Supplier Quality Manual PREPARED AND MAINTAINED BY FIRESTONE INDUSTRIAL PRODUCTS COMPANY DIVISION OFFICE 250 W. 96 th Street INDIANAPOLIS, IN 46260
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1 Supplier Quality Manual PREPARED AND MAINTAINED BY FIRESTONE INDUSTRIAL PRODUCTS COMPANY DIVISION OFFICE 250 W. 96 th Street INDIANAPOLIS, IN Firestone Industrial Products Quality Policy We will develop, produce and market competitive products and services that meet the requirements of our internal and external customers, while maintaining a safe workplace and operating in an environmentally responsible manner. Our guiding principles will be customer satisfaction, team-work, data based decision making, continuous improvement and open communications. The responsibility and recognition for our quality achievements will be shared with and delegated to all levels of the organization. Page 1 of 15
2 TABLE OF CONTENTS SCOPE... 3 PURPOSE... 3 SUPPLIER CLASSIFICATION... 3 SUPPLIER APPROVAL... 4 VERIFICATION OF PURCHASED PRODUCT... 5 SUPPLIER MONITORING... 6 SUPPLIER NON-CONFORMANCE... 6 SUPPLIER FIRST ARTICLE/PPAP SUBMITTAL PROCEDURE... 8 REFERENCES...15 DEFINITIONS...15 Page 2 of 15
3 SCOPE The Firestone Industrial Products Company Division Supplier Quality Manual establishes the minimum requirements expected from our suppliers on A and B items. An acceptable quality system is essential in qualifying and continuing as an approved supplier. Any Firestone location that supplies components to other Firestone locations must fulfill these requirements. PURPOSE The purpose of this manual is to communicate the basic supplier requirements with respect to those companies that supply production goods to Firestone Industrial Products Company. The requirements include a documented and implemented quality management system. This manual is intended to be used for new supplier development and the continual development of existing ones. Also, this manual defines supplier performance expectations and the system used to monitor performance. SUPPLIER CLASSIFICATION Supplier Classification of A, B, C or D is determined by the status of an item. Purchased materials are considered "A" items unless otherwise specified on the assembly drawing. "A" Supplier An A Supplier is a supplier that furnishes an "A" item. These items are described as items that if a defect occurs, it is likely to result in hazardous or unsafe conditions for the end user, prevents the performance of the tactical function of the end item, or reduces materially the usefulness of the product. A supplier requirements include - Supplier monitoring by our Supplier Monitoring Program First Article/PPAP approval prior to the first production shipment Supplier certification with each shipment Page 3 of 15
4 "B" Supplier A B is a supplier that furnishes a "B" item. These items are described as an item that if a defect should occur, it is not likely to prevent the performance of the tactical function of the end item. A Supplier is considered to be a "B" supplier if they do not manufacture any "A" items. These Suppliers may also be gage calibration suppliers. B supplier requirements include C Supplier Supplier monitoring by our Supplier Monitoring Program PPAP requirement defined by QA which may consist of Warrant, Dimensional Data and Samples with FSIP Drawing (also include Development Verification/Test) No certification is required unless otherwise specified on the drawing. No First Articles are required A "C" Supplier is a supplier that furnishes a "C" item. These items are classified as pamphlets, brochures, commercial fasteners, and other non-critical items. A supplier is considered a "C" Supplier if they do not manufacture any "A" and/or "B" items. Product is received and taken directly to stores. D Supplier A "D" Supplier is a supplier that furnishes a "D" item. These items are classified as seminars, schools, maintenance work, magazine subscriptions, carrier services, and all other things not to include A, B or C items. A supplier is considered a "D" Supplier if they do not supply any "A", "B", or "C" items. SUPPLIER APPROVAL Suppliers of raw materials and raw ingredients used in air springs are required to be at a minimum 3 rd party registered to ISO 9001:2008 with a goal of conformance to current ISO/TS Suppliers are required to provide objective evidence of current 3 rd party certification. Exceptions to this requirement must be approved through Division Quality Assurance. Exceptions may include: Page 4 of 15
5 Small suppliers that may not have adequate resources to implement a system according to ISO 9001 or ISO/TS Suppliers of low impact products Suppliers to aftermarket only product Specialty items In such cases, supplier quality system assessments will be conducted to evaluate continued use of suppliers not ISO 9001:2008. In these cases, there may be limitations to products or product lines that can be supplied by this supplier. A waiver must be on file and must include; A current assessment (last 2 years) of the supplier's quality system, conducted at the supplier's manufacturing location, using ISO 9001:2008 and ISO/TS as the basis for evaluation. QA to assess whether the current state of supplier's quality system can provide product that consistently meets our requirements. Any limitation to product or product lines that the supplier can supply Firestone will give as much assistance as necessary, to any supplier trying to achieve either ISO 9001:2008 or ISO/TS 16949:2009 standard. VERIFICATION OF PURCHASED PRODUCT Verification of purchased product will be done at FSIP through inprocess and final inspection at the Firestone manufacturing facilities. Should Firestone propose to verify purchased product at the supplier's premises, Firestone will specify verification arrangements and the method of product release in the purchasing documents. Where specified, Firestone's customer or the customer's representative shall be afforded the right to verify at the supplier's premises and Firestone's premises that the supplied product conforms to specified requirements. Such verification shall not be used by Firestone as evidence of effective control of quality by the Supplier. Verification by the customer shall not absolve Firestone of the responsibility to provide acceptable product, nor shall it preclude subsequent rejection by the customer. Page 5 of 15
6 SUPPLIER MONITORING The supplier will initially be given a 100% Supplier Rating. Then, the overall score will be based on Quality and Delivery performance. The Quality portion accounts for 50% of the supplier s overall supplier rating. The percentage is based on the rejection level from first article/ppap submittals, work in process, and customer rejections. This includes field returns that are concluded to be due to supplier issues. The Delivery portion accounts for the remaining 50%. The percentage is based on no days past due based on the promised date. In addition, the Supplier Quality Engineer analyzes the rejections for trends. Information is covered in the Purchasing/Quality meetings that are held on a monthly basis. The Quality Assurance Department and the Purchasing Department review the combined ratings of the A & B suppliers, to determine if any should be considered as non-conforming. Non-conforming suppliers are notified and are requested to provide a forward plan to restore a compliant rating. In the case of a special status customer notification directly related to a supplier quality or delivery issue, the Division Quality will contact the supplier. As necessary, the customer may visit supplier location to review root cause and corrective action. SUPPLIER NON-CONFORMANCE When a nonconforming product is found during first article/ppap review, in-process inspection, or through customer complaint, Plant QA is notified with pertinent information such as part number, lot number quantity, and reason rejected. Plant QA will send RMN rejection notification to the supplier. Upon receipt of the notification, the Supplier is required to notify plant QA of containment plan within 24 hours. The Buyer/Planner is to review for urgency. If not urgent, disposition is the responsibility of plant QA. The supplier has 48 hours to arrange disposition. If urgent and a waiver is a possibility, the Buyer/Planner will advise QA of intent to seek a waiver. The Buyer /Planner will Page 6 of 15
7 initiate the waiver. The waiver will route the RMN form for a sign off. The signed-off waiver is routed to the plant QA and goods are released to use. If urgent and there is a need to sort or rework goods, the Buyer/Planner will advise plant QA. Plant QA will work with the supplier to get goods turned around quickly. If goods are needed urgently, the plant has the discretion of sorting/reworking the goods and charging back the supplier. In any case, the supplier has 10 working days from the initial contact to respond back to plant QA of the root cause and planned corrective action. The cause and corrective action plan is reviewed by the plant QA for accuracy. Feedback of response time and accuracy are forwarded to the Division QA for supplier monitoring. Information is reviewed during Purchasing/Quality monthly meeting. Firestone reserves the right to charge back to cover administrative, containment, freight, and warranty identified as supplier related. Non-Conforming Product Found Plant Quality Assurance Notified Rejection Verified - RMN written by Plant QA RMN distributed to Supplier and Planner-Buyer Supplier has 24 hrs to respond with Containment Disposition of good are arranged through plant QA requested from Supplier within 48 hrs Corrective action from supplier due within 10 working days of initial contact Based on history - will not be able to sort, rework, or deviate rejected product Rework or sort of goods are arranged through Plant QA Urgent need -Rework/Sort Disposition Buyer-Planner contacts Plant QA to inform of need to arrange sort or rework Disposition of goods are arranged through Plant QA Urgent need - Waiver Buyer-Planner contacts Plant QA to info of plans to seek waiver Buyer-Planner initiates waiver request Waiver request granted or denied within 48 hrs Outcome of waiver communicated to Plant QA Corrective action reviewed by Plant QA for adequacy Forward information to Supplier Quality Engineer Adequacy, timeliness of containment, disposition and corrective action used for supplier monitoring Page 7 of 15
8 SUPPLIER FIRST ARTICLE/PPAP SUBMITTAL PROCEDURE This section of the manual defines the minimum First Article/PPAP submittal requirements for Firestone Industrial Products Company's suppliers. The procedure covers all purchased "A" Item components. Sample parts are to be made to Firestone approved drawings and specifications unless otherwise authorized in writing by Firestone Purchasing or Development Engineering. The samples shall be made from specified material(s) on regular production tooling, with no operations included which shall not be incorporated in regular production processing. Temporary tooling and processes shall be noted on the applicable Warrant of Production Samples by the supplier. Samples must be submitted prior to any regular production shipment unless authorized by Development Engineering. They may request the First Article/PPAP be sent with the first production shipment, and QA will re-verify the First Article/PPAP prior to production release. Sample submission shall include the following items: a). Correct quantity and type of samples requested. When parts are produced from duplicate tools, one sample from each mold, cavity, or die shall be inspected and submitted by the supplier. b). Marked drawing and/or complete layout report. c). Copies of all certification or other test data, as required. d). Completed "Supplier Warrant of Production Samples" form. The Warrant of Production Samples is to be used in conjunction with the marked print. Any deviations pertaining to the samples are to be attached to the warrant form along with the name of the Firestone approving authority. All known deviations must be approved, in writing, prior to sample submission. e). Sample parts used for layout. f). Inspection plans outlining inspection tests and characteristics to be examined to control the quality of the material through In-Process, and Final Inspection. g). Unless otherwise stated, the default expectation for First Article/PPAP submittal will be a Level 3. The supplier is responsible if any of the below occur. Also, the supplier is responsible for resubmitting samples for approval, unless otherwise notified by Firestone Purchasing, whenever any of the following conditions occur: a). Existing tooling transferred to a new plant location. Page 8 of 15
9 b). A change is made to an optional type construction. c). A change of manufacture which may cause non-conformance to specifications. d). Parts are produced at more than one plant location. e). Additional or replacement tooling is constructed. When there is an engineering change, samples need not be submitted unless specifically requested by Firestone Purchasing. Samples being resubmitted because of an engineering change or a correction to the original part require only the changed portion and any other area affected by the change to be re-verified and submitted for approval. Review and Approval Process Firestone Quality Assurance is responsible for inspection and review of the Supplier Sample Submission. Quality Engineering will: a). Review all Inspection Plans for adequacy. b). Check all certifications for compliance to applicable standards and/or specifications. c). Review Supplier's Layout for conformance to all applicable drawings. d). Choose certain characteristics on the samples to re-verify. The Quality Engineer will issue a First Article/PPAP Report approving the sample submission, when all elements of the review are acceptable. If any one or more of the elements of review are found to be nonconforming or lacking, a First Article/PPAP Report rejecting the sample submission will be issued. If approved, the Supplier can start normal production shipments. If not, the Supplier is to correct and resubmit sample. In the event our customer has a specified sample submission procedure, the customer's procedure will take precedence over this procedure. All sample submissions and First Article/PPAP Reports are maintained on file by Quality Assurance. The supplier is responsible for notifying Firestone of any major changes in their process that can affect fit, form, function, and/or durability. REFERENCES: QP Vendor Chargeback Procedure Page 9 of 15
10 Part Submission Warrant Part Name Cust. Part Number Shown on Drawing No. Org. Part Number Engineering Change Level Dated Additional Engineering Changes Dated Safety and/or Government Regulation Yes No Purchase Order No. Weight (kg) Checking Aid Number Checking Aid Engineering Change Level Dated ORGANIZATION MANUFACTURING INFORMATION SUBMISSION INFORMATION Organization Name & Supplier / Vendor Code Street Address Customer Name / Division Buyer / Buyer Code City State Zip Application MATERIALS REPORTING Has customer- required Substances of Concern Information been reported? Submitted by IMDS or other customer format? Yes No n/a Are polymeric parts identified with appropriate ISO marking codes? REASON FOR SUBMISSION (Check at least one) Initial Submission Change to Optional Construction or Material Engineering Change(s) Sub-Supplier or Material Source Change Tooling: Transfer, Replacement, Refurbishment, or Additional Change in Part Processing Correction of Discrepancy Parts Produced at Additional Location Tooling Inactive > than 1 year Other - please specify SUBMISSION LEVEL (Check One) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location. SUBMISSION RESULTS The results for dimensional requirements material and functional tests appearance criteria statistical process package These results meet all design record requirements: Mold / Cavity / Production Process (If "NO" - Explanation Required) DECLARATION I affirm that the samples represented by this warrant are representative of our parts which were made by a process that meets all Production Part Approval Proces Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of / hours. I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below. EXPLANATION / COMMENTS: Yes NO Yes No n/a Is each Customer Tool properly tagged and numbered? Organization Authorized Signature Print Name Phone No. FAX No. Title PPAP Warrant Disposition Approved Rejected Other Customer Signature Print Name March Yes No n/a FOR CUSTOMER USE ONLY (if applicable) Customer Tracking Number (optional) 2006 CFG-1001 This is an uncontrolled copy of an approved form. Verify it is current prior to use. QF A REV 6.0 Date Date Page 10 of 15
11 ORGANIZATION: SUPPLIER / VENDOR CODE: NAME of LABORATORY: *CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: *If source approval is req'd, include the Supplier (Source) & Customer assigned code: TEST SPECIFICATION / REV / DATE Production Part Approval Performance Test Results SPECIFICATION / LIMITS TEST DATE QTY TESTED PART NUMBER: PART NAME: DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS: SUPPLIER TEST RESULTS (DATA)/ TEST CONDITIONS OK NOT OK March 2006 CFG-1005 Blanket statements of conformance are unaccepable for any test results. SIGNATURE TITLE DATE This is an uncontrolled copy of an approved form. Verify it is current prior to use. QF B REV 6.0 Page 11 of 15
12 Production Part Approval Dimensional Test Results ORGANIZATION: PART NUMBER: SUPPLIER / VENDOR CODE: PART NAME: INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS: ITEM DIMENSION / SPECIFICATION SPECIFICATION / LIMITS TEST DATE QTY TESTED ORGANIZATION MEASUREMENT RESULTS OK NOT OK March 2006 CFG-1003 Blanket statements of conformance are unaccepable for any test results. SIGNATURE TITLE DATE This is an uncontrolled copy of an approved form. Verify it is current prior to use. QF C REV 6.0 Page 12 of 15
13 ORGANIZATION: SUPPLIER / VENDOR CODE: MATERIAL SUPPLIER: *CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE: *If source approval is req'd, include the Supplier (Source) & Customer assigned code: TEST SPECIFICATION / REV / DATE SPECIFICATION / LIMITS Production Part Approval Material Test Results TEST DATE QTY TESTED PART NUMBER: PART NAME: DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS: NAME of LABORATORY: SUPPLIER TEST RESULTS (DATA) OK NOT OK March 2006 CFG-1004 Blanket statements of conformance are unaccepable for any test results. SIGNATURE TITLE DATE This is an uncontrolled copy of an approved form. Verify it is current prior to use. QF D REV 6.0 Page 13 of 15
14 Truck Industry PART SUBMISSION WARRANT Part Name Customer Part Number Rev. (if applicable) Tool PO Number Additional Engineering Changes Shown on Drawing Number Purchase Order No. Weight (kg) Checking Aid Number Engineering Change Level Dated ORGANIZATION MANUFACTURING INFORMATION Engineering Drawing Change Level SUBMISSION INFORMATION Dated Dated Organization Name and Code Street Address Customer Name/Division Customer Contact City State Zip Application Note: Does this part contain any restricted or reportable substances. Yes No Are plastic parts identified with appropriate ISO marking codes. Yes No REASON FOR SUBMISSION Initial Submission Change to Optional Construction or Material Engineering Change(s) Sub-Supplier or Material Source Change Tooling: Transfer, Replacement, Refurbishment, or Additional Change in Part Processing Correction of Discrepancy Parts Produced at Additional Location Tooling Inactive > than 1 year Other - please specify SUBMISSION LEVEL (Check One) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. DECLARATION I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer drawings drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular production process. I also certify that documented evidence of such compliance is on file and available for review. EXPLANATION / COMMENTS: List Molds / Cavities / Production Processes Organization Authorized Signature Print Name Phone No. Fax Title Date PPAP Warrant Disposition Approved Rejected Comment: Interim Approval FOR CUSTOMER USE ONLY (if applicable) Customer Signature Print Name March THE Date This is an uncontrolled copy of an approved form. Verify it is current prior to use. QF E REV 6.0 Page 14 of 15
15 REFERENCES ISO 9001:2000 Quality Management System Requirements ISO/TS 16949:2002 Quality Management Systems Particular requirements for applications of ISO 9001:2000 for automotive production Core Tools Manuals: PPAP Manual Production Part Approval Process FMEA Manual Failure Modes and Effects Analysis APQP Manual Advanced Product Quality Planning and Control Plan SPC Manual Statistical Process Control DEFINITIONS Defective Material or component supplied that does not meet the Firestone drawing and no deviation has been issued, approving its use. Direct Materials Materials/ingredients used in air springs and rubber compounds. Indirect Materials Materials/ingredients used to facilitate production. (Note: Distributors, Transportation Providers, Packaging Companies, most Indirect Material suppliers will not be considered "raw material/ingredient suppliers" and will be exempt from the requirements set forth in this standard.) On Time Delivery Report (OTDR) A report generated by the Purchasing Department giving an on time analysis of materials received Raw Ingredients Items that are used in the mixing of rubber compounds, such as chemicals, rubber and polymers. Raw Materials Production components such as bead plates, pistons, bead wires, reinforcing materials, crimp rings, etc. Rejected Material Notice (RMN) A report generated by the Quality Assurance Department on non-compliant materials RGA# - Return Goods Authorization Number is assigned to each customer claim and processed through the Customer Service group. RMN System Rejected Material Notification system is the formal method for advising suppliers of rejected parts in Receiving, and W.I.P. Supplier Rating (SR) The rating that a supplier obtains through the RMN and the OTDR reports TM Credit Database system (Tele-magic) currently in use to capture claims, associated costs and credit approval. W.I.P. Work in Process defectives are materials/components released to inventory, in use on the floor, built into bellows or in the assembled product still in the plant. Other definitions are consistent with the terminology used in the ISO 9001:2000 and ISO/TS 16949:2002 standards. Page 15 of 15
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