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Revision level 10 WORK INSTRUCTION

P.Q. 6.2 SUPPLIED PARTS QUALITY ASSURANCE

PURPOSE

To define the needed Quality standard requirements for supply ofany production parts type, either work contracted and fullsupplied.In any case, O.G. reserve the right to request compliance withany further specific Customer requirement to their suppliers.

REFERENCE

Quality Management Manual chpt. 7.4- Headquarter-Quality Procedure ACQ 07 (O.G. internal use only)

ISO/TS 16949:2002 chpt. 7.4

MODIFICATIONS

REV. LEVEL DATE ISSUED BY DESCRIPTION

012

3

45

6

7

8910

22.01.9617.06.9705.03.98

24.06.98

10.12.0015.02.02

28.02.07

12.04.07

15.04.0825.11.0818.02.09

M. CettolinL. TosettiL. Tosetti

L. Tosetti

L. TosettiL. Tosetti

L.Tosetti

L. Tosetti

F. TreichlerI.CiliaI.Cilia

procedure issued4.3.1 - 4.9 - 4.10 - 4.11 - 4.12 introducedBox for signature of procedure responsibleMgt. introduced on coverpagepar. 4.1.2 modifiedpar. 4.1.7 introduced

Released as Work Instructionchap. 3 4 8 12 14 15 modifiedchap. 6 7 9 10 11 introducedIMDS and Run @ Rate activitiesintroduced ; flowcharts removedEngineering Specifications QF 2009-2010removedModify of evaluation criteriaModified chapter 3Par.s A03-A06-A07-A25 and chapter 8.2changed

Last revision level

Date

Issued

Suppliers Quality AssuranceI.Cilia

Responsible Management

PurchasingM. Benedetto

1018.02.09

FOR SUPPLIERS ONLY:please send back this page signed as acceptance ofthe Work Instruction

DATE COMPANY STAMP - SIGNATURE

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1 List of the main activities

(A01) Engineering documentation: verification of: drawings updated revision

level, engineering specifications and standards both by O.G. and finalCustomer (that are reported on drawings and related with the manufacturingoperation to be provided) and O.G. Work Instructions as mentioned on thepurchase order.The above mentioned engineering documentation, if not available, shallbe required to the Purchasing Dpt. which has released the order.Provisioning of both national and international Standards (i.e. UNI-ASTM-DIN etc.) is under suppliers responsibility.

(A02) Feasibility analysis: to be already provided at the offer stage, withinformation to O.G. in case of problems about material availability,manufacturing process feasibility due to engineering issues, lack of availablecapacity, eventual difficulties to maintain product characteristics.If analysis involves the need to forward an ENGINEERING CHANGEREQUEST (form no. 463), this shall be sent to Purchasing Dpt. which willaddress it to the involved Departments (Production Engineering Dpt. orProduct Development Dpt.) and send it back to supplierAccording to its result, supplier can proceed with offer analysis.

(A03) Temporary facilities or production and control facilities: ramp-up chart isrequired for planning and documentation of activities related to design andmanufacturing of fixtures and specific gages.

(A04) Design FMEA: (for suppliers of owned design products only). Designvalidation test results to be included into this activity.

(A05) Process FMEA : according to the purchase order required PPAP level, to becarried out for category of parts, or for specific processes if specials (i.e.foundries, heat treatments, steelworks, etc.) or according to O.G. request for

specific products. The manual Linee guida per lapplicazione della FMEA ANFIA Service shall be taken as reference for the indices of severity,occurrence, detection.

(A06) AQM Advance Quality Meeting :Activity to be carried out on O.G. request,supplier shall provide the following documentation during the above meeting :Eventual improvements of drawingsManufacturing cycle and sequenceControl plan (temporary)

Foreseen temporary/serial production facilities for manufacturing andinspection (documented with drawings, photos, etc.)Ramp-up chart about activities progress if fixtures and specific gagesare not the serial production onesMachinerySpecific toolingFirst release of Process FMEA

(A07) Manufacturing cycle and sequence: first release to be presented at theeventual AQM; following updates shall be retained by the supplier. Specificflowchart shall be submitted alongwith PPAP documentation if requiredby O.G. (ref. to D380 form)

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(A08) Control Plan: a temporary release (prepared according to form no. 369 orsimilar according to the ISO/TS 16949 requirements) shall be carried out forthe first production batch and shall be presented at the eventual AQM; it shallbe updated according to preliminary process capability studies carried out onthe first produced batch.

Control Plan shall report

all foreseen process inspections (set-up approvals, incominginspections, production self-controls, final inspections, etc)

Identification of safety and control characteristics, by using the specificsymbols of the drawings

inspection frequencies, that can be changed according to the processcapability

Used measurement equipment for each measurement Cp Cpk processing where required, with data record sheet

reaction plan, in case of nonconforming measurementsControl plan changes subsequent to PPAP approval shall be retained atsupplier site and promptly shared with O.G. if required.

(A09) Measurement systems capability study MSA (Measurement SystemAnalysis): to be provided for all measurement equipment dedicated to safetyand control characteristic inspections and for specific measurementequipment (measurement stations), according to the orders required PPAPlevel or to specific O.G. requirement.Periodical calibration forall measurement equipment to be provided (for allPPAP levels).

(A10) Subcontracted supplies: foreseen subcontractors list shall be submittedalongwith PPAP documentation. Evaluations, incoming material inspections,control plans and any documentation concerning subcontractors shall beshared with O.G. if required. Purchasing of steel shall only be carried out fromsteelworks approved by O.G. according to O.G. Q.F. 1001 EngineeringSpecification or from ones approved by the final Customer.

(A11) Personnel training : training courses for personnel dedicated to specialprocesses/inspections (i.e. electronic crack detection, welding etc.) shall bedocumented. Support plan to new employees shall be available (anddocumented).

(A12) Preventive maintenance: machinery/plants and fixtures preventivemaintenance plan shall be available.

(A13) Production Part Approval Process (PPAP): required documentation shallalways be submitted according to the PPAP level reported on the purchaseorder (refer to item 2 for levels table - use the PART SUBMISSIONWARRANT (PSW) - form no.150 or similar according to ISO/TS 16949requirements)

Terms of PPAP delivery

In case of deliveries to I.T.T. for Preliminary Heat Treatment, unless otherwisespecified on the purchase order.

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Delivery of initial samples with related documentation shall be provided tofinal addressee plant (indicated on the form 380 PPAP ACTIVITIESenclosed to the order), before or alongwith the delivery of first batch toI.T.T.

Specific packaging shall be used for initial samples delivery (cardboardbox, single container etc.) with very clear labels stating: INITIALSAMPLES

All documentation required by the assigned PPAP shall be attached to thecontainer. Alternatively, documentation delivery can be provided through e-mail to the Quality Control Manager of the addressee plant with indicationof initial samples transport document number.

Transport documents shall indicate the presence of one PRODUCTIONSTARTUP SAMPLE part

In case of deliveries to other Oerlikon Grazianos Supplier

Initial samples shall be delivered to the final addressee Plant (indicated onthe form 380 PPAP ACTIVITIES) before delivery of the first productionbatch; delivery alongwith the first batch to the addressee O.G. supplier isallowed but under full responsibility of the same supplier


Transport documents shall indicate the presence of No.__ PRODUCTIONSTARTUP SAMPLE pieces

Containers shall report label with very clear indication: INITIALSAMPLES.

In case of deliveries to Oerlikon Graziano Plants

Delivery of initial samples is allowed before or together with the firstproduction batch (under full responsibility of the supplier)

Use of specific container (separated from the batch)


Transport documents shall indicate the presence of No.__ PRODUCTIONSTARTUP SAMPLE pieces

Containers shall report label with very clear indication: INITIALSAMPLES.

In case of non-prime contractor foundries which fixtures have directly beencommitted by Oerlikon Graziano

Copy of D380 PPAP ACTIVITIES shall be delivered to the foundry by theprime contractor supplier

Unless otherwise specified, delivery of sample part shall be provided to theprime contractor supplier

PPAP documentation shall be delivered to the prime contractor supplierand a copy to the final addressee O.G. plant

PPAP approval (and related authorization to fixtures payout) shall beissued by the O.G. Quality Control Dpt. only after conformity verification

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about documentation and dimensional characteristics of the finished partdelivered by the prime contractor supplier

REMARK: eventual nonconformity of finished part sampling, due tomachining operations, does not compromise the casting approval (if thesame is within specification and fully documented)

(A14) PPAP approval: approval is given without any nonconformities and withcompleteness of all required documentation only. PPAP result (positive,pending or negative) is communicated through the form 380 PPAPACTIVITIES, sent by e-mail (PART SUBMISSION WARRANT form 150 orsimilar used by supplier is sent back under specific request of the same).The non-approval, due to dimensional, material or heat treatmentnonconformities, involves rejection or acceptance under deviation of deliveredparts and re-submission of PPAP for the detected nonconformities.The PPAP non-approval involves:

Stoppage of production fixtures and inspection gauges agreed payout

Suppliers duty to request a deviation for delivery of parts without PPAPapproval, for the time needed to complete the missing or nonconformingactivities

O.G.s right to debit the needed supplemental inspections due to PPAPmissed approval

REMARK: missed PPAP delivery or prolongation of PPAP approval doesnot relieve supplier from its responsibility to respect the agreed deliverydates and from charges that missed respect of the same involve (linestoppage, premium freights, additional management, etc.)

(A15) Process capability: to be carried out for important process parametersand/or safety and control (critical) characteristics.

preliminary (Ppk), to be carried out over 30 pieces of the first productionbatch (and of pre-launch stage if required by O.G.)on-going (Cpk) to be carried out regularly during mass production

Ppk >= 1,67 capable process to be regularly monitored

1,33 < Ppk < 1,67acceptable process; start with mass production

verifying that Cpk > 1,33 is maintained

Ppk or Cpk < 1,33uncapable process; apply a temporary 100%

inspections and implement a corrective action planIn any case, Cpk shall always be >= 1,33If the above mentioned requirements couldn't have to be respected, product

conformity shall anyway be ensured through 100% inspection." Above mentioned values may change according to different requirements of

O.G.s final Customer

(A16) Machine set-up : inspections on all characteristics involved in the processshall be carried out and recorded. In case of continuative productions whereset-ups are not performed, periodical verifications of process re-qualificationshall be provided and their frequency reported on the control plan.

(A17) Changes to drawings/engineering documentation: PPAP forcharacteristics involved by the change shall be submitted. Control plan andFMEA shall be updated (if needed).About activities to be carried out refer to the PPAP level (D380) issued on thestarting purchasing order.

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Terms of PPAP delivery are the same set in par. (A13) with the only followingchange to transport documents indication : No__SAMPLE pcs.- REV.LEVELYY

(A18) Changes to manufacturing process or subcontractor: prompt informationto the O.G. Quality Control Dpt. of the addressee plant shall be provided. Thiswill define if the PPAP shall be submitted and the relevant level (PPAP level ofthe starting purchasing order). Control plan, manufacturing cycle, eventualflowchart and FMEA shall be updated.

(A19) Deviation (use the DEVIATION REQUEST FROM SUPPLIER - form no. 126or similar): supplier shall never send nonconforming parts without priordeviation request, batch shall always be identified (both on packaging and ontransport documents) through the number of given deviation and O.G.sapproved deviation requestform shall always be enclosed. Deviation requestshall be sent to:

1. both Purchasing Dpt and Plant Quality Control Dpt. of O.G.s delivery plant in caseof1st batch of production for new entry parts

2. both Plant Logistic Dpt. and Plant Quality Control Dpt. of O.G.s delivery plant incase offollowing batches (mass production)

If the deviation request will have to be extended to a Drawing change request,the lower section of the form no. 126 shall be filled up and sent as abovespecified.

The Plant Quality Control Dpt. will manage the reply to the Supplier with theacceptance or the reject of the concession request.If the change is approved, the first batch shall anyway be delivered under

deviation.

(A20) Nonconformities: according to the inspection report specific requirement, theCORRECTIVE ACTION REPORT - 8D (form no. 317 or similar) shall besubmitted with indication of failure causes, immediate actions taken andforeseen long term actions. Following to the inspection report request, PPAPabout the nonconforming characteristics shall be submitted (PPAP level of thestarting purchasing order) along with the first subsequent batch.Terms of PPAP delivery are the same set in par. A13 with the only followingchange to transport documents indication : No__SAMPLE pcs.

Remark: in case of nonconformities requiring sorting operations and/orrework at O.G. plants, supplier shall be immediately available.

Missing availability may involve rejection and/or rework by O.G.personnel or by external company, with costs fully charged tothe same supplier (even without prior notification of costs).

(A21) Traceability: traceability of material and batches by marking (where possible)of heat/cast reference letter and week or month/year of manufacturing (ref.item 7 Identification and Traceability) shall always be ensured accordingto the drawing specifications. Unless otherwise specified, for all steel partsand for cast iron and aluminium safety parts, different castings shallalways be separately packaged with indication of cast code on packages andon transport documents.

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(A22) Packaging and preservation: supplier shall always submit the intended usepackaging to O.G., regardless it is specific or generic (only indication of thetype shall be given to the reference O.G.s Purchasing office)Preservation from corrosion shall be ensured for three months at least startingfrom the incoming in the O.G. Plant.Remark : in case of temporary unavailability of specific packaging,authorization to delivery with different ones shall be requested to plantLogistic Dpt.; the same shall anyway ensure preservation from damagesand product traceability.

(A23) Contamination: products directly delivered to O.G. assembly lines shall havea contamination level suitable with the drawing specification. If no specificrequirements are available on drawings or orders, refer to O.G. EngineeringSpecification Q.F. 2011.

(A24) Continual improvement: supplier shall identify opportunities for quality,service level, costs and technology improvement through data record methodslike:

Cp Cpk PPM analysis FMEA updating etc.

(A25) Certification of batches: for production parts, with exceptions of steelsupply, experimental parts, prototypes and pre-launch parts, all O.G.suppliers are under self-certification.

Unless otherwise specified, according to the product criticality, delivery shallnot come with certification documents but with CONFORMITY STATEMENT(form 112 or similar) only.All documentation certifying product conformity (material certificates,treatments, integrity, dimensional, etc.) shall be available and immediatelysent under O.G. request.This rule does not apply if defects occur (see par. A20).Remark : according to the result of quarterly analyses, O.G. has the rightto ask supplier for certification of all deliveries, based on the followingcriteria:

Involved part number has exceeded 4 times the PPM target (seepar.12 PPM TARGETS) and is therefore ranked as # (hash

sign). Notification of # ranked part numbers will occur everymonth through the QUALITY SITUATION letter.

Involved part number, despite it is not # ranked, has causedproblem at final O.G. Customer site and affects conformity ofsupplies

Certification of all deliveries is active until the part number rankingimproves to higher grades, that is no more # ranked.

DEACTIVATION OF DELIVERIES CERTIFICATION PROCEDURE IS NOTSUPPLIER COMPETENCE, BUT SHALL BE NOTIFIED BY O.G. TO THESAME.Certification shall be provided over a quantity of pieces which number isrelated to the delivery size, for all characteristics, as detailed on the below

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table. Certification paperworks shall clearly indicate the # rank of thepart number.

Delivery size Until 10 From 11 to 50 From 51 to100

From 101 to250

Over 250

Safety or criticalchars ( see #) 1 2 5 10 15

Chars withtolerance until 0.1(see #)

1 2 4 8 10

Chars withtolerance until0.25 (see #)

1 1 2 5 5

Form errors 1 2 2 5 5

Secondaryimportancechars

1 1 2 2

Soundness 1(for castings,1 per batch)

1(for castings,1 per batch)




(#) Cp-Cpk analysis of production batch required, where possible(characteristics able to be monitored during production process)For some specific cases, O.G. has the right to require size numbers higherthan the table ones, up to a 100% inspectionO.G. has the right not to provide material incoming inspections, but toreject material in case of nonconformity or missing documentation(certification).

(A26) Production stoppage: after production stoppage for twelve or more months,supplier shall submit PPAP documentation only, without sample parts (use thePART SUBMISSION WARRANT - form no. 150 or similar according toISO/TS 16949 requirements).This item is not applicable for single annual supplies.

(A27) Material incoming inspection: when subcontractors are used, specificincoming inspection procedures shall be prepared and provided inspectionsshall be documented. Such documentation shall be available for O.G.verification during surveillance visits or process audits.Direct delivery of rough parts, castings, forged parts, steel, from a O.G.supplier to a work contractor, involves for the same the verification ofpresence and conformity (according to O.G. or final Customer Engineering

Specification) of material certification enclosed to batches, correct executionof sandblasting, painting operations, absence of oxidation, slags etc.During manufacturing process, absence of cracks and blow holes shall bechecked.Control Plan shall report all of these inspections.

(A28) I.M.D.S. (International Material Data System): whenever required by D380,material composition shall be input in the web site www.mdsystem.comFailure in accomplish this item will involve the PPAP non-approval.
http://www.mdsystem.com/http://www.mdsystem.com/

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(A29) Run@Rate (Production capacity analysis): O.G. reserve the right to knowthe supplier production capacity, this involves the information to O.G. of cycletime.Whenever required, O.G. send by e-mail the D496 A-B-C form Run@Rateanalysis to the supplier which shall fill the B module of the form up and shallsend it back to O.G.If necessary, O.G. will provide the Run@rate study at supplier site by usingthe C module of D496 form.

A30) APQP (Advanced Product Quality Planning): whenever required by O.G.,supplier shall prepare a gantt for activities planning, maintain it updated andmake it immediately available under request.

(A31) Management and inspection of steel heats: all suppliers managing steel,work contractors or full product suppliers, shall follow the below items that are

also represented into a flowchart.

1) Purchase by O.G. and work contracted forgingSteelwork- Shall send material certificates by e-mail to O.G. Purchasing Dpt. and,

alongwith the certificated steel, to the Forger facility.O.G. Purchasing- Will send material certificates by e-mail to the O.G. laboratory of the final

addressee plantWork contracted forging supplier- Shall verify presence and approval status of involved heat on the O.G.

portal.- Not available, shall send material certificate and a heat blank with

indication of material, steelwork and heat number by e-mail to O.G.laboratory of the final addressee plant (indicated on the D380 formenclosed to the order)

- Positive, will proceed with forging without sending certificate and heat blank- Negative, shall not forge, shall contact O.G. Purchasing about terms of

material rejection to steelwork

- Under deviation, shall not forge, shall request deviation for the parts to beforged to O.G. laboratory of the final addressee plant

- Analysis not verified, shall immediately send heat blank with indication ofmaterial, steelwork and heat number by e-mail to O.G. laboratory of thefinal addressee plant (indicated on the D380 form enclosed to the order),

will start forging but shall not deliver material until the O.G. portal will beupdated with result of verification

O.G. Laboratory- Will provide verification of steelwork certificate and heat blank and input

result on the O.G. portal-2) Full supply of forger or of the complete supplySteelwork- Shall send material certificates, alongwith the certificated steel, to the

forger.Forging supplier- Shall verify presence and approval status of involved heat on the O.G.

portal.

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- Not available, shall send material certificate and a heat blank withindication of material, steelwork and heat number by e-mail to O.G.laboratory of the final addressee plant (indicated on the D380 formenclosed to the order)

- Positive, will proceed with forging without sending certificate and heat blank- Negative, shall not forge, shall reject material to steelwork- Under deviation, shall not forge, shall request deviation for the parts to be

forged to O.G. laboratory of the final addressee plant- Analysis not verified, shall immediately send heat blank with indication of

material, steelwork and heat number by e-mail to O.G. laboratory of thefinal addressee plant (indicated on the D380 form enclosed to the order),will start forging but shall not deliver material until the O.G. portal will beupdated with result of verification


result on the O.G. portal

3) Full supply of turned partsSteelwork- Shall send material certificates by e-mail to the prime contractor turning

supplier, and, alongwith the certificated steel, to the Forger facility.Full supply turning supplier- Shall send material certificates by e-mail to the O.G. laboratory of the final

addressee plantSubcontracted forging supplier- Shall verify presence and approval status of involved heat on the O.G.

portal.- Not available, shall send material certificate and a heat blank with

indication of material, steelwork and heat number by e-mail to O.G.laboratory of the final addressee plant (indicated on the D380 form

enclosed to the order)- Positive, will proceed with forging without sending certificate and heat blank- Negative, shall not forge, shall contact the prime contractor turning supplier

about terms of material rejection to steelwork- Under deviation, shall not forge, shall ask prime contractor turning supplier

to request deviation for the parts to be forged to O.G. laboratory of the finaladdressee plant

- Analysis not verified, shall immediately send heat blank with indication ofmaterial, steelwork and heat number by e-mail to O.G. laboratory of thefinal addressee plant (indicated on the D380 form enclosed to the order),will start forging but shall not deliver material until the O.G. portal will beupdated with result of verification

- In case of the Forger is not included into the O.G. Vendor Rating list and,consequently, is not allowed to access to the O.G. portal, the activity shallbe carried out by the prime contractor turning supplier.


result on the O.G. portal-4) Steel purchase from Reseller.Same rules of the three previous item, according to the type of supply.

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STEELWORK

.

GT (Purchasing)

Steel purchaseTURNING SUPPLIER

Full supply

FORGING SUPPLIER

Full supply

certificates

Certificates and

material

RESELLER

FORGING SUPPLIER

Work contract

FORGING SUPPLIER

(turn.supp.subcontractor)

GT (Purchasing)Steel purchase

Delivery of steelwork original

certificate to GT laboratory

of final addressee

plant

GT LABORATORYcertificates verification

CV Plant = ITT

BA Plant = BA

PT Plant = PT

CE Plant = CE

At steel arrival, delivery

of heat blank to

GT laboratory of

GT final addresee

plant

GT LABORATORY

certificates verification

Imp. CV = ITT

Imp. BA = ITT

Imp. PT = PT

Imp. CE = CE

GT WEB PORTALList of verified heats.

Every forging supplier shall verify

heat approval before proceed with

forging

Certificates and material

certificates and

material

Certificates and

materialCertificates and

material

Certificates andmaterial

Legend of heats result and supplier behavior:

Verify availability of heat to be used on the O.G. portal before forging.

Heat No. - steelwork - material If these 3 items are missing, this means that certificate nevercame to a O.G. - Do not forge and immediately send certificate.

Result:

Positive - Both certificate and blank are OK - OK to forge

Negative - one out of two verifications failed - Do not forge, steel rejection

Under deviation - material useable for some part numbers only- Forger communicatewhich part number has to be forged and ask for deviation.

Analysis not verified - positive result for certificate, blank not verified - Immediately send

blank and proceed with forging, do not deliver the forged pieces.

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REMARK: THE ABOVE MENTIONED ARE BASE ACTIVITIES, EVENTUALSTANDARDS OR PARTICULAR NEEDS OF O.G. FINAL CUSTOMERS WILL BE

NOTICED TO SUPPLIER AND COULD PARTIALLY OR FULLY REPLACE THESAME.

2 Approval levels (PPAP) required by Oerlikon Graziano

The below activities shall be performed by the supplier with submission ofdocumentation according to the assigned PPAP level (identified in the order).

YES Activities to be performed which documentation shall be submitted to O.G. andcopy retained at the supplier site.

If internal know-how preservation reason exists, some documentation (i.e.FMEA, control plans) may not be delivered to O.G., supplier shall specify it onthe PPAP and shall make such documentation available during O.G. visits or formeetings organization at O.G.

AF Activities to be performed which documentation shall be retained at the suppliersite and immediately submitted to O.G. under specific request, or hand-delivered in case of level 5 PPAP approval (at supplier site)

RC Activities to be performed under O.G.s specific request which documentationshall be submitted to O.G. and copy retained by supplier.

Activities Lev1

Lev 2 Lev 3 Lev4

Lev5

Bubbled drawing (drawing/table with numbereditems linked to the inspection report ones)

YES YES YES AF

Documentation of engineering changes not yet

reported on the drawing (if any)

YES YES YES YES AF

Design FMEA (only for owned design suppliers) RC RC AF

Process FMEA RC RC YES AF

Flowchart RC RC AF

Dimensional results report (documentation) AF YES YES YES AFMaterial, treatments, tests certification AF YES YES AF AFPreliminary process capability studies (Ppk) RC RC YES RC AF

Measurement System Analysis studies (MSA) RC AF YES RC AFControl Plan AF YES YES YES AFPart Submission Warrant (PSW) RC YES YES YES AFCertified sample pieces RC YES YES YES AFReference master samples (to be retained by theSupplier)

RC RC RC RC

List of used Subcontractors (if any) YES YES YES YES AFResult of Subcontractors initial sample reports AF AF AF AF AF

Remark: The above mentioned table requirements shall be considered as indicative; form d380PPAP ACTIVITIES, enclosed to the order, shall be taken as reference.O.G. can require activities and documentation not mentioned in the above table.

criteria for PPAP level assignment:

Level 0 It is used when PPAP submission is not required, for Preliminary Heat Treatment(isothermal annealing only), phosphating, tumbling, steel purchase, purchase fromfinal Customer, standardized components for spare parts, standardizedcomponents and interoperational stages for prototypes/experimental parts, someterm-type orders

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Level 1 It is used for open and close-type orders, , prototypes/experimental parts,catalog-purchased parts, bar shearing, plastic parts with poor design value,surface coatings of Chromium, Zinc and painting

Level 2 It is used in case of production startup of open-type orders when it does not belongto one of the other 5 levels

Level 3 It is used for production startup of automotive open-type orders or according toO.G. strategy, for O.G. and customers design new products

Level 4 It is used for some term-type orders, castings machining, finished-state parts, andspare part orders.For castings experimental parts/prototypes, machining of castings, finished parts.For the following open-type order items:

Small parts

Standardized components according to drawing

Plate blanked parts

Forged parts, electro-upset parts, heat treatments, etc.

Secondary-employed parts, also for automotive sector

Parts according to O.G. drawing that dimensionally change from catalog parts

spot orders for grinding operations, where the whole documentation isprovided by O.G. (manufacturing cycle, self-control sheet, specific

measurement equipment etc.)

Level 5 It is only used when O.G. intend to provide approval at the supplier site or incase of Customer-proposed supplier that has already achieved approvalfrom the same.

3 Prototypes Experimental parts Pre-launch parts

Prototypes, experimental parts, and in some cases pre-launch parts manufactured withtemporary tooling are not handled with PPAP level (it will always be at zero)For these parts, certification documents are always required and may change accordingto the type of product and if the involved batch is the first ordered one or it is a re-launch.

Alongwith the purchase order or advanced order note, O.G. Purchasing send the doc.D.553 to supplier, that includes :

Product identification data

Identification of full supply or work contract

First batch or re-launch

Type of required certification and quantity of parts to be certified

O.G. addressee plant

Reference Dept./person for documentation delivery

Document D.553 should always follow the batch and the certification paperworks, andshould be filled in the appropriate column (to certify the paperworks presence).O.G. reserve the chance not to inspect incoming material, and to reject nonconforming

material or incomplete/missing documentation.In any case, approval to prototype/experimental/pre-launch parts is not valid for serialproduction. For serial production, PPAP documentation will always be requiredaccording to the PPAP level demanded on the purchase order.

REMARK: Eventual orders for prototype/experimental parts manufactured withserial production tooling, unless otherwise agreed with O.G. Purchasing orS.Q.A. Depts through the delivery of D.380 PPAP ACTIVITIES, shall be fullyconsidered as prototypes or experimental parts and shall follow the rules statedby this paragraph.

4 Parts addressed to Spare Part Warehouse

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When supplied parts have to be addressed to Spare Part Warehouse (according tospecific requirement of the purchase order), certification of the first batch shall beaccording to level 4 PPAP, with exceptions of forged parts and standardizedcomponents.For the subsequent batches, supplier shall ensure:

compliance of the part with purchase order and/or drawing requirements throughrelease of a conformity statement

part identification on every single package including

part number (drawing no.) engineering change level quantity of the parts into the package appropriate packaging for product preservation during transport and storage

(preserved from damages)

preservation from corrosion for at least three months

5 Safety Parts Safety Characteristics

Safety Product is defined as the component, subgroup or group which failure ordefective functionality may cause harm to people.Safety Characteristic is defined as every drawing or standard requirements, directlyconnected to the safety of the complete product, which may cause harm to people.

5.1 Identification

In case of O.G. design, safety components and related characteristics are identified bythe symbol

placed on the related drawings.In case of Customer design, the same symbol is placed on the supply drawings withreference to the involved characteristics.

5.2 Safety Parts/Characteristics documentation management

All suppliers engineering documentation (drawings, engineering Specifications,specific Standards, etc) and process/control documentation (manufacturing cycles,instructions, control plans, data recording documentation etc.) shall report identification

of the Safety Characteristics through the symbol or the symbol S.

All engineering and process/inspection documentation shall be stored into a safe andprotected location and easily accessible for consultation, storage period shall not belower than 10 years or, in any case, according to specific O.G. requirements.

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5.3 Traceability

Traceability shall be ensured by parts marking (ref. to chap. 7) and shall be correlatedwith inspection documentation.

5.4 Inspections

Indication of Safety Characteristics on the drawings, shall involve a process controlperformed through:

Initial machine capability studies or:

Preliminary process capability studies

On-going process control regularly performed during current mass production or100% process inspection in case of not capable process.

6 Control (critical) Characteristics

Control (critical) Characteristics are dimensions, notes and prescription including

pernicious features resulting from design and process FMEA, after-sales problems,process-generated problems, design criticality.Those may be differently indicated, according to O.G. or Customer drawings.

6.1 Identification

Control Characteristics are identified on both component and assembly O.G. drawings, bythe symbol :

6.2 Control (critical) Characteristics management

All suppliers engineering documentation (drawings, engineering Specifications,specific Standards, etc) and process/control documentation (manufacturing cycles,instructions, control plans, data recording documentation etc.) shall report identification

of the Control (critical) Characteristic through the symbol or the symbol C.

6.3 Inspections

Indication of Control (critical) Characteristic on the drawings, shall involve a processcontrol performed through:

Initial machine capability studies or:

Preliminary process capability studies

On-going process control regularly performed during current mass production

or 100% process inspection in case of non capable process.

7 Identification and Traceability

Identification and traceability shall be ensured by marking.

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7.1 Marking systems

Directly obtained during product transformation through pattern, die or shell (forcastings or forged parts)

By punching

by microdot punching

by chemical etching

by acid etching

by ink or permanent paint

Note: unless otherwise specified on the drawing,type of marking shall be agreed withO.G. Design or Engineering Dpt. or Quality Control Dpt..

7.2 Marking location

Marking location is indicated on the drawing, otherwise it shall be agreed with O.G.Quality Control Dpt..

In any case, location shall not compromise part engineering characteristics andreadability (even after further machining operations).

7.3 Marking content

According to drawing requirements, marking shall inlcude

GRAZIANO Trasmissionis logo, according to following dimensions and shape.

Mark type h (mm.) E (mm.) l (mm.)No. 54 54 9,8 135

No. 40 40 7,2 100

No. 28 28 5 70

No. 22 22 4 55

No. 16 16 3 40

No. 12 12 2 30

No. 10 10 1,8 25

No. 8 8 1,5 20No. 6 6 1 15

No. 3,2 3,2 0,5 8

No. 2,4 2,4 0,5 6

No. 2 2 0,3 5

Note: E dimension shall be considered for relief markings only.

Steel heat reference letterHeat letter, obtained by forging.Its purpose is to univocally identify the material, origin and supplying steelwork .

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Forging supplier is responsible for heat management, either for work contracted andfull supplied material; heat management shall be provided for every part byassigning a progressive alphabetic letter, at every heat change.

The letters to be used shall be:A - B - C - D - F - H - I - L - M - N - O - P - R - S - T - U - V - Z.Some letters are for reserve, ( X - Y - W - K ) to be used in particular situations only(closed or spot batches).If a same part number is assigned to two suppliers, O.G. Purchasing divide theletters to be used into two groups and inform involved suppliers and I.T.T. QualityControl Dpt. about which group shall be used (i.e. first supplier will use the lettersfrom A to M and the second from N to Z).Eventual different marking systems shall always be agreed with O.G.

Date/manufacturing batch identificationMarking of manufacturing batch can be made

Monthly,

by marking month and year according to the CODE LIST FOR MONTH-YEARMANUFACTURING MARKING (form no. 135), in order to univocally identify themanufacturing batch which a piece belongs to.

Weekly.It is made by three digits, the first two indicate the manufacturing week and the third

one stands for the manufacturing year.I.e. : 427 stands for the 42

ndweek of 1997.

Remark: in case of big volumes production, O.G. reserve the chance to requirecloser traceability systems, daily, by workshift or by individual progressivemarking

part number code if required on the drawing

any additional data requested by the Customer

Control of correct identification shall be part of the standard manufacturing processcontrol and shall be reported on the control plans.

8 Nonconformities

Nonconformities detected at O.G. are noticed to supplier through the form no. 163INSPECTION REPORT. Such reports are available on the O.G.s web portal andsupplier is informed about their release by e-mail.Reasons for reports release can be:

Permanent reject

Reject to be recovered

Acceptance under deviation

Acceptance with additional time operations

Sorting request

Inspection note

O.G. also reserve the right to charge supplier with costs resulting frommanagement of defective material supplied by the same.

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8.1 Rejected parts declared by Work contractors

Rejected parts declared by Work contractors shall not be not returned to O.G. but

directly scrapped by the Supplier which shall prepare a LIST OF REJECTED PARTSFROM WORK CONTRACTORS (form no. 282) every month (it shall be forwardedwithin and not later than the 10

thof the following month); list shall be addressed to the

O.G. plant Quality Control Dpt. and in this case no inspection report is released butO.G. will update the work plans of the involved parts through the IT system and willsettle the cost of defective semifinished parts with supplier.

8.2 Rejection of forged parts / castings detected by Work contractors

If work contractor detect rejects due to wrong forging operation with quantity of morethan 10 pieces, or 2 pieces about castings, such rejects shall be delivered to QualityControl Dpt. of the addressee plant, with indication Forging/Casting rejects on the

delivery document.The Quality Control Dpt. will release an inspection report to the forging/castingssupplier.

If the amount of rejected parts is less than 10 parts (forged parts) or less than 2 parts(castings), work contractor

shall place the monthly rejected parts into a specific container

shall forward a monthly LIST OF REJECTED PARTS FROM WORKCONTRACTORS (form no. 282) to the Quality Control Dpt. of the addressee plant,within and not later than the 10

thof the following month.

If O.G. will not require return of involved parts within four months from release of

inspection report, Supplier is authorized for scrapping.

Within the 15th

of the month where reject list has been received, the Quality Control Dpt.will release inspection report to the forger/casting supplier with information about thename of work contractor retaining the rejected parts.

If the forger/casting suppliers require return of rejected parts, the QualityControl Dpt. will inform the involved Work contractor.Remark: missing retrieve of rejected parts within a four-month periodwill cause the switch of reject to Work contractor.

Both O.G. Purchasing and Supplier Quality Assurance have the authority to verifyapplication the above mentioned rules in case of visit to the Work contractor.

8.3 Corrective actions request

Corrective actions request occurs through the inspection report for some types ofrejection.Supplier shall strictly forward the corrective actions within the date reported on theinspection report, by using the 8D REPORT (form no. 317).

9 Government, Safety and Environmental Regulations

All purchased material used for product manufacturing shall comply to currentgovernment and safety regulation about forbidden, toxic and hazardous material.

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Its management shall be in compliance with environmental and safety regulationsapplicable to the country of manufacturing and sale.

10 Audit Evaluations at supplier sites

O.G. reserve the right to organize (with prior agreement) visits to Suppliers plants andeventually to their subcontractors plants with following purposes:

Review of PPAP documentation thereon retained

Verification of O.G.s specifications/instructions application and Control Plansvalidity and respect

Evaluation of manufacturing and control processes (process audit)

Verification of activities progression status before production process startup

Verification of corrective actions effectiveness in case of occurred serious nonconformities

To provide audits on Quality System or require third party Certifications

Evaluation of the Environmental System Management

To perform Run@Rate studies (production capacity verification)

11 Quality level of supply

O.G. carries out the monitoring of supply according to 3 criteria such as:

PPM Scraps (permanent and recoverable parts out of the total delivered parts),PPM/Target ratio.

I.A.D. (Defect Reliability Index): total of secondary-type nonconformities out of thequantity of delivdered parts, without considering scraps.

I.A.S. (Defective Reports Reliability Index): quantity of batches that caused therelease of a defective report, out of the total delivered batches (BEM), includingbatches that caused a claim from O.G.s Customers.

12 Information to Supplier about supply trend

The SUPPLY STATUS (form no. 162), is always accessible and available on the O.G.web portal at the section supplier quality status;this is monthly updated and includes:

PPM TARGETS For each market category, O.G. assigns on annual basis (withdecreasing trend) a PPM scraps target (sum of permanent and recoverable scraps) thatwill be used to define the Deliveries Quality Level.

GLOBAL QUALITY EVALUATION It is defined as the minimum score between theCertifications and evaluations level and the Deliveries Quality Level, calculated on the12 months rolling, and leads to 1 of the following 5 levels:

o Level A1 PARTNERo Level A APPROVED

o Level B ACCEPTEDo Level C CONDITIONEDo Level # - NON ADEQUATE

CERTIFICATIONS AND EVALUATIONS LEVEL resulting in 5 possible levels:o Level A1 BESTo Level A GOODo Level B ACCEPTABLEo Level C LOWo Level # - NOT ACCEPTABLE

The level is calculated basing on the following parameters:o Third-party Certifications or, if not available, VOG (Oerlikon Graziano

Evaluation) o AVF (Supplier Self Evaluation)

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o Admission/Evaluation visit (including Environmental evaluation)o Process Audits (if available)

DELIVERIES QUALITY LEVEL resulting in 5 possible levelso

Level A1 EXCELLENT RELIABILITYo Level A HIGH RELIABILITYo Level B FAIR RELIABILITYo Level C LOW RELIABILITYo Level # - NOT RELIABLE

The level is calculated basing on the following parameters:o PPM scraps (permanent + recoverable) PPM/Target ratio- The PPM target is

outlined on the Supply Status form and depends on the market category.o I.A.D. (Defect Reliability Index), does not consider scraps.o I.A.S. (Defective Reports Reliability Index), includes claims from O.G.s

Customers.The Deliveries Quality Level is calculated for the following timeframes:

o Past 12 months rolling (also used for calculation of Global Quality Level)o

Current yearo Each quarter of the current year

REMARK: in case of a quality level lower than A on the quarter, the Supplier isrequested to issue a corrective actions plan that allows target restore.

If no improvement of supply trend occurs, eventual activities related to newassignments to the involved supplier will be stopped.Eventual prolongation of negative trend will cause the shifting of current assignments toother suppliers.

13 Reference documentation

form no. 112 CONFORMITY STATEMENT

form no. 126 DEVIATION REQUEST FROM SUPPLIERform no. 135 CODE LIST FOR MONTH-YEAR MANUFACTURING MARKINGform no. 150 PART SUBMISSION WARRANTform no. 162 SUPPLY STATUSform no. 163 INSPECTION REPORTform no. 282 LIST OF REJECTED PARTS FROM WORK CONTRACTORSform no. 317 8-D CORRECTIVE ACTIONS REPORTform no. 369 CONTROL PLANform no. 468/380 NEW PURCHASING ORDER SUPPLY ASSIGN/CHANGE

PROPOSAL PPAP ACTIVITIESform no. 463 ENGINEERING CHANGE REQUEST FROM SUPPLIERform no. 496 RUN@RATE ANALYSISform no. 553 BATCH CERTIFICATION FOR

PROTOTYPE/EXPERIMENTAL/PRE-LAUNCH PARTS

Supplier is not obliged to use the above listed documentation; alternate formats may be usedas long as they contain the same information, as a minimum.

14 Reference O.G.s Engineering Specifications and Work Instructions

Q.F.1001 ENGINEERING SPEC. BILLETS AND ROUNDS STEEL, ATNATURAL ROLLING STATUS

Q.F.2002 ENGINEERING SPEC. ELECTRIC ARC AND GAS WELDEDJOINTS

Q.F.2003 ENGINEERING SPEC. ROUGH MATERIAL IRON CASTINGS

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Q.F.2004 ENGINEERING SPEC. LIGHT ALLOY CASTINGS - ALUMINIUMQ.F.2011 ENGINEERING SPEC. PARTS CLEANLINESSQ.F.2012 ENGINEERING SPEC. ELECTROPLATED ZINC COATING FOR

FERROUS PARTSQ.F.2013 ENGINEERING SPEC. INSPECTION OF LIP SEAL WORKING

SURFACE THROUGH STRAND TESTQ.F.2014 ENGINEERING SPEC. DETECTION OF EXAVALENT CHROMIUM

ON ZINC-PLATED FERROUS PARTSP.Q.1012 WORK INSTRUCTION HEAT TREATMENT SPECIFICATIONS

FOR ISOTHERMAL ANNEALING OFFORGED PARTS

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