Navistar Truck General Supplier Quality Requirements NTSQ-0001 Released

Transcription

1 Navistar Truck General Supplier Quality Requirements NTSQ-0001 Released General Requirements Page 1

2 Table of Contents Subject Page Purpose 3 Application 3 Scope 3 Definitions 3 Supplier Responsibilities 7 Quality System 7 APQP 8 Engineering specification and product compliance 8 Prototype parts 10 PPAP 10 Corrective action and containment 11 Corrective and preventive action response 12 Corrective action escalation 13 Process capability 14 Process capability and monitoring requirements 15 Maintaining appropriate expertise and resources 15 Safety critical parts 15 Safe work environment 15 Supplier management support 15 Labeling 16 Supplier scorecard 16 Links to Helpful Resources 17 General Requirements Page 2

3 Purpose: This document contains the basic requirements of any supplier producing and delivering service, prototype or production intent parts for saleable products built by Navistar, its wholly owned subsidiaries and contracted after-treatment providers. The expectation is that the supplier takes ownership and responsibility for the parts they supply. This document sets forth a basic list of requirements for the quality processes used by the suppliers but is not all-inclusive. Each section can be broadly defined as to be suitable for any given situation. This document provides precedent for the supplier and SDM responsibilities and obligations for service to the Navistar organization. Application: This document is intended to apply to any company supplying or potentially supplying vehicle components, services, subassemblies or assemblies to any plant or location designated by Navistar. It also applies to the supplier s quality system requirements as set forth for Navistar Purchasing and supplier quality functions. Other obligations and responsibilities also apply per contract or other agreements and this document in no way supersedes those agreements but seeks to help support or better define those requirements. Scope: This document applies to all parts, services, sub-assemblies and assembly providers supplying, or contracted to Navistar, its plants, service parts locations, wholly owned subsidiaries, and engineering locations. 1) Definitions: a. Wholly owned subsidiary i. IC: School Bus assembly locations in Tulsa, Ok. and Conway, Ar. ii. Workhorse Custom Chassis: Motor home and commercial medium duty chassis assembly location in Union City, In. iii. International Truck: Truck assembly facilities located in Springfield, Oh. (SAP), Chatham, On, Ca. (CAP), Escobedo, Mx. (Blue Diamond, EAP, International Camiones), or Garland, Tx. (GAP, SST) iv. Navistar Defense: Truck assembly facilities located in Garland, Tx. (GAP), Springfield, Oh. cab assembly (CAS), Tulsa, Ok., or West point, Ms. b. After treatment providers: Any location between the assembly location and the customers whose purpose is to add production intent items on a Navistar, IC Workhorse Custom Chassis or Navistar Defense vehicle. General Requirements Page 3

4 c. Service Part: Any part that is sent for the purpose of resale as a replacement or repair part used in a Navistar, IC, Workhorse Custom Chassis, or Navistar defense complete or incomplete vehicle. These parts are generally packaged in a unique way and are sent to a Parts Distribution Center (PDC) or a dealer. d. Service parts locations: Parts Distribution Centers (PDC), Fleet operations or Dealerships that carry parts, whether OEM or after-market, used for repair and maintenance of any Navistar complete or incomplete vehicle. This includes the brands International Truck, Blue Diamond, IC, SST, Navistar Defense (IMG), whether the location or origin of the parts is foreign or domestic. e. Engineering locations: Engineering support provided from the following: i. Truck Development and Technology Center: Located in Fort Wayne, In. ii. Truck Reliability Center: Facility located in Fort Wayne, In. iii. Product Evaluation Center: Located in Chatham, Ontairo, Canada iv. Any truck or bus assembly location providing engineering support v. Any contracted engineering service for development of Navistar truck products, including test facilities f. Automotive Industry Action Group (AIAG): The AIAG is a not-for-profit association of companies involved in the automotive industry (and Heavy Truck). The Automotive Industry Action Group is a globally recognized organization founded in 1982 by a group of visionary managers from Chrysler, Ford Motor Company, and General Motors. AIAG information and forms are accessible at g. Supplier: Any contracted individual, group or company having a contract with Navistar to supply parts, services, sub-assemblies or assemblies to Navistar plants, sites and facilities for the purpose of building vehicles. h. Parts: Any component or group of assembled components, having its own unique part number that is supplied for the purpose of building vehicles to any Navistar sites, plants or facilities. General Requirements Page 4

5 i. Services: Any non-component part of a vehicle delivered either before assembly. Example may include, finishing, addition of equipment or pre-treatments before assembly such as painting or coating. j. Sub-Assemblies: Any group of components assembled, but having no final part number of their own as an assembly, prior to delivery to Navistar locations which are assembled to other major components on the vehicle. Examples may include grilles and mounting hardware, suspension systems or bumpers and mounting brackets. k. Assemblies: Any group of components either having their own final part number or not having their own part number but serving as a final assembly which are delivered to Navistar locations for the purpose of building vehicles. Examples include wheel and tire assemblies, wiring harnesses or wheel hub and drum assemblies. l. Production Part: Any part sourced for use at Navistar Truck facilities, intended for use on saleable vehicles built at Navistar sites, plants or facilities and having completed documentation for approval per the AIAG PPAP process reference document or, latest revision or the Conditional Approval and Shipping Authorization document. m. Prototype Part: Any part that is sourced by Navistar intended for the use on non-saleable vehicles and installed at Navistar sites, plants or facilities and compliant to the requirements of the Conditional Approval and Shipping Authorization document. Prototype parts may be used on saleable vehicles where they have proven their ability to meet all engineering requirements for a production part. n. Saleable Vehicle: Any vehicles built at Navistar sites, plants or facilities which are intended for sale to the general public. General Requirements Page 5

6 o. Quality System: Business management system that incorporates the use of metrics and controls by company management that ensures delivery of parts which meet the customers engineering, quality, quantity, delivery and cost objectives and serves to support the contract signed between the supplier and Navistar. p. Registration: Certification to TS16949 current revision or ISO 9000 current revision by a registering body certifying that a company s business system is compliant to a standard and is certified to that standard. q. Requirements: Any data given to the supplier to define customer needs which may include, contracts, specifications, drawings or other inputs describing engineering, quality, quantity cost and delivery needs or others as required. r. Supplier Development Manager (SDM): Designated representative of Navistar who has been assigned to the supplier and has the responsibility to ensure the supplier delivers products from approved production processes. This person works for corporate purchasing and acts on the behalf of Navistar as a liaison between the supplier and the consuming site, plant or facility. s. Global 8D: The 8d process used by Navistar and its suppliers for communicating status and updates to problem resolutions. The process is located at the following link. t. Pyxis: Workflow application used internally to Navistar which documents the need for a corrective action, usually during a parts development process. u. Corrective Action Request (CAR): Any communication, formal or informal where the supplier has been made aware of a non-conformance that needs an action to address a suspected or identified nonconformity constitutes a CAR. Suppliers are expected to take responsibility to appropriately document and track required activities for any given CAR. The request may be in the form of a phone call, , notification of a Pyxis or notification of a need to complete a global 8D. General Requirements Page 6

7 v. Certified Shipment Process: A process of escalation where the supplier has unsatisfactorily answered repeated CARs and has logged repeat occurrences of issue. A more stringent method to protect the plants from the receipt of unusable parts is required i. Level 1 (CS1): The plant initiates a request for CS1 whereby the supplier is required to perform an additional 100% inspection after the process and before shipment to the using location. A team is formed and an action list is devised. The process continues until G8D step 5 is completed and 20 days of good product has been recorded. 90 in the case of mislabeling product. ii. Level 2 (CS2): The supplier is required to comply with CS1 plus a 3 rd party, independent sorting service is hired by the supplier to perform an off-site inspection of material prior to shipment to the plant. CS2 will continue until adequate preventive actions have been implemented and 20 Days of good product have been recorded. 90 in the case of mislabeling. iii. Level 3 (CS3): Upper management teams are formed to evaluate alternate sources of the product. No new business is awarded until completion of the G8Ds and all actions for improvement have been closed by the supplier and verified by the Navistar SDM. w. Supplier Scorecard: The supplier scorecard rates suppliers at both the business unit and plant level and provides a quantitative measurement of the effectiveness of our suppliers. 2) Supplier Responsibilities: a. Quality System: Companies supplying parts to Navistar must have established and implemented an acceptable quality system. Demonstration of a quality system that is compliant to an acceptable standard should be evidenced by registration and presentation of a certificate of registration by the certifying body. Suppliers must maintain the requirement that their suppliers also maintain an acceptable quality system. By default, Navistar requires the supplier to use forms meeting the intent of AIAG reference manuals. Any supplier not having forms can obtain them from the AIAG website at and ordering APD-0105: Supplier APQP/PPAP Forms. Other forms and documents may be acceptable if they meet the intent of the AIAG General Requirements Page 7

8 forms and have, at a minimum, the same information. Acceptability of forms will be reviewed by the assigned SDM. Acceptable quality systems are based on the ISO 9000 standard to the current release or TS to the current release. Helpful links for the governing bodies of those standards are located in the Data Resources section below. b. Advance Product Quality Planning (APQP): Suppliers are required to maintain a production process development process meeting the intent of the AIAG APQP reference manual. A supplier must be able to develop their products and production processes to meet agreed upon timelines and quality goals while still having the adequate reviews and completing required output documents. The appropriate output documents to show the steps of APQP have been followed are required regardless of abbreviated timelines or other commitments. The purpose is to meet the intent of APQP and reduce the effort required to achieve PPAP while avoiding potential pitfalls of skipping key development steps. Each phase of process development is required to have a review and signoff to show completion of all requirements of that phase. The supplier is expected to develop such reviews such that they are flexible and support the needs of Navistar. Where a supplier is not able to comply with this requirement they are required to inform the SDM of the reasons why and submit a recovery plan. Each supplier, during the development or significant change of a part, is required to produce the number of parts necessary to complete statistical studies. If those parts are not destroyed during testing, they can be used in production provided they meet the print requirements and PPAP or Conditional Approval was successful. If changes to the production process, as defined in the AIAG PPAP reference manual are made after data was gathered for a process capability study, the study may need to be repeated. Ask your SDM if retesting is required given any changes to the process prior to running the production intent process. Suppliers are required to complete form, fit and function checks for any changed or new part number. The supplier must contact their SDM for instruction to complete this check. General Requirements Page 8

9 A supplier s agreement to develop and accept the business contract constitutes their commitment to meet these requirement. c. Engineering specification and product compliance: Suppliers are expected to know and understand the engineering specifications they have been provided. Where an aspect of any provided direction is not understood, it is expected that the supplier provide in writing a request for explanation of the unclear points. These points must be forwarded to the appropriate Navistar engineer and the supporting SDM and purchasing manager. If no questions are brought forth it will be assumed that the supplier understands the requirements and intends to adhere to them. Where the supplier is not able to meet the engineering specification, they will have to submit a request for deviation to the engineer during the development phase or the SDM affected after production launch. If a deviation is not granted, the part will not be approved for production therefore it is imperative that the APQP records reflect the status and history of the change to avoid any delays during the approval process. General requirements for appropriate engineering support are detailed below: i. General requirement: 1. Meet requirements as defined in Statements of Work (SOW), Specification Transmittals, prints, models, and math data. 2. Wiring System suppliers to be capable of supplying and receiving CAD data in NDP, with the ability to transition to a Saber/UG based CAD system in conjunction with INTERNATIONAL ii. Navistar Customer Specified Components Suppliers must: 1. Provide test reports and documentation of supplier conducted testing 2. Supply UG compatible 3D engineering CAD data and drawings. iii. Navistar Engineered Systems and Components Suppliers must: 1. Provide engineering data in the form of solid Models in UG Compatible Format. General Requirements Page 9

10 2. Have the ability to provide engineering data as either CAD data or drawings. 3. Have the capability of and use electronic data exchange for engineering & CAD data throughout the life of the development program and for production maintenance. 4. Maintain designs throughout the production and service life of the components. 5. Provide on-site supplier engineers during the Product Development Process if requested by Navistar engineering locations. 6. Have production intent prototype parts development capability. 7. Use quality tools, such as, (but not limited to): a. FEA (Finite Element Analysis) b. DVP&R s (Design Verification Plans and Reports) c. DFMEA (Design Failure Mode and Effects Analysis) d. PFMEA (Process Failure Mode and Effects Analysis) 8. CFD and VSA, where warranted, in the development of Navistar components 9. Provide raw data, test reports, and detailed FMVSS compliance reports for all tests as needed. General Requirements Page 10

11 d. Prototype parts: Parts that are delivered as prototype parts are expected to be inspected and validated to the extent that they are certified to meet the design intent. For prototype parts that are made off of a production process and then modified or hand built the requirement for verification before delivery is set forth in the Conditional Approval and Shipping Authorization document. A copy of this procedure can be obtained by following this link. eral.asp e. Production Part Approval Process (PPAP): Suppliers must be able to comply with an acceptable production part approval process (PPAP) which is capable of delivering equivalent outputs described in the AIAG PPAP process reference manual, latest revision. For any part, the supplier is expected to maintain a complete file of all documents listed in the Retention / Submission Requirements Table and must be recallable for review at any time. PPAP submission level does not indicate the relief of the necessity for generation and storage of all documents which must be kept kept current through the life of the part plus one year. Suppliers must have the capability or secured the resources necessary to carry out the appropriate layout, testing and certifications to generate records of conformance to requirements. This is inclusive of production intent, service and prototype parts. The supplier is responsible for all submission requirements set forth by Navistar purchasing and the assigned SDM, and must retain and store complete PPAP or conditional approval documentation. Shipment of parts to Navistar sites, plant or facilities is authorized only after the supplier has received a copy of the signed warrant or conditional approval and shipping authorization document. No other authorization that is in the form of verbal release, or any other manner constitutes authorization. It is the obligation of any supplier to refer and Navistar representative who is requesting shipment before SDM approval to contact Navistar Purchasing and Supplier Quality. It is further the obligation of any supplier being directed to ship before approval to refuse to ship until the appropriate documentation has been General Requirements Page 11

12 returned to the appropriate supplier representative. This will avoid any possible negative repercussions by shipment without PPAP, conditional approval or having completed critical checks on parts. f. Corrective action and containment: All suppliers to Navistar are required to meet all quality, cost and delivery requirements as specified. Navistar SDMs, Plants Engineering locations and Parts Distribution Centers will communicate nonconformances directly to suppliers with requests for corrective actions. These corrective actions must be returned in a timely manner and the issues corrected to the reporting locations satisfaction. As part of a response to any CAR, immediate containment and capturing of suspect material is expected for any parts at the supplier s locations, warehouses or in transit between supplier locations, in transit to Navistar or their using locations, on the production floors at Navistar using locations, and supplied as service parts. Responsibility to find and coordinate the appropriate activity to identify and quarantine suspect material is with the supplier. The supplier is expected to make any contacts necessary to perform all actions to return and replace suspect material at their cost. Corrective actions must include formal answer of the issue, use of the 8D process and must conclude with an identified root cause, countermeasure, permanent correction and preventive action. Any response not conforming to these requirements will be rejected for completion. At Navistar the Global 8D system located at is used. When a supplier is notified they have a non-conformance requiring a G8D they are responsible for going to the website, securing a logon and password, accessing the 8D assigned to them and following through with any actions necessary to complete the request for corrective action. Suppliers are responsible to maintain visibility of any CAR until it is closed and approved by the party notifying the supplier within Navistar. g. Corrective and preventive action response: A robust corrective action and preventive action process must be maintained General Requirements Page 12

13 by the supplier such that they can comply with reporting requirements in the format described by any Navistar representative assigned to attain a corrective action from the supplier. Use of the Global 8D process is standard for issue resolution. Directions for use of this system can be given by the requesting representative of Navistar. Requested Global 8D issues can be viewed by the supplier once they have been added to a resolution. The supplier is responsible for obtaining a password from and then by following the directions on that website. The supplier is required to take ownership and provide adequate management level leadership of root-cause investigations, report on a timely basis as required by the assigned representative. The supplier is required to track and update status continuously until the closure of the issues is approved by the requesting representative. i. Except when otherwise notified any response to a CAR must include: 1. Within 24 hours of notification: Completion of D0 through D2 a. Identification and quantification of the noted issue at the supplier, in transit, in storage locations, at subassembly locations and at the using facilities b. Immediate containment response c. Replacement of found defective parts does not qualify as containment of the issue d. Containment is expected at the using plant(s), in transit and at suppliers location(s) as needed to ensure all suspect material is identified and held to prevent inadvertent use in production vehicles 2. Within 72 hours of notification: Completion of D3 through D4 a. Identification of root cause b. Implementation of an interim corrective action 3. Within 30 days or as planned due to constraints: Completion of D5 through D8 a. Implementation of permanent corrective action General Requirements Page 13

14 b. Implementation of preventive actions Appropriate communication of status and regular notification through CAR resolution and closure is the responsibility of the supplier. Status communication is important, to prevent negative information being annotated in the supplier score card. h. Corrective action escalation: Based on a supplier s response to corrective actions requests, and how G8Ds are answered, internal escalation of the issue may become necessary. Generally, the escalation of an issue will be as follows: i. Initiating point: Plant, PDC, SDM, or any other point of entry. ii. SDM: If an appropriate answer is not achieved form the supplier through the initiating point, or if multiple CARs remain outstanding, or if repeat issues occur, the SDM will be contacted for resolution. iii. Purchasing Manager: If the SDM cannot secure an adequate response, the purchasing manager will become involved and support the SDM iv. Initiation of Certified Shipping Level 1 (CS1): The supplier is expected to comply with the requirements of the CS1 process. The CS1 process can be obtained at the following link: uality_general.asp v. Initiation of Certified Shipment Level 2 (CS2): The supplier is expected to comply with the requirements of the CS2 process. The CS2 process can be obtained at the following link: uality_general.asp vi. Initiation of Certified Shipment Level 3 (CS3): Top-level Navistar purchasing management will review the supplier and propose solutions for improvement or replacement of the supplier. No new business will be awarded to the supplier until the reasons for non-compliance have been addressed and closed. vii. Supplier is Resourced: i. Process capability: The supplier is responsible to have the appropriate technologies and resources available to prove on-going process capability for defined product critical characteristics (KCCs) by, engineering specifications, assembly drawings, component General Requirements Page 14

15 drawings, design requirements documents (DRD) or any other inputs given by Navistar. The supplier is also responsible to decide on the key process controls required to ensure the process does not add any variation that could produce parts not meeting design intent. When a supplier has identified an item with a severity of 5 to 7 and an occurrence of 4 or greater, either in the Design FMEA or the Process FMEA, it will have identified a key control characteristic on the control plan. This key characteristic will be marked as significant characteristic and will have controls in place that provided statistical control for the affected feature. j. Process capability and monitoring requirements: Suppliers are required to demonstrate the ability for any production process to meet both the KCCs and process critical characteristics with a Cpk value of 1.33 minimum as calculated. A value of 1.67 may be required depending on the criticality of the feature being measured. The Cpk values need to be calculated on-going or until a waiver to discontinue is granted. A waiver may be granted if the process has demonstrated a continuous value of 2.0 minimum for more than 1 year calculated at least weekly. Any failure of the process to meet the required minimum Cpk value must be immediately reported to the appropriate SDM. Preliminary process capability must be established prior to new process approval with a Ppk value of at least 1.33 minimum calculated using the sum of squares method. This value must be demonstrated for all KCCs and process critical characteristics listed on the critical characteristics matrix. k. Maintaining appropriate expertise and resources to support processes: Suppliers are required to have the appropriate expertise and resources available to identify process critical characteristics and to keep a matrix of those characteristics for all production processes producing parts, services, subassemblies or assemblies. Where these are found to be deficient the supplier is expected to correct the condition when notified. l. Safety critical parts: It is expected of each supplier that they have researched to the extent possible to determine the need of their parts to be compliant to the FMVSS or other safety standards. General Requirements Page 15

16 The supplier is expected to be aware of the general effect on vehicle safety if any issue should arise as a result of a supplied component not meeting to expected performance. When safety characteristics are identified, the supplier must create and maintain sufficient process controls as to maintain a minimum of 1.67 Cpk value. Control plans and FMEAs must report and cover safety critical features. When a supplier has identified an item with a severity of 8 or greater, either in the Design FMEA or the Process FMEA, they must identify a key control characteristic on the control plan. This key characteristic will be marked as safety critical and will have control charting used to control that feature in production of parts. m. Safe work environment: Suppliers are expected to maintain a clean and safe work environment for the production of parts. Risk mitigation must be implemented as necessary to prevent unnecessary or unforeseen shut-down of production due to a safety related incident. Parts supplied to Navistar or its using locations are expected to be free of handling hazards such as burrs and other features that may cause the handling of a component to risk injury. Parts that present an unreasonable handling risk will be returned to suppliers at their cost for rework or replacement. n. Supplier management support: Suppliers must demonstrate adequate management support for their quality system at all levels of the organization. Management support must be adequate to support continuous improvement activities, provide containment resources in the event an issue is delivered to a Navistar site, plant or facility, and to comply with all requirements. General Requirements Page 16

17 o. Labeling: Labeling must conform to specifications as outlined in D-13 and the quick receive guide. The expectation is that all data and information on any labeling supplied conforms and indicates the correct part number, quantity and contains the appropriate lot information required. It is important to be familiar with these standards as they often constitute the most common failure of the supply base. D-13 can be accessed by following this link The quick receive guide can be accessed by following this link i. Advanced Shipping Notice (ASN): Advance Ship Notice (ASN) and Quick Receive Label Initiatives Supplier compliance with Navistar s ASN and Quick Receive Label requirements is mandatory. ASNs must be available for use by Navistar Receiving personnel when supplier shipments arrive at Navistar production plants and service parts distribution centers. Quick Receive Labels must be visible on the accompanying paperwork for scanning and subsequent retrieval of supplier ASNs. Inaccurate ASN transmissions are a reason to request a corrective action, begin an 8D or start containment under the Certified Shipping Process. ii. Electronic Data Interchange (EDI): Suppliers must implement all required transactions for all locations in the applicable Navistar business unit within 60 days of contact by Navistar (or Navistar s designated enabling service). Where a supplier is currently trading EDI transactions with one or more, but not all, of the locations in a specific Navistar business unit, the supplier must implement those transactions with the remaining locations within 72 hours of contact by Navistar. Supplier location changes for current EDI transactions must also be implemented within 72 hours of contact by Navistar. p. Supplier Scorecard: The International supplier scorecard rates suppliers at both the business unit and plant level and provides a quantitative measurement of the effectiveness of suppliers. All new suppliers need to register with the International Supplier Scorecard Analyst. The analyst will need contact information, General Requirements Page 17

18 including supplier location code to set up their user identification and password. The introduction material and CD will be mailed to the address specified by the supplier. Suppliers are rated by the following business units: Truck Supply Chain (which includes all six Assembly Plants), Service Parts, Truck Quality, Truck Business Impacts, Truck Product Development and Engine Logistics. Supplier performance is rated as green, yellow, red or blue using specific rules and specific point values and weights for the rules. Suppliers who are rated yellow, red or blue must provide detailed recovery plans to the SDM, including estimated timing to get their ratings to green status. A Supplier Scorecard Analyst has been designated as the initial point of contact for all inquiries regarding the scorecard, including disputed violations by suppliers. If a supplier needs training, a user id or password, or has general questions, please contact the analyst at InternationalScorecard@Navistar.com. 3) Links to helpful references a. Data Resources Key Control Characteristics KCC Navistar Supplier Quality Website ity_general.asp Forms Required (Can be accessed at the above link) APQP status (23 Step) report form PPAP truck industry warrant Conditional approval and shipping authorization (PRE-PPAP) Supplier request for engineering approval (SREA) Supplier request for deviation Appearance approval report (AAR) Styling approval process Material styling engineering form Certified shipment process (CS) 4P Sheet Packaging Standard D-13 General Requirements Page 18

19 EDI requirements Tooling Requirements and Documentation GD&T ANSI Y Federal Motor Vehicle Safety Standards FMVSS Canada Motor Vehicle Safety Standards CMVSS Global 8D Process Click this link and sign in to review data helpful in closing each step of the G8Ds ISO Website International Automotive Oversight Bureau (TS resource) Automotive Industry Action Group (AIAG) forms and process resource Prototype Part Identification Tag # GF-420 Navistar Distribution Center 4956 Wayne Road Battle Creek, MI or- Call ; Select options for customer service or order entry -or @stcdataentry@rrd.com ASN Requirements EDI Requirements Supplier Scorecard: Supplier Scorecard Analyst: InternationalScorecard@Navistar.com General Requirements Page 19