Quality requirements on our suppliers

Transcription

1 Quality requirements on our suppliers page 1 of 8 0. Scope of application These Quality requirements on our suppliers are valid for all deliveries of components and/or assembly groups for engines, turbocharger as well as for by produced propellers and gears to site of and have to be followed by all suppliers worldwide. 1. Principles We rely on a trustful co-operation with our suppliers. Uncertainties about the order data as well as urgent modification requests regarding the prescribed material or due to machining reasons are to be clarified by the supplier prior to the start of production with our Group Purchasing. Corresponding agreements will be made in written form by the purchase division and entered in our data processing system in order to be available to our incoming goods inspection. 2. Deviations In principle, we take it for granted that the goods delivered are in accordance with the order requirements (order text, drawings, quality guidelines etc.). In the case of deviations, we expect that the supplier himself will recognise all obvious deviations, i.e. visible and measurable deviations and will accordingly ask our incoming goods inspection for approval. The supplier has to forward the completely filled-in concession application (FK0904) to the incoming goods inspection department of that site, from where the order came from. Suppliers from China, Korea and India send their concession application (FK904) to the local supplier quality department which in turn forwards the concession application internally to the incoming goods inspection department of that site, from where the order came from In case of a component with deviation detected by the supplier, the delivery is accepted only with an approved notification Contact persons at the respectively MAN Diesel &Turbo SE locations: Location: Augsburg, Germany finish-machined purchased parts, i.e. if material purchase and the complete machining are carried out by the supplier Hr. Reckziegel, Abt. EQAS Hr. Stark; Abt. EQASF quality-supplier@mandieselturbo.com raw castings, raw materials and semi-finished products Hr. Reckziegel, Abt. EQAS Hr. Lesti; Abt. EQASR quality-supplier@mandieselturbo.com capacitive and technical subcontracting of engine parts (item No until ), i.e. if only by these items work sequences are ordered externally. Hr. Reckziegel, Abt. EQAS Hr. Homscheidt, Abt. EQASM quality-supplier@mandieselturbo.com capacitive and technical subcontracting of turbocharger parts (item No until ), i.e. if only by these items work sequences are ordered externally. Hr. Wiener; Abt. VPQ Michael.Wiener@man.eu Hr. Hofmann; Abt. VPQ Ernst.Hofmann@man.eu Location: Frederikshavn, Denmark Mr. Rene Larsen, Dept. EQDR Rene.Larsen@man.eu Dr. Zeppenfeld, EQ Schönberger, EQA Reckziegel, EQAS Wiener, VPQ Vice president Head of Engine Quality Senior Manager Head of Engine Quality Augsburg Head of Supplier Quality Head of the quality assurance turbocharger

2 Location: Copenhagen, Denmark Quality requirements on our suppliers page 2 of 8 finish-machined purchased parts, i.e. if material purchase and the complete machining are carried out by the supplier Mr. Ulrik W. Severin, Dept. EQDKS UlrikW.Severin@man.eu raw castings, raw materials and semi-finished products Hr. Torben G. Nielsen; Abt. EQDKS TorbenG.Nielsen@man.eu capacitive and technical external order placement of engine parts i.e. if only by these items work sequences are ordered externally. Hr. Torben G. Nielsen; Abt. EQDKS TorbenG.Nielsen@man.eu Location: Saint Nazaire, France all development actions on engine parts Mr. Gabriel Piou, Dept. RESTN-EQS; all corrective actions on engine parts Mr. Xavier Gandon Dept. RESTN-EQW; gabriel.piou@man.eu xavier.gandon@man.eu Location: Stockport, United Kingdom Mr. Craig.Greenbank, Dept. DLW-VK Craig.Greenbank@man.eu Location: Velka Bites, Czech Republic all parts Mr. Petr Robotka, Dept. RO-VBI-EQS Mrs.Jana Smutná, Dept. RO-VBI-EQS petr.robotka@pbsturbo.eu jana.smutna@pbsturbo.eu Location: Shanghai, PR of China Mr. Shu Xiaobo, Dept. RCSHA-EQ Location: Busan, South Korea Mr. Ilwhan Hyun, Dept. RO-PVS-EQS EQS-CN@mandieselturbo.com EQS-KR@mandieselturbo.com Location: Aurangabad, India Mr. Tulshidas Jaipurkar, Dept. RO-AUR-EQS Tulshidas.Jaipurkar@in.man.eu for information only: Location: all locations plant components for stationary and marine application Hr. Wiedemann; Abt. PQOF Manfred.Wiedemann@man.eu

3 Quality requirements on our suppliers page 3 of 8 This deviation inquiry has to be submitted to us on form sheet FK 0904 concession application in an electronically way. Detailed descriptions, if possible with a sketch or drawing section (sketch or drawing section is also to sent to us in an electronically way), parts designation, quantity concerned, code and/or drawing No. as well as our order and item numbers are required. Furthermore the cause of fault, the immediate measures, as well as planned corrective actions has to be declared to us in each deviation report. If corrective actions are not yet defined at the time of submitting the deviation report, a due date when all corrective actions will be defined and implemented needs to be informed to MDT. We will carefully check each deviation and inform you accordingly in written form. The decision (approval or rejection) for concession applications of deviating parts coming from Chinese, Korean or Indian suppliers will be sent from the incoming goods inspection department from where the order came from to the local supplier quality department. The local supplier quality department in turn will inform the supplier accordingly. However, if deviations are detected in our incoming goods inspection without approved concession application, the supplier will receive a note. with the request for a 3D (8D) Report with corrective action(s) according to item 4 to describe and implement. For serious, important deviations, we will require the supplier to make a statement, which has to be sent to the above-mentioned department (see chapter 2). According to severity of the deviation corresponding escalation steps will be agreed with the supplier. The upmost aim has to be the supply with the parts in the production plant. After the elimination of the respective failure a 100% inspection of the affected attribute can be requested for a certain time period. The inspection can be also required from independent third party. Escalation steps: 1. Sorting of the parts related to the type of defect by MAN/ or third party % inspection (with documentation) of the parts related to the type of defect by the supplier prior to shipment % inspection (with documentation) of the parts related to the type of defect by the supplier prior to shipment and a crosscheck by independent third party also prior to shipment. The costs have to be borne in all cases by the supplier. With regard to the quality requirements for components for power plants and marine which the supplier delivers directly to the port of shipment or to the customer s construction site, the form FK 0922 or the respective agreement concerning quality applies. 3. Quality assessment We carry out a quality rating for all goods received (see pages 3 and 4). Deliveries which are free from deviations rate 100 quality points, announced and approved deviations 95 points. Deviations, which are detected by our incoming goods inspection rate between 1 and 60 points depending on the defect criteria. The resulting quality number is an important criteria for to the placement of future orders.

4 Quality requirements on our suppliers page 4 of 8 Quality assessment - suppliers Criteria catalogue for the allocation of quality points for goods received for finished-machined purchase parts as well as technical and capacitive subcontracting Lot assessment 1: Faultless delivery. 100 points Lot assessment 2: 95 points Deviations announced by the supplier and approved by. Lot assessment 3: 60 points Delivery with minor faults. Acceptance without reservation and report to the supplier. Lot assessment 4: 50 points Delivery with minor faults. Acceptance with reservation and report to the supplier. Problems during assembly and engine testing cannot be ruled out completely; the parts are only usable with restriction, etc. Lot assessment 5: 30 points Rejection due to minor faults, e.g. incomplete marking, danger of injury due to insufficient deburring, missing or insufficient preservation, missing surface protection (e.g. priming), rust, missing data sheets for measuring comparison. Lot assessment 6: 10 points Rejection due to faults which would, or are expected to cause problems during assembly (code No. mix-up, impermissible deviations of dimensions which are important for assembly or various faults according to lot assessment 6). In this connection, it is unimportant whether remachining will be carried out in our company in the supplier s works or whether the parts will have to be scrapped. Lot assessment 7: 1 point Rejection due to faults which adversely effect operation or service life or may cause an engine, resp. turbocharger damage (e.g. impermissible deviations in the material data or dimensions which are vital for operation). In this connection, it is unimportant whether remachining will be carried out in our company in the supplier s works or whether the parts will have to be scrapped. Remark: Deliveries which are not free from obvious deviations, i.e. visible and measurable deviations rate 1 quality point independent of the above mentioned criteria.

5 Quality requirements on our suppliers page 5 of 8 Quality assessment - suppliers Criteria catalogue for the allocation of quality points for goods received for blanks and semi-finished parts Lot assessment 1: 100 points Faultless delivery. Lot assessment 2: 95 points Deviations announced by the supplier and approved by. Lot assessment 3: 60 points Delivery with minor faults, e.g. modification not carried out. Acceptance without reservation and report to the supplier. Lot assessment 4: 50 points Delivery with minor faults, e.g. tolerated dimensional deviation. Acceptance with reservation and report to the supplier. Lot assessment 5: 40 points Rejection due to minor faults, e.g. incomplete marking or contrary to the drawing, casting burrs, core sand, mineralisations, important documents missing (e.g. test certificates or initial samples test reports). Lot assessment 6: 30 points: 10 %, 10 points: 10 % faulty parts per goods received Rejection due to faults, which have caused, or would, resp. are expected to cause problems during machining (code No. mix-up, impermissible deviations from sizes, core sand, mineralistion, etc., which are important for machining). In this connection, it is unimportant whether remachining will be carried out in our company in the supplier s works or whether the parts will have to be scrapped. Lot assessment 7: 1 point Rejection due to faults which adversely effect operation or service life or may cause engine, resp. turbocharger damage (e.g. impermissible deviations in the material data, casting faults, US faults, leaks, cracks, inclusions, luting). In this connection, it is unimportant whether remachining will be carried out in our company in the supplier s works or whether the parts will have to be scrapped. Remark: Deliveries which are not free from obvious deviations, i.e. visible and measurable deviations rate 1 quality point independent of the above mentioned criteria.

6 Quality requirements on our suppliers MAN Diesel SE MD-AUG page 6 od 8 Quality assessment of the suppliers according to quality number QN Status Assessment Finish-machined purchase parts as well as capacitive and technical subcontracting Raw casting Semi-finished parts (forgings, preliminary machining) Raw material (sheet metals, bars, etc.) L1 Very good 99 up to up to up to 100 Good 96 up to up to up to 97 L2 Satisfactory 90 up to up to up to 90 L3 Poor 80 up to up to up to 81 Very poor 1 up to 79 1 up to 65 1 up to 70

7 Quality requirements on our suppliers MAN Diesel SE MD-AUG page 7 od 8 4. Corrective actions / 8D report for documentation of quality work With the quality notification a 3D or 8D Report according FK 0346 is demanded within specified time limits from the supplier. The standard form of 8D reports used at the supplier is also accepted. The 3 D action (D1 to D3, see below) are based on short-term measures to ensure supply chain with conform components. The following 5 measures (D4 to D8, see below) refer to the root cause and to ensure the effectiveness and sustainability of the actions. The in time returned 8D Report is evaluated according to the scheme shown below. The resulting rating number is also enter in the Q-rating of goods incoming, according to item 3 in the supplier evaluation process. If one of the 8D Rating with "0" rated, the 8D report will not be not accepted by MAN Diesel & Turbo and complained at the supplier The demands are according to the DIN EN ISO Evaluation criteria for the measures in the 8D D1 problem- / solution team not specified defined person in charge Function description, phone numbers and of person in charge and team members are defined D2 Problem description No adequate description (s) of the deviation (s) on the part available Numbers / data / facts are there for the problem description Additional information as Pictures, sketches are available D3 Immediate containment actions No suitable measure to limit damage, random test is not a measure to limit damage Measures like Out sorting / reworking of the stocks performed. Additional quality assurance defined for the time until the corrective actions are working

8 Quality requirements on our suppliers MAN Diesel SE MD-AUG page 8 od 8 D4 Root cause Cause remains unclear Cause clearly defined, no problem-solving methods used. Cause with facts, dates and figures Found cause with figures Facts and figures used (additional documentation) D5 Implemented permanent corrective actions No or incomplete corrective action(s) defined (Only Personnel Action without visualization) Measures with action plan Evaluation of actions carried out, risk analysis D6 Preventive actions to avoid reoccurrence Taken any precautionary measures Taken and documented preventive measure Vulnerability analysis, risk assessment, FMEA D7 Control of effectiveness of implemented actions No implemented measures, implementation has not started Implementation of measures in time schedule or already implemented Evaluation of the measures, measures fully implemented D8 Close of the 8D and problem solving process There are not implemented all the measures All measures are fully completed and effective After completion of all measures of 8D report the respective manager signed it and made it available for MAN Diesel & Turbo In principle, the measures from the blocks D4 to D8 are weighted higher because of their importance to sustainable corrective actions. The Assessment demands the application of generally accepted problem-solving process to come a systematically developed and substantiated Solution. This is accompanied to the demands of DIN EN ISO 9001.