Trostel, Ltd. Supplier Quality First Manual. Rev: C 6/19/09

Transcription

1 Trostel, Ltd. Supplier Quality First Manual Rev: C 6/19/09

2 Trostel, Ltd. Supplier Quality First Manual Our Quality Philosophy: OUR GOAL IS TO PROVIDE CONTINUOUS IMPROVEMENT, EMPHASIZING DEFECT PREVENTION AND THE ELIMINATION OF WASTE, THROUGHOUT THE SUPPLY CHAIN. This manual is a controlled document. Copies distributed to customers and employees are considered to be Uncontrolled unless otherwise noted. For the most current update, view supplier manual on Trostel s web site at every 90 days. Welcome to the Supplier Quality First Manual Trostel Ltd. takes great pride in being a supplier of quality parts at competitive prices. We look to our suppliers as partners in our production team. This relationship will assist us in maintaining both our quality and our value to the ultimate customer. Our world is becoming more demanding, looking for continuous improvement, and demanding better quality at lower costs. Working together to meet these goals is paramount to success. We ask all of our suppliers to take on the great challenge of partnering with our customers and us. Please join us in this challenge! Trostel, Ltd. Division: Headquarters Whitewater Sealing Products Polymer Compounding Mexico Molding Trostel Mexico S.deR.L.deC.V. Address: 901 Maxwell St. 840 Executive Dr. 736 Executive Dr AV.Fomento Industrial Lote 8 Manzana Lake Geneva, WI Whitewater, WI Whitewater WI Parque Industrial del Norte Reynosa, Tamps. CP Mexico Phone: (262) (262) (262) (899) Fax: (262) (262) (262) (899) Revision C 6/19/09 Page - 2 -

3 Table of Contents: Page Welcome Page 2 Table of Contents 3 Manual Sections: 1.0 Foreword Introduction Registration Certificate Specific Quality Elements Trostel Evaluation, Selection and Audit Requirements Trostel PPAP Requirements Trostel Specific Requirements Supplier Certification Process 15 Appendix 16 Supplier Sample Submission Request 17 PPAP Submission Warrant 18 PPAP Shipping Label 19 Quality Failure Notice-Supplier Corrective Action Request (SCAR) 20 Supplier Self Survey Supplier Request for Engineering Approval (SREA) 27 Request for Deviation/Waiver 28 Scorecard Example 29 Revision History: Initial Release: Nov 2003 Rev A: Updated sample Request, Warrant and Label Jan 2006 Rev B: Revised entire document Aug 2007 Rev C: Updated entire document Jun 2009 Revision C 6/19/09 Page - 3 -

4 1.0 Foreword 1.1 Scope This manual applies to supplier s providing products and/or services to Trostel Ltd. from here on known as Trostel. The products and/or services purchased shall be produced, controlled, inspected and tested in accordance with specifications. The intent of this manual is to explain Trostel s policy as it relates to Trostel suppliers as well as communicating basic requirements that must be met. It will also provide a means of communication between Trostel and the supplier. Note: The Trostel Supplier Quality First Manual has been developed by using the current revisions of the following manuals. Trostel requires its suppliers to use the latest version of these manuals as a supplement. Manual Published by: Description ISO TS16949 ISO Quality Systems-Automotive Suppliers APQP AIAG Advance Product Quality Planning and Control Plan FMEA AIAG Potential Failure Mode and Effects Analysis MSA AIAG Measurement System Analysis SPC AIAG Fundamental SPC QSA AIAG Quality System Assessment PPAP AIAG Production Part Approval Process T&ES AIAG Tooling and Equipment Supplement To obtain a copy of these documents, contact the following: 1.2 Position Statement Automotive Industries Action Group AIAG Lahser Road, Suite 200 Southfield, MI Phone: (248) , Fax (248) Trostel recognizes and emphasizes the importance of the objective of reducing part variability through continuously improving and maintaining the quality of its products. This recognition becomes both the supplier and Trostel s responsibility to consistently provide quality products and services that meet Trostel standards and the standards of our customers Revision C 6/19/09 Page - 4 -

5 2.0 Introduction 2.1 Supplier Requirement Suppliers are responsible for all provisions of the purchase order, current drawings, standards and specifications referenced on the drawings. This manual defines the quality systems the supplier must employ to control products and/or services subject to Trostel purchase orders. These requirements supplement and are an extension of the requirements of the purchase order. In the pages ahead, as will be seen, Trostel also has responsibilities to the supplier. Trostel has several systems designed to make the Supplier s job easier. Among these systems are an Engineering Deviation review, and consulting services by Trostel Quality Management accessed through the Purchasing Department. Feel free to contact Trostel for assistance in interpretation of Trostel drawings, gage correlations or any other problems that may come up in an effort to fill Trostel s order. Trostel will call on suppliers for assistance as necessary in applications of their products. It is only through an atmosphere of mutual assistance and free exchange that the relationship can achieve maximum benefits for each of us. 2.2 Supplier Responsibilities Resolve all questions relating to fulfillment of the contract before accepting the purchase order. Maintain specific procedures and controls necessary to assure on time shipments of consistent and acceptable quality products. These requirements are outlined on the next few pages. Trostel s Quality Management through Purchasing will assist suppliers in the interpretation and applications of these requirements if needed. Suppliers must provide and maintain a quality management system, which will assure that all products and/or services conform to the Purchase Order and ISO and TS requirements whether manufactured or processed by the supplier, or procured from subcontractors. Suppliers must perform or have performed the inspection and tests required to substantiate product conformance to drawings, specifications, and purchase order requirements. The supplier s quality system to control products and/or services shall be documented and be available for review by Trostel representatives when requested. 3.0 Registration Certification Trostel is committed to a program to procure goods and services from those suppliers who are quality leaders in their respective fields and have obtained a minimum of ISO registration (ISO/TS registration is preferred for automotive). Revision C 6/19/09 Page - 5 -

6 4.0 Specific Quality Systems Elements 4.1 Production Part Approval Process (PPAP) The supplier shall observe all Trostel requirements for production part approval (see Section 6.0). The Production Part Approval Process (PPAP-AIAG Level 4) is utilized in full unless otherwise specified by Trostel. Sample submissions and required documents shall be directed to Trostel Purchasing Supplier Quality Engineer. 4.2 Continuous Improvement The supplier management systems and practices shall promote continuous improvement in quality, cost and delivery performance. Each department within the company shall pursue continuous improvement in all aspects of performance, with emphasis on Trostel perceived quality, cost and delivery factors. Executive and operating management shall monitor selected objective indicators of performance. Long-term performance history shall be periodically evaluated and trends analyzed. Targets shall be established based on performance and particular priority given to indicators that do not attain fully satisfactory Trostel performance levels. Short-term performance shall be monitored against planned targets and formal corrective action initiated when planned targets are repeatedly missed. Education and training in formalized problem solving and analytical techniques shall be provided to employees. Performance indicators shall be updated as required based on changes in business circumstances. 4.3 Facilities, Equipment and Process Planning The supplier shall utilize a systematic approach to facilities, equipment and process planning, incorporating cross-functional involvement to optimize performance. Cross-function teams shall develop facilities, equipment and process plans. Plant layouts shall be designed to support activities such as: Minimized material travel and handling Utilizing synchronous (one-piece) material flow where practical Maximizing value-added use of floor space Revision C 6/19/09 Page - 6 -

7 Process plans shall be evaluated based on activities such as: Overall work flow Appropriate automation Ergonomics and human factors Operator and line balance Storage and buffer inventory levels Value-added labor content Mistake-proofing techniques shall be employed where appropriate based on process FMEA and other analyses. 4.4 Documentation Retention For traceability of records, the following documents must be made available for Trostel s on site review for the life of the product plus one year: Inspection documents Quality Documents Process Documents History of Product Documents Contract Documents Revision C 6/19/09 Page - 7 -

8 5.0 Trostel Evaluation, Selection and Audit Requirements 5.1 Supplier Evaluation and Selection Process When a supplier has not been approved or certified by Trostel, the choice of a new supplier takes place through the coordinating efforts of a team of individuals from Trostel s purchasing, quality and other functions as appropriate to the program. This supplier sourcing strategy must be completed prior to the awarding of a contract. The Trostel sourcing strategy includes various steps including but not limited to the following: A) Source Evaluation Identification, contact and information exchange Preliminary information review and decision on future actions Information exchange, review and recommendation Request for Quotation (RFQ) B) Source Selection Per supplier scorecard measurement Competitive economic cost Technical and support capability Available capacity Delivery performance Quality performance Quality system status based on a minimum of ISO/TS registration Supplier compliance with government, safety and environmental regulations Sample evaluation, where applicable Results of on-site technical assessment Recommendation of Trostel, Ltd. Customer directed sourcing C) PPAP Submission Documentation Submission D) Production Release The purpose of this strategy is to recommend suppliers demonstrating the capability to meet Trostel requirements. Revision C 6/19/09 Page - 8 -

9 5.2 Supplier Self Assessment Suppliers who have obtained a minimum of ISO registration and can provide proof of maintenance shall be excluded from Trostel Self-assessment requirements as agreed upon with Trostel Quality/Purchasing Management. Suppliers may be required to submit a self-assessment of their quality systems as follows: 1) During the supplier evaluation and selection process if they are a new supplier wanting to become part of the Trostel supplier base. 2) At least once every other year to ensure quality system adherence and Trostel requirements are being met. 3) At Trostel s request when deemed necessary. Suppliers are responsible for auditing the total quality system in the plant and must have a documented audit procedure. The AIAG quality system assessment (QSA) for ISO/TS16949 is used by Trostel in auditing our supplier base. Audit results must be reviewed by the supplier s management and documented corrective action must remain on file per the agreed upon retention period. Trostel will periodically review the audit results. Suppliers will work with Trostel to facilitate on-site audits for Trostel and Trostel customers. 5.3 Supplier Quality System Audit Suppliers who have obtained ISO/TS16949 registration and can provide proof of maintenance shall be excluded from Trostel Quality System Audit requirements as agreed upon with Trostel Quality/Purchasing Management. Summary of third party reports conducted at suppliers sites shall be shared with Trostel Quality Management upon request. Revision C 6/19/09 Page - 9 -

10 6.0 Trostel PPAP Requirements (For supplier bulk materials, contact Trostel Purchasing.) 6.1 Prototype Submissions A prototype submission is a verification that the prototype sample part conforms to Trostel specifications. The supplier shall submit to Trostel Purchasing department (Trostel nonproduction level 6 unless otherwise noted by Trostel): Warrant Material Certification Six (6) Sample Pieces Dimensional layout of the six (6) sample pieces MSDS sheets (if required) Supplier shall deliver the sample pieces and required documentation on or before the date specified. 6.2 Production Part Approval Process (PPAP) Once production tooling and processes are completed, the supplier shall submit a Production PPAP which meets the requirement of Trostel s PPAP Sample Submission Request sheet to the designated submission level. The PPAP sample submission layout (if applicable) shall be in accordance with the latest AIAG PPAP manual. Results of six (6) parts may be reported on a single report and submitted with the PPAP package. If a multiple cavity tool, the supplier shall include a complete dimensional and note layout on one part from each cavity. Submitted samples shall be 100% inspected to the required specifications. The supplier shall detail specific dimension, laboratory and any other required specifications. (The supplier s form and format is acceptable.) The official PPAP submission label shall be placed on the outside of the package in which the PPAP is sent. A sample of this label is found in the Appendix PPAP Sample Submission Request Sheet Trostel Purchasing generates the PPAP Sample Submission Request sheet. This sheet outlines the requirements and documentation that is needed from the Supplier according to the designated PPAP submission level. A sample copy of this sheet has been provided in the Appendix along with a copy of the PPAP Sample Submission Warrant. 6.3 Material and Engineering Standards Testing Certification The Supplier shall send material certifications unless otherwise documented in writing. Certifications shall include actual test data, which indicate capability and control of the lot or lots of material. (A Supplier s lot shall be a quantity of a product produced under similar conditions so that the product within the lot is expected to be homogeneous in all significant attributes. Unless otherwise stated in the control plan or other applicable purchase documents, a lot shall consist of no more than eight hour s production produced within one day.) Certifications shall be signed and dated by the appropriate personnel. The following information shall be included on the certifications: Supplier s case or trace number; multiple lots must be listed individually Supplier date of manufacture All specifications to which the component s lot of material is tested. Include a legible copy of the test results. Revision C 6/19/09 Page

11 6.4 Critical Characteristics Noted on Print The supplier shall submit capability studies on critical characteristics noted on the print. The supplier s data must show that their process meets or exceeds the critical characteristic requirements on the print. A standard of 32 pieces shall be used unless otherwise noted on the Trostel Supplier Sample Submission Request. A Gage R & R study shall also be submitted for each gage used in the study. (Reference the AIAG MSA Manual unless otherwise noted by Trostel.) 6.5 Production Shipments Suppliers shall not ship parts, components, supplies, fixtures, equipment or provide a service to Trostel without approval from Trostel Purchasing Department. The Supplier will only ship subsequent regular production to Trostel after the Production PPAP has been approved by Trostel Purchasing Quality Management and confirmed by Trostel Purchasing. Trostel Purchasing will provide approvals to ship based on quality performance and delivery Packaging Unless otherwise specified, packaging will be recommended by the supplier and approved by Trostel. Products shall be packaged in containers that protect the product from damage that can occur during transportation, material handling, stacking and the environment. Pallets need to be 4 way accessible Labeling Packaging shall be clearly labeled with the standard AIAG bar coded label containing Trostel s Part Number, Purchase Order, Quantity etc., in accordance with Trostel Supplier Requirements for Packaging and Transportation Production Chemical Products Suppliers shall not ship parts where the chemical composition or vendor of any chemical product used in the production of parts for Trostel Ltd. (Mold Releases, Drawing Lubricants, Rust Inhibitor, etc.) has changed after the PPAP approval was issued to the supplier. Prior approval for use must be requested from Trostel Ltd. by submitting an S.R.E.A form. (See appendix) Revision C 6/19/09 Page

12 7.0 Trostel Specific Requirements 7.1 Supplier Request for Engineering Action Trostel maintains a system to allow suppliers to request engineering action. If the supplier concern, out of tolerance condition or a suggestion for improvement, the supplier contacts the Buyer to start the process Supplier Request for Engineering Action to Initiate a Change Trostel maintains an engineering service to resolve engineering print and all concerns. If the supplier has a concern or suggestion which can be solved without engineering assistance, a complete description along with documentation should be sent to Trostel Purchasing. We encourage our suppliers to submit cost saving suggestions that will not affect product quality or reliability and are beneficial to both of us. Use the SREA form in the Appendix. Trostel Purchasing will communicate the results of these request reviews to the supplier Supplier Request for Engineering Action for a Deviation / Waiver All typical situations requiring deviations/waivers include, but are not limited to: Non conformance at Receiving Inspection Dimensional Metallurgical PPAP not approved to latest design level Omission of required documentation Non-approved supplier Non Conformance found in-process Incomplete physical compliance testing PPAP sample noncompliance Product found at the supplier that was produced to previous design level A deviation/waiver request is a document generated by the supplier that can either approve or reject known nonconformities. Additional information may be requested from the supplier. Deviations/waivers are issued for specific quantities or time periods. Deviation/waiver requests issued on a pre-approved basis will not affect the Quality performance rating. A Supplier Corrective Action Request (SCAR) will not be issued nor will a corrective action be requested. The approved deviation/waiver request number must be affixed to each container of affected material prior to shipment to Trostel. The material will be inspected and if the declared discrepancies fall within the limits approved in the deviation/waiver, the shipment will be accepted. A Supplier Correction Action Request (SCAR) will be issued and an 8-D corrective action will be requested for any deviations/waivers not pre-approved. Nonconformities found by Trostel will affect the supplier s performance rating. A copy of the Supplier Request for Deviation / Waiver is provided in the Appendix. Revision C 6/19/09 Page

13 7.2 Supplier Inspection Requirements Suppliers may be required to submit inspection data with each shipment unless waived by Trostel Purchasing/Quality Management Scheduled Production Shipments The data may be in a format of the supplier s choosing provided the following are included: Trostel Purchase Order Number Trostel Part Number Trostel Part Name Trostel Drawing Number and rev level Specification and tolerance required to be met Actual numerical results where applicable Indication of any data that is out of specification Dimensional Layout Requirements 7.3 Quality Failure Notice a. The supplier may be requested to do a layout per the current Trostel approved supplier drawing in conjunction with the Supplier Self Survey. b. The layout may be in a format of the supplier s choosing provided that the following are included: Trostel Part Number Trostel Part Name Specification and tolerance required to be met Trostel Drawing Number and rev level Actual numerical results where applicable Indication of any data that is out of specification c. The supplier shall keep layout data and make it available to Trostel upon request. When discrepant material is found within Trostel, a Supplier Corrective Action Report (SCAR) will be issued. Trostel Purchasing Management will send a copy to the supplier. The supplier will respond with meaningful corrective action in the space provided on the SCAR or attached supporting documents. The corrective action response should state the cause of the discrepancy, and short-term corrective actions. Corrective actions must be meaningful and effective. The initial, short term corrective action, containment action response and quantity to be contained must be provided within 24 hours and the final corrective action within fourteen (14) business days. If you require additional time to reply, a written request should be directed to Trostel Purchasing Supplier Quality Engineer. Administrative charges may be debited to the supplier for each SCAR issued. In addition, rework, sorting, shipping, warranty or other associated costs may be borne by the supplier. Revision C 6/19/09 Page

14 7.4 8-D Supplier Corrective Action In addition to the short-term corrective action response required on the Quality Failure Notice/Supplier Corrective Action Request form, the following is required: 1) 8-D report for all SCAR concerns. 2) Suppliers must respond to Trostel with the first 3 steps of the 8-D reports in writing within 48 hours. 3) Suppliers must submit the preliminary report in writing within 10 days so that Trostel can submit our report to our customer within 2 weeks. 4) Suppliers must complete the final 8-D report in writing within 30 days with a revised Control Plan. Revision C 6/19/09 Page

15 8.0 Trostel Certified Supplier A Trostel Certified Supplier is a supplier whose proven history of meeting Trostel s quality requirements has enabled them to be authorized to self-release material and/or services to the purchaser. 8.1 Criteria to become certified Consideration for acceptance in this program will be based upon recognition for superior performance (Green Preferred Status on the Trostel Supplier Scorecard* for a minimum of one (1) year) in the following categories: Product Quality Delivery Responsiveness to Trostel s needs PPAP on time Additional criteria would include passing an on site audit by having the support structure of quality, design, service, engineering etc. with a commitment to continuous improvement and achieving ISO or TS certification. 8.2 Responsibilities after certification in order to maintain it The supplier would also have to accept the responsibilities to continually ensure a management approach that will result in continuous quality, productivity and cost improvements. 8.3 Benefits to the supplier New business opportunities and/or joint projects Long term business relationships Improved product quality & productivity Share in reduction of costs Reduction of inventory Shorten lead time/elimination of shipping delays Promote teamwork & pride in workmanship Please contact Trostel Quality Engineer for more information. *Supplier Scorecard = Suppliers critical to Trostel production will be provided a monthly scorecard which measures performance metrics that Trostel deems critical for successful supply chain management. (See Appendix) Review Team Vince Consolo, Ron Crane, Jose Hernandez, Dick Peterson, Geri Skoczylas, Brad Steusloff, Ramakrishnan Sukumar, Nate Salais, Carl Guest, Ross Lund, Tim Baker Approval Date 6/25/09 Revision C 6/19/09 Page

16 APPENDIX Revision C 6/19/09 Page

17 SAMPLE SAMPLE Revision C 6/19/09 Page

18 SAMPLE Revision C 6/19/09 Page

19 THIS LABEL MUST BE ADHEARED TO THE OUTSIDE OF THE SAMPLE SUBMISSION CARTON(S) PLEASE. PPAP SUBMISSION # 3370 TROSTEL SAMPLES DO NOT USE FOR PRODUCTION P/N #: DUE DATE: 05/21/09 P. O. #: N/A ENG LVL: E QTY: 0 From: Tryson Metal Stampings Ship to: TROSTEL, LTD. Attn: Ron Crane 840 Executive Drive Whitewater WI SAMPLE Revision C 6/19/09 Page

20 Sample Revision C 6/19/09 Page

21 TROSTEL QUALITY SYSTEM SUPPLIER SELF SURVEY SUPPLIER DATE CODE PLEASE COMPLETE THE FOLLOWING QUESTIONS AND PROVIDE INFORMATION REQUIRED SUPPLIER SURVEY PREPARED BY: Date Name Title Signature Plant Location: Address, City, State, Zip code LIST KEY CONTACT PERSONNEL Web Page Telephone Facsimile OTHER DIVISIONS Top Management Quality Production Materials/Shipping Sales Purchasing Controller LIST MAJOR PRODUCTS/PROCESSES/SERVICES QUALITY CERTIFICATIONS ISO9000 yes no TS16949 yes no ISO14001 yes no Other yes no If pursing certification, target date for completion and certification type yes no Completion Date Type LIST MAJOR CUSTOMERS If yes, please forward copy of certificate(s) and result of most recent audit Quality Awards and Ratings Ford yes no Chrysler yes no General Motors yes no Other yes no If yes, please forward copy of certificates(s) and rating(s) Additional Information Trostel should know: x LIST MAJOR SUBCONTRACTED PRODUCTS/PROCESSES/SERVICES General Information: Total No. of Employees: Hourly Salaried Shifts Plant Area (Sq. Ft.) Annual Sales Union yes no If yes, Union Name & Contract Expires When Revision C 6/19/09 Page

22 TROSTEL QUALITY SYSTEM SUPPLIER SELF SURVEY SUPPLIER DATE CODE PLEASE COMPLETE THE FOLLOWING QUESTIONS 1.0 MANAGEMENT RESPONSIBLITIES Is there a quality policy statement and is it communicated to all employees? Yes No Are there clearly defined and documented responsibilities and authority for all personnel affecting quality? Yes No Is there a periodic Top Management review of Quality System effectiveness supported by appropriate records? Yes No Is there a documented business plan(s) that considers the Quality System requirements? Yes No 2.0 QUALITY SYSTEM Is there a Quality Manual meeting Quality System requirements for documentation of a comprehensive Quality System? Yes No Are there adequate supporting procedures for each element of the quality manual? Yes No Is the Quality planning process consistent with the elements of the Quality System; Advanced Quality plans, resource Yes No and compatibility reviews, inspection/test methods, control plans and FMEA's, specification and standards review? Are feasibility reviews conducted to confirm the compatibility of design with the manufacturing process, including Yes No capacity planning and utilization? Are Control Plans utilized to define and document how requirements for quality will be met? If so, are Control Plans Yes No revised when appropriate for product & process changes or when processes are found to be unstable or non-capable? Do Control Plans cover 3 phases; Prototype, Pre-launch, Production, unless exempted by Trostel Purchasing & Quality? Yes No 3.0 CONTRACT REVIEW Are contract review activities adequately documented & maintained to ensure that order requirements are understood Yes No and are within capability prior to order acceptance? Are records of contract review maintained? Yes No Is there a system to review/verify order release? Yes No 4.0 DESIGN CONTROL (Applies to Design responsible Suppliers only) Is there a system for advanced product planning, including review by and communication to appropriate personnel? Yes No 4.2- Are design plans utilized for the development testing and validation of designs? Yes No Are appropriate resources and facilities available to use computer aided design, engineering and analysis? Yes No Have formal documented design reviews been conducted per the design plan? Yes No Is the design output verified through review against input requirements and appropriate qualification testing? Yes No Is there a system used to confirm that the final product (production, tooling & process) meets the required design Yes No outputs including all appropriate testing & inspection? Is there a comprehensive prototype program (unless waived by Trostel Purchasing & Quality or made unncessary by Yes No the generic nature of the product supplied? SAMPLE Revision C 6/19/09 Page

23 TROSTEL QUALITY SYSTEM SUPPLIER SELF SURVEY SUPPLIER DATE CODE 5.0 DOCUMENT CONTROL Is there a system for identification, review, approval and distribution of all documents which are relevant to the Yes No quality system which includes; review & approval of documents by the issuer and personnel responsible for implementation; changes to documents reviewed and approved by the same functions as the original approval; process to ensure that the latest revision is in use at all affected locations; prompt removal of obsolete documents from all affected locations? Are new and revised documents reviewed and approved by authorized personnel prior to issue? Yes No Is there a master list identifying document revision status? Yes No Is there a system for controlling design changes? Yes No 6.0 PURCHASING Are subcontractors evaluated and selected based on their ability to meet quality system and quality Yes No assurance requirements? Is there a system to endure that purchased products conform to all specified requirements? Yes No Is there a system for on-site assessments conducted on subcontractors and is the supplier performance (including Yes No delivery) monitored? 7.0 CUSTOMER SUPPLIED PRODUCT Is there a system to ensure that customer supplied products conform to all specified requirements? Yes No 8.0 PRODUCT INDENTIFICATION AND TRACEABILITY Is there a system for determining and maintaining product/process traceability; including manufacturing sources? Yes No Is traceability maintained and recorded throughout production processing and shipping (containers include Yes No traceability code/lot/batch? Are records maintained to trace shipping lots to specific manufacturing lots? Yes No 9.0 PROCESS CONTROL Have documented job instructions been developed that are accessible at the work station, communicated, verify Yes No setups, monitor special characteristics, identify required gauges, tools and equipment, provide sample size and frequency, reaction plans for nonconformance, appropriate approvals and date, operation name and number, keyed to process flow, part name and number,revision date for instructions, visual controls? Are process control requirements being met? Yes No Is there an effective planned routine maintenance system? Yes No Is there an effected planned preventive maintenance system? Yes No Are process control records reviewed and maintained? Yes No Are appropriate governmental certificates indicating compliance to the identified applicable regulations available? Yes No Is there a system for controlling process changes which include customer notification of a change before implementation? Yes No SAMPLE Revision C 6/19/09 Page

24 TROSTEL QUALITY SYSTEM SUPPLIER SELF SURVEY SUPPLIER DATE CODE 10.0 INSPECTION AND TESTING Is there a system for determining inspection/test requirements for all products at all stages of manufacturing? Yes No Is there a system for inspection/test of product at; receiving, in-process, final and audit? Yes No Are accredited laboratory facilities used when required by Trostel Purchasing and Quality? Yes No Do inspection/test instructions include; characteristics to be inspected, sample size and frequency, acceptance Yes No criteria, reaction plan for non-conformance, records required? 11.0 INSPECTION, MEASURING AND TEST EQUIPMENT Is there a system for controlling, calibrating and maintaining inspection, measurement and test equipment? Yes No Is measurement system analysis conducted (Gauge R&R) for all gauges, measuring and test equipment noted on Yes No one control plan? Is each item of inspection, measurement and test equipment identified with unique designation (including Yes No employee-owned equipment? Are inspection, measurement and test equipment properly handled, preserved and stored to maintain Yes No calibration and fitness for use? Do calibration records include; unique identification, frequency of checks, check method, person or source performing Yes No the calibration, acceptance criteria, reaction to unsatisfactory results, next due date? 12.0 INSPECTION AND TEST STATUS Is there a system to identify the inspection/test status of product; at receiving, after each operation, at final Yes No audit/inspection? 13.0 CONTROL OF NONCONFORMING PRODUCT Is there a system for identification, documentation, segreation to a designated area, disposition of non-conforming Yes No and suspect product? Are reworked products reinspected and/or tested according to the control plan? Yes No 14.0 CORRECTIVE AND PREVENTATIVE ACTION Are corrective actions developed using disciplined problem solving methods to eliminate the causes of the non- Yes No conformance and are these actions documented? Are the customer complaints and reports of nonconformance documented, corrective actions implemented and Yes No verified and submitted for management review? SAMPLE Revision C 6/19/09 Page

25 TROSTEL QUALITY SYSTEM SUPPLIER SELF SURVEY SUPPLIER DATE CODE 15.0 HANDLING, STORAGE, PACKAGING AND DELIVERY Is there a system for approval and control of premium freight costs? Yes No Is there a system capable of producing bar code labels to the AIAG B-3 bar code standard? Yes No Is the working environment clean and well organized? Yes No Is there an inventory management system to optimize inventory turns and stock rotation? Yes No If delivery performance is not 100% to schedule, are there appropriate analyses and corrective actions being Yes No implemented? 16.0 CONTROL OF QUALITY RECORDS Are records available for review by Trostel personnel? Yes No Is there a system to identify, control and retain quality records? Yes No 17.0 INTERNAL QUALITY AUDITS Are internal quality audits planned, scheduled, performed, documented and corrective actions timely recorded and Yes No evaluated for effectiveness? 18.0 TRAINING Do qualifications for jobs affecting quality include; identification of appropriate education, training needs Yes No and experience? Is there a system for qualifying employees for assigned positions? Yes No 19.0 SERVICING Is there a system for identifying responsiblities and assuring that contracted service is performed (when applicable)? Yes No 20.0 STATISTICAL TECHNIQUES Is there a system that identifies statistical requirements, implements methods, reviews and manages the application? Yes No 21.0 PRODUCTION PART APPROVAL Is there a system for Trostel approval of new and/or changed products or processes prior to release for production? Yes No 22.0 CONTINUOUS IMPROVEMENT Is there evidence that continous quality and productivity improvement efforts are a key element of the business? Yes No Is there a continuous improvement system, documented, projects identified and tracked? Yes No 23.0 MANUFACTURING CAPABILITIES Does the plant layout minimize material travel and handling, facilitate synchronous material flow and maximize Yes No value added floor space? Are resources available for tool and gauge maintenance and repair? Yes No Is there a system for tool management, design, fabrication and full dimensional layout? Yes No SAMPLE Revision C 6/19/09 Page

26 TROSTEL QUALITY SYSTEM SUPPLIER SELF SURVEY SUPPLIER DATE CODE Trostel Use Only Purchasing Review By: Date Supplier Class Supplier Code Quality Review By: Date Survey Score: Supplier Status: SAMPLE Revision C 6/19/09 Page

27 SAMPLE SAMPLE Revision C 6/19/09 Page

28 Supplier Request for Deviation / Waiver SUPPLIER SECTION Company Name: Part Number: Name of Requestor: Part Description: Date of Request: Drawing No: Drawing Date: Revision: PO No: Quantity Affected: Shipments Affected: Shipping Location: Request Description: Reason: Supporting Documentation Attached? Yes No TROSTEL SECTION Deviation No. Dept Management Status of Request Signature Date Engineering Approve Production Approve Purchasing Approve Material Control Approve Quality Approve Reject Reject Reject Reject Reject Cust Notification Required: Yes No Date Notified: Notified By: Notification Comments: Revision C 6/19/09 Page

29 EXAMPLE Revision C 6/19/09 Page