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R16001.R12 PASA Supplier Quality Manual

Panasonic Automotive Systems Company of America (PASA)

Supplier Quality Manual

Issue Date: October 21, 2013 Document R16001.R12


Panasonic Automotive Global Organization

It is the supplier’s responsibility to assure that only the latest revision of this Quality Manual is used.

The latest revision can be obtained from our website:

http://www.panasonic.com/business/automotive/resources-support/supplier-quality.aspx

All prior editions are obsolete and should not be used.

PASDL

Dalian, China

AIS

Yokohama, Japan

PASCZ

Pardubice, Czech

PASA

Farmington Hills, MI, USA

PASMX

Reynosa, MX

PASA

Peachtree City, GA, USA

PASMY

Penang, Malaysia


PASA Supplier Quality Manual Table of Contents

1.0 Supplier Quality Manual Acknowledgement and Supporting Forms

1.1 Supplier Acknowledgement and Acceptance of Supplier Quality Manual ................. 6 1.2 Escalation Contacts .................................................................................................. 6 1.3 Supplier Profile/Manufacturing Plant Information ...................................................... 6 1.4 Exceptions Form ....................................................................................................... 6

2.0 Introduction

2.1 PASA Quality Policy .................................................................................................. 7 2.2 Principles of Panasonic ............................................................................................. 7 2.3 Purpose .................................................................................................................... 7 2.4 Scope ........................................................................................................................ 7 2.5 Language .................................................................................................................. 8 2.6 e-Business Capabilities ............................................................................................. 8 2.7 Reference Documents .............................................................................................. 8

3.0 Definitions

3.1 5S ............................................................................................................................. 9 3.2 Advance Product Quality Planning (APQP) .............................................................. 9 3.3 Agile .......................................................................................................................... 9 3.4 American National Standards Institute (ANSI) .......................................................... 9 3.5 Approved Vendor List (AVL) ..................................................................................... 9 3.6 Automotive Industry Action Group (AIAG) ................................................................ 9 3.7 Controlled Shipping (CS1, CS2) ............................................................................... 9 3.8 GPWeb ..................................................................................................................... 9 3.9 Panasonic Automotive System Company of America (PASA) .................................. 9 3.10 Production Part Approval Process (PPAP) ............................................................... 9 3.11 Shall versus Should ................................................................................................ 10 3.12 Supplier Change Request (SCR) ............................................................................ 10 3.13 Supplier Corrective Action (SCA) ............................................................................ 10 3.14 Supplier Risk Assessment Guideline ...................................................................... 10


4.0 Supplier Requirements

4.1 General ................................................................................................................... 11 4.2 Supplier Quality Manual .......................................................................................... 11 4.3 Quality Requirements ............................................................................................. 11 4.3.1 Quality System Requirements ...................................................................... 11 4.3.2 Self-Assessment ........................................................................................... 11 4.3.3 Continuous Improvement .............................................................................. 12 4.4 Purchasing Requirements ....................................................................................... 12 4.4.1 Financial Data ............................................................................................... 12 4.4.2 Quoting ......................................................................................................... 12 4.4.3 Purchase Orders ........................................................................................... 12 4.4.4 Return Material Authorization (RMA) ............................................................ 12 4.4.5 Procurement Policy ....................................................................................... 12 4.4.6 Supplier Corporate Social Responsibility ...................................................... 12 4.4.7 Green Procurement Policy ............................................................................ 12 4.4.8 GPWeb ......................................................................................................... 13 4.4.9 Conflict-Free Mineral Sourcing Policy ........................................................... 13 4.5 Part Aging ............................................................................................................... 13 4.6 Packaging/Shipping Requirements ......................................................................... 13

5.0 Pre-Production Activities and Expectations

5.1 Advanced Product Quality Planning (APQP) .......................................................... 14 5.1.1 General ......................................................................................................... 14 5.1.2 APQP Follow Up ........................................................................................... 14 5.1.3 Run at Rate ................................................................................................... 14 5.1.4 Containment Plan ......................................................................................... 14 5.1.5 Statistical Techniques ................................................................................... 14 5.1.6 Analytical Techniques ................................................................................... 14 5.1.7 Measurement System Analysis (MSA) .......................................................... 15 5.1.8 Error Proofing ............................................................................................... 15 5.1.9 Preventive/Predictive Maintenance ............................................................... 15 5.1.10 Continual Improvement Process ................................................................. 15 5.2 Production Part Approval Process (PPAP) ............................................................. 15 5.2.1 Basic Requirements ...................................................................................... 15 5.2.2 Submission Timing ........................................................................................ 15 5.2.3 Language7 .................................................................................................... 15 5.2.4 Dimensions ................................................................................................... 16 5.2.5 Packaging Plan ............................................................................................. 16


5.3 PPAP Submission Level Requirements .................................................................. 16 5.3.1 General ......................................................................................................... 16 5.3.2 Mechanical and Plastic Parts ........................................................................ 16 5.3.3 Electrical Parts .............................................................................................. 16 5.4 Supplier Assessments ............................................................................................ 16 5.4.1 Types of Assessments .................................................................................. 16 5.4.2 Assessment Response ................................................................................. 17

6.0 Mass Production Activities and Expectations

6.1 Management of Company Owned Asset ................................................................ 18 6.2 Sub-supplier Quality Assurance .............................................................................. 18 6.3 Customer Directed Suppliers .................................................................................. 18 6.3.1 Customer Directed Suppliers – Customer Responsible ................................ 18 6.3.2 Customer Directed Suppliers – PASA Responsible ...................................... 18 6.4 Non-Conforming parts/Supplier Corrective Actions................................................. 18 6.4.1 Analysis of Non-Conforming parts ................................................................ 18 6.4.2 Supplier Corrective Actions ........................................................................... 19 6.5 Part Deviation ......................................................................................................... 19 6.6 Supplier Scorecard ................................................................................................. 19 6.6.1 General ......................................................................................................... 19 6.6.2 Criteria .......................................................................................................... 20 6.6.3 Performance Results .................................................................................... 20 6.7 Change Control ....................................................................................................... 20

7.0 Service and Part End of Life (EOL) Activities and Expectations

7.1 General ................................................................................................................... 21 7.2 Service Parts .......................................................................................................... 21 7.3 End of Life (EOL) Parts ........................................................................................... 21

Appendix

List of PASA Document Referenced in the Supplier Quality Manual ................................. 22 Supplier Quality Manual Acknowledgement Form ............................................................. 23 Escalation Contacts Form .................................................................................................. 24 Supplier Profile Form ......................................................................................................... 25 Supplier Quality Manual Exceptions Form ......................................................................... 26

1.0 Supplier Quality Manual Acknowledgement and Supporting Forms


1.1 Supplier Acknowledgement and Acceptance of Supplier Quality Manual The Supplier Quality Manual Acknowledgement and Acceptance form has been designed to document the supplier’s acknowledgement and receipt of PASA’s Supplier Quality Manual. It is critical that suppliers become fully knowledgeable of the Supplier Quality Manual content so that they understand PASA’s expectations and what documentation must be submitted. The appropriate leaders within a supplier’s organization shall review the manual and take appropriate actions to become fully compliant. Any questions should be directed to the supplier’s purchasing or supplier quality contact.

1.2 Escalation Contacts

The Escalation Contacts form is required so that each department at PASA has an appropriate contact should there be an issue with quality, environmental, or purchasing requirements.

1.3 Supplier Profile/Manufacturing Plant Information The Supplier Profile form is required as part of PASA’s risk management. This information helps PASA determine if a supplier’s location is affected during a natural or manmade disaster. In addition it provides important information to PASA regarding a supplier’s capability and capacity.

1.4 Exceptions Form The Supplier Quality Manual Exceptions Form is used when a supplier takes exception to one or more sections of the Supplier Quality Manual. The supplier shall list any clauses they wish to take exception with, sign the form, and submit it with the rest of the forms listed in Sections 1.1, 1.2, and 1.3 of this document. PASA will then review the exceptions and determine if the exceptions are “Accepted” or “Rejected”. If the exceptions form is “Accepted”, then PASA accepts the supplier’s proposal and no further submission is required. If the exceptions form is “Rejected”, then PASA and the supplier will review the reason why the exceptions were rejected. PASA and the supplier will then work together to resolve any differences.

2.0 Introduction


2.1 PASA Quality Policy Statement At Panasonic Automotive Systems Company of America (PASA), quality is a commitment that encompasses every team member of the organization with improved customer satisfaction and continual improvement of the Quality Management System as our goal. A customer-first approach is paramount throughout PASA’s cascading levels of management review of organization performance focusing on quality, cost, development and delivery or QCDD.

PASA will thrive and grow as the leading manufacturer in car electronics through execution of the process approach of TS16949 and conformance to customer requirements.

2.2 Principles of Panasonic

Contribution to Society We will conduct ourselves at all times in accordance with the basic management objective, faithfully fulfilling our responsibilities as industrialists in our community in which we operate.

Fairness and Honesty: We will be fair and honest in all our business dealings and in our personal conduct. No matter how talented or knowledgeable we may be, without personal integrity we can neither earn the respect of others nor enhance our own self-respect.

Cooperation and Team Spirit: We will pool our abilities to accomplish the goals that we share. No matter how much skilled we are, without cooperation and team spirit we will be a company in name only.

Untiring effort for Improvement: We will constantly strive to improve our ability to contribute to society through our business activities. Only through such untiring effort can we fulfill or Basic Management Objective and help to realize lasting peace and prosperity.

Courtesy and Humility: We will be cordial and modest, always respecting the rights and needs of others in order to strengthen healthy social relationships and improve the quality of life in our community.

Adaptability: We will continually adapt our thinking and behavior to meet the ever-changing condition around us, taking care to always act in harmony with nature in order to ensure progress and success in our endeavors.

Gratitude: We will act out of a sense of gratitude for all the benefits we have received, confident that this attitude will be a source of boundless joy and vitality, enabling us to overcome any obstacles that we encounter.

2.3 Purpose

The purpose of the document is to define Panasonic Automotive Systems Company of America’s (PASA) product quality requirements, quality management system expectations, environmental requirements, and environmental management systems expectations to suppliers including original equipment manufacturers (OEM) and distributors. PASA has adopted the internal quality policy listed above and utilizes the seven principles of Panasonic to reflect its corporate beliefs.

2.4 Scope This manual details the minimum supplier requirements for all direct material/service suppliers. This manual may also apply to indirect material/service suppliers when it is required by a PASA Purchase Order.

2.0 Introduction


2.5 Language PASA’s official language is English. Unless otherwise approved by PASA Supplier Quality and Advance Purchasing departments, all official communications with PASA will be done in English. Documents may display the native language when integrated with parallel translation. If this is done, only the English translation is valid.

2.6 e-Business Capabilities

Suppliers (or trading representatives) shall have E-mail, Internet access, and Internet Browser capability. This is required in order to access PASA’s web based Agile database application and communications.

2.7 Reference Documents - The following is a list of AIAG / ISO/ ANSI documents referenced in this

standard (always refer to the latest revision):

Manual Publisher Description

TS16949 IATF Technical

Specification ISO9001 ISO Quality System

APQP AIAG Advanced Product

Quality Planning and Control Plan

FMEA AIAG Potential Failure

Mode and Effects Analysis

MSA AIAG Measurement

System Analysis SPC AIAG Fundamental SPC

PPAP AIAG Production Part

Approval Process

ANSI 20.20 ANSI ESD Standards for

electrical parts

J-STD-020 IPC/JEDEC MSD Standards for

electrical parts

Specific information regarding these documents can be found on the following websites: www.AIAG.org www.IPC.org www.ANSI.org www.ISO.org www.iatfglobaloversight.org

3.0 Definitions


3.1 5S – Part of Lean Manufacturing methodology for workplace organization. The five S’s are “seiri” (sort), “seiton” (set in place), “seiso” (shine), “seiketsu” (standardize), and “shitsuke” (sustain).

3.2 Advanced Product Quality Planning (APQP) – AIAG (Automotive Industry Action Group) provides guidelines throughout the development process to develop a quality product that will satisfy the customer.

3.3 Agile – PASA’s Engineering database system which all PPAPs, Supplier Change Requests (SCRs), and Supplier Corrective Actions (SCAs) are input.

3.4 American National Standards Institute (ANSI) – An institute which oversees the creation, promulgation and use of thousands of norms and guidelines that directly impact businesses in nearly every sector.

3.5 Approved Vendor List (AVL) – A list of PASA approved suppliers.

3.6 Automotive Industry Action Group (AIAG) – A not-for-profit association of companies involved in the automotive industry who work collaboratively to streamline industry processes via global standards development.

3.7 Controlled Shipping (CS1, CS2) – A containment process to certify conformity of material to

specified requirements used when current controls are not sufficient to prevent PASA from receiving non-conforming material. (Manufacturer performs CS1. An independent party performs CS2.)

3.8 GPWeb – A global database system used by PASA suppliers to register chemical composition data

for all products shipped to PASA. The information is necessary to determine if parts are environmentally friendly and can be Green Part Approved for use in PASA’s finished products.

3.9 Panasonic Automotive System Company of America (PASA) – Refers to Peachtree City, GA

and Reynosa, Mexico (PASMX). 3.10 Production Part Approval Process (PPAP) – defines requirements for production part approval,

including production and bulk material per the AIAG (Automotive Industry Action Group) standard. This process verifies that the supplier properly understands all engineering design records and specification requirements and that the process has the potential to produce product consistently during actual mass production.

3.0 Definitions


3.11 Shall/Should: The world “shall” in this document indicates a mandatory requirement. The word “should” indicates a mandatory requirement with some flexibility allowed in compliance methodology. Suppliers choosing other approaches to satisfy a “should” must be able to show that their approach meets the intent of TS16949 or ISO9001.

3.12 Supplier Change Request (SCR) – Form used by supplier to document any changes made to the process or material selection.

3.13 Supplier Corrective Action (SCA) – 8D (discipline) corrective action form in the Agile database. 3.14 Supplier Risk Assessment Guideline – Documents established to define Panasonic Automotive

Systems Company of America assessments and approvals processes of new and existing suppliers.



4.1 General The guidelines listed in this section include the typical requirements for a supplier to be qualified at PASA. For any specific requirements or questions, contact your Supplier Quality Engineer or Purchasing representative.

4.2 Supplier Quality Manual

The supplier shall sign and complete all forms in the Supplier Quality Manual as described in Section 1.0.

4.3 Quality Requirements

4.3.1 Quality System Requirements - Minimum quality system requirements for suppliers to PASA are:

Registration to TS16949 latest revision (preferred) unless otherwise specified by

customer.

If supplier is not TS16949 certified, then the supplier shall be registered to ISO9001 by an accredited third party certification body, unless otherwise specified by the customer.

If the supplier is not registered to either of the above certifications then PASA shall

perform an on site assessment to determine if the supplier is compliant to ISO9001 as a minimum. This shall only be done in some very special cases as deemed by PASA’s Advance Purchasing and Supplier Quality organizations.

Copies of TS16949/ISO9001 certificates shall be submitted to PASA. Should the status of any certification change (for example, new certification, de-certification, reassessments, etc.) the supplier shall notify PASA and provide a copy of the latest certification status.

PASA or PASA’s’ customers retain the right to perform verification activities at the supplier’s premises (including customer directed suppliers). PASA shall determine the intended verification arrangements and the method of product release.

4.3.2 Self-Assessment Suppliers (OEMs and distributors) shall complete the Initial Assessment Form (F74112). This form shall be returned to PASA Supplier Quality along with evidence of applicable quality system. This may be followed up by an on-site assessment conducted by PASA or other designated PAS organization.



4.3.3 Continuous Improvement The supplier shall have a system to continuously improve their quality, service, and delivery to PASA. The supplier should have a set of goals and objectives established to aid in achieving this. PASA reserves the right to assess the supplier’s continuous improvement activities and make recommendations for improvement. Additional requirements for Continuous Improvement can be found in Section 5.1 of this Quality Manual.

4.4 Purchasing Requirements

4.4.1 Financial Data Suppliers shall submit to PASA purchasing all pertinent financial information. This may also include credit references and customer references.

4.4.2 Quoting Upon receiving any Request for Quote (RFQ), the supplier shall supply detailed reports as defined by PASA on tool design, tool shop, and production facility capacity. All drawings in the quote package must have process control dimensions marked.

4.4.3 Purchase Orders The supplier shall meet PASA’s requirements listed on the purchase order, drawings, and addendums. The supplier shall also meet the requirements shown in all attachments of this Supplier Quality Manual.

4.4.4 Return Material Authorization (RMA)

The supplier shall provide PASA with a Return Material Authorization (RMA) number as requested to authorize return of supplier defective material. The determination whether to issue credit, replace or scrap, at the supplier’s expense, the defective material will be negotiated between the supplier and PASA purchasing.

4.4.5 Procurement Policy Refer to details at: http://panasonic.net/procurement/procurement_policy.html

4.4.6 Supplier Corporate Social Responsibility

Refer to details at: http://panasonic.net/procurement/for_suppliers.html

4.4.7 Green Procurement Policy

Refer to details at: http://panasonic.net/procurement/green/



4.4.8 GPWeb All parts must be registered by the supplier in the GPWeb system at: https://eww.gpscmn.panasonic.co.jp/prtl/QZZZ000A.do

Contact the PASA GPWeb Helpdesk for assistance at: [email protected]

4.4.9 Conflict-Free Mineral Sourcing Policy Refer to details at http://panasonic.net/sustainability/en/supply_chain/minerals/

All suppliers must provide and updated information related to the use of conflict minerals within their products regardless of your SEC reporting requirement status. All suppliers must report these to us using the latest version and instruction of the Conflict Minerals Reporting Template found at: http://www.conflictfreesmelter.org/ConflictMineralsReportingTemplateDashboard.htm

4.5 Part Aging

The supplier shall meet PASA’s requirements for age of parts received. Supplier should refer to PASA document R74013 for the latest on age requirements for all part types.

4.6 Packaging/Shipping Requirements

Suppliers should obtain a copy of R62004, Requirements for Shipping and Palletizing product to PASA. This document provides the supplier the specific requirements for Domestic and International shipping, as well as expedited delivery.



5.1 Advanced Product Quality Planning

5.1.1 General The supplier shall utilize the planning procedures from the AIAG Advanced Quality Planning and Control Plan (APQP) manual for new programs. All elements of the APQP must be incorporated into the planning process, unless waived in writing by PASA Supplier Quality. All documents including Process Flow Diagram (PFD), Potential Failure Mode and Effects Analysis (PFMEA), and Process Control Plans shall include all processes for the manufacturing of the component (including incoming inspection of raw material, internal transportation, packaging, etc.).

5.1.2 APQP Follow Up The supplier may be requested to provide documented evidence as to the completion and results of APQP activity at various steps in the process. PASA also may request periodic meetings with the supplier to review and critique their activities.

5.1.3 Run-at-Rate All suppliers are required to perform a Run at Rate or High Volume Production Trial before production begins. This is defined as a production trial using all production processes, tooling, equipment, and personnel to run the product at the quoted production rate. The supplier must be able to show that they can meet the production demands of PASA.

5.1.4 Containment Plan Suppliers must have an early production containment process (e.g. GP-12, Pre-launch control plan). This is defined as the supplier having extra controls in place for a minimum of the first 30 days production to ensure all requirements are met during the start of production.

5.1.5 Statistical Techniques The supplier shall monitor process performance using the appropriate statistical techniques in accordance with the AIAG SPC Manual. Additional areas where statistical techniques can be used are Gage R&R studies, Defect Analysis, and Continual Improvement Processes. All results shall be documented and retained by the supplier and shall be made available upon request from PASA.

5.1.6 Analytical Techniques The supplier should use the appropriate analytical techniques to improve capability and for problem resolution. Examples of analytical techniques are Design of Experiment (DOE), Benchmarking, and Theory of Constraints. All results shall be documented and retained by the supplier and shall be made available upon request from PASA.



5.1.7 Measurement System Analysis (MSA) The supplier shall perform measurement system analysis (MSA) in accordance with the AIAG MSA Manual. Other methods may also be implemented by the supplier with approval from the PASA Supplier Quality Engineer. All results shall be documented and retained by the supplier and shall be made available upon request from PASA.

5.1.8 Error Proofing The supplier shall utilize the Error Proofing technique in accordance with the TS16949 Quality Systems Requirement Manual. All results shall be documented and retained by the supplier and shall be made available upon request from PASA.

5.1.9 Preventive/Predictive Maintenance The supplier shall implement a preventive/predictive maintenance system in accordance with the TS16949 Quality Systems Requirement Manual. All results shall be documented and retained by the supplier and shall be made available upon request from PASA.

5.1.10 Continual Improvement Process The supplier shall implement continual improvement projects and efforts in their company in accordance with the TS16949 Quality Systems Requirement Manual. All results shall be documented and retained by the supplier and shall be made available upon request from PASA.

5.2 Production Part Approval Process (PPAP)

5.2.1 Basic Requirements The supplier shall submit the PPAP package in accordance with the AIAG PPAP Manual unless otherwise specified by a PASA Supplier Quality Engineering representative.

5.2.2 Submission Timing For most programs, the PPAP shall be submitted prior to the PP2 build and no later than High Volume Production Trials (HVPT) or Run-at-Rates (R@R). No part is allowed to be shipped for mass production without PPAP approval unless deviation is provided in writing by PASA Supplier Quality.

5.2.3 Language PASA requires all suppliers to submit a PPAP in English unless otherwise approved by PASA Supplier Quality Engineer.



5.2.4 Dimensions All dimensions that are marked as critical on the PASA drawing (usually designated on the drawing with CD or K ) must have a capability study submitted with the PPAP package. The capability study must be on a minimum 30 pieces for a Ppk study, or 100 pieces for a Cpk study. If the Ppk is less than 1.67 or the Cpk is less than 1.33, the supplier shall create and action plan that defines containment and process improvement activities. Critical dimensions must also have controls in place that are in both the PFMEA and Control Plan.

5.2.5 Packaging Plan

For mechanical and plastic parts, the PPAP submittal shall also contain a packaging plan with compliance to packaging per International Safe Transit Association.

5.3 PPAP Submission Level Requirements

5.3.1 General

Regardless of the PPAP submission levels, the supplier must retain all PPAP documentation at their location.

5.3.2 Mechanical/Plastic Parts

The supplier shall use Level 3 submission as the default for all submissions unless otherwise specified by the Supplier Quality Engineer. Suppliers of mechanical parts must submit drop tests results from a specified height for all packaging as part of the PPAP package.

5.3.3 Electrical Parts The supplier shall use Level 3 submission as the default for all submissions unless otherwise specified by the Supplier Quality Engineer. Suppliers of electrical parts may also be asked to submit samples to send for evaluation by CET (Component Evaluation Team).

5.4 Supplier Assessments

5.4.1 Types of Assessments PASA may conduct an assessment on site at the supplier. Assessments may be done due to (but not limited to) new supplier, customer return(s), customer requirement, etc. The types of assessments PASA conducts are:

Initial Assessments – Quality Systems and Process Assessments for new suppliers.

PASA assesses to the TS16949 standard Note: This is not a Quality Systems/TS16949 audit.

New Model Assessments (Uses Process Control Plan Assessment Sheet) – Product

specific assessment for either new or existing suppliers, as well as “A” rank parts. General Assessments – Usually process specific assessments performed at existing



suppliers.

Customer Specific Assessments – In some special cases, assessments may be done to meet customer requirements using their specified form(s).

Assessments will be done by the Panasonic Assessment Team. The Panasonic Assessment team is typically led by Supplier Quality and may consist of members from Advance or Production Purchasing, Engineering, and CET (Component Evaluation Team).

5.4.2 Assessment Response Once an assessment is done by PASA, the supplier may receive an action item list on areas to improve. Depending upon the severity of the finding, the supplier will need to prepare a formal response:

MAJOR Finding(s): Requires immediate containment response while PASA is still on

site at the supplier. Corrective actions shall be sent in 5 business days. Note in certain cases (such as new equipment installation) that the corrective action can include timing for a project to be completed.

MINOR Finding(s): Requires a response (typically in 10 business days, but at the discretion of the Supplier Quality Engineer). Note in certain cases (such as new equipment installation) that the corrective action can include timing for a project to be completed.

OBSERVATIONS require no formal response from the supplier.



6.1 Management of Company Owned Asset The supplier shall sign and return the PASA Tooling Agreement which outlines our expectations associated with doing business. All tooling is subject to audits and approval by PASA.

6.2 Sub-supplier Quality Assurance

The supplier shall have a system in place for evaluating, selecting, and monitoring sub-suppliers. The supplier shall ensure all sub-suppliers are capable of meeting PASA’s quality objectives. PASA reserves the right to audit supplier and sub-supplier facilities.

6.3 Control of Customer Directed Suppliers 6.3.1 Customer Directed Suppliers – Customer Responsible

For any customer directed supplier in which the customer is responsible for the quality, cost, and delivery of the parts, PASA shall have no involvement or control of that supplier and part.

6.3.2 Customer Directed Suppliers – PASA Responsible

For any customer directed supplier in which PASA is responsible for the quality, cost, and delivery of the parts, that supplier shall follow all PASA requirements as outlined in this Supplier Quality Manual.

6.4 Non-Conforming Parts/Supplier Corrective Action

6.4.1 Analysis of Non-Conforming Parts

When there is a non-conforming part found, an SCA is created in PASA’s Agile system and the part is returned to the supplier for analysis.

Priority is typically given to customer line returns and warranty returns. The Supplier Quality Engineer will help prioritize returns with the suppliers.

The Supplier Quality Engineer will work with the supplier on an acceptable time frame for

analysis. In the case of complex parts or failures, it is expected that interim reports be issued.

If the analysis proves the returned part is not defective, then the SCA is closed.

If the analysis confirms the part is defective, then the supplier shall submit a corrective

actions as detailed in Section 6.4.2.



6.4.2 Supplier Corrective Actions (SCA’s) A Supplier Corrective Action will be issued to a supplier when confirmed defective or non-conforming product has been received at PASA, or has been reported back to PASA by our end customer. When PASA issues a supplier an SCA, the following shall occur:

The supplier must provide initial containment and interim response regarding the

defective product within 24 hours.

The final corrective action for the defect must be received from the supplier within 7 calendar days. Extensions may be granted at the discretion of the Supplier Quality Engineer (based upon part complexity, sub-supplier issues, etc.).

The supplier will submit the corrective action in an 8-D/5P/5Y format. Submission of the

corrective action may be done using the Agile system.

PASA may then verify the corrective action on site at the supplier.

Repetitive quality issues may negatively affect the supplier’s business with PASA. 6.5 Part Deviation

The supplier may request a deviation for non-conforming products by submitting a request through PASA via the Agile system. Suppliers are required to notify PASA of any product non-compliance issue prior to shipping product to PASA. Various departments within PASA (depending upon the scope of the issue) will work with the supplier to assure product requirements.

PASA has the authority to reject any supplier deviation request for reasons including, but not limited to, non-conforming product conditions that may impact the customer in product function or performance.

When a deviation request is approved, the supplier can then ship parts to PASA.

6.6 Supplier Scorecard

6.6.1 General The supplier shall be assessed by PASA Supplier Quality and Purchasing in regards to their ongoing quality performance. Suppliers must strive for zero defects as PASA and PASA’s customers demand zero defects.



6.6.2 Criteria In accordance with PASA’s Quality Policy, PASA will use the following criteria for evaluating suppliers:

Quality – Including PASMX line PPM, customer line, and warranty returns. Cost – Price reductions/concessions. Delivery – 100% on time delivery of parts.

6.6.3 Performance Results PASA will notify each supplier monthly of their quality, cost, and delivery performance using the Supplier Scorecard. Suppliers with a “C” for 3 months in a row may be asked to submit a Quality Improvement Plan. Furthermore, suppliers with poor performance may be subject to 100% sorting by a third party until such time that quality of incoming material improves to zero defects. (i.e. CS1/CS2, controlled shipping). An on-site assessment by Supplier Quality may also be scheduled to evaluate their issues.

6.7 Change Control Requirements

Suppliers must notify PASA Supplier Quality in writing (using the Supplier Change Request Form) prior to making any changes to part construction or manufacturing processes. The change request will be tracked and approved using the Agile system. The supplier should make every effort to notify PASA a minimum of 6 months prior to the proposed change. The PASA Supplier Quality Engineer will work with the supplier to determine the feasibility of the proposed changes, timing, and PPAP submission requirements. Changes that require notification and PPAP submittal are listed below. This list is not all-inclusive - suppliers must check with their supplier quality engineer before making any changes.

Use of other raw material than on the PPAP. Production from new or modified tool. Production following refurbishment or rearranging of existing tooling or equipment. Production from tooling/equipment transferred to different plant locations. Change of supplier for components or services. Product or Process changes related to component of the production product manufactured

internally or by subcontractor(s). Change in Test / Inspection Method.

All changes must be approved in writing by PASA supplier quality engineering prior to implementation.

7.0 Service and Part End of Life (EOL) Activities and Expectations


7.1 General Reference PASA’s Basic Purchase Agreement (BPA) for all specific items related to service parts and end of life (EOL) parts.

7.2 Service Parts PASA has the same quality requirements for service parts as for production parts.

7.3 End of Life Parts

The supplier shall notify Purchasing if an original part used in production will no longer be available for service requirements. The supplier shall offer a suitable replacement that is available and will meet the original design intent. If that is not available, then the supplier shall support a Last Time Buy plan to meet service requirements.

Appendix


Appendix: List of PASA Documents Referenced in this Quality Manual

Document Number Document Title Document Description

R62003 Bar Code Label Guidelines Specifies all requirements PASA has for bar

code labels.

R62004 Requirements for Shipping and

Palletizing Specifies all requirements PASA has for

palletizing and shipping product.

F73111 Supplier Change Request Form used by supplier to communicate any

process or material change to PASA.

R74013 Part Shelf Life Matrix Lists part age requirements of all materials used

by PASA to manufacture.

F74112 Supplier Assessment Forms Forms used by PASA to assess suppliers.

Includes Initial Assessment, New Model Launch, and Supplier Action Item List (SAIL).

Basic Purchasing Agreement Specifies all business and legal requirements of

suppliers that do business with PASA.

It is the supplier’s responsibility to assure that only the latest revision of these documents are used.

The latest revision can be obtained from our website:

http://www.panasonic.com/business/automotive/resources-support/supplier-quality.aspx

All prior editions are obsolete and should not be used.

Appendix


Supplier Acknowledgement and Acceptance of Supplier Quality Manual (SQM)

The Supplier’s Management personnel referenced below shall print this page, sign the applicable area acknowledging receipt of this manual and accept the conditions stated here-in. Supplier Name Quality Manager (print) signature Date Executive Operations Manager (print) signature Date Please send the following items back to PASA:

□ Signed acknowledgement of this page.

□ Escalation contact list (Page 24 of this manual).

□ Supplier Profile (Page 25 of this manual).

□ Copies of Quality/Environmental certifications.

□ Completed Initial Assessment Form (F74112).

□ Exceptions List (Page 26 of this manual). PASA prefers that each supplier E-mail the above documents to: [email protected], phone: 770-631-5808 The supplier may also fax to PASA Supplier Quality Department at 770-486-2275 or mail to: Panasonic 776 Highway 74 South Peachtree City, GA 30269 Attention: Supplier Quality Department

Appendix


PASA Supplier Quality Manual Escalation Contacts Company Specific Information

Company Name:

DUNS No. Company website address:

Division or Parent

Company

Effectivity Date:

Mailing Address: City, State, Zip:

Remit to address:

Key Contacts:

Name: Phone Number: Fax Number: E-mail Address Pager/Cell Number:

C.E.O

President

Quality

Engineering

Sales

Manufacturing

Environmental (product related)

24 hr Contact

Multiple Locations? (Y/N) If Yes, all “Plant Specific Information” shall be completed for each manufacturing location

Core Commodities: Type Of Business

(Check one with “X”) Manufacturer Distributor Service

Years/Months in Business: Previous year sales Current year projected sales

Appendix


Supplier Manufacturing Plant Information Plant Specific Information (Separate page to be duplicated for each manufacturing plant location)

Mfg/Distribution Location(s):

(Address, City, State, Zip)

DUNS # Location #

Remit to address: Nearest Airport:

Structure Type (Brick/Sheet metal/etc) Structure Age

Size of Facility (in Sq. Ft.) Total Sq. Ft: Plant Warehouse Lab

Facilities (Check w/ “X”) Prototype Production Tooling Lab

R&D Capabilities (Check w/ “X”) Prototype Production Tooling Lab

Outside Suppliers used for Testing-Must be A2LA certified (Name and

address)

CAD Capabilities (e.g. CATIA, Ideas, IGES, etc)

CAD translations (Name and addressed of outsourced supplier

used for translations)

Outside Suppliers used for Tool manufacturing and repair (Name

and address)

Outside containment inspection suppliers (Name and address)

Total Number of Employees

Management Production Eng/Tech Design Other

Number of shifts/day:

Hours/shift (Less planned downtime):

Days/week: Weeks/year:

Scheduled Vacation Shutdowns Inventory turns/year

Union Affiliation? Agent/Local Contract Expiration Date

Employee Involvement/Suggestion Program (Y/N)

Bonus Incentive Plans (Y/N) Attendance bonus (Y/N)

Profit Sharing (Y/N)

Value Analysis Program (Y/N)

Major Customers 1. 2. 3. 4

Current PPM: 1. 2. 3. 4.

% On-time Delivery: 1. 2. 3. 4.

Warranty Returns: 1. 2. 3. 4.

Major Sub-Suppliers 1. 2. 3. 4.

Current PPM: 1. 2. 3.

% On-time Delivery: 1. 2. 3.

Warranty Returns: 1. 2. 3. 4.

Name of the person completing Profile (Please print):

Date:

Signature:

millerw

Cross-Out

millerw

Typewritten Text

4.

millerw

Typewritten Text

4.

Appendix


Supplier Quality Manual Exceptions Form

List any exceptions (if applicable) to this Quality Manual by clause number on the lines below and sign. The exceptions are NOT accepted by PASA unless PASA Supplier Quality and Purchasing approve them. The supplier will receive notification if the exceptions are accepted or rejected.

Clause Number

Clause Description Exception Taken (describe fully)

Additional Comments: ________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ Supplier Name Quality Manager (print) signature Date Executive Operations Manager (print) signature Date PASA Acceptance: Name/Title/Department (print) signature Date Name/Title/Department (print) signature Date