LOTUS SUPPLIER HANDBOOK rev14 09/05/2018. Supplier Handbook

Transcription

1 rev14 09/05/2018 Supplier Handbook Issue 14 May 2018

2 SECTION 0.0 Foreword to Issue 14 The LOTUS Supplier Handbook Issue 14 was issued with revisions to the following: Chapters re-organised Section 2.0 APQP Requirements page 8-10 Section 3.0 PPAP Requirements, page Section 4.0 LOTUS Specific Requirements. page Section 5.0 Production Requirements. Page Section 6.0 Supplier Performance Measurement and Corrective Action. Page Glossary page 48 It is the objective of LOTUS to secure the highest quality, cost effective components and materials, consistently delivered on time. This objective can only be achieved by establishing long term, close working relationships with suppliers, who adopt the LOTUS quality philosophy. The Handbook is issued to the current and potential suppliers of prototype, production and service parts for use on LOTUS Products and Client Products built by LOTUS. The purpose of the Handbook is to ensure that Tier 1 suppliers fully understand, and comply with LOTUS Product Quality requirements and our commitment to Total Quality management including continual improvement. It is the responsibility of Tier 1 suppliers to communicate the relevant details of this Handbook to their Tier 2 suppliers, and to ensure their compliance with its requirements. The LOTUS Supplier Handbook Issue 14 supersedes all previous handbooks issued. Any queries reference this handbook should be addressed to the LOTUS SQA department SECTION 0.0 Forward to this issue... 1 Table of Contents 2 USING THIS DOCUMENT Organization Guide to Symbols used in this document Supplier Feedback 4 SECTION LOTUS SUPPLIER REQUIREMENTS... 6 SECTION ADVANCED PRODUCT QUALITY PLANNING (APQP) Scope Advanced Product Quality Planning Responsibilities in APQP Key Components Definition 8 UNCONTROLLED IF PRINTED Page 1 of 50

3 2.5 APQP Reviews 9 SECTION PRODUCTION PART APPROVAL PROCESS (PPAP) Reference The PPAP Process Significant Production Run Documentation Retention/Submission Requirements Table Prototype / Pre-production Part Approval PPAP Requirements and Submission Guideline Design Records of Saleable Product - Drawing Marking of Polymeric Parts Authorised Engineering Change documents, if any Customer engineering approval, if required Design Failure Mode Effects Analysis (DFMEA) (for design responsible suppliers) Process Flow Diagrams Process Failure Mode Effects Analysis (PFMEA) Control Plan Measurement System Analysis Studies Dimensional Test Results (ISIR) Material/Performance Test Results Process Capability Study Qualified Laboratory Documentation Appearance Approval Report, (AAR) if applicable Sample Production Parts Master Samples Checking Aids Records of Compliance with Specific LOTUS CARS Requirements Part Submission Warrant (PSW) ELV/RRR Data Sheet LOTUS specific Packaging Approval LOTUS specific Tooling Records LOTUS specific Parts Approval Checklist LOTUS specific Approval Status (PPAP Submissions) Periodic Re-submission 25 SECTION LOTUS SPECIFIC REQUIREMENTS Special Characteristics Special Characteristic Requirements Document and Data Control Document Control Document Changes Control of Records Document Retention Batch Control Requirements Tooling Requirements 31 SECTION PRODUCTION REQUIREMENTS Supplier Request for Process Change (SRPC) Supplier Request for Concession (SRC) Packaging Requirements 39 UNCONTROLLED IF PRINTED Page 2 of 50

4 SECTION SUPPLIER PERFORMANCE MEASUREMENT AND CORRECTIVE ACTION Managing Nonconforming Product Corrective Action Response Reporting Corrective Action Response Rating Corrective Action Response Timing Reject Return of Supplied Product Supplier Corrective Action Request (SCAR) 45 GLOSSARY APPENDIX UNCONTROLLED IF PRINTED Page 3 of 50

5 Using This Document 0.1 Organization SECTION 0.0 This document defines the expectations and working procedures intended to assist suppliers in achieving and maintaining a successful working business with LOTUS CARS and their client(s). This document is organised in chapters related to our main processes and gives a guide to completing the LOTUS PPAP Workbook. Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Supplier Supplier Requirements Requirements APQP APQP PPAP PPAP Lotus Lotus Specific Specific Requirements Requirements Production Production Requirements Requirements Non Non Conforming Conforming Product Product 0.2 Guide to Symbols used in this document MANDATORY REQUIREMENTS ARE HIGHLIGHTED IN THIS FORMAT 0.3 Supplier Feedback Feedback concerning this document is welcomed and encouraged. Any suggestions, including suggestions for additional information or improvements to this document, should be communicated to the LOTUS SQA department. UNCONTROLLED IF PRINTED Page 4 of 50

6 SECTION 1.0 Basic Requirements Performance Expectations and Management Requirements Results Results Performance Performance Processes Processes Attitude: Never satisfied. Let nothing happen by chance. Strive for ZERO defects Supplying products to the vehicle industry is a very demanding business. It requires the ability to produce complex assemblies employing state of art technologies. To achieve this level of performance, the vehicle industry and their suppliers have developed specialised processes and systems to support the demands of this type of production while delivering high levels of quality expected by the vehicle customer. LOTUS CARS has adopted these quality processes and systems, and successful application by our suppliers is important to our shared success. The success of our performance is determined by the final customer. These customers are the people who rely on safe, high performance, reliable transportation solutions. We believe that achieving this level of quality and reliability can only be achieved by robust processes and rigorous monitoring. This requires a Customer focused mind set, a continuing search for effective solutions, and opportunities for continuous improvement. UNCONTROLLED IF PRINTED Page 5 of 50

7 Lotus Supplier Requirements SECTION The aim of LOTUS Supplier Management Philosophy is to select suppliers who are registered to one of the following: ISO/TS16949:2009 / IATF16949:2016 ISO 9001:2008 / 15 Under certain circumstances and/or to achieve specific objectives this criteria may be waived if the product or process supplied is key to project requirements. This waiver shall only be granted with the agreement of the LOTUS SQA Department and demonstration of adequate process control. LOTUS operates Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP) and expects the supplier to be conversant with this system. Suppliers will be subject to audits at various stages of Project and Production programs. These audits are used to confirm assurance of capacity and capability to produce conforming products and encourage a culture of continuous improvement within the supplier base. The following sections in this guide are requirements that suppliers shall follow when supplying LOTUS CARS or their Client(s). Authority to deviate from these shall be obtained in writing before supply of product. UNCONTROLLED IF PRINTED Page 6 of 50

8 SECTION 2.0 ADVANCED PRODUCT QUALITY PLANNING (APQP) Driving Quality Scope Planning Responsibilities Scope Planning Responsibilities Key Key Components Components APQP APQP Reviews Reviews At LOTUS we strive to deliver products and services that exceed customer expectations. To stay competitive LOTUS requires continuous development of new products and regular improvements of existing products. Supporting the introduction of new products requires a well-defined and organised process for project planning and launch. LOTUS organises all new product introduction into projects. Suppliers are required to have an effective project planning process that is capable of supporting the LOTUS process and timing for project management. LOTUS uses the AIAG guideline for APQP as the standard method for suppliers bringing products to production. Suppliers are expected to develop a detailed Advanced Product Quality Plan for the development and prove-out of processes used to produce LOTUS products. The following chapter describes the expectations related to APQP requirements. UNCONTROLLED IF PRINTED Page 7 of 50

9 ADVANCED PRODUCT QUALITY PLANNING (APQP) SECTION Scope LOTUS recognises that ultimate quality of delivered parts is determined during the design and development phase of the production process LOTUS requires suppliers to use Advanced Product Quality Planning (APQP) as a tool to support process development, integration and validation. The AIAG publication Advanced Product Quality Planning (APQP) and Control Plan should be used as a reference in developing these plans.. LOTUS expects suppliers to create product launch plans to support: Launch of all new components intended for serial production Significant changes to existing products or process Development of new manufacturing processes Suppliers are responsible to develop and drive APQP for ALL components 2.2 Advanced Product Quality Planning The objective of the planning process is to deliver the project on time, at cost and at the highest level of quality. The initial development of the APQP should begin upon receipt of the RFQ. This initial plan should be included as part of the RFQ response package APQP identifies the tasks to be completed, expected timing, assigned responsibility for completion and the critical plan. 2.3 Responsibilities in APQP Successful projects require a level of cooperation and teamwork between customer and supplier. Here is a short list of the key areas of responsibility. The SUPPLIER is responsible for: Assigning a dedicated project manager or APQP leader Organising a cross-functional APQP project team Developing and executing an APQP Plan to support a successful product launch LOTUS is responsible for: Identifying the LOTUS team members Assigning a Supplier Quality Engineer (SQE) to support the completion of APQP activities with the project team Identifying key milestones and project parameters 2.4 Key Components Definition All parts used in the vehicle are important to the customer satisfaction and the safe, reliable operation of the final product. However, there are some parts that require additional attention. At the start of a project, a cross-functional project team identifies parts that will be subjected to closer control and monitoring. These parts are designated Key Components. The LOTUS buyer will notify suppliers of parts selected as Key Components and any associated requirements. Suppliers of Key Components will typically be expected to participate in APQP and joint steering committee reviews during the project. UNCONTROLLED IF PRINTED Page 8 of 50

10 Key component selection criteria SECTION 2.0 Safety Critical components Regularity or legal requirements Parts with critical characteristics Supplier designed products Complex part or component Parts that constitute vital function in a system High value part or component Expensive or long lead time tooling Long lead-time part Parts with known or potential quality concern Extensive verification or validation testing Parts with features that cannot be verified prior to use by a customer (unchecked characteristics) New Technical Concepts 2.5 APQP Reviews APQP Reviews are formal meetings where LOTUS reviews supplier s project plan and status. During this meeting LOTUS and the supplier jointly confirm that the project is on track with respect to deadlines and results Suppliers of key components are required to report the project status at regular, established intervals during the project development. As a general rule, these reviews are held prior to the project milestone gates or drawing revision release. Suppliers should prepare for these project review meetings by completing or updating the APQP Status Report, their project plan and the project milestone dates The official APQP Review meeting (Kick-off Review) should occur within two weeks after the award of business. The final review is concurrent to the launch of the product. This review is intended to ensure that all open issues are resolved, that there is adequate capacity to support on-going productio0n needs and a lessons learnt has been conducted to improve future APQP activities To support these reviews, LOTUS has developed a checklist designed to document the project status at each review. Suppliers are responsible to complete and maintain the information for each review meeting. The completed form will be used by the joint team as the basis for evaluating the project status. (The supplier may use their own reporting format providing approval has been given by LOTUS SQA) Forms and guides to APQP are available on request from LOTUS SQA Department UNCONTROLLED IF PRINTED Page 9 of 50

11 SECTION 3.0 PRODUCTION PART APPROVAL PROCESS (PPAP) Approval of New or Revised Parts Reference Reference PPAP PPAP Process Process Significant Significant Production Production Run Run Documentation Documentation Retention Retention Submission Submission Requirements Requirements Prototype Prototype Pre-production Pre-production Part Approval Part Approval PPAP PPAP Requirement Requirement Guidelines Guidelines The purpose of Production Part Approval Process (PPAP) is to determine if all LOTUS engineering design record and specification requirements are properly understood by the supplier and that the manufacturing process used to produce parts for LOTUS is fully developed, thoroughly tested and capable of serial production of parts conforming to the technical specifications. For the PPAP LOTUS follows the AIAG requirements. Sample parts and the supporting documentation are submitted to show evidence that: The design records and specifications have been properly understood and met. The manufacturing process has the capability to produce conforming parts in the actual production environment. The manufacturing process has the capacity to support production quantities at consistent quality level. All completed PPAP workbooks and documents shall be submitted for approval by to: UNCONTROLLED IF PRINTED Page 10 of 50

12 PRODUCTION PART APPROVAL PROCESS (PPAP) SECTION Reference Suppliers shall ensure that the PPAP document and sample submissions are in accordance with the requirements of the Automotive Industry Action Group (AIAG) PPAP Manual Fourth Edition LOTUS requires its suppliers to follow the Customer Notification and Submission requirements as specified in the AIAG PPAP Manual. This includes but not limited to: Introduction of new components Changes to an existing part Drawing or specification changes Corrections to a prior discrepancy Supplier process / location change Material changes or substitutions Changes of sub-tier supplier Tooling change of any type All changes must be communicated to the responsible LOTUS SQA engineer. 3.2 The PPAP Process The word shall indicates mandatory requirements. The word should indicates a recommendation. Paragraphs marked Note are for guidance in understanding or clarifying the associated requirement PPAP shall apply to internal and external supplier sites supplying production parts, service parts or production materials. An organisation supplying standard catalogue production or service parts shall comply with PPAP unless formally waived by the authorised LOTUS SQA engineer The LOTUS Buyer will issue a PPAP Purchase Order and request PPAP submission to level 4. For some suppliers and parts alternative PPAP submission level will be requested. Suppliers are responsible to verify that all technical documentation and PPAP level has been supplied. All items or records may not be required for every LOTUS part number from every supplier. In order to determine with certainty which items must be included, consult the design drawing, specifications and the LOTUS SQA engineer Suppliers shall adhere to the LOTUS PPAP process and quality documentation requirements for each stage of the project. It is the responsibility of the Supplier to ensure that all quality targets are met in line with the project timing requirements. Any issues, delays or changes to the PPAP timing should be communicated to the LOTUS buyer and SQA engineer Processes must be developed to meet all drawing tolerances and requirements The supplier is responsible for the PPAP preparation: Suppliers shall submit approval paperwork with every change. Suppliers are responsible for the planning, approval, corrective action, follow-up and retention of PPAPs submitted by sub-suppliers and sub-contractors. Cpk studies for PPAP approval must be completed on minimum of 30 pieces 100% dimensional evaluation is required on five parts selected from the Significant Production Run For suppliers delivering small production runs, the requirement for Cpk studies and Significant Production Run may be waived with approval by the LOTUS SQA engineer Upon satisfactory completion of all required PPAP activities, prior to delivery of parts, the supplier shall complete the required information on the Part Submission Warrant (PSW) UNCONTROLLED IF PRINTED Page 11 of 50

13 When completing the PSW: SECTION 3.0 Suppliers are requested to use the LOTUS form A4-A in the LOTUS PPAP Workbook A separate PSW shall be completed for each LOTUS part number unless otherwise specified by LOTUS SQA engineer The PSW shall be signed by the authorised supplier representative before submission The LOTUS SQA engineer shall review all PPAP workbook submissions along with an assessment of the sample parts for physical appearance and vehicle fit and function. The LOTUS SQA engineer shall then assign one of the following: Fully approved and in compliance with all specifications Interim approval Not approved Any interim submissions must be clearly identified on the PSW and Parts Approval Checklist with details in the explanation / comments section Where interim approval is given, it must be supported by a Supplier Request for Concession (SRC) (A4-A-6441) see Section 05. All concessions require review and approval by both LOTUS Product Engineering and SQA. Approval of the concession requires a plan from the supplier to address all open issues. The completed form shall be submitted by to the LOTUS SQA engineer. Any SRC if required must be obtained and approved by the LOTUS SQA engineer before the supply of any documentation or product. 3.3 Significant Production Run A Significant Production Run (SPR) is required for all new part introductions and is the basis for the Production Part Approval Process. The purpose of the production trial run is to ensure the effectiveness of the manufacturing process by running production products off production tools, materials, equipment, cycle times, and environments while using production operators, gauges, and other production methods. The Significant Production Run requires that an adequate quantity of parts be produced to allow: Overall process stability Accurate calculation of manufacturing cycle time Determine production throughput time Capacity assessments Completion of capability studies Due to the fact that small production trial runs are common with LOTUS the supplier shall use the guidelines described in below. LOTUS requires a minimum of 30 production pieces to be studied for preliminary capability When LOTUS specifies special characteristics and the estimated annual usage is less that 500 parts, the supplier shall either Perform 100% inspection and record result OR Conduct an initial process capability study with a minimum of 30 parts and maintain SPC control charts during production This shall be documented in the control plan UNCONTROLLED IF PRINTED Page 12 of 50

14 SECTION For special characteristics that can be studied using variable data the supplier shall use one of the following techniques to study process stability. X-Bar and R Charts, n = 5, plot minimum 6 subgroups OR Individual X Moving Range, plot minimum 30 data points For initial process capability studies using 30 to 300 parts, the supplier shall use the following as acceptance criteria for evaluating initial process study results for processes that appear stable. Where LOTUS has an ongoing Minimum Cpk Capability requirement of : The Process Potential (30 Piece Ppk Capability Study) Minimum Acceptance Criteria is: SC 1.33 SC 1.67 CC 1.67 CC 2.00 If the process is unstable the supplier shall identify, evaluate and, wherever possible, eliminate special causes of variation prior to the PPAP submission. The supplier shall notify LOTUS SQA of any unstable processes that exist and shall submit a corrective action plan to LOTUS prior to any submission. Parts used for PPAP must be taken from the SPR. The PPAP must be fully approved or have interim PPAP with approved concession before starting serial production. 3.4 Documentation Suppliers are required to submit a Level 4 PPAP package for all components unless other arrangements have been agreed between LOTUS and the supplier The minimum requirements for a Level 4 PPAP include: Design Record of Saleable Product The Production release of LOTUS drawing Process Flow Diagrams Process FMEA Control Plan Dimensional results (ISIR) - see LOTUS PPAP workbook; doc A4-A Material / Performance test results - see LOTUS PPAP workbook; doc A4-A / 10.1 Appearance Approval Report (if applicable) Part Submission Warrant ELV data sheet LOTUS Specific Packaging Approval LOTUS Specific Part approval checklist LOTUS Specific It is the responsibility of the supplier to prepare the part approval submission for each part according to the standard and timing required by the LOTUS SQA Engineer. Suppliers shall only submit PPAP based on released drawings. Suppliers are required to submit the current revision of the LOTUS drawing in the PPAP package. This is to ensure that the PPAP has been conducted on the correct revision of specifications. PPAP cannot be approved based on supplier s drawings. Balloons supporting dimension checks must be made on the LOTUS drawing. UNCONTROLLED IF PRINTED Page 13 of 50

15 SECTION Documents must be legible and readily identifiable. Documents must be submitted in English unless the LOTUS SQA Engineer authorises a concession. All documents must be dated and reference the relevant customer part number, purchase order no. and engineering drawing change level. ELV/RRR Data shall be supplied for all parts as part of the submission paperwork to gain Full Approval Suppliers will be notified via a signed PSW regarding the status of the PPAP (approval, rejected, or interim) If full approval is assigned, the PSW shall be signed by the LOTUS SQA engineer and returned to the supplier for their records and as authority to ship parts into LOTUS Interim approval shall be assigned if issues are found that do not directly affect part fit / function. Interim approval shall be supported by an approved Supplier Request for Concession (SRC) (A4-A- 6441) see section 05. Approval of the concession requires a plan from the supplier to address all open issues. The PSW shall then be signed by the LOTUS SQA engineer and returned to the supplier for their records and as authority to ship parts into LOTUS If not approved the LOTUS SQA engineer will contact the supplier to agree corrective actions and timing to achieve PPAP approval. If parts are required by LOTUS an approved Supplier Request for Concession (SRC) (A4-A-6441) see section 05 is required. Approval of the concession requires a plan from the supplier to address all open issues Exception to default PPAP level 4: Upon LOTUS request, suppliers may be required to submit a level 3 PPAP package for Key Safety Components 3.5 Retention/Submission Requirements Table Requirements Level 1 Level 2 Level 3 Level 4 Level 5 1 Design Record of Saleable Product - Drg R S S S R 2 Engineering Change Documents, if any RR S S S R 3 Customer Engineering Approval, if required R R S S R 4 Design FMEA R R S R 5 Process Flow Diagrams R R S S R 6 Process FMEA R R S S R 7 Control Plan R R S S R 8 Measurement System Analysis Studies R R S R 9 Dimensional Test Results (ISIR) R S S S R 10 Material / Performance Test Results R S S S R 11 Process Capability Studies R R S R 12 Qualified Laboratory Documentation R S S R 13 Appearance Approval Report (AAR) if applicable S S S S R 14 Sample Production Parts R S S R 15 Master Samples R R R R 16 Checking Aids R R R R 17 Records of Compliance with Specific Lotus Cars Requirements R R S R 18 Part Submission Warrant (PSW) S S S S R 19 ELV / RRR Data Sheet Lotus Specific S S S S R 20 Packaging Approval Lotus Specific S 21 Tooling Records Lotus Specific 22 Parts Approval Checklist Lotus Specific S S S S R S = The supplier shall submit a copy of the records or documentation and retain a copy at appropriate locations R = The supplier shall retain at appropriate locations and make available to LOTUS upon request = The supplier shall retain at appropriate locations and submit to LOTUS upon request UNCONTROLLED IF PRINTED Page 14 of 50

16 3.6 Prototype / Pre-production Part Approval SECTION Prior to a full production part approval submission, a limited submission will be required for trial build purposes, M1 and VP builds. This allows LOTUS to determine the pedigree of the components used for trial builds / testing. The following documentation shall be submitted: Design Record of Saleable Product Design FMEA (where supplier has design responsibility) Process Flow Diagrams Dimensional results (ISIR) - see LOTUS PPAP workbook; doc A4-A Material / Performance test results - see LOTUS PPAP workbook; A4-A / 10.1 Sample Product All shipments of prototype parts must be clearly identified with purchase order no. part number, part level and marking that allows the part to be identified as a prototype. The purpose is to identify prototype parts in the production environment. UNCONTROLLED IF PRINTED Page 15 of 50

17 3.7 PPAP Requirements and Submission Guideline SECTION Design Records of Saleable Product - Drawing The supplier shall have all design records for the saleable product/part, including design records for components or details of the saleable product. Where the design record is in electronic format, e.g. CAD/CAM maths data, the supplier shall produce a hard copy (e.g. pictorial, geometric dimensioning & tolerance (GD&T) sheets, drawing) to identify measurements taken. Note: For any saleable product, part or component, there will be only one design record, regardless of who has design responsibility. The design record may reference other documents making them part of the design record. Forms used: A4-A-6484 A4-A-6486 A4-A-6147 Team Feasibility Commitment see Workbook Preliminary Feasibility Evaluation see Workbook Team Feasibility Checklist see Workbook Latest drawing / CAD model at agreed release level. Drawing must be ballooned for easy reference when reading dimensional results (ISIR) Drawing must be released stamped and signed by engineer Marking of Polymeric Parts Where applicable the supplier shall identify polymeric parts with ISO symbols such as specified in ISO Plastics Generic Identification and marking of plastic products and/or ISO 1629 Rubber and lattices Nomenclature The following weight criteria shall determine if the marking requirement is applicable. Plastic parts weighing at least 100g (using ISO 11469/1043-1) Elastomeric parts weighing at least 200g (using ISO 11469/1629) Note: Nomenclature and abbreviation references to support the use of ISO are contained in ISO for basic polymers and in ISO for fillers and reinforcements Authorised Engineering Change documents, if any The supplier shall have any authorised engineering change documents for those changes not yet recorded in the design record but incorporated in the product, part or tooling. Authorised Engineering changes along with the approved and signed marked-up print drawing Customer engineering approval, if required The supplier shall have evidence of customer engineering approval for all concessions away from the design record. Form used: A4-A-6441rev6 Supplier Request for Concession see Appendix Supplier Request for Concession SRC A4-A-6441rev6 see Section 05 page 34 The Engineering request number to be included on PSW. UNCONTROLLED IF PRINTED Page 16 of 50

18 SECTION Design Failure Mode Effects Analysis (DFMEA) (for design responsible suppliers) The supplier shall develop a Design FMEA for parts or materials for which they are design responsible. The purpose of the Design FMEA is a quality tool applied during the design stage to ensure that system / vehicle functions and potential related failures are understood and appropriate countermeasures taken to prevent them occurring or reaching the end customer. Note: A single Design FMEA may be applied to a family of similar parts or materials. (The supplier may use their own format providing approval has been given by LOTUS SQA) Retain and submit on request signed copy of review sheet SECTION Process Flow Diagrams The supplier shall have a process flow diagram that clearly describes the complete production process steps and sequence, as appropriate, and meets the specified LOTUS needs, requirements and expectations. Note: Process flow diagrams for families of similar parts are acceptable if the new parts have been reviewed for commonality. Form used: A4-A Process Flow Diagram see Workbook (The supplier may use their own format providing approval has been given by LOTUS SQA) Signed Process flow diagram. Process Flow shall describe production process steps & sequence. The Process flow shall show all CC s and SC s Process Failure Mode Effects Analysis (PFMEA) The supplier shall have a Process FMEA in accordance with and compliant to LOTUS specified requirements. The Process FMEA is a quality tool applied during the process planning stage to ensure that potential variation in manufacturing and assembly processes are controlled such that part and vehicle key functions are not affected. A Process FMEA must be completed for all components, with the exception of Proprietary Parts, and must cover all of the manufacturing and assembly processes employed at the supplier from material delivery through to despatch of parts to LOTUS. Note: A single Process FMEA may be applied to a process manufacturing a family of similar parts or materials if reviewed for commonality. Form used: A4-A Process FMEA template see Workbook (The supplier may use their own format providing approval has been given by LOTUS SQA) Document shall be in English The Process FMEA shall show all CC s and SC s PFMEA, shall be signed by supplier and LOTUS SQA e.g. front sheet UNCONTROLLED IF PRINTED Page 17 of 50

19 SECTION Control Plan The supplier shall have a Control Plan that defines methods used for process control and complies with LOTUS specified requirements. Note: Control Plans for families of parts are acceptable if the new parts have been reviewed for commonality. Form used: A4-A Control Plan see Workbook (The supplier may use their own format providing approval has been given by LOTUS SQA) Document shall be in English The Control Plan shall show all CC s and SC s as required by the Design Record Production Control Plan shall be signed by supplier and LOTUS SQA Measurement System Analysis Studies The supplier shall have applicable Measurement System Analysis studies, e.g. Gauge Repeatability & Reproducibility (R&R), bias, linearity, stability, for all new or modified gauges, measurement and test equipment. Form used: A4-A Gauge R&R Study see Workbook (The supplier may use their own format providing approval has been given by LOTUS SQA) Gauge R&R studies for all equipment used for statistical studies in section new or modified If R&R is between %, Action plan must be included R&R study Sheets must be traceable to the list of equipment & checking aids on the Control Plan Dimensional Test Results (ISIR) The supplier shall provide evidence that dimensional verifications required by the Design Record and the Control Plan have been completed and results indicate compliance with specified requirements. The supplier shall have dimensional results for each unique manufacturing process, e.g., cells or production lines and all cavities, moulds, patterns or dies. The supplier shall record, with the actual results; all dimensions (except reference dimensions), characteristics, and specifications as noted on the Design Record and Control Plan. The supplier shall indicate the date of the Design record, change level, and any authorised engineering change document not yet incorporated in the design record to which the part was made. The supplier shall record the change level, drawing date, organisation name and part number on all auxiliary documents (e.g. supplementary layout results sheets, sketches, tracings, cross sections, CMM inspection points, geometric dimensioning and tolerance sheets, or other auxiliary drawings used in conjunction with the part drawing) Copies of these auxiliary materials shall accompany the dimensional results according to the Retention/Submission Requirements Table. A tracing shall be included when an optical comparator is necessary for inspection. Dimensional result reports are required for six product samples that must include drawing dimensions and specifications. Additionally, each product supplied must have all special characteristics measured. A dimensional result report for sub component(s) must be provided when requested. The results must be recorded and submitted on the Initial Dimensional Test Results (ISIR) form. Each individual part must be clearly identifiable so that relevant inspection reports cavities/material batch etc. can be traced. The method and position of marking must be agreed with LOTUS SQA. All results must be referenced against the drawing tolerance. Any deviations to the drawing specification should be highlighted on the inspection report. Special characteristics must be clearly identified as such on the dimensional report. UNCONTROLLED IF PRINTED Page 18 of 50

20 SECTION 3.0 Measurements must be made using equipment with suitable discrimination and sensitivity. The instrument discrimination must divide the tolerance (or process variation) into ten parts or more. Example: Specification of 10 +/- 0.5 must be measured using equipment with discrimination of a minimum of two decimal places. Specification of 10 +/ must be measured using equipment with discrimination of a minimum of three decimal places. All measuring equipment used must be calibrated. Gauges and test equipment used must be accurate, discriminate, repeatable and reproducible. LOTUS SQA agreement is required to use gauges with a percentage gauge repeatability and reproducibility (% Gauge R&R) of 10%. Go/No Go information is not acceptable in lieu of measured dimensions. Any deviations to the above requirements must be agreed in writing with LOTUS SQA prior to submission. Form used: A4-A Dimensional Test Results (ISIR) see Workbook Measurements for six random samples as described in Design Records and Control Plan for all production lines, cells, cavities, processes, patterns, tools, colours and dies Dimensional Results Sheet (ISIR) A4-A for each sample submitted clearly identified Each measurement must be traceable to the submitted drawing/cad hard copy (ballooned I.D.) ALL SC s and CC`s must be marked on the Dimensional Results sheet Dimensional Results sheet must include date of design record, and change level, engineering change documents, supplier name and LOTUS part number. Dimensional Results sheet shall be signed and dated with inspection facility used SECTION Material/Performance Test Results The supplier shall have records of material and/or performance test results for tests specified on the Design Record or Control Plan. For products with customer-developed material specifications and a customer approved supplier list, the supplier shall procure materials and/or services (e.g. painting, plating, heat-treatment, welding) from suppliers on that list Forms used: A4-A A4-A Material Test Results see Workbook Performance Test results see Workbook Tests must be performed for all parts and product materials when chemical, physical or metallurgical requirements are specified by the Design Record or Control Plan. Complete Production Part Approval Material and Performance Test results for tests required by Design Record and related specifications. Any authorized engineering change documents that have not yet been incorporated in the Design Record. Test results must be traceable to the submitted Design Records and Control Plan Certificate of Conformance for each batch of material used for the Production Part Approval All documents must show Change Level, drawing date, LOTUS part number, part name, supplier name, date of testing, quantity of parts tested. UNCONTROLLED IF PRINTED Page 19 of 50

21 SECTION Process Capability Study The level of initial process capability or performance shall be determined to be acceptable prior to submission for all Special Characteristics designated by LOTUS or supplier. Note 1: Where no special characteristics have been identified LOTUS reserves the right to require demonstration of initial process capability on other characteristics. Note 2: The purpose of this requirement is to determine if the production process is likely to produce product that will meet LOTUS requirements. The initial process study is focused on variables not attribute data. Assembly errors, test failures, surface defects, are examples of attribute data, which is important to understand, but is not covered in this initial study. To understand the performance of characteristics monitored by attribute data will require more data collected over time. Unless authorised by LOTUS SQA attribute data is not acceptable for PPAP submissions. For those characteristics that can be studied using X-bar R charts, a short term study should be based on a minimum of 25 sub groups containing at least 100 readings from consecutive parts of the significant production run (see 2.3) However due to the typically small batch sizes for LOTUS product, alternative quantities and capability requirements can be applied as detailed in section A Cp of less than 1.33 signals trouble staying within the tolerance. A Cpk of less than 1.33 signals trouble with exceeding the closest tolerance. Forms used: A4-A A4-A Rate Sign Off see Workbook Cpk Calculator Sheet see Workbook (The supplier may use their own format providing approval has been given by LOTUS SQA) Results for all Special Characteristics (Critical, Significant) as required by Design Record and Control Plan to be included for each part number, cavity, tool, process, etc. SPC data of 100 consecutive readings have been taken from production tooling & production process (or as agreed by Lotus) for all Special Characteristics (Key, Critical, Significant, etc.) as required by Design Record and Control Plan Qualified Laboratory Documentation Inspection and testing for PPAP shall be performed by a qualified laboratory as defined by LOTUS requirements (e.g., an accredited laboratory). The qualified laboratory (internal or external to the supplier) shall have a laboratory scope and documentation showing that the laboratory is qualified for the type of measurements or tests conducted. When an external/commercial laboratory is used, the supplier shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date (s) of the tests and the standards used to run the tests shall be identified. Documentation for all laboratories used, acceptance criteria is based on the latest ISO/IEC STANDARD. (or National equivalent). Certificate to standard to be submitted Appearance Approval Report, (AAR) if applicable The purpose is to ensure master samples are made demonstrating that off tool/off process parts meet the appearance criteria (colour and texture) and satisfy the design intent. A separate Appearance Approval Report (AAR) shall be completed for each part or series of parts if the product/part has appearance requirements on the Design Record. UNCONTROLLED IF PRINTED Page 20 of 50

22 SECTION 3.0 Upon satisfactory completion of all required criteria, the supplier shall record the required information on the AAR. The completed AAR and representative production products/parts shall be submitted to the location specified by LOTUS to receive disposition. AARs (complete with part disposition and authorised LOTUS signature) shall then accompany the PSW at the time of the final submission based upon the submission level requested. Note: AAR typically applies only for parts with colour, grain, or surface appearance requirements. Form used: A4-A Appearance Approval Report see Workbook One Appearance Approval Report (AAR) per part number Each AAR must be signed by supplier and LOTUS Quality / Styling Sample Production Parts The supplier shall provide sample product (typically 6 parts) as requested by LOTUS and as defined by the submission request. Forms used: A4-A A4-A Sample Part Label see Workbook Sample Part Packing Label see Workbook Samples from production tooling & production process from each part number, cavity, tool, etc. to be submitted for functional evaluation. Parts must be marked with Part number, cavity, revision, tool, etc. and sample number that corresponds to dimensional report. Sample parts shall be packed and labelled with Sample Part Packing Label A4-A Master Samples The supplier shall retain a master sample for the same period as the production part approval records, or a) until a new master sample is produced for the same customer part number for customer approval, or b) where a master sample is required by the Design Record, Control Plan or inspection criteria, as a reference or standard. The master sample shall be identified as such, and shall show the LOTUS SQA approval date on the sample. The supplier shall retain the master sample for each position of a multiple cavity die, mould, tool or pattern, or production process unless otherwise specified by LOTUS SQA. The Master Samples shall be recorded on a Master Sample List. Note: When part size, sheer volume of parts, etc makes storage of a master sample difficult, the sample retention requirements may be modified or waived in writing by the responsible LOTUS SQA Engineer. The purpose of the master sample is to assist in defining the production standard, especially where data is ambiguous or in insufficient detail to fully replicate the part to its original approval state. Form used: A4-A A4-A Master Sample List see Workbook Master Sample Label see Workbook Any waivers for storing of master samples shall be obtained. Each master must be clearly identified (Part number,description, Revision level, Production Process and date, Supplier and LOTUS SQA signature and approval date) Masters must be for each cavity, mould, tool or production process, etc. Two masters to be retained for each cavity, mould, tool or production process, etc. unless written waiver from customer is obtained. UNCONTROLLED IF PRINTED Page 21 of 50

23 SECTION Checking Aids Suppliers should design and manufacture a fixture or gauge that is capable of measuring and confirming the special characteristics of the part as specified in the Design Record. This activity applies to all bespoke gauges / fixtures. If requested by LOTUS the supplier shall submit with the PPAP submission any part specific assembly or component checking aids. The supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The supplier shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. The supplier shall provide preventative maintenance of any checking aid for the life of the part. (see Glossary Active Part ) Measurement system analysis studies e.g., gauge R & R, accuracy, bias, linearity, stability studies shall be conducted in compliance with customer requirements. Note: Checking aids can include fixtures, variable and attribute gauges, models, and templates specific to the product being submitted. Forms used: A4-A Checking Aid Approval Request see Workbook A4-A Checking Aid Change Request see Workbook A4-A Checking Aid Record see Workbook A4-A Checking Aid List see Workbook Preventive maintenance of checking aids must be provided. List of all checking aids used specifically for part, assembly or component: Gauge number, proof of calibration, location stored. All checking aids must have Gauge R&R s see section page 19 All engineering changes to checking aids must be listed All checking aids must be referenced on PSW Front page. All Lotus owned tooling to be marked as so, and a photo of the gauge to be included in the PPAP package. SECTION Records of Compliance with Specific LOTUS CARS Requirements In addition to the requirements described in the AIAG PPAP Fourth Edition, LOTUS requests the planning and completion of the following activities. ELV/RRR see page 25 Packaging Approval see page 26 Tooling Sign Off and Records see page 26 Parts Approval Checklist see page 26 The supplier shall have records of compliance to all applicable customer-specific requirements Part Submission Warrant (PSW) Upon completion of all PPAP requirements, the supplier shall complete the Part Submission Warrant (PSW) The supplier shall ensure that the correct information is entered onto the PSW regarding the question on the document Has the customer required Substances of Concern information been reported? If the part/assembly contains any such substance, even if the amount is within the allowable limits identified within the European Directive, then the YES box on the PSW MUST be ticked. UNCONTROLLED IF PRINTED Page 22 of 50

24 SECTION A separate PSW shall be completed for each customer part number unless otherwise agreed by LOTUS SQA If production parts will be produced from more than one cavity, mould, tool, die, pattern, or production process, e.g. line or cell, the supplier shall complete a dimensional evaluation (see 3.7.9) on one part from each. The specific cavities, moulds, line etc, shall then be identified in the Mould/Cavity/Production Process line on a PSW, or in a PSW attachment The supplier shall verify that all of the measurements and test results show conformance with the LOTUS requirements and that all required documentation is available and, for Levels 2, 3, and 4, is included in the submission as appropriate. The responsible official of the supplier shall approve the PSW and provide contact information. Note 1: One warrant per customer part number can be used to summarise many changes providing that the changes are adequately documented, and the submission is in compliance with LOTUS program timing requirements. Note 2: PSW s may be submitted electronically in compliance with the LOTUS requirements Part Weight (Mass) The supplier shall record on the PSW the part weight of the part as shipped, measured and expressed in kilograms to four decimal places (0.000) unless otherwise specified by LOTUS SQA. The weight shall not include shipping protectors, assembly aids or packaging materials. To determine part weight, the supplier shall individually weigh ten randomly selected parts, calculate and report the average weight. At least one part shall be measured from each cavity, tool, line or process to be used in product realisation. Note: This weight is used for vehicle weight analysis only and does not affect the approval process. Where there is no production or service requirement for at least 10 parts, the supplier should use the required number for calculation of the average part weight. Form used: A4-A Part Submission Warrant see Workbook A separate PSW shall be included for each part number used. Warrant shall be as per Lotus form A4-A Each section must be completed fully. Weight to be shown in Kg (0.0000) unless otherwise agreed by LOTUS SQA. Weight to be measured as the average of ten samples. SECTION ELV/RRR Data Sheet LOTUS specific The supplier affirms that parts submitted comply with the requirements of the End of Life Vehicle Directive 2000/53/EC and its latest amendments at the time of manufacture. The supplier shall submit a fully completed and signed copy of the LOTUS ELV / RRR Data Sheet where required by the submission level. This data sheet requires the supplier to self-certify a detailed breakdown of the material specifications and weights of all component parts. Form used: A4-A ELV Data Sheet see Workbook ELV/RRR Data Sheet, A4-A , to be completed by Vendor and returned to the designated contact at LOTUS UNCONTROLLED IF PRINTED Page 23 of 50