Supplier Specific Requirements Manual 2015

Transcription

1 Cncentric Itasca Inc. 800 Hllywd Ave Itasca, IL USA Tel: Supplier Specific Requirements Manual 2015 Supplier Specific Requirements Manual 2014 (Issue 2, Octber 2014) Cncentric Itasca USA

2 1.0) Scpe / Purpse: The intent f this dcument is t define the quality requirements necessary t ensure a successful partnership between Cncentric Itasca and ur suppliers. Cncentric Itasca recgnizes and cnfrms t the Glbal ISO/TS16949 and ISO9001 standards and ther custmer requirements Identified by the custmer and relevant service part rganizatins. Accrdingly, all Cncentric Itasca prductin suppliers are required t establish, dcument, implement and maintain effective prductin, quality, and management systems in cmpliance with these standards and requirements. This includes thse requirements specified thrugh Cncentric Itasca Custmer requirements. Cncentric Itasca recgnizes the imprtance f the envirnment and therefre strngly recmmends suppliers t pursue the intents f ISO If a supplier is nt ISO/TS16949 cmpliant they must submit a plan t achieve these certificatins. Until such certificatin is achieved a Cncentric Itasca Supplier Quality Engineer r an alternate qualified Cncentric Itasca emplyee will audit that supplier every 6 mnths at the supplier s expense. 1.1) Secnd Party Custmer Apprval Guidelines: Cncentric Itasca requires suppliers t maintain and verify all sub cntractrs certificatins r cmpliance t current ISO9001 r TS16949 quality system requirements. Until such certificatin is achieved a Representative frm said Sub-Supplier r an alternate qualified Sub-Supplier emplyee will audit that supplier every 6 mnths. 1.2) Supplier Apprval Requirements: The requirements listed belw are minimum requirements fr suppliers t Cncentric Itasca. The Cncentric Itasca Suppler Quality Engineer may update these requirements accrding t new standards, regulatins, r as deemed necessary. The supplier must be ISO 9001 r TS16949 registered unless therwise apprved by Supply Chain Management. Sub-cntractrs shuld als be a minimum f ISO9001 apprved. If a nn-iso9001 subcntractr is t be used, then this must be cmmunicated and frmally agreed by Cncentric Itasca. As a minimum, this subcntractr shall have been subjected, by the supplier, t a standard system and prduct audit, which will cntinue, as a minimum, n an annual basis. (As part f Cncentric Itasca TS certificatin, ur custmer must give frmal apprval t Cncentric Itasca if any f ur suppliers r sub-cntractrs are nn ISO9001 apprved.) 2.0) Advanced Prduct Quality Planning (APQP): Suppliers are expected t use advanced quality planning tls t supprt the develpment f all new prducts and / r services. The plans shuld fllw the guidelines established in the Advanced Prduct Quality Planning and Cntrl Plan (APQP) manual. The Autmtive Industry Actin Grup (AIAG) publishes this dcument. Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

3 3.0) Prductin Trial Run: Suppliers must perfrm a prductin trial run t verify that their actual prductin prcess and any critical sub-supplier prcess is capable f meeting expected vlumes at an acceptable quality level. The supplier s prcess must be able t prduce 120% f the quted vlume with prductin tls and equipment, and in the quted wrk patterns, fixtures, and tling. Prductin trial run parts may be used as validatin samples as part f the PPAP submissin. 4.0) Prductin Part Apprval Prcess (PPAP): All suppliers are required t btain full apprval frm Cncentric Itasca as per the requirements f the AIAG Prductin Part Apprval Prcess (PPAP) Manual current editin. All sample submissins are t PPAP Level 3 and submitted by (sft) unless therwise specified by the Cncentric Itasca Supplier Quality Engineer. The minimum number f measured samples shall be three, but samples must be supplied frm each pattern / fixture / machine. Sectined samples are als required fr any features that require the pump be sectined in rder t btain the measurement. Suppliers may be required t submit annual layuts t Cncentric Itasca drawings with either critical r majr features identified t verify cntinued cnfrmance t the specificatins. Re-submissins may be submitted in electrnic frmat at a PPAP level 4. Level 4 submissins shall cnsist f at least the part submissin warrant (PSW) and capability data fr critical and majr features. This requirement may be waived by the Supplier Quality Engineer in the event f the supplier publishing mnthly / quarterly capability data fr these features. Suppliers must submit prduct r prcess change requests in advance f any changes t the Cncentric Itasca Supplier Quality Engineer. Changes in prduct r prcess designs and specificatins may require end custmer apprval and validatin f the changes prir t Cncentric Itasca PPAP apprval. Suppliers must allw a minimum f 10 business days fr prcessing f all PPAP requests. The 10-day time line is established frm the date f parts receipt alng with fully cmpleted PPAP dcumentatin t the Supplier Quality Engineer. Suppliers must statistically study all critical, majr, and key characteristics unless therwise directed by the Cncentric Itasca Supplier Quality Engineer. These elements must be included in the PPAP dcumentatin. In general, Cncentric Itasca requires a Quality (Cpk) index greater than r equal t 2.0 fr critical parameters with a lng term target f Majr parameters 1.67 with 1.33 as acceptance criteria fr a lng term target and initial studies n majr and key characteristics. 5.0) Nn-Cnfrming Parts: Suppliers are required t infrm Cncentric Itasca Supplier Quality Engineer f any risk r ptential risk befre shipping nn-cnfrming parts. The supplier must prvide shipping infrmatin t include the fllwing: 1. Nn-Cnfrming Parts cncern identified 2. Quantity f parts ptentially affected Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

4 3. Advice / invice numbers 4. Crate / Pallet numbers 5. Expected arrival date at Cncentric Itasca 6. Cntainment actins detail including srt results 7. Cnfirmatin f arrangements t supprt srting f parts at Cncentric Itasca and/r its custmer 8. Cncentric Dck Alert labels n 4 sides f each pallet sent t the Itasca facility. 6.0) Crrective Actin Cncern (CAR): Cncentric Itasca will ntify the supplier when a nn-cnfrmance has ccurred. A resulting Crrective Actin Request (CAR) may be required. Cncentric Itasca will accept the supplier s crrective actin dcumentatin as lng as it meets the general requirements f autmtive prblem slving methds (8D). Cncentric Itasca Supplier Quality Engineer will prvide a cpy f a crrective actin template with the CAR reprt. The fllwing items must be cmpleted in assciatin with a nn-cnfrmance CAR request: Shrt-term actin and cntainment f the parts must be cmmunicated by submissin f an interim CAR reprt within 24 hurs f issue. This may invlve request/s by Cncentric Itasca fr allcatin f third party agent in rder t srt parts. Fixed cst penalties may be allcated fr each CAR issued as advised by Cncentric Itasca Purchasing Department. Establish and maintain a lng-term actin plan within 30 days f CAR being issued. Supplier shall fllw timeliness f their respnse t these due dates within the CAR fr each actin plan. The Cncentric Itasca Supplier Quality Engineer will review all respnses which must include updated cpies f any relevant dcumentatin. This may include but is nt limited t: Wrk Instructin Cntrl Plans FMEA - signed Training Matrix - Quality Alerts. Unacceptable respnses will be returned t the supplier fr further analysis. Cncentric Itasca Supplier Quality Engineer reserves the right t srt prduct at the suppliers agreed cst t keep the Cncentric Itasca line running. If rt cause is determined t nt fall within a supplier s respnsibility, charges will be deleted r an apprpriate reversal f a Debit Mem will take place. Repetitive nn-cnfrmance, adverse quality trends, r ther issues may escalate the crrective prcess t include but nt limited t: Frmal prcess / prduct audit f the supplier s facility by a Supplier Quality Engineer. Fcused prblem slving activity with agreed measures and targets. Rutine reprting t Cncentric Itasca Supplier Quality Engineer t ensure time lines and actin items are cmpleted. These activities shall be mnitred by the Supplier Quality Engineer and may include the active participatin f senir management frm the supplier. Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

5 7.0) Screcard System: All strategic suppliers will be given a screcard n a mnthly basis. This screcard is t be used as a tl t determine the perfrmance f suppliers in the areas f quality, delivery, and cmmercial. Suppliers are encuraged t use this as a tl t see hw Cncentric Itasca views them as a supplier. Suppliers with the lwest ranking scres with be evaluated fr the Fcus 3 prgram (described in the next sectin) Supplier Scre Card Example (Page 1) Cmpnents f Page 1 Mnth Scre This represents the scre fr the current mnth (0-100 Pints) 6 Mnth Average The average f the current mnths scre and the previus 5 mnths Mnthly Scre Chart Mnthly scre charted fr the current mnth and the previus 5 mnths PPM Chart - Mnthly scre charted fr the current mnth and the previus 5 mnths PPM The actual pints fr the current mnths PPM (see page 2 f the screcard fr hw the pints are calculated) Srts - The actual pints fr the current mnths srts (see page 2 f the screcard fr hw the pints are calculated) On Time CAR s - The actual pints fr the current mnths n time CAR s (see page 2 f the screcard fr hw the pints are calculated) OEM Spills - The actual pints fr the current mnths OEM spills (see page 2 f the screcard fr hw the pints are calculated) On Time Delivery - The actual pints fr the current mnths n time delivery (see page 2 f the screcard fr hw the pints are calculated) Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

6 Quality Certificatins - The actual pints fr the current mnths PPM (see page 2 f the screcard fr hw the pints are calculated) VAVE Ideas - The actual pints fr the VAVE ideas (see page 2 f the screcard fr hw the pints are calculated). Once VAVE is implemented these pints will remain fr the next 12 mnths. Nte that this area allws the supplier t earn extra pints. Cst Reductins - The actual pints fr the cst reductins (see page 2 f the screcard fr hw the pints are calculated). Once reductins are given these pints will remain fr the next 12 mnths. Nte that this area allws the supplier t earn extra pints. Cmments This is a manual field fr Cncentric Itasca Supply Chain t enter ntes. Ntes such as late CAR s may be entered int this field. Supplier Scre Card Example (Page 1) Cmpnents f Page 2 Definitins f hw all the individual cmpnents are scred in pints Raw Data In the lwer right hand crner f the page the bx will shw the raw date used fr each calculatin. 8.0) Fcus 3 Prgram: The Fcus 3 prgram is a tl that Cncentric Itasca will use t help develp underperfrming suppliers. The screcard system will be the tl used t identify which suppliers are t be placed in the prgram based n quality and/r delivery issues. Once a supplier is placed int the prgram the fllwing actins will take place: Items f fcus will be identified (i.e. quality issues, CAR respnses, Delivery) Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

7 Weekly meetings will be held t develp a list f actin items (a visit t Cncentric Itasca at sme pint is recmmended t see the impact f the issue(s) that Cncentric Itasca is facing) An actin plan will be put tgether which will define actins items and milestne dates. Once all actin items are crrected and the supplier shws a 3 mnth imprvement in screcard pints they will be evaluated by Cncentric Itasca Supply Chain fr remval frm the prgram All new suppliers will be a part f this prgram based n audits cnducted by Cncentric Itasca r anther divisin f Cncentric (lcal t the regin) 9.0) Supplier Audits: Cncentric Itasca realizes the imprtance f auditing suppliers. Audits f suppliers by Cncentric Itasca r anther divisin f Cncentric is preferred. Limitatins f travel may cause a Supplier Audit Survey t be cnducted in place f an nsite audit. If a Supplier Audit Survey is requested by Cncentric Itasca the supplier will be given 2 weeks t cmplete the audit. 10.0) Prcess Change Ntificatin (PCN): A prcess change is defined as any deviatin frm the currently apprved PPAP prcess. All prcess changes must be submitted with supprting data t shw the effect f change in regards t quality, cst and/r cycle time. A prcess change must be submitted prir t the implementatin f the change t allw fr prper PPAP prcessing and apprval. 11.0) Packaging Requirements: The supplier is respnsible fr the packaging f direct materials t assure their prper cnditin and quality upn delivery t Cncentric Itasca Inc. Parts must arrive at Cncentric Itasca Inc. withut damage, rust/crrsin, r cntaminatin. Packaging shall be defined and agreed upn prir t the first direct material shipment t Cncentric Itasca Inc. Althugh packaging authrizatin is required, such authrizatin des nt relieve the supplier f their respnsibility t ensure adequate packaging fr prper delivery f parts t Cncentric Itasca Inc. Packaging shall nt be a surce f cntaminatin. Barrier materials, (e.g. plastic bags), may be required. The supplier shall be respnsible t wash returnable packaging when necessary. Packaging is part f the supplier manufacturing prcess and shall be included as apprpriate in the supplier s FMEA, Quality Plan, Surce Release Plan, PPAP when these tls are used. Standard Packaging - Each supplier shall utilize a single size cntainer, package, and/r pallet cntaining a standard quantity fr each part number supplied. This requirement shall be valid fr expendable and returnable packaging. The supplier is respnsible fr cmpleting and submitting the Cncentric Itasca Inc. Packaging Data Sheet t the apprpriate Cncentric Itasca Inc. supply chain representative. Submit Prpsal: All packaging "mdificatins" r "new" prpsals require authrizatin. Labratry simulatin testing may be required and shuld be cnsidered by the supplier t assure that the prduct and packaging will withstand real-wrld lad cnditins, handling, and any applicable transprtatin mdes that may becme necessary. If testing is required, cntact yur Cncentric Itasca Inc. packaging representative. A sample shipment may be required t test and prve that the packaging withstands delivery cnditins and t allw Cncentric Itasca Inc. t review the packaging. (See sectin 4.0) Returnable packaging shall be used when it is cst effective r when it is needed t meet specific Cncentric Itasca Inc. bjectives. When returnable packaging is nt justifiable r feasible, Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

8 envirnmentally friendly materials (recyclable) shall be used. If returnable packaging is required, suppliers shall be respnsible fr string returnable packaging at their site. Cncentric Itasca Inc. expects suppliers t practively supprt and participate in actins t assure that the fllwing cnditins always exist when returnable packaging is utilized: The supplier uses the shipping pack as authrized. This pack has been designed t meet the requirements set frth in this dcument. Management f returnable s and transprtatin lgistics are perfrmed in the mst cst effective methd cmpatible with delivery requirements. An established minimum number f cntainers are available at the supplier s lcatin when they are needed. The supplier shall have authrized back-up packaging available. The internal dimensins and quantity f parts in the back-up packaging shall be the same as the authrized returnable packaging. The external dimensins shall nt exceed the dimensins f the returnable packaging. Whenever back-up packaging is used, Cncentric Itasca Inc. shall be ntified prir t shipping with an explanatin. Parts must arrive at Cncentric Itasca Inc. withut damage, rust/crrsin, r cntaminatin. Packaging Requirements Skid/Pallet Requirements: (Expendable r Returnable) Size: N Larger Than 48 x48 Stringers fr wden pallets shall have a minimum height f 3½. All wd pallets shall cnfrm t the Natinal Wd Pallet Cntainer Assciatin Vluntary Standard fr Wd pallets (NWPCA). Cncentric Itasca Inc. prefers stringer, duble deck, nn reversible, wd pallets. All pallets shall be 4-way entry. Pallets shall be capable f being cnveyed n standard gravity r pwered rller cnveyr. Imprts int the U.S. utilizing wden packaging shall be free f bark and pests and accrding t U.S. regulatins. See Internet site fr the mst current regulatins: N material shall extend ver the pallet edge. Other pallet sizes require specific plant apprval. Strapping Optins: (Cncentric Itasca Inc. prefers plyester strapping material that is frictin welded rather that secured with a metal clip) Nn-Metallic Strap (D NOT use metal banding) Stretch Wrap r Shrink Wrap Tape Special "Seat Belt" Pallets (must be apprved) Crrugated Specificatins: Crrugated (paper fiber bard) packaging material must have strength t adequately withstand transprtatin and handling rigrs frm the supplier s shipping dck t Cncentric Itasca Inc. s receiving dck. Crrugated packaging shall be f adequate strength t supprt multiple stacking f unit pallet lads. Crrugated material must have adequate ECT r burst test strength t prtect the prduct. Crrugated packaging shall nt utilize metal staples. Plastic Crrugated partitins are preferred especially when in direct cntact with cmpnents due t the cncern fr cntaminatin Weight Limitatin: Max. Shipping Pack = 2,200 Lbs. r as uniquely specified Max. Sub Pack < 30 Lbs. Smallest packaging unit(s) such as plastic bags may be cnsidered t package parts inside ttes, cartns, and/r bulk cntainers. Hwever, when bags are used, they shall be marked with Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

9 the Cncentric Itasca Inc. part number, quantity, and lt number r as uniquely specified. This label als requires bar cde 128 (unless therwise specified). If stacking exceptins are required, label accrdingly: DO NOT STACK, STACK ONLY 2 HIGH, etc. Labeling Requirements Cncentric Itasca Inc. requires that all suppliers are t use bar cde labels. The labels are used t eliminate the threat f errr. Labels are t adhere t the specificatins as detailed and illustrated in the Autmtive Industry Actin Grup's publicatin "Shipping/Parts Identificatin Label Standard" (AIAG-B-10) Fr a cpy r additinal infrmatin cntact: Autmtive Industry Actin Grup (248) Lahser Rad Suite 200 Suthfield, Michigan Excerpts f AIAG standard are included herein. There are features that Cncentric Itasca has added in additin t AIAG standards. In case f cnflict, Cncentric Itasca Inc. requirements shall take precedence. General Label Specificatins Label Size: (AIAG) 4.0 inches (102mm) high by 6.0 inches (152mm) r 6.5inches (165mm) wide. Any deviatins will need t be apprved n the Cncentric Itasca Inc. Packaging Data Sheet. Visual Requirements, Quantity and Placement: Bar cde print quality must pass verificatin per ANSI guidelines. Label t be white in clr with black printing. Minimum 2 labels per shipping pack n 2 different sides 2 labels may be replaced with 1 larger label with duplicate infrmatin that can be wrapped arund a crner f the shipping pack. All features f the label are t be in clear view At least 20 frm the bttm r centered tp t bttm if the pack is shrter Quality Infrmatin: Suppliers shall nt include infrmatin relating t quality n shipping identificatin labels. All quality related infrmatin must be directly cmmunicated thrugh the Supplier Quality Engineer (SQE) assigned t that supplier. Adhesives: Adhesive types can be pressure sensitive r dry gummed as lng as adherence t the package substrate is assured and applicatin is wrinkle-free. Nte: If labels are applied t returnable packaging, the adhesive must nt leave a residue after the label is remved, and the label must be easily remved withut tearing. Paper is nt preferred n returnable packaging. Returnable Packaging: Card hlders are recmmended t cntain and prtect labels in cnjunctin with returnable packaging. Adhesive-backed labels shall be applied directly t placards r t stretch/shrink wrap. D nt apply labels directly t the returnable, unless the label stck is plyester material r equivalent AND the adhesive is classified as a remvable type. The supplier is respnsible fr the remval f all ld labels. Data Identifiers: All barcdes are t have data identifiers at the beginning. Use data identifier cdes as defined by ANSI DI/AI standard MLH available frm: American Natinal Standard Institute (212) Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

10 Required Fields See Belw Chart fr field requirements, fnt sizes, and data identifier specifics: Shipping Pack Labels Individual packs (sub-packs) shall have an AIAG label n each pack. A unique serial number must be placed n the pack label. The data identifier S must be n pack labels. PACK LABEL EXAMPLE Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA

11 Master labels are required when shipping multiple packages f the same part number n ne pallet. (e.g.. several small cartns inside a larger pallet bx) A unique serial number must be placed n the master label. The data identifier 4S must be n master labels. When a master label is used, serial numbers n individual sub packs may be ptinal (btain apprval if serial numbers are nt included n sub pack labels). When a shipping pack requiring a master label is stretch r shrink wrapped, securely attach the master label t the utside f the wrap. MASTER LABEL EXAMPLE Address Label In additin t the AIAG shipping/parts I.D. label r master label, include 2 address labels n the uter shipping pack. Place these labels near the parts I.D. label, where pssible, n adjacent sides. Include address and dck designatin as per Cncentric Itasca Inc. Purchasing dcumentatin. Include the invice number in human readable and in bar cde frmat. Cncentric Itasca Inc. requires invice numbers t be 12 r fewer characters in length. Dck Lcatin/Bldg. N. and shipping address as specified in the Purchase Order. Supplier Specific Requirements Manual 2014 (Issue 1, Octber 2014) Cncentric Itasca USA