JSP Supplier Quality Assurance Manual

Transcription

1 Changes to the Supplier Quality Assurance Manual: The 2011 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 that supply parts / materials to all JSP U.S. locations. Listed below are all JSP U.S. Locations: Butler, PA (Resins production and molding) Detroit, MI (Resins production) Tullahoma, TN (T1 Resins production) Tullahoma, TN (T2 Resins production and molding) In the event that you any questions regarding this information, please contact Stacey Butcher Cotter at (931) , or at Stacey.cotter@jsp.com. Revision 7 July 27, 2012 Revision 7 Page 1

2 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 TS16949, ISO9001 and ISO14001 standards. Revision 7 Page 2

3 Supplier Responsibilities: Suppliers are expected to meet the following basic requirements: 1. Suppliers of automotive components (Critical to Quality) are required to be ISO9001 certified, and ultimately TS16949 compliant. Suppliers are also required to comply with the International Material Data System (IMDS). In addition, JSP highly recommends suppliers be registered to ISO14001 (environmental standard). Those suppliers who are NOT certified to ISO9001 (automotive and resins suppliers) are required to submit a timetable for ISO9001 certification. Non-certified suppliers are also required to complete the JSP Supplier Quality System Survey by April 1 st of each year. Failure to comply with this requirement will result in the issuance of a Supplier Corrective Action Request (SCAR). 2. 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. 3. Provide technical support in problem solving and the development of new ideas. 4. Prompt response to: a. Request for Quotation b. Engineering information c. Quality and Delivery concerns and subsequent actions 5. Inform the JSP Purchasing and Quality departments of changes in economic or other conditions that might affect operating or supply decisions. Revision 7 Page 3

4 6. Stress continuous improvement in your operations to ensure continual competitive pricing and quality. 7. Provide Level 4 PPPAP submissions for prototype and pre-launch shipments. At a minimum this will include a PSW, layout data, prototype control plans and material certifications. 8. 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, 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. 9. 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. 10. Acquire JSP approval for all gages and/or fixture concept designs or drawings. 11. Submit extended shutdown containment plans. 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, field returns, special status via customer notification, etc. Revision 7 Page 4

5 2. Delivery (30 points) points are lost for missed due dates or incorrect quantities, with no communication to JSP. 3. Performance (25 points) points are lost for SCAR responsiveness, PPAP accuracy, 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 are given a quarterly rating as follows: World Class Supplier % On Approved Supplier List Excellent Supplier % On Approved Supplier List Average Supplier % On Approved Supplier List, Supplier development may be necessary Below Average Supplier % Supplier development necessary Unacceptable/Poor Supplier <=70% Remove from Approved Supplier List A SCAR is issued when a supplier has two consecutive quarters below or equal to 70%. Customer dictated suppliers shall be held to the same criteria as those sourced directly by JSP. All remaining suppliers (services) are subject to an annual evaluation based upon Delivery and Conformance to Requirements of product and/or services being provided to JSP. 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 processes. Mistake-proofing methodologies shall be incorporated in the preventive action process. Revision 7 Page 5

6 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 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. 5. Dimensional Layout should include 3 pieces per cavity (on CFG1003) and should include variable data on all features shown on the design record. 6. Initial Capability studies Ppk or Cpk of 1.67 minimum on features identified as critical by the JSP engineering and quality departments. If using a supplier developed drawing, the critical features are to be identified with a solid black diamond. It is the suppliers responsibility to monitor on-going process capability, as studies 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. Revision 7 Page 6

7 8. Physical Property testing test results should include certifications from accredited laboratories. 9. IMDS entry for each part number (JSP IMDS code 7931). 10. Numbered drawings these are to coincide with the dimensional layout(s). 11. Measurement System Analysis (GR&R) on equipment and/or tools used to measure capability features. 12. Samples on per cavity per mold/line JSP may also need samples for acceptable visual features (weld lines, sinks, etc.). 13. information this is to be based upon quoted volumes plus 15%. 14. JSP Packaging Approval sheets 15. Annual submission of the AIAG Special Process Assessment for components produced with heat treating (CQI-9), coating (CQI-11), or plating (CQI-12). 16. Annual Level 4 submission (by December 1 st of each year). JSP and the supplier shall agree on the PPAP submission date(s). In the event that the supplier cannot submit PPAP by the required due date, the supplier shall provide notification in writing of the contributing factors and new timing for the submission. 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 New Product Delivery Notice. This tag must be printed on yellow paper and should be adhered to each box or container being shipped. Revision 7 Page 7

8 Suppliers will notify JSP of all production and 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 to verify the quality system and manufacturing processes at a supplier manufacturing site for compliance to the system. 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, 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. 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, 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 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 Revision 7 Page 8

9 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. 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 ISO 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 ( Revision 7 Page 9