PRODUCT DEVELOPMENT / NEW PART DEVELOPMENT
he initial sample procedure is a process that confirms that we fully understand the requirements and specifications defined by the customer and that we can guarantee these under series production conditions.
To ensure a smooth, fast, and complete sampling process, the following points must be observed to complete initial sample inspection submission:
- Advanced Product Quality Planning (APQP) is a systematic approach to planning and developing new products. It involves identifying and controlling potential problems early in the product development process.
- Production Part Approval Process (PPAP) is a set of requirements that must be met before a new part can be released for production. It ensures that the part meets the customer’s requirements and that the manufacturing process is capable of producing the part consistently.
- VDA is a German association of the automotive industry. It develops and publishes standards for the automotive industry, including the VDA 2.1 Part Approval Process.
- First Article Inspection (FAI) is an inspection of the first production article of a new part. It is used to verify that the part meets the customer’s requirements and that the manufacturing process is capable of producing the part consistently.
The documentation requirements for VDA and PPAP are different at some points. We combine VDA and PPAP scope together and require one extended package of documentation. The only difference is the cover sheet design, which is different according to VDA or PPAP.
The initial sample procedure is an important part of the product development process. By following the procedure, we can help to ensure that the customer’s requirements are met and that the manufacturing process is capable of producing the part consistently. This can help to reduce the risk of product recalls and improve the overall quality of the product.
Here are some additional details about the initial sample procedure:
- The procedure is typically initiated by the customer.
- The supplier must provide the customer with a sample of the product that meets the customer’s requirements.
- The customer will inspect the sample and provide feedback to the supplier.
- The supplier will make any necessary changes to the product and submit a new sample to the customer.
- The process will continue until the customer is satisfied with the product.
The initial sample procedure is an important step in ensuring that the customer receives a quality product. By following the procedure, the supplier can help to avoid costly delays and product recalls.
IN-HOUSE WORKSHOP & TOOL MANUFACTURING AND SOURCING
Our in-house workshop enables us to manufacture high-quality tools in a short amount of time. We use high-quality raw materials, such as carbon and HSS, and we manufacture our tools using multi-axis CNC and wire cutting machines and lathe machines. We also use the latest heat treatments and special coatings to enhance our tools and produce high-volume components with sustained quality.
To optimize the inspection of components and achieve zero rejection, we ensure error-proof designs for all our in-process tooling, jigs, and fixtures.
Here are some of the benefits of having an in-house workshop:
- Quicker delivery: By manufacturing our own tools, we can reduce the time it takes to get tools to our customers.
- Improved quality: By controlling the entire manufacturing process, we can ensure that our tools meet our high standards of quality.
- Adaptability: We can quickly adapt to changes in customer requirements or market conditions.
- Cost savings: By manufacturing our own tools, we can save money on the cost of purchasing tools from outside suppliers.
We are committed to providing our customers with the highest quality tools and services. Our in-house workshop allows us to do this by providing us with the flexibility, control, and cost savings that we need to succeed.
Our manufacturing procedures are carefully documented by our engineering team so that our workforce can implement them. This ensures that we consistently produce quality products by following the procedures.
We use the five core tools as per the latest version of AIAG (e.g. SPC, FMEA, APQP, MSA, and PPAP). To control production rejection, we use SPC tools and techniques such as CP and CPK and control charts to ensure consistent quality is achieved by monitoring and controlling variations within acceptable limits.
We design dedicated gauges and devices to minimize in-process inspection to avoid human errors and misinterpretation while using measurement instruments.
We monitor in-time adherence to deadlines using timeline charts and other rigorous operational planning techniques, such as production planning on a monthly and weekly basis, and production delivery charts.
For subcontracted processes and outsourced jobs, our onsite engineers train and supervise the workforce of our associated manufacturing units, ensuring that all our documented SOPs are followed and any non-conformities (if any) are addressed.
We are committed to producing high-quality products that meet the needs of our customers. Our manufacturing procedures are designed to ensure that we consistently produce quality products, and we are constantly looking for ways to improve our processes.
SYSTEMATIC DOCUMENTS AND RECORDS KEEPING
PRE-DELIVERY INSPECTION AND QUALITY ASSURANCE
To conformance of customers’ product specifications.
Our production batches are supported with comprehensive final inspection report (FIR), made on random sampling basis.
Our FIR set includes documents like dimensional inspection report, raw material test report, Hardness test if required, Plating test if any, ROHS and REACH complaints statement, SPC if required, FMEA if required, Process flow Diagram if required etc. as specified by clients.
PACKING, DISPATCHING & LOGISTIC
We provide specialized packing services to safeguard our products against physical contingencies such as drops, crushes, and vibrations, as well as climatic conditions during transportation and storage.
Our dispatch and logistics team ensures efficient handling, storage, and transportation of products through effective monitoring and coordination with various agencies. This allows us to optimize delivery timelines and provide a seamless experience.
We operate under the following Incoterms:
EXW – Ex-Works or Ex-Warehouse: Under this term, the seller makes the goods available to the buyer at their premises or another designated location, such as a worksite, factory, or warehouse. The seller is not responsible for loading the goods onto a collection vehicle or clearing them for export, if applicable.
FCA – Free Carrier (Indian Named Port): With FCA, the seller delivers the goods to the carrier or a person nominated by the buyer at their premises or another specified place. It is crucial to define the exact point within the named place of delivery, as the risk transfers to the buyer at that precise location.
FOB – Free On Board: Under FOB, the seller delivers the goods on board the buyer’s nominated vessel at the named port of shipment or procures goods that have already been delivered. The risk of loss or damage to the goods transfers to the buyer once they are on board the vessel. The buyer assumes all costs from that moment onward.
CIF – Cost, Insurance and Freight: CIF entails the seller delivering the goods on board the vessel or procuring goods that have already been delivered. The risk of loss or damage to the goods transfers to the buyer when the products are on the ship. The seller is responsible for contracting and paying for the costs and freight required to bring the goods to the named port of destination. Additionally, the seller arranges insurance coverage against the buyer’s risk of loss or damage during carriage. However, it’s important to note that the insurance obtained by the seller may only offer minimum cover. If the buyer desires more insurance protection, they must either reach an explicit agreement with the seller or make separate insurance arrangements.
DAP – Delivered At Place (Import Duty is on Buyer’s Account): Under DAP, the seller delivers the goods when they are made available to the buyer at the named place of destination, ready for unloading from the arriving means of transport. The seller bears all risks associated with bringing the goods to the named place.
We prioritize the safety and secure handling of your products throughout the entire process to ensure their integrity during transportation and storage. Our aim is to provide a reliable and efficient service tailored to your specific needs.
HANDLING OF COMPLAINTS
We respond to our customer’s complaints by applying problem solving technic such as CAPA, 8D report etc. to effectively address the toot cause and then apply appropriate irreversible remedial measures by using control parameters.
We then provide detailed “Investigated action report” to our customer for their satisfactory approval and closure of the complaint.
Complaint can be escalated to our sales or Key contact person directly or it can be reach to us at email@example.com