supplier quality manual - agm automotive recovery_____18 ppap requirements 19 scoring criteria: ppap...
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Supplier Quality Manual
QF-SQR001 / Rev. Date: 10/14/2017 / Rev. Level: E
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COMMITMENT TO SUPPLIERS 4SUPPPLIER CERTIFICATION REQUIREMENTS 5SUBCONTRACTOR DEVELOPMENT 6CERTIFICATE OF CONFORMANCE 6ENGINEERING AND PROCESS CHANGES______________________ __________7MATERIAL LABELING 8IMDS 8RIGHT OF ACCESS 8SCORING CRITERIA AND PERFORMANCE TRACKING 9 - 10SCORING CRITERIA: QUALITY (PPM) 11SUPPLIER QUALITY INCIDENT TRACKING 12SCORING CRITERIA: QUALITY WRITTEN CONCERNS 12SCORING CRITERIA: ON TIME DELIVERY 13SCORING CRITERIA: SHIPMENT ACCURACY 14SCORING CRITERIA: COMMUNICATION 15CONTAINMENT REQUIREMENTS 16 - 17COST RECOVERY_________________________________________________________________18PPAP REQUIREMENTS 19SCORING CRITERIA: PPAP ON-TIME SUBMISSION 20SUPPLIER PPAP DOCUMENTATION REQUIRMENTS 21SUPPLIER PPAP DOCUMENTATION LINKS 22PPAP SUBMISSION REQUEST 23PROCESS SIGN OFF CHECKLIST 24PROCESS FLOW REQUIREMENTS 25PROCESS FMEA REQUIREMENTS 26 - 28CONTROL PLAN REQUIREMENTS 29 - 30OPERATOR INSTRUCTION EXAMPLE 31CORRECTIVE ACTION REQUIREMENTS 32 - 34BREAK POINT LABEL_________________________________________________________35ENGINEERING CHANGE NOTICE LABEL_________________________________________36ACKNOWLEDGEMENT AND ACCEPTANCE 37
Supplier Quality ManualTable of Contents
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REV Description of Change Author Effective DateA Initial Release M. Rodgers 1/1/10B Modified scorecard requirements J. Brewster 8/1/11C Update Problem Report / Costs J. Brewster 12/8/13D Updated to Include Aerospace Supplier Requirements L. Murden 12/5/2014EF
Revision History
Added IATF Requirementse L. Murden 10/14/2017
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Supplier Quality ManualIntroduction
Commitment to Our Suppliers
OUR SUPPLIER RELATIONSHIPS ARE THE KEY TO OUR SUCCESS; CONTINUED SUCCESS WILL RELY ON EFFECTIVE COMMUNICATION WITH OUR SUPPLIERS TO MEET OR EXCEED OUR CUSTOMER EXPECTATIONS.
IT IS OUR COMMITTMENT TO COMMUNICATE TO OUR SUPPLY BASE OUR CONTINUAL IMPROVEMENT PHILOSOPHY AND THAT THIS INFORMATION WILL BE BENEFICIAL IN DEFINING THE EXPECTATION’S OF AGM AUTOMOTIVE AND OUR VALUED CUSTOMERS.
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Supplier Quality Manual
Supplier Certification Requirements
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Subcontractor Development
With the increasing demands for higher quality at a lower cost, the entire supply chain is responsible for increasing quality and contribution to a lower overall cost. It is AGM’s expectation that all AGM production suppliers work closely with their supply base to insure that the quality level of received product meets AGM and its customers requirements and expectations. The primary area of focus is in the communication and documentation of customer requirements, which is achieved through APQP (Advanced Product Quality Planning). Through the APQP process, the subcontractor is informed of customer requirements and expectations and develops the process foundation.
Certification of Conformance
When required by AGM, each shipment shall include a Certification of Conformance.The Certificate of Conformance must contain a statement that all inspections, processing,and tests have been performed as required by the drawing requirements and/or PurchaseOrder. Products controlled by heat numbers, certification numbers, batch numbers, orcure dates must be linked to the Certificate of Conformance by the controlling number,and show physical and chemical values when applicable.
Supplier Quality Manual
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Engineering & Process Changes
AGM’s continuous improvement philosophy encourages process improvements both internally and at supplier facilities. However, prior to any engineering and or process changes being implemented, the effects of the change are required to be assessed, verified and validated to ensure compliance to AGM requirements and AGM’s customer requirements. PPAP approval is required for any process changes including change of the manufacturing location. The supplier is also responsible to complete Early Launch Containement, per page 17 of this manual.
When an Engineering Change Notice (ECN) is issued by AGM the supplier is required to provide AGM with breakpoint and obsolescence information. The supplier is required to identify the next 2 shipments, unless otherwise specified by AGM, with the ECN Breakpoint Label, see page 37. The label (6” x 6” minimum) is required on all boxes. If product is not properly identified with the breakpoint label and the correct information the supplier will be issued another QI and their scorecard will be negatively impacted.
Supplier Quality Manual
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Material Labeling All product shipping into any AGM facility must be bar code labeled. All labels must follow the AIAG format and contain the follow information at a minimum, whne specified by AGM. Additional requirements may be required based on AGM customer requirements.
Part Number Quantity Part Description Date of Manufacture Part Revision Level Lot Number
IMDS Requirements- Automotive ProductIn 2000, the European Union established the End of Life Vehicle (EVL) Directive, which states that “All OEMs & Suppliers must account for prohibited, restricted and reportable substances for all components. International Material Data Sheets (IMDS) provide substance breakdowns necessary to safely recycle vehicle at the end of their useful life.
AGM Automotive requires IMDS to be submitted to AGM’s site code 34118 through the MDSystem, which can be accessed at http://www.mdsystem.com and observe the requirement of the IMDS Recommendation 001.
Suppliers must include IMDS data with their PPAP submissions. If the data is not received with the PPAP submission, AGM Automotive reserves the right to refuse PPAP sign-off. Additionally, AGM may issue a QI and the supplier score card may be negatively affected by late or non-submittal of IMDS.
Right of Access
Supplier shall provide AGM, its customer(s), and/or a specified third party(statutory/regulatory agency) right of access to the facility and all records related toproduct ordered by AGM or its customers. AGM, its customer(s) representative(s), and/or a specified third party reserves the right to perform an audit or inspection at thesupplier’s facility to verify that supplied product conforms to specified requirements. This verification does not absolve the supplier of the responsibility to provide acceptableproduct and does not preclude subsequent rejection by AGM or its customer.
Supplier Quality Manual
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Supplier Quality Manual Scoring Criteria and Performance Tracking
Suppliers performance is tracked by five categoriestotaling 100 points on a rolling 12 month calendar accordingto the following categories:
PPM = 30 points. Written Concern Quantity = 10 points. On-Time Delivery Percentage = 30 points. PPAP On-Time Submission = 15 points. Communication = 15 points.
At the end of each month supplier scorecards will be sentout and the scores are determined according to the belowranking chart. Any category score or overall score in thered or NBH the supplier is required to submit correctiveaction.
RankingOn‐Time Delivery
PPM Communications PPAPWritten Concerns
Total
Gold 30 30 14‐15 14‐15 10 98‐100Green 27‐29 27‐29 12‐13 12‐13 8‐9 86‐97Yellow 21‐26 21‐26 9‐11 9‐11 6‐7 66‐85Red 11‐20 11‐20 5‐8 5‐8 4‐5 36‐65NBH 10 or less 10 or less 4 or less 4 or less 3 or less 35 or less
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Supplier Quality Manual Scoring Criteria and Performance Tracking
At the end of the calendar year below are the requiredactions based on the yearly performance results:
Gold – No actions required.
Green – No actions required.
Yellow Corrective action recommended for anycategory in yellow. Improvement Plan Recommended.
Red Corrective action required for any one category in red. Improvement plan required if total score is inred. AGM supplier audit may be required (AGM travelcost will be supplier responsibility).
NBH (New Business Hold) Improvement plan required to be removed fromnew business hold. AGM supplier audit is required (AGM travel costwill be supplier responsibility) to be removed from
QF-SQR001 / Rev. Date: 12-5-14 / Rev. Level: D
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Supplier Quality Manual Quality - PPM
Quality -PPM The PPM category accounts for 30 points of the overall scorecard rating. Supplier PPM (parts per million) is calculated on the basis of the amount of non-conforming materials versus the total amount processed through production in the fiscal month, which includes any AGM customer field returns. This calculation is then normalized to reflect a constant basis of one million units received.
Non-conforming material identified as the responsibility of the supplier will be noted as PPM, except;
If a supplier shows diligence and immediately notifies AGM of a potential problem When there is mutual agreement between AGM quality and the supplier that the part
rejection was unjustified.
The AGM plant affected by the non-conforming parts will decide whether of not the supplier should sort product on location at AGM facility. A supplier must report all non-conforming product found in sorting. AGM quality will decide whether all non-conforming products will be classified as PPM, or only those parts which were found by AGM.
A supplier must give AGM Quality team an RMA (Return Material Authorization) within 24 hours of the time the PPM was reported. AGM reserves the right to claim compensation from a supplier for any sort activities ($50 per hour USD) or downtime resulting from supplier PPM
PPM calculation and EXAMPLE: A supplier ships 100,000 parts to a plant, 10 of which are non-conforming. The scorecard’s calculation will be (10/100,000) x 1,000,000 = 100 PPM’s.
(REFER TO THE TABLE BELOW FOR THE RATING RANGE.)
PPM SCORE PPM SCORE0-25 30 326-350 17
26-50 29 351-375 1651-75 28 376-400 1576-100 27 401-425 14
101-125 26 426-450 13126-150 25 451-475 12151-175 24 476-500 11176-200 23 501-525 10201-225 22 526-550 9226-250 21 551-575 8251-275 20 576-600 7276-300 19 601-625 6301-325 18 626 or Higher 5
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Supplier Quality Manual Quality – Written Concerns
Supplier Quality Incident Tracking
AGM issues a Problem Report (PR) for reporting and resolving supplier quality, delivery, customer satisfaction and warranty issues. Suppliers must formally respond to a Quality incident with a systemic countermeasure process (See page 30 for the required formats).
PR(s) created for supplier issues are considered written complaints and are part ofthe supplier’s scorecard.
Suppliers must give an initial responce within 24 hours with containment actions,48 hours for oversees suppliers.
Permanent corrective action implementation and verification of effectiveness isrequired within 30 days. AGM approval is required in the event that permanentactions cannot be achieved in 30 days.
Quality –Written Concerns (PR) The written concern category accounts for 10 points of the overall scorecard rating. The written concern catagory is calculated on the basis of the quantity of Probelm Reports issued through production in the fiscal month. See the table below for the scoring breakdown.
QI Quantity SCORE 0 10
1-2 93-4 85-6 77-8 69 5
12 411 312 213 1
14 or more 0
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Supplier Quality Manual Delivery Performance
Delivery The delivery score accounts for 30 points of the overall scorecard. Delivery ratings are calculated on the basis of the amount of shipments that have errors versus the total amount of shipments in a given fiscal month. This information is then calculated into a percentage.
Delivery ratings are based on the number of occurrences when it is determined to be the supplier’s responsibility:
EXAMPLE: During one month, a supplier sends 36 shipments. Out of the total 36, 1 shipment is late and 1 shipment is short of the quantity ordered.
The delivery percentage calculation will be (36-2)/36 x 100= 94.4%
DELIVERY OCCURRENCE Shipments Count % Points
Late Deliveries- 1 Early Deliveries- Premium Freight- Damaged Parts- Over Shipment- Short Shipment- 1 Incorrect Quantity- Reference Wrong Purchase Order - Missing Paperwork - Incorrect Freight Carrier - Referencing Incorrect Part Number-
Other: ___________________________________________________________________ Delivery Total: 36 2 94.4 28
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Supplier Quality Manual Delivery Performance (continued)
The potential for more than one occurrence, per shipment does exist.
The system automatically calculates the delivery percentage and associated points based on the following formula:
(TOTAL SHIPMENTS - NUMBER OF OCCURENCES)/TOTAL SHIPMENTS) X 100
Delivery Rating Range Chart
DELIVERY OCCURRENCE PERCENTAGE SCORE 100 3099.0 29
98.6 - 98.9 28 98.3 – 98.5 27 98.0 – 98.2 26 97.6 – 97.9 25 97.3 - 97.5 24 97.0 – 97.2 23 96.7 – 96.9 22 96.4 – 96.6 21 96.1 – 96.3 20 95.8 – 96.0 19 95.5 – 95.7 18 95.2 – 95.4 17 94.9 – 95.1 16 94.6 – 94.8 15 94.3 – 94.5 14 94.0 – 94.2 13 93.7 – 93.9 12 93.4 – 93.6 1193.1 – 93.3 10 92.0 - 93.0 9 90.0 – 91.9 8 89.0 – 89.9 7 88.0 – 88.9 6 86.0 – 87.9 5 84.0 – 85.9 4 82.0 – 83.9 3 80.0 – 81.9 2 75.0 - 79.9 1
Less than 75.0 0
THE GOAL FOR DELIVERY FOR EACH MONTH IS 100%
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Supplier Quality Manual Communication
Communication Communication Accuracy category accounts for 15 points of the overall scorecard and is based on the following criteria:
Occurrence Description No Release Acknowledgement Returned Signed Purchase Order Not Returned Lack of Response (E-Mail/Phone calls)/ Late Quality Incidents (QI) Other: _________________________
Total Score for Communication 10
Communication Occurence SCORE 0 151 142 133 124 115 106 97 88 79 6
10 or more 5
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Supplier Quality Manual Containment Requirements
Containment Requirements All suppliers are required to have a documented containment process, which must include methods of identifying corrective action and containing suspect material in order to prevent non-conforming material from entering back into production or being received by an AGM facility.
If a supplier’s containment process fails and non-conforming parts are delivered to an AGM facility, we may require containment depending on the severity of the rejection. Containment is 100% inspection of all parts at the suppliers facility and is required in addition to any current quality checks. A sort of ALL material for the specified defect must be performed at the supplier’s facility under the following guidelines:
The product acceptance standards and measurement/testing processes must beagreed upon by AGM Quality.
Data must be collected for all non-conformances and corrective actions. Ifrequired by AGM the results must be reported.
Problem solving must be formal, data driven, and documented. AGM prefersit’s suppliers to use the 5 Phase, 8-D or 3 X 5 Why problem solving method.
The supplier is required to provide AGM with breakpoint information and identify the next 2 shipments, unless otherwise specified by AGM Quality, with the Breakpoint Label(6” x 6” minimum) on page 36. The label is required on all boxes.
In addition to setting up containment at its own facility, a supplier must also manage containment activities of parts at all AGM Automotive facilities and all material that is intransit to AGM Automotive. AGM Quality department will notify the supplier by e-mail using the Problem Report. In the Problem Report AGM Automotive will requestcorrective action. Corrective action updates will be required through out the containmentprocess.
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Supplier Quality Manual Containment Requirements (continued)
Containment - Continued If the supplier’s containment is ineffective and AGM Automotive receives defected material after the breakpoint, or during the breakpoint requirement (including labeling) are not met, a third party containment may be required. If this occurs the supplier will be issued another Problem Report and their scorecard will be negatively impacted. The presence of the third party sorting company does not relieve the supplier of Containment Activities.
Early Launch Containment New launches and product or process changes may require containment based on the supplier readiness and the risk of the product. Requirement for Early Launch Containment (ELC) will be communicated on the P.O. or by AGM Quality. To be released from Early Launch Containment the following criteria must be met. You must maintain containment through the pre established ELC date, 30 days or 3 lots of material with zero defects.
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Supplier Quality ManualCost Recovery
Cost Recovery Policy Suppliers to AGM Automotive are liable for all costs incurred by AGM Automotive during containment activities when the cause is the supplier responsibility. The “Cost Recovery Report” will be submitted monthly to each supplier. The guide lines are outlined as such:
External Cost Recovery: Charges incurred at an AGM Customer by an outside sorting company and found to be the responsibility of the supplier will be charged back. This cost is at the rate billed by the outside sorting company. In this case a copy of the invoice will be available upon request.
Internal Cost Recovery: When a sorting activity is performed at an AGM Plant by AGM personnel a minimum charge of 50.00 per hour per person on the sort will apply. The supplier will be charged for all rejected parts associated with the sort. Copies of the sorting activities will be made available upon request.
Administrative Cost Recovery: Each Problem Report has an administrative charge of $250.00 USD covering the collection of data and documentation and management of containment activities.
Non Responsive Cost Recovery: A Cost Recovery Charge may be assessed if failure to submit an approved Corrective Action by the due date listed on the PR and a new PR will be issued. The amount of this charge may vary based on severity of the quality concern, the number of late Corrective Actions and the number of days late. To avoid Non Responsive Cost Recovery plan to submit corrective Actions on time. You can also avoid this charge if you contact AGM Quality requesting additional time for your Corrective Action. Non Responsiveness negatively impacts your Supplier Score Card in the communication section.
EXAMPLES OF COSTS THAT CAN BE CHARGED BACK TO THE SUPPLIER:- Rework / Repair (Supplier Fault)- Premium Freight Costs including Air Charter, if required- Overtime to Avoid Production Interruption- Disposition of Scrap (Supplier Fault)- Production Downtime for AGM and End Customer- Sorting of Suspect Material In-House, at Customer Location or Third Party Warehouse- On-Line Containment- Outside Lab Testing- Customer Returns including hourly charges,- Receiving Inspection, Material Handling and Freight transportation-on-site inspections associated with Scrap and Replacement Material- Delays in Customer PPAP or other approvals-Late submission of IMDS
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Supplier Quality Manual
Supplier PPAP Documentation Requirements
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Supplier Quality Manual PPAP Performance
PPAP On-Time Submission and Acceptability PPAP approval is required for new product. AGM identifies the supplier PPAP documentation requirements on the PPAP Request Form.
Occurrence Description Late Submission Unacceptable Paperwork Missing Paperwork Other: _________________________
PPAP Occurence SCORE 0 151 142 133 124 115 106 97 88 79 6
10 or more 5
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Supplier Quality Manual PPAP Requirements
All production suppliers are required to obtain full PPAPapproval from AGM Automotive per the current revision ofthe requirements of the AIAG Production Part ApprovalProcess (PPAP) Manual and any additional requirements of the AGM Automotive Supplier Requirements Manual.
PPAP approval is required for new product. AGM identifies the supplier PPAP documentationrequirements on the PPAP Request Form.
PPAP approval is required for any changes to theproduct and/or process, including change in location or supplier.
All submissions are to be at Level 3 unless otherwisespecified in writing from AGM.
AGM may request an updated PPAP if the PPAP onfile is over one year old.
Annual validation testing is required to verifycontinuing conformance on all parts and components,
QF-SQR001 / unless otherwise
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Supplier Quality ManualDocumentation Links
Process Flow
Design FMEA
Process FMEA
Control Plan
Operator Instructio
ns
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Supplier Quality ManualPPAP Submission Request
Any items with check mark are required with submission
If submission is after the due date the supplier will be issued a Quality Incident
SUBMISSION DUE DATE:PRINT REV. LEVEL:
(If Applicable)PPAP LEVEL REQUESTED:
SAMPLE SIZE:APPLICATION:
QUALITY CONTACT: TEL #: (248) 776-0600FAX #: (248) 776-0601
SUPPLIER MANUFACTURING INFORMATION PPAP Submit to Information:
Supplier:Address:
Tel #:Fax #: E-Mail:Quality Contact:
COMMENTS/SPECIAL INSTRUCTIONS:
PPAP Submission Requirements1 Design Records/Print 12 Initial Process Study
2 Engineering Change Documentation (if any) 13 Qualified Laboratory Documentation
3 Customer Engineering Approval (if any) 14 Appearance Approval Report
4 Design FMEA 15 Sample Parts
5 Process Flow Diagrams 16 Master sample
6 Process FMEA 17 Checking Aids
7 Control Plan 18 PSW (Part Submission Warrant)
8 Operator Instructions 19 Capability (CPK) Study
9 Measurement System Analysis Study 20 Run @ Rate
10 Dimensional Results 21 Process Sign Off Checklist
11 Material Certifications, Performance Testing 22 Other:
QF-063SUPPLIER PPAP SUBMISSION REQUEST
Rev. Date: 8-10-10Rev. Level: A
Submit PPAP to:
PART #:
NEW PART #:
PART NAME/DESCRIPTION:
1000 E. Whitcomb AvenueMadison Heights, MI 48071
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Supplier Quality ManualProcess Sign Off Checklist
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Supplier Quality ManualProcess Flow Requirements
QF-010
Product Program Issue Date ECL ECLSupplier Name SUPPLIER Part Name NAMESupplier Location CITY STATE Part Number NUMBER
Legend:
Operation Transportation Inspection Delay Storage
Operation or Event Description of EvaluationOperation or Event and Analysis Methods
Develop and flow the sequential work activities or steps
Describe the sequential work activities
Determine the methods foreach activity
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Supplier Quality ManualProcess FMEA Requirements
Process Step -Function and Number must be same asthe process flow
List the requirements for each process function
Manner in which the process could fail
The effects of a failuremode as perceived by the customer
See AIAG severity evaluation criteria
Special product or process characteristics
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # Rev. (PROCESS FMEA) FMEA Number:
Item: Process ResponsibilityAutom Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Core Team: Date (Rev.)
C Potential O Current Current DProcess Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action ResultsStep Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P.s r c Date v c t N.
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Supplier Quality ManualProcess FMEA Requirements (cont.)
Indication of how the failure could occur
See AIAG occurrence evaluation criteria
Description ofcontrols to eliminate the cause of the failure
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # Rev. (PROCESS FMEA) FMEA Number:
Item: Process ResponsibilityAutom Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Core Team: Date (Rev.)
C Potential O Current Current DProcess Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action ResultsStep Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P.s r c Date v c t N.
Description of controls to identify the cause of the failure
See AIAG detection evaluation criteria
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RPN= severity x occurrence x detection
Completed actions
Preventive / Corrective actions to reduce rankings of severity, occurrence and detection
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # Rev. (PROCESS FMEA) FMEA Number:
Item: Process ResponsibilityAutom Prepared by:
Model Year(s)/Vehicle(s) Key Date Date (Orig.)
Core Team: Date (Rev.)
C Potential O Current Current DProcess Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action ResultsStep Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P.s r c Date v c t N.
Name and organization responsible and target completion date
After completed actions determine and record the resulting severity, occurrence and detection rankings
Supplier Quality ManualProcess FMEA Requirements (cont.)
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Supplier Quality ManualControl Plan Requirements
CONTROL PLANControl Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)NUMBER ECLPart Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)NAMESupplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)SUPPLIER CODE
MACHINE,PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTIONNUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
CHARACTERISTICS METHODS
Prototype Pre-Launch Production
Number must be same asthe process flow and PFMEA
Machine model & tool numbers required
Number must be same asthe process flow
Must match print, FMEA and process flow
Any feature of the part, component or assembly on drawing Any variables
that have a cause and effect of a productcharacteristic
Any characteristic designated as critical, key, safety or significant.
30
CONTROL PLANControl Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)NUMBER ECLPart Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)NAMESupplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)SUPPLIER CODE
MACHINE,PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTIONNUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD
CHARACTERISTICS METHODS
Prototype Pre-Launch Production
Quantity to be inspected
Document the gage, fixture, tool or test equipment include the gage number
Describe how the operation is controlled include procedure number
Specify the actions necessary to avoid operating out of control
Tolerances from various engineering documents Freque
ncy tobe inspected
Supplier Quality Manual Control Plan Requirements (cont.)
31
Supplier Quality Manual First Article Inspection Documents (Aerospace)
Along with the PPAP submission products for Aerospace must have the completed First Article Inspection forms per the latest version of AS9102.
32
Supplier Quality ManualFirst Article Inspection Documents (Aerospace continued)
Along with the PPAP submission products for Aerospace must have the completed First Article Inspection forms per the latest version of AS9102.
33
Supplier Quality ManualOperator Instruction Example
Date
Procedure:1 2 3 4
5 6 7 9
Description:
Operation:
Rev. Level Quality EngineeringApprovals:
Production
Part No:
Customer:Customer Part #:
Revision:
Picture of Process Step, Tool, Fixture, Machine, etc.
Title of Work Instruction
Describe the Process Step
34
Supplier Corrective Action
Requirements
Supplier Quality Manual
35
Supplier Quality Manual8 – D Example
Program Name:Dave Opened:Date Revised:
Date Closed:CCIR #
QF-058
D8. Congratulate the Team
Rev. Date: 1-11-08
D3. Implement and Verify Interim Containment Actions (Containment)
D4. Find and Verify Root Cause
D1. Form the Team (List team members name and titles)
D2. Describe the Problem (object, concern, qualification)
D5. Corrective Actions
D6. Verify Corrective Action
D7. Actions to Prevent Recurrence of the Problems
8-D AnalysisAGM AUTOMOTIVE, INC.
1000 E. Whitcomb AvenueMadison Heights, MI 48071
8-D Report
Phone: 248-776-0600 Fax: 248-776-0601
Problem Status
Customer:Contact:
Part Number:Part Name:
RMA #:
36
Supplier Quality Manual3 x 5 Why Example
Date:
Issue title:
Problem on part:
5 Why Corrective Action Owner Due Date
P1
P2
P3
P4
P5
P-RC
M1
M2
M3
M4
M5
M-RC
Q1
Q2
Q3
Q4
Q5
Q-RC
C1
C2
C3
C4
C5
C-RC
Why did the manufacturing process not prevent the defect?
Why did the quality process not protect GM from the defect?
Based on the above 5 why analysis, what are the common
system deficiencies?
3 x 5 Why
Why did the planning process not predict the defect?
PredictPlanning process -
informational content in FMEAs and CPs
PredictPlanning process -
informational content in FMEAs and CPs
ProtectQuality process -containment & Responsiveness
ProtectQuality process -containment & Responsiveness
PreventManufacturing process -standardized work and
error proofing
PreventManufacturing process -standardized work and
error proofing
37
Supplier Quality ManualBreakpoint Label
QF-012
QINUMBER
ECNNUMBER
SUBMITTED BY
ATTENTION TO
BREAK POINT NOTICE (REQUIRED ON EVERY BOX)
DETAIL OF CHANGEQUANTITY
SUBMITTED BY QUANTITY REASON FOR CONTAINMENT
ATTENTION TO
BREAK POINT DATE
ENGINEERING CHANGE NOTICEPART
NUMBER
PARTNUMBER
Rev. Level: B Rev: Date: 8-01-11
DRAWING LEVEL
SUPPLIER
USE FOR QUALITY INCIDENTS (Blue Paper)
1)PART NUMBER (number for which the Breakpoint is written)
2)QI NUMBER (quality incident number)3)SUBMITTED BY (person who fills out break point
label)4)ATTENTION TO (whom the break point is directed
to)5)BREAKPOINT DATE (date material is certified) 6)QUANTITY ( b f i b )
1 2345
6 7
8
QF-SQR001 / Rev. Date: 12-5-14 / Rev. Level: D
38
Supplier Quality Manual Engineering Change Notice Label
QF-012
QINUMBER
ECNNUMBER
SUBMITTED BY
ATTENTION TO
BREAK POINT NOTICE (REQUIRED ON EVERY BOX)
DETAIL OF CHANGEQUANTITY
SUBMITTED BY QUANTITY REASON FOR CONTAINMENT
ATTENTION TO
BREAK POINT DATE
ENGINEERING CHANGE NOTICEPART
NUMBER
PARTNUMBER
Rev. Level: B Rev: Date: 8-01-11
DRAWING LEVEL
SUPPLIER
USE FOR ENGINEERING CHANGE NOTICE (Orange Paper)
1)PART NUMBER (number for which the Breakpoint is written)
2)ECN NUMBER (quality incident number)3)SUBMITTED BY (person who fills out break point
label)4)ATTENTION TO (whom the break point is directed to)5)QUANTITY (number of parts in box) 6)DETAIL OF CHANGE (what changed on the part)
1 23
45 6
78
QF-SQR001 / Rev. Date: 12-5-14 / Rev. Level: D
39
Supplier Quality Manual Acknowledgement & Acceptance
ACKNOWLEDGEMENT OF ACCEPTANCE OF REQUIREMENTS
Operations:
________________________ ________________ Signature Date
Quality:
________________________ ________________ Signature Date
Purchasing:
________________________ ________________ Signature Date
Please review the entire Supplier Manual and AGM Website with your team and sign, date and return the “ACKNOWLEDGEMENT OF ACCEPTANCE OF REQUIREMENTS” page only to AGM-NA Director of Quality.
By signing and dating this document you as a “Supplier” to AGM are acknowledging and accepting all the requirements with in the Supplier Manual and “Terms and Conditions”.
The “ACKNOWLEDGEMENT OF ACCEPTANCE OF REQUIREMENTS” must be signed and returned back to AGM with in 7 days on receipt.