measures

against the

differences

between planned

and actual

outputs.

Confirm the

accuracy of jigs/

testing devises/

inspection

equipment.

Check the

operation state of

inspection

equipment in the

line during

continuous

production test

runs


March 1, 2018



Outline


Stage Ⅱ Stage Ⅲ Stage Ⅳ Stage Ⅴ Stage Ⅵ

5 Validity testing A plan that will be used to confirm required

part characteristics, based on roles and

responsibilities agreed with Honda.

Carry out tests on specifications specified

in the applicable drawing (specifications

included).

Concerns on

required quality

and measures

against them

Draw up a test

plan.

Commence

variation testing.

Progress

performance

management

against the plan.

Complete

variation testing.

Address

concerns from

the previous

stage.

Production and

delivery in line

with Honda’s

production plan.

Practice quality


【SQM 4-1 Early

Mass Production

Quality Control】

and【SQM 4-2

Mass Production

Quality Control】

6 QA device validity

testing (function)

A plan used to validate QA device. Decide QA

device concept.

QA device setup

plan

Manage planned

and actual

outputs.

Verify QA device. Check the

operation state of

QA devices in the

line during

continuous

production test

runs

7 Production capability Plan to determine the number of

man-hours and manpower needed for the

planned volume of vehicle production to

ensure delivery time and quantity.

Set the maximum

production

capacity and

decide schedule

for procurement

of needed

resources.

Manage planned

and actual

outputs.

Measures

against the

differences

between planned

and actual

outputs.

Perform line trials

with permanent

facilities.

Verify continuous

production

Check quantity.

8 Process proficiency of

operators.

Develop required control documents and

draw up plans for improving operators’

proficiency in the line.

Draw up training

plans.

Commence

training with

actual parts.

Draw up control

documents.

Commence

training with

required line takt

time.

Complete

operators’

proficiency

requirements.


March 1, 2018



Outline


Stage II Stage III Stage IV Stage V Stage VI

9 Color matching

verification

A verification plan to reproduce the

required color.

Know about

specified parts

and their color.

Draw up

verification plans.

Manage planned

and actual

outputs.

Select paint.

Agree the final

master sample

Agree the master

sample for mass

production

products.

Address

concerns from

the previous

stage.

Production and

delivery in line

with Honda’s

production plan.

Practice quality


【SQM 4-1 Early

Mass Production

Quality Control】

and【SQM 4-2

Mass Production

Quality Control】.

10 Grain and gross

matching verification.

Plan to reproduce the required

appearance (grain and gross).

Understand the

scope of subject

parts.

Draw up a plan.

Manage planned

and actual

outputs.

Agree the final

master sample.

(depth or trends

of impression of

grain pattern,

etc.).

Agree the master

sample for mass

production

products

11 Illumination master Plan to ensure the illumination

specification comply with the master

sample.

Understand the

scope of subject

parts.

Draw up a plan.

Manage planned

and actual

outputs.

Agree the final

master sample.

Agree the master

sample for mass

production

products

12 Feeling master Plan to ensure feeling complies with the

master sample.

Understand the

scope of subject

parts.

Draw up a plan.

Manage planned

and actual

outputs.

Agree the final

master sample.

Agree the master

sample for mass

production

products

13 Control items at each

manufacturing

process

Plan to conduct process FMEA, etc. and

determine items requiring control in a

process.

Determine

possible causes

by conducting

process FMEA.

Decide on control

items for the

manufacturing

process.

Process

improvement.

Process

improvement

14 Lot No. Display Detail Plan to define lot control numbers to

display on the parts, hand in “Lot No.

Display Details” to Honda, and to carry out

lot identification.

Understand the

scope of subject

parts.

Decide the Lot

No. Display

Details.

Process set-up

plan for lot

identification.

Manage planned

and actual

outputs.

Check devices

for display of part

lot.

Check

continuous lot

number display in

the line.


March 1, 2018



Outline



15 Process quality

control table

An action plan for the process quality

control table.

Decide process

sequence

(process system

diagram)

Formulate the

process quality

control table.

Verify processes

in line with the

process quality

control table.

Address

concerns from

the previous

stage.

Production and

delivery in line

with Honda’s

production plan.

Practice quality


【SQM 4-1 Early

Mass Production

Quality Control】

and 【 SQM 4-2

Mass Production

Quality Control】

16 Approval mark Application for part approval and approval

mark display.

Confirm

regulatory

requirements.

Understand the

scope of subject

parts.

Draw up a plan

for gaining

approval.

Manage planned

and actual

outputs.

Agree on

approval mark

identification

methods.

Part approval

application.

Evaluate

products

(conformity with

drawings).

Gain part

approval.

Display an

approval mark on

the parts.

Submit an

approval

certificate and

test reports to

Honda.

17 Material identification Material identifiation for the recycling of

materials of parts.

Understand the

scope of subject

parts.

Agree

identification

methods.

Evaluate

products

(conformity with

drawings

including

specifications.


March 1, 2018



Outline



18 Management of

compliance with laws

and regulations.

Plan to ensure compliance of products

with laws and regulations.

Confirm

restrictions.

Understand the

scope of subject

parts/materials.

Draw up a plan

to ensure

compliance.

Confirm

conformity of

purchased

materials.

Carry out

inspection to

ensure

compliance with

laws and

regulations.

Present or

submit inspection

results.

Address

concerns from

the previous

stage.

Production and

delivery in line

with Honda’s

production plan.

Practice quality


【SQM 4-1 Early

Mass Production

Quality Control】

and 【 SQM 4-2

Mass Production

Quality Control】

19 Mass Production

Transition Declaration

Confirm transition of production to mass

production.

Mass Production Transition Declaration



March 1, 2018




1 Manufacturing management plan 20 years


1) SQM 2-2 Regulatory Compliance Certification


3) SQM 3-5-3 Grain and Color Adjustment


5) SQM 3-9-1 Validity Testing


7) SQM 4-2 Mass Production Quality Control



3-2 Process Design

May 1, 2019

3-2 Process Design

1 Overview

1) Honda shall define the requirements for suppliers to design a process.

2) The supplier shall clarify requirements for designing a process, and maintain the manufacturing process at an appropriate quality level.

2 Definitions

The definitions of terms used in this manual are as follows. For other terms and definitions,

refer to【SQM 6-1 Glossary of Terms and Definitions】

№ Term Definition

1 Recall, etc. A general term for market action, which includes recall, improvement campaign, service campaign and extended warranty.

2 Recall An act of implementing improvement measures by submitting a notice to the competent authorities in accordance with Paragraph 3 of Article 63 (Report, etc. of Corrective Action) of Road Vehicles Act (Law No.185 of 1951).

This includes the implementation of equivalent actions in foreign countries in accordance with the laws and regulations of those countries.

3 Improvement campaign An action taken by Honda to implement improvement measures by submitting a notice to the competent authorities in accordance with Article 9 (Improvement Campaign) of Circular Notice "Handling Procedure for Notification, etc. of Recall" (Jishin No.1530 of December 1, 1994, hereinafter referred to as "Circular Notice").

4 Service campaign An act of implementing improvement measures by submitting a notice to the competent authorities in accordance with Article 10 (Implementation of Service Campaign) of Circular Notice.

5 Extended warranty An act of extending the warranty period, submitting a notice to the competent authorities, and implement improvement measures.

3 Requirements

3.1 Process Control Item Setting

3.1.1 The supplier shall, to ascertain quality requirements through the drawing (specifications included) and maintain appropriate quality, set control items in consideration of the following when designing manufacturing processes (refer to

【SQM 5-2 Error Proofing 】and【SQM 5-5 Process FMEA】).

1) Part design input requirements

2) Required production capacity and process capability

3) Capability and accuracy of production equipment

4) Capability and accuracy of measuring equipment

5) Experience from past process designs

6) Past problems attributed to process designs

7) Predicted defects manifested from Process-FMEA, Design-FMEA and other methods, and/or manufacturing control items emerging from FTA.

8) Incorporation of error proof measures as necessary

9) Necessary inspection and testing


3-2 Process Design

May 1, 2019

3.1.2 The supplier shall classify defined control items into quality characteristics items and process control items, and establish control methods respectively.

3.1.3 The supplier shall create a process quality control table based on the results of

paragraph 3.1.1 and 3.1.2 above in accordance with【SQM 3-2-1 Process Quality

Control Table】.

3.2 Designation and Control of Critical Items

3.2.1 The supplier shall designate control items that meet any of the following conditions as critical items.

1) An item which has a mark（○Q ） on its product drawings, specifications, etc.

2) A control item which is specified in the Model CP List.

3) A control item which directly affects the inspection item with item importance ranked “A” as defined in the inspection criteria for Parts.

4) An item related to quality characteristics and manufacturing conditions that may result in a defect of an important function (such as running, turning, stopping, guard, insulation, protection, exhaust gas controlling or identification) as defined in Honda Engineering Standard (HES A 3050).

5) An item for which recall, etc. was taken in the past. Items involved in a recall, etc. in the past

6) An item for which a focused control is judged to be required based on the process capability evaluation, the past quality performance (market quality information, in-house quality information, in-process failure), the manufacturing quality criteria, etc.

3.2.2 The supplier shall control critical items with consideration to the following requirements.

1) Identify critical items on process quality control table, operation standard, etc.

2) Submit data of periodic inspections or testing, if so required by Honda.

3) Assign personnel who are trained with the knowledge of the relevant processes.

4) Assess the process capability in accordance with 【SQM 5-1 Process Capability ,

if so required by Honda.

5) If applicable, apply contaminants control in accordance with 【SQM 2-8

Contaminants Control】.

3.2.3 If critical items are processed by a sub-supplier, the supplier shall be responsible for managing the sub-supplier in a manner that all requirements in this

manual are thoroughly implemented ( refer to 【SQM 2-1 Important Safety Parts】、

【SQM 2-4 Sub-Supplier Quality Assurance 】and 【SQM 3-2-1 Process Quality

Control Table】).


3-2 Process Design

May 1, 2019

3.3 Work environment

3.3.1 The supplier shall, if deemed necessary in accordance with quality characteristics and control items of parts, manage work environment with consideration to the following conditions.

1) Dust-proof room designed to prevent contaminants from entering inside.

2) Temperature controlled room to maintain precision of measuring instruments.

3) Quiet environment suitable for auditory testing.

4) Illumination condition for visual inspection process.

5) Antistatic facility.

6) Others

3.3.2 The supplier shall address product safety and means to minimize potential risks to employees (e.g. protection mat for falling parts, necessary protectors, etc.).

3.4 Result review

3.4.1 The supplier shall put the process into operation in accordance with the process quality control table, operation standard, etc. The Quality Assurance Representative, Facility Quality Representative or appointed deputy shall review the results of process design. The record of the review results shall be kept retrievable when so requested by Honda.

3.4.2 The supplier shall maintain documents used for designing processes, and utilize them in the investigation, analysis, and measures when a problem occurs, as well as in the development of the next model.






5) SQM 5-2 Error Proofing

6) SQM 5-5 Process FMEA



3-2-1 Process Quality Control Table March 1, 2018



1 Overview

1) Honda shall define contents and provide operation procedure for process quality control table.

2) The supplier shall control and maintain the process quality control table and use for the following purposes.

a) Management of control items for in-process quality assurance.

b) Monitoring of process control conditions.

c) Accumulation and conveyance of skills and technology, etc.

2 Definitions



No Term Definition

1 Quality

Characteristics Property and performance subject to quality evaluation, and standards and criteria to control them.

2 Production Conditions

Control items for the set up condition and its standards and/or criteria necessary to ensure quality required for respective manufacturing processes.

3 Requirements

3.1 Preparation criteria

The supplier shall design manufacturing processes, conduct process FMEA, etc., and draw up process quality control table in accordance with drawings, specifications, etc. issued by Honda and/or those draw up by the supplier and verified by Honda.

3.2 Subject Parts and Processes

3.2.1 Process Quality Control Table shall be made for all parts ordered by Honda. For the parts with the same or similar process sequence, quality characteristics, production condition, etc., a representative process quality control table may be accepted with the attachment of “Process Quality Control Table (Appendix) List of Applied Parts“(Form-5) set forth in section 8.11.

The differences between process sequence, quality characteristics and production conditions of similar parts shall also be clearly entered appending to the process quality control table of the representative parts.

3.2.2 Regardless of the preceding section, the supplier may exclude standardized parts that comply with standards such as ISO (International Organization for Standardization), JIS (Japanese Industrial Standards), and HES (Honda Engineering Standards) from the subject parts for the process quality control table. However, if so requested by Honda, the supplier shall follow the direction and provide the process quality control table for review.

3.2.3 The supplier shall include all processes from the receiving of materials and component parts to the shipping of finished product to Honda (or to the supply parts user) in the process quality control table. Process quality control table shall be made per delivery package (per delivery package to the receiving party if shipped as supply parts).

3.2.4 The supplier shall, in the event of employing an outsourced process after receiving component parts, encompass all processes from the release to the delivery of parts from outsourced service providers in the process quality control table.

3.2.5 If any of the important quality characteristics designated by Honda is processed at sub-suppliers, the supplier shall include such outsourced processes in supplier’s process quality control table.




3.3 Submission Procedure

3.3.1 The supplier shall be notified by Honda of the scope of process quality control table

to be submitted to Honda. Honda shall issue ”Process Quality 〔Notice for

Submission of Process Quality Control Table〕” (Form-1) in section 8.1 when

applicable.

However, if excluded from such submission, the supplier shall manage process quality control table in a manner that is readily available for Honda to view if so requested by Honda.

3.3.2 The supplier shall, with approval of its Quality Assurance Representative or the Facility Quality Representatives submit the original of the process quality control table to Honda by the date specified.

3.3.3 The supplier shall if there are any changes made to the contents of the process quality control table submitted to Honda, revise and resubmit the process quality control table to Honda immediately. Related processes, i.e. change point control,

shall be completed in accordance with【SQM 4-4 Change Point Control 】, etc.

3.3.4 The supplier shall submit a process quality control table using the forms below.

1) “Process Quality [Process Quality Control Table Issuance Report]”

(Form -2)

2) “Process Quality Control Table (I)” (Form -3)

3) “Process Quality Control Table (II)” (Form -4)

4) “Process Quality (Appendix)” (Form -5)

(Used when issuing as a representative for multiple parts.)

3.3.4.1 The supplier may choose to use its format in lieu of “Process Quality Control Table (I)” and “Process Quality Control Table (II)” on the condition that Honda confirms all items set forth in those forms are covered in the supplier’s format.

3.3.4.2 The supplier shall, if a note was added referring other documents e.g. “XX standards, etc.” in the quality characteristics field and the production conditions field control the cited documents in a manner that is readily available for Honda to view.

3.3.4.3 The supplier shall, if Honda requests submission of a process quality control table made by sub-suppliers, submit that of the Quality Assurance Representative or the Facility Quality Representative approved.

3.4 Process Quality Control Table Entries

The suppler shall follow the direction provided in section 8, and make appropriate entries with required information in “Process Quality Control Table (I)” and “Process Quality Control Table (II)”.

3.5 Use of Process Quality Control Table

The supplier shall put the process quality control table into practice in accordance with “Process Quality Control Table Operation Flowchart” in section 7.

3.6 The supplier shall, if the need for a new process quality control table arises due to the launch of production at a new plant or in a new line after new model start-up, report to Honda in advance, and proceed according to the directions, such as prior presentation of parts, submission of a new process quality control table on the specified date, etc.

4 Key points

1) Conduct process FMEA and define control items required as manufacturing standards.

2) Perform casting parts pressure leakage testing with the parts for which the final fabrication was completed.

3) Choose cleaning agent taking into consideration chemical reactions with substances used subsequently, such as rust inhibitor, lubricant, etc.

4) In the event of confirming the status of reflection of the requirements in the process quality control table, cross check the requirements for products with drawings (specifications included).






1 Process Quality Control Table 20 years after the issue of discontinuation

order.


1) SQM 3-5-1 Model CP List

2) SQM 3-5-4 Parts Inspection Criteria






7 Flowchart

7.1 Model CP List

“Process Quality Control Table Operation Flowchart” （Model CP List）

Contact

New model

preparation

section

Purchasing,

Planning

or

Purchasing,

Planning

or

Receiving

Inspection

section

new model

preparation

section

New model

preparation

section

　　　　NG New model

preparation

section

OK

Receiving

Inspection

section

or

Procurement

Receiving

Inspection

NG section

or

Procurement

OK

*　Model CP List (Control item) :

　　Regarding specified items in 3.1.1Model CP List, specified 1) Part number / name and 2) Inspection item.

**　Model CP List (Quality control method) :

　　For the contents above, suppliers set and reflected 3) Quality judgment criteria, 4) Inspection method and

5) Inspection frequency regarding specified items in 3.1.1Model CP List.

Receiving

Inspection

section

Suppler Honda

Pre

-Pro

duct

ion

Sta

ge

(Not required to submit)

Pro

duct

ion

Sta

ge

Request submission of Process Quality Control Table

Drawings

Create Process Quality Control Table (I) and (II) and process verification

Issuance of "Notice for Submission of Process Quality

Control Table "

Create "Process Quality Control Table

Issuance Report"

Approve

Review Process Quality Control Table

Verify Process Quality Control Table

A need for revision of Process Quality Control Table is

identified

Review Process Quality Control

Table

Approval


Process Quality Control Table submission request

Receipt

Notice of PQCT submission request

Create "PQCT issuance Report"

ReceiptStore Process Quality Control Table originals

Receipt

Process design- Process FMEA

- Problem containment system- Error proofing

Submit by due date

Return the original after verification

Establish and issue Model CP List

（Control item）*

- Reflect process FMEA review- Review instructions from Honda- Drawing change details

Model CP ListReply (Quality control

method) **Agreement and confirmation

whether contents of reply are in accordance with Process Quality Control

Table. ( Dashed line)Only for target components of Model CP List, confirm whether Model CP List (Quality control method)** is in accordance with Process Quality Control Table.


(When Model CP List is revised)

As with establishment and issuance of Model CP List, confirm whether it is in

accordance with Process Quality

Control Table. Refer to §3-5-1.

Submit by due date




7.2 Parts Inspection Criteria

“Process Quality Control Table Operation Flowchart” （Parts Inspection Criteria）

Contact

New model

preparation

section

Purchasing,

Planning

or

Procurement

new model

preparation

　　 - Reflect process FMEA review section

　　 - Review instructions from Honda

　　 - Drawing change details

New model

preparation

section

　　　　NG New model

preparation

section

OK

Procurement

NG Procurement

OK

Suppler Honda

Pre

-Pro

duction S

tage

(Not required to submitt)

Pro

duction S

tage

・When submission is required by Honda

・When PQCT is revised

Request submission of Process Quality Control Table

Drawing

Create Process Quality Control Table (I) and (II)

Review Process Quality Control

Issuance of "Notice for Submission of Process Quality Control Table "

Create "Process Quality Control Table Issuance

Report"

Approve

Review Process Quality Control Table


A need for revision of

Process Quality Control Table is

identified

Review Process Quality

Control Table

Approva


Process verification with Process Quality Control

Establish and issue inspection Criteria

Process Quality Control Table submission request

Receipt

Notice of PQCT submission requestCreate "PQCT

issurance Report"

ReceiptStore

Process Quality

Control Table originals

Receipt

Process design

- Process FMEA

- Problem containment system- Error proofing

Submit by due date

(Not required to submitt)





8 Forms

8.1 Notice for Submission of Process Quality Control Table (Form 1) (referential)

(Form - 1)

Process Quality [ Notice for Submission of Process Quality Control Table ]

To:

Quality Assurance Representati

◇ Please submit ( new / revised ) Process Quality Control Table for the following parts.

№

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

◇ Submission due date, organization and contact information are as follows.

　- Routing: Issue Division =>

01121

VendersProcurem

entDept

Honda Motor Co., Ltd. �

Issue date: / /

Month day Year

Material DivisionDiv/BL/MO

Approved by Created by

Model Part Number Part Name Grounds for submission

Due date / / (month/day/year)

Location Dept/BL/MO

Original to be retained until: / (month/year)

Contact info.

Dept/BL/MO

Phone No.

Fax No.

(Copy) => Supplier

(Original: attached to Process Quality Control Table)

=> Issue Division (retain original)




8.2 Process Quality Control Table Issuance Report (Form 2) 1/2

(Form - 2)

Process Quality [Process Quality Control Table Issuance Report]

Honda Motor Co., Ltd.

Section:

To: Issue date: / / (YYYY/MM/DD)

New # of original:

Revised # of revisions made:

Reason:

Comments from the confirmation division.

01121 Original to be retained until: / (year/month)


�

Facility name:

Company Name

Contact Person Name

Address

Telephone

Notification

cla

ssific

ation Due to submission request notice (new/revised)

Notification

documentDue to an arrangement with Mr./Ms _______, Honda

Due to company reasons.

Part Number Part Name

Honda

Supplier

Received on / / (yyyy/mm/dd)

This notification takes effect

from the delivery date below.

Returned on / / (yyyy/mm/dd)

Returned by

from / (month/day)

Received by

Please complete all

applicable fields

enclosed by bold line.

Please place a circle in the box of your reason.

Confidential Supplier Quality Manual 3-2-1 Process Quality Control Table

March 1, 2018


8.3 Process Quality Control Table Issuance Report (Form 2 ) Entry procedure 2/2

(Form - 2) Sample

Process Quality [Notification of Process Quality Control Table Issuance] Sample

Honda Motor Co., Ltd. No. Description

1 Fill in the issue date in A.D. year.

Facility name: Division: 2 Sign or seal after all required fields were completed by the supplier.

5 Fill in the name of the company and the contact person for inquiries from Honda.

6 Fill in the address and phone number of the company.

9 Fill in the reason for submitting this Process Quality Control Table.

12 Fill in the scheduled date for commencement of carry-in of the subject part in this notification.

13 For Honda use only (no entry required).


01121 Original to be retained until: / (month/year)

from / (day/month)

10

-1. Fill in the part number in this Process Quality Control Table.

-2. Fill in the part number if there is a part number at the supplier that corresponds to Honda's and a slash

if there is not.

Process Quality [Notice Requiring Submission of Process Quality Control Table]

3Quality Assurance Representative or a person responsible for plant quality signs or seals upon confirming the contents filled in

by the writer.

To:

4

-1. If the submission of this issuance notification is due to the submission request notice, fill in the name of

the organization for submission provided in [Notice Requiring Submission of Process Quality Control

Table] that corresponds to this issuance notification.

-2. Fill in the name of the person in charge in the receiving section in relation to parts in the Process

Quality Control Table if the notification is issued on their reasons.

11 Fill in the part name that corresponds to the part number.


7

Put a circle in the box that is most appropriate, and

-1. circle New or Revised if the submission is due to the submission request notice.

-2. Write the name of the person from Honda if the submission is due to arrangement made between

person from the company and Honda's representative.

8

Circle New or Revised and

-1. fill in the number of the Process Quality Control Table submitted if New.

-2. fill in the number of revised areas in the Process Quality Control Table if Revised.

Not

ifica

tion

Issue date: / / (mm/dd/yy)


Company Name

Contact Person Name

Address

Telephone No.

Please complete all applicable fields within the bold lines.

lease place a circle in the box of your reason.

Due to submission request notice (new/revised)

Due to an arrangement with Mr./Ms_______ , Honda

Due to company reasons.

Notif ication document

New

Revised

# of original:

# of revisions made:

Reason for issuing notification:

Part Number

Supplier

Part Name This notification takes effect from the delivery date below.

/ / (month/day/year)

Honda

Returned on

Received on

/ /

Comments

1

3 2

45

6

7

8

9

10 11 12

1413

15Returned by

Received by


March 1, 2018


8.4 Process Quality Control Table (I) ( Form 3 ) 1/4

Form - 3 Entry Procedures (Y08111)

Process Flow Diagram

Sup

RCVD

Flow process chart symbols shall conform to JIS Z8206 (composite symbol: combine sub-job symbol in main job symbol)

○ □ Main job - machining /sub job -quality inspection.

○ ◇ Main job - quality inspection /sub job - quantity inspection. ･･･ Initial Establishment 15 Approved by Checked by Prepared by

▽ ー Code Date Revision Record

05071 Route: dept. prepared => dept. checked => dept prepared.

Original to be retained until :

Model�

Designation of parts 　HS　HA　HB　Others

Part Number Process Quality Control Table (Ⅰ)

Order Type

Part Name

Component Part Order List

Supplier NameMFG

No Part Number Part Name

Machining Quantity inspection Flow line crossing

Transfer Quality inspection Control classification in process sequence

Storage Process sequence

YYYY/MM

／

Dept Checked

Creation Division

Honda Motor Co., Ltd.Suzuka, Hamamatsu, Kumamoto,

Saitama, Tochigi, Pur.

22

23

Dept. prepared ( supplier or dept in charge.) Dept. checked.

Approved by Confirmed by Created by

　

(Received)

8


March 1, 2018


8.5 Process Quality Control Table (I) ( Form -3 ) entry procedure


9. Process Flow Diagram- Set 'lot formation criteria' within the range in which a product was or was

1 considered to be produced under equal conditions. For example, by material

charge, process setup change, or processing machine, etc. Sup

2 - Set up a lot size based on a set production quantity per day in the process design RCVD

3 calculated with the set product quantity for amortization, and the aforementioned

lot formation criteria (actual lot size may vary according to production plan). 10 11 12 13- For 'names of recording forms', fill in the names of forms in which the lot formation

and lot sizes are recorded.

-5. In case that symbols other than indicated in the process drawing symbol column are

used, add such symbols and explanations in the margin.

10

4 Enter the part name shown in the drawing.

5 Enter the name of the supplier and the responsible section. 11

6

12 Cross out 'RCVD' for received parts in Component Order List field with a diagonal line.

Circle the applicable item; 'SUP" for supplied by Honda or MFG for self-supplied parts.

13

7 For Honda use only (no entry required) 14

8

15 Enter "establishment".

16

9 Draw the process diagram from receipt of component parts to processing and shipment.

-1. Enter the process name in ( ), if it is performed at the supplier.

-2. Attach an additional form or an A3 size sheet if more space is needed. 17 Enter the date of revision in the western calendar.

-3. Other types of sheets can be attached if appropriate. 18

-4. Follow procedures below for lot control parts.

a. 19

b. 20 For Honda use only (no entry required)

21 Enter the date, month and year after 15 years of issuance of production closing order.

22

Designated lot size/lot formation criteria

Names of recording forms 23 Enter total page count.


○ □ Main job - machining /sub job -quality inspection. 16 17 18 19 20

○ ◇ Main job - quality inspection /sub job - quantity inspection. ･･･ 14 Initial Establishment 15 Approved by Checked by Prepared by



Original document retention period: YY/MM

／

Dept

CheckedStorage Process sequence Creation Division

Enter the page number using consecutive numbers for every part number provided in the

"Notice for Submission of Process Quality Control Table".


Transfer Quality inspection Control classif ication in process sequence

Write a summary of the revision. In case that the original or form format is to be renewed by

the revision, write "original rewritten due to XX" (insert reasons).

Place a '●' to the left of appropriate process drawing code for lot formation process. In the latest revision, sign or seal the names of supplier's quality assurance representative or

facility quality representative. Be reminded that all signatures and seals affixed to previous

versions will remain and be printed out by the preparing section, if computers are used to

revise the content of this document.

'Lot forming process' is "a process of forming and identifying a manufacturing lot

according to the priority of quality characteristics, process layout, equipment,

process capability, etc. to track and control manufacturing records of parts".

For the process marked '●', write designed 'lot formation criteria and designated lot

size' and "names of recording forms" in a square box to the right of the process

name.

(see below for reference).

Signatures and signs of previous version will be printed by the revising section, if computers

are used to revise the content of this document.

Enter the part number and the part name shown in the drawing and the first three digits for

type number. Be reminded to use the part number from Honda (Honda's part number).Signature or seal of the supplier's quality assurance representative or facility quality

representative. Be reminded that all signatures and seals affixed at the time of

establishment will remain and be printed out by the preparing section, if computers are

used to revise the content of this document.

Enter the name of the designated sub-supplier if this is 'SUP', or the supplier name if 'MFG'.

Enter the establishment date in the western calendar. If revising the form for reasons other

than a new establishment, transcribe the establishment date of previous versions.Signatures and signs made during time of establishment will be printed by the revising

section, if computers are used to revise the content of this document.

Fill in a serial number each time revision is made. In the event that a new form is created or

revision column is rewritten due to short of revision field, the revision number is to be the

sequential to the last version. Implement identification to prevent misuse of previous

versions, and exercise control over and maintain previous versions in a manner that they are

easily retrievable when needed.

Enter the part name shown in the drawing. Enter first three digits for the type number.

If there are multiple part classification no. or type no., one of the following may be taken for

parts that process sequence, quality characteristics, production conditions, etc. are the

same or similar.

-1. Include in the same field.

-2. Prepare and attach a Process Quality Control Table (Appendix), List of Applied Parts.

Write "see List of Application (appendix) for part numbers" in the part number column. Enter the serial number. For parts with the Process Quality Control Table, circle the serial

number that applies.


Enter the Part Classification No. (enter the name of the representative Part Classification

No. if there are more than one). No Part Number Part Name

Order Type

Supplier NameMFG

Circle the designation mark in the "critical safety parts rank" in the drawing.

Process Quality Control Table (Ⅰ)

Part Name4

Model 1 Designation of parts 　 HS　HA　HB　Others

Part Number 3



22

23

21

2

12


Approved Confirmed by Created by

5

6

(Received)

8

8

7




8.6 Process Quality Control Table (I) (Form -3) 3/4

Basic Drawing Symbol

NumberSymbol

NameSymbol Remarks

1 Processing

2 Conveyance ○

Diameter of the conveyance

symbol is 1/2 - 1/3 of that of the

processing symbol.

can be used instead of ○.

However, this symbol does not

show the direction of

conveyance.

3 Storage

4 Retention

5Quantity

Inspection

6Quality

Inspection

Supplementary Drawing Symbol

Number Symbol

1

2

3

Combined Symbol

�

Perform conveyance as well as processing

primarily conducted.

Perform quality inspection as well as quantity

inspection primarily conducted.

Perform quantity inspection as well as

processing primarily conducted.

Combined Symbol Description

Perform quantity inspection as well as quality

inspection primarily conducted.

OmissionOmission of part of process

sequence.

When functions or states of two component processes exist in one component process, those component

process symbols can be combined. In such case, "main" component process symbol should be placed outside

and "sub" component process symbol inside. As for the conveyance symbol when combined, the symbol to be

used is .

StreamlineOrder relations of component

processes.

If order relation is unclear, add an arrow at

the end of the line or in between to specify

the direction. Intersection of the streamline

should be indicated with .

ClassificationControl classification in

process sequence.

Inspection

Process where volume or

quantity of raw materials,

materials, parts or products

are measured to compare

the results with standards

and to learn the difference.

Process where quality

characteristics of raw

materials, materials, parts or

products are tested to

compare the results with

standards and to judge

ACCEPT or NOT ACCEPT

for lots, or GOOD or NOT

GOOD for parts.

Symbol Name Description Remarks

Conveyance

Process where positions of

raw materials, materials,

parts or products are

changed.

Stagnation

Process where raw

materials, materials, parts or

products are systematically

stored.

State where raw materials,


are behind the schedule.

Process

ComponentDescription

Processing

Process where shapes or

natures of raw materials,


are transformed.


March 1, 2018


8.7 Process Quality Control Table (I) ( Form -3 ) Entry Procedure 4/4


※Refer to Appendix "List of applied parts"

Process System Diagram

Sup

RCVD

① 42651-S5A-010 HUB,REAR,WHEEL ○ Chuo Kogyo

2 42652-S5A-000 RETAINER,RR,BRG ○ Shinjuku SS

③ 42653-S5A-000 RIM,RR,WHEEL ○ Koto SS

4 42654-S5A-000 WASHER, TUNGUED ○ Kita Kogyo

5 42655-S5A-000 COLLAR, DISTANCE ○ Kita Kogyo

6 42656-S5A-000 FLANGE, DRIVEN ○ Itabashi SS

7 42657-S5A-000 TIRE, RR ○ Nerima Tire

8 94001-12000 NUT,HEX,12mm ○ Kita Kogyo

9 42658-S5A-000 SLEEVE, RR,AXLE ○

⑩ 42659-S5A-000 SPROCKET DRIVEN ○ Osaki SS

11 (This is just a sample and further omitted)

*Symbols other than process drawing symbols

　　　　　　●: lot formation process


○ □ Main job - machining /sub job -quality inspection.

○ ◇ Main job - quality inspection /sub job - quantity inspection. ･･･ Initial Establishment 15 Approved by Checked by Prepared by



Original to be retained until : 　　YYYY/MM �

／

Dept Checked

Creation DivisionStorage Process sequence

Transfer Quality inspection Control classification in process sequence

Supplier NameMFG


No Part Number Part Name

Part NameWHEEL ASSY REAR


H 1 Process Quality Control Table (Ⅰ)

Order Type

A 0 0 05 0 S 5

Toshima Kogyo

Model S5A Designation of parts HS　HA　HB　Others

Part Number 4 2 6



1

5


Approved by Confirmed by Created by

Quality Assurance Division

XXXXX Co., Ltd.

大下

(Received)

CartCart

Hand

Hand HandCart Forklift

12

Conveyer

Conveyer

11

2

3

4

5

6

7

8

9

10

1 B1 C１

Balance weight TireTongued

washer

Driven

sprocket

Acceptance

inspection

- type,

appearance

RetainerRR wheel

hub

Acceptance

inspection

- size,

appearance

Acceptance

inspection

- type,

appearance

Acceptance

inspection

- type,

appearance

Oil sealDistance

collarWheel

rimBearing Spoke nipple

BRG & seal press fit

　　- Press fit area assembly

Retainer tightening & rivet punch

　　- tightening torque, riveting condition

Sprocket assembly

　　 - Torque

Tongued washer rivet

　　- riveting condition

Wheel assembly

　　- assembly composition, appearance

Run out adjustment

　　- run out, spoke tighteningTire assembly

　　- balance mark, nut tightening

Air filling

　　- run out, air pressure

Balancing

　　- weight installation

conditionCompletion inspection

　　- run out, assembly,

appearance

Release

HandHand

●

●

●

●

Cart

100 qty / shift

(record form name)

Cart

12

11

3

4

5

6

7

8

9

10

1 C１

●

●

●

●

100 units/ shift

(record form name)

100 units/ shift

(record form name)

100 units / shift

(record form name)

100 units/ shift

(record form name)

西田

KITAGAWA YAMAMOTO KAWAGUCHI NOZAWA HARADA

＊＊BL○○BL△△BL☐☐BL

Cart


March 1, 2018


8.8 Process Quality Control Table (II) (Form 4) 1/3

(Form - 4)

Process Name

Equipment Name

(Supplier Name) №C o n t r o l I t e m

SpecificationPerson in

charge (PIC)

Check

MethodFrequency

Data

FormatControl Item Control Value

Person in

charge (PIC)

Check

MethodFrequency

Data

Format

01121 ↑Complete vehicle's Failure Mode Classification : 1. Driving function failure, 2. Turning function failure, 3. Stopping function failure, 4. Guarding function failure, 5. Insulation function failure,

6. Protection function failure, 7. Exhaust gas control function failure, 8. Identification function failure

MF

G O

rder

Quality CharacteristicsProduction Condition Control

Schematic Drawing

Failu

re M

ode

Critic

al Ite

m

Submission

frequency

of Data

Critic

al Ite

m

(Equipment, die, fail safe equipment, oil pressure, voltage, temperature, and others)


March 1, 2018


8.9 Process Quality Control Table (II) (Form 4) Entry Procedure 2/3

① ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑬ ⑮ ⑯ ⑰ ⑱ ⑲

① ⑤ Enter a sequence number for each process.

⑥ Enter a quality control item. (e.g. appearance, diameter, surface roughness, hardness, weight etc.)

② ⑦

③ ⑧

⑨

⑩

(1)

(2)

(3)

(4) ⑪

(5) ⑫

(6)

(7) ⑬

(8) ⑭

④

⑮

⑯

⑰

-1. ⑱

-2.

-3.

⑲

-4. ⑳

-5.

-6.

01121 ↑

Failure mode classification for completed unit: 1. Driving function failure, 2. Turning function failure, 3. Stopping function failure, 4. Guarding function failure, 5. Insulation function failure, 6. Protection function failure, 7. Exhaust g

Enter the name of the form used manage control items (e.g. check sheet, check list, daily report, record sheet, etc. ).

Provide a sketch of an area of the part to be processed, delivery destination, etc., as necessary.

Note: If the "Process Quality Control Table (II)" is prepraed per process, create a separate entry for each of main and sub

procecss flows. If there are more than one sub process flows, make an entry for each sub process flow.

An item for which a focused control is judged to be required based on the process capability evaluation, the past quality

performance (market quality information, in-house quality information, in-process failure), the manufacturing quality

criteria, etc.

An item for whichrecall, etc. was taken in the past.

An item related to quality characteristics and manufacturing conditions that may result in a defect of an important

function (such as running, turning, stopping, guard, insulation, protection, exhaust gas controlling or identification).

Enter the job title of the person in charge of controlling of control items.

Enter the check method for control items or the name of the equipment used.

An item which has a mark "Q" on its product drawings, specifications and etc. Enter the frequency of checking control items.

A control item which is specified in the Model CP List. Example: once/hr, per work resumption, once/shift, etc. ("per work resumption" means every resumption of work which

has been put on hold or stopped due to setup, operational break, etc.)A control item which directly affects the inspection item with item importance ranked "A" as defined in the inspection

criteria for parts.

Insulation function failure: receiving an electrical shock against user's will. In the case of the Model CP List issued by Honda, enter “when Honda requests”. Or enter the frequency of submitting data

requested by inspection criteria for parts and Honda. Protective function failure: unsatisfactory protective function for passengers and users.

Exhaust gas controlling function failure: unsatisfactory exhaust gas controlling function. Same as ④

Identification function failure: unsatisfactory visibility and identification display function. Enter a control item (e.g. temperature, eccentricity, speed, machining allowance, etc.) for well-maintaining specification limits

specified in the quality characteristics field.Enter the number of the item appears first on the list if the there are more than one that apply, or place a circle, etc. on the

number to distinguish it as important item. Enter the standard value and units of measure for the parameter selected in the control item column. Use SI units as a rule.

When using a conventional unit at the same time, put it in parentheses ( ).The supplier and Honda perform adjustments on circled items as necessary. Set the control method in a way that enables the

monitoring of trend control, etc. for quality characteristics and manufacturing condition control.

Running function failure: sudden running or sudden non-running against driver's will. ("per work resumption" means every resumption of work which has been put on hold or stopped due to setup,

operational break, etc.)Turning function failure: non-turning or turning against driver's will.

Stopping function failure: non-stopping or stopping against driver's will. Take a lot-size change into consideration, when setting the frequency of checking in units of lot, day, etc.

Guard function failure: splashing, or contact with high temperature/rotating parts against user's will. Enter the name of control record forms. (e.g. check sheet, inspection check sheet, control chart, etc.)

Enter in correspondence with operation numbers in process system diagram. If it is an outsourcing process, circle the

manufacturing order number.

Enter the name of the process or machine tools. If it is an outsourced process, enter the supplier's name with parentheses. Enter reference values or specification limits and a unit (If it can't be quantified, enter limits or samples, etc.).

Use SI units as a rule. When using a conventional unit at the same time, put it in parentheses ( ).

Perform FMEA etc., and enter in this column the applicable no. from "Failure Mode Classification for complete unit"

(equivalent to the meaning of failure of important functions as described in HES A 3050) at the bottom margin of this form.

The supplier and Honda coordinate and build consensus on the failure mode classification, if necessary.

The "Failure Mode"means the state of a vehicle failure detected by analysis such as FMEA, etc.

The classfication of each failure mode is defined as the follows.

Enter the job title of the person in charge of control items. (E.g. PIC of inspection, operator, etc. )

Enter the check method of a control item or the name of the equipment used. Enter the check method used for control items

and thename of equipment used.

Enter the frequency of checking control items.

Example: n=10/lot, n=5/day, 100 % Inspection, n=3/at start-up, n=3/resumption

⑳

Control Value PICCheck

MethodFrequency

Data

Format

② ⑫ ⑭

Schematic DrawingQuality Characteristics Submission

frequency of

Data

(facilities, die, fail safe equipment, oil pressure, voltage, temperature, and others)

№ Control Item Specification PICCheck

MethodFrequency

Process Quality Control Table (II)(Form - 4) Entry procedure

MF

G O

rde

r

Process Name

Facility Name

(Supplier Name)

Fa

ilure

Mo

de

Critica

l Item

Critica

l Item

Control of Manufacturing Conditions

Data

FormatControl Item


March 1, 2018


8.10 Process Quality Control Table (II) ( Form -4 ) Entry Procedure 3/3

Process Name

Facility Name

(Supplier Name) № Control Item Specification

Person in

charge

(PIC)

Check

MethodFrequency

Data

FormatControl Item Control Value

Person in

charge (PIC)

Check

MethodFrequency

Data

Format

01121 ↑Failure Mode Classification by Complete vehicle team : 1. Driving function failure, 2. Turning function failure, 3. Stopping function failure, 4. Guarding function failure, 5. Insulation function failure,

6. Protection function failure, 7. Exhaust gas control function failure, 8. Identification function failure

same as

above3Amount of

grease filled

Grease must be

filled all aroundsame as above same as above

2 AppearanceNo dirt adhesion, no

contaminationsame as above Visual same as above

Type 6200Person in

charge of

acceptance

Identification

documents n=10/cartC1 Bearing

Acceptance

Inspection

1

3Amount of grease

filled on the lip

Grease must be fi l led all

aroundsame as above same as above

same as

above

2 AppearanceNo dirt adhesion, no

contaminationsame as above Visual

35 x 47 x 8Person in

charge of

acceptance

Identification

documents n=5/cartB1　

Oil seal

Acceptance

Inspection

1 Type

Press fit jig

perpendicularity0.005/40 same as above same as above same as above same as above

0.01 or less same as aboveSpecial

testing device 1/Month same as aboveVisualsame as

above

Press fit jig

concentricity3

Assemble

distance collar

Must be

assembledsame as above

Oil pressure L side3.92±0.098MPa

(40±1kg/c㎡)same as above same as above same as above same as abovesame as above same as above same as above

Inspection

check sheet

once a

month O

2.94±0.098MPa

(30±1kgf)Operator

Oil pressure

gauge

During

operation

Check

sheet

O 2Oil seal press

fit positionsame as above

Depth testing

device n=1/50 O Oil pressure R side2 Bearing &

Oil seal press fit

Honda 2ton oil

pressure press

machine

Ito Giken Industrial

Co., Ltd.

3 O 1Bearing press fit

position

At 0.2 mm or lower from

case surface Operator

same as aboveBoundary

sample100%7 Airplane cloth appearance same as above

Roughness

standard piecesame as above same as above2 O 6 Shoe surface roughness 　or less same as above

same as above same as above5 Drum diameter run out 0.05mm or less same as above

Run out

measuring

device

same as above4 Drum diameter φ200 same as above Caliper cage same as above

3 Oil seal bore diameter φ35 same as above same as abovesame as

abovesame as above

2 Bearing bore diameter φ35 same as above Cylinder cage same as above same as above

42651-AB1-010PIC of

acceptance

Identification

documents n=5/LotInspection

check sheet

1

Wheel hub

Acceptance

Inspection

1 Type

(Form - 4) Entry procedure

MFG

Order

Quality CharacteristicsControl of Manufacturing Conditions (facilities, die, fail safe equipment, oil

pressure, voltage, temperature, and others)Schematic Drawing

Failure M

ode

Critical Item

Submission

frequency of

Data

Critical Item

0 mm

-0.018

0 mm

-0.10

+0.2 mm

0

6S

▽▽▽

25

Leave two lines blank, taking into consideration items to be added

later. Do the same for the rest.


March 1, 2018


8.11 Process Quality Control Table (Appendix) (Form -5)

(Form - 5)

Created

by

Revision

codeNo. Part Number Remarks

01121

This appendix is to be attached on top of Process Quality Control Table (I) when there are two or more

parts that the table is required to be applied to.

Process Quality Control Table (Appendix)

List of Applied Parts �

Part Name

Original to be retained until　: / (year/month)


3-3 Delivery Packaging July 1, 2014

Honda Motor Co., Ltd 1/6


1 Overview

1) Honda shall examine and agree the proposed packaging style for delivery of parts.

2) The supplier shall determine and obtain agreement from Honda on packaging style for delivery of parts, and preserve the conformity of product during handling, delivery, and storage from the time of shipment from the supplier to the time of use by Honda.

2 Definitions



No. Term Definition

1 Delivery packaging A state of parts in a container or on a cart to be shipped out from a supplier to a manufacturing plant of Honda.

3 Requirements

3.1 Delivery Packaging Preparation

3.1.1 Selection of Subject Parts

The supplier shall, in order to put forward a proposal on delivery packaging to Honda, select subject parts that fall into the following categories.

1) Parts that require attention to delivery packaging to maintain quality.

2) Parts that require attention to delivery method and delivery packaging due to their shape, weight, etc.

3) Parts that require special protection and security against theft or for confidentiality.

4) Other parts required by Honda.

3.1.2 Arrangement of delivery packaging

The supplier shall, with consideration to the following items, make an arrangement for delivery packaging.

1) Damage to parts (breakage, scratch, deform, tear, loose, detached, stain).

2) Deterioration of parts (swell, rust, discoloration, color fading, hardening, softening).

3) Collapse or protrusion of parts.

4) Interference (between parts, parts and container, etc.)

5) Shock protection (protection material, dunnage, partition)

6) Identification (display location, clarity: misuse prevention, display of lot and content information, etc, first-in, first-out.)

7) Environment such as water, heat, air, light, dust, foreign particles, etc.

8) Synchronization with Honda’s production line.

9) Transfer of parts at the supplier ’s site (consideration to size and weight limits for the lift, elevator, conveyer, etc.).

10) Workability (easiness in taking out, weight, easiness in holding, misassembly prevention)

11) Environment protection (reuse, recycle, returnable).

12) Personnel safety (projection, pinching, etc.).

13) Efficiency of loading and transportation of parts.

14) Prevention of past problems from recurring.

15) Regulations and policies with respect to containers of parts and products.




3.1.3 Delivery Packaging Specification

3.1.3.1 The supplier shall, in reference to section 7 “Delivery Packaging Specification Form”, prepare a “Delivery Packaging Specification Form” or create an equivalent form, and submit to Honda.

3.1.3.2 The supplier shall, if any instruction is given by Honda in regard to the “Delivery Packaging Specification Form” follow the instruction.

3.1.4 Delivery Packaging Verification Meeting

3.1.4.1 The supplier shall, if so requested by Honda, build a container or cart sample in accordance with the “Delivery Packaging Specification” and participate in a delivery packaging verification meeting.

3.1.4.2 The supplier shall, for issues raised at a delivery packaging verification meeting, carry out measures and revise the “Delivery Packaging Specification Form “by the date specified by Honda.

3.1.5 Production of Containers and Carts

The supplier shall accommodate a container or cart in accordance with “Delivery Packaging Specification Form”.

3.2 Improvement of Delivery Packaging During Mass Production

The supplier shall, if the need of improvement of delivery packaging arises, create a new “Delivery Packing Style Specification Form”, submit to Honda, and make such improvements in delivery packaging. However, no new “Delivery Packaging Specification Form” is required if such improvements are not related to the matters agreed upon with Honda in the previously issued “Delivery Packaging Specification Form”.

3.3 Control of Returnable Containers and Carts

The supplier shall define inspection methods including procedures, frequency, subject items, etc. to control containers and carts that are used repeatedly.

4 Key Point

1) Containers and carts shall be identified with the name of the owner i.e. company name






6 Flowchart

Contact

　　Selection

NG OK

Material

Service

Division

Pro

ductio

n S

tage

Supplier Honda

Pre

-pro

ductio

n S

tage

Material

Service

Division

Determine parts requiring a delivery packaging specif ication to be made taking into consideration the

follow ing:

- Quality maintenance

- Restriction of shapes, weight, carry-in

methods and others

- Burglar proof, maintaining confidentiality

- Requirement from Honda

- Improvement of existing delivery packaging.

- Others

Judgment of necessity of packing style verification

Review packaging style of parts

Create and submit Delivery Packaging Specification Form

Deliv ery Packaging Specification Form

Prototyping of containers and carts

Hold a meeting to verify delivery packaging.(verify part protection, workability, etc.)

Carry out measures against problems exposed. Revise and resubmit Delivery

Packaging Specification Form

Approval of Delivery Packaging Specification Form

Deliv ery Packaging Specification Form

Create containers and carts

Inspect and use the containers and carts

Required

Not requiredPrototyping

procedure

Resubmission

Confidential Supplier Quality Manual 3-3 Delivery Packaging

July 1, 2014


7 Forms

7.1 Delivery Packaging Specification Form (entry procedure)

Supplier　Name Approved by Prepared by

Part Number Issue Date

Part Name Control No.

Size W T Size W T

L/W/H Kg L/W/H Kg

Section/signature Comments

　OK/NG

　OK/NG

　OK/NG

Size W T Kg Size W T Kg

L/W/H T-WT Kg L/W/H T-WT Kg

Cushioning Quantity qty Dunnage Quantity units

Carry-in route Distance Km Carry-in route Distance Km 　OK/NG

Document Classfication Code Retention Period of Original : 5 years Expairation : YY/DD

�

Material

JudgementHonda Motor Co., Ltd. Factory

Q1. Will container and/or cart

be newly made?

(1) Yes (2) No (3) Modified

Q2. Is material of dunnage

changed?

(1) Yes (2) No

Supplier Code

New/Modified

package

Auxiliary

materialsY

Address

NDrawing

indicationY N Material

Fax

Tel

Refer to Entry Procedure-B

Address

App

ly M

odel

Delivery Packaging Specification Form (modified, new, others)

Current part

Current package

New/Modified part

Results by sections concerted.

Material Service

Division, Honda

Review

process

現行容器

１

２

３４

５

６７

８

９

１０

１１１２

１３

１４

１５

１６１７

１８１９

２２

２３

２４２５２６２８２９

３０

３１

３２

３３

３４３５３６３７

３７

３７

３７３７

３７

２０２１２７



July 1, 2014


7.2 Delivery Packaging Specification Form (entry procedure)

No. Entry procedure

1 Enter the supplier code.

2 Enter the name of your company.

3 Enter the part number subject to change (or new part number for new parts).

4 Enter the part name subject to change (or new parts name for new parts).

5 Enter the name of the applicable model. Prior to entry, obtain proper information from material service section of the delivery destination.

6 Enter the size of current parts (measurements).

7 Enter the weight of a unit of the current parts.

8 Attach a picture of the parts.

9 Enter the size of the container currently used (measurements).

10 Enter the type of dunnage currently used in the container (e.g.：partition, polyurethane

dunnage/foam, mirror mat and etc.).

11 Enter the weight of a unit of the container currently used.

12

Enter the total weight of the currently used container with parts loaded.

[The total weight equals the weight of a container plus the weight of parts loaded to the maximum capacity of the container.]

13 Enter maximum capacity of the container currently used.

14 Enter the names of major highways, relay points and the total distance from the production plant of current parts (please start with the location of the plant).

15 Attach a picture of the container currently used (attach a picture that shows specifications).

16 Enter the length, width and height of new parts subject to change.

17 Enter the weight of a single unit of the parts (new) subject to change.

18 Enter changes to be made to the current parts (new parts).

(If there is no major change, or remains unchanged, cross out with a diagonal line.)

19 Attach a picture of the parts subject to change (new parts).

20 Circle the appropriate mark (“Y” or “N”) regarding auxiliary materials of new parts subject to change (e.g.: caps, plugs, plastic bags and etc.).

21 Circle the appropriate mark (“Y” or “N”) regarding drawing indications for the usage of auxiliary materials.

22 Enter the name of auxiliary material of new parts subject to change (e.g.: plastic, polyvinyl chloride, rubbers and etc.).

23 Enter the size of the container by length, width and height for new parts subject to change.

24 Enter the dunnage used for the container of new parts subject to change.

25 Enter the material of dunnage used for the container of new parts subject to change.

26 Enter the name of major highways, relay place-name and the total distance from the production plant of parts subject to change (please start with the location of the plant).

27 Enter the weight of a container to be used for new parts subject to change.

28

Enter the total weight of the container to be used for new parts with the parts loaded.

[The total weight equals the weight of a container plus the weight of parts loaded to the maximum capacity of the container]

29 Enter the maximum capacity of the container used for new parts subject to change.



July 1, 2014


No. Entry procedure

30 Enter changes made to the current containers (new container).


31 Enter changes made to the current wadding.


32 Attach a picture of the changed container (new). (Cross out with a diagonal line if remains unchanged.)

33 Enter the phone number of the contact person in your company.

34 Enter the facsimile number of the contact person in your company.

35 Signature of your company’s authorized representative for approval.

36 Signature of your company’s authorized representative for preparation.




March 1, 2018



1 Overview

1) Honda shall require suppliers of problem parts, which were found in the pre-production stage and its cause was considered attributable to the supplier, to conduct analysis and take countermeasure against the cause.

2) The supplier shall conduct analysis and take countermeasure for the cause of the problem in accordance with a request from Honda and report the results to Honda. For problems in the pre-production stage, it is important that measures for the problem be preferentially implemented and results be evaluated for effectiveness by the subsequent pre-production trial event.

2 Definitions



No. Term Definition

1 Supplier drawing

A drawing of parts drawn and issued by a supplier, which Honda had outsourced the design, development, and manufacturing to, in accordance with the basic requirements of preliminary specifications provided by Honda, or a “parts supplier’s drawing” which referred to as a supplier’s drawing.

3 Requirements

The supplier shall, if a problem with parts delivered from the supplier is found at Honda during the pre-production stage, and if the supplier is so informed by Honda, promptly take measures that include prevention of problem recurrence.

3.1 The supplier shall undertake analysis of problem parts, investigate the cause of the problem, and report to Honda’s new model section.

3.2 If the cause of the problem is attributable to the supplier ’s drawings, etc., the supplier shall issue a “Countermeasure Request [Countermeasure Request Form]“ in accordance

with 【SQM 4-6-1 Countermeasure Request Form】and request necessary changes to

drawings, etc. to Honda (new model preparation section).

3.3 If the cause of the problem is attributable to the suppliers’ manufacturing processes, the supplier shall seek improvement in manufacturing processes following consultation with Honda (new model preparation section). If so requested by Honda, the supplier shall report to Honda (new model preparation section) the result of the improvement

using ”Analysis Record [Analysis Report]” in【SQM 4-5 Corrective Action Report】or

equivalent forms.



1 Analysis Record [Analysis Report] or equivalent

form 20 years

2 Countermeasure Request [Countermeasure

Request Form] 20 years



2) SQM 4-6-1 Countermeasure Request Form



3-5-1 Parts Inspection Criteria

May 1, 2019



3-5-1 Model CP List

1 Overview

1) Honda shall issue Model CP List to two-wheeled / four-wheeled suppliers to request inspections or process assurance with respect to quality characteristics of parts which inspections or process assurance is mandated by laws and regulations.

2) The two-wheeled / four-wheeled supplier shall report inspection results with respect to quality characteristics of parts specified in Model CP List to Honda.

2 Definitions



No. Term Definition

1 Model CP List A list which sets forth methods to specify legality control items of individual parts, set items to be assured at inspections or processes, and control them.

3 Requirements

3.1 Receipt of Model CP List

The supplier who received Model CP List from Honda shall review the following matters 1) and 2) specified in Model CP List and configure matters from 3) to 5).

The supplier shall reflect the contents from 3) to 5) in the Process Quality Control Table with mutual agreement reached with Honda.

3.1.1 Matters Specified in Model CP List

Major matters specified in Model CP List shall be as follows.

1) Part number/ part name

2) Control item

3) Quality judgment criteria

4) Inspection method

5) Inspection frequency



May 1, 2019


3.2 Inspection

3.2.1 Reflection in Process Quality Control Table

The supplier shall confirm that control items and others specified in Model CP List are included in process quality control table, and reflect the frequency of data submission to Honda as “when Honda requests” in process quality control table.

3.2.2 Implementation of Inspection

The supplier shall implement inspections in accordance with process quality control table.

3.2.3 Record of Inspection Results

The results of inspection shall be recorded and stored in the Inspection Check Sheet, etc.

3.2.4 Sub-Supplier Management

If control items specified in Model CP List are performed by sub-suppliers, the supplier shall collect the inspection results from such sub-suppliers and provide Honda with the results.

3.2.5 Submission of Inspection Check Sheet

The supplier shall submit the inspection sheets to Honda in conformity with Honda’s request. The inspection results provided by sub-suppliers shall be included in the Inspection Check Sheet, etc. to be submitted to Honda.

If the following items (1)～(6) are not included in Inspection Check Sheet, the data

and/or records shall also be submitted. However, items of 100% inspection on manufacturing line are excluded.

(1) Inspection units (control numbers such as part number / part name /

manufacturing number that can identify inspected products, lot number etc.)

(2) Inspection start date / completion date

(3) Inspection items, inspection equipment (including information that can identify

test equipment) or inspection method.

(4) Photos of equipment /parts under inspection, photos of inspection tester,

(control number for inspection date, inspection tester, and mfg. number that can

identify inspected products and others that can identify control number such as

lot number.

(5) Judgment criteria and inspection results.(photos, data of before and after the

inspection of the equipment/parts)

(6) Inspector / Approver



1 Record of inspection results (Inspection Check

Sheet, etc. for submission) 20 years





May 1, 2019


6 Flowchart

Contact

Purchasing,

Planning

or

Receiving

Inspection

section

Purchasing,

Planning

or

Receiving

Inspection

section

Receiving

Inspection

section

Receiving

Inspection

section

Receiving

Inspection

section

Receiving

Inspection

section

* Model CP List (Control item) :

** Model CP List (Quality control method) :

*** Model CP List :

　　Regarding specified items in 3.1.1Model CP List, specified 1) Part number / name and 2) Inspection item.

For the contents above, suppliers set and reflected 3) Quality judgment criteria, 4) Inspection

method and 5) Inspection frequency regarding specified items in 3.1.1Model CP List.

　　Regarding specified items in 3.1.1Model CP List, reflected all items from 1) to 5).

Supplier HondaP

re-P

rodu

ctio

n S

tage

Pro

duct

ion

Sta

ge

- When change occurs (Production)

- Review instructions from Honda

Set quality judgment criteria, inspection method and

inspection frequency required for mass production

assurance regarding control items specif ied in Model

CP List.

Establish and issue Model CP List

(Control item)*

Model CP List(Control item)*Agreement

Inspection settingProcess quality control tablePrep. operation control doc. Inspection equipment

Reply Model CP List (Quality control

method) **.

Establish and issue Model CP List***.

Model CP List***

Agreement

Inspection

Submit Inspection results

inspection report, etc. Confirm Control records

Model CP List(Quality control method)**

Model CP ListRevision occurs in (Quality

control method) **.

Revision occurs in Model CP List

(Control item)*.

Re-set quality judgment criteria, inspection

method and inspection frequency required for mass production assurance regarding control

items specified in Model CP List.

Agreement

Re-set inspectionReview Process Quality Control Table

Review Operation StandardReview inspection equipment

Re-reply Model CP List (Quality control method)**

Revise and issue Model CP List***

Model CP List***

Agreement

Perform inspection

Submit inspection results

Inspection results, etc.Confirm

Control records

Model CP List(Quality control method)**

Model CP List

- When spec. is changed

- When other Model CP List is revised

Refer to §3-2-1.Perform confirmation whether Model CP List is in accordance with Process Quality Control Table.

Refer to §3-2-1.

Perform confirmation w hether

Model CP List is in accordance

w ith Process Quality Control

Table.



July 1, 2014



1 Overview

1) Honda shall, if a supplier produces limit samples of parts for which acceptability is determined by visual inspection, etc., examine and approve such samples.

2) The supplier shall control limit samples approved by Honda, and judge the acceptability of manufactured parts for quality.

2 Definitions



No. Term Definition

1 Limit sample A sample of parts which demonstrates quality limits for conformance or nonconformance.

3 Requirements

3.1 Preparation of Limit Samples

3.1.1 The supplier shall, if it is difficult to quantitatively define or explain the characteristics required for parts, produce limit samples at the direction of Honda or at its discretion.

3.1.2 The supplier shall, if necessary, identify areas showing the limits by circling with a line or marking with an arrow, and clearly identify the limit sample by attaching a tag, etc.

3.1.3 The supplier shall produce limit samples prior to the transition to mass production

stage (refer to【SQM 3-9 Transition to Mass Production】).

3.1.4 The supplier shall produce limit samples for posting at the site, based on the limit sample agreed upon with Honda if necessary. Honda may require a duplicate sample for its possession.

3.2 Limit Sample Control Forms

3.2.1 The supplier shall create a limit sample control form in accordance with the example provided in section 7, however, the format may be changed depending on the type, size or shape of the limit sample.

The following items shall be included in the control form at a minimum.

1) Date of production of the limit sample

2) Control number

3) Inspection items (scratch, color, roughness, unevenness, wrinkle, shape, etc.)

4) Applicable part number or part name

5) Effective period

(Time-dependent change of limit samples shall be taken into consideration when establishing an effective period.)

6) Signature field

3.2.2 The supplier shall issue a limit sample control form per limit sample, include the signature of the person responsible, and submit the form to Honda with the limit sample.

3.3 Consensus on Limit Sample

3.3.1 The supplier shall build consensus on limit samples with Honda prior to the

transition to mass production (refer to【SQM 3-9 Transition to Mass Production】). No

parts, which are to be examined with limit samples, shall be released until consensus is achieved with Honda.

3.3.2 The supplier shall, if a limit sample produced by Honda is provided, adopt the limit sample. However, the supplier may discuss the level of limit sample with Honda as necessary.



July 1, 2014


3.4 Maintenance and control of limit samples

3.4.1 The supplier shall retain limit samples considering damage, deterioration, etc.

3.4.2 The supplier shall, if duplicates of the limit sample are made, number the duplicates and control with a ledger.

3.4.3 The supplier shall review and revise limit samples and their effective periods. Where changes are made, the suppliers shall rebuild a consensus on the subject matter with Honda.

3.4.4 The supplier shall periodically verify that limit samples are retained in the same condition as agreed with Honda


No Type of Record Retention Period

1 Limit sample control form

Until a production closing order is issued.

2 Limit sample duplicate ledger

Until a production closing order is issued.






July 1, 2014


6 Flowchart

Contact

OK

NG

　・extend the effective period

　・criteria change, etc.

OK

NG

HondaSupplier

Pro

du

ctio

n s

tag

e

Procurement

quality section

New model

promotion

section

New model

promotion

section

Procurement

quality section

Pre

-pro

du

ctio

n s

tag

e

supplier decisionIssue instructions for

preparation

Prepare limit sample

Prep. limit sample

control form

Approved Agreed

Duplicate a sample for

displaying limits

Create a duplicate ledger

Create new, revise or

update/renew/extend limit

samples Revise

control

forms

Approved Agreed

Duplicate a sample for

displaying limits

Create a duplicate ledger



July 1, 2014


7 Forms

An example of a limit sample control form is shown below, however other forms may be accepted on the condition that all necessary information set forth in section 3.2.1.are included.

Example of a limit sample control form

Honda Motor., Co., Ltd.

(enter the name of section )

�

Supplier name

( enter name of section)

1. Do not use limit samples that have passed the effective period for the purpose of inspection.

2. If it is necessary to use limit samples continuously, notify Honda and file for a continued use of

the samples.

Limit Sample Control Form Date of Preparation

YYYY/ MM/ DD

From 　 YYYY/MM/DD　　To 　YYYY/MM/DDEffective period

Applicable part

number

Inspection item

(scratch, color, roughness,

unevenness, shape, etc.)

Part name

Control Number

Confidential Supplier Quality Manual 3-5-3 Grain and Color Adjustment

July 1, 2014



1 Overview

1) Honda may coordinate and build consensus with suppliers on the specification of textures of grain and color that cannot be specified on the drawing (specifications included).

2) The supplier shall clarify requirements to be coordinated in response to a request from Honda for textures of grain and color, of parts.

2 Definitions



No. Terms Definitions

1 Grain Uneven pattern of part surface by the arrangement of

particulate constituents.

2 Grain process supplier A supplier specified by Honda who performs grain embossing

on the part mold.

3 Color Color of part exterior

4 Color application plate Color master set forth in HES Z 0013.

5 Approved actual part

sample A part sample with which color was agreed with Honda.

3 Requirements

3.1 Grain Adjustment

3.1.1 The supplier shall verify the type and scope of grain embossing by drawing (specification included).

3.1.2 The supplier shall, in accordance with a request from Honda, attend a “grain go meeting” held by Honda and coordinate the direction and depth of grain as well as manufacturability with Honda and its grain process supplier. Honda shall record the results of the coordination in the “Instructions for Grain Direction and Grained Finish Depth” and the supplier shall keep a copy of the results.

3.1.3 The supplier shall, after the receipt of “Grain Instruction”, produce part molds in accordance with the agreement specified in “Grain Direction and Depth Instructions”. Molds shall be produced in a manner that the delivery of parts will be in time for the appointed delivery date.

3.2 Color Adjustment

3.2.1 The supplier shall confirm drawings (specifications included) for the color assigned to parts, fill in a “color-matching reference chart” found in section 6 or equivalent form with necessary information, and submit it to Honda.

The supplier shall request Honda a color application plate for colors newly adopted.

3.2.2 The supplier shall examine colors by visual and by measurement using color measuring equipment (colorimeter, etc.). Record evaluation results including visual checks and measurements in the “color matching reference chart” or equivalent form set forth in section 6.

3.2.3 The supplier shall, in response to a request from Honda, attend a “color coordination meeting”, check the color of parts manufactured with color application plate, and record the results of the check in the “color matching reference chart” or equivalent form. The “color matching reference chart” or equivalent form shall be presented if so requested by Honda.

Confidential Supplier Quality Manual 3-5-3 Grain and Color Adjustment

July 1, 2014


3.2.4 The supplier shall sign and date on the approved actual parts for which the final agreement was entered into with Honda, and maintain the approved actual part sample in a manner that prevents discoloration or damage.



1 Color application plate Revise as needed

2 Approved actual part sample

Until a closing order for the production is issued.





July 1, 2014


6 Form: color matching reference chart Event Evaluator

Color

Material Supplier Evaluation

(grade) Method SupplierForming or

coatingCriteria

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

Judg

ment

Evaluation

Details

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LusterHue

LightnesSaturatio

LusterHue

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LusterHue

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LusterHue

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LusterHue

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LusterHue

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LusterHue

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Luster�

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

Third Evaluation

1

Second Third Evaluation First Evaluation SecondFirst Evaluation Second Third Evaluation First EvaluationThird Evaluation First Evaluation Second Third EvaluationSecond Third Evaluation First Evaluation SecondNo. C/C

Part

NumberPart Name

Grain

No.

Gloss

Value

Coloring (coating) First Evaluation

Date Part Origin

Color Matching Reference Chart



May 1, 2019



1 Overview

1) Honda shall issue Parts Inspection Criteria to suppliers to verify quality characteristics of parts to which verification is mandated by laws and regulations.

2) The supplier shall report inspection results with respect to the quality characteristics of parts specified in Parts Inspection Criteria.

2 Definitions



No. Term Definition

1 Parts Inspection

Criteria

Inspection Criteria [System/Device and Parts], which set forth acceptance criteria to be applied to inspection of individual constituent parts of a product.

3 Requirements

3.1 Receipt of Parts Inspection Criteria

The supplier who received Parts Inspection Criteria from Honda shall review requirements for inspection and reflect them in Process Quality Control Table, etc.

3.1.1 Matters Specified in Parts Inspection Criteria

Major matters specified in Parts Inspection Criteria shall be as follows.

1) Part number/ part name

2) Inspection item

3) Item importance

4) Quality judgment criteria

5) Inspection method

6) Inspection plan (Honda’s inspection plan and frequency)

7) Data format

8) Inspection section (Honda’s section to which the result is submitted)

3.1.1.1 Severity ranking

Honda shall assign an item importance to each inspection item, which indicates the degree of severity of respective quality characteristics. Definition of item importance and its criteria are as follows.

Item Importance

Definition

A

Conditions which are judged to pose a serious threat to human lives such as the following when a problem with the structure, equipment, or function of the product occurs.

1) Condition that disables vehicle operation (run, steer, or stop).

2) Condition that associated with electrification, burn, or injury.

3) Condition that associated with fire.

4) Condition that associated with pollution.

5) Condition that disables protection of vehicle occupants.

B

Conditions other than described in A and that cause significant loss of function or merchantability as the product when a problem with the performance, function, or structure of parts occur.

C Conditions that do not comply with either A or B above.



May 1, 2019


3.2 Inspection

3.2.1 Reflection in Process Quality Control Table

The supplier shall confirm that quality characteristics and inspection frequency specified in Inspection Criteria are included in process quality control table, and reflect the frequency of data submission to Honda in process quality control table.

3.2.2 Implementation of Inspection

The supplier shall implement inspections in accordance with process quality control table.

3.2.3 Record of Inspection Results

The results of inspection shall be recorded and stored in the Inspection Check Sheet, etc.

3.2.4 Sub-Supplier Management

If inspection items specified in Inspection Criteria are performed by sub-suppliers, the supplier shall collect the inspection results from such sub-suppliers and provide Honda with the results.

3.2.5 Submission of Inspection Check Sheet

The supplier shall submit the inspection sheets to Honda in conformity with Honda’s

request. The inspection results provided by sub-suppliers shall be included in the

Inspection Check Sheet, etc. to be submitted to Honda.

If the following items (1)～(6) are not included in Inspection Check Sheet, the data

and/or records shall also be submitted. However, items of 100% inspection on

manufacturing line are excluded.

(1) Inspection units (control numbers such as part number / part name /

manufacturing number that can identify inspected products, lot number etc.)

(2) Inspection start date / completion date

(3) Inspection items, inspection equipment (including information that can

identify test equipment) or inspection method.

(4) Photos of equipment /parts under inspection, photos of inspection tester,

(control number for inspection date, inspection tester, and mfg. number that can identify inspected products and others that can identify control number such as lot number.

(5) Judgment criteria and inspection results.(photos, data of before and after the

inspection of the equipment/parts)

(6) Inspector / Approver



1 Record of inspection results (Inspection Check

Sheet, etc. for submission) 20 years





May 1, 2019


6 Flowchart

Contact

Pur. div

HondaSupplier

Procurment

div

Procurment

div

Verify

Inspection setting

Process quality control table

Prep. operation control doc.

Inspection equipment

Confirm

Control records

Inspection

Submit Inspection results

Part Inspection Criteria

Est. Revise/Issue

Part

Insp.Criteri

inspection

report, etc.



Oct 1, 2018



1 Overview

1) Honda shall provide basic requirements for measuring and monitoring equipment for suppliers to use.

2) The supplier shall define installation and control methods of measuring and monitoring equipment in accordance with the requirements specified by Honda to assure the results of measuring and monitoring of parts delivered to Honda.

2 Definitions



No. Terms Definition

1 Measuring equipment

A general term for measuring instruments (gauge, measuring instrument, standard, etc.), testing device, testers, analytical equipments, etc., including related software of computer systems.

For definitions of terms used for measuring instruments, testers, analytical equipment, etc., refer to JIS Z 8103 “Glossary of terms used in measurement”.

2 Monitoring

device

Equipment to use to “monitoring: the observation of a system (all or part) to verify proper performance and detect improper performance. Actual observation is made by measuring one or more variants of the system, and subsequent comparison of the value obtained from such measurements with the specified value.” in 24103, section 4.1 of JIS B0155.

3 Reference material

A material used for inspecting instrumental errors of equipment (weight, block gauge, reference solution, etc.),whose physical/chemical amount is certified (actually measured values are indicated) based on the material examination results.

4 Routine check A pre-use check of equipment for appearance and function performed by the using department of the applicable equipment.

5 Regular check An inspection of equipment for problems with the term and extent specified.

6 Regular

inspection Periodic inspection of equipment for appearance and function.

7 Calibration A process of establishing the relationship between the value measured by the measuring device and its true value with standards and reference materials to correct deviations.

3 Requirements

3.1 Assurance of Measurement Validity

The supplier shall, when performing inspection, measurement, testing or monitoring, etc., to assure the quality required for parts, use equipment in which accuracy, function and precision are ensured in accordance with the following.

3.2 Accuracy of Measurements

3.2.1 The supplier shall, when selecting equipment, consider traceability to international or national standards.

3.2.2 The supplier shall calibrate or verify equipment against measurement standards traceable to international or national measurement standards. Where no such standards exist, reference materials used for calibration or verification shall be recorded.



Oct 1, 2018


3.3 Check, Inspection and Calibration

3.3.1 In order to confirm that there is no abnormality in the equipment, the business partner conducts daily inspection and saves the record.

3.3.2 The supplier shall establish a schedule for regular check, regular inspection, and calibration to ensure precision, function, and accuracy of equipment, perform checks and regular inspections and calibrations of equipment accordingly, and maintain records.

3.3.3 The supplier shall identify equipment to enable the calibration status to be determined.

3.4 Reaction Plan to Abnormal Conditions

3.4.1 The supplier shall, if any abnormality is found in the equipment, stop immediately use of the equipment and take remedial measures.

3.4.2 The supplier shall, if any repairs are made to the equipment, recalibrate prior to resume use of the equipment as necessary.

3.4.3 The supplier shall, when equipment is found not to conform to requirements, evaluate effect to parts, safety and pollution prevention, and if applicable, request related sections to take appropriate actions.

3.4.4 Records of the nature of the abnormality and any subsequent actions taken shall be maintained.

4 Key point

1) Determine the frequency of checks and calibrations based on previous records, data, etc.

2) If there are more than two units of the same type of equipment and normally one unit is reserved as a spare, check the setting, etc. at the time of use when using a spare unit.

3) Equipment shall be safeguarded from adjustments that would invalidate the measurement result.

4) Criteria for judging the adequacy of equipment shall be approved by qualified personnel.

5) If wears or changes due to aging affect the validity of measurement, draw up plans for checks and repairs of consumable parts (area) in view of the frequency of use, duration of life, cycle of replacement, etc.

6) In case of any abnormality or nonconformity to requirements is found during use, check, or calibration of equipment, stop immediately use of the equipment, and verify conformity of parts previously measured by the equipment.



1 Routine maintenance records 1 year

2 Periodical check and calibration

records 20 years

3 Repair records 20 years after abolishment



2) JIS Z 8103

3) JIS B 0155



October 1, 2018



1 Overview

1) Honda shall provide suppliers with requirements of operation control documents, which the suppliers make available to their operators, in order for the suppliers’ manufacturing processes to be in a controlled state.

2) The supplier shall formulate operation control documents in accordance with requirements prescribed by Honda, provide to its operators and utilize for training.

2 Definitions



No Term Definition

1 Operation control

documents

A generic term for documents to provide operators with directions for work sequences, set-up condition, etc. in order for each of the fabrication, assembly, inspection, equipment maintenance, transportation, and administrative processing, etc. to be controlled per process, product, operation, etc. Documents such as operation standards, condition control tables, specifications, signs or displays showing photographs or illustrations to caution, and check/inspection standards for inspecting equipment are included.

2 Operation standard

A set of documents that describe requirements and procedures to be followed such as illustrations of work, work sequences, jigs and tools, quality characteristics and standards, operation key points, inspection methods, parts to be used, facilities, actions to be taken when abnormality occurs, and other cautions (it is referred to as “ work instruction” in ISO/TS”).

3 Requirements

The supplier shall define requirements for work area, equipment, tools, etc. to maintain manufacturing processes in a controlled state. Operation control documents such as operation standard described in the following section shall be formulated and provided to operators. All operation control documents shall be maintained in the same manner as operation standard.

3.1 Preparation of Operation Standard

3.1.1 The supplier shall, in accordance with the following information, etc., define procedures to be followed in the process and formulate operation standards.

1) Drawings (specifications, etc. included)

2) Process quality control table

3) Instruction manuals for facilities, measuring equipment, etc.

4) Past problem history

5) Handling instructions for materials, etc.

6) Instructions for safe work

3.1.2 The supplier shall include the following information in the operation standards.

1) Part name and process name

2) Component parts to use

3) Work sequence instruction

4) Control items, control methods, quality characteristics, criteria (limit sample, master sample included)

5) Name of machine and/or tool used and direction for use.



October 1, 2018


6) All key points other than above (key points include possible failure modes, such as potential nonconformity problems or effects on the product, which may occur if the operation standards are not being followed).

7) Points relating to lot control, FIFO, etc.

8) Reaction plan for abnormal condition. （Descriptions of reporting rules and

routes, etc.）

9) Directives for changeover of materials, lines or machines.

10) If applicable, check and maintenance of equipment.

11) Precaution statement for thorough compliance with operation standard. (Statement to prohibit operations other than in the operation standards.)

3.1.3 The supplier shall formulate operation standards with consideration of the following.

1) Describe reaction plans for abnormal condition with concrete case examples.

2) Describe quality characteristics and acceptance criteria quantitatively or qualitatively (Quantitative description is advisable when possible. For characteristics with qualitative criteria, it is important that a judge acquires a normal condition of the quality characteristics and is able to identify the degree of abnormally.).

3) Clarify inspection methods and operation key points.

4) Provide detailed and easy-to-understand instructions with illustrations and photographs.

5) Describe control points clearly for past problem information.

6) Explain with easy to understand training material using plain language and audiovisual aids.

7) Mark important quality characteristics with a symbol specified by Honda（○Q）or

supplier’s equivalent symbol.

8) Review validity of operation control documents during pre-production stages. Modify complicated operations and revise confusing expressions throughout the production preparation stage.

3.2 Issue of Operation Standards

3.2.1 The supplier shall, prior to issuing operation standards, verify legitimacy of operations and validate operation standards with actual work.

3.2.2 The supplier shall finalize and issue operation standards before starting production of parts. Operation standard shall be approved by appropriate personnel designated by the supplier.

3.3 Revision Control for Operation Standards

The supplier shall, in the event of any changes made to the contents of operation standards, control as follows.

3.3.1 When revising operation standards, record history and reasons of revisions, and identify the current revision status.

3.3.2 Follow section 3.2 when revising operation standards.

3.3.3 Identify and distinguish operation standard that become obsolete due to the revision or abolition in a manner that prevents unintended use. Obsolete duplicates shall be handled in the same manner.

3.3.4 Ensure that relevant versions of applicable operation standards are available for operators at point of use.

3.4 Use of Operation Control Documents and Training of Operators

3.4.1 The supplier shall use operation control documents and train operators of respective processes to provide knowledge and skills, etc., necessary to perform assigned tasks.

3.4.2 The supplier shall establish procedures and criteria to determine the necessary competence for personnel performing work. Achieving competence of personnel shall be evaluated and training records shall be maintained.



October 1, 2018


3.4.3 The supplier shall apply the preceding sections of 3.4.1 and 3.4.2 to all regular and temporary employees.

4 Key points

1) Remnant auxiliary materials in production facilities shall be removed when verifying the equipment set-up.



1 Operation standard 20 years after the issue of discontinuation

order.

2 Training record 20 years




3-8 Parts Delivery

July 1, 2014


3-8 Parts Delivery

1 Overview

1) Honda shall present suppliers with requirements for handling, transportation and storage, etc., of parts when delivering from suppliers to Honda.

2) The supplier shall define basic requirements for handling, transportation and storage of parts in accordance with the requirements set by Honda and preserve the conformity of product.

2 Definitions


Definitions】.

3 Requirements

3.1 The supplier shall conform to the following requirements in order to prevent quality degradation of parts until the time of delivery to Honda.

3.1.1 Handling of parts

3.1.1.1 The supplier shall use first in, first-out inventory control method for transportation and storage of parts, and for the release and receipt of parts between processes.

The supplier shall use the first-in-first-out inventory management system for release and receipt of parts during internal processing, storage, and delivery.

3.1.1.2 The supplier shall, for fabrication and assembly of parts, take measures to eliminate foreign particles, and to prevent shock, external damage, etc. to the parts during transportation or from use of tools.

3.1.2 Storage of parts

3.1.2.1 The supplier shall, when storing work-in-process parts within the process, employ identification method, such as part number, material mark, quantity, commencement date of storage, etc., suitable for respective parts.

3.1.2.2 The supplier shall, when storing parts, determine locations suitable for storage. Duration of storage, packaging or delivery packaging, and geographical condition (ambient environment), etc. shall be taken into consideration.

3.1.3 Identification of parts

3.1.3.1 The supplier shall, when delivering parts for new mode and/or trial event, consult with Honda (new model preparation section) for identification method.

3.1.3.2 The supplier shall, for parts in the production stage, deliver to their respective destinations in accordance with the instructions for delivery

packaging and the identification for delivery set forth in 【SQM 3-3 Delivery

Packaging 】and 【SQM 4-3 Identification and Traceability】.

3.1.3.3 Mixed loading, such as shipping multiple different parts in a single container may be allowed after consultation with Honda (Material service). The supplier shall clearly define the identification method for the mixed loaded parts to be easily identifiable.

3.1.4 The supplier shall be informed of a specific time and location of delivery, if an order of parts other than for mass production (diversion of trial parts, replacement parts for unexpected shortage, parts for exceptional order, etc.) was placed.

3.1.5 Response to Receiving Inspection Result.

3.1.5.1 The supplier shall, if notified by Honda of delivery failure such as misshipment, wrong shipment, etc., take action to respond to the matter.

3.1.5.2 The supplier shall, for delivery failure such as misshipment, wrong shipment, etc., investigate the cause and implement measures to prevent recurrence.

4 Key point

1) Apply special identification method after consultation with Honda, if delivering parts for other than mass production (e.g. parts for the next model, production prototype parts, etc.).


3-8 Parts Delivery

July 1, 2014



1) SQM 3-3 Delivery Packaging





March 1, 2018



1 Overview

1) Honda shall present suppliers with evaluation items for verifying transition to mass production. Honda may attend selected suppliers’ evaluation events.

2) The supplier shall verify completion of pre-production stage and issue a Mass Production Transition Declaration, and enter into mass production stage.

2 Definitions



No. Term Definition

1 Mass Production

Transition Declaration

A declaration by the quality assurance representative, facility quality representative, or deputy of a supplier stating that the requirements prescribed by Honda for quality and mass productivity of parts have been satisfied.

3 Requirements

3.1 The supplier shall verify completion of pre-production stage by evaluating the following, and confirm that manufacturing lines for mass production are in a controlled state.

3.1.1 Production

1) Permanent die, mold and injection mold.

2) Application of permanent facilities, jigs and tools, testing devices.

3) Production capacity (cycle time, nonadjusted ratio).

4) Logistics (packaging preparation, transportation testing)

5) Manpower arrangement

3.1.2 Quality

1) Reflection status of past problems (problems found in-house, upon delivery and in the market).

2) Corrective actions taken against problems identified during preceding evaluation events.

3) Conformance of quality characteristics specified on drawings or specifications.

(validity testing, dimensional accuracy, operational feeling, appearance, etc.).

4) Implementation of Process FMEA (condition value and set value, etc., set to the process)

5) Precision of special checking fixture (including master and limit samples).

6) Process capability (Cpk) Note: for single specification limit case, Cp control shall apply.

7) Reliability of QA devices, error proofing.

8) Easiness of mounting to Honda products.

9) Process quality control table and operation control documents.

10) Employee training and education

11) Verified status of sub-suppliers’ production readiness.

3.2 The supplier shall confirm that items listed in section 3.1 are completed and compliant with requirements, and issue Mass Production Transition Declaration prior to going into mass production.

3.3 The supplier shall, if any problems are found during the process of issuing Mass Production Transition Declaration, draw up a corrective action plan and implement measures immediately.

Mass Production Transition Declaration shall be reissued upon completion of the measures, as needed.

3.4 The supplier shall, if so requested by Honda, present or submit data and documents that provide evidence of Mass Production Transition Declaration to Honda.



March 1, 2018




1 Data and documents that provide evidence of Mass

Production Transition Declaration 20 years




3-9-1 Validity Testing March 1, 2018


3-9-1 Validity Testing

1 Overview

1) Honda shall, considering the level of importance, novelty, etc., select critical control parts for which suppliers are required to report results of validity testing.

2) The supplier shall draw up an implementation plan for validity testing to prove the conformity of parts to applicable drawings (specifications included), etc., and complete all testing prior to mass production startup.

2 Definitions


Definitions】.

3 Requirements

The supplier shall plan and implement validity testing in accordance with the following requirement.

3.1 Preparation of Test Plan

1) Review requirements designated on drawings (specifications included).

2) Determine necessary tests to perform.

3) Draw up a test plan.

4) If so requested by Honda, submit the test plan to Honda.

Format of the test plan shall follow the “Validity Test Plans/Actual Results” set forth in section 7. The supplier may choose to use its own form if Honda determines that the conditions are met.

3.2 Monitoring of Test Plan

1) Monitor changes to drawings (specifications included) and review the test plan, if necessary.

2) Monitor progress on validity testing against plan.

3) Complete tests and maintain results.

3.3 Approval of Test Result

1) Check test results and make judgments.

2) Take corrective actions where necessary.

3) The person in charge approves test results.

3.4 If requested by Honda, the supplier shall provide or submit plans of validity testing and test results.



1 Validity test plans/actual results 20 years




3-9-1 Validity Testing March 1, 2018


6 Flowchart

Contact

Yes

No

Not good

Good

New Model

Preparation

Section

Submit

�

HondaSupplier

Submit

New Model

Preparation

Section

Verify test plan

Drawings, etc.

Verify contents

Draw up test plan

Specification

change

Need to

change the

Test

Result

Summarize test results

Approve test results

Maintain records

Check test results

Pro

du

ctio

n P

rep

ara

tio

n S

tag

e

Confidential Supplier Quality Manual 3-9-1 Validity Testing

March 1, 2018


7 Forms

7.1 Validity Testing Plan/Actual Performance Table (blank)

No

Actual Test item

Plan Test plan

Rev no. Date Natuere of the change Supplier Honda

�

　Model code

　Part number

Honda event schedule

　Part name

　Design change number

Part origin

No

Actual

Scheduled

start date

Scheduled

completion date

Date started

(start)

Date completed

(actual)Test result n

Test itemPlan

Test planCriteria Test condition n Test period Judgement

/

Prepared section ( supplier name )

Approved by Prepared by

Plan

Approved by Prepared by

Actual

Confirm section

Confirmed

by

Person

in charge

Plan

Confirmed byPerson

in charge

Actual

Honda Motor Co., Ltd.

Validity Test Plan/Actual

PerfomanceTable


March 1, 2018


7.2 Validity Testing Plan/Actual Performance Table (Entry procedure 1/2)

　Part name

　Design change number

Part origin

�

　Model code

　Part number

Honda event schedule

Test plan

Rev no. Date Natuere of the change Supplier Honda

No

Actual Test item

Plan

JudgementCriteria Test condition n Test period

Test planNo

Actual

Scheduled

start date

Scheduled

completion date

Date started

(start)

Date completed

(actual)Test result n

Test itemPlan

Validity Test Plan/Actual

PerfomanceTable

/

Prepared section ( supplier name )

Approved

by

Prepared

by

Plan

Approved

by

Prepared

by

Actual

Confirm section

Confirmed

by

Person

in charge

Plan

Confirmed

by

Person

in charge

Actual

Honda Motor Co., Ltd.1 2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20 21 22


March 1, 2018


7.3 Validity Testing Plan/Actual Performance Table (entry procedure 2)

No Item (section) Instruction

1 Supplier signature

Enter company name and supplier code. Enter signature of the person in charge of and the person prepared the test plan and results. Enter the date of signature.

2 Honda signature For Honda use only (no entry required).

3 Model code Enter the code of a model in which the part is used.

4 Part number Enter Honda’s part number.

5 Part name Enter Honda’s part name.

6 Design change No.

Enter Honda’s design change number used in the part subject to the test.

7 Part origin Enter the origin of part subject to the test

※For the definition of parts origin, see 6-1 Definition of terms.

8 Revision Enter revision history.

9 Honda event schedule

Enter timing for production and other events of Honda.

10 Test item Enter the item subject to the test.

11 Criteria Enter criteria for the test.

12 Test condition Standards, measuring equipment, environments, etc., of the test.

13 n Enter the number of samples planned per test item.

14 Test period Enter the time period required for the test.

15 Scheduled start date

Enter the scheduled date of the start of the test.

16 Scheduled Completion date

Enter the scheduled date of completion of the test.

17 Date started Actual date of the test started.

18 Date completed Actual date of the test completed.

19 Test result

Enter the result of the test. Enter the minimum and maximum values measured for quantitative tests. For qualitative tests, enter results described in accordance with the expressions used in the column of limit values of respective tests.

20 n Enter the number of samples used per test item.

21 Judgment Enter either accepted or rejected based on test results.

22 Test schedule Enter the anticipated schedule per test item.

Note

1 Origin of items to be tested

If necessary, test results lie between upper and lower limits.

Note1. This applies only to parts designated by Honda. The format in which results (data) are presented is under the supplier ’s control, however, it should be easily understandable.



March 1, 2018




1 Overview

1) Honda shall provide a verification method for process capability and mass productivity, which Honda requires suppliers during early stage of mass production.

2) The supplier shall perform verifications of process capability and mass productivity in accordance with requirements prescribed by Honda during the early stage of mass production. The verification results shall be presented to Honda if so requested.

2 Definitions


Definitions】.

3 Requirements

3.1 The supplier shall perform the following during the early stage of mass production. Also, if so requested by Honda, present or submit records of verification results.

3.1.1 Process Capability Verification

The supplier shall perform verification of process capability to confirm if quality characteristics of parts are controllable by manufacturing conditions. For process capability verification, the data with sample size of n=100 or more is desirable. A minimum of 30 data sets should be used (not applicable for the parts for which destructive testing is required or with quality characteristics assured by tooling) and the process capability should be met at least one of the following requirements.

1) Cpk≧1.33 or P＜0.01 range is observed.

2) If 1.0≦Cpk＜1.33 or 0.01≦P≦0.3, 100 % inspection or sampling inspection is

incorporated in the process and the result shows no nonconformities In case of any nonconformities detected, a procedure to take a retroactive action for the product lot which may be affected is employed before dispatch of the lot . Moreover, control process capability and seek improvement.

3) If Cpk＜1.0 or 0.3＜P, 100% inspection is conducted.

4) Investigate and determine whether or not insufficient process capability is due to a shift of the median or dispersion, and take measures.

Note: for single specification limit case, Cp control shall apply.

3.1.2 Mass Production Verification

The supplier shall confirm production capacity by continuous production for two hours or with a sample size of n=200 or more and verify feasibility of target yield, cycle time, and maximum production capacity and operators’ proficiency level of skills.

If continuous production for two hours or with a sample size of n= 200 or more is not attainable, consult with Honda (new model preparation section).

3.2 The supplier shall, if above verification results do not satisfy the target, report to Honda as needed and take measures immediately to achieve the target.

3.3 The supplier shall conduct process control or inspection as set forth in the following examples for the period until the target value is reached.

1) Implementation of tightened inspection (increased frequency of sampling, add extra inspection items, etc.)

2) Intensify manufacturing conditions that affect quality (tighten conditions, etc.).

3) Intensify monitoring of processes (increase frequency of process audit, etc.).

4) Temporal containment of specified nonconformity.



March 1, 2018


3.4 The supplier shall, based on information of delivery quality and market quality obtained from Honda, improve quality of parts.

3.5 The supplier shall direct and control necessary sub-suppliers of component parts to perform quality control of the same degree as set forth in this manual at the early stage of mass production.



1 Process capability verification records 20 years

2 Mass production verification records 20 years





March 1, 2018



1 Overview

1) Honda shall present suppliers with requirements to continuously maintain and improve the quality control system developed during pre-production stage, which includes change point control in the mass production stage.

2) The supplier shall, for all changes to be made to operator, manufacturing process, manufacturing method and/or parts, continuously maintain and improve the state of manufacturing process control in accordance with the method employed for the pre-production stage.

2 Definitions



No. Term Definition

1 Corrective action An action designated to prevent recurrence of nonconformity, once it has occurred.

3 Requirements

3.1 Work Standardization and Operator Training

3.1.1 Standardization of continuous work

The supplier shall, to maintain and improve quality of parts, continuously review work procedures, key points, etc., and standardize them using process quality control

table and/or operation control documents (refer to【SQM 3-2-1 Process Quality

Control Table 】and【SQM 3-7 Operation Control Documents】).

3.1.2 Education and Training

The supplier shall, for operators who are newly assigned to a process, provide education and training to acquire knowledge, skills, etc., necessary to perform tasks

within the process. ( refer to【SQM 3-7 Operation Control Documents】).

3.2 Process Control

3.2.1 Process FMEA

The supplier shall review and revise Process FMEA if any changes were made to the

process after completing the process FMEA ( refer to【SQM 5-5 Process FMEA】).

3.2.2 QA device (facilities, jigs and tools included)

The supplier shall regularly check the function of QA devices with respect to the following matters. If test parts are used to check QA devices, validate the test parts regularly.

1) Abnormality is detected as intended.

2) No false alarm goes off when normal.

3.2.3 Measuring Equipment

The supplier shall, in order to assure accuracy and precision of measuring equipment, perform regular checks and calibrations, and record and maintain results.

( refer to 【SQM 3-6 Measuring Equipment Control】).

3.2.4 Production Equipment.

The supplier shall identify control items of production equipment that affect quality, such as replacement criteria for expendable supplies. Procedures to manage the control items shall be established.

3.2.5 Control of Consumables and Auxiliary Materials

The supplier shall identify control items of production equipment that affect quality, such as replacement criteria for expendable supplies. Procedures to manage the control items shall be established.



March 1, 2018


3.2.6 Control of Manufacturing Conditions

The supplier shall regularly confirm and record manufacturing conditions set in the process which affects quality of parts (e.g. at the beginning, during, and the end of work, or daily, weekly or monthly), and monitor the control state of the process with results of the confirmation. If there is any abnormality found, follow corrective action procedure specified by its own.

3.2.7 Process Trend Management

The supplier shall conduct a sampling inspection or 100 % inspection to assure the quality of parts Record of the quantity of parts manufactured, nature of nonconformity, and quantity of nonconforming parts shall be maintained and utilized for the purposes in the following.

1) Understand dispersion, stability and process capability.

2) Implement measures against a process in which reduction in quality was found.

3) Prevent potential problems identified through an analysis of occurrence trend.

4) Forecast quality level for the next production and next model. Reflect findings in process design, equipment design, etc.


The supplier shall control change points of process and parts to ensure traceability of

parts (refer to 【SQM 4-4 Change Point Control】) .

3.4 Identification and Traceability

The supplier shall identify parts by suitable means and record manufacturing history to

ensure traceability of parts (refer to【SQM 4-3 Identification and Traceability】).

3.5 Inspection and Testing of Parts

3.5.1 The supplier shall perform inspection and testing at a frequency that allows the detection of problems with parts prior to delivery to Honda.

3.5.2 The supplier shall, if there are any changes were made to the inspection and testing method or frequency, etc., necessary for each part, reflect such changes in the Process Quality Control Table and operating standard documents immediately.

The supplier shall, if there are any changes made to the method, frequency, etc., reflect such changes immediately in the process quality control table and operation control documents of each part.

3.5.3 The supplier shall control records of inspection or testing results in a manner that allows the supplier to present or submit upon request by Honda.

3.5.4 The supplier shall periodically verify the effectiveness of limit samples and master samples in order for the inspection and testing to be performed correctly.

(【SQM 3-5-2 Preparation of Limit Samples】)

3.6 Control of Nonconforming Parts

The supplier shall define and document procedures for handling of nonconforming parts. Procedures including identification of nonconforming or suspect parts, quarantine of nonconforming parts, criteria for disposal of nonconforming parts, etc., shall be

established with defined roles and responsibilities (refer to【SQM 4-5-1 Delivery Quality

Problem】).

3.7 Corrective Action

The supplier shall define and document procedures for corrective action to take against

quality nonconformity occurred in-house, in Honda or in the market (refer to 【SQM 4-5

Corrective Action Report】,【SQM 4-5-1 Delivery Quality Problem】and 【SQM 4-5-2

Market Quality Problem】).



March 1, 2018




1 Monitoring data of manufacturing conditions of production

facilities which affect quality. 20 years

2 Training record 20 years



2) SQM 3-5-2 Preparation for Limit Samples

3) SQM 3-6 Control of Monitoring and Measuring Devices

4) SQM 3-7 Operation Control Documents





9) SQM 4-5-2 Market Quality Problem





March 1, 2018



1 Overview

1) Honda shall provide requirements for identification and traceability control, which is to verify necessary information immediately, determine the cause and scope of parts affected, and take prompt countermeasures in the event that nonconformity occurs at a supplier’s production stage or after shipment.

2) The supplier shall identify parts in accordance with requirements prescribed by Honda, and control traceability.

2 Definitions



No. Term Definition

1 Traceability The ability to trace the history, application or location of a product or servicing by record identification.

2 Delivery lot A group of parts which are delivered to Honda or a location specified by Honda in a batch, corresponding to the ”delivery slip”.

3 Manufacturing lot A group of parts manufactured or deemed manufactured under the same condition.

4 Manufacturing

history

A record of production corresponding to the identification of a manufacturing lot, which includes the date and amount of manufacture, and results of inspection.

5 Manufacturing lot

control

Control method that forms a manufacturing lot and subsequently control traceability of parts by identifying such lot and its manufacturing history.

6 Manufacturing lot forming process

Manufacturing process for which manufacturing lot shall be formed and identified in order to track and control traceability of parts, which is determined by quality characteristic priority, process layout, equipment, process capability, etc.

7 Key process In the case where there are two or more manufacturing lot forming processes, a representative process for lot retrieval in those manufacturing lot forming processes.

8 Lot-out parts Parts returned from Honda by the unit of delivery lot due to nonconformity, such as not satisfying specifications.

3 Requirements

3.1 Identification

The supplier shall identify parts and their component parts by suitable means throughout all production processes, i.e. from receiving of materials to delivery of finished goods to Honda (all delivery destinations designated by Honda included).

If Honda requires use of barcode labels, attach barcode of specified standard.

3.1.1 Identification of Parts

The supplier shall follow the directions from Honda in regard to identification. If no direction is given, consult with Honda.

If parts are designated by Honda as lot-control-specified parts, identification of manufacturing lot number, etc. of the parts shall be determined after consultation with Honda regarding location and method, etc. for identification display.

3.1.2 Identification of Delivery Lot

Submit designated “Delivery Slip” to Honda for each delivery lot.



March 1, 2018


3.1.3 Identification of Delivery Container

Each delivery container shall be identified by parts specification card, etc.

Information below shall be contained in the identification.

1) Company name

2) Honda part number

3) Honda part name

4) Delivery date specified by Honda

5) Quantity

6) Number of containers

7) Others (to be decided after consultation with Honda where necessary)

3.2 Traceability Control

The supplier shall control records of manufacturing history and parts release so that the parts are traceable to the delivery lot. Ensure traceability in a manner that manufacturing history is traceable throughout all stages from component parts to finished goods.

3.2.1 Manufacturing Control

The manufacturing history shall include the following information.

1) Date of manufacture and quantity of parts manufactured

2) Manufacturing condition of the lot and quality characteristics confirmation based on the process quality control table at the time of manufacturing.

3) Process changes other than those mentioned in 2) which may affect quality, and

results of the action taken and confirmation ( Refer to【SQM 4-4 Change Point

Control】).

3.2.2 First-in, First-out

All parts which contain component parts and work-in-process parts shall be controlled on a first-in, first-out basis. This also applies to items which generally do not circulate, such as inventory in the warehouse, emergency stock, repair parts, etc.

All parts including component parts and work-in-process parts shall be controlled based on a first-in, first-out basis hereinafter referred to as “FIFO”). Items out of regular circulation, such as warehousing parts, emergency stock, repair parts, etc. shall be handled in the same manner.

3.2.3 Handling of in-process nonconforming parts (off-line repair/rework).

Maintain traceability of parts quarantined and awaiting further treatment.

3.2.4 Handling of Lot-Out Parts

When disposing lot-out parts, record the reason, date, and quantity, etc. of parts being disposed in the manufacturing history.

In principal, due to its critical nature, lot-out parts shall not be repaired or modified.

Those which are determined that repair, sorting, concession, etc., (herein after referred to as “repairs, etc.“) can be made shall be handled in accordance with

【SQM 4-5-1 Delivery Quality Problem】

3.2.5 Traceability Control for Purchased Parts

To ensure traceability, the supplier shall assure that sub-suppliers employ the same degree of control for manufacturing history.

( refer to 【SQM 2-4 Sub-Supplier Quality Assurance】)



March 1, 2018


3.3 Manufacturing Lot Control

The supplier shall, if parts are designated by Honda as lot-control-specified parts, determine the matters set forth in section 3.3.3.1 in consultation with Honda’, formulate a manufacturing lot on a FIFO basis, and control manufacturing history.

3.3.1 Lot-Control-Specified Parts

If the following conditions apply, the supplier shall control parts as lot-control-specified parts.

1) Important safety parts designated as HS, HA or HB on product drawing

(including processing charts, etc.) (Refer to【SQM 2-1 Important Safety Parts).

Parts that cover ISO26262 Functional Safety Standard specified in the Requirements Specification (function requirements specification) issued by Honda are included.

2) Parts other than important safety parts specified by Honda with “Lot-Control-Specified Parts Notice” set forth in section 7.1.

3.3.2 Formation of Manufacturing Lot

Manufacturing lot shall be formed in the range of parts that are or are deemed manufactured under the same conditions in accordance with the classification shown below. Manufacturing lot size shall not exceed the volume of production per day.

No. Classification Criteria for Manufacturing Lot Formation

1 Material Form a manufacturing lot for each material charge No. or batch.

2 Mean Form a manufacturing lot when tooling in a process (including inspection process) is set up.

3 Equipment Form a manufacturing lot for each manufacturing assignment which is made to two or more machines, equipment, molds, production lines, etc.

4 Work shift Form a lot for each production date or work shift.

3.3.3 Control of Manufacturing Lot

3.3.3.1 The supplier shall determine the following matters in consultation with Honda.

1) Manufacturing lot forming unit, manufacturing lot forming process and key process.

2) FIFO control method

3) Display method of manufacturing lot identification (manufacturing lot number structure, identification display method on each delivery container, display languages, barcode labels, etc.).

3.3.3.2 The supplier shall establish a system for recording manufacturing lot, which enables manufacturing lot and delivery lot to be retrieved from the manufacturing history of parts.

The method of manufacturing lot control, manufacturing lot number display, etc. shall be defined in “Lot control (Lot Number Display Details)” in accordance with section 7.2, and confirmed by Honda upon Honda’s request prior to starting mass production.

The designated format of “Lot Control (Lot Number Display Details)” is recommended for use. However, in case that Honda confirms that the format submitted by the supplier is equivalent to “Lot Control (Lot No. Display Details)” format, it may be substituted for Lot control (Lot No. Display Details)”.

3.3.3.3 If any changes to the process that may affect quality are found in a lot other than the manufacturing lot forming unit set forth in section 3.3.2 above, record such changes as a manufacturing history and separate the lot.

3.3.3.4 If a need arises to change matters prescribed in section 3.3.3.1 at the production stage or to add lot-control-specified parts, it shall be determined after consultation with Honda (receiving quality section) and take appropriate actions.



March 1, 2018




1 Lot-Control-Specified Parts Notice 20 years after the issue of

discontinuation order.

2 Lot Number Display Details, or equivalent 20 years after the issue of

discontinuation order.

3 Record of manufacturing history of parts 20 years









March 1, 2018


6 Flowchart

Identification and Traceability

Contact

or

Receiving

History

Section

Ma

ss P

rod

uciton

Sta

ge

Legend: 　　　　　　　For cases when Honda assign lot control parts in addition to the important safety parts as so designated in drawings.

Supplier Honda

New Model

Preparation

Section

Pre

-Pro

duction S

tage

New Model

Preparation

Section

New Model

Preparation

SectionVerify display contents

Drawing

Lot Number Display Details

Manufacture partsCarry out lot control

Specify Important Safety Parts

Select lot-control-specified parts

Lot-Control-Specified Parts

Notice

Record of manufacturing

history

Carry-inManufacturing/

Assembly

Record of manufacturing

history

Decision of lot control standard items1) Lot forming unit2) Lot forming process and key process3) FIFO control.4) Lot number display method.5) Recording of lot control.



March 1, 2018


7 Forms

7.1 Lot-Control-Specified parts notice (blank)

Lot control [specfied parts]

Contact Section

The following parts have been decided as lot-control-specified parts in addition to important safety

parts (HS, HA and HB of important safety part rank) indicated in the title field of the drawing.

No. ModelCritical

Process

2. Maintain [Lot Number Display Details] in a manner that it can be submitted if so requested.

4. Parts are should be controlled on a "first-in first-out"basis.

05101

3. When display a lot mark on each part(if there is no specification on the drawing),consult

with for display method.

Honda Motor Co., Ltd. (Name of facility)

Issue Date: / / (YY/MM/DD)

Issue Section

�To:

Lot-Control-Specfied Parts Notice

Part Number Part Name

(Note) 1. Upon receiving this notice,clarify the lot control method for parts subject to lot control in

[Lot Number Display Details] or the like.



March 1, 2018


7.2 Lot Number Display Details (blank)

ロット形成工程を記載して代表工程を○で囲む。 ENTER LOT FORMING PROCESSES AND CIRCLE KEY PROCESS

05101

当用

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LOT NO. IDENTIFICATION METHOD

製造部門名SUPPLIER NAME

STRUCTURE OF LOT №

表示場所

部番PART №

部品名

ロット形成工程

PART NAME

代表工程

LOT FORMING PROCESS

LOCATION OF LOT NO. IDENTIFICATION

ロット番号構成

表示方法

〔ロット表示明細〕LOT № DISPLAY DETAILS

ロット管理

略図 ILLUSTRATION OF PARTS LOT CONTROL

製造部門SUPPLIER

本田技研工業株式会社HONDA MOTOR CO., LTD

担当者PERSON IN

責任者APPROVED BY

発行日DATE OF ISSUE

担当者PERSON IN CHARGE

確認者責任者APPROVED BY


PERSON RESPONSIBLE FOR CONFIRMATION

SEL

EC

T P

RO

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SS



March 1, 2018


7.3 1/2 Lot Number Display Details (entry procedure) 1/2



March 1, 2018


Lot Number Display Details (entry procedure) 2/2

No. Entry instructions Section

① - Enter part number of a part that corresponds to this [LOT No. DISPLAY DETAILS].

② - Enter part name that corresponds to the part number.

③- Enter company name.

④ - List lot forming processes in process order, and circle key processes for lot control. If creating in line with a notification regarding lot control specification of parts, include in the lot forming processes the critical process written on the notification.

(Example) casting, gear cutting, induction hardening, delivery

⑤ - Enter the structure of lot control number. (Example) 52005

KJuly

2525th

⑥ - Enter the location on the product where lot control number is to be shown.

⑧ - Describe lot control method for each process to be lot-controlled.

⑦ - Enter identification method of lot control number. (Example) Stamping, applying labels,

(Example)

<Casting>

<Gear cutting>

<Delivery>

(1) Lot structure(2) Lot number(3) Lot control record



(4) Lot number structure standard

Number of casting per day for each die number5K06 2 (July 6, 2005. Die number 2)① Release date (MM/DD) / Number released

Number processed per day for each gear cutting5K08 5 (July 8, 2005. No. 5 machine)

① Casting lot No. ② Gear cutting lot No.

③ Release date (MM/DD) / Number released

Number delivered per day5K10 (July 10, 2005)

① Casting lot No.

② Induction hardening lot No.

③ Delivery date (MM/DD) (Honda-designated delivery date, time) / Number of goods delivered

：：：

：：：

：

：：

-Supplier’s PIC and Quality Assurance Representative to sign or affix his or her seal. The Facility Quality Representative can act as a deputy to the Facility Assurance Representative.

⑨⑩

⑪ Enter the date of issue starting from the last two digits of the year. (YY/MM/DD)

For Honda use only (no entry required).

⑫⑬

⑭⑮

Supplier

Supplier

Honda

Supplier

Year The last number of the year

Month Jan Feb March April May June July Aug Sept Oct Nov Dec

A B C D E H K M R S T V

Day Use the date as it is



March 1, 2018


Lot Number Display Details (entry example)

ロット形成工程を記載して代表工程を○で囲む。 ENTER LOT FORMING PROCESSES AND CIRCLE KEY PROCESS

０７　０４　０４

年　月　　日

開発

品管

05101

'07/04/25品責者

９００１８－Ｓ００－００００

ＢＯＬＴ,　ＦＬＧ ○○○○(株)

On the side of the container.

材料－冷間加工－熱処理－メッキ－出荷/検査

担当者

担当者責任者

Labeling

'07/04/25

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LOCATION OF LOT NO. IDENTIFICATION

ロット番号構成

表示方法

LOT NO. IDENTIFICATION METHOD

製造部門名

SUPPLIER NAME

STRUCTURE OF LOT №

表示場所

部番

PART №

部品名

ロット形成工程

PART NAME

〔ロット表示明細〕LOT № DISPLAY DETAILS

ロット管理

略図 ILLUSTRATION OF PARTS LOT CONTROL

製造部門SUPPLIER

本田技研工業株式会社HONDA MOTOR CO., LTD


責任者APPROVED BY



確認者責任者APPROVED BY


PERSON RESPONSIBLE FOR CONFIRMATION

SE

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ESS

●材料 ①ロットの構成：コイル材ごとの番号付け

②ロット番号：０７０４０２Ａ（意味：０７年４月２日、鋼種Ａ）

③ロットの管理記録：素材記録、材料ロットを関連つけて記入する。

●冷間加工

●熱処理

●メッキ

①ロットの構成：材料ロットごとの１日加工数

②ロット番号：０７０４０３（意味：２００７年４月３日）

③ロットの管理記録：材料ロットNo、冷間加工数を関連つけて記入する。

①ロットの構成：冷間加工ロットごとの１日熱処理数

②ロット番号：０７０４０４（意味：２００７年４月４日）

③ロットの管理記録：冷間加工ロット、熱処理ロット／熱処理数を連係つける。

①ロットの構成：熱処理ロットごとの１日メッキ数

②ロット番号：０７/０４/０５（意味：２００７年４月５日）

③ロットの管理記録：熱処理ロット、メッキロット／メッキ数を連係つける

●検査/出荷 ①ロットの構成：メッキロットごとの検査数

②ロット番号：０７/０４/０５（意味：２００７年４月５日）

③ロットの管理記録：メッキロット、検査/出荷ロット／検査数/出荷を連係つける

Lot No.

Foop

No. of part processded per day( boxed)

Lot No.

No. of heat treated parts per day (box ed)

Lot. No.070404

Lot.No070404

Lor No.

ロット番号07/04/05

ロット番号07/04/05

Lot. No07/04/05

Lot No.07/04/05

● Cold working ① Lot structure : total no. of parts processed per day.

② Lot number : 070403A ( reads April 3, 2007)

③ Lot control record: record material lot number in conjunction

with total number of cold-working processes.

● Material ① Lot structure : numbering per coil.

② Lot number : 070402A ( reads April 2, '07, steel type: A)

③ Lot control record: record material records in conjunction with

material lot number.

● Heat treatment ① Lot structure : total no. of parts processed per cold working lot.

② Lot number : 070404A ( reads April 4, 2007)

③ Lot control record: record in conjunction with cold-working lot,

heat treatment lot and total of heat treated parts.

● Plating ① Lot structure : total no. of parts plated per heat treatment lot.

② Lot number : 07/04/05 ( reads April 5, 2007)

③ Lot control record: record in conjunction with heat treatment lot,

plating lot and total of plated parts.

● Plating ① Lot structure : inspection lot per plating lot.

② Lot number : 07/04/05 (reads April 5, 2007)

③ Lot control record: record in conjunction with plating lot, inspection lot,

release lot, no. of inspected parts and no. of released parts.

Confidential Supplier Quality Manual 4-4 Change Point Control

March 1, 2018



1 Overview

1) Honda shall provide requirements to control all change points with respect to labor, manufacturing process, manufacturing method, and parts during a supplier’s production process.

2) The supplier shall maintain traceability of all change points in accordance with requirements prescribed by Honda.

2 Definitions



No. Term Definition

1 Change point

Occasions where changes in part specifications, scheduled or sudden manufacturing plan changes, and equipment changes, etc., occur.

Furthermore, sudden changes include the following examples:

1) Suspending and restarting the production line

2) Process changes such as equipment abnormalities

3) Sudden changes in operator

4) Follow-up of an operation delay

2 Initial

production parts (IPP)

Parts of the initial lot released from an originating section to its next section or of the initial lot released from a supplier to Honda, to which the supplier applied changes in specification, manufacturing method, etc. This applies to parts ordered for mass production use only.

3 Specification change IPP

The IPP to which specification change was implemented by supplier in accordance with the “Application Change Instruction” issued by Honda.

4 Quality

improvement IPP

The IPP for which quality improvement was implemented by supplier in accordance with the “Rejection Countermeasure Request,” “Market Quality Information [Analysis/Countermeasure Request],” , “Honda Trouble Report” or other forms issued by Honda.

5 Self-controlled

IPP

The IPP falling under the items other than specification change IPP or quality improvement IPP, which is self-controlled by supplier through confirming and recording quality, process-ability, assemble-ability, etc. after changes.

6 Prior

confirmation

Presentation to Honda of specification change IPP before mass production start (before implementing the change) to confirm compliance with specification change.

7 IPP

presentation

Presentation to Honda of self-controlled IPP, etc. before mass production start to confirm quality compliance, process-ability, assemble-ability, etc.

8 Delivery location

A destination of delivery specified on the delivery slip.


March 1, 2018


3 Requirements


The supplier determines the control procedure regarding change point control and records the requirements. The following items are to be included in the control point record:

1) Change point content

include at least ‘‘Examples of IPPs in section 7’’

2) The date the change point occurred or was discovered

3) The production day or release day

4) In applicable cases, inspection results, etc.

3.2 IPP Classification

The supplier shall classify information regarding change points into specification changes, quality improvement, and self-control according to the established procedures for each respective category listed below (refer to ‘‘Section 7 Examples of IPPs and Change Point Control’’ for categories).

3.2.1 Specification Change IPP

3.2.1.1 The supplier shall, based on the Application Change Instruction from Honda, confirm the items requiring prior confirmation and the items requiring immediate application to mass production.

3.2.1.2 The supplier shall perform fabrication, assembly and inspection of IPP to which a specification change is applied, and shall take appropriate measures if any problem is found.

3.2.2 Quality Improvement IPP

3.2.2.1 The supplier shall perform fabrication, assembly and inspection of IPP for which quality improvement is implemented in accordance with a quality improvement request from Honda, and take appropriate measures if any problem is found.

3.2.2.2 The supplier shall submit IPP, inspection data and etc. described in above section 3.2.2.1 to a quality improvement instructing section of Honda and obtain confirmation. The supplier shall consult with Honda about how to proceed with the quality improvement IPP, etc. if necessary.

3.2.3 Self-controlled IPP

3.2.3.1 The supplier clarifies what they will report to Honda in advance within self-controlled IPP. Furthermore, the report is of the following items:

・Changes to the written content of the “Process Quality Control Table”

・Anything applicable to “Section 7 Examples of IPPs”

・Anything deemed necessary by the quality assurance representative or the

facility quality representative.

3.2.3.2 The supplier shall, when reporting to Honda, fill out the slip from form 9.1 ‘‘Self-Controlled IPP Communication Form.’’ The submission phase for planned change points is three months prior to a supplier‘s production starting, and when a sudden change point occurs. Furthermore, in urgent cases, Honda should be contacted first and their instructions followed.

3.2.3.3 Upon obtaining the approval of the quality assurance representative or facility quality representative, the supplier submits the ‘‘Self-Controlled IPP Communication Form ’’ to Honda.

3.2.3.4 The supplier shall review the “Self-Controlled IPP Communication Form” returned by Honda for indicated items (IPP items, number of inspection samples, time of submission, etc.), and proceed with the work outlined in the form.

3.2.3.5 The supplier shall perform fabrication, assembly, and inspection of self-controlled IPP, and if a problem is found, take appropriate measures.

The supplier shall perform fabrication, assembly, and inspection of self-controlled IPP, and shall take appropriate measures if any problem is found.


March 1, 2018


3.3 Judgment for Mass Production

3.3.1 The supplier shall obtain approval for mass production from Honda with respect to change points for IPP specification changes. Inspection samples of IPP, inspection data and IPP tags (refer to “IPP Control [IPP]” in section 9.5) shall be submitted to Honda for approval by the specified date.

3.3.2 The Quality Assurance Representative or Facility Quality Representative of the supplier shall determine applicability to mass production based on processing, assembly, and inspection results, excluding change points in 3.3.1. Furthermore, self-controlled IPP notified to Honda will be based on set requirements from the “self-controlled IPP communication form” and shall determine applicability to mass production.

3.3.3 In the ‘‘self-controlled IPP communication report,’’ the supplier submits the results from determining applicability of self-controlled IPP to mass production to Honda.

3.4 Mass Production and Release

3.4.1 The supplier shall start mass production of IPP which has been approved for mass production while controlling and following supplier procedures.

3.4.2 The supplier shall comply with the FIFO order and release IPP accordingly.

3.4.3 The supplier shall issue and attach an IPP tag to the specification IPP and the quality improvement IPP and submit inspection data to Honda. The supplier shall, if required by Honda, also issue and attach IPP tag to the applicable self-controlled IPP and submit inspection data to Honda.

3.4.4 If there are more than one delivery locations, IPP tag shall be attached to each initial lot released for each of the locations. In the case where an IPP lot is divided and delivered in multiple containers, attach a supplemental IPP tag to each container (refer to section 9.7). Handling of supplemental IPP tags may be consulted with Honda (material service section) in advance.

3.4.5 If the same IPP is used for multiple parts, i.e. assembled into parts of multiple types or variations, the supplier may consult with Honda (receiving quality section) for use of IPP tags.

3.5 Process Control

3.5.1 The supplier shall monitor the process of IPP after transition to mass production for a period of one month, as a rule, focusing on the conformity of quality. Length of the monitoring period may be adjusted at the discretion of the quality assurance representative or facility quality representative of the supplier.

3.1.1 The supplier shall, in the case where there are any specified items from Honda on the control after application to mass production, implement such items.

3.6 Sub-Supplier Control

The supplier shall direct and control its sub-suppliers and ensure IPP control of the same level as this manual requires for the component parts processed by sub-suppliers.

3.7 Controlling IPP of Supply Parts

3.7.1 The supply parts supplier shall provide supplier parts users of information about IPP prior to transition to mass production.

3.7.2 The supplier shall, if receiving supply parts with IPP tag attached, ensure traceability of the IPP and re-attach IPP tag to the initial lot released to Honda containing the IPP of supply parts.

3.7.3 The supplier shall, when dividing the IPP lot of supply parts to use for multiple types or variations of parts, issue and attach a new IPP tag for each initial lot released to Honda containing the supply parts IPP.


March 1, 2018


4 Key point

1) Confirm quality of parts before and after the change, if an unexpected change occurs.

2) In the process of communicating specification change IPP, do not omit or abbreviate digits of part number in order to prevent miscommunication.

3) When adopting a new material for coated parts, verify its durability, adhesion, etc. by coating tests.

4) In the event of transferring production, provide the party to which the production is transferred with necessary information to carry on the same quality control items specified in standards.



1 Self-Controlled IPP Communication

Form 20 years

2 Record of change points 20 years

3 IPP control 〔IPP〕 20 years

4 Inspection data attached to IPP 20 years




March 1, 2018


7 Examples of IPP

No Classification Item Description

1 Specification

change IPP

specification

change

・When changing based on notification of specification change.

2 Quality

improvement

IPP

Quality

improvement

・ When improving quality based on request from quality

improvement instruction section.

3 Self-controlled

IPP

New supplier ・ Addition of a new supplier (including supplier’s plant

expansion).

・Supplier change (including supplier manufacturing facilities).

・Change of destination of delivery.

・ Change in manufacturing process from in-house to

outsourced, or vice versa.

・When changing the manufacturing site

Material

change

・Material supplier change

・ Change of material such as HM-supplied material to

self-procured material is made and vice versa.

・Change of material not related to a specification change

(including rust preventive oil, lubricant , etc.).

Change in

process

conditions or

methods

・Change in method of casting or forging.

・Change in sintering conditions (process, temperature, time,

etc.).

・ Change in heat treatment conditions (temperature, time,

heating method, cooling method, etc.)

・Change in molding conditions for rubber and synthetic resin.

・Change in welding conditions.

・Change in cutting conditions.

・Change in machining datum or setting method.

・Change in plating, buffing or coating conditions.

・Change assembly conditions.

Process

sequence

change

・Consolidate, abolish or change in process sequence.

・Change in process from temporary to permanent, or vice

versa.

Machine

change

・Modify or repair of the machine.

・A new machine is used.

・Machine is relocated.

・When changing to mass production machine ⇔ alternative

machine.

・When changing software such as programs.

Jig and tool

change

・Change in master sample for parts fabrication.

・New or modified jigs and tools.

Die/mold

change

・Modification or renewal of dies/molds.

・When changing to permanent mold ⇔ temporary mold.

Inspection

method

Change

・New or modified checking fixture or inspection equipment.

・Change in measuring instruments or measuring criteria.

・When changing inspection method, criteria, frequency, scope

etc.

（＊）

Operator

change (*)

・When a change in operator of critical process, which is

particularly designated as a process requiring IPP control whenever operator change is made, occurs.

Change in

delivery

method or

delivery

packaging

・Change in delivery and packaging methods and containers.

Operator change: Items require IPP control. Advance notice to Honda may not be required.


March 1, 2018


8 Flowchart

8.1 Specification change IPP

Contact

Procurement

Section

Receiving

Quality

Section

Receiving

Quality

Section

Supplier Honda

Specific

ation C

hange I

PP

Keep track of changes to the specification

Specification change notice.( notify whether or not a Prior

Confirmation is required)

Application Change

Instruction

IPP fabrication, assembly andinspection

Issue IPP tag

Create Inspection Check Sheet

Transition to MP

Correction

Judge transition to

MP

MP

IPP tag judged OK

③

Issue IPP tag

Release

Attach IPP tag to the product

Control IPP ③ tag

Verify IPP OK

NG

NG

OK

Prior confirmation is required

Prior Confirmationnot required

Issue IPP tag


ReceivingInspection

RetunIPP ③ tag

IPP ③ tag

Store IPP tag (①)

IPP tag (①) is disposed after receiving (③)


March 1, 2018


8.2 Quality improvement IPP

Contact

Quality improvement instructing section means either RQ Sec or MQ Sec.

Supplier HondaQ

ualit

y I

mpro

vem

ent

IPP

Analysis and C/M for problem

Quality problem occurred

Quality improvement

request

IPP fabrication, assembly and inspection

Confirm reply and contents

of C/M

Correction

Transition to MP

Mass Production

Attach IPP tag to the product

Control IPP ③ tag

OK

NG

OK

NG

QualityImprovement

IndicationSection

Receiving

QualitySection

MarketQualitySection

QualityImprovement

IndicationSection

Release

RetunIPP ③ tag

IPP ③ tag

Issue IPP tag


Receivinginspection

Receivingquality

sectionor

MarketQuality

Section ofdelivery

destinationStore IPP tag (①)

IPP tag (①) is disposed after receiving (③)


March 1, 2018


8.3 Self-Controlled IPP

Contact

Receiving

Quality

Section

Receiving

Quality

Section

Receiving

Quality

Section

Receiving

Quality

Section

Supplier Honda

Self-c

ontr

olle

d IP

P

Correction

IPP tag judged OK③

Release

Control IPP tag（③）

Keep track of changes

Release

(control change

records)

Receive reply,

review

IPP

Issue IPP tag

Create inspection

IPP Presentationnot requried

IPP Presentation Required

Issue IPP tagCreate

Inspection

Receiving

Inspection

Return IPP

tag（③） IPP tag

③

Attach IPP tag to the

product

NG

OK

IPP Presentation RequiredIPP Presentationnot required

※Store IPP tag（①）

※IPP tag（①） is disposed of after receiving（③）


Approval

Self-controlled IPP Communication Form


determine transition to mass production

Verify

Verify IPP tag（③）

IPP fabrication, assembly, and inspection

Mass production

Self-controlled IPP Communication Form

Create

inspection

verify and replyNG

OK

Determine necessary information

Actual machine verification inspection


March 1, 2018


9 Forms

9.1 Self-Controlled IPP Communication Form

QA Rep Conf irmation PIC

Part No

Part Name

Part Characteristic Yes/NoAffect

Yes/NoImportant

Quality

Characteristics

Part

Inspection

Criteria*

Part Approval

Chemical

Substance

Others

　

16022

Oth

ers

Issued on　　　YYYY/MM/DD

Quality Characteristics

Affected

*Matters specified in Parts Inspection Criteria and Model　CP　List

Jig,

tool

cha

nge

Change Items Reason for Change

New

sup

plie

r

Mat

eria

l Cha

nge

Pro

cess

con

ditio

n/ m

etho

d ch

ange

Proc

ess

Serie

s C

hang

e

Mac

hine

cha

nge

Tran

spor

t, de

liver

y pa

ckag

ing

chan

ge

Change Details

Tool

ing

Cha

nge

Insp

ectio

n M

etho

d C

hang

e

mass production important

monitoring items

af ter transition to mass

production

（general rule 1 month）

Process FMEA

（Prevention）

（Outflow Prevention）

（Past Trouble Verif ication）

IPP Measurement

・Process Quality Control Table

Operation Control Standards

Rev ision/Establishment

・Operator Training Practice

Others

Evaluation Details

Schedule

Production

Date

Scheduled

Delivery

Date

Process FunctionS

ched

uled

Dat

e

Com

plet

ed D

ate

Validation Test

Assessment Items

To:

Company/Section Name

Planned

Sudden

Original to be retained until：　(YYYY/MM)

Honda　Confirmation

Honda Response Supplier Evaluation Results

Self-Controlled IPP Communication Form

YYYY/MM/DD

YYYY/MM/DDYYYY/MM/DD

Section Name Section Name

QA Rep Conf irmation Submitter

Conf irmation Submitter Receipt Conf irmation Submitter

Control No.


March 1, 2018


9.2 Self-Controlled IPP Communication Form (Entry Procedure)


Part No

Part Name


Yes/NoImportant

Quality

Characteristics

Part

Inspection

Criteria*

Part Approval

Chemical

Substance

Others

　

16022 Original to be retained until：　(YYYY/MM)



To:

Company/Section Name

Planned

Sudden *Matters speci fied in Parts Inspection Cri teria and

Model　CP　Lis t

Process Function

Sche

dule

d Da

te

Com

plet

ed D

ate

Validation Test

Assessment Items


monitoring items


production


Process FMEA

（Prevention）



IPP Measurement





Others

Evaluation Details

Schedule

Production

Date

Scheduled

Delivery

Date

Jig,

tool

cha

nge

Change Items Reason for Change

New

sup

plie

r

Mat

eria

l Cha

nge

Proc

ess

cond

ition/

met

hod

chan

ge

Proc

ess

Serie

s C

hang

e

Mac

hine

cha

nge

Tran

spor

t, de

liver

y pa

ckag

ing

chan

ge

Change Details

Tool

ing

Cha

nge

Insp

ectio

n M

etho

d C

hang

e

Oth

ers

Issued on　　　YYYY/MM/DD

Quality Characteristics

Affected


YYYY/MM/DD





Control No.

１

２

３

４５６

７８

９

１１１

１３

１５１６

１

１８

２０

２１

２２

２３

１４１９


4-4 Change Point Control March 1, 2018


9.3 Self-Controlled IPP Communication Form (Entry Procedure)

NO.

Honda

Honda

※Before reporting, enter No. 1-17. When reporting evaluation results, enter 19-22.

Supplier

Supplier Evaluation ResultsEnter decision after transition to mass production and completion

evaluation results.

YYYY/MM/DD Enter the date of the decision for transition to mass production.

Submitter/Confirmation/Quality

Assurance Representative

The submitter, confirmer, quality assurance representative or

facility quality representative add their signature or seal.

Mass Production Important

Monitoring Items after

Transition to Mass Production

(general rule 1 month)

Enter the predominant items for inspection after transition to

mass production.

Honda　Confirmation Column for Honda Use　Leave Blank

Completed Date Enter the date the evaluation details were completed.

Evaluation Details

Enter determined evaluation items/evaluation content regarding

quality characteristics affected by change items/change details.

Furthermore, the supplier may attach a separate sheet if

information will not fit on the form.

Schedule Date Enter the schedule date for completing the evaluation details.

Reason for Change Enter the reasons for changes regarding the change details.

Quality Characteristics AffectedEnter the quality characteristics that will be affected by the

change items/change details.

Honda　Response Column for Honda Use　Leave Blank

Scheduled Production Date Enter the scheduled date for beginning mass production.

Schedule Delivery DateEnter the scheduled date for delivery of the requested parts to the

applicable facility.

Part Number/ Part Name

Enter in ''change items'' the applicable part number/part name in

change items. In addition, if there are multiple parts, enter the

part number/part name of a representative part, and attach on a

separate paper the part numbers/part names of all parts received

at the applicable facility.

Item Entry method

Submitter/Confirmation/Quality

Assurance Representative

The submitter, confirmer, quality assurance representative or

facility quality representative add their signature or seal.

Planned/ Sudden

For change details, in the case of planned change points, put [○]

in the ''plan'' column, and in the case of sudden change points,

put [○] in the ''sudden'' column.

Entered

by

Issuance Enter date of issue.

Supplier

Company/ Section Name Enter company name and section name.

To:Enter the receiving quality section and applicable Honda factory

for parts delivery.

Yes/NoRegarding each part characteristic of changed parts, in applicable

cases mark ''Y,'' and in unapplicable cases mark ''N.''

Affect Yes/NoRegarding each part characteristic of changed parts, in affected

cases mark ''Y,'' and in unaffected cases mark ''N.''

Change Item

Enter ''○ '' for appliable change items. In addition, if the change

items are not applicable, enter ''○ '' in other, and in the change

content column enter those details.

Change Details Insert concrete details regarding change items.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

20

21

22

23

19


March 1, 2018


9.4 Self-Controlled IPP Communication Form entry procedure


Part No

Part Name


Yes/NoImportant

Quality

Characteristics

Yes No

Part

Inspection

Criteria *

No

Part Approval No

Chemical

SubstanceYes No

Others ○ ○ ○ ○

　

16022

IPP Measurement ・part accuracy （n=5） Apr-14

Feb-14

Original to be retained until：　(YYYY/MM)

Apr-14






・ process quality control table / process flow

chart / arrangement sequence of components

・operation standard establishment / training

・production conditions control chart revision

Mar-14 Feb-14

Others・confirmation and revision of IMDS registration

dataMar-14

Validation Test ・unit endurance tester （n=1）　vibration enduranceApr-14

Process FMEA

（Prevention）



・process FMEA implementation of changing

point entryMar-14

Process Function

process capabilities investigation (n=30)

requirement quality whole entry

・macro examination （n=5）　by SX8 SPEC

Mar-14 Mar-14 Apr-14

①Welding Process (Inc.) JNCC→JEC (Inc.)

②Welding Wire KC－28→KM－50S

③Shielding Gas CO2→Gas Blending Ar：CO2＝8：2

④New Welding Jig

①welding process

transfer of control due

to process

reorganization

②change due to

relocation of line

③change due to

relocation of line

④launching new jigs

due to jig deterioration

・requirement quality characteristics /

evaluation results.

Standards have no difference in quality

for goods before and after changes,

and the process function is satisf ied at

the same time. Maintenance of each

report type and training is complete,

and no problems are judged regarding

mass production f low .

May-14

Feb-14

・w elding macro inspection

frequency

　once a w eek

　（regular frequency once

a month）

・parts precision

measurement

　three coordinate

measuring machine

　continuously n=1/day

　（regular frequency

testing device start

n=1/day）

　　

・factory person in charge

on site rounds 1 time/day

Apr-14


monitoring items


production


Schedule

Production

Date

Scheduled

Delivery

Date


Jig,

tool

cha

nge

Assessment Items Evaluation Details

Sch

edul

ed D

ate

Com

plet

ed D

ate

Tool

ing

Cha

nge

Insp

ectio

n M

etho

d C

hang

e

Tran

spor

t, de

liver

y pa

ckag

ing

chan

ge

Oth

ers

BEAM ASSY, RR AXLE Sudden

Change Items Change Details Reason for ChangeQuality Characteristics

Affected

Nishida*Matters specified in Parts Inspection Criteria and Model　CP　List

New

sup

plie

r

Issued on　　　2014/JAN/13

42100－TF0－0030 Planned ○Endo Sato

To:　Honda Motor Co.,Ltd.Suzuka Factory.Parts Quality Department

Company/Section Name (Inc.) JNCC　Quality Assurance Division　Inspection Department

Mat

eria

l Cha

nge

Pro

cess

con

ditio

n/ m

etho

d ch

ange

Proc

ess

Serie

s C

hang

e

Mac

hine

cha

nge

・welding quality

・parts accuracy

・parts strength

・welding wire

chemicals


2014/Apr/21




Endo Sato Nishida


Control No.




9.5 IPP Control 〔IPP〕

該当箇所のNo.を○印する。　　CIRCLE APPLICABLE No.

１．　仕様変更初物　INITIAL PRODUCTION OF SPEC. CHANGE

２．　品質改善初物　QUALITY IMPROVEMENT ACTIVITY

３．　自主管理初物　VOLUNTARY INITIAL PARTS CONTROL

太線以外は、取引先又は発行部門で記入してください。（１．　先行確認　ADVANCED QUALITY CONFIRMATION）

TO BE COMPLETED BY SUPPLIER EXCEPT WHERE INDICATED IN BOLD LINES （２．　初物提示　SUBMIT ACTUAL INITIAL PARTS）

　管　理　Ｎo.

　CONTROL No.

　発行年月日

　DATE OF ISSUE

発　　行　　者搬　入　数

PERSON ISSUING QUANTITY

最終搬入取引先発　　行　　者搬　入　数

FIRST SUPPLIER PERSON ISSUING QUANTITY

部番　　　初物内容　HOW CHANGED

PART No.

部品名

PART NAME

仕様通知

SPEC. NOTICE No.

1 仕様変更 :SPEC CHANGE 6 機械変更 :MACHINE CHANGE

2 新規取引先 :NEW SUPPLIER 7 治工具変更 :JIG/TOOL CHANGE

3 材料変更 :MATERIAL CHANGE 8 金型変更 DIE/MOLD CHANGE

4 加工条件・方法変更:MANUFACTURING METHOD CHANGE 9 検査方法変更 :INSPECTION METHOD CHANGE

5 工程系列変更 :MANUFACTURING PROCESS ORDER CHANGE10 搬送方法・荷姿変更:TRANSPORTATION METHOD/TYPE OF PACKING CHANGE

初物品には、検査成績表を添付し搬入して下さい。　DELIVER INITIAL PRODUCTION PARTS WITH INSPECTION RESULT SHEETS.

　１）　本エフの①は、取引先又は発行部門控。　SHEET① MUST BE KEPT BY SUPPLIER OR DEPARTMENT ISSUING .

　２）　本エフの②③④は、各工程、取引先責任者のサインをして次工程に流してください。

SHEETS②③④ MUST BE PASSED TO NEXT PROCESS WITH SIGNATURE OF RESPONSIBLE PERSON FOR THE PROCESS.

責任者署名：SIGNATURE OF RESPONSIBLE PERSON

①　発行取引先　　②　中間工程取引先　　③　中間工程取引先

　　FOURTH SUPPLIER 　THIRD SUPPLIER 　SECOND SUPPLIER

　　④　最終搬入取引先　　⑤　本田技研受付　　⑥　本田技研検査

FIRST SUPPLIER HONDA RECEIPT HONDA INSPECTION

検査部門控保存期限：年

DUPLICATE FOR INSPECTION DEPARTMENT RETENTION PERIOD，　　　　　　　 YEARS

03011

SUPPLY JUDGMENT

PASS・FAIL

DATE　　 DATE DATE

量産移行判定

DATE　　　DATE DATE可　・　否

PRODUCTION LINE

A取　引　先　又　は　発　行　課

DATE LOT No.SUPPLIER OR DEPARTMENT ISSUING

B DATE LOT No.

該当

箇所

のＮ

o.を

○印

する

。C

IRC

LE A

PP

LIC

AB

LE N

o.

取引

先又

は発

行課

と最

終搬

入取

引先

が同

一の

場合

上段

を斜

線の

こと

WH

ER

E "

A" A

ND "

B" A

RE C

OM

MO

N, S

TRIK

E O

UT "

A"

INITIAL PRODUCTION PARTS

初物管理〔初物品〕 ①

1

2

3

4 5

6 7

8

9

10

11

12 13 14

15

16

※




9.6 IPP Control ( IPP) entry procedure

No. Item Description Who

－ General Use a diagonal line, etc. in the column to cross out items not

applicable.

Use the western calendar for dates.

Seal may be accepted in the signature field.

Regarding the circled number on copy, IPP tag is consisted of

4 sheets, with circled number specified accordingly to the

number of sheets. Here, it indicates the first sheet. First sheet

⇒① Second sheet⇒② Third sheet ⇒③ Fourth sheet ⇒④

Supplier

1 Classification Circle applicable item number.

2 Control No. Enter IPP control number.

3 Date of issue Enter the date and year of IPP tag issue.

4

5

Supplier name or IPP issuing section

IPP Issuer and

delivery quantity

Use a diagonal line to cross out if supplier issuing IPP and

supplier delivering final products to Honda are the same.

If IPP issuer is different from supplier delivering parts to

Honda, enter the name of the section (supplier name) and

issuer, production date and delivery quantity, etc. in 4 and 5.

6

7

First supplier (delivering supplier) IPP Issuer and quantity delivered

If the supplier issuing IPP and the supplier delivering final

products to Honda are the same, the IPP issuing supplier to

fill out section 6 & 7 with the name of the supplier, issuer,

quantity, etc.

If IPP issuer is different from the supplier delivering parts to

Honda, the delivering supplier to fill out section 6&7 with the

name of the supplier, issuer, production date and quantity, etc.

8 Part no.& name Enter part number and part name.

9 Specification notice no.

Enter revision number provided on the specification notice. If no reservation number is provided, cross out with a diagonal line.

10 IPP detail Circle applicable number and enter a brief description of the reason for the change (diagram may be accepted).

11 Fourth supplier (issuing supplier)

Enter the person in charge of releasing IPP and the date of shipment.

12 First supplier (delivering supplier)

(if the IPP originating supplier and the delivering supplier are the same, the supplier delivers parts to Honda fill out with the person responsible for delivery and delivery date.)

13 Receipt by Honda For Honda use only (no entry required). Honda

14 Inspection by Honda


15 Judgment for mass production


※entry column for verification results from Honda upon return

Prior confirmation cases: Honda’s results of determining applicability to mass production and the judge

IPP Presentation cases: Honda’s existing equipment verification confirmation results

First products after mass production commencement cases:

Honda’s acceptance inspection results

16 Retention period Enter the retention period of IPP tags (20 years in western calendar from issue)

supplier


March 1, 2018


9.7 IPP (supplemental tag)

初　　物ＩＮＩＴＩＡＬ　ＰＲＯＤＵＣＴＩＯＮ　ＰＡＲＴＳ

SUPPLEMENTAL TAG　　

　　初物管理　№

　　INITIAL PRODUCTION

　　　　CONTROL №

　　１　仕　様　変　更　№

　　　　SPEC NOTICE №

　　２　新規取引先　　　NEW SUPPLIER

　　３　材料変更　　　　　　MATERIAL CHANGE

　　４　加工条件・方法変更　MANUFACTURING METHOD CHANGE

　　５　工程系列変更　　　　MANUFACTURING PROCESS ORDER CHANGE

　　６　機械変更　　　　　　MACHINE CHANGE

　　７　治工具変更　　　　　JIG/TOOL CHANGE

　　８　金型変更　　　　　　DIE/MOLD CHANGE

　　９　検査方法変更　　　　INSPECTION METHOD CHANGE

　　10　搬送方法・荷姿変更　TRANSPORTATION METHOD/TYPE

　　　　　　　　　　　　　　　OF PACKING CHANGE

　　該当№を○で囲んでください。 CIRCLE APPLICABLE №

　　仕様変更の場合は仕様変更№も記入して下さい。

　　IN CACE OF SPEC CHANGE ENTER NUMBER

初物品エフに記入の管理№

と同一№を記入するEnter the same control number used in the IPP tag.

Confidential Supplier Quality Manual 4-5 Corrective Action Report

March 1, 2018



1 Overview

1) Honda shall provide requirements for reporting of corrective action in cases where nonconformity occurs in quality of parts made by suppliers.

2) The supplier shall report corrective actions in accordance with requirements prescribed by Honda.

2 Definitions


Definitions】.

3 Requirements

3.1 The supplier shall, in the case where nonconformity is detected at the supplier site and where there is a possibility of the nonconforming product being flowed out to the delivery

destination, take corrective action in accordance with【SQM 4-5-1 Delivery Quality

Problem】.If there is no possibility of an outflow, the supplier shall follow its own procedure

to take corrective action and maintain records.

3.2 Where “Rejection Countermeasure Request” or “HTR (Honda Trouble Report)” is issued

by Honda, the supplier shall take corrective action in accordance with 【SQM 4-5-1

Delivery Quality Problem】.

Response to Honda shall be submitted directly using “Rejection Countermeasure Request” (refer to section 6.1), or “HTR” (section 6.2) and etc.

The “Analysis Record [Analysis Report]“ (section 6.3 and 6.4) shall also be submitted along with above documents upon Honda’s request or based on the supplier ’s judgment

( Refer to 【SQM 5-4 5 Principles for Problem Solving】).

3.3 If requested by Honda to take corrective action and conduct analysis against non-compliance by “Market Quality Information [Analysis/Countermeasure Request],” the supplier shall respond to Honda using “Analysis Record [Analysis Report]”, etc. in

accordance with【SQM 4-5-2 Market Quality Problem】.

3.4 In the case where the response due date cannot be met, the supplier shall consult with Honda, and if necessary, issue an interim report on “Rejection Countermeasure Request”, “HTR”, or “Market Quality Information [Analysis/Countermeasure Request]”.

3.5 The supplier shall implement change point control for the initial parts to which corrective

action was taken in accordance with 【SQM 4-4 Change Point Control】.

3.6 The supplier shall provide feedback on the results of corrective action to the new model section and to the problem-causing source. The information shall be utilized for recurrence prevention of nonconformity and/or prevention of potential problems.

3.7 If non-compliance or quality non-compliance originating from a sub-supplier occurs, the supplier is responsible for implementing reliable countermeasures and preventive

measures（refer to 【SQM 2-4 Sub supplier quality assurance】）.



1 Rejection Countermeasure Request 20 years

2 Analysis Record [Analysis Report] 20 years

3 Records of corrective actions taken against

in-house problems 5 years


March 1, 2018





3) SQM 4-5-2 Market Quality Problem

4) SQM 5-4 5 Principals for Problem Solving



March 1, 2018


6 Forms

If using both “Rejection Countermeasure Request” or “HTR” and “Analysis Record [Analysis Report]”, enter the date and number, etc., in order for the “Analysis Record [Analysis Report]” referred to by the “Rejection Countermeasure Request” or “HTR” and “Analysis Record to be identifiable.

6.1 “ Rejection Countermeasure Request ” entry procedure

Control No.

Reply deadline ：

Where to reply ：

Confirmation after countermeasure

： No ・ Yes

： All ・ Limited 〕

Note

07121

Date on which confirmation has been completed YYYY/MM/DD

Original to be retained until: YYYY/MM

Model / name checked 〔Name ：〕

Issuing section or inspection section Chief Inspecting Engineer

Occurrence after

countermeasureDate of occurrence: Approved byConfirmed by

Person in

charge

Model, type, serial number, etc.:

Approved byConfirmed byPerson in

charge

(YYYY/MM/DD)

Date: YYYY MM DD

Date Approved by Confirmed byPerson in

charge

Countermeasure / reply section:

YYYY MM DD Model Type

Ca

teg

ory

Product number

Category of reply (intermediate / final) Date on which countermeasures taken, product number, etc. Countermeasure request section:

Result of investigation / analysis and causeCountermeasure (If there is not enough space to enter, an attachment

sheet may be used.)

Where to call To (Extension )

YYYY MM DD

To

Transmission №, etc.

Destination/Transmission Destination Transmission

Category ＡＴＭＴＣＶＴ

Frame No.

E model / type

Engine No.

Date of occurrence －－Discovering

section

F model / type

Priority Subject

*1Number of

occurrenceSupplier No. Part No.

Approved by Confirmed byPerson in

charge

Rejection Countermeasure RequestT via

Issuing date:　YYYY MM DD

Issu

ing

o

-Enter the cause and details of improvement measures.If using an attachment sheet, enter the title of the attachment, date and so on.(Example) : For details, see "Analysis Record [Analysis Report], titled ".........", dated XX, XX

2008. -If it is an interim report, enter the reason.

①

-Circle the applicable category. -If the final report will not be ready until after the reply deadline, prepare an intermediate report. -The "final report" is defined as a report after permanent countermeasure parts are adopted by a supplier. So, it is not a final report until countermeasure parts are put into

use.

②

③-Enter supplier name and section name

-Enter the date of report (YYYY/MM/DD).-Approval field … Rank A: Person responsible for quality assurance or for the quality of a facility. Rank B/C: Head of a section responsible for quality.-Supplier signature (pencil not permitted): signature or seal.- If it is an interim report, first make a photocopy of the form with the signature field blank, then sign on the photocopy.

*To be filled by Supplier

*1: For Honda use only (no entry required).

Priority is determined by the following in-house criteria.Importance ranking for nonconformities

(4) Condition that associated with pollution.

(5) Condition that disables protection of vehicle occupants.

(6) Others which do not conform to regulations.

Importance

Rank

BConditions which are described under A and which significantly impair

functions and merchantability of products.

C Conditions not described in A or B.

Definition

A

Nonconformities which cause or may cause the following phenomena.

(1) Condition that disables vehicle operation (run, steer, or stop).

(2) Condition that associated with electrification, burn, or injury.

(3) Condition that associated with fire


4-5 Corrective Action Report March 1, 2018


6.2 HTR

(INITIAL) (ANSWER)

TO ATTN: FROM: TO ATTN: FROM:

DATE: DATE:

MGR: MGR:

AMGR: AMGR:

ISSUE: ISSUE:

MODEL TROUBLE REPORT NO.

PART NUMBER REPORTED BY 1.SHORTAGE

UNPACK DATE 2.WRONG PARTS SHIPPED

PART NAME TROUBLE PART QTY/TOTAL PART QTY 3.DAMAGE

4.RUST

PC NO: PARTS REPAIRABLE 5.DEFECTIVE PARTS

LOT NO: PARTS NOT REPAIRABLE 6.REPLACEMENT BY D/C

CASE NO: CONDITION OF NEXT LOT 7.OTHER

EAT AHEAD QTY SHIPPING

NECESSARY COLOR METHOD

NOT NECESSARY RTA

DETAILS : (EX.PICTURE)

ANSWERT/REPORT NO

P/C NO ＥＴＡ OTHER

ＤＥＴＡＩＬＳ：

�

PART REPLACEMENT QTY

BOAT A IR

TROUBLE CATEGORY

TROUBLE REPORTDIST

BOAT

AIR

OTHER

REPLACEMENTPARTS


March 1, 2018


6.3 ”Analysis Record [Analysis Report]” Blank

９９１２２ Original to be retained until: / (YYYY/MM):

Determine the facts (part analysis, factor analysis, production quality status )

Appropriate countermeasures

(Detail, estimated effects, PPA)

Feedback to the Source (Reflection on system &

mechanism)

Occurrence Situation(Symptom, complaint, number of occurrences, treatment)

Analysis Record [ Analysis Report ]Approved by

Cre

ate

d S

ect

ion

Confirmed by Created by

YYYY/MM/DDTheme

Part No.

Part

Name

Why Why Analysis

Find the Cause (Occurrence mechanism, reproduction test, why why analysis)

Confirmation of C/M Effectiveness (Effectiveness

history)

Steps 1 2 3 4 5

Conte

nts

Occur-

rence

Out-

flow


March 1, 2018


6.4 “Analysis Record [Analysis Report] “entry procedure

1 2 3 5

99122 Original to be retained until: YYYY/MM

Steps 4

Co

nte

nts

Theme

Part No.

Part Name

Approv ed by

Cre

ate

d S

ectio

n

Confirmed by Created by

Confirmation of C/M Effectiveness (actual outcome)

Why Why Analysis

-Countermeasure request receipt date (In the last line, enter the date agreed upon with the requesting department.)

Enter the date of issue.

YYYY/MM/DD

1. Enter the outline (measurements) of the troubled area.

①Enter trouble area clearly.

②Enter results against criteria/standards.

(assembled condition, damage, accuracy, material, strength, etc.)

③Enter lot number of concerned parts clearly.

④Enter summary of conclusion from the claim part analysis.

2. Enter results of reproducibility test, etc.

3. Enter factor analysis for problem occurrence.

・ Analysis through cause and effect diagram or FMEA, KT method

・ Verification of cause and fact

①Enter investigation results of occurrence factors and outflow factors.

Describe the situation of products in the production line at the time.

・Enter results of investigation on the situation at the time of discovery of the problem lot (any changes to 4Ms or not) .

・Enter investigation results of history of the same symptoms in the past.

② Verify causes resulted in the occurrence, after having lined up procedures and rules defined in Operation Standards.

③Enter specifically what was the problem and what was missing.

4. Enter the quality status of parts currently under production

(acknowledge the current status through x-R control chart, histogram, process

capability index)

5. Understand the applicable scope of occurrence (occurrence ratio, or, number ofunits) along with its evidence.

Make an estimate based on changes made to lot, man, model,

equipment,condition, operation methods, or environment

1. Describe the causes of outbreak factor and outflow factor.

・ Investigate the cause through cause and effect diagram, FMEA, KT method

・ Cause of manufacturing problems must be determined down to tangible factors (such as

equiment, jigs, inspection tools)

If the cause is due to intangible factors, conduct interviews with the persons involved with the

failure at the time of occurrence, and determine the facts.

2. describe reproducibility, etc. of the symptom against the cause.

(Verify by reproduction test, work-site, reality).

1. Enter description of C/M.

・ Decide the measures to take (such as KT method)

・Devide the C/M into occurrence and outflow factors.

Make sure that the C/M is taken to intangible attributes,

even if the cause was originated in human errors.2. Enter the date of C/M, applicable parts, model, VIN No. etc.

3. Describe predection of C/M effectiveness for temporary C/M or forpermanent C/M.

1. Describe confirmed outcomes of C/M or timing of the confirmation either at the manufacturing process or in the market.

・Describe the outcomes by comparing the difference of quality data,

quantity, etc. before and after of taking measures.

1. Describe factors, which countermeasure for tangible attributes was taken to and will be continuously maintained, to reflect to the system.

(Design requirements, Drawing, Reference, and Standards)

2. Include a system that eleminated factors of the true causes (includes horizontal development).・Cross-cutting/horizontal approach to similar processes/lines・ Standards, criteria, accumulation of know-how and techniques

C/M for Cause①・・・・・②・・・・・③・・・・・C/M for Outflow ①・・・・・②・・・・・

Enter brief description of the model, part name, symptom, etc.If "Rejection Countermeasure Request" or "Market Quality Information [Analysis, Countermeasure

Request 〕" have already been issued, use the same theme title.

：Example

Cause of Occurrence①・・・・・・

②・・・・・・

③・・・・・・Cause of Outflow①・・・・・・②・・・・・・

Analysis Record [ Analysis Report ]

Occur-rence

Out-flow

Find the Cause (Occurrence mechanism, reproduction test, why why analysis)

Occurrence Situation(Symptom, complaint, number of occurrences, treatment) Determine the facts (Part analysis, factor analysis, production quality status )

Appropriate Countermeasure(Detail, estimated effects, PPA)

Feedback to the Source (Reflection on system & mechanism)

Enter the supplier name, a making section name.

-Enter model and type.-Enter occurrence date.-Enter where the problem occurred. (In the market, at Honda)

-Enter the number of occurrences.-Mileage, registration date ,frame no. (if it occurred in the market)-Symptom or claim at the time of trouble occurrence.

-Enter details of corrective action taken for the problem model or parts.Enter the name of consistuting parts (ASSY parts, COMP parts)-The production plant where the nonconforming of products has occurred.

(Supplier name, Facility name)-Enter the production date of when the nonconforming product occurred

*Do not enter "number" of the item*Enter any necessary information if there are any besides the above.

Creator, confirmer and approver sign in the appropriate boxes.

4. Describe countermeasure for already-shipped units.(Parts,Product)5. Enter the necessity of handling parts stock

6.Enter PPA of the countermeasure

Enter the process of finding out causes. (occurrence factors, outflow factors)

Characteristics of problems

Why? Why? (true causes）Why? Why?

Confidential Supplier Quality Manual 4-5-1 Delivery Quality Problem

December 1, 2016



1 Overview

1) Honda shall provide requirements for the handling of delivery quality problem in the case where nonconformity is found in parts delivered from a supplier to Honda or to a delivery destination specified by Honda.

2) The supplier shall, in accordance with requirements prescribed by Honda, define procedures to eliminate nonconforming parts from Honda, and prevent nonconforming parts from being flowed out to the market.

2 Definitions


Terms and Definitions】for other terms.

No. Term Definition

1 Concession

Concession is the act of using raw materials, parts, etc. that do not conform to specified requirements in limited quantities or for a certain time period.

However, those which affect product safety, prevention of environmental pollution, and/or regulatory compliance of products shall be exempt from the scope of concession.

2 Nonconforming

parts Parts that do not conform to drawings (specifications included) or limit samples.

3 Delivery destination Honda (including destinations of service parts and KD parts) or designated suppliers to which supply parts are delivered.

3 Requirements

3.1 The supplier shall, if nonconformity is found and if there is a possibility of the nonconforming parts delivered to a delivery destination, immediately contact the delivery destination with information including the following, and determine actions to take.

If any contact address is unknown, the supplier shall contact to the contact address described in “6-2 Honda Contacts Conversion Table”.

1) Part name and part number

2) Place of delivery

3) Date of delivery and lot number of parts delivered.

4) Details of nonconformity

5) Instructions for delivery destinations to distinguish nonconforming parts

6) Cause of nonconformity

7) Details and timing of countermeasures (delivery of replacement parts included)

8) Identification method for conforming parts after countermeasure taken.

3.2 The supplier shall, if notified that nonconformity or possible nonconformity is found at a delivery destination, consult with the delivery destination and determine actions to take, along with the following.

1) Investigate in-process parts and stock parts for possible nonconformity, and identify the scope of nonconformity.

2) Investigate outflows of nonconforming parts to other locations. If possible outflow is detected, contact the delivery destination concerned and take appropriate actions in accordance with section 3.1.

3) Investigate the cause of nonconformity.

4) Contact delivery destination with information on details and timing of measures to take (delivery of replacement parts included).

5) Identification method for conforming parts to which measures were taken.


December 1, 2016


3.3 The supplier shall, if Rejection Countermeasure Request or HTR is issued by the delivery destination after actions described in section 3.1 and 3.2 are agreed, respond to such

request by the specified date (refer to【SQM 4-5 Corrective Action Report】) .

3.4 Identification and Quarantine of Nonconforming Parts

3.4.1 Nonconforming Parts at Delivery Destination

The supplier shall, when provided by the delivery destination, following instructions on identification and quarantine of nonconforming or possible nonconforming parts at the delivery destination.

3.4.2 Nonconforming Parts before Delivery

The supplier shall, if nonconformity is detected in parts before delivery, identify nonconforming parts by marking, tagging, using different containers, etc., and distinguish them from normal parts.

3.5 Type of Action After Deliberation

3.5.1 Sorting

The supplier shall sort and separate nonconforming parts from delivered parts, if so requested by the delivery destination.

3.5.2 Concession

If the nonconformity does not affect product safety, prevention of environmental pollution, or regulatory compliance, and does not impair the function of Honda products, the supplier may apply for a concession of parts, including ones being repaired in accordance with section 3.4.3.

3.5.2.1 The supplier shall complete “Repair Record [Concession Request]” form found in section 8 with required information, and submit to Honda.

1) Model: name of the model for which a concession is requested.

2) Part number, part name: part number and name subject to concession

3) Quantity: total number of parts subject to concession

4) Scheduled date of delivery: enter the date of scheduled delivery using the western calendar.

5) Nature of nonconformity: details of nonconformity resulted in a concession.

6) Future action: recurrence prevention measures.

7) Diagram: a sketch describing the details of nonconformity.

3.5.2.2 The supplier shall receive “Repair Record [Concession Request]” from Honda and confirm the decision of concession.

3.5.2.3 When delivering concession parts, attach “Repair Record [Concession Request]” received from Honda to the initial delivery lot of parts. Parts accepted by concession shall be identified from conforming products for each release lot.

3.5.3 Repair

The supplier may perform repair and correct nonconformity if so approved by the delivery destination. Where correction is deemed possible, the supplier shall propose repair to the delivery destination. The place for performing repair, for instance at the delivery destination or at the supplier site, shall be included in the proposal.

For parts that are rendered nonconforming as a result of repair, follow concession procedure set forth in section 3.5.2, or they shall be disposed in accordance with section 3.5.4 without repair.

3.5.3.1 The supplier shall, when repairing nonconforming parts recovered from the delivery destination, re-inspect repaired parts. The re-inspection shall be performed by the person responsible for the inspection concerned. Obtain approval of the inspection results from the delivery destination. Attach an IPP tag specified by Honda to the repaired parts if re-delivering to the delivery

destination (refer to 【SQM 4-4 Change Point Control】).

3.5.3.2 The supplier shall obtain approval of the result if repairs of nonconforming parts are performed at the delivery destination.


December 1, 2016


3.5.4 Disposition

The supplier shall identify nonconforming parts to dispose by a mark, tag, container, etc. and separate from conforming parts until the parts are disposed. Honda may possibly dispose the parts concerned.

3.5.5 Actions To Take When Nonconforming Parts Are Used

The supplier shall comply with instructions given by the delivery destination for replace, repair, etc. if it becomes clear that nonconforming parts have been used by the delivery destination.

4 Key point

1) The supplier shall give consideration to sorting operations, such as assigning associates with knowledge of the inspection concerned, to prevent errors in sorting of parts.



1 Repair and re-inspection record 5 years


1) SQM 4-4 Change point control




December 1, 2016


7 Flowchart

Contact

Receiving

Quality

Section

Receiving

Quality

Section

Receiving

Quality

Section

Procurement

Section

Pro

ductio

n S

tage

HondaSupplier

Legend: 　　　　　　For cases when supplier applies for concession.

Discovery of problem parts

Notify delivery destinations

Analyze causes and take measures.

Issue Rejection Countermeasure

Request or HTR (Honda Trouble Report)

Discovery of problem parts.

Preliminary analysis

Investigate if problem parts w ere shipped out to

the destination.

Take measures to the parts

Handling of problem parts

Examine

Reply to Rejection

Countermeasure Request, or HTR

Modify

Judge

Return

Examine

Identify parts to be disposed

Dispose parts

Inspect

Concession

Concession

Judge NG or OK

NG

Put back into manufacturing

process

NG

Put back into manufacturing

process

OK

OK

OK

NG


December 1, 2016


8 Forms

8.1 Repair Record [Concession Request] form

Repair Record [Concession Request] ② Issued : YYYY/MM/DD

Ｓ・Ｍ･Ｃ・Ｙ・Ｋ・Ｔ

Illustration

・C/M

*Attach a separate sheet if unable to fill in here.

・ Condition/Reason

Date: YYYY/MM/DD

・ Manufacturing Instruction No. ・Repair Record [Concession Request] Processing Sequence

95121 Original to be retained until　: YYYY/MM

�

YYYY/MM/DD

YYYY/MM/DD

No

No. of Con. Req.

Applying Department

Planned delivery dateSupplier NameSupplier Code No.

Model Part Number Part Name

Department Manager Person in Charge

ApprovalContents

Functions, Performance (Required / Not Required)

VIN No. Confirmation (Required / Not required)

Prior Confirmation (Required / Not Required)

No

Department

Yes

No

No

Yes

Yes

SP

EC

IAL N

OT

EV

INC

onfir

mat

ion

Machining (Required / Not required)

Assembly (Required / Not required)

Yes

Quality Manager

AP

PLIE

DE №

F №

APPROVAL

Approved Rejected

Signatures of Confirmation-Process Managers

JU

DG

ED

BY

Control Number

Applying

Sec.Applying

Sec.

Q.

Sec.Q.

Sec.Quality

Section

Related

Sec.

・Description of Problem

Final

Inspection

Sec.

Assembly

SecPromo.

Sec.

Applying

Sect.

Supplier

Attach

to

article

(Occurred

In-house)

(Occurred

at

supplier)

Concession

Approval



December 1, 2016


8.2 Repair Record [Concession Request] entry procedure

Repair Record [Concession Request] ② Issued : YYYY/MM/DD

Ｓ・Ｍ･Ｃ・Ｙ・Ｋ・Ｔ

Illustration

・C/M

*Attach a separate sheet if unable to fill in here.

・ Condition/Reason

Date: YYYY/MM/DD

・ Manufacturing Instruction No. ・Repair Record [Concession Request] Processing Sequence

95121 Original to be retained until　: YYYY/MM

Quality Manager

AP

PLIE

DE №

F №

APPROVAL

Approved Rejected

Signatures of Confirmation-Process Managers

JU

DG

ED

BY

�

SP

EC

IAL N

OT

EV

INC

ON

F Machining (Required / Not required)

Assembly (Required / Not required)

Yes

No

No

Yes

Yes

No

Department

Yes

ApprovalContents

Functions, Performance (Required / Not Required)

VIN No. Confirmation (Required / Not required)

Prior Confirmation (Required / Not Required)

Applying Department

Planned delivery dateSupplier NameSupplier Code No.

Model Part Number Part Name

Department Manager Person in Charge

No. of Con. Req.

No

YYYY/MM/DD

YYYY/MM/DD

Control Number

Applying

Sec.Applying

Sec.

Q.

Sec.Q.

Sec.Quality

Section

Related

Sec.

・Description of Problem

Final

Inspection

Sec.

Assembly

SecPromo.

Sec.

Applying

Sect.

Supplier

Attach

to

article

(Occurred

In-House)

(Occurred

at

Supplier)

Circle applicable SS (factory) symbol.

Enter schematic drawing of the

problem, etc.

＊To be completed

by Supplier

Enter model name, part number, and part name applying for the concession.

Enter supplier code no. and supplier name.

Enter the number of

applicable concession parts.

Enter the date based on the western calendar

that concession parts are planned to be

delivered.

Enter description of the problem which is the reason for requesting concession.

Enter preventive measures against recurrence of the concession.

Concession

Approval



March 1, 2018



1 Overview

1) Honda shall, where problem occurs in the market after products are sold, and where the problem is deemed attributable to the supplier from which the concerned parts were purchased, request the supplier to perform analysis of the problem and to take preventive measures against recurrence.

2) The supplier shall analyze market problems required by Honda, and if it is attributable to its own conduct, take measures to prevent the problem from recurring.

2 Definitions



No. Term Definition

1 Call-in part A part that was recovered from a marketed product as a possible problem part and collected from the market by Honda for analysis of causes.

3 Requirements

3.1 Analysis and Measures of Market Quality Problem

3.1.1 The supplier shall, if Honda issues “Market Quality Information [Analysis / Countermeasure Request], analyze the details of the problem in compliance with the request, and take measures if the cause is attributable to its conduct.

3.1.2 The supplier shall respond to Honda by submitting an “Analysis Record [Analysis Report]” with photographs, data, etc. attached by the date specified on “Market Quality Information [Analysis / Countermeasure Request]

(refer to【 SQM 4-5 Corrective Action Report】 for the use of [Analysis /

Countermeasure Request]) .

3.1.3 The supplier shall, if response due date cannot be met, issue an interim report including reasons for the delay.

3.1.4 The supplier shall obtain call-in parts and related information from Honda for improvement of part quality and reliability. The supplier shall be aware of how its parts affect customers of Honda products, and perform analysis of problems in a positive manner.

3.2 Monitoring o of Market Quality Information

3.2.1 The supplier shall review, monitor, and analyze market quality information via electronic data distributed by Honda, and continuously seek to reduce market quality problems.

3.2.2 The supplier may request Honda for additional call-in parts, if the need for further investigation arises from a result of its own autonomous analysis on market quality information. However, Honda may confer with the supplier for reimbursement of transportation costs, etc. incurred due to recovery of the parts.

3.2.3 The supplier shall report the results of investigation, analysis, etc. to Honda’, if received call-in parts from Honda.

3.2.4 The supplier shall define procedures for control and storage of recovered parts and related information provided by Honda, and store them properly. The recovered parts shall be disposed of by a method provided by and agreed with a providing section of Honda after completion of investigation and analysis (after reporting to Honda) or after conclusion of agreements on warranty claim.



March 1, 2018


4 Key point

1) When identifying the subject parts at the time of nonconformity occurrence, all manufacturing lots including ones shipped to overseas facilities shall be included in the scope.



1 Supporting data to Analysis Record [Analysis Report] 20 years




7 Flowchart

7.1 Flowchart for treating market quality information.

Contact

Ma

ss P

rod

uctio

n S

tag

e

HondaSupplier

Market

Quality

Section

Market

Quality

Section

Market

Quality

Section

Monitor and analyze market

quality informationObtain market quality

information and actual parts

Primary analysis

Report results

Collection

Obtain market quality

information and actual parts

Request supplier to provide

analysis and contermeasure

　Analysis, C/M and reccurence

prevention.

　・Verify accuracy of parts

・Verify processes.

・reproduction test

　・countermeasure

　・Recurrence prevention, etc.

Verify results

Market Quality

Information

[Analysis/Countermeasur

e Request]

Analysis Record

[Analysis Report]

Request collection of

problem parts.



March 1, 2018


7.2 Flowchart for scope identification when nonconformity occurs.

ContactSupplier Honda

Ma

ss P

rod

uctio

n S

tag

e

Market

Quality

Section

Market

Quality

Section

Market

Quality

Section

Verify production history

・check shipping records

・examine change points, etc.

in the manufacturing process.

・determine production volume

・investigate sub-suppliers, etc.

Information

�・problem description

・part name

・part number

・vehicle identification

number

・date of production

Identify the scope

　Identify the scope of the problem

※including those that were shipped

out to other Honda facilities overseas.

　Notify the scope and destination of

problem parts.

Take

countermeasure



March 1, 2018



1 Overview

1) Honda shall provide requirements to ensure a smooth implementation of the specification change issued by Honda to suppliers.

2) The supplier shall establish procedures to process specification changes to parts in accordance with the requirements of Honda.

2 Definitions



No Term Definition

1 Specification

change

A change to the entry in the field for notating changes to component parts in the product drawing or specification change notice.

3 Requirements

3.1 The supplier shall respond to Honda by the date specified, if Honda requests a survey for specification change by issuing a specification change questionnaire or by other means.

3.2 The supplier shall implement the following when Honda issues a specification change notice.

3.2.1 Review concerned drawings (specifications, etc. included) by using electronic data processing system or other methods. The drawings (specifications, etc. included), may be provided along with the specification change notice.

3.2.2 The supplier shall, when received a specification change notice, review details of the change, examine the following items, and respond to Honda by the date specified.

1) Application timing

2) Compensation for tooling

3) Compensation for parts

4) Changes in cost

5) Remarks and others

3.2.3 If prior confirmation is required in the specification change instruction, follow the

procedure set forth in【SQM 4-4 Change Point Control】for the confirmation.

3.2.4 If the need arises to change Process FMEA, process quality control table, operation standard, etc. along with the specification change, implement such changes.

3.2.5 Comply with 【SQM 4-4 Change Point Control】for IPP control as a result of

specification change.

3.2.6 If the need arises to change the application timing stated in specification change notice, immediately inform Honda of new timing of application.

4 Key point

1) The order of specification change shall be controlled by the order in which the changes were applied. The supplier shall verify the revision level when using drawings.



1 Initial Product Control [Initial

Production Part] 20 years

2 Inspection data attached to IPP 20 years



March 1, 2018





7 Flowchart to be followed when a specification change is directed by Honda.

Contact

Procurement

Section

Procurement

Section

Procurement

Section

Procurement

Section

Ma

ss P

rod

uctio

n S

tag

e

HondaSupplier

Return by the date

specified

Return within 5

business days.

When application timing

notified was changed

See 【SQM 4-4 Change Point Control】

Investigate

Verify drawings, etc.

Issue Specification

Change Questionnaire

Issue Specification

Change Notice

Receive

Apply specification

change

Control change points

(IPP control)

Receive

Fill in the

questionnaire

Revise process quality

control table, operation

standard, etc.

Complete

Specification Change

Notice

Confidential Supplier Quality Manual 4-6-1 Countermeasure Request Form

March 1, 2018



1 Overview

1) Honda shall provide suppliers with procedure for requesting a specification change.

2) The supplier shall request Honda for a specification change while identifying the need for specification change.

2 Definitions



No Term Definition

1 Countermeasure

request

An action to be taken by a supplier to request Honda for a change to the drawings (specifications, etc., included) by using “Countermeasure Request [Countermeasure Request Form]”.

3 Requirements

3.1 The supplier shall make a countermeasure request to Honda for a specification change of parts by submitting a “Countermeasure Request [Countermeasure Request Form] “set forth in section 6

The supplier shall review the following items before making a countermeasure request and clearly define the need for the specification change by providing the related data attached.

1) Purpose of the countermeasure request (e.g. quality improvement, workability improvement, cost reduction, etc.)

2) Evidence for the validity of the countermeasure request (e.g. prove that the root cause of a problem is attributable to the specification).

3) History of previous countermeasure requests of the same kind (e.g. if a duplicate request exists, investigate the reason for the request not being processed).

4) Effectiveness of a countermeasure request (e.g. if a specification change is effective to solve problem and if the change will not cause secondary problems).

5) Cost performance (e.g. if the benefits will justify increased costs for parts)

3.2 The supplier shall submit “Countermeasure Request [Countermeasure Request Form] “to Honda’s purchasing-cost or procurement section.

Countermeasure requests shall be submitted prior to establishing permanent tooling at the production preparation stage, however, in cases where one of the following conditions applies, submission of a countermeasure request on a case-by-case basis will be accepted.

1) Countermeasure request for regulatory or safety noncompliance issues.

2) Countermeasure request which may result in an increase in production capability, a significant increase in workability or quality, or a significant reduction in costs, etc.

3) Countermeasure request which is not for current parts, but is expected to apply in the future.

3.3 The supplier shall receive a decision from Honda for the proposed”Countermeasure Request [Countermeasure Request Form] “.



1 Countermeasure Request

[Countermeasure Request Form] 20 years

2 Supporting data to Countermeasure

Request [Countermeasure Request Form] 20 years




March 1, 2018


6 Forms

6.1 Countermeasure Request Form (blank)

試作・量産 □立上発行DATE：

START UP 推進No．

PROTOTYPE ・ MASSPRODUCTIONCTRL．No．

申請区（REQUEST DEPT．）ＴＥＬＮo．：購買 CP．資材 PUR 品管 QCD 認証 CERTF Ｅ部門 SS 設計 DES．Ｄ部門 HG

DATE：・・・・・・・・・・・・・・

責任者責任者担当者責任者責任者責任者責任者最終責任者責任者最終責任者

RESP． RESP． CHARGE RESP． RESP． RESP． RESP． FINAL RESP. RESP． FINAL RESP.

機種：イベント：カテゴリー：部品名：MODEL： EVENT： CATEGORY： P NAME：

標題：部番：TITLE： DWG No.：

目的： CODE 原因： CODE 仕向地：通知 No.：PURPOSE： No.： CAUSE： No.： VARIATION： REVIS No.：

内容

DESCRIPTION

対策案項目ＯＬＤＮＥＷ差 DIFF.

PROPOSED COUNTERMEASURE COST変動（円）

COST DIEF．(＄/￡）

WT　変動　（g）

WT　DIEF.　(g)

新規追加投資

INVESTMENT

［千/＄/￡］

損失［千/＄/￡］

(型修正､廃却）

LOS　(DIE　REP．)

管理費 OVERHEAD

　　［千/＄/￡］

型改修日程確　認

DIE　MODIFICATION CHECK

SCHEDULE

品管部門 QCD．（課） SECT.

SPR

HS

関連部門 RELATED DEP. （課） SECT. 認証部門 CERTIFICATION DEPT.

回答部門記入欄 COLUMN OF REPLYING DEPT.

部門名担当予定日：

DEPT. CHARGE EXPECT DATE：

通知 No.：REVIS No：

�

・・

－－

・・

Ａ・Ｂ・Ｃ

重要度 PRIORITY

・・

対策要求[対策要求票] COUNTERMEASURE REQUEST FORM

－－

／

OK NG 返却RETURN

保留HOLD


March 1, 2018


6.2 Countermeasure request form (entry procedure 1/7)

試作・量産 □立上発行DATE：

START UP 推進No．

PROTOTYPE ・ MASSPRODUCTIONCTRL．No．

申請区（REQUEST DEPT．）ＴＥＬＮo．：購買 CP．資材 PUR 品管 QCD 認証 CERTF Ｅ部門 SS 設計 DES．Ｄ部門 HG

DATE：・・・・・・・・・・・・・・

責任者責任者担当者責任者責任者責任者責任者最終責任者責任者最終責任者

RESP． RESP． CHARGE RESP． RESP． RESP． RESP． FINAL RESP. RESP． FINAL RESP.

機種：イベント：カテゴリー：部品名：MODEL： EVENT： CATEGORY： P NAME：

標題：部番：TITLE： DWG No.：

目的： CODE 原因： CODE 仕向地：通知 No.：PURPOSE： No.： CAUSE： No.： VARIATION： REVIS No.：

内容

DESCRIPTION

対策案項目ＯＬＤＮＥＷ差 DIFF.

PROPOSED COUNTERMEASURE COST変動（円）

COST DIEF．(＄/￡）

WT　変動　（g）

WT　DIEF.　(g)

新規追加投資

INVESTMENT

［千/＄/￡］

損失［千/＄/￡］

(型修正､廃却）

LOS　(DIE　REP．)

管理費 OVERHEAD

　　［千/＄/￡］

型改修日程確　認

DIE　MODIFICATION CHECK

SCHEDULE

品管部門 QCD．（課） SECT.

SPR

HS

関連部門 RELATED DEP. （課） SECT. 認証部門 CERTIFICATION DEPT.

回答部門記入欄 COLUMN OF REPLYING DEPT.

部門名担当予定日：

DEPT. CHARGE EXPECT DATE：

通知 No.：REVIS No：

94041�

・・

－－

・・

Ａ・Ｂ・Ｃ

重要度 PRIORITY

・・

対策要求[対策要求票] COUNTERMEASURE REQUEST FORM

－－

／

OK NG 返却RETURN

保留HOLD

⑤

⑨-a ⑩-a ⑪-a

⑫ ⑬ ⑭ ⑮

⑯

⑰

⑱-a

⑥-b ⑥-c

⑥-d ⑥-e

⑨-b

⑩-b

⑪-b

⑱-b

⑱-c

⑱-d

⑱-e

⑱-f

⑥-a


March 1, 2018


Countermeasure request form (entry procedure 2/7)

6.2.1 Issuing of Countermeasure Request Form

6.2.1.1 Submit one page for one case

In cases where there are numerous part numbers (parts and models, etc.), a list may be attached on a separate sheet.

6.2.1.2 Requirements for Issuing Countermeasure Request Form

Note1) If entry is unnecessary, or the subject is non-applicable, write a forward slash in the entry field.

Note2）The ‘’P S M’’ in the ‘’entered by’’ column indicate that entry is

necessary in the P, S, and M periods respectively. (prototype, start-up, mass

production) Note3) When applying from an electronic processing system, etc., the standard's content will be changed to match the format.

NO Item Description

①～④ For Honda use only (no number is provided in entry procedure 1/6).

⑤ Page Enter the total number of pages as the denominator.

⑥ Request department

⑥-a Request dept: enter the company name, plant name and section name.

⑥-b Phone number: enter the phone number.

⑥-c Date: Enter the date (month, date, and year) on which the responsible person signed.

⑩-Enter other dates in the same manner.

Ref) date (Arabic numerals), month (English) and year ( last 2 digits of the year in the western calendar)

⑥-d Responsible person (left): if not applicable, cross out with a diagonal line.

Responsible person (center): enter the name of the person responsible for the entry of data into this form.

⑥-e Person prepared (right) : person who prepared this form.

⑦、⑧ For Honda use only (no number is provided in entry procedure 1/6).


March 1, 2018


Countermeasure request form (Entry procedure 3/7)

NO Item Description

⑨ Model ⑨-a Enter the code of a model subject to countermeasure (code).

Enter the part type number provided in the “DWG No.” section (part number or drawing number) in the drawing title block.

In cases where multiple model names do not fit in the entry section, enter the information in the description column or attach on a separate sheet.

Drawing title block

Enter the part number provided in the DWG No. in the drawing title block or part category number of the drawing number.

Title ⑨-b Explain details of the request briefly with part name, expected outcomes (target),etc. (example: heat resistance of XX, interference prevention for XX, etc.)

⑩ Event ⑩-a Enter the event if there is one that resulted in a request and it is necessary to specify.

However, if the event is unknown or the necessity of entry is not certain, consult Honda before making an entry. If the entry of event is needed, cross out this section with a diagonal line.

Category ⑩-b Enter the category of subject parts. Consult Honda if information to be included in this section is unknown before making an entry.

E.g.: B-F21

1 2 3 4 5

－

6 7 8 9

－

主 No

Main No. 部品類別 No Part category.

種別 No.

Type No. 試作記号

Prototype code

10 11 12 14

15

－

補足 No. Supplemental No

※Check the

DWG.No section in the drawing title block (in the boxed area)

(Example)


March 1, 2018



NO Item Description

⑪ Part Name ⑪-a Enter the name of the subject parts.

Enter the information provided in the NAME section (part name or drawing name) in the drawing title block.

Drawing title field

Enter the part name or drawing name in the latest drawing in full.

Part Number or Drawing Number

⑪-b Enter the number of the subject part or drawing.

If applicable, enter the information provided in the DWG.No. section (part number or drawing number) in the drawing title block.

Drawing title block

※ Enter part name or drawing name in the latest drawing in full.

※Do not enter the prototype part number during mass production

countermeasure requests or the facility preparation part number.

※If a countermeasure request is made for multiple parts, all part

numbers or drawing numbers of own production that may be affected are included in the part number section or in a separate sheet.

※If more than two countermeasure requests are made for a part,

prepare a countermeasure request form for each case.

※Check the

NAME section in the drawing title block (in the boxed area).

※Check the

NAME section in the drawing title block (in the boxed area).

(Example)

(Example)


March 1, 2018



NO Item Description

⑫ Code No. Enter the applicable purpose code number (refer to the following table).

No. Purpose of CM Request

1 Quality (except no. 2 through no. 5). 2 Improve durab lity (strength, weather resistance, heat

resistance, low-temperature res stance) 3 Eliminate interference and secure clearance (except wiring

or piping). 4 Improve wiring and piping. 5 Improve anticorrosive quality. 6 Improve marketable value ( except no.7) 7 Reduce vibration and noise, and improve steering stability

and ride quality. 8 Improve maintainability. 9 Increase productivity (process ability, workability) 10 Facilitate common use and consolidation. 11 Carry out VA and reduce cost. 12 Maker/supplier layout. 13 Facilitate procurement. 14 Simplify parts control. 15 Comply with criteria, standards, or regulations. 16 Response to patent issues. 17 Correct errors in bill of material and drawing, and put them

(except 18) in order. 18 Rationalize drawing formation. 19 Release finished drawing. 20 Address problem for in-use vehicle.

21 Meet special procurement demand. 22 Add specification (including knock-down parts). 23 Others (no responsible section).

“Purpose code list” for motorcycle and power equipment.

No. Purpose of request

1 Improve merchantability/marketable value (appearance value, reliability, workability/operatability, comfortableness, function)

2 Improve productivity (yield rate, formability, process ability, machining accuracy, heat treatment, surface treatment)

3 Improve operatability ( workability, assemleability, control)

4 Facilitate procurement (change of M/L, sourcing or manufacturing method)

5 VA, cost reduction (consolidation, common use and lightening of parts)

6 Improve servicing (maintainability, service parts).

7 Enhance adaptability to society (compliance with laws and regulations, standards, and criteria, environmental preservation)

8 Response to patent issues.

9 Release drawings (issue of finished drawing/reference drawing/ correction of clerical error, error in BOM).

10 Others,


March 1, 2018



NO Item Description

⑬ CODE No.

Cause code no.

Enter the cause code that is most appropriate (refer to the following table).

No. Reasons for Countermeasure Request

1 Release of drawings for remaining items. 2 Error on drawing.

3 Error in bill of material. 4 Imperfect design (layout, interference, requirement) 5 Insufficient adjustment by test . 6 Poor communication among HG sections concerned.

7 Improvement of assemble-ability and process-ability that are verifiable only in the mass production line (request from production line, manufacturer, etc.).

8 Insufficient study by plant, EG or manufacturer. (insufficient adjustment among sections in charge of actual operation).

9 Unexpected external factor. (Influence of other companies, top management direction, specification change request from sales section.

10 Event. (VA, lightweight contest, electrodeposition verification, wiring verification, maintainability verification, noise verification, etc.)

11 Market quality information, etc. 12 Others.

⑭ Variation Cross out with a diagonal line.

⑮ Revis. no. Enter the final notice number of the part (base part) subject to countermeasure request.

If applicable, enter the part type number provided in the “DWG No.” section (part number or drawing number) in the drawing title block.

Drawing title block

Enter the final notice number of the revision record.

⑯ Description Describe the phenomenon (request contents) clearly and concisely.

Where possible, illustrate the phenomenon.

If data, etc., are available, attach them (detailed as much as possible).

※ Suppliers to describe Honda locations to which they deliver parts

(including overseas), because parts subject to countermeasure may be used in multiple Honda products as part of parts.

※Check the NAME

section in the drawing title block (in the boxed area).

(Example)


March 1, 2018



NO Item Description

⑰ Proposed C/M

Describe proposed countermeasure against phenomenon clearly and concisely. Where possible, illustrate the phenomenon. If data, etc., are available, attach them (detailed as much as possible). Regarding countermeasures, when it is necessary to coordinate verification with the related Honda sections, a prior request is necessary. Also, when coordination with related HG occurs, the HG representative‘s full name and HG to which he/she belongs is filled in.

⑱ Effects of C/M

Calculates the amount if the countermeasure is applied and enters the amount. OLD: cost before countermeasure. New: cost after countermeasure. Diff: difference between OLD and NEW.

⑱-a Cost difference-calculate the cost incurred by the requesting section.

⑱-b WT difference – the requesting section calculates the difference in weight.

⑱-c New investment – calculate the cost needed by the requesting section.

⑱-d Loss – calculate the cost incurred in die modification, disposition, etc. due to countermeasure.

⑱-e For Honda use only ( no entry required)

⑱-f Die modification schedule – enter schedule of die modification.

Check For Honda use only (no entry required).

Note: cross out fields that will not be affected and no entries to be made with a diagonal line.

Confidential Supplier Quality Manual 5-1 Process Capability

October 1, 2008


5 Reference


1 Overview

This manual is to provide basic concepts and points to consider for evaluating process capability to prove that a manufacturing process has the ability to consistently achieve intended quality levels, and for taking actions to the outcome of such evaluation.

2 Definitions



No. Term Definition

1 Process capability

The ability to achieve quality requirements of a process in a controlled state.

2 Process capability

Index

A quantified measure of process capability, and “a value calculated by dividing the specification range by 6σ for a certain characteristic”

”Process in a controlled state” in the definition above for process capability means that the characteristic value is normally distributed, and this forms the basis of the process capability index.

3 Standard deviation

One of the numeric values which correspond to the distribution of statistical values and random variables, and expressed by σ.

6 σ represents the value of σ (standard deviation) multiplied by six times.

4 50 %

Tolerance limit band

Setting up of inspection standard tolerance at 50 percent of the tolerance specified on drawings.

3 Requirements

3.1 Concept of Process Capability

Process capability is the ability of a stable process to achieve the required quality, and which is expressed by X±3σ representing the distribution range of dispersion of product quality produced by a standardized process.

σ² =

σ：Standard deviation

n：Number of data

Xi：Individual data

：Mean value of individual data

6σ

σ

－ X

Fig.1: Illustration of process capability

－ Σ（Ｘｉ－Ｘ）²

ｎ－１

－ X


October 1, 2008


3.2 Process Capability Index.

Process capability index is expresses as Cp (an index used when the center (= average) of the distribution of data plotted at the median between the upper and lower limits) or Cpk (used when the mean is displaced from the center between the upper and lower limits).

The “k” in Cpk stands for “Katarori” in Japanese language for shift or offset.

3.2.1 Process Capability Index (Cp)

Compare the deviation range 6σwith the product specification range and determine

the ability of a process to manufacture products meeting required specifications.

Cp＝ specification range / 6σ (if a single specification limit, Cp＝｜specification limit

－ mean｜/3σ).

1) If Cp ≧ 1.00, the process capability is not considered adequate, however

almost no nonconforming products will be produced.

(99.7% or more products are within the specification range): perform a thorough process control and maintain it in a controlled state). if Cp becomes close to 1, there will be a possibility that nonconforming products will occur, so take appropriate actions as necessary.

2) If Cp ≧ 1.33, the process capability is considered adequate.

(99.99 % or more products are within the specification range): this is an ideal state so maintain.

3.2.2 Process Capability Index (Cpk)

Even if Cp ≧ 1, nonconformity can occur if the mean value is displaced from the

center of the specification limits. Use Cpk process capability index for judgment, which takes deviation into consideration.

Take appropriate action for the mean value to be the center of the specification limits if the mean is shifted from the center.


October 1, 2008


3.3 Calculation of Process Capability Index

The followings are examples of calculation of process capability.

Classification Relationship bet/ distribution

and specification limits Formula Calculation Example

Bo

th-s

ided

sp

ecific

ation

lim

its

Cp

Cpk

Sin

gle

-sid

ed

spe

cific

atio

n lim

its

Upper limit (SU)

Lower limit (SL)

〔e.g.〕Mean: ｘ＝50 Standard deviation: σ＝1-48

Upper limit: SU=52 Lower limit : SL＝49

〔note〕K : degree of katayori or deviation I I: absolute value

Formula for K

S

SU

σ

SL SU

σ

K

－ X

Median of the specification

SU－SL

6σ Cp =

52－49

6×0.48 Cp =

3

2.88 = = 1.04

(SU＋SL） / 2－x K =

(SU－SL） / 2

－

SU－SL Cpk = (1-K)

6σ

When K ≧ 1, Cpk=0.

(52＋49）/ 2－50 K =

(52－49） / 2

K = 0.3333

52－49 Cpk = (1-0.3333）

6×0.48

Cpk = 0.69

SU

σ

－ X

SL

σ

－ X

－ x－SL

3σ Cp =

When x ≦ SL, Cp=0.

－

SU－x

3σ

－

Cp =

When x ≧ SU, Cp=0. －

52－50

3×0.48 Cp =

Cp = 1.39

50－49

3×0.48 Cp =

Cp = 0.69

－

SL SU

－ X Median

Low

er

limit

Upper

limit

a

b

K = ( median － mean)

(range of the upper and lower specification limits/2)

= (SU＋SL） / 2－x

(SU－SL） / 2

－

When K ＞ 1, X is outside the upper or lower

limit.

When the median value equals to X, K = 0.

－

－


October 1, 2008


【Bad example of the mean】

【Bad example of distribution】

If Cpk＝NG, even if Cp＝OK,

nonconformity my not be contained and dispatched to the market.

SL SU － X

shift

Median of specification

L

ow

er

limit

Upp

er

limit

Although distribution range is

within product specification

limits, the mean value is

shifted and a deviation is

generated.

The degree of deviation is

large and nonconformity may

possibly occur.

SL SU － X

3σ

Low

er

limit

Upp

er

limit

Although the mean is in the center of the product specification limits, the distribution range is largely exceeding the upper and lower limits.

Nonconformity is very likely

to occur.



October 1, 2008


3.4 Process Capability Judgment and Measures

Following examples demonstrate the determination process capabilities by the process capability based on the process capability index and subsequent responses.

Relationship bet. distribution & specifications

Cpk Judgment Measures Estimated percent

defective

Cpk ≧ 1.67

Process capability is more than sufficient.

Inspection method:

100 % inspection or sampling inspection.

Slight increase in product dispersion is of no concern

Consider simplification of control, reduction of costs, etc.

0.06/ 100000 units or

less

1.67 ＞ Cpk

≧ 1.33

Process capability is sufficient.

Inspection method:

100% inspection or sampling inspection.

This is the ideal state, so it is maintained.

0.06

/100000

to

6.3

/100000 units

1.33 ＞ Cpk

≧ 1.00

Process capability is not sufficient.

Inspection method:

Sampling tests are completed and no nonconformity is found, or a procedure is employed to take retroactive action for the possible nonconforming product lot before dispatching from the supplier.

Process improvement is required until a Cpk of 1.33 is achieved.

Maintain the process in a controlled state.

6.3

/100000

to

2.6

/1000 units

1.00 ＞ Cpk

≧ 0.67

Process capability is insufficient.

Inspection method:

determine whether or not the lack of process capability is due to a displacement of the median or dispersion. Investigate and take measures.

2.6/ 1,000

to

45.6/ 1000

units

SL SU

－ X

σ

SL SU

－ X

σ

SL SU

－ X

σ

SL SU

－ X

σ



October 1, 2008


3.5 Key Points for process capability

3.5.1 Correct sampling: points to estimate the characteristics of the general population are as follows.

1) Random sampling = do not use data collected only under the same conditions.

2) Measurement accuracy= calculate to one more decimal place than the specification value.

3) Avoidance of factors causing problems = obtain data from the condition in which problem factors do not exist.

4) Clarify the definition of the lot and comprehend lot-to-lot dispersion. Check at least 3 lots and determine the acceptance by increasing n.

3.5.2 Interpretation and Judgment of Data

3.5.2.1 Confirm data distribution and its shape (on a normal distribution)

If multiple tooling are used, verify data for each die or mold. For fabrication method previously employed, comparison with actual performance may also be effective to check the degree of dispersion and median.

If it is not a normal distribution, change variables.

3.5.2.2 Check dispersion from the median with Cpk.

3.5.2.3 Use sufficient quantity of n. If n is small, it is important to take into account that the reliability of data may be reduced when making the judgment (increase or adjust the number of n, if it is very close to 1.33).

3.5.3 Condition Setting with Allowance

When determining process capability based on data analysis, judgment shall be made taking into consideration the preceding sections 3.5.2.1 and 3.5.2.2. Where conditions affecting results are under control, it can be said that a process has an acceptable process capability if manufacturing output is confirmed to be within the specification range even if conditions are slightly deviate from the upper and lower limits.

Condition setting with appropriate allowance backed by data is important.

case d

epth

, carb

uri

zed d

epth

, ri

vet

dia

mete

r

Current value, temperature, time, application quantity

Failure mode Failure mode

Control range

Control range

Control item

Man

ufa

ctu

rin

g

co

nd

itio

n



October 1, 2008


3.6 Evaluation at the Production Preparation Stage

3.6.1 Concept of 50 Percent Tolerance Band

At pre-production stage in which n is limited, in order to assure process capability during mass production by such small size of n, the population shall be aimed to come closer to the center of the specification limits.

If deviations close to the upper and/or lower limit are found in the evaluation of measurements with such small n, it is more likely for deviations to go beyond the specification at mass production stage. In such cases, die/mold change, etc. will become necessary during mass production.

When ensuring initial quality as part of production preparation activities, evaluate dispersion in the specification range set at 50 percent of the specification limits shown on drawings.

3.6.2 Judgment Criteria

All measured values shall be within one half of the tolerance given on the drawing.

This may not be mandatory if it is proved that the specifications will be satisfied for mass production.

Note: the requirements above are in effect for pre-production stage where n is insufficient. In mass production stage, process capability shall be evaluated with Cpk based on n of sufficient size, and necessary improvement actions shall be taken accordingly.

It is intended for the mean to be closer to the center of specification limits in the early stage of production. Reduction of tolerance itself shall not be the purpose of employing the 50 percent tolerance band. As long as the original drawing tolerance is met, products beyond the 50 percent tolerance shall be considered conforming.

3.6.3 Measures Against Out-Of-Specification

3.6.3.1 When employing judgment criteria set forth in the preceding section 3.6.2 and if deviations out of the tolerance range (50 percent of tolerance on drawing) are found, continue on measuring in mass production, and determine the process capability(Cpk) based on data with n=100 or more.

3.6.3.2 Criteria for judging process capability using data size n=100 or more and subsequent measures shall be in accordance with section 3.4.



1 Records of process capability study 5 years after study



50% Tolerance Band Tolerance on the drawing

Mean

Evaluation range

It may deviate from specifications at mass production stage.

50% of tolerance specified on

drawing

50% of tolerance specified on

drawing

●

●

●

●

●

●

●

●

●

●



October 1, 2008


6 Operation flow

Process is in a controlled state

Note ： quality is built

into a product through

a process.

Process can achieve

optimum performance

only under a controlled

state.

Process is not in a

controlled state

Requirements

not met

Requirements metContinue to strive for

minimizing variations

in manufacturing

Determine product specifications

(drawings, specifications included )

Clarify important quality characteristics of parts.

Set process parameters for part characteristics to control.

Make the process to be in a controlled state.

Calculate Cpk

Supplier

judgment

Perform corrective

adjustments to stabilize

process

Determine the frequency of part inspection during mass production (100 %

inspection or sampling inspection to be carried our depending on the calculated

Cpk). During mass production, maintain consistent process capability (Cpk)

(record requirements in the process quality control table)

Supplier

judgment

Deliver parts to Honda

Perform corrective

adjustments of process


5-2 Error Proofing

October 1, 2008


5-2 Error Proofing

1 Overview

This manual is to provide points to consider when employing error proofing methods to detect abnormalities in manufacturing and inspection processes and to prevent outflow of nonconformity.

2 Definitions



No. Term Definition

1 Error

proofing A system of products or manufacturing processes that prevents nonconforming products from being manufactured.

3 Requirements

3.1 Concept of Error Proofing

Basic concepts of error proofing are as follows.

3.1.1 Prevention: an action to focus on processes in which operational errors causing accidents or quality troubles occur, and take action to prevent such errors from occurring.

Three tips are show below for prevention of operation errors.

1) Eliminate factors causing additional work or constraining operations, and render such work or caution unnecessary.

2) Replace manual operations with other more assured methods (i.e. employ machines and/or equipment).

3) Design operations to be easy for operators to perform.

3.1.2 Mitigation of errors: focus attention on diffusion process of error effects, and take action to contain nonconformity resulted from errors.

Two tips are provided below, which are to avoid spillover effects of operation errors.

1) Employ measures to preclude subsequent processes from proceeding operations until the cause of error is removed or corrected.

2) In order to minimize effects to products when operation error occurs, provide shock-absorbing dunnage, protectors, etc., or arrange operation sequences into parallel.

3.2 Scope of Error Proofing

The scope of error proofing shall include the following processes or operations. Request a specification change where employing error proofing safeguards into product specifications for misassembly or reverse assembly of parts.

If product specification is subject to error proofing, request a specification change.

3.2.1 Process or operation to which occurrence or outflow of a market quality problem is attributed.

3.2.2 Process or operation which is deemed necessary with consideration of the

following items along with the result of a process FMEA (refer to 【SQM 5-5 Process

FMEA】) conducted by the supplier.

1) Possibility of occurrence: frequency of occurrence per error mode

2) Degree of criticalness: degree of severity per error mode

3) Degree of spreading prevention: degree of detection per error mode

4) Process or operation for which application of error proofing is directed by Honda.


5-2 Error Proofing

October 1, 2008


3.3 Type and Method of Error Proofing

After determining the scope of error proofing application, in accordance with section 3.1” Concept of Error Proofing”, examine error proofing methods suitable to the process or operation concerned.

Concrete examples of error proofing are as follows.

1) If operation error occurs, parts will not be mounted on jigs.

2) Machine will not start if an operation error or a problem with parts exists.

3) Correct dispersion in operations or equipment automatically, while proceeding with work.

4) Subsequent process verifies operation results of a preceding process and detect problems.

5) Identify parts, jigs, etc., by color, size and shape to distinguish.

6) Automate work operations.

7) Take measures against parts fall including shock absorption when dropped.

3.4 Verification of Error Proofing

Prior to applying error proofing to a process or operation, confirm the following functions, etc. and verify effectiveness of the error proofing.

1) Capability of detecting operation errors, problems with parts, etc.

2) Detection capability of difference in parts location and/or arrangement.

3) Functions to prevent easy change and unwanted operation of the equipment.

4) Possibility of the error proofing function to damage parts.

3.5 Effectiveness Evaluation

If error proofing is applied to a process or operation, assess the effectiveness of the error proofing on a regular basis.

The assessment shall be made based on information and data obtained from results of error proofing techniques as in the following examples.

1) Ratio of problem products detected.

2) Quantity and details of problem products that were not detected and flowed out into subsequent process.

3) Operating ratio and failure ratio of error proofing.

4) Increase or decrease in costs, labor, etc. for error proofing.

3.6 Feedback from Error Proofing

Following information with regard to problems detected by error proofing shall be provided to the responsible party and shall be utilized for problem containment and root cause elimination.

1) Problem parts detected by error proofing.

2) Quantity and details of detected problem products.

3) Corrective action taken against the problem detected.

4) Specification change request (countermeasure request form, etc.)





5-3 Control Chart March 1, 2018


5-3 Control Chart

1 Overview

This manual is to explain the concept of control chart and provide entry method to record data into the chart. Control chart shall be used to continually improve the quality of products and the effectiveness of quality management systems.

2 Definitions



No. Term Definition

1 Variable

(continuous data)

Data obtained by measurement. Unit of measure can be made precise depending on the measuring device.

2 Discrete

value Data obtained by counting and it cannot be divided into units smaller than one.

3 Group

Group or grouping is the act of collection of data into units. In general, a group is a set of data collected through random sampling per unit such as day, shit or batch, etc.

* batch: a set of material (conditions) processed in a single production process.

3 Requirements

Concept of Control Chart：

Manufacturing process fluctuates and is affected by various factors. A control chart is a visual technique used to visualize the control state of a manufacturing process, where data shows temporal changes in certain quality characteristic. It is assumed that a considerable error exists when control chart shows deviations of characteristics from a predetermined control limit value.

3.1 Control Chart

Control chart is a chart (line chart with control limits identified) used to investigate (process analysis) or monitor (process control) stability of a manufacturing process that determines with quality characteristics.

Control chart shall be used not to discover nonconformities but to prevent problems from occurring. (This is on the basis that specification limits are outside the control limits.)

3.2 Types and Choices of Control Charts

There are various types of control charts, while all are fundamentally similar.

Appropriate chart shall be selected for each purpose based on the subject matter of control.

Selection of control chart depends on the type of data used, i.e. continuous or discrete data.




Type of data Type and outline of control charts

Variable (continuous data)

Length

Weight

Time

A representative control chart for continuous data

process control and it displays the maximum and

minimum difference values (R) between the mean

and the data. Usually analysis is done using a set of

control charts as pair of which one is for control of

data distribution and the other is for control of

deviations. This is the most widely used control chart.

Strength Constituent

Yield

An alternative to the X bar and R chart and used to

control processes from which measurement data will

be obtained. A control chart using X (median: the

central value in a distribution) rather than X bar and

displays middle value (X) and range (R). The median

of a set of data arranged in order of increasing or

decreasing magnitude is expressed by X.

Purity

Filled content,

etc.

X chart

The X control chart is a control chart which plots a set

of data points for each calculated value. It allows

immediate plotting of dada where grouping of data is

not practical or where data is obtained one by one

over a certain period of time due to batch production.

This X chart has the characteristics that it does not

cause a delay in time from the point of obtaining data

to judgment and response to process conditions.

Discrete value

Percent defective p chart

The p chart is used to calculate the mean percent

defective in a certain period of time. The percent

defective awakens operators or management

personnel to the changes in the rate.

Number of

defects np chart

The np chart is used when the number of defects in

the sample is expressed by np and when n, which is

used to express the number of products generally

contained in the sample, is a fixed number.

The np-chart is a control chart used to study mainly

the problem rate and number of defects as the p

chart.

Number of

problems c chart

A control chart which is used where sample size of

data (area, length, etc.) is fixed to control processes

by using values from the discrete data such as the

number of problems, problem points, accidents, and

repair, etc.

Number of

problems per unit u chart

A control chart which is used to control processes by

using data from the discrete data as with the c chart.

The U chart is used where the sample size of data is

not fixed.

＿

X – R chart

(X bar R

chart)

～

～

～

(X median

R chart)

～ X – R chart




3.3 Representative Control Charts

3.3.1

is mainly used to monitor changes in mean values (between-group variation: dispersion between groups), and R- charts is to monitor changes in the dispersion of values (within-group variation: dispersion within a group). X-chart and R-chart are frequently used in combination.

3.3.2 Preparation of

3.3.2.1 Collection of Data

Collect as much data as possible about the characteristics which provide important information of the process. Ensure that collected data is comparatively new, is applicable to the process in the future, and have a clear record.

3.3.2.2 Grouping

Group data based on data history, and sort by lot sequence and sampling measurement sequence etc.. The number of data in one group (the sample size) is generally expressed by n, and the number of groups, by k.

3.3.2.3 Datasheet

Create a datasheet with consideration of section 3.3.2.1 and 3.3.2.2. and enter data. Examples of datasheets are provided in section 7. No specific style of form is designated.

3.3.2.4 Calculation of Mean Value

Calculate the mean, round to one more decimal place that the measured value. Find the mean value ( ) per group.

3.3.2.5 Calculation of Range Find the range (R) per group.

R is used to indicate dispersion within a group and is a difference between the maximum and the minimum values within a group.

R＝X max－X min

X1＋X2＋X3＋……Xn

n

X =

X – R chart

X – R chart

Defect x

Specification limit

problem Control limit

(UCL）

(CL)

Take action here

Control limit

(LCL） Specification limit

X－R chart

★

－

X – R chart

X




3.3.2.6 Calculation of Grand Mean ( ).

Add of all groups and divide by the number of groups, K.

Calculate the mean to two more decimal places than the measured value. (Do not round off since it will be used in later calculations.)

3.3.2.7 Calculation of Range Mean Value

Add all the R values of each group and divide by k

Calculate the mean to one more decimal place than the measured value.

(Do not round off since it will be used in later calculations.)

3.3.2.8 Calculation of Control Limits

control chart

Centerline : CL＝

Upper control limit line : UCL＝＋A2R

Lower control limit line : LCL＝－A2R

R chart

Centerline : CL＝

Upper control limit line : UCL＝D4R

Lower control limit line : LCL＝ignored when n is equal to or smaller than 6.

3.3.2.9 Entry of Control Lines

Set scale on the control chart so that the spacing between the upper and lower control lines will be about 20 to 30 mm and enter CL, UCL and LCL on the chart. Draw center line (CL) by solid line and draw limit lines by broken lines in the case of data analysis or dashed-dotted lines in the case of process control.

In case the control chart for analysis is extended for application to process control, the line is changed from broken line to dashed-dotted line. Also enter CL, UCL, LCL and each value near the lines.

3.3.2.10 Plotting

For plotting normally, “●” is used for X and “x” is used for R. Plots outside of the

control limits (including those on the limits) should be so marked as to facilitate

identification. (e.g. ”◎” or in red, etc.).

Control limit line coefficient

n A2 D4

2 1.880 3.267

3 1.023 2.575

4 0.729 2.282

5 0.577 2.115

Centerline : solid line ( )

analysis : broken line ( )

process control : dashed-dotted line ( )

X1＋X2＋X3＋……Xk

k X =

R1＋R2＋R3＋……Rk

k R =

X

X

X

X

X

R

Limit line

X




3.3.2.11 Points to Remember

In general, set control limits based on the dispersion of data when preparing a control chart.

In some cases control limits are set at the upper specification limit and the lower specification limit with an optimistic view of no nonconformance being expected. However if control limits are set at the specification limits, the chart will not allow detection of possible abnormality and it is a misuse of the chart.

Count the dispersion of data in setting control limits (action lines) on a chart when using specification limit. Use the chart to prevent problems from occurring by taking precautions when dispersion is observed in the red zone.

3.3.3 p Chart

P chart does not require a fixed sample size. P chart is used in control of the process in which percent defective can be expressed in percentage. For instance, when finished- or semi-finished goods of 100 sheets, 100 units or n in general are inspected for quality, 5 (r or np in general) out of 100 of products are found to be non-conforming, therefore the percent defective P is 5/100, .05 or 5%. The percent non defective may also be used.

3.3.4 Preparation of p control chart

3.3.4.1 Data Collection

Collect data of inspection results with number of units inspected (n) and number of units rejected (np). Minimum of 20 sets of data shall be collected.

Data shall be collected and recorded with respect to each lot, machine, date, time, etc.

3.3.4.2 Grouping

Form a group with the collected data. The size of a group n should not be too large or too small since groups with many p=0 points are not appropriate.

3.3.4.3 Determination of Percent defective

Fill in a datasheet with the group number, n, np, etc., and calculate a percent defective for each group (p).

Multiply by 100 for percentage.

3.3.4.4 Determination of Average Percent defective

（note that this is not the mean value of the percent defective p of each group）

3.3.4.5 Calculation and Entry of Control Limits.

Centerline ：CL＝p

Upper control line：UCL＝

Lower control line：LCL＝

p＝ no. of rejects

size of a group ＝

np

n

total of rejects

total of units inspected ＝

Σnp

Σn

－ p=

3 √ p ( 1－p ）

p＋

n

－－－

3 √ p ( 1－p ）

p－

n

－－－




3.3.4.6 Control Chart Preparation

3.3.4.7 Points to Remember

If the sample size n varies among groups, center line will remain the same, but control limits shall be calculated for each group and a limit value be applied for each point.

Thus, limit lines on the control chart may be uneven, and control range becomes smaller as n becomes larger. If n is larger than 500, use a stratification approach since the control range becomes exceptionally small.

3.4 Reading of Control Charts

In order to understand the condition of processes i.e., acceptable, marginal or critical, it is necessary to read trends in data points appeared on control chart. The purpose is to take actions proactively when abnormality is observed in control chart.

3.4.1 The criteria for judging process conditions, whether or not a process is in a controlled state (or stable state), are as follows.

It is advisable that evaluations be made on the basis of at least 25 plotted points.

3.4.1.1 No plotted points outside control limits; no out-of-control points.

However a process is considered as being in a controlled state if the following cases apply.

when 25 consecutive points are within the limits.

One point or less out of 35 consecutive points lies outside the limits.

(And, this one point exhibits no particular abnormality.)

1) Two points or less out of 100 consecutive points lie outside the limits.

(and, these two points exhibit no particular abnormality.)

2) No bias in sequence, trends, cycles, etc. in the order of plotted points.

3.4.2 Data Point Exceeds Control limits

The points outside control limit lines are referred to as being “control-out” or “out of control”. Reasons for points being control-out are as follows.

(1) Due to a random cause resulting in the point lies outside the limit lines, or

(2) An abnormality has occurred in the process and resulted in the point being outside the control limit lines.

Phenomenon described in (1) above may occur with a probability of three times in 1000 plots. If control-out occurs, take action on the premise that 2) above is most likely to have occurred and probe the cause of abnormality.

out of control

out of control

Control limit

Control limit

Circle the point

●

●

●

●

●

●

●

●

● ●

● ●

●




3.4.3 Run of Data Points

A series of points appear consecutively on one side of the centerline (median line, to be precise, may be substituted by the centerline) is called a run. The length of a run is the number of consecutive points to one side of the centerline.

A run with seven or more points is judged as indicating control-out state.

3.4.4 Data points show a cycle

When data points show a cyclic pattern of always declines on Mondays, there must be a reason.

Investigation into the cause of cycles peculiar to the process is very useful in terms of process analysis. Although these cycles are not easy to identify, it is ideal to analyze them with experiences and engineering knowledge over a long period of time and develop control methods well matched to the rhythm (cycle).

It is necessary to discern the cause of the cycle and carefully evaluate the process condition to determine whether or not a process is in a controlled state.

3.4.5 Shows Trends (Upward or Downward)

If there is an upward or downward run of consecutive seven points or more, it is also judged as out of control. In case of a steep rising or falling, take immediate action to investigate the cause when any obvious trends in the plot of data is observed.

control limit

control limit

●

● ●

●

● ●

●

● ● ● ● ●

● ● ● ●

● ●

●

●

●

control limit

control limit

●

●

●

● ●

●

● ● ●

● ●

● ● ●

● ●

●

● ● ● ● ● ●

control limit

control limit

● ●

● ● ● ● ●

●

● ● ● ● ● ● ●

●

circle the plotted points




3.4.6 Two Spikes on Chart

It is also considered abnormal if there are two spikes appear in the plot of raw data. There may be a mix up of data of two or more.

(e.g.) two spikes have different patterns, etc.

3.4.7 All Points Gathered Around the Centerline

If the process is in a controlled state, the plotted points must be distributed randomly. When considering distribution confirmed by control limit lines at ±3σ, the slope down gradually becomes lower from the center to the edges so that points are less likely to occur about the center line when they get close to the control limits Compared to the vicinity of the centerline, points appear less readily as the control limits are approached. In other words, points should not occur concentrated about the center line.

It is often the case that there is either a problem with the grouping, or groups contain abnormal data.

It is also judged abnormal if 15 or more consecutive points fall between ±σ.

(e.g.) measurement error

3.4.8 Consecutive Points on One Side of the Centerline.

If one of the following conditions appear on one side of the centerline (median line to be precise), the process is judged as out of control controlled state.

1) 10 or more points out of 11 consecutive points

2) 12 or more point out of 14 consecutive points

3) 14 or more point out of 17 consecutive points, or

4) 16 or more point out of 20 consecutive points.

control limit

control limit

●

● ●

●

●

● ●

● ●

● ●

●

●

● ● ●

●

●

●

● ● ●

10 out of 11 consecutive points are on one side of CL.

control limit

control limit

●

●

● ●

● ● ● ● ●

● ● ● ● ● ● ●

●

control limit

control limit

●

●

●

● ●

●

●

●

●

●

●

●

●

●

●




3.4.9 Few Points Along the Centerline

Under normal circumstances, a large number of points should be near the centerline if the sample follows a single normal distribution. Accordingly, the chart above shows an abnormality.

This is often found when plotting data on the chart with sample groups taken from each of two machines with different process average. It is necessary to stratify the sample groups and draw control chart for each machine.

3.4.10 Points Close to the Control Limit Lines.

Evaluate as control-out in the following cases when points are near the control limit lines, beyond the line two third of the distance from the center line to the control limit lines.

1) 2 out of 3 consecutive points



The above conditions shall be judged abnormal since probability of the process being beyond ±2σ range from the centerline is approximately 5 percent.



1 20 years after creation

2 p control chart 20 years after creation



control limit

control limit

●

● ●

●

● ● ●

●

●

●

● ● ● ●

●

●

● ●

●

●

●

X – R control chart

control limit

control limit ●

● ●

●

●

●

●

●

●

●

●

●

●

●

●

●




6 Operation flowchart

　　・Collect samples to form 25 groups of

　　 size 4 or 5.

　　・Calculate the center line and

　　 control limit lines.

　　・Plot and check data on a control chart.

　　　　・Plotted points are

　　　　 randomly dispersed

　・Data points are outside 　　　　 from the centerline.

　　 the control limits. 　　　　・Points are inside the CL

　・Run, trend, cycle, etc. 　　　　・No run, trend, or cycle.

exist. 　　　　・Process is stable and

　　　　predictable.

　　　　・Estimate σ

　　　　・Find Cpk

　・Identifiable cause

exists.

Cpk<1 1≦Cpk<1.33 Cpk≧1.33

Eliminate identifiable

causes

Evaluate process

capability

Process not in a

statistically controlled

state.

Process in a statistically

controlles state.

Evaluate w/ control

chart

Process output

Need improvement

100 % inspetion

Study if improvement is

necessary / Sampling

inspection

Maintain status

quo (monitoring)

Make improvement

Confidential Supplier Quality Manual 5-3 Control Chart

March 1, 2018


7 Examples of Forms

7-1

Notes for entry

1. Enter X and R values in solid lines.

2. Enter UCL and LCL in dotted lines. Measurement period: from 　　yy/mm/dd to 　yy/mm/dd.

Original to be retained until 　 YY/MM/DD

Confirmed by Prep. by Approved by

�

Standard Sampling frequency Measuring equipmentSupplier or process zone Part number Part name Quality characteristics

Control limit line coefficient

Ｘ5

Total

Mean Ｘ

Range Ｒ

Measured date

Ｎｏ.Lot

Size

ｎ A2 D4

２ 1.88 3.27

３ 1.02 2.57

４ 0.73 2.28

５ 0.58 2.11

Confirmation

Notes

Unit（　　）

Mea

sure

men

tsＸ

　C

hart

Ｒ C

hart

Ｘ1

Ｘ2

Ｘ3

Ｘ4

〔Ｘ－Ｒ Chart 〕

Ｘ＝Ｘ total / no. of samples sets

＝ ÷

＝

Ｒ＝Ｒ total / no. of samples sets

＝ ÷

＝

Ｘ chart

ＵＣＬ＝Ｘ＋Ａ2Ｒ

＝＋

×

＝

ＬＣＬ＝Ｘ－Ａ2Ｒ

＝－

×

＝

Ｒ chat

ＵＣＬ＝Ｄ4Ｒ

＝ ×

＝

ＬＣＬ＝Ｄ3Ｒ

Disregard samples

of 6 or less.

X – R control chart

Confidential Supplier Quality Manual 5-3 Control Chart

March 1, 2018


7-2 P control Chart

Date: 　　　　　 YY/MM/DD

Original to be retained until 　 YY/MM/DD

�

Total

Notes

（％）

Description

Be sure to provide the following

information.

1. Causes and measures taken if points

had been found lying outside the control

limits.

2. Specify changes if there is a change to

the contents of a control chart.

3. Any changes to operation standards, or

to other major items which require changes

to a process.

Number of defective units

Defect rate　（％）

Part Name Part Name

　　　　　－　　　　　　－　　　　　　　

Number processed

Item

〔 P Chart 〕

DateNo.

of units


5-4 5 Principals for Problem Solving October 1, 2018



1 Overview

This manual is to provide the concept of “5 Principles for Problem Solving”, which is used by suppliers to investigate and eliminate the root cause of nonconformity of parts and of quality management system.

2 Definitions



No. Term Definition

1 Problem A condition characterized by discrepancy between an ideal state and an actual state.

2 5 Principals for Problem

Solving

A tool consists of the following five steps for problem solving. Also referred to as 5P.

“ investigation and comprehension of the facts”

“ identification of causes (why-why analysis) ”

“ appropriate measures”

“ verification of the effects of measures”

“ feedback to upstream sources”

3 Requirements

3.1 The concept of “5 Principals for Problem Solving”.

It is important, for the purpose of quality control, to never repeat the same problem. When a problem occurs, thoroughly observe and understand the facts on the basis of the Three Realities Principle of spot, thing, situation, and take appropriate measures to prevent problem recurrence.

A thorough analysis of root causes is essential for effective measures to prevent problem recurrence.

Implement 5 Principles for Problem Solving to identify the root causes and eliminate causes of nonconformity.

3.2 Steps for 5 Principals for Problem Solving

3.2.1 Fact Findings and Situation Assessment

3.2.1.1 Begin investigation immediately to avoid impediments in the following.

1) Spot, thing, and situation change by the minute.

2) Memories of personnel concerned begin to fade.

3.2.1.2 Review the facts by 5W2H and study factual information in detail. Obtain additional information on nonconformity if necessary.

1) Who

2) What

3) When

4) Where

5) Why

6) How

7) How many/How much

3.2.1.3 Classify information into process and actual problem part and analyze.

Perform analysis of actual problem parts based on the following information.

1) Information on nonconformity (information on symptom, situation and environment of problem occurrence)

2) Appearance of nonconforming parts (visual check)




3) Comparison of dimensions with drawing specifications.

4) Test result

5) Reproducibility analysis

6) Date of manufacture, identification mark, lot number

Perform analysis of processes based on the following information.

1) Work shift, operators, etc. when problem occurred.

2) Presence of abnormality in operation and/or equipment when problem occurred.

3) Adequacy of listing in the process quality control table and operation standard, etc.

4) Quality records (daily report, inspection record, control chart, problem summary, etc.)

5) Nonconformity and repair history.

3.2.1.4 Classify information into the following categories based on the results of analysis, and identify the primary cause of the nonconformity.

1) Machine

2) Material

3) Manpower

4) Method

5) Others

3.2.2 Identifying causes (why-why analysis )

3.2.2.1 For each symptom, classify causes into occurrence, outflow, and expansion (by cause) and conduct analysis in aspects of both hardware side and software side.

3.2.2.2 Repeatedly ask “why” as many times as necessary and analyze until the root cause is identified.

3.2.2.3 Benefit of performing why-why analysis

1) Level of problem can be clearly defined and communicated.

2) Relationship between multiple causes is easily understood.

3) Multiple causes can be identified.

4) Factors that can not be the cause can be identified along with the reasons.

5) Investigation process of causes is traceable

6) Differences between individuals can be eliminated. Attention can be focused on the problem itself, not the history of the problem.

7) Attention can be focused on causes, not symptoms.

8) Support systems for problem solving can be established by gaining consent from related sections and persons, etc.

3.2.2.4 Conduct why-why analysis involving as many persons concerned as possible. A cause for which all participants come to the same conclusion is most likely to be the root cause.

3.2.2.5 Verify adequacy of why-why analysis flow in view of the following points.

1) Same or similar factors not repeatedly appeared?

2) Flow of why-why analysis not being reversed?

3) No conflict in the story from the occurrence of a problem to discovery of the root cause (no deviation from story).

3.2.3 Appropriate measures

3.2.3.1 Determine measures deemed most effective for identified root cause.

3.2.3.2 Examine measures, whenever possible, in aspects of both hardware side and software side.

3.2.3.3 Measures shall be appropriate not only for the process or operation concerned but also for the organization in totality.




3.2.3.4 Implement measures focusing more on the elimination of cause, rather than prevention of outflows

3.2.3.5 Measures shall be employed on a permanent basis (elimination of causes). If judged necessary based on the degree of severity, urgency, and negative effects, etc., take interim measures (containment of nonconforming products).

Timing to implement permanent measures shall be defined in advance when interim measures are taken.

3.2.4 Verification of Effectiveness of Measures

3.2.4.1 Verify effectiveness of measures with reasonable number of units or time period, and confirm no recurrence of problems from the same cause.

3.2.4.2 Verify both products and processes.

(e.g.) Product: disassemble completed products for verification, if necessary.

Process: verify the process in which problems were found.

3.2.4.3 Effectiveness shall be verified per shift, operator, etc., depending on the cause of problems or the nature of measures.

3.2.4.4 Verify that the results of measures will not have any adverse effect on other products, processes, operations, etc.

3.2.5 Feedback to Upstream Sources

3.2.5.1 Revise the following standards and reflect the results of measures.

1) Manufacturing quality standard

2) Process quality control table

3) Operation standard

4) Others

3.2.5.2 Share information with related organizations and sections to prevent nonconformity from occurring in similar operations, processes or systems.

1) Sections/areas in which similar operations, processes, or systems are used.

2) Section found the nonconformity.

3) Section responsible for designing processes.

4) Section responsible for designing products

5) Section responsible for controlling quality system documents.

Confidential Supplier Quality Manual 5-4 5 Principals for Problem Solving

October 1, 2018


3.3 Why-why Analysis Method

Root Cause/Task

4th “Why” 1-1-1-1-1

3rd “Why” Why does 1-1-1-1 occur ?

1-1-1-1 1-1-1-1-2

2nd “Why” 1-1-1 Why does 1-1-1 occur ?

1-1-1-2 1-1-1-2-1

1st “Why” 1-1 Why does 1-1 occur ? Why does 1-1-1-2 occur ?

【Tangible cause 】 1-1-2-1 1-1-2-2-1

1-1-2 Why does 1-1-2 occur ? Why does 1-1-2-2 occur ?

1 1-1-2-2 1-1-2-2-2

【Cause of Occurrence】

1-2-1-1 1-2-1-1-1

1-2 1-2-1 Why does 1-2-1 occur ? Why does 1-2-1-1 occur ?

【Intangible cause】 Why does 1-2 occur ? 1-2-1-2 1-2-1-2-1

Why does 1-2-1-2 occur ?

2-1-1-1 2-1-1-1-1

2-1-1

2-1 2-1-1-2 2-1-1-2-1

2 2-1-2 2-1-2-1 2-2-1-1-1

～【Cause of Outflow】

～ 2-2 2-2-1 2-2-1-1 2-2-1-1-2

3 3-1 ～～～～

【Cause of Expansion】

3-2 ～～～～

Start from the problem symptom. Sort out and systematize

relevant factors until the root cause is revealed.

問題の現状（事象）

A

B

C

D

E

F

G

H

I

Pro

ble

m S

tatu

s /

Sym

pto

m

5th “Why”



October 1, 2018


4 Key point

1) Identification of root causes is the key to the why-why analysis. In order to take adequate measures, it is crucial to properly determine root causes. Avoid the common error of attributing problem causes to humans, which results only in emphasizing importance of better guidance and instruction. In such cases, the root cause remains uneliminated, and the same problem is likely to recur.

2) If root causes are in manufacturing processes, it can often be solved by own section but further check will reveal that modification of manufacturing method or specifications contributes to quality stabilization. Thus, discuss with related sections for possible improvement.




5-5 Process FMEA October 1, 2018


5-5 Process FMEA

1 Overview

This manual explains the concept of and procedures for Process FMEA, and provides and provides entry method for the Process Design FMEA worksheet.

2 Definitions



No. Term Definition

1 Process FMEA

worksheet A format used to implement process FMEA and to record results.

3 Requirements

3.1 Process FMEA

The process FMEA is an approach for process improvement used to investigate potential failures and apply appropriate measures to prevent and contain these failures.

Process FMEA shall be properly documented and always maintained as a “living document”, which is continuously revised to reflect changes in manufacturing processes.

In the manufacturing process design stage, prevention of problems from occurring or recurring is achieved by process design base on consideration of various factors such as quality, delivery timing, cost, safety, environment, etc., on the other hand, Process FMEA is to determine whether a process is adequately controlled or in need of improvement by reviewing the results of a process design (process quality control table).

Suppliers shall initiate process FMEA from the manufacturing design stage of parts. Implement or review process FMEA in case where changes are made to parts, manufacturing processes or environment even in the mass production stage.

3.2 Process FMEA worksheet

The supplier may implement process FMEA by entering required information into respective fields of the Process FMEA worksheet. Completed Process FMEA worksheet is also an implementation record of Process FMEA.

The supplier shall complete a Process FMEA worksheet, revise as necessary for changes in processes, and control in a manner that it can be submitted or presented upon request from Honda.

The Honda- recommended format is provided in the end section of this manual. Suppliers may use different format on condition that all information required on the Honda form is included.

3.3 Procedure for Process FMEA Implementation and Worksheet Entry

The following explains the items inscribed in Honda’s Process FMEA worksheet. Refer to instructions for required information and remarks for entry. Each item number below corresponds to the number of fields in the entry method form.

3.3.1 Process FMEA Control Number

Identify each Process FMEA by use of numbers, symbols, etc. to ensure traceability.

3.3.2 Model

Enter Model Name, Type and Model Year.

3.3.3 Honda Part Name and Part Number

Enter part name and part number of Honda subject to process FMEA. If the supplier uses its own part name and part number, such name and number may be listed along with the ones of Honda.

3.3.4 Suppler Name, Supplier Code and Address

Enter supplier name, supplier code, and location of the plant where the process is operated for the purpose of Honda to identify the subject supplier.




3.3.5 Issue Date and Revision Date

Enter the date of issue or revision of the process FMEA worksheet. Process FMEA shall be initiated in the manufacturing process design stage and continuously maintained through the mass production stage. Revise the process FMEA worksheet as necessary and reflect changes in the condition of relevant processes.

3.3.6 Preparation, Review and Approval

Columns to enter signature of the supplier ’s personnel who prepared ( made entries in the worksheet), reviewed, and approved the process FMEA worksheet.

Besides the person who prepared the worksheet, the person who is responsible for reviewing and approving the Process FMEA shall sign. The person assigned for review and approval of the worksheet may also double as the person in charge of Process FMEA implementation set forth in section 3.3.8.

3.3.7 Column for Honda Use Only

Where applicable, Honda uses the column for signature of the person from Honda who reviewed or approved the process FMEA.

3.3.8 Engineer

Enter the name and section of the person who is in charge of the Process FMEA and who implements the Process FMEA.

Efficacy of Process FMEA relies on the comprehension of the subject process. During the development of Process FMEA, involve representatives of all affected areas such as design, manufacturing, inspection, quality, etc. and collect as much knowledge as possible. List all persons participated in the development of the Process FMEA in the Engineer field.

3.3.9 Process Name and Process Number.

Enter the name and number of the process being analyzed. Identify in a manner that links Process FEMA to the relevant process quality control charts and operation standards.

If a process is composed of multiple work elements, break the process into as small as possible. List each work element separately and examine failure mode.

3.3.10 Process Function

Describe the process being analyzed (what is done and how it is done). Associated component parts and operations may also be included for better description of the purpose of the process.

3.3.11 Failure Mode

Describe a failure mode (problem symptom) that might occur in the process.

Describe failure modes elicited from Design-FMEA etc. (which is conducted during design/development stage), manufacturing control items elicited from FTA, known defects based on past troubles, and so on for each process function.

Failure modes include operation failures, process defects, and detection failures due to inspection etc..

If there is any new failure mode, it shall be added in the list.

3.3.12 Effect of Failure

Describe effects of the failure mode (what is the results if a failure occurs).

Include direct effects to the concerned parts or assembled parts (of the subsequent processes) resulted from the failure mode, and where possible, include possible effects when those parts are used in Honda products.

3.3.13 Identification

Enter (Q) for important quality characteristic specified by Honda (refer to HES A 3051).

3.3.14 Severity of the effect (S for severity)

In order to quantitatively describe the severity of a failure mode identified in section 3.3.12, rank the degree of effect and enter the corresponding number the larger the




number is more severe the effect is. Determine severity based on the degree of effects to subsequent processes, to Honda, and to the market when a failure mode is flowed out.

Criteria for ranking shall be established in reference to the table provided below.

Justification for the evaluation criteria shall be provided as required in section 3.3.24.

The ranking is often expressed on a scale of 0 to 10. Other measurement scales such as 1-4 scale (linear scale: 1, 2, 3, and 4, or exponential scale: 1, 2, 3, 4, 8, etc.) are also acceptable, as long as the employed scale is effective for evaluation and severity is well-expressed.

Ranking Severity Ranking on a 1-10 Scale (example)

10

Extremely

Severe

Failure mode of parts that impairs the safety of Honda products and leads to a fatal accident and/or involves a violation of regulatory requirements (without predictability)

9 Failure mode of parts that impairs the safety of Honda

products and leads to a fatal accident and/or a violation of regulatory requirements (with predictability).

8

Severe

Failure mode of parts that causes loss or deficiency of primary performance, function, or structure of Honda products.

Failure mode that leads to a serious accident.

7

Failure mode of parts that may cause loss or deficiency of primary performance, function, or structure of Honda products.

Failure mode that may lead to a serious accident.

6 Failure mode of parts that may but may not necessarily cause

loss or deficiency of performance, function, or structure of Honda products.

5

Moderate

Affected Honda products are usable or operable but at a reduced level of performance or function.

4 Lead to multitudes of warranty claims against Honda products

with respect to fit and finish, appearance, noise in use or operation, feeling, etc.

3 Lead to warranty claims against Honda products with respect

to fit and finish, appearance, noise and feeling in use or operation, etc.

2 Mild

Lead to complaints against fit and finish, appearance, noise and feeling when in use or operation, etc. Defect noticed by limited users.

1 No discernible effect or effect can be ignored.

Ranking Severity Ranking on a 1-4 Scale (example)

4 Failure mode of parts that impairs (or may impair) the safety

of Honda products, which leads to a fatal accident and/or involves a violation of regulatory requirements.

3 Failure mode of parts that impairs the safety of Honda

products and leads to a fatal accident and/or involves a violation of regulatory requirements (without predictability).

2

Failure mode of parts that reduce (or may reduce) performance level of Honda products. Honda products are usable and operable but at a reduced level of performance or function with respect to fit and finish, appearance, noise and




feeling in use or operation, etc.

1 No discernible effect or effect can be ignored.

3.3.15 Cause of the failure mode

List every possible cause assignable to every potential failure mode (conditions for process malfunction or parts nonconformity to occur and mechanisms of problem causes to be developed).

3.3.16 Occurrence (O)

Enter the probability of occurrence of the failure mode set forth in section 3.3.15. in numerical values. The higher the value is, the higher the certainty is.

The probability of occurrence is the likelihood of a failure occurring, not the failure mode, severity, or probability of detection.


Justification for evaluation criteria shall be provided as required in section 3.3.24.

Ranking criteria shall preferably be quantitative and supported by statistical evidence.

If it is not practical to use Cpk or percent defective as a statistical basis, use alternative scales such as quantitative scale or time based scale for lot, batch, etc., to set the ranking criteria.

The ranking is often expressed on a scale of 0 to 10. Other measurement scales such as a 1-4 scale (linear scale: 1, 2, 3, and 4, or exponential scale: 1, 2, 3, 4, 8, etc.) are also acceptable if the employed scale is effective for evaluation and probability of occurrence is well-expressed.

Raking

Occurrence Evaluation Criteria on a 1-10 Scale (example) on a 1-10 Scale (example)

Cpk P（%） Percent defective (estimate)

10 Continual・Frequent

＜0.33 ≧32 1/2 or more

9 ≧0.33 ＜32 1/3 or less

8

≧0.50 ＜13 1/8 or less

7 ≧0.67 ＜ 5 1/20 or less

6 ≧0.83 ＜ 1.2 1/80 or less

5 ≧1.00 ＜ 0.3 1/400 or less

4 ≧1.17 ＜ 0.05 1/2,000 or less

3 ≧1.33 ＜ 0.01 1/15,000 or less

2 Rare・

Almost absent

Low

Remote

≧1.50 ＜ 0.0007 1/150,000 or less

1 ≧1.67 ＜ 0.00006 1/1,500,000 or less




Ranking Occurrence Evaluation Criteria on a 1-10 Scale (example)

10 Continual・Frequent

Frequently occur More than once a day

9 Once every 3 to 4 days

8

High incidence rate Once a week

7 Once a month

6 Moderate incidence rate

Once every 3 months

5 Semi annually

4 Low incidence rate

Annually

3 Once every 1 to 3 years

2 Low

Remote Almost never occurs

Once every 3 to 5 years

1 Less than once every 5 years

Ranking Criteria for Occurrence on a 1-4 Scale (example)

4 It occurs consistently or frequently. With high probability,

High probability or consistent or frequent occurrence.

3 Moderate probability or occasional occurrence.

2 Low probability, or little occurrence

1 Very little occurrence

3.3.17 Current Process Control

Describe methods of process control, testing, and inspection that are currently in practice for the purpose of preventing or detecting the failure mode and cause and mechanism of the failure mode. Such methods include QA devices, error proofing or inspection processes, preventive maintenance of machines and tools, and the use of statistical process control techniques such as control charts, etc.,

Improvement of process control will work favorably for the improvement of rate and possibility of detection.

(e.g. improvement in the rankings of occurrence probability and detection possibility by use of QA devices, event probability by implementing preventive maintenance or detection possibility by the use of control charts, etc.) .

3.3.18 Detection Possibility（D）

Enter the probability of detection of a failure mode occurred by the method provided in section 3.3.17 on a 1 to 10 scale. The higher the value in the ranking, the more difficult it is to detect a failure mode.

Since detection possibility is the likelihood of detection on the premises that a failure mode has occurred, occurrence probability has no effect on the detection possibility.

The detection probability describes the probability of a process control to detect failure when all parts in process might have a failure mode. Monitoring of delivery quality performance and market warranty claim (containment confirmation) is effectual for the verification of failure mode delectability.



Prospect of detecting the failure mode before delivery to Honda shall determine the ranking. Factors such as difficulty level of visual check, tightness of inspection level including method, frequency, etc. shall be considered.




The ranking is often expressed on a scale of 0 to 10. Other measurement scale such as a 1-4 scale (linear scale: 1, 2, 3, and 4, or exponential scale: 1, 2, 3, 4, 8, etc.) is also acceptable as long as the employed scale is effective for evaluation and detectability is well-expressed.

Ranking Detection Evaluation Criteria: 1-10 Scale (example)

10 Impossible

(very difficult)

Failure cannot be detected before delivery to Honda.

No process controls available to detect failure.

9

Failure is likely to be flowed out to Honda.

Process controls currently in place cannot detect failure.

8

Extremely difficult to be detected failure before shipping.

Process control currently in place will probably not detect failure.

7

Failure is detectable by periodic sampling inspection.

Difficult to detect failure by current process control.

Failure can be detected by periodic sampling inspection.

Process controls currently in place have poor chance of detection of failure.

6

Failure can be detected by regularly conducted sampling inspection.

Process controls currently in place may overlook failure.

5

Moderate chance of detection

Failure can be detected by 100% final inspection.

Process controls currently in place may detect failure. (e.g. trends monitored using statistical process control, etc.)

4

Failure can be detected in the subsequent process.

Process controls currently in place can detect failure. (e.g. trends monitored using statistical process control in addition to the 100% inspection, etc.)

3

Failure can be detected in the subsequent process.

Process controls currently in place can detect failure (monitor trends by using statistical process control in addition to 100% inspection, etc.).

2

Failure can be detected within the process.

Process control such as QA devices, etc. is in place for 100% inspection with automatic error detection feature.

1 Certain

( easy)

Can be detected within the process. Detection is easy and no attention is required.

Process control system such as QA device, etc. is in place for 100% inspection with automatic error detection and removal features.

Ranking Detection Evaluation Criteria : 1-10 Scale (example)

4 Not detectable

3 Less likely to be detected or overlooked).

2 Likely to be detected.

1 Almost certain to be detected.




3.3.19 Risk Priority Number（RPN）

Enter the value obtained by multiplying severity (S), occurrence (O), and detection (D) ranking numbers together.

［Risk priority number (RPN) ＝Severity (S)× Occurrence (O)× Detection (D) ］

The RPN is for the risk evaluation, which is to rank order of concerns in the process.

Risk of failure modes shall be evaluated in consideration of three aspects, severity, occurrence, detection, and priority of corrective actions shall be determined accordingly.

The RPN is a quantitative measure, which determines the priority for corrective actions to be taken to a failure mode. The higher the RPN, the higher the priority for corrective action, since more attention to the particular manufacturing process of the product is required

Criteria of prioritizing corrective actions based on RPN shall be established in reference to the table provided below.


Ranking

RPN = S×O×D RPN Evaluation Criteria : 1-10 Scale (example)

RPN Measures

1000 Top priority 436 ～ 1000

Top priority.

Immediate measures required.

130 ～ 435 High priority.

Implement measures.

27 ～ 129

Moderate priority.

Monitor the occurrence of a failure mode and implement measures accordingly.

8 ～ 26

Low priority.

Implement measures where time and resources allow.

1 Least priority 1 ～ 7 Accept as a remaining risk.

No further measures required.

Ranking

RPN = S×O×D RPN Evaluation Criteria : 1-4 Scale (example)

RPN Measures

12 ～ 64 12 or more (Immediate) measures required.

6 ～ 9 6 or more Monitor the occurrence of a failure

mode and implement measures accordingly

1 ～ 4 6 or less No further measures required.

3.3.20 Action Plan and Target Implementation Date

Enter action plan and target date of completion for the anticipated failure mode.

Implement an action plan for failure mode by priority. Higher the risk priority number (RPN) is, sooner the measures shall be taken.

Measures such as inspection, etc., may be employed as interim. Permanent measures including changes to design and/or manufacturing process shall be implemented in order for the root cause of a failure mode to be eliminated.

If RPNs are the same, prioritize the one of greater severity, and contemplate to reduce the rate of occurrence by taking measures.




3.3.21 Action Taken

Record measures that have been implemented such as control method change, installation of inspection equipment, etc.

If follow-up activities were conducted in addition to the original plan, keep a record of such activities as well. Especially, if any changes were made to design as part of measures, process FMEA shall be implemented continuously.

The FMEA is a living document and should always reflect the latest design level as well as the latest relevant actions.

3.3.22 Effective Date of Measure and Responsible Person

Enter target completion date for measures and person in charge of the measures.

3.3.23 Verification of Actions Taken

Reassess the severity (S), occurrence (O), detection (D) and risk priority number (PRN) rankings of each failure mode after having implemented the planned actions. Examine if further analysis and countermeasure is necessary.

In order to validate that further measures for remaining risks are not necessary where measures are deemed to be completed or will not be implemented, evaluation criteria shall be established as required in section 4.3.24.

3.3.24 Criteria

Define evaluation criteria for each of the risk evaluation aspects, such as severity (S), occurrence (O), detection (D), and risk priority number (PRN), and the tolerance level for risks remaining.



1 Process FMEA worksheet 20 years after the issue of discontinuation

order.



Confidential Supplier Quality Manual 5-5 Process FMEA

October 1, 2018


6 Forms

6.1 Process FMEA worksheet

Process FMEA Worksheet For Honda use only Revision No. Approved by Confirmed by Prepared by

Process FMEA control no.： 00

Honda part no. ： Supplier part number：

Honda part name ： Supplier part name： Process FMEA was carried out by (dept or person) ：

Supplier name ： Supplier code：

Supplier address (factory location) ：

Process FMEA was carried out by (dept or person) ：

※※Completion confirmation ：with consideration given to acceptance level of residual risks, confirm completion of a Process FMEA (no further measures required), and enter the name of the person confirmed and the date of confirmation.

To parts/components To Honda products

Rank Rank

10 10

9 9

8 8

7 7

6 6

5 5

4 4

3 3

2 2

1 1

Page 　　　　　　 of 　　　　　　　.

Model/Type/Model Year：

Countermeasure ( risk minimizing activities)

※Identification： Enter the symbol (Q) for the quality characteristic Honda designated as important quality characteristic (see HES A 3051)

Description of revision

Establishment

Verification of C/M (re-evaluate risks)

Risk priority number (RPN) ［RPN = S×O×D］

Date of date est./revision

9

8

RPN

Occurrence

rate

(O)

PIC of

CM

Detection probability (D)

Evaluation criteria

No. Process name

Function of the process

(what does this process

do ?)

Failure mode

Influence if a failure mode occurs Serious

ness

(S)

C/M

application

date

Current process control method

(prevention/detection of

a failure mode)

Detection

probability

(D)

Risk

priority

（RPN）

Proposed C/M

Response

Identify-

cation

※

Completion

confirmatio

n

Risk evaluation Scope of risk evaluation

Seriousness

(S)

Occurrence

rate

(O)

Detection

probability

(D)

Risk

priority no.

(RPN)

C/M

date

(target)

C/M carried out

(including follow-ups)

3

2

1

Occurrence (O)

7

6

5

4

Rank

10

Cause of failure mode

(Occurrence mechanism)

Seriousness (S)

Evaluation criteria Evaluation criteria


5-5 Process FMEA

October 1, 2018


6.2 Process FMEA Worksheet (Entry procedure) Complete in reference to section 3.3 above.

Process FMEA Worksheet For Honda use only Revision No. Approved by Confirmed by Prepared by

Process FMEA control no.： 00

Honda part no. ： Supplier part number：

Honda part name ： Supplier part name： Process FMEA was carried out by (dept or person) ：

Supplier name ： Supplier code：

Supplier address (factory location) ：

Process FMEA was carried out by (dept or person) ：

※※Completion confirmation ：with consideration given to acceptance level of residual risks, confirm completion of a Process FMEA (no further measures required), and enter the name of the person confirmed and the date of confirmation.

To parts/components To Honda products

Rank Rank

10 10

9 9

8 8

7 7

6 6

5 5

4 4

3 3

2 2

1 1

Page 　　　　　　 of 　　　　　　　.

Model/Type/Model Year：

Countermeasure ( risk minimizing activities)

※Identification： Enter the symbol (Q) for the quality characteristic Honda designated as important quality characteristic (see HES A 3051)

Description of revision

Establishment

Verification of C/M (re-evaluate risks)

Risk priority number (RPN) ［RPN = S×O×D］

Date of date est./revision

9

8

RPN

Occurrence

rate

(O)

PIC of

CM

Detection probability (D)

Evaluation criteria

No. Process name

Function of the process

(what does this process

do ?)

Failure mode

Influence if a failure mode occurs Serious

ness

(S)

C/M

application

date

Current process control method

(prevention/detection of

a failure mode)

Detection

probability

(D)

Risk

priority

（RPN）

Proposed C/M

Response

Identify-

cation

※

Completion

confirmatio

n

Risk evaluation Scope of risk evaluation

Seriousness

(S)

Occurrence

rate

(O)

Detection

probability

(D)

Risk

priority no.

(RPN)

C/M

date

(target)

C/M carried out

(including follow-ups)

3

2

1

Occurrence (O)

7

6

5

4

Rank

10

Cause of failure mode

(Occurrence mechanism)

Seriousness (S)

Evaluation criteria Evaluation criteria

3.3.9 3.3.10 3.3.11 3.3.12 3.3.13 3.3.14 3.3.15 3.3.16 3.3.17 3.3.18 3.3.19 3.3.20 3.3.21 3.3.22 3.3.23

3.3.2

3.3.3

（3.3.3）

3.3.4 3.3.4

3.3.8 3.3.8

3.3.7

3.3.5 3.3.6

3.3.24

（3.3.14）

3.3.24

（3.3.16）

3.3.24

（3.3.18）

3.3.24 （3.3.19）



October 1, 2018


6 Supplement


Terms Definitions

A

Approved actual part sample

A part sample with which color was agreed with Honda.

Automatic transmission, etc.

Component parts constituting an automatic speed change mechanism, such as AT (automatic transmission), CVT (continuously variable transmission), 4WD (4-wheel drive), MCU (moment control unit), etc., and parts assembled to them.

C

Calibration A process of establishing the relationship between the value measured by the measuring device and its true value with standards and reference materials to correct deviations.

Call-in part A part that was recovered from a marketed product as a possible problem part and collected from the market by Honda for analysis of causes.

Change point All changes including unexpected changes, such as a blackout, in addition to a planned change to a part specification and manufacturing plan.

Cleanliness rank A ranking of contaminants control parts such as automatic transmission, etc. in the order of influence of contamination on the function of the automatic transmission, etc.

Color Color of part exterior Color application plate Color master set forth in HES Z 0013. Component parts (Sub-) parts that constitute the parts provided by supplier. Composite quality characteristics

A quality characteristic that will be demonstrated or explicated by a combination of supply parts and manufacturing parts.

Concession

Concession is the act of using raw materials, parts, etc. that do not conform to specified requirements in limited quantities or for a certain time period. However, those which affect product safety, prevention of environmental pollution, and/or regulatory compliance of products shall be exempt from the scope of concession.

Contaminants Foreign matter such as grain, grit, chip, burr, dirt, dust, etc.

Control priority ranking A ranking of contaminants control parts, which are not included in the definition of automatic transmission, etc., by safety, function and performance.

Corrective action An action designated to prevent recurrence of nonconformity, once it has occurred.

Countermeasure request

An action to be taken by a supplier to request Honda for a change to the drawings (specifications, etc., included) by using

“Countermeasure Request [Countermeasure Request Form]”.

D

Declaration of compliance with regulatory requirements

A course of action by the quality assurance representative, facility quality representative, or responsible person who was appointed and entrusted by the quality assurance person of a supplier to verify that the specifications of parts designed by the supplier comply with regulatory requirements.

Delivery destination Honda (including destinations of service parts and KD parts) or designated suppliers to which supply parts are delivered.

Delivery location A destination of delivery specified on the delivery slip.

Delivery lot

A group of parts which are delivered to Honda or a location

specified by Honda in a batch, corresponding to the”delivery

slip”.

Delivery packaging A state of parts in a container or on a cart to be shipped out from a supplier to a manufacturing plant of Honda.



October 1, 2018


Terms Definitions

Discrete value Data obtained by counting and it cannot be divided into units smaller than one.

Design-FMEA

Design-FMEA is a method to prevent defects at production design timing by forecasting/extracting the potential defects, come up with occurrence rate, and evaluate the severity in case of the occurrence.

E

Error proofing A system of products or manufacturing processes that prevents nonconforming products from being manufactured.

Extended warranty An act of extending the warranty period, submitting a notice to the competent authorities, and implement improvement measures.

F

5 Principals for Problem Solving

A tool consists of the following five steps for problem solving. Also referred to as 5P.

“ investigation and comprehension of the facts”

“ identification of causes (why-why analysis) ”

“ appropriate measures”

“ verification of the effects of measures”

“ feedback to upstream sources”

50 % Tolerance limit band

Setting up of inspection standard tolerance at 50 percent of the tolerance specified on drawings.

FTA

A method to evaluate "unfavorable cases" logically and quantitatively by placing the case at the top (Top case). Develop the cause into lower levels sequentially. Apply "logical symbols" and indicate links between upper levels and lower levels to evaluate the "unfavorable case".

G

Grain Uneven pattern of part surface by the arrangement of particulate constituents.

Grain process supplier A supplier specified by Honda who performs grain embossing on the part mold.

Group

Group or grouping is the act of collection of data into units. In general, a group is a set of data collected through random sampling per unit such as day, shift or batch, etc. * batch: a set of material (conditions) processed in a single production process.

H Honda-owned property When necessary, after consulting with the supplier, Honda will lend machines, dies, tools and jigs, etc. needed to manufacture parts, etc.

I

Important quality characteristics

Important quality characteristics set forth in HES A 3051.

Important safety parts Important safety parts set forth in HES A 3050.

Improvement campaign

An action taken by Honda to implement improvement measures by submitting a notice to the competent authorities in accordance with Article 9 (Improvement Campaign) of Circular Notice "Handling Procedure for Notification, etc. of Recall" (Jishin No.1530 of December 1, 1994, hereinafter referred to as "Circular Notice").

Initial production parts (IPP)

Parts of the initial lot released from an originating section to its next section or of the initial lot released from a supplier to Honda, to which the supplier applied changes in specification, manufacturing method, etc. This applies to parts ordered for mass production use only.

IPP presentation Presentation to Honda of self-controlled IPP, etc. before mass production start to confirm quality compliance, process-ability, assemble-ability, etc.



October 1, 2018


Terms Definitions

K Key process In the case where there are two or more manufacturing lot forming processes, a representative process for lot retrieval in those manufacturing lot forming processes.

L

Lead section of Honda A section of Honda, which acts as a planning center for the Quality Assurance Visit and issues individual audit plans to notify suppliers of the audit.

Limit sample A sample of parts which demonstrates quality limits for conformance or nonconformance.

Lot-out parts Parts returned from Honda by the unit of delivery lot due to nonconformity, such as not satisfying specifications.

M

Manufacturing Management Plan

A management plan to monitor progress of the activities specified in the Stage Management.

Manufacturing history A record of production corresponding to the identification of a manufacturing lot, which includes the date and amount of manufacture, and results of inspection.

Manufacturing lot A group of parts manufactured or deemed manufactured under the same condition.

Manufacturing lot control Control method that forms a manufacturing lot and subsequently control traceability of parts by identifying such lot and its manufacturing history.

Manufacturing lot forming process

Manufacturing process for which manufacturing lot shall be formed and identified in order to track and control traceability of parts, which is determined by quality characteristic priority, process layout, equipment, process capability, etc.

Mass Production Transition Declaration

A declaration by the quality assurance representative, facility quality representative, or deputy of a supplier stating that the requirements prescribed by Honda for quality and mass productivity of parts have been satisfied.

Measuring equipment

A general term for measuring instruments (gauge, measuring instrument, standard, etc.), testing device, testers, analytical equipments, etc., including related software of computer systems. For definitions of terms used for measuring instruments, testers,

analytical equipment, etc., refer to JIS Z 8103 “Glossary of

terms used in measurement”.

Model CP List A list which sets forth methods to specify legality control items of individual parts by Honda, set items to be assured at inspections or processes by suppliers, and control them.

Monitoring device

Equipment to use to “monitoring: the observation of a system

(all or part) to verify proper performance and detect improper performance. Actual observation is made by measuring one or more variants of the system, and subsequent comparison of the value obtained from such measurements with the specified

value.” in 24103, section 4.1 of JIS B0155.

N Nonconforming parts Parts that do not conform to drawings (specifications included) or limit samples.

O Operation Control Documents

A generic term for documents to provide operators with directions for work sequences, set-up condition, etc. in order for each of the fabrication, assembly, inspection, equipment maintenance, transportation, and administrative processing, etc. to be controlled per process, product, operation, etc. Documents such as operation standards, condition control tables, specifications, signs or displays showing photographs or illustrations to caution, and check/inspection standards for inspecting equipment are included.



October 1, 2018


Terms Definitions

Operation standard

A set of documents that describe requirements and procedures to be followed such as illustrations of work, work sequences, jigs and tools, quality characteristics and standards, operation key points, inspection methods, parts to be used, facilities, actions to be taken when abnormality occurs, and other cautions (it is

referred to as “ work instruction” in ISO/TS”).

P

Parts Inspection Criteria Inspection Criteria [System/Device and Parts], which set forth acceptance criteria to be applied to inspection of individual constituent parts of a product.

Prior confirmation Presentation to Honda of specification change IPP before mass production start (before implementing the change) to confirm compliance with specification change.

Part classification NO

The part classification number is given to show what model the part is made for, or what model the part is exclusively for.

※For DWG.No. of drawing title block (Boxed space on the

bottom)

Main No. Part

Classification No. Prototype Code

Type No. Suppiementary No.

Part origin

See Table 6-1-1

Problem A condition characterized by discrepancy between an ideal state and an actual state.

Process capability The ability to achieve quality requirements of a process in a controlled state.

Process capability Index

A quantified measure of process capability, and “a value

calculated by dividing the specification range by 6σ for a

certain characteristic”.

“Process in a controlled state”in the definition above for process

capability means that the characteristic value is normally distributed, and this forms the basis of the process capability index.

Process FMEA worksheet

A format used to implement process FMEA and to record results.

Production Conditions Control items for the set up condition and its standards and/or criteria necessary to ensure quality required for respective manufacturing processes.

Production prototype parts

Parts that are used to validate possible specification changes during mass production stage prior to implementing such changes.

Purchased parts All component parts and materials that a supplier procures from its sub-suppliers in order to produce products to be delivered to Honda.

Q

Quality Characteristics Property and performance subject to quality evaluation, and standards and criteria to control them.

Quality improvement IPP

The IPP for which quality improvement was implemented by supplier in accordance with the “Rejection Countermeasure Request,” “Market Quality Information [Analysis/Countermeasure Request],” , “Honda Trouble Report” or other forms issued by Honda.

Quality records Quality Records are the all records set forth in the “Control of

Records" section of each article of this SQM, regardless of form or medium ( paper, electronic, magnetic and other media)



October 1, 2018


Terms Definitions

R

Recall

An act of implementing improvement measures by submitting a notice to the competent authorities in accordance with Paragraph 3 of Article 63 (Report, etc. of Corrective Action) of Road Vehicles Act (Law No.185 of 1951).

This includes the implementation of equivalent actions in foreign countries in accordance with the laws and regulations of those countries.

Recall, etc. A general term for market action, which includes recall, improvement campaign, service campaign and extended warranty.

Reference material

A material used for inspecting instrumental errors of equipment (weight, block gauge, reference solution, etc.), whose physical/chemical amount is certified (actually measured values are indicated) based on the material examination results.

Regular check An inspection of equipment for problems with the term and extent specified.

Regular inspection Periodic inspection of equipment for appearance and function.

Retention

The act of preserving less-frequently-used documents (including electronic medium) in a location such as archive and stockroom outside the worksite in a manner that allows prompt retrieval when needed.

Routine check A pre-use check of equipment for appearance and function performed by the using department of the applicable equipment.

S

Self-controlled IPP

The IPP falling under the items other than specification change IPP or quality improvement IPP, which is self-controlled by supplier through confirming and recording quality, process-ability, assemble-ability, etc. after changes.

Service campaign An act of implementing improvement measures by submitting a notice to the competent authorities in accordance with Article 10 (Implementation of Service Campaign) of Circular Notice.

Specification change A change to the entry in the field for notating changes to component parts in the product drawing or specification change notice.

Specification change IPP

The IPP to which specification change was implemented by

supplier in accordance with the “ Application Change

Instruction” issued by Honda.

Stage Management

A management method that controls supplier activities on a step-by-step basis. The processes of pre-production and mass production are divided into 6 stages from stage I to stage VI. Main activity to be completed at each stage is described below.

Stage Ⅰ：Obtain product requirements from Honda. (Stage I will

be omitted hereafter since this stage consists of activities prior to the Pre-production.)

Stage Ⅱ：Formulate a manufacture management plan.

Stage Ⅲ：Promote activities required based on the manufacture

management plan.

Stage Ⅳ：Verify quality maturation status.

Stage Ⅴ：Confirm the prospect of transition to mass production

and declare completion of production preparation.

Stage Ⅵ：Mass production.

Storage The act of organizing frequently-used documents in a manner that allows fast retrieval during daily business operations.



October 1, 2018


Terms Definitions

Standard deviation

One of the numeric values which correspond to the distribution of statistical values and random variables, and expressed by σ.

6 σ represents the value of σ (standard deviation) multiplied by six times.

Sub-Supplier ( tier 2 and beyond)

A service provider whom a supplier purchases parts from and outsources services to such as fabrication, testing, etc., and including those who beyond the first service provider, it is collectively referred to as sub-suppliers.

Supplier (tier 1supplier)

A first tier supplier to Honda who receives orders for parts directly from Honda.

Supplier drawing

A drawing of parts drawn and issued by a supplier, which Honda had outsourced the design, development, and manufacturing to, in accordance with the basic requirements of preliminary specifications provided by Honda, or a “parts supplier’s drawing” which referred to as a supplier’s drawing.

Supplier in-house visitor A member who was selected by a supplier from its own employees and leads assessment during a Quality Assurance Visit (supplier quality audit).

Supply part supplier A company which has a direct contract with Honda, and provides supply parts to another company designated by Honda.

Supply part user A supplier who uses supply parts as components in the manufacture of parts to Honda.

Supply parts

Component parts provided to a supplier by Honda to manufacture parts to be delivered to Honda. This applies when Honda purchases a part from a supplier (supply parts supplier) and/or manufactures a part, which is provided to another supplier (user) for a fee to manufacture parts delivered to Honda.

T

Total quality characteristics

Quality characteristics of the final products completed by a supply part user.

Traceability The ability to trace the history, application or location of a product or servicing by record identification.

V Variable (continuous data)

Data obtained by measurement. Unit of measure can be made precise depending on the measuring device.



October 1, 2018


Table 6-1-1

Terms Definition

Part

origin

Part origin is a part characteristic and control for each part maturation stage.

It is described and controlled based on the definitions of “Elements” and “Part level” in the list of

“Definition of part origin”.

Part origin is stated based on the description of part level in the list of “Definition of part origin”.

List of “Definitions of part origin”.

ToolPart

DimentionTexture

Proto type(PR)

・Parts not produced on MPTool.Prototype tooling istemporary tooling notintented for MP use.

Proto type

Meetdrawing

(Handworkallowed)

No textureRequired

Temporaryallowed

Temporaryallowed

Temporaryallowed

Temporaryprocess andsequence

Temporaryallowed

NMassociate/Engineer

Norestriction

T1 ・Produce with MP tool

MP Tool(except

blank,trim,pierce,bender

)

↑ ↑ ↑

・MP jig

available

・Temporary

allowed

・MP

inspection

fixture

available

・Temporary

allowed

↑MP materialand country

of origin↑ ↑

T2・Produce with MP tool forall process.

MP Tool ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑ ↑

T3

・Performance is equivalentto MP and enables start ofPV test・Enable a Texture-Go fortexture parts

↑

Meetdrawing(without

handwork)

TextureReady

Equivalentto MP

MP MP

※Process

equivalent to

MP/Sequenc

e is MP.

↑ ↑ ↑

T4(Texture parts

only）

・Texture applied and allowsfor apperance evaluation.

↑ ↑TextureRequired

↑ ↑ ↑ ↑ ↑ ↑ ↑

LT・MP condition for allprocess except massproduction volume.

↑ ↑ ↑ MP ↑ ↑MP process

andsequence.

↑MP

associate(any shift)

MP finallocation

MP・MP assurance isguranteedfor both qualityand quantity

↑ ↑ ↑ ↑ ↑ ↑MP processand cycle

time.↑

MPassociate(all shift)

↑

BuildLocation

Elements

Part Origin Description Equipment JIGInspection

FixtureProcess Material Manpower

※Mass production equivalent process: Process that is identical to mass-production.

Process that can produce products with quality and volume that is assured in mass-production.



March 1, 2018



Purchasing Operation Office Purchasing Operation Office Purchasing Operation Office Purchasing Operation Office Purchasing Operation Office

Parts Cost BL Parts Cost BL Parts Cost BL Parts Cost BL Parts Cost BL

Purchasing Div-Ⅰ Purchasing Div-Ⅰ Purchasing Div-Ⅰ Purchasing Div-Ⅰ Purchasing Div-ⅠRaw Material Strategy BL Raw Material Strategy BL Raw Material Strategy BL Raw Material Strategy BL Raw Material Strategy BL

Purchasing New Model Office Purchasing New Model Office Purchasing New Model Office Purchasing New Model Office Purchasing New Model Office

M.R.O. BL M.R.O. BL M.R.O. BL M.R.O. BL M.R.O. BL

Regional Operations（Japan） Regional Operations（Japan） Regional Operations（Japan） Regional Operations（Japan） Regional Operations（Japan）

Functional Parts Cost BL Functional Parts Cost BL Functional Parts Cost BL Functional Parts Cost BL Functional Parts Cost BL

Powertrain & Drive System Parts Cost BL Powertrain & Drive System Parts Cost BL Powertrain & Drive System Parts Cost BL Powertrain & Drive System Parts Cost BL Powertrain & Drive System Parts Cost BL

Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div

QD Planning BL QD Planning BL QD Planning BL QD Planning BL QD Planning BL

Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div

Production Improvement BL Production Improvement BL Production Improvement BL Production Improvement BL Production Improvement BL

Transmission Quality Dept

Parts Quality Dept Power Train Quality BL Parts Quality Dept Parts Quality Dept Regional Operations（Japan）Parts Procurement Dept. Parts Procurement Dept. Parts Procurement Dept.

Parts Quality Dept

Parts Procurement Dept. Parts Quality Dept

Powertrain 　Strategic 　Planning　Office Parts Procurement Dept.

Regional QD Support BL Regional QD Support BL Powertrain　Planning　Center

Powertrain 　Strategic 　Planning　Office New　Model　BlockPowertrain　Planning　Center

QD Management BL New　Model　Block QD Management BL

Parts Quality Dept Power Train Quality BL Parts Quality Dept Parts Quality Dept Transmission Quality Dept

Parts Procurement Dept Parts Procurement Dept Parts Procurement Dept Parts Procurement Dept Transmission Quality Dept

Parts Quality Dept Parts Quality Dept Automobile Production, Suzuka Factory

Engine PlantEngine Management Dept. Parts Procurement Dept.

Material Service　Dept Material Service　Dept Material Service　Dept Material Service　Dept Transmission Control BL

Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div

Domestic Parts Distribution Dept( Saitama ) Domestic Parts Distribution Dept( Saitama ) Domestic Parts Distribution Dept( Suzuka ) Domestic Parts Distribution Dept( Suzuka ) Domestic Parts Distribution Dept( Suzuka )

Vehicle Assurance Control Dept Power Train Quality BL Vehicle Assurance Control Dept Vehicle Assurance Control Dept

Vehicle Assurance Control Dept

Vehicle Assurance Office

Purchasing Operation Office

Purchasing Operations, Automobil Purchasing

Supervisory Unit

Purchasing Technical Div

Regional Operations（Japan）

Production　Operations, Production　Planning

Supervisory　Unit




Supervisory　Unit

Automobile Production, Suzuka Factory



Supervisory Unit

Purchasing-

Cost

Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing

Honda R&D Co.,Ltd.TAC

Analysis Dept

TAC

Analysis Dept

TAC

Analysis Dept

TAC

Analysis Dept

TAC

Analysis Dept

Market quality

Engine Plant Vehicle Assurance Office Vehicle Assurance Office Automobile Production

Suzuka FactoryVehicle Assurance Office

Honda R&D Co.,Ltd. Honda R&D Co.,Ltd. Honda R&D Co.,Ltd. Honda R&D Co.,Ltd.

Suzuka Plant

Material

service

Production Operation Office Production Operation Office Production Operation Office Production Operation Office

Procurement

Purchasing Operation Office Purchasing Operation Office Purchasing Operation Office Suzuka Plant

Automobile Production Purchasing Div


Automobile Production Purchasing Div

Receiving

quality

Purchasing Operation Office Engine Plant Purchasing Operation Office Purchasing Operation Office Suzuka Plant

New model

preparation

sectionPurchasing Technical Div

Purchasing Operations

Enforcement charge

section

Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing




Engine Plant

Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing

Supervisory Unit Supervisory Unit Supervisory Unit Supervisory Unit Supervisory Unit


Purchasing-Planning


Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div


Automobile (Drivetrain)


Saitama area Suzuka area


Automobile Production

Saitama Factory



Suzuka Factory

Production Operations

Transmission Factory

Suzuka Plamt

Automobile (Frame) Automobile (Powertrain) Automobile (Frame) Automobile (Powertrain)

Delivery

Contact



March 1, 2018


Procurement Dept

Purchasing Div-Ⅰ No.1 Dept Purchasing Div-Ⅰ No.1 Dept Purchasing Div-ⅠRaw Material Strategy BL No.2 Dept Raw Material Strategy BL No.2 Dept Raw Material Strategy BL

Purchasing New Model Office Purchasing New Model Office Purchasing New Model Office

M.R.O. BL M.R.O. BL M.R.O. BL

Regional Operations（Japan） Regional Operations（Japan） Regional Operations（Japan）

Functional Parts Cost BL Functional Parts Cost BL Functional Parts Cost BLPowertrain & Drive System Parts Cost BL Powertrain & Drive System Parts Cost BL Powertrain & Drive System Parts Cost BL

Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div

QD Planning BL QD Planning BL QD Planning BL QD Planning BL QD Planning BL QD Planning BL

Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div Purchasing Technical Div

Production Improvement BL Production Improvement BL Production Improvement BL Production Improvement BL Production Improvement BL Production Improvement BL

Motorcycle Plant Power Product Quality Department Management Dept

Procurement Assurance Dept. Procurement Dept Motorcycle Operations, Kumamoto Factory Venders Procurement Dept Quality Control Dept Production Planning Dept.

Motorcycle Plant Motorcycle Plant

Procurement Assurance Dept. Procurement Assurance Dept. Production Operations

Powertrain 　Strategic 　Planning　Office Development　Promoting　Centeｒ Transmission Factory Powertrain 　Strategic 　Planning　Office

Powertrain　Planning　Center Development　Promoting　Department Powertrain　Planning　Center

New　Model　Block Procurement Dept New　Model　BlockDevelopment　Promoting　Centeｒ Development　Promoting　Centeｒ

Development　Promoting　Department Development　Promoting　Department

Powertrain New-Model Promotion BL

Motorcycle Plant Motorcycle Plant Power Product Quality Department Quality Control Dept

Procurement Assurance Dept. Procurement Assurance Dept. Quality Dept Quality Dept

Motorcycle Plant Motorcycle Plant

Procurement Assurance Dept. Procurement Assurance Dept. Motorcycle Plant Venders Procurement Dept Procurement Dept

Procurement Assurance Dept. Venders Procurement Dept

Power Product Dept Manufacturing　MoPlant Control Department Plant Control Department Material Service Dept

Moka Drivetrain PlantDrivetrain Plant Management Dept.

Power Product Quality Department Quality Control Dept

Motorcycle Products Engineering Dept Hamamatsu Product Engineering Dept Quality Dept

Analysis supervision Dept. Quality Control & Planning Dept.

※ In the case of KD parts, each region's Production Parts Logistics Section is the contact point for logistics quality. Each region's Product Parts Logistics Section is as follows:

Saitama area： Production Operations, Production Planning Supervisory Unit, Global Parts Logistics Division, International Parts Exchange Dept.(Saitama)

Suzuka area： Production Operations, Production Planning Supervisory Unit, Global Parts Logistics Division, International Parts Exchange Dept.(Suzuka)

Hamamatsu area： Production Operations, Production Planning Supervisory Unit, Global Parts Logistics Division, International Parts Exchange Dept.(Hamamatsu)

Power Product Operations Hosoe Outboard Engine Plant Manufacturing　Mo

Kumamoto area： Motorcycle Operations Kumamoto Factory Production Operation Office ProductionControl Department

Power Product Operations Kumamoto Power Product Plant Power Product Department

*4-5-1 Delivery Quality Problem 　If any contact addresses of the delivery destinations described in the clause 3.1 are unknown, the supplier shall contact to the following contact addresses:

(1) If the supplier knows the delivery destination but does not know the contact address,　Automobile　Saitama area（Frame） [email protected] Automobile Saitama area （Powertrain） [email protected] Automobile Hamamatsu area （Drivetrain） [email protected]　Automobile Suzuka area （Frame / Powertrain） [email protected] Automobile Suzuka area （Drivetrain） [email protected] Automobile　Tochigi area （Powertrain） [email protected]

　Motorcycle Kumamoto area [email protected] Power Product Kumamoto area （Power Product） [email protected] Power Product Hamamatsu area （Outbroad Engine） [email protected]

(2) If the supplier does not know any delivery destinations of a part composing of an automobile product,　Automobile　ALL [email protected]

※In the case of service parts, Japan Regional Operations, Spare Parts Division, and Quality Control Department are the contact points for receipt quality.

※The Honda Contact Conversion Table contains information describing Honda's contact sections for general parts. Please note that there are some exceptions for materials, coatings and brake fluids.

Supervisory Unit


Supervisory Unit Supervisory Unit

Honda R&D Co.,Ltd. Quality　Control　＆Verification　Dept. Honda R&D Co.,Ltd.Quality Assurance Division

Honda R&D Co.,Ltd. Quality Assurance DivisionTAC

Analysis Dept

TAC

Analysis Dept

TAC

Analysis Dept

Market quality

Quality Control Office Quality Control Office Quality Control Office

Motorcycle Operations Power Product Operations

Quality Assurance Division

Motorcycle Plant Motorcycle Plant Hamamatsu Plant Moka Powertrain Part Plant

Powertrain Part Procurement Warranty Control

Dept

Power Product Operations

Quality Control Office

Procurement

Motorcycle Operations Kumamoto Factory Production Operation Office Production Operations, Transmission Factory Production Operation Office

Production Operation Office

Material

service



Supervisory　Unit


Supervisory　Unit


Supervisory　Unit

Receiving

quality

Hamamatsu Plant

New model

preparation

section

Purchasing Division



Enforcement charge

section

Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing Purchasing Operations, Automobil Purchasing





Automobile Production Purchasing Div Automobile Production Purchasing Div Automobile Production Purchasing Div


Supervisory UnitPurchasing Operations

Purchasing-Planning


Supervisory Unit Supervisory Unit Supervisory Unit Supervisory Unit

Power Product Operations Purchasing Operations, Automobil Purchasing

Purchasing Planning Office Purchasing Planning OfficeSupervisory Unit Supervisory Unit Supervisory Unit

Motorcycle Power Product Automobile Power Product Automobile

Purchasing-

Cost

Purchasing Operations, Automobil Purchasing Purchasing Division Power Product Operations Purchasing Operations, Automobil Purchasing

Kumamoto area Hamamatsu area Tochigi area

Motorcycle Operations

Kumamoto Factory


Kumamoto Power Product Plant

Production Operations

Transmission Factory


Hosoe Outboard Engine Plant

Automobile Operations


Drivetrain Business Unit

Pow ertrain Unit Factory

Automobile

Delivery

Contact



July 1, 2014



Transaction flow chart of the proposal for SQM revision

Contact

Purchasing

Technical

Division

Supplier Honda

Purchasing

Technical

Division

Purchasing

Technical

Division

Purchasing

Technical

Division

Problem in SQM operation

Sturdy countermeasure

Proposal for SQM Revision

ApplicationReceive and confirm content of proposal

Issue SQM revision

NoticeConfirm

Confirm and break down

Maintain SQM

Judgement for adoption

IMPACTⅢ or e-mail

To supplierIMPACTⅢ or e-mail

Approval of quality assurance representative

N

Y

Handling inquiry

IMPACTⅢ or e-mail





Note: Send proposal for SQM revision

For IMPACT Ⅲ: Send through “Contact” of IMPACT Ⅲ.

For e-mails: Send from [email protected]



July 1, 2014


Entry procedure for the proposal of SQM revision

Entry procedure

〔Proposal for SQM revision〕

Please complete the form below and send it to the PIC of SQM in Honda

SQM heading / term Company name Quality assurance

representative Person prepared Date of issue

①

② ③ ④ ⑤

Reason

⑥

Current writing

⑦

Proposal content for SQM revision / Comment

⑧

Response from Honda

Column for Honda Date received PIC Author of response Date replied

Deadline for the retention of original: YYYY/DD/MM

① : Identify the part of SQM proposed for revision. (e.g. 3-2-1 Process Quality Control Table 3.3.3)

② : Enter the name of your company.

③ : Quality assurance representative sign here for approval

④ : Enter the name of person prepared the proposal.

⑤ : Enter the date of submission to Honda.

⑥ : Clarify reason why revision is needed.

⑦ : Enter original text.

⑧ : Enter proposal to correct the problem.

※If there is any attachment for ⑥,⑦ and ⑧, Enter「See attachment」


6-4 Master List

May 1, 2019


6-4 Master List

Control

Number Document Title

Date of

approval Description

Content 2016/12/1

GIS：Partially revised due to requirement addition and

misdescription correction regarding Global Inspection Standard.

1 Preface 2019/5/1 Reflected the name change in public quality standard.

1-1 Structure of SQM 2016/12/1 GIS： Partially revised due to requirement addition

regarding Global Inspection Standard.

1-2 Production Process Image 2016/12/1 GIS： Partially revised due to requirement addition

regarding Global Inspection Standard.

1-3 SQM Outline 2019/5/1 Reflected the changes in the text.

2-1 Important Safety Parts 2014/7/1

Revised to align with revisions to related documents as

well as revisions to important quality characteristics and

requirements regarding inspection process ability.

2-2 Regulatory Compliance

Certification 2019/5/1

Revised to clarify the roles and responsibilities for Honda

and suppliers.

2-3 Designation of Quality

Representative 2018/3/1

Partially revised due to review of name change in responsible division.

2-4 Sub-Supplier Quality

Assurance 2018/3/1

Revised to reflect changes in Honda’s documentation control standard and the retention period.

2-5 Control of Honda-Owned

Property 2018/3/1


2-6 Control of Supply Parts 2014/7/1 Revised to align with corrections to “Reference

Materials.”

2-7 Supplier Quality Evaluation 2014/7/1 Revised to align with revisions to related documents and

GQI application.

2-7-1 Delivery Quality Evaluation 2018/3/1 Partially revised due to review of name change in responsible division.

2-7-2 Supplier Quality Audit 2018/3/1 Revised to reflect changes in Honda’s organization name, documentation control standard, and the retention period.

2-8 Contaminants Control 2014/7/1 Revised to align with corrections to “Reference

Materials.”

2-9 Control of Quality Records 2019/5/1 Revised to add the requirements for quality record

creation and its approval.

3-1 Stage Management 2018/3/1 Revised to reflect changes in Honda’s documentation

control standard and the retention period.

3-2 Process Design 2019/5/1 Revised to add a statement to allow methods besides

Process・Design FMEA.

3-2-1 Process Quality Control Table 2018/3/1 Revised to reflect changes in Honda’s documentation control standard and the retention period.

3-3 Delivery Packaging 2014/7/1 Revised to align with corrections to “Reference

Materials.”

3-4 Countermeasure at

Pre-production Stage 2018/3/1

Revised to reflect changes in Honda’s documentation


3-5-1 Model CP List 2019/5/1 Revised due to change in receiving inspection method.

3-5-2 Preparation of Limit Samples 2014/7/1

Revised to align with corrections to “Reference

Materials.”

3-5-3 Grain and Color Adjustment 2014/7/1 Revised to align with corrections to “Reference

Materials.”


6-4 Master List

May 1, 2019


Control

Number Document Title

Date of approval

Description

3-5-4 Inspection Criteria for Parts 2019/5/1 Revised due to change in receiving inspection method.

3-6 Control of Monitoring and Measuring Devices 2018/3/1



3-7 Operation Control Documents 2018/10/1 Requirements at the time of Operation standard

creation.

3-8 Delivery of Parts 2014/7/1 Revised to align with corrections to “Reference

Materials.”

3-9 Transition to Mass Production 2018/3/1 Revised to reflect changes in Honda’s documentation


3-9-1 Validity Testing 2018/3/1 Clarified part origin and revised to reflect changes in Honda’s documentation control standard and retention period.

4-1 Early Mass Production Quality

Control 2018/3/1



4-2 Mass Production Quality

Control 2018/3/1


4-3 Identification and Traceability 2018/3/1 Revised IPP examples in SQM to align with HQS, revised SQM to reflect changes in Honda’s documentation control standard, and retention period.

4-4 Change Point Control 2018/3/1 Revised to reflect changes in Honda’s documentation


4-5 Corrective Action Report 2018/3/1 Revised to reflect changes in Honda’s documentation


4-5-1 Delivery Quality Problem 2016/12/1 Revised due to requirement addition regarding contacts in Honda.

4-5-2 Market Quality Problem 2018/3/1 Revised to reflect changes in Honda’s documentation


4-6 Specification Change 2018/3/1 Revised to reflect changes in Honda’s documentation


4-6-1 Countermeasure Request

Form 2018/3/1



5-1 Process Capability 2008/10/1 Formulated as the first issue.

5-2 Error Proofing 2008/10/1 Formulated as the first issue.

5-3 Control Chart 2018/3/1 Revised to reflect changes in Honda’s documentation


5-4 5 Principals for Problem

Solving 2018/10/1 Correction of mistakes

5-5 Process FMEA 2018/10/1 Recommendation of Process design that failure modes

extracted from design FMEA/FTA etc. are utilized.

6-1 Glossary of Terms and

Definitions. 2018/10/1 Correction of mistakes

6-2 Honda Contacts Conversion

Table 2018/3/1

Revised to reflect contacts in Honda and organizational

change.

6-3 Proposal for SQM Revision 2014/7/1 Revised to reflect organizational changes.

6-4 Master List 2019/5/1 Revised to align with SQM revision.