Revcor Supplier Quality Manual

Transcription

1 Revcor Supplier Quality Manual Documentation The Revcor is governed by comprehensive documentation as referenced herein. Procedures, work instructions, practices, forms, drawings, and similar documentation used by our organizations departments and outside suppliers whose direct or supportive participation in processes affecting product Quality, are formally documented and controlled. All such documents are contained in readily identifiable, easily accessible libraries (paper and computer files), which are placed at convenient locations within the company, provided directly to suppliers, or available on our company website. The associated distribution list for this document is maintained in the Document Control system. If this document is not stamped with Controlled in red ink, this document is uncontrolled and not subject to notification of changes. 251 Edwards Avenue, Carpentersville, Illinois 60110, USA

2 Supplier Quality Manual Preface Statement of Authority The described in this Supplier Quality Manual has been specifically designed to meet the requirements of ISO9001 and to provide a framework to allow accomplishment of our quality objectives and goals in the company s business activities operated from its corporate headquarters at: 251 Edwards Avenue Carpentersville, Illinois And additional manufacturing plant located at: Avenida Manimex No Parque Industrial El Puente Cd. Reynosa, Tamaulipas, Mexico C.P The Chief Executive Officer (CEO) or Chief Operating Officer (COO) has the ultimate responsibility for definition, implementation and maintenance of this Business Management System and the continual improvement of its effectiveness. To ensure that these responsibilities and authorities are effectively carried out, they are delegated to the Director of Quality. These responsibilities include identifying and recording problems affecting quality and taking or requiring actions to be taken to prevent recurrence. This authority includes halting shipments or work in progress until the nonconformance is resolved. In addition, additional responsibilities are defined and delegated as described in this Quality Manual and the referenced procedures. This Supplier Quality Manual and its related operating procedures are mandatory, and any changes to the must be authorized as described in our Document Management System. Lee Frick, Vice President Materials Kim A Howarter, Director of Quality A09, Revision 01, 2/5/18 Page 2 of 10

3 Supplier Quality Manual Table of Contents 1. Purpose Quality Requirements for Supplier Definitions Documentation Revcor / Organization Interface Advanced Product Quality Planning (APQP) Production Part Approval Process (PPAP) Preservation, Packaging and Shipping Process Audits Quality Data Submissions Specification / Requirement Change / Deviation Requests Nonconformance, Corrective and Preventive Actions Organization Quality Performance Statistical Techniques Measurement System Analysis (MSA) Preventive / Predictive Maintenance Continual Improvement Process (CIP) Cost Recovery Quality Records Purpose 1.1. This Supplier Quality Manual is a supplement, providing additional Revcor specific requirements which organizations shall follow. This manual, with the ISO 9001 standard, includes both Supplier and Revcor responsibilities. Material supplied to Revcor shall be produced, controlled, inspected, and tested according to the requirements set forth in this document and other applicable specifications. 2. Quality Requirements for Supplier 2.1. Revcor encourages all of its suppliers to be third party registered to ISO Copies of ISO 9001 certificates shall be submitted to Revcor. Acceptance of accreditation(s) shall be communicated to Revcor. Should the status of any accepted accreditation change, (i.e. new certification, de-certification, reassessments, etc.) the supplier shall notify Revcor To be considered as a new Supplier to Revcor, a Supplier shall: Adhere to this Supplier Quality Manual Submit a completed Supplier Profile and Quality Questionnaire, D , to Revcor. 3. Definitions 3.1. Supplier is defined as an organization that provides material, components or services to Revcor that are used in production of Revcor products The word 'shall' indicates mandatory requirement The word 'should' indicates a mandatory requirement with some flexibility allowed in compliance methodology. Organizations choosing other approaches to satisfy a 'should' must be able to show that their approach meets the intent of ISO A09, Revision 01, 2/5/18 Page 3 of 10

4 3.4. Product is defined as any part, product, service, etc. supplied to Revcor for which this standard is applicable. 4. Documentation 4.1. The supplier shall maintain and conform to the latest revision level of the required part print or referenced purchase order documentation Revcor specific documentation related to product conformance may include, but is not limited to the following: Parts list, Product structure (bill of materials) Part Print Purchase Order specification 4.3. The following is a list of AIAG / ISO / ANSI documents referenced in this standard. Refer to the latest version. Manual Published by Description ISO 9001 ISO Quality System APQP AIAG Advance Product Quality Planning FMEA AIAG Potential Failure Mode Effects Analysis MSA AIAG Measurement System Analysis SPC AIAG Fundamental SPC PPAP AIAG Production Part Approval Process ANSI Y 14.5 ANSI GD&T To obtain information of these documents, contact the following: Revcor / Supplier Interface 5.1. General communication from suppliers shall flow through the Revcor Buyer unless otherwise specified. The official business language for all documents referenced in this quality standard shall be English. Other languages may be used with prior Revcor approval Communication is the key to any successful partnership. Revcor involves the organization from product concept through mass production. 6. Advanced Product Quality Planning (APQP) 6.1. Suppliers shall utilize the planning procedures from the AIAG Advanced Quality Planning and Control Plan (APQP) manual. All elements of the (APQP) must be incorporated into the planning process, unless waived in writing by Revcor. All A09, Revision 01, 2/5/18 Page 4 of 10

5 documents including Process Flow Diagram, PFMEA and Process Control Plans shall include all processes for the manufacturing of components, including incoming inspection, internal transportation, secondary operations, outside services and packaging. All operations shall be keyed to the Process Flow Diagram, PFMEA and Process Control Plan. 7. Production Part Approval Process (PPAP) 7.1. Suppliers shall submit specific PPAP requirements in accordance with the latest revision of the AIAG PPAP Manual. The PPAP Process generates quantitative evidence that your tooling and production processes are capable of producing the materials or components according to Revcor s stated requirements. It also demonstrates that Revcor s suppliers recognize and understand all requirements for the material or component being purchased PPAP documentation must be successfully completed and approved by Revcor before the component or material can move into production or ship to Revcor. If PPAP cannot be completed before production must start a temporary deviation must be submitted by the organization and approved by Revcor Deviations from any PPAP requirement must be documented on a deviation and submitted with the PPAP documentation The submission level shall be level 2 as the default for all submissions unless specified otherwise by Revcor Examples of situations where a PPAP submission is required include: New production part Production equipment or processes have been markedly changed Transfer of equipment or tooling to a new production location Tooling has been rebuilt or replaced New material or material revision Change of material supplier Tooling has been inactive for more than two years or as requested Change in test / inspection method Part or material revision Measurement Results Correlation: All samples shall be sequentially numbered and correlated to the dimensional reports. Blueprints should be numbered (including all drawing notes) and correspond to a dimensional report. All results shall be taken from master samples and these samples shall be submitted with the PPAP. The measurement method used shall be identified on dimensional report The organization shall ship production intent material to Revcor only if the PPAP submission has been approved in writing by Revcor. 8. Preservation, Packaging and Shipping Revcor expects our suppliers to guarantee that all production and aftermarket materials or components are packaged and preserved in a manner that prevents damage or deterioration during delivery to, and storage at Revcor s facilities. A09, Revision 01, 2/5/18 Page 5 of 10

6 8.2. Material and components that are damaged (or that deteriorate) as the result of inadequate packaging or preservation will be rejected. (For Raw Material Coils reference Doc. No Packaging, Handling, Storing, and Appearance Requirements for Coil Material Supplied to Revcor) 8.3. Revcor expects you to label material and components on all interior and exterior containers. Labels must be located so that markings can be easily read when stored on shelves or stacked. 9. Audits 9.1. Revcor monitors all supplier quality and delivery performance and reserves the right to request an adhoc process audit as deemed appropriate by Revcor Conditions which may warrant an audit include the following: New Supplier Quality performance Delivery performance Engineering changes Process changes Plant location changes (eg. tool transfer) 9.3. As a Revcor Supplier, you shall audit conformance to the requirements of your Quality System and the effectiveness of the system. Revcor expects that your audits will generate evidence (records of audits conducted, findings, corrective actions, etc.) that can be reviewed by Revcor. 10. Quality Data Submissions The organization may be required to submit Quality Data (i.e. SPC charts, process monitoring results, material certifications, preventative & predictive maintenance data, etc.) upon request to the Revcor. Original documentation shall be retained at the organization. 11. Specification / Requirement Change / Deviation Requests General Requests for changes or deviations (temporary or permanent) to specifications or requirements shall be documented. Approval shall be made through Revcor. (Reference Doc. No. A ) Material substitutions are not allowed unless specifically permitted by the drawing, purchase order, or approved in writing by the designated Revcor Purchasing Representative. Deviations to our prints and or specifications shall be requested in writing, and approved through Revcor Deviations Deviation from the specification is time or quantity limited. These deviations shall be temporary and are not considered permanent. All deviated parts are to be labeled with a description of the Deviation. Prior to shipment, supplier shall notify Revcor of a deviated shipment Permanent Changes Permanent changes, either Organization or Revcor initiated, shall be appropriately documented. These changes may require a new PPAP submission as specified by Revcor. A09, Revision 01, 2/5/18 Page 6 of 10

7 Organization initiated change requests shall be submitted to Revcor Purchasing along with all supporting documentation. The organization shall make no changes until Revcor approval has been granted. 12. Nonconformance, Corrective and Preventive Actions Revcor Suppliers will have quality systems that are capable of detecting and controlling non-conforming material or components to prevent shipment to our facilities. If non-conforming material or components are inadvertently shipped, immediately advise your Revcor designated Purchasing Representative When Revcor has notified the organization of a 'Nonconformance' issue, the organization is responsible for: Initial Containment. This containment action shall: Be implemented within 48 hours (2 business days) of notification by Revcor personnel. (All verbal notifications to Revcor shall be followed up with written documentation) Containment actions shall include all affected material in the organization's control, in transit to Revcor, in the possession of Revcor, or finished product shipped to Revcor customers The organization shall notify Revcor of their containment actions and to discuss coordination of containment of material at Revcor and Revcor customers Certified Shipments All shipments of affected material shall be 'certified' (i.e. in compliance with the containment actions) until corrective action issues are formally closed by a Revcor Supplier Development Representative All material shall be shipped per approved methods and identified with certified labels on the outside of all containers Initial Response A written initial response shall be submitted to Revcor Purchasing within 48 hours (or otherwise specified time frame) of formal notification of the concern. Each stated criteria below shall contain an implementation date and assigned responsibility. This initial response shall, at minimum, contain: Revcor Corrective Action Number and Date of Nonconformance Problem Description Containment action description Containment action verification(quantitative results) Certified material shipment dates and identification Root Cause analysis status Formal Corrective Action Report A Formal Corrective Action Report shall be submitted to Revcor within 10 working days (or otherwise specified time frame) of formal notification of the concern Documentation A09, Revision 01, 2/5/18 Page 7 of 10

8 FMEAs, Control Plans and other appropriate documentation shall be revised to reflect changes resulting from the concern. These documents shall be maintained on file and provided to Revcor for review as required Action/Timing Plans Revcor expects that the corrective actions will be implemented within 10 days, validated and closed within 30 days. If additional time is required for resolution of corrective actions, a written action/timing plan shall be submitted to Revcor for approval Organization Containment Level Procedures If organization containment actions are not effective, progressive Revcor initiated procedures shall be implemented for the organization. Any reoccurrence will result in the 30 day inspection period to start over. The inspection period begins once root cause has been identified and corrective actions are in place Controlled shipping level 1 ( CS1 ) - The organization shall implement 100% inspection for a period not less than 30 days with no re-occurrence of the issue Controlled shipping level 2 ( CS2 ) - A containment process under Revcor control. Containment conducted at Revcor site, organization, or third party location at the organization s expense. This process may be used if Level 1 containment is ineffective at containing a nonconformance. The organization shall implement this inspection for a period not less than 30 days with no reoccurrence of the issue Corrective Action Report, 8D Report A written corrective action 8D report with implementation/effective dates and assigned responsibilities shall contain, at a minimum, the items listed below: Description of the concern and Revcor Corrective Action Number Containment action Root Cause of the concern with verification Corrective action Verification of containment and corrective action. This is a measure of the action's effectiveness utilizing appropriate statistical or process performance analysis methods Preventive measures for 'Lessons Learned' and applicable to similar products and processes Preventive actions assess the applicability of the action taken to similar processes. These are actions with a proactive and predictive intention with the focus on avoiding occurrences Verify Process Flow Diagrams, PFMEAs and Process Control Plans have been updated Reference Doc. No. A Supplier Corrective Action Changes to the product and/or the product documentation (i.e. drawings, specifications, Control Plans, PFMEAs, Flow charts, Bill of Material's, etc) due to corrective action implementation shall be documented through revision A09, Revision 01, 2/5/18 Page 8 of 10

9 levels/dates. Change in revision levels/dates may require PPAP submission. Contact Revcor for required PPAP submission levels/dates. Supportive documentation (i.e. laboratory analysis, statistical results, etc.) may be requested by the Revcor. 13. Organization Quality Performance Revcor Supplier Rating Reports shall be communicated to Key suppliers on a monthly basis or as requested The results of the assessments shall be communicated by the organization to their management Performance assessments deemed unacceptable by Revcor shall require corrective actions by the organization. These corrective actions shall be submitted to and approved by Revcor. 14. Statistical Techniques Where applicable, the organization should monitor process performance utilizing the appropriate statistical techniques (i.e. First time yield, SPC, etc.) in accordance with the AIAG Statistical Process Control manual Additional areas in which statistical techniques may be applied are as follows: Predictive maintenance programs Capability Studies Gage R&R studies Defect analysis Continual Improvement Processes The results of the statistical techniques shall be documented and retained at the organization's location. This information shall be made available upon request by Revcor. 15. Measurement System Analysis (MSA) The organization should perform measurement system analysis (frequency to be determined by the organization) in accordance with the AIAG Measurement System (MSA) manual. Other analytical methods and acceptance criteria may be implemented with approval Revcor. Results of MSA analysis shall be documented and retained at the organization's location. This information shall be available upon request by Revcor. 16. Preventive / Predictive Maintenance The organization shall implement a preventive / predictive maintenance program for each process machine used during the manufacture of products purchased by Revcor. The organization shall document and maintain this program and it shall be available upon request by Revcor. 17. Continual Improvement Process (CIP) The organization shall implement continual improvement efforts throughout their entire organization. Results of the Continual Improvement Process shall be documented and retained at the organization's location. This information shall be made available upon request by the Revcor. A09, Revision 01, 2/5/18 Page 9 of 10

10 Supplier Quality Manual 18. Cost Recovery Revcor reserves the right to recover costs associated with receiving and handling nonconforming or otherwise problematic material or components from suppliers. Revcor s Cost Recovery applies to, but is not limited to: Receiving department inspections/rejections Production line costs resulting from rejects, sorting, unplanned schedule changes, rework, work around, line stoppages, etc Finished goods inventory hold, inspection and rework Epidemic field failures and field rework Late deliveries resulting in overtime, expedited freight, etc Chronic administrative costs resulting from quantity discrepancies, invoice discrepancies, chasing Corrective Action Reports, etc. 19. Disqualification Revcor reserves the right to disqualify a supplier for future production based on quality and / or delivery performance Repeat offenses for items where a corrective action has already been completed by the supplier may cause disqualification not only for the product involved but in total. 20. Quality Records Revcor Suppliers shall retain the records that demonstrate compliance with control plans and industry standards for the materials or components we purchase from you. Please notify Revcor in writing if your records retention timeframe is less than seven years. A09, Revision 01, 2/5/18 Page 10 of 10