supplier quality manual quality requirements scg · pdf filesupplier quality manual quality...
TRANSCRIPT
TRANSPORT
10/10/2010
Supplier Quality Manual
Quality requirements
SCG-STD-006-01
P 2
External parts from suppliers highly contribute to high quality products, solutions and
services we have to offer our customers.To achieve this high quality level , we are
determined to establish and develop close and long term relationships with our
suppliers .
Involvement of our suppliers is managed through this manual, describing AT
standardized global approach , setting out the minimum required basics tools &
requirements.
This AT worldwide policy is mandatory to achieve our targets, satisfy our customers
and to establish with our panel of suppliers common sustainable growth.
Jean-Michel Geffriaud Valérie Gallego
Senior Vice-President Sourcing & Components Sourcing Quality Vice-President
INTRODUCTION
P 3
Our Requirements / Our common basics
Our requirements:
¤ Quality targets achieved
¤ On Time deliverables during development & execution phases
¤ Partnership behaviour
Our common Basics:
¤ No Safety and Regulation concerns
¤ No issue impacting Alstom Transport premises & fields.
¤ No product/process change without AT agreements
¤ No delay in Project Quality deliverables
¤ Key product/process characteristics under control
¤ Cost Of Non Quality (CONQ) reduced year after year
¤ Customer Secure, reactivity when issues & root cause eradication
¤ Proactive quality mindset & improvement plan
P 4
Our Way or Working
Our Supplier Quality approach is aligned on our Sourcing processes, along the three
main steps of the relationship with the supplier :
¤ Panel entrance and management : Only qualified suppliers may deliver to AT
¤ Prevention in Product & Process before deliveries : to support Quality Built-up
¤ Performance management in execution : To meet defined Quality targets
This Supplier Quality Manual describes :
¤ AT requirements towards suppliers for each of these steps,
¤ Expected way of working and way of managing the activities,
¤ Associated Quality tools to be implemented,
¤ Key Performance Indicators (KPIs) that will allow to assess
achievement of targets.
P 5
Sourcing Quality Management Process & Quality Basics
PERFORM SUPPLIER
SELECTION
MANAGE SUPPLIER
INTEGRATION
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
PANEL ENTRANCE
PREVENTION - SPQD
PERFORMANCE in EXECUTION
SOURCING
QUALITY
BASICS
GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE
PANEL ENTRANCE : Process leading a supplier to be introduced in the AT panel, according to a list
of pre-requisites (system certifications, Co-development & industrial assessments, sustainable development criteria)
PREVENTION - SPQD (Supplier Product Quality Development) MANAGEMENT: Process held during the Product &
Process development phases, in order to guarantee the compliance of the Product to the Quality/Cost/Delivery
targets in a sustainable way
PERFORMANCE MANAGEMENT IN EXECUTION: Continuous process of assessment of the Supplier
according to the Quality performance of the deliveries.
GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE: Continuous process of assessment of the Supplier
according to the performance in all the sectors of the relationship (Execution & Product/Process development)
This performance is synthesised by a colour code.
P 6
Sourcing Quality Management Process
PANEL ENTRANCE
PROCESS
PERFORM SUPPLIER
SELECTION
INDUSTRIAL CAPABILITY
QUALIFICATION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
P 7
PANEL ENTRANCE PROCESS
PANEL ENTRANCE PROCESS:
A supplier will be integrated into the vendor list with a “Panel “ status when complying with AT business
criteria, as financial strength, industrial footprint, technical expertise, and has successfully passed the
following items:
¤ Quality Management System ( 3 rd party certification or AT classification )
¤ AT Sustainable development charter sign-off
¤ Process qualification on technical know-how (including special processes)
¤ Sustainable development qualification
¤ Co-development qualification (if the supplier is requested to develop the design of the part)
¤ Capacity check ( if necessary )
AT Sourcing Quality is in charge of performing these assessments and to pronounce the GO/NOGO status
according to their results..
In case of NOGO, only a waiver signed-off by the Product Line Sourcing Quality Development Director can
authorize a temporary panel entrance.
P 8
PERFORM SUPPLIER
SELECTION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
SYSTEM CERTIFICATION
PURPOSE:
To guarantee that the supplier has put in place a consistent Quality
Management System able to satisfy AT requirements in the scope of
the supply
CONTENT
The supplier shall be ISO 9001 certified.
For Rolling Stock and Components, for the safety or critical parts and
sub-systems, the supplier must be IRIS certified.
Certified or at least shall commit to get the IRIS certification within the
following year.
In case of the supplier not ISO 9001 or IRIS certified, AT keep right to
perform
a classification audit according to its own standard.
INDUSTRIAL CAPABILITY
QUALIFICATION
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
PANEL ENTRANCE PROCESS
P 9
SUSTAINABLE
DEVELOPMENT CHARTER
PURPOSE:
The Sustainable Development is a core value within Alstom.
It is a strong component of Alstom strategy and means responding strongly
and actively to Alstom stakeholders societal needs and anticipating new
environmental, social and economic developments.
As key actors in the development and production processes, suppliers has to
Commit to the same values, and cascade to their own suppliers.
CONTENT
The supplier is requested to sign-off the charter and commit to AT requirements
in terms of:
¤ Labour standards
¤ Ethics
¤ Environment
¤ Occupational Health and Safety
¤ Product and services life cycle
PERFORM SUPPLIER
SELECTION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
INDUSTRIAL CAPABILITY
QUALIFICATION
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
PANEL ENTRANCE PROCESS
P 10
PURPOSE:
The Process Audit is performed to assess the capability of the supplier to
manufacture and supply parts according to the AT standards and control its
special processes.
CONTENT
This audit is divided in two main sections, one is generic whatever the processes,
the other is related to the control of the special processes (a specific questionnaire
per type of process )
TARGET
To be qualified, the supplier shall get:
¤ Overall score above 80%
¤ No Critical “Corrective Action Request”
INDUSTRIAL CAPABILITY
QUALIFICATIONPERFORM SUPPLIER
SELECTION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
Generic
1. Process Management, control of I/0 data
2. Purchasing , Procurement
3. Production, Workstations
4. Finished products checks and tests
5. Preparation, storage, handling & shipment of product
6. Non conformities management
7. Personneel, training, skills management
Casting Cabling Electronic Board
Forging Riveting Heat treatment
Extrusion Brazing Rubber-Metal
Machining Stratification Glazing
Welding Gluing
Painting Winding
Special Processes
INDUSTRIAL CAPABILITY
QUALIFICATION
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
PANEL ENTRANCE PROCESS
P 11
PURPOSE:
The Co-Development Audit is performed to assess the capability of the supplier to
¤ perform a product & process development according to the AT standards.
¤ bring innovation through a controlled process.
CONTENT
This audit is divided in three main sections:
¤ Project Management
¤ Product / Process Development
¤ Innovation Management
TARGET
To be qualified, the supplier shall get:
¤ Overall score above 80%
¤ No Critical “Corrective Action Request”
PERFORM SUPPLIER
SELECTION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
CO-DEVELOPMENT
QUALIFICATION
INDUSTRIAL CAPABILITY
QUALIFICATION
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
PANEL ENTRANCE PROCESS
P 12
PURPOSE:
The “Quick Supply Chain Assessment” is performed to evaluate the ability of the
supplier to control its supply chain and production planning.
CONTENT
This audit is focused on the management of all the items related to the supply
Chain activity
¤ Long & Medium term planning
¤ MRP
¤ Scheduling of the production
¤ Change management
¤ Inventories
In case of high risk detected, this audit shall be followed by a full Supply Chain audit.
TARGET
To be qualified, the supplier shall get:
¤ Overall score above 80%
¤ No Critical “Corrective Action Request”
PERFORM SUPPLIER
SELECTION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
CAPACITY CHECK
INDUSTRIAL CAPABILITY
QUALIFICATION
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
PANEL ENTRANCE PROCESS
P 13
PURPOSE:
The sustainable development audit is performed to assess the compliance of the
supplier to Alstom requirements as defined in the Sustainable Development Charter.
CONTENT
This audit is focused on the following items:
¤ Management involvement
¤ Labour standards
¤ Ethics
¤ Environment
¤ Occupational Health and Safety
¤ Product and services life cycle
TARGET
To be qualified, the supplier shall get:
¤ Overall score above 80%
¤ No Critical “Corrective Action Request”
PERFORM SUPPLIER
SELECTION
SYSTEM CERTIFICATION
SUSTAINABLE
DEVELOPMENT CHARTER
SUSTAINABLE DEVELOPT
QUALIFICATION
INDUSTRIAL CAPABILITY
QUALIFICATION
CO-DEVELOPMENT
QUALIFICATON
CAPACITY CHECK
SUSTAINABLE DEVELOPT
QUALIFICATION
PANEL ENTRANCE PROCESS
P 14
Sourcing Quality Management Process
PREVENTION DURING
PRODUCT DEVELOPMENT (BEFORE FIRST DELIVERIES)
SPQD PROCESS
MANAGE SUPPLIER
INTEGRATION
PREVENTION - SPQD
P 15
SPQD PROCESS :
The target of the SPQD process is to achieve product and process maturity at FAI (or FAT) stage.
The supplier is requested, during the development phases of a new product, to align its development
schedule on the requirements of AT regarding the Quality deliverables.
The backbone of the Quality in development will be the SPQD PLAN, that will be defined jointly at the
beginning of the development, and will include all the steps for the risk prevention and the Quality
Assurance build-up.The schedule will be compliant with the overall Project master schedule.
The AT Supplier Part Quality Development representative will be in charge of tracking and monitoring the
supplier Quality performance plan on a regular basis, and ensuring the achievement of the targets, both
qualitatively and on time, from the business award to the FAI (or FAT).
A focus will be done on the Product & Process risk, and on the consistency & efficiency of the control plan.
The performance of the supplier in the development phase (ability to achieve the targets) will be an input
in the overall supplier ranking (see SUPPLIER PERFORMANCE DASHBOARD chapter).
The Rolling Stock & Components Way of Working and requirements are detailed in the Appendix 1.
SPQD PROCESS
P 16
Sourcing Quality Management Process
SUPPLIER PERFORMANCE
MANAGEMENT DURING
EXECUTION
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 17
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
PERFORMANCE MANAGEMENT DURING EXECUTION :
During the execution phase, the performance of the supplier by commodity is consolidated and monitored
by the Supplier Quality representatives.
This performance is measured through the following indicators:
¤ Non Conformities results at AT premises (e.g.:NCR rate = Non Conformity Report rate, corresponding to
the number of Non Conformities over the number of deliveries) , and the reactivity to solve the issues.
¤ Number of issues during the revenue service, and the reactivity to solve the issues.
¤ Number of FAI/FAT GO on time and their number of non conformities
¤ Cost Of Non Quality (CONQ) generated by the supplier non-conformities
The result of this performance assessment is synthesized through a colour code: Black, Red, Yellow or Green.
The rules to attribute these colours are defined hereafter.
P 18
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
PURPOSE:
Rank the suppliers in terms of Quality targets achievements and reactivity in the
Execution & Product Development phases.
CONTENT
The rules for ranking the suppliers is performed through a colour code (Green,
Yellow, Red or Black Quality status).
The following matrix describes the colour code assignment criteria, the AT owners
for the supplier management; and the AT required reaction rules.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 19
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
Criteria AT Owners Tools and Management
Requirements
Green
¤ Development and Execution results exceeding the
target
¤ Improvement plan ongoing
¤ Proven Reactivity
Yellow
¤ Punctual Quality issues
¤ Quality results at target
¤ Improvement plan ongoing
¤ Proven Reactivity
¤ Local Quality representative
¤ Local Sourcing representative
¤ 8D managed locally
¤ CONQ recovery
¤ Management review involving Supplier
management, local Quality and Sourcing
representatives
¤ Improvement plan managed by local
Quality and Sourcing representatives
Red
¤ Execution results at AT premises out of target or
in continual degradation over the last 3 months,
¤ Safety related issue linked to a lack of process
control at supplier.
¤ 2 major revenue service issues within the last 3
months.
¤ Product Development results out of target, ie:
§ At least 2 FAI NOGO on the same product, with
supplier responsibility
§ At least 3 successive FAI NOGO on various
products.
¤ AND in all cases, no proven reactivity, ineffective
action plan
¤ Commodity Manager or Domain
Director
¤ Sourcing Quality representative
¤ 8D managed locally
¤ Reinforced control plan managed
locally.
¤ CONQ recovery.
¤ Upgrade plan managed by AT Quality
and Sourcing representatives.
¤ Management review involving Supplier
management, Commodity manager or
Domain director, Supplier Quality
Development representative.
¤ Definition of the Red status exit
conditions (performance targets and
due date) by Supplier Quality
Development representative.
¤ NBOH (New Business On Hold) panel
status preparation.
Black
¤ Ineffective action plan to exit the Red position.
¤ No involvement from supplier management
¤ Product line Sourcing Top
management
¤ Sourcing Quality Top management
¤ Exit plan set-up.
¤ CONQ recovery
E
S
C
A
L
A
T
I
O
N
P
R
O
C
E
S
S
P 20
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
CHANGES MANAGEMENT
PURPOSE:
Alstom requests its suppliers to inform in writing AT of any Product or Process
changes that it wants to implement. AT formal acceptation is mandatory before this
change request can be considered as approved.
CONTENT
Before applying the change, the supplier will assess the risks in terms of impact on
QCD performance and contractual requirements, and submit for approval the
Product and/or Process validation plan.
Process modifications includes:
¤ Location of the production site (manufacturing transfer)
¤ Production process
¤ Tools
¤ Material
¤ Subcontractors.
The supplier will submit the updated Product and/or Process documentation, AT
keeps right to assess the modified process, either at Supplier or Subcontractor
premises.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 21
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
CHANGES MANAGEMENT
CONTENT (ctd)
After validation, the modification will be formalized in the contractual
documentation.
The configuration management of the Product is under Supplier’s responsibility.
The control and monitoring of the modification will be performed using the
following information:
¤ Reference(s) impacted
¤ Serial number of the first modified product (including sub-assemblies if
impacted)
¤ Production date
¤ If applicable, State of hardware and software (revision level)
¤ AT modification number
¤ If applicable, reference of the AT waiver.
The supplier will inform AT in case of obsolescence.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 22
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
8D MANAGEMENT
PURPOSE:
To guarantee an efficient problem solving approach, Alstom requires from its
suppliers to implement the 8D tool in the analysis and corrections of the issues.
CONTENT
The 8D will at least presents the following items:
¤ Description of the problem
¤ Team in charge
¤ Problem Characterisation
¤ Containment: curative actions (within 48 hours after the problem notification)
¤ Root causes definition and validation **
¤ Permanent corrective actions (within 30 working days after the problem
notification)
¤ Preventative actions
¤ Lessons learnt
** The root causes identification will integrate the causes of non-detection and
the causes of occurrence of the problem.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 23
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
QUALITY WALL
RESIDENT
PURPOSE:
In case of not secured control plan , reoccurrence of deliveries of defective parts
detectable at supplier premises, Alstom may require the temporary implementation
of a Quality Wall or a resident to secure the Quality of the delivered products
CONTENT
The Quality Wall is managed by a third party company, mandated to ensure the
checking according to a check-list validated by Alstom Supplier Quality.
The conditions to remove the Quality Wall are defined at the starting of the activity
(number of parts or duration without defect found)
The results of the checking are registered, and communicated to Alstom.
In the meantime, the supplier commits to implement the corrective actions to
tackle the internal issues.The Quality Wall is removed when the targets defined
initially are reached.
A resident is a person full time in charge of supporting the supplier in its
management or problem solving approach. The rule to remove the permanent
remains the same than for the Quality Wall.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 24
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
COST OF NON QUALITY
(CONQ) MANAGEMENT
PURPOSE:
Alstom requests its suppliers to be liable for the financial impact of a non
conforming deliveries, either when detected at AT premises (S1) or in the Revenue
Service (S2).
CONTENT
The financial impact of the non-conformities detected at AT premises will be
reported in the CONQ S1 account. They will include:
¤ a fixed fee
¤ the variable cost for the non conformity management (sort-out, rework, …)
¤ the variable cost for the AT impact on production (line stoppage, …)
The financial impact of the non-conformities detected during the revenue service
will be reported in the CONQ S2 account. They will include:
¤ the variable cost of the non conformity management (retrofit, rework, …)
¤ the potential penalties requested by the customer.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION
SUPPLIER PERFORMANCE
DASHBOARD (colour status)
8D MANAGEMENT
QUALITY WALL
RESIDENT
COST OF NON QUALITY
(CONQ) MANAGEMENT
CHANGES MANAGEMENT
P 25
Sourcing Quality Management Process
GLOBAL PERFORMANCE
MANAGEMENT AND
UPGRADE
GLOBAL PERFORMANCE
MGT & IMPROVEMENT
SUPPLIER UPGRADE
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
P 26
GLOBAL PERFORMANCE
MANAGEMENT & IMPROVEMENT
PURPOSE:
Alstom requests its supplier to develop a continuous Quality improvement plan aiming
at increase their performance all along the development and production steps.
CONTENT
The improvement plan will be based on the analysis of the typology of the defects and
the weaknesses highlighted during the development and production phases..
Besides, AT will re-assess the suppliers ability to be compliant with the AT panel
criteria every 3 years at minimum according to the” Panel Entrance” “ rules.
Any deviations following these audits will be managed through the improvement plan.
However, in case of too high risks for deliveries highlighted during this assessment,
Supplier Quality Development representative can ask for a Red status
The improvement plan will be challenged by the Alstom Sourcing Quality
representatives and reviewed during the management reviews held on a regular basis
with the key suppliers.
GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE
SUPPLIER UPGRADE
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
GLOBAL PERFORMANCE
MGT & IMPROVEMENT
P 27
SUPPLIER UPGRADE
PURPOSE:
Alstom requests its Red supplier to develop a strong upgrade Quality plan to
recover yellow status and be maintained in the Alstom Panel.
CONTENT ( specific Red )
For the RED SUPPLIERSRED SUPPLIERS, AT will request a robust action plan, aiming to leave
this status within the 6 following months.
AT Sourcing and Supplier Quality Development representatives will be in
charge of monitoring this plan at supplier premises, and validating the
effectiveness of the corrective and preventive action plans..
AT Sourcing and Supplier Quality Development representatives could support
this plan through training and workshops if necessary in the supplier area.
Regular meetings are required at supplier and AT management level to
measure the improvement .
Note : A Quality wall is mandatory for the start of production of any product
manufactured at a red supplier.
GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE
SUPPLIER UPGRADE
SUSTAIN SUPPLIER
QCD PERFORMANCE
& CONTRACT
GLOBAL PERFORMANCE
MGT & IMPROVEMENT
P 28
Sourcing Quality Management Process
APPENDIX 1
PREVENTION DURING
PRODUCT DEVELOPMENT (BEFORE FIRST DELIVERIES)
SPQD Plan For
Rolling Stock & Components
MANAGE SUPPLIER
INTEGRATION
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 29
MANAGE SUPPLIER
INTEGRATION
SPQD Plan For Rolling Stock & Components
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
SPQD PLAN
PURPOSE:
The SPQD plan (Supplier Product Quality Development plan) summarizes
Way of monitoring the supplier Quality activities during the development of a
new Product, in line with the project schedule
CONTENT:
At the early beginning of the project, the SPQD plan is defined and agreed by AT
Quality representative and the supplier.
SPQD plan detailed items are described on the following sheets.
As a first activity, SPQD Quality specification contractualizes the project Quality
targets and agreed Quality specific requirements.
S
P
Q
D
P
L
A
N
P 30
SPQD Plan For Rolling Stock & Components
INPUT DELIVERABLES
Quality Specification sent to the Supplier (clause by clause)
Quality Specification agreed between AT & Supplier (clause by clause)
Supplier Quality Status analysis (Red/Yellow/Green in Development or
execution)
Request for concession if necessary
Criticality assessment for governance
Detailed SPQD plan build-up with the supplier (SPQD FU sheet)
List of the previous S1 & S2 failures and
related analysis.REX analysis
Drawings / Specifications
RAMS study
Product Risk analysis (D-FMEA or other)
¤ Checking of the right implementation of the risk analysis outputs
¤ List of Critical Product Characteristics identified
List of Critical Product Characteristics
Process flow & lay-out
Process Risk analysis (P-FMEA or other)
¤ Checking of the right implementation of the risk analysis outputs
¤ List of Critical Process Characteristics identified
Sub-Suppliers CPF list
List of Critical Product Characteristics
Validation of the critical sub-suppliers bought-out parts on
Product/Process.
List of Critical Product Characteristics
List of Critical Process Characteristics
P.FMEA
Product/Process Control Plan consistent with the Process risk analysis.
Product validation plan results
Check that the design conformity files are available and validated by
Engineering
Product conformity to requirements Validation
PRODUCT FAI STATUS (see FAI sheet)
Product/Process Control PlanProcess qualification through audit on Product specifics
PROCESS FAI STATUS (see FAI sheet)
FAI Status Request for concession if necessary toward the PrQM
Criticality assessment of the supplierReinforced Final Inspection or Quality Wall (for red suppliers) at supplier
premises
NCR dataChecking of the 3 first deliveries performance vs target.
8D management if any deviation
All documents related to the SPQD activity SPQD file to transfer ans handover to SQA
Key suppliers SPQD activities
Supplier color status and reasons why
Colour status
Project schedule
Quality Targets per commodity
Quality Targets per supplier (if any)S
P
Q
D
P
L
A
N
I
T
E
M
S
1
2
3
4
5
6
7
7
P 31
MANAGE SUPPLIER
INTEGRATION
SUPPLIER PERFORMANCE
FEED-BACK
PURPOSE:
The monitoring of the supplier Quality activities during the development of a new
product will be adapted to its current and past performance during the execution
phase.
CONTENT
According to the product & supplier criticality, 3 levels of monitoring are defined
(from 1 to 3). The frequency of the follow-up will be adapted accordingly and
integrated.in Product & Process Quality assurance plan.
NB: Suppliers with non fully qualified processes will be followed-up as the “RED”
criticality ranking.
SPQD Plan For Rolling Stock & Components
G/Y Red Purple
Safety A & B Class 2 1 1
Non Safety A & B+ Class 2 1 1
B- class or Safety C Class 3 1 2
Supplier Status
Product
Risk
1
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 32
MANAGE SUPPLIER
INTEGRATIONRETURN OF EXPERIENCE
PURPOSE:
This is the first level of the risk analysis.
To guarantee the non reoccurrence of issues already happened in the past, the
supplier will perform an analysis of the Product & Process Design failures and
Check that the new Product concepts gets rid of the risks
CONTENT
The supplier will present a preliminary analysis based on the previous issues
on the same type of products.
Based on the root causes analysis, It will demonstrate that the previous deviations
have been taken into account and will not be carried out on the new development.
It will allow to define the Quality targets for the projects
SPQD Plan For Rolling Stock & Components
2
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 33
MANAGE SUPPLIER
INTEGRATIONPRODUCT RISK ANALYSIS
PURPOSE:
All along the life-cycle, prevent the risks on the product due to the design.
Define the design validation activities.
Determine the Critical Product Characteristics.
CONTENT
The supplier will give the evidence of a Product risk analysis integration in the
Design activity. The supplier will be able to demonstrate its identification of the
critical Product characteristics.
The Product risk analysis can preferably be performed through a Design Failure
Modes and Effects Analysis (D-FMEA).
The activity will be performed by the supplier, and validated by AT Supplier Quality
function.
SPQD Plan For Rolling Stock & Components
3
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 34
MANAGE SUPPLIER
INTEGRATIONPROCESS RISK ANALYSIS
PURPOSE:
All along the production, prevent the risks on the product due to the manufacturing
conditions..
Determine the Critical Process Characteristics.
CONTENT
The supplier will give the evidence of a Process risk analysis integration in the
Design activity. The supplier will be able to demonstrate its identification of the
critical Process characteristics.
The Process risk analysis can preferably be performed through a Process Failure
Modes and Effects Analysis (P-FMEA).
The activity will be performed by the supplier, and validated by AT Supplier Quality
function.
SPQD Plan For Rolling Stock & Components
4
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 35
MANAGE SUPPLIER
INTEGRATION
SUB-SUPPLIERS
MANAGEMENT
PURPOSE:
Insure that the supplier
¤ transmits AT Product and Process requirements to its own suppliers
¤ manages its own critical products/suppliers though a Quality Plan in line with AT
expectations
CONTENT
Requirements of AT regarding the sub-supplier management are described on the
following sheet.
SPQD Plan For Rolling Stock & Components
5
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 36
Sub-Suppliers (Tier 2) Management Requirements
As a key process in the achievement of the supplier Quality targets, a special focus will be done on the management
of the Tier 2 suppliers
The reference to assess this activity will be the following:
¤ The list of critical Products/Suppliers is identified
¤ These critical suppliers are qualified for their process scope (focus on special processes)?
¤ A FAI process has been implemented for these products
¤ A waiver process exists in case of sub-supplier NOGO FAI (including containement too secure the deliveries)
¤ A list of required documents for each delivery exists
¤ The critical product characteristics are identified for bought-out parts?
¤ The Tier 2 product/process control plan are available and validated?
¤ The Incoming Inspection Insrtuctions are defined and consistent with the critical characteristics?
¤ The measurement means are defined and adapted?
¤ The rules for segregation of the producs according to their Quality status are defined and applied?
¤ The rules for Non Conformity management are defined and applied
SPQD Plan For Rolling Stock & Components
P 37
MANAGE SUPPLIER
INTEGRATION
PRODUCT & PROCESS
CONTROL PLAN
PURPOSE:
Describe the Product/Process control activities during the manufacturing of the
Product, and the reaction rules in case of drift.
CONTENT
The Product & Process control plan is built from the Incoming Inspection
to the Dispatch activities.
It will detail the Product & Process control operations, their frequency, their
responsible and the related registration documents.
The Work-instructions and Quality instructions will be aligned on the control
plan.
The Product & Process Control plan will be submitted by the supplier, and
validated by AT Supplier Quality function..
SPQD Plan For Rolling Stock & Components
6
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 38
Control plan Requirements Requirements
The control plan is the backbone of the operational Quality implementation all along the process steps.
It must describe, from Incoming Inspection to Dispatching the prevention and detection activities, either on process
or on product.
The requested elements to be detailed are the following:
¤ Process Type or Operation Description
¤ Machine, device or tool
¤ Product and/or Process Characteristics to put under control
¤ Product and/or Processspecifications and tolerances
¤ Evaluation/Measurement technique
¤ Person in charge
¤ Sampling (size and frequency)
¤ Records
¤ Control Methods
¤ Reaction rules in case of N/C detection
SPQD Plan For Rolling Stock & Components
P 39
Control plan requested to the supplier
Process
Number
Machine,
device, jig,
tools, asset #,
etc
Product Process Evaluation
Measurement
Technique.
(gage # if
applicable)
Control
Method
Reaction
Plan
Freq.
Supplier Name:
Date of last revisionControl Plan Number Control Plan Revision Level Supplier Key Contact/Phone Written by
Approval datePart Number Part Revision Level Part Name Approved by
Characteristics Methods
Process Name/
Operation Description
Class Product/Process
Specification/
Tolerance
Sample
Size
SPQD Plan For Rolling Stock & Components
P 40
MANAGE SUPPLIER
INTEGRATIONFAI
PURPOSE:
Validate the First Article according to the product definition and requirements,and
validate its manufacturing process.
CONTENT
Based on a Product check-list, the Product FAI will allow to check the
compliance of the product to the technical & documentation requirements.FAI will
also be performed for carry-over parts for which the validation has been performed
more than 1 year ago.
The validation of the Process will be performed according to FAI Process
validation check-list.
The final statement of the activity will be based on the Product & Process
qualification level, following a X-Y-N code, where:
X
Y
N
Letter linked to the qualification level of the manufacturing process of the FAI part.
Letter linked to the qualification level of the product conception validation of the FAI part.
Number linked to the ownership of the corrective action plan to be deployed.
SPQD Plan For Rolling Stock & Components
7
SUPPLIER PERFORMANCE
FEED-BACK (colour status)
RETURN OF EXPERIENCE
SUB-SUPPLIERS
MANAGEMENT
PRODUCT RISK ANALYSIS
PROCESS RISK ANALYSIS
PRODUCT & PROCESS
CONTROL PLAN
FAI
P 41
SPQD Plan For Rolling Stock & Components
Ranking of X can take 2 levels, given by the SPQD representative:
A
R
Ranking of Y can take 4 levels, given by the Engineering representative:
A
E
I
R
Ranking of N can take 3 levels, given by the SPQD representative:
0
1
2
Product/Process FAI accepted, no need for additional action plan.
Action plan needed, suppplier ownership.
Action plan needed, AT ownership.
"Rejected", Product conception do not guarantee the function & the compliance to specifications.
"Accepted", Manufacturing process of the FAI part is qualified.
"Rejected", Manufacturing process of the FAI part is not qualified.
"Accepted", Prodcut conception is able to guarantee specifications compliance
"External use possible", Product conception is not able to guarantee specifications compliance on minor deviations, not
jeopardizing Safety, Reliability, Fitting.Nevertheless, correction expected.
"Internal use only", Product conception is not able to guarantee specifications compliance on major deviations (out of
Safety) or conformity not fully demonstrated (long term test results missing). Product can be accepted under concession.
P 42
SPQD Plan For Rolling Stock & Components
Process
Qualification
status
Product
Conception
validation
status
Responsab ility
A 0
1
2
1
2
I
Major non conformity, not jeorardizing Safety & Regulation
items or long term test results missing
Corrective action plan to be
supplied by the supplier.
Concession by the SPQD
mgr, Engineering & PrQM
needeed.
Major non conformity, not jeorardizing Safety & Regulation
items or long term test results missing
Corrective action plan to be
supplied by AT. Concession
by the SPQD mgr,
Engineering & PrQM
needeed.
CriteriaComments
Reaction rules
A
Product conforming to the definition and specifications,
complying with the usage conditions.
FAI valided, no need for
additional action plan.
E
Minor non conformities, not jeopardizing Safety, Relaibility
or Fitting, but correction requested as soon as possible.
Corrective action plan to be
supplied by the supplier.
Concession by the SPQD mgr
& Engineering needeed.
Minor non conformities, not jeopardizing Safety, Relaibility
or Fitting, but correction requested as soon as possible.
Corrective action plan to be
supplied by AT. Concession
by the SPQD mgr &
Engineering needeed.
P 43
SPQD Plan For Rolling Stock & Components
A 1
1
2
1
2
1
2
Concession by SPQD mgr,
TSS & PrQM needed.
Produit/Process corrective
action plan to be supplied by
the supplier.
Major non-conformities but not jeodardizing safety or
regulation, or long term test results missing. The process is
not capable to guarantee the reproducibility of conforming
parts. No delivery without reinforced Quality checkings &
Quality Wall.
Concession by SPQD mgr,
TSS & PrQM needed. Produit
corrective action plan to be
supplied by AT, Process
corrective action plan to be
supplied by the supplier.
R
Product not conforming to the definition or the
specifications (safety/regulation), and/or not complying to
usage conditions.
No delivery allowed
Product not conforming to the definition or the
specifications (safety/regulation), and/or not complying to
usage conditions.
No delivery allowed
R
Product conception guarantees the compliance to the
specifications, but the process is not capable to guarantee
the reproducibility of conforming parts. No delivery without
reinforced Quality checkings & Quality Wall.
Process corrective action
plan to be supplied by the
supplier. Concession by the
SPQD mgr, TSS & PrQM
needeed.
E
Minor non-conformities not jeopardizing safety, nor
reliability nor fitting but corrections needed asap.. The
process is not capable to guarantee the reproducibility of
conforming parts. No delivery without reinforced Quality
checkings & Quality Wall.
Concession by SPQD mgr,
TSS & PrQM needed.
Produit/Process corrective
action plan to be supplied by
the supplier.
Minor non-conformities not jeopardizing safety, nor
reliability nor fitting but corrections needed asap.. The
process is not capable to guarantee the reproducibility of
conforming parts. No delivery without reinforced Quality
checkings & Quality Wall.
Concession by SPQD mgr,
TSS & PrQM needed. Produit
corrective action plan to be
supplied by AT, Process
corrective action plan to be
supplied by the supplier.
I
Major non-conformities but not jeodardizing safety or
regulation, or long term test results missing. The process is
not capable to guarantee the reproducibility of conforming
parts. No delivery without reinforced Quality checkings &
Quality Wall.
P 44
FAI Requirements
FAI is split in Product conformance on one side, and Process validation on the other side:
Product conformance status, given by AT engineering representative, includes:
¤ Technical drawings & specifications.
¤ Functional tests results
¤ Configuration management
¤ Visual inspection
¤ Fire and smoke
¤ Marking and identification
Process validation, given by AT Sourcing Quality representative, takes into account:
¤ Supplier documents and Implementation : Quality Control Plan, Working & Inspection instructions
¤ Dies, fixtures, jigs
¤ Special processes control in accordance with norma (including the operators training level)
¤ Packaging
The final status of the FAI, including both Product & Process conformance status is given by the Sourcing Quality representative
Only Product with accepted FAI can be delivered to AT. Otherwise, deviation request is needed to allow the delivery.
SPQD Plan For Rolling Stock & Components
TRANSPORT
www.alstom.com