655 Wheat Lane Wood Dale, IL Supplier Quality Assurance Manual Meets ISO 9001:2000 Standard Requirements

Transcription

1 PGL/PSI 655 Wheat Lane Wood Dale, IL Supplier Quality Assurance Manual Meets ISO 9001:2000 Standard Requirements Document Number: Revision: B.2 Date: APRIL/2013 Document Number: Revision: B Page 1 of 39

2 Table of Contents I. Quality Policy II. III. IV. Introduction New Suppliers Existing Supplier Evaluation Method V. Purchase Orders VI. VII. VIII. IX. Purchase Order Changes/Engineering Changes Certifications Supplier Dimensional Certification Data First Article Requirements X. Nonconforming Material XI. XII. XIII. XIV. XV. XVI. XVII. Corrective Action Request Control of Inspection, Measuring and Test Equipment Sub Contractor Control Deviations From Specifications Packaging Delivery Requirements Bar Code Requirements Document Number: Revision: B Page 2 of 39

3 APPENDIX... PGL-PSI Form Number A. Supplier Profile and Quality Survey... QF Rev. B, Date:08/01/06 B. Purchase Order... QF Rev. B, Date:08/01/06 C. Purchase Acknowledgement Form... QF Rev. B, Date:08/01/06 D. Corrective Action Request... Form CAR, Rev. 3/16/11 SL E. Request for Deviation... QF Rev. B, Date:08/01/06 F. Certificate of Conformance... QF Rev. B, Date:08/01/06 G. First Article Layout.. QF Rev. C, Date:01/14/08 H. Example Balloon Print... QW , Rev. B, Date:08/01/06 I. Supplier Inspection Data., Rev. B, Date:08/01/06 J. Supplier Request for Engineering Approval. QF Rev. B Date:04/15/13 Document Number: Revision: B Page 3 of 39

4 I. Quality Policy Our commitment is to provide high quality, value-added power solutions for diesel, gas, and alternative fuel engines and engine parts to industrial, construction, and agricultural markets. Our goal is advanced through this policy by: Applying systems of processes and procedures that capture our collective knowledge and experience. Accepting change as the key to our survival and continued growth. Ensuring that all employees understand their responsibility for quality through individual goals and competencies. We will learn from our customers, experiences, and environment to further enhance our processes and procedures, resulting in greater knowledge and continual improvement. Gary S. Winemaster President Power Great Lakes, Inc. Document Number: Revision: B Page 4 of 39

5 II. Introduction Power Great Lakes is an OEM supplier of Perkins and Wis-Con Diesel, Gas, and Alternative Fuel engines to the Industrial, Construction & Agricultural market. Power Great Lakes has served an important role as the link between our engine manufacturers and OEMs since Working as the OEMs partner, PGL can develop drop-in power solutions that allow OEMs to tailor their equipment to individual customer needs. The Engineering Staff at PGL is knowledgeable and experienced. Computer-aideddesign (CAD) is used to adapt engines for specific requirements. In order to make electronic data exchange with our customers simple, a variety of electronic file formats are available for engine drawings. PGL s production staff draws from extensive engine and parts inventory in order to assemble custom-trimming power packages according to clients schedules including provisions for just-in-time delivery. With Power Great Lakes as your value added partner in power, you ll be working with a company that is committed to you and your customer s successes. Document Number: Revision: B Page 5 of 39

6 III. New Suppliers PGL-PSI Purchasing and Quality Assurance Team evaluate all new suppliers. All new potential suppliers must submit the following items 1 & 4. Purchasing may request items 2. and 3. if deemed necessary. 1. PGL-PSI Supplier Profile Quality Survey (see Appendix A) 2. Financial Statements 3. Dunn & Bradstreet rating 4. Confidentiality Agreement After the above information has been received, PGL-PSI Supplier Evaluation Team (SET) reviews all of the information and makes one of the following determinations: 1. Add the supplier to the supplier list as approved or conditionally approved 2. Schedule an on-site survey (if needed) 3. Request additional information from the supplier (if needed) 4. Eliminate the supplier from further consideration Document Number: Revision: B Page 6 of 39

7 IV. Existing Supplier Evaluation Method The PGL-PSI Supplier Evaluation Team (SET), consisting of Purchasing and Quality representatives, gathers the appropriate data to evaluate the suppliers. Based upon supplier on-time delivery, quality defects and price, supplier will be approved or not approved These overall evaluations also categorizes the supplier into one of the following sourcing by PGL-PSI Purchasing: 1. Approved These suppliers are given priority in sourcing decisions 2. Restricted Cannot purchase from, Review long term partnership 3. Special These are special suppliers GM, Perkins and Caterpillar. (Note: Special Suppliers defined as those which PGL will not replace, due to contractual agreements). PGL-PSI encourages the supplier to incorporate systems and procedures to improve scores in the appropriate areas. If there are any questions, please contact your PSI purchasing representative. Document Number: Revision: B Page 7 of 39

8 V. Purchase Orders The supplier is responsible for meeting all of PGL-PSI purchase order requirements (see Appendix B). The supplier for each purchase order must review the following items. If the supplier cannot meet the requirements, the supplier must notify PSI Purchasing. 1. The purchased item part number. 2. The latest revision level of the drawing. 3. The order quantity and accuracy of price. 4. Delivery requirements. Once the Purchase Order has been reviewed, the supplier must sign and return it to the assigned purchasing representative for acknowledgment. Document Number: Revision: B Page 8 of 39

9 VI. Purchase Order Changes/Engineering Changes When an engineering drawing or engineering specification has been revised, PGL-PSI purchasing will send the supplier an Acknowledgement Form (see Appendix C) along with the latest engineering drawing. The supplier should review the Drawing to see if the change affects their production or inventory. The supplier should document on the drawing transmittal form: 1. What is required to make this change? (I.e. tooling modification, fixture change, material, etc.) 2. When can this change be implemented? 3. Will the following open purchase orders affect this change? 4. Will this change affect work in process or inventory? 5. When will we receive parts to the latest print level along with first article data/part? 6. Does this change affect current pricing of the part? If so, how much? Suppliers are required to answer the above questions on the Acknowledgement Form and return back to PGL-PSI purchasing department within 5 working days. Document Number: Revision: B Page 9 of 39

10 VII. CERTIFICATIONS Supplier are required to submit Material, Plating or Heat Treat Certifications as applicable with each shipment or a Certificate of Conformance (C of C) which list each requirement as per the drawing (see appendix F). Document Number: Revision: B Page 10 of 39

11 VIII. SUPPLIER DIMENSIONAL CERTIFICATION DATA On certain parts, suppliers will be required to submit inspection data with each shipment until further notification by PGL-PSI Quality and the purchase order. PGL-PSI Quality will complete form Supplier Inspection Form (see Appendix I) with the required dimension that will need to be inspected. The supplier will be notified via purchase order when this is required. Document Number: Revision: B Page 11 of 39

12 IX. First Article s First Article Inspection is performed by the Supplier in accordance with the PGL-PSI drawing specified on the Purchase Order. Each characteristic, feature or note on the drawing should be inspected and verified for conformance, and the results recorded as follows: (Note: see appendix G for layout example and appendix H for balloon print example) 1. Actual measurements/results for variables data (Must indicate pass or fail on the inspection report) 2. Pass/fail for attributes data 3. A balloon print identifying the item checked which correlates with the actual measurement or feature or note 4. Certificate of Conformance or Items 5. and Raw material certifications 6. Plating certifications (if plating is called out on the drawing) 7. Other special process certifications 8. Key Product/Safety Characteristics There are two (2) types: a) This symbol identifies Fit Function Characteristics for Key Dimensions on Components, materials or assemblies, which are key to having particular quality, reliability or performance significant to the finished product. Any dimension which has been identified with the Fit Function symbol will require the supplier to submit a 30 piece capability study with a minimum of a 1.33 CPK and will require the supplier to perform X bar & R charts as part of the normal process b) This symbol identifies Safety Compliance Characteristics for Key Dimensions on Components, materials or assemblies, which are key to having particular safety requirements significant to the finished product. Document Number: Revision: B Page 12 of 39

13 Any dimension which has been identified with the Safety Compliance symbol will require the supplier to conduct 100% testing as part of normal production process, submit a 30 piece capability study with a minimum of a 1.33 CPK and will require the supplier to perform X bar & R charts as part of the normal process 9. If the tooling/process produces multiple parts simultaneously (.e. multiple cavity (die/mold) then an inspection layout from each cavity is required. If the part has multiple engineering design levels (i.e. casting dimension vs. machining dimensions) then a layout is required for each stage (casting layout & machine layout) for each cavity. The inspection layout data and only the completed final parts need to be submitted. The First Article Part and Inspection Report, Note; all documents as stated above (1 9) are so identified and shipped to PGL-PSI as part of the First Article inspection report. If the items 1 9 are not submitted the inspection report will be rejected and returned for re-submittal. First Articles are required for the following: 1. A new part being ordered for the first time; 2. a design change to the current part (only inspection for the change is required); 3. a part that is purchased for engineering which will be used for production in the future; or 4. a part from new tool which has been ordered to replace a worn tool. PGL-PSI quality will review the First Article package for completeness, accuracy and legibility, verifies randomly selected characteristics and features for accuracy, compliance and documents fit check results at assembly process, as required. Conforming First Article Reports are approved and distributed. Nonconforming First Article Reports are returned back to the supplier so that corrections can be made. Continuous rejections for a First Article may prompt the supplier to lose future business if non-compliant First Articles continue to be received. Document Number: Revision: B Page 13 of 39

14 X. Nonconforming Material The supplier will be notified of nonconforming material and will be asked for authorization to return, scrap or rework the material. A debit memo will be issued against the supplier s account for all returned/scrapped material. The supplier is responsible for freight charges associated with the return of discrepant material and all non-conformance issues will be reflected in the supplier s quality rating. Document Number: Revision: B Page 14 of 39

15 XI. Corrective Action Request (CAR) PGL-PSI will notify the supplier of a part s nonconformance with a Corrective Action Request (CAR) (see Appendix D). A CAR can be issued for a part as a result of receiving inspection rejection, defective parts in stock or found defective during our assembly process or failure by the supplier to meet our on-time delivery/quality requirements. PGL-PSI requires that the CAR be returned prior to the required due date indicated on the report. The listed due date is the maximum allowed time to respond. Even the smallest problem can be very detrimental to our manufacturing operations, so your quickest response is required. The CAR response should include the corrective and preventive action and a break point for stock. Two or more CAR s for a specific part or non-response to a CAR could cause PGL-PSI to immediately re-source from another supplier. Document Number: Revision: B Page 15 of 39

16 XII. Control of Inspection, Measuring and Test Equipment The supplier must have established and maintained documented procedures to control, calibrate and maintain inspection, measuring and test equipment and devices used to demonstrate the conformance of product to the specified requirements. Inspection, measuring and test equipment should be used in a manner that ensures that the measurement uncertainty is known and is consistent with the required measurement capability. All inspection, measuring and test equipment must be in compliance to the requirements of ISO and standards traceable to the National Institute of Standards and Technology (NIST). Document Number: Revision: B Page 16 of 39

17 XIII. Sub-contractor Control The supplier takes full responsibility for any sub-contracted (outsourced or alternate) process and will have final approvals or inspection in place to assure all sub-contracted components conform to all specifications dictated by the drawing(s). Document Number: Revision: B Page 17 of 39

18 XIV. Deviations From Specifications PGL-PSI expects all material and or parts supplied to meet all of PGL-PSI requirements. Nonconforming parts are NOT to be shipped to PGL-PSI without approval in writing. The supplier is expected to complete the Request for Deviation Form (Appendix E) and submit it to PGL-PSI s purchasing. If the Request for Deviation is approved, then the Request for Deviation Form will be returned back to the supplier with approved signatures. UNDER NO CIRCUMSTANCE WILL PRIOR or FUTURE VERBAL AGREEMENTS BE ACCEPTED. Document Number: Revision: B Page 18 of 39

19 XV. Packaging Suppliers are held responsible to ensure packaging is sufficient to protect material from shipping damage (nicks, dings, scratches, etc.). Document Number: Revision: B Page 19 of 39

20 XVI. Delivery Requirements The supplier will adhere to formerly accepted shipment dates as specified on the purchase order. The acceptable window for deliveries is no earlier than 5 days and no later than 2 day from the delivery date specified on the purchase orders. PGL-PSI reserves the right to specify preferred carriers, but the supplier is responsible for proper transportation in order to meet agreed delivery dates to support manufacturing. Document Number: Revision: B Page 20 of 39

21 XVII. Bar Code Requirements The following instruction is to be used as a guideline when a supplier is developing bar code shipping labels for products that will be delivered to PGL-PSI. Unless stated otherwise, USS Code 39 will be used to barcode the necessary information. For additional guidelines and references, refer to the Automotive Industry Action Group (AIAG) publication titled Trading Partner Labels Implementation Guideline #B-10 *. 1. Part Number: The part number as defined by PGL-PSI and documented on the Purchase order, which is given to a supplier. 2. Revision: The Revision is configuration of the part in PGL-PSI s engineering drawing. It is also noted in the item master field for the revision. 3. Description: The description as stated on the purchase order is also what is called out on the engineering drawing. 4. Supplier Name: The name of the party that produces, provides, or furnishes a product or service that PGL-PSI has placed an order with. 5. SPLR ID: The numeric code used to identify the supplier in PGL-PSI s manufacturing system. It is also noted on the Purchase order. 6. Quantity: The number of parts, items or other units of measure in the container. 7. Purchase Order Number: A purchase order number is a commercial document issued by PGL-PSI, indicating the products, quantities and agreed prices for products or services that the Supplier will provide. 8. Manufacturing Date: Date of fabrication two digits month, two digits day, and two digits year. Document Number: Revision: B Page 21 of 39

22 * Automotive Industry Action Group, Lahser Road Suite 200, Southfield, Michigan Phone: (248) Fax: (248) * Automotive Industry Action Group, Lahser Road Suite 200, Southfield, Michigan Phone: (248) Fax: (248) Document Number: Revision: B Page 22 of 39

23 XVIII. Supplier Request for Engineering Approval (SREA) Any External supplier is required to gain approval Supplier Request of Engineering Approval (SREA) prior to the implementation of a change related to any of the following events. Raw material or process used to make the raw material. Location of manufacturing equipment even if being moved within the facility. Type of machine, tool or process used to manufacture or assemble the product. Change of supplier or change in the process at your supplier impacting PSI product. Any changes additions or rotations involving more than 20% of the current production staff working on PSI product. Additional of tooling, complete replacement or major refurbishment of existing tooling. Cost saving opportunity. Deviation from print temporary or permanent. Manufacturing or Process changes. Formulary and Packaging Changes. Any revisions to software which operates inside of the product. Potential Exceptions: Tooling changes for expendable tooling or general maintenance due to normal wear do not apply to the SREA procedure unless one or more of the conditions listed above apply. The supplier is also allowed to utilize any one of a group of same machines such as lathes, CNC machines, welding stations, etc without the submission of a SREA as long as the machines are of the same make and a single machine setup procedure is common to all of the production machines. The supplier must complete the following sections with the headings identified on the SREA Form prior to submitting to the PSI Lead Engineering/Quality Representative: PSI Site / Main site, PSI Contact Information. Supplier Name, Address, Supplier Code, Supplier Contact Information and SREA Submission Date. Part Number (PSI and supplier), Part Description, Revision level. Supplier must identify all the items that have been submitted with the SREA Plan. Cost Impact (Supplier must gain approval from PSI Purchasing prior to the SREA submission). Document Number: Revision: B Page 23 of 39

24 Requested Implementation Date of the process change. Reason for the Change and when the need for this was discovered. Potential effects for the change to PSI and supplier. Supplier. Authorization Signatures. NOTE: It is the supplier s responsibility to investigate all required data to support a request of a proposed design change and submit this data to PSI Engineering for approval. If the supplier does not know the appropriate PSI Engineering contact, the supplier is requested to contact the PSl Purchasing or Quality contact. The supplier is required to submit the SREA Plan to the PSI Lead Quality Representative at least 3 months (90 days) prior to scheduled implementation. The supplier is required to submit the SREA Plan to each PSI site affected by the change. If multiple sites are affected, the facility that uses the highest volume of that part should take the lead to coordinate the approval of the SREA. In this situation, the PSI Supplier Quality Engineer/Manager is the most applicable PSI Lead Quality Representative to coordinate between the different user sites. A PSI Supplier Quality Engineer/Manager may also assist or take over the lead role of coordinating a SREA due to complexity of the process change or other PSI business need. Receipt of the SREA As a rule, direct all SREA submission to the Supplier Quality Engineer/Manager. Notification of SREA Disposition from PSI The PSI Lead Quality Representative returns the SREA with the PSI disposition of the Supplier Process Change Plan and Sample Submission Requirements to the supplier Contact noted on the SREA. If the supplier SREA Plan is approved, the supplier is authorized to proceed with the SREA Requirements and Sample Submission Requirements. If rejected, resubmittal of the supplier SREA Plan will be required for approval prior to the supplier making any changes. Supplier Sample Submission The supplier is to proceed with the sample submission at the given Approval Stages Identified on the SREA Form. Some process changes may require a Document Number: Revision: B Page 24 of 39

25 more comprehensive evaluation in order to gain approval for production. Examples would include material changes or manufacturing process moves from one location to the other. The supplier must submit a signed copy of the SREA to PSI prior to each sample submission and include the following: Build Date of the sample submission parts. Ship date of the sample submission parts. Lot number and Serial Number break of the sample submission parts. ID method of the sample submission Samples must be identified on the outside of the shipping container The PSI Lead Quality Representative will provide evaluation results of the sample submission at each stage and return the SREA to the supplier. The SREA will indicate an approval to continue to the next sample submission stage or a rejection. After the sample submissions are complete and the PSI Lead Quality Representative has approved the sample submissions, the supplier is authorized to proceed to Mass Production for the proposed process change. Document Number: Revision: B Page 25 of 39

26 Appendix A Supplier Profile and Quality Survey QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 26 of 39

27 Appendix A Supplier Profile and Quality Survey cont d QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 27 of 39

28 Appendix A Supplier Profile and Quality Survey cont d QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 28 of 39

29 Appendix A Supplier Profile and Quality Survey cont d QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 29 of 39

30 Appendix B Purchase Order QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 30 of 39

31 Appendix C Purchase Acknowledgement Form QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 31 of 39

32 Appendix D Corrective Action Request Document Number: Revision: B Page 32 of 39

33 Appendix E Request for Deviation QF Rev. B, Date:08/01/06 Document Number: Revision: B Page 33 of 39

34 Appendix F Certificate of Conformance QF Rev. B, Date: 08/01/06 Document Number: Revision: B Page 34 of 39

35 Appendix G First Article Layout Document Number: Revision: B Page 35 of 39

36 Appendix H Balloon Print Document Number: Revision: B Page 36 of 39

37 Appendix I Supplier Inspection Data Document Number: Revision: B Page 37 of 39

38 Appendix J Supplier Request for Engineering Approval Document Number: Revision: B Page 38 of 39

39 Revision Log Date Change Author June/06 Revised entire Quality Manual Document D. LaVizzo Sept/06 Clarified special supplier (no rev change required) D. LaVizzo April 2013 April 2013 April 2013 Added Supplier Request for Engineering Approval (SREA) in Appendix J Added updated copy of First Article Layout in Appendix G Added Index XVIII Supplier Request for Engineering Approval Description. R. Katak R. Katak R. Katak Document Number: Revision: B Page 39 of 39