HSS Otomotiv Quality System

HSS Otomotiv Quality System is based on requirements of ISO 9000:2000 and ISO/TS 16949:2002, customer care and expectations, flexibility for continuous improvements and developments, aims of the company, productivity and competitiveness and terms of markets. To prove the existence of the Quality System in the organization of the company and to allow the system to make a progress without depending on people Quality Management System must be organized as written documents. Quality Handbook, Processes, Process Main Activities, Process Procedures, Forms, Organization Diagram, Determinations of Authorities and Responsibilities, Instructions and Specifications provide written proofs for the existence of Quality Management System.

HSS Otomotiv ve Lastik Sanayi A.S. production and service quality is attained by Management, Quality Management, Purchasing, Data Processing, Production, Research and Technology, Technical Facilities, Sales and Marketing, Financial and Administrative Operations Processes which are included in Quality Management System.

HSS Otomotiv ve Lastik Sanayi A.S.

Management Process

A. Determination of Company Profile,

B. Determination of Aims of the Company and Inspection of Aims,

C. Preservation of the Present Situation and Official Obligations.

Quality Management Process

A. Creation of Quality Management System,

B. Constant Improvement/Development

C. QMS Practise and Investigation,

D. Control Activities,

E. The Process of Elimination of Inappropriate Situations,

Purchasing Process

A. Preservation of the Present Situation (Routine Purchasing Activities),

B. Supplier Management,

C. Access Quality Control

Data Processing

A. Preservation of the Present Situation,

B. New Software and Hardware Management

Production Process

A. Planning of Production,

B. Production

C. Continuous Improvement/Development

Research and Technology Process

A. New Process/Product Development,

B. Production Investigation (Product Tests)

C. Process /Product Alterations,

D. Laboratory Management,

E. Technical Document Management.

Technical Facilities Process

A. Machine/Mould Management,

B. Control Tools Management,

C. Continuous Improvement/Development.

Sales and Marketing Process

A. Preservation of the Present Situation (Series Orders),

B. New Product Activities,

C. Customer Market Management,

D. Product Transportation, Storage, Packaging, Shipment,

E. Retail Outlet Management

Financial and Administrative Operations Processes

A. Financial Plan Preparation, Investigation and Cost Analysis

B. Quality Costs,

C. Employee Satisfaction Management

Quality Control Activities

HSS Otomotiv ve Lastik Sanayi A.S. quality control activities which are included in Quality Management System are executed by Quality Management Department and the other related units.

Quality Management Process

Internal Audit Activities

Control Activities in Quality Management Process is performed by means of annual audits that include all units in quality system. Those audits provide all the items of related system standards, all the related units and the items of the units. Audits are performed according to annual audit plan in the following intervals:

System audit is performed two times a year by the audits who are independent and assigned by Management representative.

Process Audit is carried out for all the processes twice a year by means of corresponding audits held by independent units.

Product Audits are carried out according to product audit plan and needs concerning internal quality problems, new product activities and plans for products determined by technical facilities unit.

Work Safety Audits are made every two week; working environment is supervised and determined if there is any situation that might jeopardise work safety.

However, for these periods specified above, the intervals between audits can be changed or rescheduled on account of customer complaints, alterations in the organization, and internal or external quality deficiencies in quality system.

Failure Prevention Activities

1. Precautions for preventing failures that have to be taken before the occurrence of failures (Precautions against Failures): As a consequence of the audits of the units, a team is made up in order to determine the possibility of failures that are likely to be made by related units. An analysis of possible failure is done and the results are fixed to a notice board. Supplementary techniques can be used such as brainstorming and fishbone in order to try to develop ideas and think of ways of solving problems and these techniques can be used to determine precautions against failures to put into practise. The effectiveness of precautions against repeated failures can be audited by related units and Unit Quality Chiefs. Eventually prevention activities are discussed in Management Quality Meeting.

Failure Modes and Effects Analysis (FMEA): When a new product is put into production, when process alterations are made, and when an important quality problem occurs, Failure Modes and Effects Analysis (FMEA) is decided to be made. Afterwards technical design, process flow charter, product tree, operation cards, control instruction and plans are arranged and then Failure Modes and Effects Analysis (FMEA) Team is chosen. Process intervals are determined in the Failure Modes and Effects Analysis (FMEA) meetings and activities. Definitions of examinations concerning production process and production function; process phases, functions and the determination of functions of all parts and characteristics that fulfil the functions are FMEA Team’s responsibility. Failure modes, effects, causes and control processes are determined and recorded in a form by FMEA Team through examining the tables about probability, strength, inventiveness points. After the date of corrective and preventive actions and authorities have been determined, the predictable risk priority indicator is determined and when the risk priority indicator is under 100, corrective and preventive actions will be set into progress. When an investment has to be made in corrective and preventive actions, investment approval will be received by relevant unit. The effectiveness of corrective and preventive actions is inspected by relevant units and FMEA results are considered in management quality meetings.

Quality Activities in Purchasing Process

Quality Control Activities begins with Supplier Determination Activities in Purchasing Process. ISO 9000:2000, ISO/TS 16949 is requested from suppliers as the basic requirements of quality system. If the supplier fulfils those system requirements the supplier will be beyond the scope of quality system progress. Supplier who is within the scope of progress is audited in accordance with “Supplier System Audit” at first to find out the status of supplier in the scope ISO 9000:2000 – ISO/TS 16949. An interview is held with supplier and a process programme is requested. If requested by supplier HSS Otomotiv Quality Management Unit gives education to supplier and support them in progress programme. The progress is audited by means of system audits periodically (at least annually)

The first control in Purchase Process is measurement control and first sample control which includes material, function, steadiness phases. The determination of the appropriateness of first samples (first sample control report) phase is followed by making the order for initial mass production and administrative approval of initial mass production, access quality control of initial mass production and serial purchase phases.

Access Quality Control Administrative Approval/Control: The sum of order, deadline date and identification control are checked and if the shipped materials are the materials that needs technical approval such as mould, axle, computer parts (hardware or software); materials are delivered notifying related (expert) units.

In the controls that are held in accordance with access quality control plan the products which are examined by access quality control unit are measured and the results are recorded in form of consignment measurement.

Control Activities in Production Process

1. Preproduction control work obligations: Work obligations are distributed to workers and checked with preproduction control form of preproduction process terms by Unit Manager, Unit Executive or Shift Executive.

2. Controls during Production: Cord fabric cutting, stainless steel wire, rolling and vulcanizing process, activities are carried out according to material and production information, control plans and work obligations. In case of inappropriateness during the production controls, the problem is resolved by starting corrective and preventive actions in accordance with relevant process procedure. When the problem cannot be determined or when team-work is required, the problem resolving techniques are used such as brain-storm CEDAC – 8D methods.

3. The Final Decision Committee Working: The Final Decision Committee Working System is used in every process from access quality control to final product. The Final Decision committee is a committee which takes place when workers cannot decide finding solutions by current control plan, other documents and personal experiences against problems that might affect quality. The Final Decision Committee is charged to find solutions towards changeable situations, to take emergency precautions, to decide to use the material and/or product in spite of the bias when the conditions do not affect quality.

4. Production Final Control: Control Plan in production is the process of examining air springs in accordance with fault searching technique after vulcanization. At the end of Production Final Control the air springs which are separated for the Final Decision Committee or renovation or separated as scrapped items are examined again by Unit Manager or Shift Executive and the damaged parts are marked and sent to renovation unit. The renovated air springs are vulcanized and sent to the Final Decision Committee section. The air springs which are regarded as scrapped items by the Final Decision Committee are examined again and marked and sent to scrapped items section. If the air springs are sent to shipping section with metal parts, metal assembly is made according to metal assembling instructions. After assembling metal parts, air springs are examined according to sticking, perpendicularity, leakage, eye, axis deviation criteria. “Leakage Test was made”, “Axis control was made” labels are placed on air springs afterthe examination and the air springs are sent to shipping unit.

Control Activities in Shipment Process

Air springs, which are ready to transfer to sales depertment, are controlled 100% by a team which includes Production Manager and Shift Supervisors according to failure inspection key two times a month (without giving prior notice).

Results of the controls are recorded in stud control investigation and recording form. The products, which are produced and readied for delivery by production depertment, are received with “Product Delivery Receipt”. The in box quantity and the correctness of products received are checked by Shipment Department according to shipment control plan. The products are transferred to trackback form after quantity verification and controls and shelved in the stock area filling in the control cards.