QUALITY ASSURANCE GUIDE FOR SUPPLIERS

Transcription

1 QUALITY ASSURANCE GUIDE FOR SUPPLIERS Version of 01/03/2017

2 Index INDEX 2 INTRODUCTION 3 GOAL 3 1. Request for Quotation RFQ 4 2. Selection and evaluation 5 3. Development of New Products Inputs for quotation request Initial samples report 7 3. Validation 8 4. Serial Supply of Direct Materials Technical Reception Non-conforming Products Costs related with non-conformities Environmental Requirements 11 ATTACHMENTS 12 VersIon 01/03/2017 Page 2 of 29

3 Introduction The mission of Simoldes Group Plastics Division is to be the preferred choice of its customers, employees and suppliers, contributing to a sustained growth of their shareholders satisfaction. To achieve this goal it is fundamental that all the products produced and purchased by Simoldes Group comply with the required specifications. Acquisition of world class performance levels is only possible by associating suppliers to a common quality assurance policy which allows that all quality procedures are applied throughout the whole productive flow. The development of a close collaboration between Simoldes and its suppliers, from the product conception stage to serial supply, is crucial to reach the zero defects target. The present guidebook sets out the product quality principles that must guide the relationship between Simoldes and its Suppliers. Goal To guarantee products quality assurance from the reception phase in our facilities till the final customer use, establishing a common way of communication and share of good practices between Simoldes Group companies and their suppliers. VersIon 01/03/2017 Page 3 of 29

4 1. Request for Quotation RFQ Request for Quotation (RFQ) is the process that precedes supplier selection and allows the supplier to offer goods or services. The documents associated to this stage are: I. Tools a. Injection Tool Specification M041PP02 (Attachment A) allows the identification of specific characteristics of the tool of the part b. Tool specifications defines the general specifications for all tools of Simoldes Group II. Equipment a. Equipment Specification M037PP02 (Attachment B) allows identifying the equipment specific characteristics b. Equipment Specifications defines the general specifications for all the Equipment of Simoldes Group III. Checking Fixtures a. General Checking Fixtures Specifications for construction of checking fixtures and Specific Checking Fixtures Specifications for construction of checking fixtures define the characteristics / specifications required to build checking fixtures. IV. Materials / Components e Subcontracting a. RFQ - M011PS02.I (Attachment C): Part Price Breakdown allows identifying what is included in the price offered (materials/processes/logistics...); Packaging Concept defines general rules to concept packaging of products and components. V. Logístics Services / Shipments a. Specific Requirements for Logistics Services/ Regular Transports defines the specific characteristics associated to Logistic Services and Transports. Besides these documents, others may be sent as a complement to the reference file. At this stage, the General Purchase Conditions of Simoldes Group are sent to the supplier and applied to all RFQ. VersIon 01/03/2017 Page 4 of 29

5 2. Selection and Evaluation The materials purchased by the companies of Simoldes Group are classified in two families: I. Direct Materials: materials that are fully part of the customer final product (raw materials, product components and packaging) II. Indirect Materials: materials which are not included in the customer s final product and services in general. a. Related to the final product: production and control tools, engineering and laboratory services b. Not related with the product - NPR (Non Product Related): Services and transport/general, equipment and materials to the maintenance and production. All adjudications are preceded of a supplier selection process. There are two processes in the supplier selection: Supplier belonging to the Simoldes Panel and previously qualified Supplier out of the panel (new) In this last case (supplier out of Simoldes panel), it is necessary to fulfill the Supplier Identification Sheet / Quality Assurance System Inquiry M007PS02 (Attachments D(1) and D(2)). In this document, besides identification data, it s made an inquiry about the elements of the Supplier s Quality Assurance System. The supplier s quality certification proof must be sent by the supplier. An audit of the supplier s processes may be requested by Simoldes, at this stage. Panel suppliers are biannually evaluated by Simoldes, according to M016PS02. This Supplier evaluation generates three types of classification levels: A, B and C. Supplier A Low Risk; Supplier B Moderate Risk; Supplier C High Risk. All suppliers evaluated with B must submit an improvement action plan, related to the points identified in the evaluation. Suppliers evaluated with C may not be awarded w i t h new products or services, till i m p l e m e n t ation of corrective actions for the deviations identified in the evaluation. VersIon 01/03/2017 Page 5 of 29

6 Biannual Evaluation of Direct Materials Suppliers M016PS02 (Attachment E(1) This evaluation covers different areas, namely: Q - Quality : PPM; Quality Claims; N er of Customer Disruptions; Quality System Certification level; 8D Answer delay for step 4 D - Logistics : Logistic Claims Annual Evaluation of Direct Materials Suppliers M016PS02 (Attachment E(2) This evaluation covers different areas, namely: Q - Quality : PPM; Quality Claims; N er of Customer Disruptions; Quality System Certification level; 8D Answer delay for step 4 C - Cost : Productivity, Price vs Market D - Logistics : Logistic Claims D - Development : Innovation hability; Codevelopment M - Managment : Attitude; Organization; Financial Situation Annual Evaluation of Indirect Materials Suppliers M016PS02 This evaluation covers the following purchase areas: Calibration and Lab Tests, Engineering Serv.: Service performance, price, reply delay, delivery delay, geographic proximity M016PS02 (Attachment F(1)) Production Means: Capacity and Technical Autonomy, delivery delay, financial capacity, quality of execution, technical assistance and reply delay M016PS02 (Attachment F(2)) Shipments: Service performance, price, reply delay and financial capacity M016PS02 (Attachment F(3)) Annual Quality Commitment - M006PS02 Applying the zero defect strategy, annually, we share with our Suppliers a Quality Commitment, structured by business area, which must assure Simoldes and Customers requirements, through partnerships and Improvement Processes. The document M006PS02 (Attachment G) is annually sent to each Supplier / Economic Group and defines the Quality Targets, PPM s, Incidents (Quality and Logistics) and Answer delay 8D Step 4 of the current year. In case of deviations on the defined Targets, the supplier will be alerted biannually and an action plan will be required for its correction. VersIon 01/03/2017 Page 6 of 29

7 Note: The suppliers of materials included in products supplied to VW Group, must appoint and communicate (if requested) a Product Safety Representative (PSB). This demand is required to their sub-suppliers. (VDA 6.3). 3. Development of New Products 3.1. Offer Inputs Matrix Product Specification: components & subcontracting - M008PS02 (Attachments H(1) and H(2)) - determines the particular specifications required for the product and i t s supplied by Purchasing Direction, during the quotation phase, through Matrix. This matrix mentions the applicable specific requirements, such as standards, drawings, expected volumes, logistics, quality targets, critical characteristics definition, necessary documentation to Initial sample report, etc. As a specialist, Supplier must request, through Purchasing Direction, all the complementary information needed to quote its goods or services to guarantee that they meet the targets. In order to clarify all issues related to specifications, it may be held a meeting between technical teams Initial sample report After acquisition, the supplier must submit, in the requested date (see Product Specifications matrix), samples together with the Initial Sample Report (*). The Initial Sample Report aims to demonstrate the conformity of the product according to the requested specifications and must include all required items in the Product Specifications matrix. This Initial Sample Report must present a front page duly fulfilled. For this purpose, supplier can use the Suppliers Initial Samples Front Page or VDA/PSW format according to M017PS02 / M018PS02 from Attachments I(1) and I(2). Initial samples must be produced in serial conditions, without reworks or any other type of treatment that doesn t represent the process to implement in serial. A new Initial Sample Report must be presented whenever there are: Technical / specifications ions changes Changes in the supplier s production process or in the production location Changes of materials/components of the supplied product Product Requalification every 3 years: Dimensional, Functional and Laboratory tests VersIon 01/03/2017 Page 7 of 29

8 In the absence of an express statement, it is understood that supplier, understand and applies the hereby specifications and Final Customer Specific Requirements (OEM), as well its application within their suppliers. In order to ensure the quality of the products supplied to Simoldes Plásticos Group, supplier must regularly requalify them in accordance to ISO/TS (section Lay out inspection and functional testing). For this, it s necessary a complete requalification, at least every 3 years. Supplier must keep the productive capacity according to the Initial Sample Report, during product serial life and aftersales (+15 years after serial production). That s why it is demanded to supplier to keep the initial sample report during this period. (*) Initial Sample Report: PPAP ( Production Part Approval Process ) or PSW (Parts Submission Warrant) 3.3. Validation From the Initial Sample Report analysis, one of the following decisions will be taken: Approved: Authorization for supply, without restrictions. Conditionally Approved: Authorization for limited supply, in quantity or time. The conditional supply period must allow the implementation of the action, in order to conclude the validation processes, for definitive approval. Rejected: No authorisation for supply. Demands corrections; a new presentation of initial samples and correspondent initial sample report. The correction of non-conformities must be implemented during a period of time agreed between both sides, before the start of supplies (pre-serial or serial). Any supply can be started without previous validation of Simoldes Quality Direction. Products that do not have Initial sample report (ex: raw-materials and masterbatches) must also be submitted to the samples validation process. VersIon 01/03/2017 Page 8 of 29

9 4. Serial Supply of Direct Materials 4.1. Technical Reception In its productive and logistic process, the supplier is responsible for the implementation of adequate methods and tools to assure the supply of products, according to the specifications and Initial Sample Report presented. Having this assumption as a fundamental base, the technical reception of the products in the companies of the Simoldes Group is done according to the following methodology: Condition I - Control 20 samples in 5 consecutive lots, if OK change for condition II Condition II - Control 5 samples in 3 consecutive lots, if OK change for condition III; change for condition I if 1 non-conform part has been detected Condition III - Product in Quality Assurance, control 5 samples of 1 lot per semester; change for condition II if 1 non-conform part has been detected According to the product, the companies of Simoldes Group, determine the characteristics to be controlled, as well as the checking fixtures Non-conforming Products Non-conformities may be detected by the companies of Simoldes Group in different process phases, namely: In the incoming inspection In the manufacturing process In the final customer Non-conformities may be of different types: Quality: Dimensional, functional, aspect, expiration date, mix of references/parts Logistics: Quantities, delivery delay and packaging NOK Documentation: Related to q uality of the product (documentation about expiration date; certificates, batch number, others) and logistics (delivery notes or other non-existing documents or wrongly fulfilled) In case of non-conformity detection, companies of Simoldes Group will send to supplier a Report of Nonconformity (RNC), identifying the problem, b y u s i n g the document m a t r i x M015PP06 of Attachment J(1) or other equivalent document (same content). VersIon 01/03/2017 Page 9 of 29

10 It is expected from the supplier the following treatment: a) Promote the sorting of all suspect/non-compliant material in supplier facilities or in Simoldes Group facilities b) Define and inform containment actions to the problem within a period of 24h c) Send new products after sorting, duly identified, to stocks replacement d) Identify the causes of the incidents and implement the respective corrective and preventive action plan. This action plan must be submitted in 8D format (example M016PP06, Attachment J(2)) and sent in a period of 7 days after receiving the Non-conformity Report 4.3. Costs related with non-conformities For each non-conformity it is made a survey of the costs involved during the whole supply chain, according to the Costs Synoptic of Attachment K. All costs involved will be previously sent to the supplier, with the respective detail, through the Non- conformity Report. The supplier have 24 hours to clarify any related doubt before debit is issued by the companies of Simoldes Group. 5. Environmental Requirements Within the scope of Environmental Management System, Simoldes Group intends to sensitize its suppliers to the adoption of environmentally sustainable practices. The suppliers of Simoldes Group must: Assure compliance with all environmental requirements imposed by applicable legislation Develop productive practices in order to minimize the generation of solid wastes, emission of air pollutant and emission of liquid effluents Assure the implementation of policies to control the consumption of natural resources Implement, whenever possible, environmental management systems that allow its sustainable development Note for all the suppliers of hazardous substances and mixtures: These suppliers must assure that the product safety data file and their respective labels are in the language of the destination country of the supplies. VersIon 01/03/2017 Page 10 of 29

11 Attachments VersIon 01/03/2017 Page 11 of 29

12 Attachment A VersIon 01/03/2017 Page 12 of 29

13 Attachment B VersIon 01/03/2017 Page 13 of 29

14 Attachment C VersIon 01/03/2017 Page 14 of 29

15 Attachment D(1) VersIon 01/03/2017 Page 15 of 29

16 Attachment D(2) VersIon 01/03/2017 Page 16 of 29

17 Attachment E(1) VersIon 01/03/2017 Page 17 of 29

18 Attachment E(2) VersIon 01/03/2017 Page 18 of 29

19 Attachment F(1) VersIon 01/03/2017 Page 19 of 29

20 Attachment F(2) VersIon 01/03/2017 Page 20 of 29

21 Quality Assurance Guide for Suppliers Attachment F(3) VersIon 01/03/2017 Page 21 of 29

22 Attachment G VersIon 01/03/2017 Page 22 of 29

23 Attachment H(1) VersIon 01/03/2017 Page 23 of 29

24 Attachment H(2) VersIon 01/03/2017 Page 24 of 29

25 Quality Assurance Guide for Suppliers Attachment I(1) VersIon 01/03/2017 Page 25 of 29

26 Attachment I(2) VersIon 01/03/2017 Page 26 of 29

27 Attachment J(1) VersIon 01/03/2017 Page 27 of 29

28 Attachment J(2) VersIon 01/03/2017 Page 28 of 29

29 Attachment K Costs Synopsis Complaints Treatment Costs Complaint formalisation Non-compliance management 125 Corrective containment actions Components in stock Semi-finished Semi-finished stock stock 100 Finished-product stock (plant, warehouse, customer) Sorting action 25 /h Part's destruction by Group Yes Parts destruction 25 /h No Issuance of Debit Note VersIon 01/03/2017 Page 29 of 29