Supplier Quality Manual. QF-SQR001 / Rev. Date: 10/14/2017 / Rev. Level: E

Transcription

1 Supplier Quality Manual QF-SQR001 / Rev. Date: 10/14/2017 / Rev. Level: E 1

2 Table of Contents COMMITMENT TO SUPPLIERS 4 SUPPPLIER CERTIFICATION REQUIREMENTS 5 SUBCONTRACTOR DEVELOPMENT 6 CERTIFICATE OF CONFORMANCE 6 ENGINEERING AND PROCESS CHANGES 7 MATERIAL LABELING 8 IMDS 8 RIGHT OF ACCESS 8 SCORING CRITERIA AND PERFORMANCE TRACKING 9-10 SCORING CRITERIA: QUALITY (PPM) 11 SUPPLIER QUALITY INCIDENT TRACKING 12 SCORING CRITERIA: QUALITY WRITTEN CONCERNS 12 SCORING CRITERIA: ON TIME DELIVERY 13 SCORING CRITERIA: SHIPMENT ACCURACY 14 SCORING CRITERIA: COMMUNICATION 15 CONTAINMENT REQUIREMENTS COST RECOVERY 18 PPAP REQUIREMENTS 19 SCORING CRITERIA: PPAP ON-TIME SUBMISSION 20 SUPPLIER PPAP DOCUMENTATION REQUIRMENTS 21 SUPPLIER PPAP DOCUMENTATION LINKS 22 PPAP SUBMISSION REQUEST 23 PROCESS SIGN OFF CHECKLIST 24 PROCESS FLOW REQUIREMENTS 25 PROCESS FMEA REQUIREMENTS CONTROL PLAN REQUIREMENTS OPERATOR INSTRUCTION EXAMPLE 31 CORRECTIVE ACTION REQUIREMENTS BREAK POINT LABEL 35 ENGINEERING CHANGE NOTICE LABEL 36 ACKNOWLEDGEMENT AND ACCEPTANCE 37 2

3 Revision History REV Description of Change Author Effective Date A Initial Release M. Rodgers 1/1/10 B Modified scorecard requirements J. Brewster 8/1/11 C Update Problem Report / Costs J. Brewster 12/8/13 D Updated to Include Aerospace Supplier Requirements L. Murden 12/5/2014 E F Added IATF Requirementse L. Murden 10/14/2017 3

4 Introduction Commitment to Our Suppliers OUR SUPPLIER RELATIONSHIPS ARE THE KEY TO OUR SUCCESS; CONTINUED SUCCESS WILL RELY ON EFFECTIVE COMMUNICATION WITH OUR SUPPLIERS TO MEET OR EXCEED OUR CUSTOMER EXPECTATIONS. IT IS OUR COMMITTMENT TO COMMUNICATE TO OUR SUPPLY BASE OUR CONTINUAL IMPROVEMENT PHILOSOPHY AND THAT THIS INFORMATION WILL BE BENEFICIAL IN DEFINING THE EXPECTATION S OF AGM AUTOMOTIVE AND OUR VALUED CUSTOMERS. 4

5 Supplier Certification Requirements 5

6 Subcontractor Development With the increasing demands for higher quality at a lower cost, the entire supply chain is responsible for increasing quality and contribution to a lower overall cost. It is AGM s expectation that all AGM production suppliers work closely with their supply base to insure that the quality level of received product meets AGM and its customers requirements and expectations. The primary area of focus is in the communication and documentation of customer requirements, which is achieved through APQP (Advanced Product Quality Planning). Through the APQP process, the subcontractor is informed of customer requirements and expectations and develops the process foundation. Certification of Conformance When required by AGM, each shipment shall include a Certification of Conformance. The Certificate of Conformance must contain a statement that all inspections, processing, and tests have been performed as required by the drawing requirements and/or Purchase Order. Products controlled by heat numbers, certification numbers, batch numbers, or cure dates must be linked to the Certificate of Conformance by the controlling number, and show physical and chemical values when applicable. 6

7 Engineering & Process Changes AGM s continuous improvement philosophy encourages process improvements both internally and at supplier facilities. However, prior to any engineering and or process changes being implemented, the effects of the change are required to be assessed, verified and validated to ensure compliance to AGM requirements and AGM s customer requirements. PPAP approval is required for any process changes including change of the manufacturing location. The supplier is also responsible to complete Early Launch Containement, per page 17 of this manual. When an Engineering Change Notice (ECN) is issued by AGM the supplier is required to provide AGM with breakpoint and obsolescence information. The supplier is required to identify the next 2 shipments, unless otherwise specified by AGM, with the ECN Breakpoint Label, see page 37. The label (6 x 6 minimum) is required on all boxes. If product is not properly identified with the breakpoint label and the correct information the supplier will be issued another QI and their scorecard will be negatively impacted. 7

8 Material Labeling All product shipping into any AGM facility must be bar code labeled. All labels must follow the AIAG format and contain the follow information at a minimum, whne specified by AGM. Additional requirements may be required based on AGM customer requirements. Part Number Quantity Part Description Date of Manufacture Part Revision Level Lot Number IMDS Requirements- Automotive Product In 2000, the European Union established the End of Life Vehicle (EVL) Directive, which states that All OEMs & Suppliers must account for prohibited, restricted and reportable substances for all components. International Material Data Sheets (IMDS) provide substance breakdowns necessary to safely recycle vehicle at the end of their useful life. AGM Automotive requires IMDS to be submitted to AGM s site code through the MDSystem, which can be accessed at and observe the requirement of the IMDS Recommendation 001. Suppliers must include IMDS data with their PPAP submissions. If the data is not received with the PPAP submission, AGM Automotive reserves the right to refuse PPAP sign-off. Additionally, AGM may issue a QI and the supplier score card may be negatively affected by late or non-submittal of IMDS. Right of Access Supplier shall provide AGM, its customer(s), and/or a specified third party (statutory/regulatory agency) right of access to the facility and all records related to product ordered by AGM or its customers. AGM, its customer(s) representative(s), and/or a specified third party reserves the right to perform an audit or inspection at the supplier s facility to verify that supplied product conforms to specified requirements. This verification does not absolve the supplier of the responsibility to provide acceptable product and does not preclude subsequent rejection by AGM or its customer. 8

9 Scoring Criteria and Performance Tracking Suppliers performance is tracked by five categories totaling 100 points on a rolling 12 month calendar according to the following categories: PPM = 30 points. Written Concern Quantity = 10 points. On-Time Delivery Percentage = 30 points. PPAP On-Time Submission = 15 points. Communication = 15 points. At the end of each month supplier scorecards will be sent out and the scores are determined according to the below ranking chart. Any category score or overall score in the red or NBH the supplier is required to submit corrective action. Ranking On Time Written PPM Communications PPAP Delivery Concerns Total Gold Green Yellow Red NBH 10 or less 10 or less 4 or less 4 or less 3 or less 35 or less 9

10 Scoring Criteria and Performance Tracking At the end of the calendar year below are the required actions based on the yearly performance results: Gold No actions required. Green No actions required. Yellow Corrective action recommended for any category in yellow. Improvement Plan Recommended. Red Corrective action required for any one category in red. Improvement plan required if total score is in red. AGM supplier audit may be required (AGM travel cost will be supplier responsibility). NBH (New Business Hold) Improvement plan required to be removed from new business hold. AGM supplier QF-SQR001 / audit Rev. Date: is / Rev. required Level: D (AGM travel cost 10 will be supplier responsibility) to be removed from

11 Quality - PPM Quality -PPM The PPM category accounts for 30 points of the overall scorecard rating. Supplier PPM (parts per million) is calculated on the basis of the amount of non-conforming materials versus the total amount processed through production in the fiscal month, which includes any AGM customer field returns. This calculation is then normalized to reflect a constant basis of one million units received. Non-conforming material identified as the responsibility of the supplier will be noted as PPM, except; If a supplier shows diligence and immediately notifies AGM of a potential problem When there is mutual agreement between AGM quality and the supplier that the part rejection was unjustified. The AGM plant affected by the non-conforming parts will decide whether of not the supplier should sort product on location at AGM facility. A supplier must report all non-conforming product found in sorting. AGM quality will decide whether all non-conforming products will be classified as PPM, or only those parts which were found by AGM. A supplier must give AGM Quality team an RMA (Return Material Authorization) within 24 hours of the time the PPM was reported. AGM reserves the right to claim compensation from a supplier for any sort activities ($50 per hour USD) or downtime resulting from supplier PPM PPM calculation and EXAMPLE: A supplier ships 100,000 parts to a plant, 10 of which are non-conforming. The scorecard s calculation will be (10/100,000) x 1,000,000 = 100 PPM s. (REFER TO THE TABLE BELOW FOR THE RATING RANGE.) PPM SCORE PPM SCORE or Higher 5 11

12 Quality Written Concerns Supplier Quality Incident Tracking AGM issues a Problem Report (PR) for reporting and resolving supplier quality, delivery, customer satisfaction and warranty issues. Suppliers must formally respond to a Quality incident with a systemic countermeasure process (See page 30 for the required formats). PR(s) created for supplier issues are considered written complaints and are part of the supplier s scorecard. Suppliers must give an initial responce within 24 hours with containment actions, 48 hours for oversees suppliers. Permanent corrective action implementation and verification of effectiveness is required within 30 days. AGM approval is required in the event that permanent actions cannot be achieved in 30 days. Quality Written Concerns (PR) The written concern category accounts for 10 points of the overall scorecard rating. The written concern catagory is calculated on the basis of the quantity of Probelm Reports issued through production in the fiscal month. See the table below for the scoring breakdown. QI Quantity SCORE or more 0 12

13 Delivery Performance Delivery The delivery score accounts for 30 points of the overall scorecard. Delivery ratings are calculated on the basis of the amount of shipments that have errors versus the total amount of shipments in a given fiscal month. This information is then calculated into a percentage. Delivery ratings are based on the number of occurrences when it is determined to be the supplier s responsibility: EXAMPLE: During one month, a supplier sends 36 shipments. Out of the total 36, 1 shipment is late and 1 shipment is short of the quantity ordered. The delivery percentage calculation will be (36-2)/36 x 100= 94.4% DELIVERY OCCURRENCE Shipments Count % Points Late Deliveries- 1 Early Deliveries- Premium Freight- Damaged Parts- Over Shipment- Short Shipment- 1 Incorrect Quantity- Reference Wrong Purchase Order - Missing Paperwork - Incorrect Freight Carrier - Referencing Incorrect Part Number- Other: Delivery Total:

14 Delivery Performance (continued) The potential for more than one occurrence, per shipment does exist. The system automatically calculates the delivery percentage and associated points based on the following formula: (TOTAL SHIPMENTS - NUMBER OF OCCURENCES)/TOTAL SHIPMENTS) X 100 Delivery Rating Range Chart DELIVERY OCCURRENCE PERCENTAGE SCORE Less than THE GOAL FOR DELIVERY FOR EACH MONTH IS 100% 14

15 Communication Communication Communication Accuracy category accounts for 15 points of the overall scorecard and is based on the following criteria: Occurrence Description No Release Acknowledgement Returned Signed Purchase Order Not Returned Lack of Response ( /Phone calls)/ Late Quality Incidents (QI) Other: Total Score for Communication 10 Communication Occurence SCORE or more 5 15

16 Containment Requirements Containment Requirements All suppliers are required to have a documented containment process, which must include methods of identifying corrective action and containing suspect material in order to prevent non-conforming material from entering back into production or being received by an AGM facility. If a supplier s containment process fails and non-conforming parts are delivered to an AGM facility, we may require containment depending on the severity of the rejection. Containment is 100% inspection of all parts at the suppliers facility and is required in addition to any current quality checks. A sort of ALL material for the specified defect must be performed at the supplier s facility under the following guidelines: The product acceptance standards and measurement/testing processes must be agreed upon by AGM Quality. Data must be collected for all non-conformances and corrective actions. If required by AGM the results must be reported. Problem solving must be formal, data driven, and documented. AGM prefers it s suppliers to use the 5 Phase, 8-D or 3 X 5 Why problem solving method. The supplier is required to provide AGM with breakpoint information and identify the next 2 shipments, unless otherwise specified by AGM Quality, with the Breakpoint Label (6 x 6 minimum) on page 36. The label is required on all boxes. In addition to setting up containment at its own facility, a supplier must also manage containment activities of parts at all AGM Automotive facilities and all material that is intransit to AGM Automotive. AGM Quality department will notify the supplier by using the Problem Report. In the Problem Report AGM Automotive will request corrective action. Corrective action updates will be required through out the containment process. 16

17 Containment Requirements (continued) Containment - Continued If the supplier s containment is ineffective and AGM Automotive receives defected material after the breakpoint, or during the breakpoint requirement (including labeling) are not met, a third party containment may be required. If this occurs the supplier will be issued another Problem Report and their scorecard will be negatively impacted. The presence of the third party sorting company does not relieve the supplier of Containment Activities. Early Launch Containment New launches and product or process changes may require containment based on the supplier readiness and the risk of the product. Requirement for Early Launch Containment (ELC) will be communicated on the P.O. or by AGM Quality. To be released from Early Launch Containment the following criteria must be met. You must maintain containment through the pre established ELC date, 30 days or 3 lots of material with zero defects. 17

18 Cost Recovery Cost Recovery Policy Suppliers to AGM Automotive are liable for all costs incurred by AGM Automotive during containment activities when the cause is the supplier responsibility. The Cost Recovery Report will be submitted monthly to each supplier. The guide lines are outlined as such: External Cost Recovery: Charges incurred at an AGM Customer by an outside sorting company and found to be the responsibility of the supplier will be charged back. This cost is at the rate billed by the outside sorting company. In this case a copy of the invoice will be available upon request. Internal Cost Recovery: When a sorting activity is performed at an AGM Plant by AGM personnel a minimum charge of per hour per person on the sort will apply. The supplier will be charged for all rejected parts associated with the sort. Copies of the sorting activities will be made available upon request. Administrative Cost Recovery: Each Problem Report has an administrative charge of $ USD covering the collection of data and documentation and management of containment activities. Non Responsive Cost Recovery: A Cost Recovery Charge may be assessed if failure to submit an approved Corrective Action by the due date listed on the PR and a new PR will be issued. The amount of this charge may vary based on severity of the quality concern, the number of late Corrective Actions and the number of days late. To avoid Non Responsive Cost Recovery plan to submit corrective Actions on time. You can also avoid this charge if you contact AGM Quality requesting additional time for your Corrective Action. Non Responsiveness negatively impacts your Supplier Score Card in the communication section. EXAMPLES OF COSTS THAT CAN BE CHARGED BACK TO THE SUPPLIER: - Rework / Repair (Supplier Fault) - Premium Freight Costs including Air Charter, if required - Overtime to Avoid Production Interruption - Disposition of Scrap (Supplier Fault) - Production Downtime for AGM and End Customer - Sorting of Suspect Material In-House, at Customer Location or Third Party Warehouse - On-Line Containment - Outside Lab Testing - Customer Returns including hourly charges, - Receiving Inspection, Material Handling and Freight transportation -on-site inspections associated with Scrap and Replacement Material - Delays in Customer PPAP or other approvals -Late submission of IMDS 18

19 Supplier PPAP Documentation Requirements 19

20 PPAP Performance PPAP On-Time Submission and Acceptability PPAP approval is required for new product. AGM identifies the supplier PPAP documentation requirements on the PPAP Request Form. Occurrence Description Late Submission Unacceptable Paperwork Missing Paperwork Other: PPAP Occurence SCORE or more 5 20

21 PPAP Requirements All production suppliers are required to obtain full PPAP approval from AGM Automotive per the current revision of the requirements of the AIAG Production Part Approval Process (PPAP) Manual and any additional requirements of the AGM Automotive Supplier Requirements Manual. PPAP approval is required for new product. AGM identifies the supplier PPAP documentation requirements on the PPAP Request Form. PPAP approval is required for any changes to the product and/or process, including change in location or supplier. All submissions are to be at Level 3 unless otherwise specified in writing from AGM. AGM may request an updated PPAP if the PPAP on file is over one year old. Annual validation testing is required to verify continuing conformance on all parts and components, unless otherwise QF-SQR001 / 21

22 Documentation Links Process Flow Design FMEA Process FMEA Control Plan Operator Instructio ns 22

23 PPAP Submission Request SUPPLIER PPAP SUBMISSION REQUEST 1000 E. Whitcomb Avenue Madison Heights, MI QF-063 PART #: NEW PART #: (If Applicable) PART NAME/DESCRIPTION: APPLICATION: SUPPLIER MANUFACTURING INFORMATION Supplier: Address: SUBMISSION DUE DATE: PRINT REV. LEVEL: PPAP LEVEL REQUESTED: SAMPLE SIZE: QUALITY CONTACT: TEL #: (248) FAX #: (248) PPAP Submit to Information: Submit PPAP to: If submission is after the due date the supplier will be issued a Quality Incident Tel #: Fax #: Quality Contact: COMMENTS/SPECIAL INSTRUCTIONS: PPAP Submission Requirements 1 Design Records/Print 12 Initial Process Study 2 Engineering Change Documentation (if any) 13 Qualified Laboratory Documentation 3 Customer Engineering Approval (if any) 14 Appearance Approval Report 4 Design FMEA 15 Sample Parts Any items with check mark are required with submission 5 Process Flow Diagrams 16 Master sample 6 Process FMEA 17 Checking Aids 7 Control Plan 18 PSW (Part Submission Warrant) 8 Operator Instructions 19 Capability (CPK) Study 9 Measurement System Analysis Study 20 Rate 10 Dimensional Results 21 Process Sign Off Checklist 11 Material Certifications, Performance Testing 22 Other: Rev. Level: A Rev. Date:

24 Process Sign Off Checklist 24 QF-077 Process Sign Off Check List Supplier Program Mfg Location Supplier Code Part Number(s) Part Name(s) Change Level PSO Date Completed Document Yes No 1 Part Number, Description and Change Level Part Print Any alerts or deviations 2 Design FMEA 3 Test Sample Sizes and Frequencies DVP&R 4 Process FMEA 5 Process Flow Diagram and Manufacturing Floor Plan Process Flow Diagram Facility Floor Plan Cell Material Layout 6 Control Plan 7 Quality Planning 8 Incoming Material Qualif/Cert Plans Certificate of analysis Copies of sub-tier PSWs Plan for lot control Plan for lot tracebility 9 Parts Handling Plan Nonconforming product procedure Container maintenance plan Routing/Traveler cards 10 Operating Instructions Set-up Sheets Operator Instructions Gage Instructions Rework/Repair Instructions Evidence of operator training 11 Tooling, Equipment and Gages Identified Tool List 12 Special Product/Process Characteristics Identified List of SCs/CCs/KPCs/KQCs 13 Process Monitoring DFMEA including AIAG checklist A-1 PFMEA including AIAG checklist A-7 Control Plan including AIAG checklist A-8 14 Error and Mistake Proofing List of Error Proofing Methods by Operation including destinction between prevention and detection 15 Layered Process Audit Plan Acceptable LPA plan with frequency and structure chart 16 Evidence of Product Specifications Compliance Report Indentifying Charactersitics to be Checked during PSO 17 Line Speed Demonstration Evidence of a production demonstration run (See PSO PDR log) Evidence that the supplier can meet quoted capacity 18 Outgoing Material Qualif/Cert Plans Outgoing inspection plan including early launch containment 19 Parts Packaging and Shipping Specifications Shipping Procedure Packaging Instructions Final Dunnage Matrix Copy of Shipping Label 20 Gage and Test Equipment Evaluation Gage R&R Quality Org Chart w/plant Responsible Personnel Highlighted Risk analysis of subcomponent suppliers Evidence of problem solving methods (e.g. Blank 8D form) Control charts 1st piece approval procedure Calibration Records Checking Fixture Layout 21 Preventative Maintenance Plans PM Plans for all machinery 22 Initial Process Study Cpk/Ppk or Control Charts from PDR (build pre PSO) D

25 Process Flow Requirements QF-010 Product Program Issue Date ECL ECL Supplier Name SUPPLIER Part Name NAME Supplier Location CITY STATE Part Number NUMBER Legend: Operation Transportation Inspection Delay Storage Operation or Event Description of Evaluation Operation or Event and Analysis Methods Develop and flow the sequential work activities or steps Describe the sequential work activities Determine the methods for each activity 25

26 Process FMEA Requirements POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Print # Rev. (PROCESS FMEA) FMEA Number: Item: Process ResponsibilityAutom Prepared by: Model Year(s)/Vehicle(s) Key Date Date (Orig.) Core Team: Date (Rev.) C Potential O Current Current D Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results Step Failure Ef f ect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R. Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P. s r c Date v c t N. Process Step - Function and Number must be same as the List the process flow function Manner in which the process could fail requirements for each process The effects of a failure mode as perceived by the customer Special product or process characteristics See AIAG severit y evaluat ion criteria 26

27 Process FMEA Requirements (cont.) POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Print # Rev. (PROCESS FMEA) FMEA Number: Item: Process ResponsibilityAutom Prepared by: Model Year(s)/Vehicle(s) Key Date Date (Orig.) Core Team: Date (Rev.) C Potential O Current Current D Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results Step Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R. Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P. s r c Date v c t N. Indication of how the failure could occur See AIAG occurre nce evaluati on Description of criteria controls to eliminate the cause of the failure Description of controls to identify the cause of the failure See AIAG detectio n evaluati on criteria 27

28 Process FMEA Requirements (cont.) POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS Print # Rev. (PROCESS FMEA) FMEA Number: Item: Process ResponsibilityAutom Prepared by: Model Year(s)/Vehicle(s) Key Date Date (Orig.) Core Team: Date (Rev.) C Potential O Current Current D Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results Step Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R. Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P. s r c Date v c t N. RPN= severity x occurrence x detection Preventive / Corrective actions to reduce rankings of severity, occurrence and detection Comple ted actions Name and organization responsible and target completion date After completed actions determine and record the resulting severity, occurrence and detection rankings 28

29 Control Plan Requirements CONTROL PLAN Prototype Pre-Launch Production Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.) Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.) NUMBER ECL Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.) NAME Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.) SUPPLIER CODE MACHINE, CHARACTERISTICS PART/ PROCESS NAME/ DEVICE, SPECIAL METHODS PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EV ALUATION/ SAMPLE REACTION NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN TOLERANCE TECHNIQUE METHOD Number must be same as the process flow and PFMEA Number must be same as the process flow Machine model & tool numbers required Must match print, FMEA and process flow Any feature of the part, component or assembly on drawing Any variables that have a cause and effect of a product characteristic Any characteristic designated as critical, key, safety or significant. 29

30 Control Plan Requirements (cont.) CONTROL PLAN Prototype Pre-Launch Production Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.) Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.) NUMBER ECL Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.) NAME Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.) SUPPLIER CODE MACHINE, CHARACTERISTICS PART/ PROCESS NAME/ DEVICE, SPECIAL METHODS PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN TOLERANCE TECHNIQUE METHOD Tolerances from various engineering documents Document the gage, fixture, tool or test equipment include the gage number Quantity to be inspected Freque ncy to be inspect ed Specify the actions necessary to avoid operating out of control Describe how the operation is controlled include procedure number 30

31 First Article Inspection Documents (Aerospace) Along with the PPAP submission products for Aerospace must have the completed First Article Inspection forms per the latest version of AS

32 First Article Inspection Documents (Aerospace continued) Along with the PPAP submission products for Aerospace must have the completed First Article Inspection forms per the latest version of AS

33 Operator Instruction Example Title of Work Instruction Picture of Process Step, Tool, Fixture, Machine, etc. Revision: Approvals: Rev. Level Date Quality Engineering Part No: Description: Customer: Customer Part #: Operation: Procedure: Production Describe the Process Step

34 Supplier Corrective Action Requirements 34

35 8 D Example Program Name: Dave Opened: Date Revised: Date Closed: CCIR # D1. Form the Team (List team members name and titles) 8-D Analysis AGM AUTOMOTIVE, INC E. Whitcomb Avenue Madison Heights, MI Phone: Fax: Problem Status 8-D Report Part Number: Part Name: Customer: Contact: RMA #: D2. Describe the Problem (object, concern, qualification) D3. Implement and Verify Interim Containment Actions (Containment) D4. Find and Verify Root Cause D5. Corrective Actions D6. Verify Corrective Action D7. Actions to Prevent Recurrence of the Problems D8. Congratulate the Team QF-058 Rev. Date:

36 3 x 5 Why Example 3 x 5 Why Date: Issue title: Problem on part: 5 Why Corrective Action Owner Due Date Why did the planning process not predict the defect? P1 P2 Predict Planning process - informational content in FMEAs and CPs P3 P4 P5 P-RC Why did the manufacturing process not prevent the defect? M1 M2 M3 Prevent Manufacturing process - standardized work and error proofing M4 M5 M-RC Why did the quality process not protect GM from the defect? Prot ect Quality process - containment & Responsiveness Q1 Q2 Q3 Q4 Q5 Q-RC Based on the above 5 why analysis, what are the common system deficiencies? C1 C2 C3 C4 C5 C-RC 36

37 Breakpoint Label PART NUMBER BREAK POINT NOTICE (REQUIRED ON EVERY BOX) QI NUMBER SUBMITTED BY QUANTITY REASON FOR CONTAINMENT 3 ATTENTION TO 4 BREAK POINT DATE ENGINEERING CHANGE NOTICE PART ECN NUMBER NUMBER SUBMITTED BY QUANTITY DETAIL OF CHANGE QF-012 ATTENTION TO DRAWING LEVEL SUPPLIER 8 Rev. Level: B Rev: Date: USE FOR QUALITY INCIDENTS (Blue Paper) 1) PART NUMBER (number for which the Breakpoint is written) 2) QI NUMBER (quality incident number) 3) SUBMITTED BY (person who fills out break point label) 4) ATTENTION TO (whom the break point is directed to) QF-SQR001 / Rev. Date: / Rev. Level: D 5) BREAKPOINT DATE (date material is certified) 6) QUANTITY ( b f i b ) 37

38 Engineering Change Notice Label BREAK POINT NOTICE (REQUIRED ON EVERY BOX) PART QI NUMBER NUMBER SUBMITTED BY QUANTITY REASON FOR CONTAINMENT QF-012 ATTENTION TO BREAK POINT DATE PART NUMBER SUBMITTED BY 3 ATTENTION TO 4 ENGINEERING CHANGE NOTICE 1 ECN NUMBER 2 QUANTITY SUPPLIER DETAIL OF CHANGE DRAWING LEVEL USE FOR ENGINEERING CHANGE NOTICE (Orange Paper) 1) PART NUMBER (number for which the Breakpoint is written) 2) ECN NUMBER (quality incident number) 3) SUBMITTED BY (person who fills out break point label) Rev. Level: B Rev: Date: ) ATTENTION TO (whom the break point is directed to) 5) QUANTITY (number QF-SQR001 / of Rev. Date: parts / Rev. in Level: D box) 38 6) DETAIL OF CHANGE (what changed on the part) 7

39 Acknowledgement & Acceptance ACKNOWLEDGEMENT OF ACCEPTANCE OF REQUIREMENTS Operations: Signature Date Quality: Signature Date Purchasing: Signature Date Please review the entire Supplier Manual and AGM Website with your team and sign, date and return the ACKNOWLEDGEMENT OF ACCEPTANCE OF REQUIREMENTS page only to AGM-NA Director of Quality. By signing and dating this document you as a Supplier to AGM are acknowledging and accepting all the requirements with in the Supplier Manual and Terms and Conditions. The ACKNOWLEDGEMENT OF ACCEPTANCE OF REQUIREMENTS must be signed and returned back to AGM with in 7 days on receipt. 39