GENERAL QUALITY REQUIREMENTS

Transcription

1 GENERAL QUALITY REQUIREMENTS version: 02 author: Ralevski P. checked by: Kainz C. system release: further applicable document to: - CONTENTS 1. Abbreviations list and definitions Introduction System Requirements Project Management Product Release Audits Process Control and Product Monitoring Quality Targets Failure Analysis Escalation Process Change Management Traceability Warranty Responsibility / Product Liability... Page 1 / 6 GQR_en_02.docx Print date:

2 1. Abbreviations list and definitions 8D-Report Cmk/Cpk Control Plan DFMEA GQR PCN ISIR PFMEA PPAP PPF PPM RFQ QAA 8 Disciplines Method used to approach and to resolve problems by identifying, correcting, and eliminating recurring problems. Machine / process capability ratio. Indicators showing the ability to sustain the production process stable within the required limits, as close to the target value as possible. The Control Plan follows the PFMEA steps, and provides more details on how the "potential issues" are checked in the incoming quality, assembly process or during inspections of finished products. Design-FMEA (Failure Mode and Effects Analysis) Preventive tool to evaluate ALL possible risks to the product design that can lead to a failure and defining countermeasures to minimize the risk at the same time. General Quality Requirements (Allgemeine Qualitätsanforderugnen) ist eine Level1- Dokument welches die allgemeinen Regeln und Qualitätsanforderungen für alle GG- Lieferanten definiert siehe Product Change Notification Initial Sample Inspection Report Prozess-FMEA (Failure Mode and Effects Analysis) Preventive tool to evaluate ALL possible risks to the product ion process that can lead to a failure and defining countermeasures to minimize the risk at the same time. Production Part Approval Process Produkt- und Prozess-Freigabe (Product and Process Release) Parts per million Basic indicator showing the quality performance by (re)counting the number of defective parts per million parts delivered. Request for Quotation Quality Assurance Agreement Quality Wall Temporary measure to secure that only non-defective parts reach the customer by 100% check QTLV SQA Qualität Technische Liefer-Vereinbarung (Technical delivery specification) Defines the requirements and characteristics of supplied articles, materials and/or product groups Quality Assurance VDA Verband der Automobilindustrie (German Association of the Automotive Industry) - / (applicable norms) VDA 2 VDA 6.3 Standard for product and process release Standard for the execution of process audits Page 2 / 6 GQR_en_02.docx Print date:

3 2. Introduction 2.1 This General Quality Requirements (GQR) describes quality rules that the suppliers of direct materials (hereinafter called the supplier) and Gebauer & Griller Kabelwerke Group (GG) have to apply for successful partnership in order to achieve the goal zero defects. 2.2 Quality agreement structure and validity Document level Name Content Acceptance Concerns Level 3 GG annual performance targets Yearly targets for Quality and Logistics The targets after review shall be signed GG strategic suppliers Level 2 GG Quality Assurance Agreement (QAA) The business unit (automotive / non-automotive) and commdity special requirements The terms and conditions after review and the mutual agreement shall be signed. GG production material suppliers GG technical delivery specification (QTLV) Product- / Productgroupspecific requirements By submission of an offer resp. accepting the according order Level 1 GG General Quality Requirements (GQR) General quality requirements The terms and conditions of the GQR are accepted with the RFQ GG s Note: Non-conformance costs and liabilities and costs related to claims are described in purchasing agreement. 3. System Requirements 3.1 shall be certified according to ISO 9001 and/or TS standard. The supplier must inform GG immediately in case of the certificate s revocation. Note: Any deviation and the time plan for certification need to be agreed in Level 2 Quality Agreement Page 3 / 6 GQR_en_02.docx Print date:

4 4. Project Management 4.1 Project planning coordinated with GG is required for all specific designed components. It is not required for catalogue parts, raw materials and other project/gg nonspecific supplies. 4.2 The supplier shall cooperate with GG upon request to work on the following documents of the supplied component: - DFMEA (Design FMEA) - PFMEA (Process FMEA) - Definition of special / critical / safety characteristics - Control Plan 5. Product Release 5.1 The supplier is responsible to obtain GG Quality approval before the first parts delivery for pre-serial or serial production (excluded are prototype parts or test parts deliveries). Quality approval process in GG is in line with VDA2. The submission level and required documents are mutually agreed with the supplier in Level 2 Quality Agreement. 6. Audits 6.1 The supplier permits process / product audits on its premises upon GG s request 6.2 Process audits are performed according to VDA 6.3 and can be extended to GG specific questions 6.3 GG has to inform the supplier about the intention of the audits at least 4 weeks ahead or 24 hours for critical quality problems 6.4 is responsible to provide Corrective Action plan for all recorded non-conformities within a defined time period 7. Process Control and Product Monitoring 7.1 The supplier is responsible to install process control (SPC) or 100% product monitoring for all special / critical / safety characteristics provided in technical documentation. 7.2 Process capabilities ratios are agreed in Level 2 or 3 documents. 7.3 The supplier is responsible to establish a Quality Wall upon customer request ( e.g. start of new products, special / critical / safety characteristics, repeated or continuous quality problem). 8. Quality Targets 8.1 The common objective of GG and supplier is to reach ZERO defects. 8.2 PPM / complaint targets are defined in an yearly announcement (Level 3 Quality Agreement) and are intermediate milestones to reach Zero Defect target Page 4 / 6 GQR_en_02.docx Print date:

5 9. Failure Analysis 9.1 The supplier is responsible to respond to any GG official complaints by means of an 8D report. 9.2 Response time Problem notification to supplier Sorting or replacement of suspect parts initiated and the first OK delivery (clean point) communicated Starting point Within 24 hours Problem analysis completed and supplier corrective actions communicated 10 days * * working days after problem has been communicated and/or sample of defective parts were delivered to supplier 10. Escalation Process Escalation level ESCALATION LEVEL 1 ESCALATION LEVEL 2 Reason Actions Responsible Response time - Severe quality problem ( e.g. GG line stop due to supplier s quality, GG s customer quality problem) - C supplier evaluation - Repeated or continuous quality problem - Violation to GG Quality requirements or GG Quality Agreement - Escalation Level 1 not sufficient - Critical Quality Problem (e.g. Warranty problem, GG s customer line stop due to quality problem) - Repeated C supplier evaluation Reinforced quality checks / Quality Wall Establish Monitoring of over monthly meetings (visits and/or telephoneconferences) Establish Presentation of to GG Monitoring of over weekly meetings and perform audit at supplier GG SQA Management / GG Purchasing GG SQA 24 hours Within 1 week For a period of 12 weeks Within 3 days Within 5 days For a period of 12 weeks New Business on Hold (NBoH) GG Purchasing After 12 weeks in Level 2 status Page 5 / 6 GQR_en_02.docx Print date:

6 11. Change Management 11.1 The supplier is responsible to provide GG with the goods using the manufacturing processes; equipment and location as it was released in PPAP process (refer to point 4.). An intended change requires a PCN, GG needs to be notified for approval min. 3 month ahead of implementation. A written GG approval is mandatory prior to delivery of the changed product Deviation agreement The supplier is responsible to obtain approved Deviation Request before delivery of product with the technical deviation. 12. Traceability 12.1 The aim of traceability is to minimize the impact and consequences of quality problems. is responsible for maintaining an appropriate traceability system Forward traceability required information to identify already delivered suspect material. It requires traceability information visible on the label of packing and/or part itself 12.3 Backward traceability required information to identify suspect source material at supplier. It requires as min. part number, lot number or production date is responsible to provide traceability data upon GG request. Response time Product realisation 2 working days < 2 years from production date 5 working days > 2 years from production date 12.5 Archiving Required archiving period for all traceability related information is 15 years from production date. 13. Warranty Responsibility / Product Liability 13.1 If our customers discover field scrap parts and the cause of the fault lies clearly with a purchased part/purchased material, the supplier is obliged to handle these as described in the article 8 of these GQR Furthermore GG has to obtain full Risk assessment from the supplier to determine whether another customers / products can be affected GG expects that the national and international standards of product liability are known to the suppliers and that the deliveries correspond to these Specifications. Product liability risks, especially in case of recall measures are covered by the supplier through appropriate insurance and at their own expense in sufficient degree in favor of damage prevention. Note: Warranty and liabilities conditions are described in the General Purchase Conditions. Page 6 / 6 GQR_en_02.docx Print date: