rehau supplier quality manual · rehau uses an internal document “checklist ii” form 6488 or...

REHAU SUPPLIER QUALITY MANUALFOR PURCHASED PARTS / AUTOMOTIVE

Issue 1

Status 08/2017

The current valid version applies - to be found under http://www.rehau.ch/logrl

www.rehau.com Construction

Automotive

Industry

Created : July 2017, A. Plichta Released: August 2017, B. Lehmann

http://www.rehau.ch/logrl

Construction

Automotive

Industry

www.rehau.com A. Plichta, June 17, of 24

SUPPLIER QUALITY MANUAL

CONTENTS

1. PURPOSE

2. SCOPE

3. QUALITY MANAGEMENT SYSTEM

3.1 General Requirements

3.2 End Customer Expectations

4. SUPPLY CHAIN MANAGEMENT

4.1 Audits/assessment of Quality Management System

4.2 Supplier Evaluation/Target Agreements

4.3 Contract Review

4.4 Delivery Expectations

4.5 Contingency Plan

4.6 Customer Specific Requirements

4.7 Qualification of Subcontractors

4.8 Control of Material and Packaging Provided by REHAU

4.9 Transfer of Services to Third Parties/ Sub-contractor Management

4.10 Sustainability, Environment and Safety

5. PRODUCT AND PROCESS DEVELOPMENT

5.1 Product Development and Launch Process

5.2 Continuous Improvement Program

5.3 PPAP

5.4 Layout Inspection and functional testing / Requalification

5.5 Prelaunch Controls Plan/Safe Launch

5.6 Control Plan

5.7 Special Characteristics/MP points

5.8 PFMEA

5.9 Testing Requirements

5.10 Error Proofing

5.11 IMDS

5.12 Packaging Approval

5.13 Nonconforming Product

5.14 REHAU Quality Cooperation (RQC)

6. TOOLING, EQUIPMENT AND GAUGES

6.1 REHAU Tooling (Molds, Equipment, Gauges and or other items)

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6.2 Identification of REHAU owned tooling

6.3 Tooling/Equipment Design Approval

6.4 Trial Runs

7. LOGISTICS

7.1 REHAU Logistics Guidelines

7.2 Repair of Containers

8. APPENDIX AS LISTED IN THE MANUAL

8.1 PPM Targets

8.2 Part History Tracking Sheet

8.3 Packaging Data Sheet

8.4 PPAP Checklist (AIAG and VDA), Sampling Coordination Meeting RECORD

8.5 RQC (REHAU QUALITY COOPERATION)

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1. PURPOSEThe purpose of this supplier quality manual is to provide for our current and potential new suppliers REHAU’s expectationsand requirements that are the foundation of a long term mutually beneficial and profitable relationship. The supplier ensuresthat REHAU requirements are understood and implemented within the supply chain. Deviations from the defined REHAUprotocol between supplier and REHAU have to be agreed upon in writing.

REHAU expects all suppliers to acknowledge and comply with the requirements contained within this manual. REHAU

would also like its suppliers to commit to these requirements formally by signing the signature page (last page) of this

document and sending it back to the purchasing organization at email [email protected]

2. SCOPE

This REHAU Automotive LLC standard applies to all processes of direct material procurement and is supplemental to the provisions of the following REHAU documents:

Supplier Agreement (SA) Supplier Amendment Purchase Orders (PO) Technical Delivery Specification (TDS) Quality Assurance Agreement (QAA) Warranty Agreement (WA) Non-Disclosure Agreement (NDA) REHAU Logistics Guideline REHAU Quality Cooperation (RQC) REHAU Standard Purchase Terms

Deviations from this REHAU Automotive Standard have to be agreed upon in writing.

3. QUALITY MANAGEMENT SYSTEM

3.1 General Requirements

REHAU requires its suppliers to maintain a QM system based on ISO 9001 and to consider the requirements of ISO/TS16949 and the forthcoming IATF16949. Also, the requirements of VDA shall be considered. The supplier should have a quality management system that provides for continual improvement and defect prevention.

The supplier must inform REHAU without delay of non-compliance or loss of ISO 9001/ISO TS 16949/ISO IATF 16946 certificate. If so, REHAU has the right to perform a process audit to confirm Quality Systems requirements are still in place.

mailto:[email protected]

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In the event of mergers, acquisitions or affiliations and similar activities that might affect the structure of the company or its organizations/plants, the supplier shall verify the QM system and inform REHAU without delay of the circumstances and the result of the verification.

3.2 End Customer Expectations

Suppliers are also required to be familiar with the end customer quality requirements, as it is a requirement of REHAU to cascade these requirements down to the supply base. (Nissan, MBUSI, BMW, VW, KIA, Ford, Fiat, GM for example). REHAU expects its suppliers to make themselves familiar with our end customer requirements in their “Customer Specific Requirement” publications. This includes but is not limited to annual layout and/or functional testing. CCC (China Compulsory Certificate) requirements are needed also, if applicable.

4. SUPPLY CHAIN MANAGEMENT

4.1 Audits/Assessment of Quality Management System

REHAU shall be allowed to carry out audits of their suppliers and their subcontractors after timely announcement. REHAU reserves the right to carry out audits even in cases where certification has already been obtained from third parties. The supplier provides all necessary documentation/data and allows access to all areas that are relevant to REHAU. Audits and evaluation performed by REHAU shall use VDA specifications (i.e. Process Audit VDA6.3) in connection with ISO 9001/TS16949 /IATF16949. If required, improvement measures will be agreed with the supplier, indicating the responsibilities and the dates by which completion is required. The effectiveness of the corrective measures may be monitored in a follow-up audit. REHAU also shall be allowed to carry out audits with no previous notification in case of product failure or repetitive complaints.

The supplier is responsible to carry out self-audits. Self-audits serve the supplier as verification relating to compliance with all requirements (i.e. VDA, ISO9001/TS16949/IATF16949), customer- and product specific requirements. Self-audits need to be performed from qualified auditors. Auditors should be qualified to VDA 6.3. Results from self-audits including improvement actions may be requested by REHAU in accordance with the supplier in specific cases (i.e. accumulation of claims) and need to be presented to REHAU upon request. As minimum the following self-audits using VDA are agreed -Product audit acc. to VDA6.5 for each produced product in series production (product groups) once per year-Process audit acc. to VDA6.3 for each produced product in series production once under series conditions for PPAP

REHAU will treat gained information from audits or self-audits confidential.

4.1.1 New Supplier Selection

REHAU uses an internal document “Checklist II” form 6488 or the VDA 6.3 Potential Analysis form 7948 for this activity.

4.2 Supplier Evaluation/Target Agreements

The supplier is obligated to deliver fault-free products and services (target: zero-defect). If no specific targets are agreed (i.e. in the technical delivery specifications purchasing TDS, supplier agreement, agreements for ramp-up management) the target is understood to be zero ppm.

A specific agreement relating to ppm values does not imply a quality level that is accepted by REHAU. See Appendix 1. The agreement on quality targets and measures does not limit the supplier’s liability for warranty claims and claims for

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damages by the customer as a result of defective deliveries. Defective deliveries/services will not be accepted by REHAU and will be charged to the supplier.

Ongoing supplier performance is one of the factors considered in the REHAU supplier evaluation process. When placing and extending orders REHAU will give preference to suppliers that are assessed as efficient under the REHAU supplier evaluation scheme. REHAU evaluates suppliers with regards to commercial topics and technical topics. These can include but are not limited to:

Deviation from delivery date Complaints Commercial Support Production Expertise Problem solving in case of claims Technical support in serial development

If quality targets have been agreed between REHAU and the supplier (ppm targets for instance), then escalation shall ensue in case those targets are not met. In this case the supplier is obligated to present REHAU with an action plan setting out corrective measures for stabilizing the supply and for sustainable improvement of performance in agreement, and is also to agree on further steps with REHAU. Please also see section 5.14 REHAU Quality Cooperation and Appendix 5.

4.3 Contract Review

The supplier is obliged both in the quotation and in the order phase to check the documents received as to their completeness, correctness, compatibility, the fulfillment of quality targets required and their feasibility (capacity to manufacture, maintenance of delays etc.) The supplier will point out to REHAU in writing all documents and facts that seem not clear or incorrect to them. This applies to measurement procedures and methods.

If further documents are referred to, the supplier is bound to get them and to ensure that always the latest versions are used.

- Guidelines/standards (i.e. DIN, ISO, EN and ASTM standards) which are in the public domain are to be procuredfrom the corresponding bodies.

- Guidelines/standards and documents of REHAU or its customers shall be submitted by the purchase departmentupon request.

4.4 Delivery Expectations

REHAU issues forecasts, requests confirmations and accepts Advanced Shipment Notices (ASN) through the REHAU supplier portal. Suppliers should request a Login and Password for this portal. REHAU issues PO’s that show material required dates. It is important to note that these are in house arrival dates. REHAU expects that the supplier use appropriate lead times to ensure that product arrives to schedule. On time delivery is key part of meeting our customers’ expectations. The product we receive from our supply base also needs to meet these expectations. Supplier’s delivery performance is calculated through tracking non- compliance to shipping dates, quantities, expedited freight and PO’s.

4.5 Emergency Plan

The supplier must submit an emergency/recovery plan for any quality, delivery loss, or spill that could affect production flow of material into any REHAU facility or any service for REHAU.

4.6 Customer Specific Requirements

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Specific OEM’s customer specific requirements are an integral part of doing business in the automotive industry and are a part of the contract with REHAU. It is expected that all suppliers become knowledgeable in and practice all applicable OEM’s customer specific requirements.

4.7 Qualification of subcontractors

If no subcontractors are appointed by REHAU, the supplier is responsible for the selection of suitable sub-contractors. The supplier will in all cases evaluate the quality capability of its sub-contractors and involve them in the advance quality planning as far as necessary. The PPF or PPAP process must be fully applied to its sub-contractors. The supplier’s subcontractor should at minimum maintain an ISO 9001 quality management system. The supplier is responsible for the quality through their completed supply chain.

4.8 Control of Material and packaging provided by REHAU

The supplier has to manage the incoming materials and packaging with regards to their quantities, identities and visually recognizable damages.

4.9 Transfer of Services to Third Parties/Sub-contractor Management

Where services are transferred to third parties, the supplier is obligated to transfer the quality assurance stipulations in adequate form to the sub-contractor. This includes providing REHAU with a supplier list, conveying customer-specific requirements (REHAU and end customer), continuous traceability of data and documentation as well as other specification the supplier deems necessary to convey.

If required REHAU may, in agreement with the supplier, view the assessment documentation of sub-contractors and audit sub-contractors after timely announcement (if applicable together with the end customer).

If the supplier intends to change sub-contractors, the supplier must notify REHAU of this in accordance with the Supplier Agreement in order to agree the required assessment and release (PPAP) process.

4.10 Sustainability, Environment and Safety

The supplier ensures compliance with all the relevant statutory regulations relating to industrial safety and environmental protection during the production and handling of the products / service to be supplied. This applies to required materials, machinery, equipment, workplaces, storeroom organization and transport service. Responsible handling of natural resources must also be ensured. Health-promoting measures in the workplace are to be supported.

5. PRODUCT AND PROCESS DEVELOPMENT

5.1 Product Development and Launch Process

In the case of product- and / or process development, the supplier shall employ on its own established methods (as appointing the project management, milestone plans, advanced product quality planning for prototypes / pre-series / series, associated monitoring mechanisms). REHAU is to be kept informed of the development progress made. REHAU reserves the right to check /inspect the development work also on-site at the supplier.

Series delivery may happen only via PPAP approval from REHAU.

The supplier must take measures that ensure the realization of the contractual product desired by REHAU without any deviations in quality, delivery, reliability, or production volume. At the award or the changeover of existing parts a pre-award

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review will be held with the supplier’s cross-functional team prior to the release of the purchase order for materials, products or services related to production. The intent of the meeting will be to ensure the Supplier has a thorough understanding of the requirements and expectations of the job in addition to REHAU understanding the supplier’s capabilities, program risks and limitations. At the launch of any new programs or change to existing parts or processes the Suppliers product and process development practices are expected to follow the elements as defined in the Advanced Product Quality Planning manual or VDA 3 maturity level assurance process . A complete schedule has to be prepared for each project, preferably in a Gantt Chart, considering at least the following points:

Start and final date of individual activities Planning of manufacturing equipment and tools Purchase of external parts\tooling Establishment of the process FMEA First off tool parts Pre-series part production Test planning of pre-series and series parts. Production readiness of tooling and facilities Production parts PPAP of components delivered by subcontractor(s). Review of Production Control Plan by REHAU PPAP submission Production Readiness (capacity study/run at rate)

The supplier is responsible for planning and determining the scope of the tests (characteristics, number of random samples, capability parameters etc.) under consideration of statistical methods for quality assurance. In individual cases (i.e. REHAU risk classification for products), the scope of inspections can be stipulated by REHAU (i.e. in the TDS). The series production accompanying inspections defined with advanced quality planning must be suitable for verifying the conformity of the products with the specifications at any time. Minimum 3 samples for dimensional reports per part number per cavity, but must be agreed by project engineer.

If REHAU does not specify any special characteristics requiring statistical process control and associated capability limit values (i.e. in the drawings, TDS), then the supplier shall be responsible for selection and assessment of special characteristics and for the intended use essential product characteristics and process parameters.

For special characteristics the short-term or long-term capability study needs to be provided. If the capability for a special characteristic cannot be shown with a capability study proof needs to be presented via secondary characteristics or a 100%inspection needs to take place. REHAU expects a level of 1.67 Ppk.

The supplier is responsible for needed and correct marking of special characteristics within the documentation (i.e. drawings, technical documents, FMEA, control plan).

5.2 Continuous Improvement Program

Suppliers are expected to demonstrate a commitment to continuous improvement in products and processes provided to REHAU. Quality system emphasis should be placed on preventing nonconformity rather than detecting nonconformity. Supplier’s continuous improvement program should be part of their yearly defined goals and approved by management. Suppliers should be able to evaluate the effectiveness of their continuous activities via audit results, analysis of data, corrective and preventative actions and management review, for example. PPM agreements between REHAU and its supplier can be used as such instrument to measure improvement activities. Suppliers are also encouraged to develop or maintain the ability to offer cost avoidance/reductions through effectively implementing internal quality improvement programs. A RPN (Risk Priority Number) reduction program is also beneficial in continuously improve the supplier’s processes. REHAU reserves the right to request copies of the Continuous Improvement Programs.

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5.3 PPAP

The formal sampling process serves for technical verification of degrees of readiness and as proof of suitability for bought-in products /provided services. Before the start of serial delivery, initial samples based on the product and process specifications must be submitted to REHAU.

Sampling is based on the specifications of VDA 2 or 3 (AIAG PPAP) process. The documentation has to be presented to REHAU in German or English language.

Details / requirements for sampling (e.g. level, number of sample parts, forms, and data format) will be agreed within the REHAU-TDS.

Every type of change made to components, manufacturing process or manufacturing place which might affect the agreed specification or the product quality is to be communicated with a sampling process. The execution and scope of new sampling is to be agreed with REHAU at an early stage.

REHAU specific PPAP requirements are outlined in the TDS and the Sampling Coordination Meeting Record appendix number 4 which include but are not limited to:

PSW Evidence of part marking (i.e. picture) Part History Tracking Sheet (Appendix 2) Measurement report of 5 samples per cavity Measurement Roadmaps Material test report Process flow Serial control plan Process capability study IMDS MSA Certification, Approvals, Homologation Samples OEM part numbers, REHAU part numbers and current date must be included on all PPAP documents.

If insufficient or incomplete PPAP’s from supplier s results in special efforts at REHAU (i.e. rejection of customer-PPAP caused by incomplete supplier PPAP) these special efforts might be charged to the supplier after being informed and provided an opportunity for corrective actions.

5.4 Layout Inspection and Functional Testing / Requalification

The supplier agrees to perform a “layout-inspection and functional testing” / requalification test (complete measurement of all product dimensions shown on related specifications) at regular intervals, annually unless specified otherwise in the TDS. The result of the “layout-inspection and functional testing” / requalification test will be communicated by the supplier to REHAU upon request.

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5.5 Prelaunch Control Plan / Safe Launch

REHAU requires all suppliers to utilize a containment program for all pre-production, ramp-up, and system fill activities. A containment program will be kept in place until REHAU’s exit criteria is met. This means that the supplier’s process is capable of sustained production meeting all contractual requirements. REHAU will agree upon the pre-launch control plan / safe launch with the supplier. Data collected from the containment process needs to be made available to REHAU personnel as required. The exit criteria for the safe launch plan is shipment of zero defect parts that meet either the defined period of time or number of pieces. Any defect discovered during the SLP (Safe Launch Period) period restarts the containment program.

5.6 Control Plan

The production control plan includes all test and process controls from the incoming goods control of external parts received from sub-contractors up to the delivery to REHAU. The production control plan has to be transferred to REHAU in the Production Part Approval Process. The control plan must include the frequency, method and quantity of checks made to each process. The special characteristics need to be identified as such. Measurement equipment used and specification and tolerance need to be shown.

5.7 SPECIAL CHARACTERISTICS

Product is designated with special characteristics because variation is likely to significantly affect customer satisfaction with fit, form or function. These designations are defined by REHAU or our customer and are listed on the design record. These characteristics shall be identified on all PFMEA’s and control plans that are developed in accordance with AIAG’s PFMEA and APQP manuals. Special characteristics can include product characteristics and process parameters. All special characteristics shall be defined as (SPC) characteristics. All Critical characteristics shall be defined as (CC).

CC = product characteristic or process parameter with reasonably anticipated variation which affects a products safety or compliance with regulatory requirements as judged by the REHAU internal cross function APQP team assigned to the project.

SPC = product characteristic or process parameter with reasonably anticipated variation which affects a product’s fit/form/function or has need for high visibility as judged by the REHAU internal cross function APQP team assigned to the project.

If REHAU does not specify any special characteristics requiring statistical process control and associated capability limit values (i.e. in the drawings, TDS), then the supplier shall be responsible for selection and assessment of special and for the intended use essential product characteristics and process parameters.

5.8 PFMEA

When fully implemented, the FMEA discipline requires a Process FMEA for all new parts/processes, changed part/process, and carryover parts/processes in new applications or environments. It should be initiated before or at the feasibility state, prior to tooling for production, and take into account all manufacturing operations, for individual components to assemblies. It should also be completed after an 8D study (to prevent recurrence of problem), or a Design of Experiments study. Previous FMEAs or “generic” FMEAs may be used as a start point. The team approach with experts from design, manufacturing and process when preparing FMEAs is recommended.

Critical and or special characteristics shall be identified on all PFMEA’s and Control Plans. These characteristics can include product characteristics or process parameters.

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5.9 TESTING REQUIREMENTS

REHAU will identify material test requirements that will to be completed by the supplier to satisfy production part approval. These requirements are found within the TDS and REHAU drawings.

5.10 ERROR PROOFING

During the APQP process the supplier shall implement necessary error proofing into the manufacturing process to eliminate or reduce the manufacture of defective product. These methods should be recorded in the PFMEA and Control Plans. Suppliers shall also use error-proofing methods in their corrective action process.

5.11 IMDS

In the case of products intended for EU member states the supplier shall confirm compliance with Registration, Evaluation, Authorization and Restriction of Chemicals (IE. REACH) associated with material composition. All data on the composition of the supplied products is to be entered into the IMDS (www.mdsystem.com) under REHAU AG + Co, company ID 210. Target for an approved IMDS entry by REHAU is at least 4 weeks prior to the agreed initial sampling date. In case that national directives and stipulations are applicable, additional to EU directives the supplier has to consider these regulations and shall agree a way of necessary data-exchange with REHAU.

5.12 PACKAGING APPROVAL

As part of the development process, packaging for supplied components needs to be approved by REHAU. The supplier should draw up the preliminary proposal at the quoting phase and present it to purchasing so that REHAU can evaluate the supplier’s proposal and their understanding of protecting the quality of supplied components. Open discussion with the supplier regarding part packaging at a very early stage is crucial in order to meet the project overall timing. The supplier must submit the REHAU packaging data sheet (PDS) for approval. See Appendix 3.

5.13 NONCONFORMING PRODUCT

If REHAU raises a complaint about products delivered / services provided, the supplier shall provide REHAU with an initial written response including immediate containment actions within 24 hours of the notification by REHAU.

1. Product Quality Complaints to be returned to the Quality Dept at REHAUa. Within 24 hours

1. Documentation of containment actionsa) Must contain details back to the raw material

2. Coordination of sort/rework/scrap requirementsa) Includes at supplier and REHAU locations

3. RMA Detailsa) Provide RMA Number for any product needing to be returned for analysisb) UPS (United Parcel Service) account information, and address

4. Initial corrective actions statement in the form of an 8Db. Within one week

1. Credit Notec. Within two weeks

1. Final 8D report to REHAU

http://www.mdsystem.com/

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2. Logistic Complaints to be returned to the Logistics Dept at REHAUa. Within 24 hours

1. Documentation of containment actionsa) Must contain details back to the raw material

2. Initial corrective actions statement in the form of an 8Db. Within one week

1. Credit Notec. Within two weeks

1. Final 8D report to REHAU

3. All other communication regarding content of claim should be directed to the “forwarder” listed on page one of theclaim report.

The supplier shall provide REHAU with a written interim report including short-term actions for handling the complaint at the latest after 3 working days in the form of an 8D report. Unless otherwise agreed in particular cases, the supplier provides a supplemental / final 8D report to REHAU latest two weeks following the receipt of the complaint.

In case of deadlines for written responses not being met by the supplier, REHAU reserves the right to undertake immediate actions (IE. sorting or return of complained goods) even without the explicit agreement of the supplier in order to minimize potential subsequent losses (IE. line stoppage / production interruption at the OEM or REHAU). If the actions are not effective or not in place, REHAU has the right to request a third party inspection at the supplier’s expense until the actions are 100% implemented and effective.

The supplier assesses the effectiveness of the corrective measures in order to avoid the possibility of repeat complaints and provides REHAU with a formal final report for 8D processing. Introduced measures resulting from complaints need to be introduced to other production lines / product in use for REHAU if applicable preventive (control circuit). In individual cases REHAU reserves the right to verify the effectiveness of the communicated corrective measures on-site at the supplier.

4. REHAU will include a nominal processing fee on all complaints.

5.14 REHAU QUALITY COOPERATION (RQC)

REHAU Quality Cooperation will be used to promote and ensure a quality-compliant cooperation between REHAU and the supplier. RQC is a three-stage standard escalation process of REHAU for the dealing with serious quality and logistics problems of our suppliers. The RQC process defines binding standards to eliminate weaknesses and faults at its suppliers. Continued positive and negative quality and logistics services of a supplier will be considered with regard to new projects accordingly. Suppliers that meet the zero-fault objective and, respectively, practice an exemplary fault rectification and prevention, will not be placed into the RQC process. Please refer to Document 5470. See Appendix.

6. TOOLING EQUIPMENT AND GAUGES

6.1 REHAU Tooling (Molds, Equipment, Gauges and or other items)

Suppliers contracted to design and manufacture tooling, equipment and gauges that are funded by REHAU are required to provide a detailed drawing of proposed tooling, equipment and gauge designs to REHAU for review prior to commencing work. Final tooling, equipment, and gauge detailed drawings must be supplied to REHAU in an electronic format such as Unigraphics, Catia, IGES, STP. REHAU reserves the right to request and/or review software simulation results for processes (i.e. mold flow analysis, coating/painting analysis).

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6.2 Identification of Customer owned tooling

All tooling that resides at the Supplier’s facility requires an asset tag plaque clearly establishing ownership. The supplier is responsible to protect and safeguard from damage all customer owned tooling, equipment and gauges. If the property is found to be lost, damaged or otherwise found to be unsuitable for use the Supplier shall immediately report this to the REHAU buyer. All tooling and equipment owned by the customer shall be permanently marked so that the ownership of each item is visible and can readily be determined.

The Supplier must have a documented process and schedules for Preventive Maintenance. The maintenance schedule must include all REHAU and REHAU customers owned equipment and tooling. Supplier is responsible for identifying and stocking critical spare parts.

6.3 Tooling/Equipment Design Concept

Suppliers must provide REHAU with basic “concept” designs at the time of quote. Detailed designs must be provided prior to the start of tool or equipment build. In some cases, such as for production tooling, that information may be required in the form of math data or CAD. Designs must take into consideration the expected life of the program, the expected service requirements if applicable and must ensure the quality of product produced or qualified with these tools, fixtures, gauges, equipment or other devices throughout the life cycle.

6.4 Trial Runs

Trial runs are common and required to validate/verify tooling and equipment. REHAU will typically define those requirements as part of the RFQ and /or statement of work. In the event REHAU does not call out this requirement then the supplier must propose the trial run plan and successfully pass the trials prior to PPAP approval by REHAU. Verification of production capacity (run at rate) should also be included.

7. LOGISTICS

7.1 REHAU Logistics Guidelines


7.2 Maintenance and Repair of Containers

For returnable containers and packaging to be effective, they must be regularly inspected and in good working condition. In most cases, the responsibility for inspection and maintenance of returnable containers will belong to the supplier of the product. The Supplier, with REHAU, will define any exceptions during the APQP development period. Suppliers must have a formal plan and resources to inspect and repair returnable containers as needed. If a supplier elects to outsource this activity, they are still responsible for the effectiveness of the activity and any/all quality concerns resulting from poor practices.


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APPENDIX

1. PPM Target Agreements

The supplier is obligated to deliver products according to the below PPM Targets.

Customer PPM Date PPM Date PPM Date

Calculation units (quantities) per delivered lot PPM = ------------------------------------------------------------------------ x 1,000,000

Delivered units (quantities) per delivered lot

Only claims will be taken into account for calculation which are undoubtedly the supplier’s fault

Faulty units/quantities will be counted irrespective of their complexity

Upon completion of the error analysis the quantity claimed will be corrected in case of unjustified claims

Upper limits of error rates refer to part numbers but may be defined by part complexity

Logistics errors affecting the course of production will be also evaluated (labeling, quantity, on time performance)

Information on quality data obtained:

The supplier will regularly receive updates of error rates.

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2. Part History Tracking Sheet

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3. Packaging Data Sheet

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4. PPAP Checklist

AIAG Retention/Submission Requirements Table

Submission Level

Requirement Level 1 Level 2 Level 3 Level 4 Level 5

1 Design Record R S S * R

- for proprietary components/details R R R * R

- for all other components/details R S S * R

2 Engineering Change Documents, if any R S S * R

3 Customer Engineering approval, if required R R S * R

4 Design FMEA R R S * R

5 Process Flow Diagrams R R S * R

6 Process FMEA R R S * R

7 Control Plan R R S * R

8 Measurement System Analysis Studies R R S * R

9 Dimensional Results R S S * R

10 Material, Performance Studies R S S * R

11 Initial Process Studies R R S * R

12 Qualified Laboratory Documentation R S S * R

13 Appearance Approval Report (AAR) S S S * R

if applicable

14 Sample Product R S S * R

15 Master Sample R R R * R

16 Checking Aids R R R * R

17 Records of Compliance R R S * R

With Customer-Specific Requirements

18 Part Submission Warrant (PSW) S S S S R

Bulk Material Checklist S S S S R

S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate locations.

R = The organization shall retain at appropriate locations and make available to the customer upon request.

* = The organization shall retain at appropriate location and submit to the customer upon request.

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VDA Submission Level

1 2 3

1 Cover Sheet Initial sample report (EMPB) X X X

2

Test results (e.g. dimensions, material characteristics, function, appearance, weight, reliability, handling, acousitcs, smell, processibility data etc). V V

3 Samples (number resp. quantity as per agreement) A A A

4

Documents (e.g. customer drawing, CAD data, specifications, approved design modifications, etc) V V

5 Design-, development release X X

6 FMEA E

7 Process diagram (production and test steps) X X

8 Production and test plan E

9 List of test means (specific for the product) X

10 Test equipment capability test, where suitable (result) V

11

Evidence that legal requirements will be observed as far as agreed upon with the supplier (e.g. environment, saftey, recycling) X X

X Requirement for the respective submission level

V In the individual case the volume has to be agreed upon with the supplier

A The number of samples has to be agreed upon with the supplier

E Only for insight

Note Consequences

1

Accepted Trial of mounting, as well as functional, material and dimensional tests are without objection. Documentation is complete.

Series Release

3

Conditionally usable, re-sampling necessary

Samples with slight deviations. The deviations must be remedied as soon as possible. Documentation is complete.

Re-sampling Re-sampling necessary, Possible consequences for supplier assessment

6

Rejected

E.g. : Pieces with major deviations - machining, mounting and functionaltest. Incomplete documentation.

No Series release New sampling required (Consequences for supplier assessment)

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5. REHAU Quality Cooperation (RQC)

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Supplier Manual Acknowledgment Form

The supplier acknowledges that he/she has read and understands the REHAU expectations written in the Supplier Quality Manual. The

supplier’s Management Team will sign off below and forward a copy via e-mail to the REHAU email [email protected]

to keep on file for record retention.

Facility Name Stamp Here ________________________________________________________________________________

Quality Manager Name___________________________________________________________________________________

Signature_____________________________________________________________________________________________

Date ________________________________________________________________________________________________

mailto:[email protected]