JSP Supplier Quality Assurance Manual

Transcription

1 Changes to the Supplier Quality Assurance Manual: The JSP Supplier Quality Assurance Manual has been reviewed for updates and revisions needed to keep our forms, policies and procedures current. The updates will be communicated to suppliers via notification, and are noted in this document with an underline. This manual will apply to all Suppliers of parts, materials, and services that impact all JSP U.S. locations. Listed below are all JSP U.S. Locations: Butler, PA (Resins production and molding) Detroit, MI (Resins and sheet foam matrix production) Tullahoma, TN (T1 Resins production) Tullahoma, TN (T2 Resins production and molding) Jackson, MI (Molding and sheet foam production) In the event that you any questions regarding this information, please contact Stacey Butcher Cotter at (931) , or at Obsolete verbiage removed from Revision 15. Revision 15 Revision 15 Page 1

2 July 24, 2017 Mission Statement: JSP s mission is to provide our customers with low cost, high quality product. Our customers value our products and services based on our commitment to quality, on-time delivery, product design, and engineering innovation. JSP must also commit to a supplier selection and development process that will promote our mission and maintain our Quality and environmental policy. The basis of the Supplier Quality Assurance Manual is for JSP and its suppliers to, as a team, not only uphold our goals and objectives, but to consistently meet or exceed our customer s expectations. JSP operates as a team environment that involves the ideas, talents and efforts of all employees. JSP also welcomes its suppliers to join this team to assist us in achieving our goals and maintaining our mission. JSP Quality and Environmental Policy: JSP is fully committed to providing products and services that comply with customer specifications, at a competitive price and to deliver them on time. Our products are produced in a manner that manages impact to the environment, prevents pollution and complies with all federal, state and local regulations. To accomplish these goals, JSP s top management has established quality, business and environmental objectives that are measured, monitored and updated regularly. These products, processes and systems are continuously improved to enhance customer satisfaction. The quality and environmental objectives are communicated to all employees and each employee has the responsibility to support these objectives by doing their job right the first time. Our quality and environmental management systems are designed to meet the requirements of the IATF/TS16949, ISO9001 and ISO14001 standards. Revision 15 Page 2

3 JSP Supplier Sustainability Policy: It is JSP s expectation that all suppliers share our values and standards in regards to the following guidelines. It is also expected that suppliers will develop and implement their own employee code of conduct: Human Rights Suppliers are expected to respect internationally recognized human rights, as defined by the Universal Declaration of Human Rights and Associated Covenants, and the International Labor Organization (ILO) Declaration on the Fundamental Principles and Rights at Work, including the prevention of trafficking, slave, forced, bonded, indentured or prison labor; Child Labor Suppliers will not use child labor, and are expected to abide by the local legal minimum age for employment or the age for completing compulsory education; Forced Labor and Compulsory Labor Employment within the supplier s facility must be voluntary and freely chosen, and workers shall be free to terminate their employment; Wages and Benefits Suppliers are expected to comply with all applicable wage and hour laws, including minimum wage, overtime, maximum hour rules, meal and rest periods, and to provide legally mandated benefits; Discrimination Suppliers should not engage in discrimination based on race, color, age, gender, sexual orientation, ethnicity, disability, pregnancy, religion, political affiliation, union membership or marital status in hiring and employment practices; Working Conditions Suppliers are expected to comply with all applicable health and safety laws, rules, regulations and industry standards; Freedom of Association and Collective Bargaining Suppliers must respect their employee s right to associate freely, join or not join labor unions, seek representation, and join workers councils in accordance with local laws. Employees shall be able to communicate and share grievances with management regarding working conditions and management practices without the fear of reprisal, intimation, or harassment. Revision 15 Page 3

4 Bribery and Corruption Suppliers are expected to conduct business with integrity and in full compliance with anti-corruption laws, and shall not participate in any and all forms of bribery, corruption, extortion and embezzlement. Data Privacy and Protection of Information of Intellectual Property - Suppliers are expected to exercise care and discretion in handling personal data related to employees, customers, shareholders, etc., in both paper and electronic form. All intellectual, sensitive and proprietary information or property, including but not limited to patents, copyrights, trade secrets, etc. should be safeguarded against theft, unauthorized disclosure, misuse, trespass and careless handling. Supplier Responsibilities: Unless informed otherwise by the JSP Quality Assurance department, suppliers are expected to meet the following basic requirements: 1. Unless designated a Small Company Supplier by JSP, suppliers of automotive components and services (Critical to Quality) and certain bulk materials are required to develop, implement and improve a quality management system certified to ISO9001, and ultimately TS16949/IATF16949 compliance. Suppliers are also required to comply with the International Material Data System (IMDS). In addition, JSP highly recommends that suppliers be registered to ISO14001 (environmental standard). Those suppliers who are NOT certified to ISO9001 (automotive and certain resin suppliers) are subject to on-site system audits by JSP to determine conformance to ISO9001. Any supplier designated a Small Company will be qualified via the JSP Small Company Survey, in addition to JSP s supplier approval process. 2. Compliance with all applicable governmental and safety constraints on restricted, toxic and hazardous substances, as well as environmental, electrical and Revision 15 Page 4

5 electromagnetic considerations applicable to the service or product provided (i.e. each part number must be approved via the IMDS system). 3. All materials and services are to be provided per the JSP purchase order, engineering drawings or electronic data, specifications, processes and Quality Assurance requirements. Should there be any deviation from JSP requirements, a formal request for deviation (TDN) must be made prior to implementation. Material lead times should be given in working days, rather than calendar days, to prevent manufacturing interruptions caused by delayed material receipt % on-time delivery, per the due date listed on the purchase order. 5. Provide packing lists with each shipment. The packing lists can either be attached to the Bill of Lading or physically attached to the shipment. In addition, packing lists must reference the JSP purchase order number and describe the product and quantity. 6. Provide technical support in problem solving and the development of new ideas. 7. Prompt response to: a. Request for Quotation b. Engineering information c. Quality and Delivery concerns and subsequent actions 8. Inform the JSP Purchasing and Quality departments of changes in economic, ownership or other conditions that might affect operating or supply decisions. 9. Stress continuous improvement in your operations to ensure continual competitive pricing and quality. 10. Provide Level 4 PPPAP submissions for prototype and pre-launch shipments. At a minimum this will include a PSW, layout data, bubbled drawing(s), prototype control plans, material certifications, and sample parts (to be sent to S. Cotter). Any out of Revision 15 Page 5

6 specification conditions identified at any stage of the launch process should be brought to the attention of the JSP Quality Assurance group PRIOR to the shipment of material. A TDN (temporary deviation notice) may be required. 11. If required, suppliers of packaging materials and/or non-automotive components shall provide a First Article report. At a minimum this package will consist of a cover page and layout. 12. As determined by the JSP Quality Assurance department, suppliers are required to report the process capability of significant characteristics, via an annual Level 4 PPAP, dependent upon JSP customer requirements. At a minimum this will include a PSW, material certifications, drawings, performance testing, and process capability studies on critical features. An IMDS re-submission may also be required. This annual PPAP is due December 1 st of each year. 13. If requested, the supplier shall provide a Certificate of Conformance with each shipment. If not already established and identified on the design record, the JSP Quality Assurance department will assist the supplier in selecting features this document should cover. Those features selected must be detailed on the Certificate of Conformance. 14. Acquire JSP approval for all gages and/or fixture concept designs or drawings. 15. Develop and Test contingency plans to ensure that no interruption of service will occur. This plan should include contingencies for any outsourced processes as well. JSP reserves the right to review shutdown/start-up containment plans, capacity reports and contingency plans as necessary. Re-validation of product must be documented and identified to JSP in the event that a contingency plan must be activated. 16. The supplier shall be prepared to provide service parts for up to 15 years after the conclusion of production (reference JSP Terms and Conditions). Revision 15 Page 6

7 17. Comply with AIAG labeling requirements (reference the JSP Labeling Specification). 18. Perform a risk assessment as part of APQP, including the identification of any risks associated with outsourced processes or services. The supplier shall notify JSP of any and all outsourced processes and services associated with parts purchased by JSP. 19. The supplier shall utilize the CQI-19 Sub-Tier Supplier Management process when purchasing components or services. Assessments and/or risk evaluation results may be requested by JSP or JSP s customer. 20. Subscribe to the AIAG Core Tools (SPC, FMEA, MSA, APQP and PPAP). 21. Determine the necessary competence of the persons involved in all aspects of producing and shipping product to JSP via the purchase order. This includes taking action to acquire the necessary competence to produce and ship material within specification, as well as verifying the level of competence of any actions taken, Evidence of competence must be appropriately maintained. 22. Comply with all state and local statutory and regulatory requirements in the country of receipt, shipment and customer identified country of destination. Monitoring Supplier Performance: JSP s Critical to Quality suppliers are rated monthly in the following categories: 1. Quality (40 points) points are lost for each SCAR issued, including customer disruptions, special status via customer notification, etc. 2. Delivery and Disruptions (30 points) points are lost for incorrect/inaccurate shipping labels, barcode labels that cannot be scanned, missed due dates, incorrect quantities, or for the use of incorrect and/or unapproved packaging without prior JSP approval. Revision 15 Page 7

8 3. Performance (25 points) points are lost for insufficient or late SCAR responses, PPAP accuracy, RFQ timeliness and completeness, long term agreement (LTA) participation, customer and field/warranty returns, and special project participation, etc. 4. Premium Freight (5) points are lost for the occurrence of premium freight by the supplier. Monthly scores are evaluated and suppliers are given a quarterly rating as follows: Excellent Supplier % On Approved Supplier List and Low Risk Acceptable Supplier % On Approved Supplier List and Medium Risk (Supplier development may be necessary) Unacceptable Supplier <=74.9% Supplier Development required and High Risk Each supplier will receive a Risk Assessment ranking of Low, Medium or High based upon a rolling average of four quarters of performance history. New suppliers will remain at Medium or High, depending on the complexity of the design, until this history is gathered. JSP reserves the right to deviate from this ranking. All remaining suppliers (bulk and packaging and/or non-automotive materials and services) are subject to an annual evaluation based upon Delivery and Conformance to Requirements of product and/or services being provided to JSP. A risk assessment will also be assigned for suppliers of non-automotive components and/or services. Supplier Preventive Action and Mistake-Proofing: The supplier shall include in their quality system, steps to detect, analyze and eliminate potential causes of nonconformities. The supplier shall apply controls to ensure the effectiveness of the preventive action, rather than detection only. Preventive action shall also be applied to similar Revision 15 Page 8

9 processes (horizontal deployment). Mistake-proofing methodologies shall be incorporated in the preventive action process. Supplier APQP and PPAP Requirements: (Critical to Quality Component Suppliers Only) The supplier shall conform to all requirements in the latest edition of the Automotive Industry Action Group (AIAG) APQP and PPAP manuals (Advanced Product Quality Planning and Production Part Approval Process, respectively). Parts cannot be shipped without written or electronic approval from the JSP Quality Assurance department. All PPAP submissions are to be submitted against Level 3 requirements, unless otherwise noted by the JSP Quality Assurance department. These requirements include: 1. Part Submission Warrant 2. Process Flow including the receipt of components through pack/label/shipment of finished goods. 3. Process FMEA this document should mimic the steps of the process flow. 4. Pre-production (Containment) and Production Control Plans these should mimic the steps of the process flow and FMEA. The actions taken in the containment control plan should be in place for a minimum of 3 production runs. Features deemed critical by JSP and/or identified to be PTC s should be identified as such on the control plan(s). JSP reserves the right to approve the method of controlling these features. Controls of any outsourced services should also be included on the suppliers control plan(s). If there is a pass-thru part or service, the supplier shall provide JSP with a copy of the appropriate control plan for said part or service. 5. Dimensional Layout should include 3 pieces per cavity and should include variable data on all features shown on the design record. Revision 15 Page 9

10 6. Initial Capability studies Ppk or Cpk of 1.67 minimum on features identified as critical by the JSP engineering and quality departments, included PTC s (passthrough characteristics). If using a supplier developed drawing, the JSP Engineering group must approve the drawing, and critical features are to be clearly. It is the supplier s responsibility to monitor on-going process capability, as studies are required with the annual PPAP submission and may be requested at any time by JSP or JSP s customers. 7. Raw Material Certifications submitted copies should not exceed 1 year from its publication date. 8. Physical Property testing test results should include certifications from accredited laboratories. A copy of the results on the laboratory letterhead should accompany the PPAP. A copy of the laboratory certification should also be included. 9. Performance testing test results should include certification from accredited laboratories. A copy of the results on the laboratory letterhead should accompany the PPAP. A copy of the laboratory certification should also be included. 10. IMDS entry for each part number (JSP IMDS code 7931). 11. Numbered drawings these are to coincide with the dimensional layout(s) and capability studies. 12. Measurement System Analysis (GR&R) on equipment and/or tools used to measure capability features. 13. Samples one per cavity per mold/line JSP may also need samples for acceptable visual features (weld lines, sinks, etc.). 14. Run@Rate information this is to be based upon quoted volumes plus 15%. 15. JSP Packaging Approval sheets Revision 15 Page 10

11 16. Annual submission of the AIAG Special Process Assessment for components produced with heat treating (CQI-9), coating (CQI-11), plating (CQI-12), welding (CQI-15), or molding (CQI-23). 17. Annual Level 4 submission (by December 1 st of each year). 18. Provide detailed project schedules beginning with production kick-off and ending with PPAP submission to JSP. There may be instances where project schedules are also required for prototype orders. Any outsourced process either during tool/fixture builds and/or secondary process is to be clearly communicated to JSP and noted on the project schedule. 19. Evidence of conformance to any Customer Specific Requirement s (CSR s) from JSP s customer. JSP and the supplier shall agree on the PPAP submission date(s). In the event that the supplier cannot submit the PPAP by the required due date, the supplier shall provide notification in writing of the contributing factors and new timing for the submission. JSP may require a limited PPAP package for any prototype or pre-production shipment. These requirements will be communicated by the JSP Quality department or designee. All supplier PPAP documentation must be no more than one year old from the date of JSP s submission to the customer. Any PPAP greater than one year old is subject to an update request by JSP. Parts shipped prior to PPAP approval, or those which are the first shipment resulting in a change, must be identified with the JSP Product Delivery Notice. This tag should be adhered to each box or container being shipped. Suppliers will notify JSP of all post-ppap product and production process changes in advance that affect parts and/or materials supplied to JSP. The JSP Quality Assurance department will determine and communicate PPAP requirements for such changes. Please note, that supply of product cannot be jeopardized while transition is taking place. In addition, JSP reserves the right Revision 15 Page 11

12 to verify the quality system and manufacturing processes at a supplier manufacturing site for compliance to the system. For any outsourced process or service, JSP reserves the right to review controls and/or records being utilized, and to make recommendations for improvement. For any part that bypasses JSP and ships directly to a customer, the supplier must first obtain JSP s approval for inspection and release criteria. Supplier APQP and PPAP Requirements: (Bulk Material Suppliers Only) While bulk materials are qualified and approved via the JSP Scale-Up process (SUR), JSP reserves the right to ask that the supplier conform to all requirements in the latest edition of the Automotive Industry Action Group (AIAG) PPAP Manual for Bulk Materials. All PPAP submissions are to be submitted against the requirements established and documented via the Bulk Materials Requirements Checklist, which will be developed by the supplier, and approved by JSP. Supplier First Article Requirements: (Non-Automotive Suppliers to JSP) The supplier shall submit a First Article package upon the award of business by JSP. This package shall include, at a minimum: 1. First Article form should include part number, description, picture of part and approval signature. 2. Layout consisting of a map and layout results. For any outsourced process or service, JSP reserves the right to review controls and/or records being utilized, and to make recommendations for improvement. For any part that bypasses JSP Revision 15 Page 12

13 and ships directly to a customer, the supplier must first obtain JSP s approval for inspection and release criteria. Toll Molder Requirements: In certain circumstances JSP will utilize the services of toll molders. The toll molder is responsible for the IMDS submission/approval for any component found within the part being molded. JSP has established a minimum list of requirements for such molders, as follows. JSP reserves the right to require annual dimensional layouts, material certification reviews and test and/or performance data reviews. JSP will perform an annual assessment of any company contracted for toll molding services. Supplier Development and Audits: In some cases, supplier development may be necessary. The need for development will be determined based upon performance issues, second party findings, third party quality management system certification status and a supplier s risk analysis or ranking. Actions will be implemented to resolve open performance issues and to promote continuous improvement. JSP may also determine a need for a second party audit at the supplier s manufacturing location, or at the location of an outsourced process or service. This activity will be scheduled based upon the suppliers risk assessment, monitoring of performance, QMS development, or product and/or process audits for new or under-performing products or services. Supplier Corrective Action Request (SCAR) Process: Supplier Corrective Action Requests are issued in the event of any nonconformance to the requirements set forth by JSP, including but not limited to quality, delivery or disruption, Revision 15 Page 13

14 customer service, etc. Mistake-proofing methodologies shall be incorporated in the corrective action process. Process and/or system improvements shall be carried over to similar processes within the supplier s facility (horizontal deployment). Supplier responses shall be made on the JSP SCAR form within 2 days for short term corrective action, and 15 days for long term corrective action. Containment Policy: All suppliers are required to implement containment activities during the launch of a new product, after an extended shutdown period, in the event that the supplier s contingency plan is activated, or in the event of specific failures as determined by JSP. Containment activities must include inspection of 100% of all parts produced, until such time the supplier is released from containment by the JSP Quality Assurance department. Visits to JSP International require proper Personal Protective Equipment (PPE), which includes but is not limited to steel toe shoes, un-tinted safety glasses and hearing protection. Site specific PPE may also be required. Visitors are also required to review and sign off on the JSP ISO14001 Contractor Training guidelines. Cost Recovery (Section II of SCAR Form): All suppliers are subject to the costs incurred by JSP for nonconforming material. The suppliers responsibilities will include any sorting of suspect material within a JSP facility, at a JSP customer facility, or third party warehouse. This would also include any additional receiving inspection, material handling and freight associated with the replacement or scrapping of material. An administrative fee of $250 will be assigned to each supplier for any delivery exception that may occur. Additional fees may occur for any other disruption, including but not limited to, quality nonconformances, downtime issues, etc. Revision 15 Page 14

15 Component Labeling Requirements: Component shipping labels are to adhere to the JSP Labeling Specification, which can be located on the JSP website ( Questions regarding this specification should be directed to Shawn Fouse at or (724) Electronic Data Interface (EDI): For those suppliers who are planning to implement an EDI system, please refer to the JSP EDI Technical Specification located on the JSP website ( Please direct any questions or concerns to JSP EDI Support Line at (610) Environmental Requirements: It is the policy of JSP to provide products with minimal impact to the environment. It is highly recommended that all Critical to Quality suppliers to JSP be compliant to the requirements of ISO14001, with the intent on minimizing the impact of their specific raw materials and operations on the environment. For more details on ISO14001, please visit JSP Temporary Deviation Notice (TDN): Any changes to the manufacturing process or part design (if implementation is required prior to changes to the design record and/or JSP approval) require the submission of a TDN to the JSP quality representative. This form can be found on the JSP website ( and should be submitted to the JSP Quality Assurance representative for review. Revision 15 Page 15

16 Service Part Requirements: JSP may order service parts from the supplier up to 15 years after production requirements have ended. Service orders provided by the supplier shall be labeled per the guidelines found in the Component Labeling Requirements. In addition, each package (box, rack, returnable, etc.) shall be tagged with the JSP Product Delivery Notice tag. Additional requirements (inspection data, etc.) shall be established with the JSP Quality Assurance department. Revision 15 Page 16