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1 Supplier Quality Manual QF-SQR001 / Rev. Date: 3/28/2018 / Rev. Level: G

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Page 1: Supplier Quality Manual · COST RECOVERY 18 PPAP REQUIREMENTS 19 SCORING CRITERIA: PPAP ON-TIME SUBMISSION 20 SUPPLIER PPAP DOCUMENTATION REQUIRMENTS 21 SUPPLIER PPAP DOCUMENTATION

1

Supplier Quality Manual

QF-SQR001 / Rev. Date: 3/28/2018 / Rev. Level: G

Page 2: Supplier Quality Manual · COST RECOVERY 18 PPAP REQUIREMENTS 19 SCORING CRITERIA: PPAP ON-TIME SUBMISSION 20 SUPPLIER PPAP DOCUMENTATION REQUIRMENTS 21 SUPPLIER PPAP DOCUMENTATION

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Supplier Quality Manual

Table of Contents

COMMITMENT TO SUPPLIERS 4 SUPPPLIER CERTIFICATION REQUIREMENTS 5 SUBCONTRACTOR DEVELOPMENT 6 CERTIFICATE OF CONFORMANCE 6 ENGINEERING AND PROCESS CHANGES 7 MATERIAL LABELING 8 IMDS 8 RIGHT OF ACCESS 8 SCORING CRITERIA AND PERFORMANCE TRACKING 9 - 10 SCORING CRITERIA: QUALITY (PPM) 11 SUPPLIER QUALITY INCIDENT TRACKING 12 SCORING CRITERIA: QUALITY WRITTEN CONCERNS 12 SCORING CRITERIA: ON TIME DELIVERY 13 SCORING CRITERIA: SHIPMENT ACCURACY 14 SCORING CRITERIA: COMMUNICATION 15 CONTAINMENT REQUIREMENTS 16 - 17 COST RECOVERY 18 PPAP REQUIREMENTS 19 SCORING CRITERIA: PPAP ON-TIME SUBMISSION 20 SUPPLIER PPAP DOCUMENTATION REQUIRMENTS 21 SUPPLIER PPAP DOCUMENTATION LINKS 22 PPAP SUBMISSION REQUEST 23 PROCESS SIGN OFF CHECKLIST 24 PROCESS FLOW REQUIREMENTS 25 PROCESS FMEA REQUIREMENTS 26 - 28 CONTROL PLAN REQUIREMENTS 29 - 30 OPERATOR INSTRUCTION EXAMPLE 31 CORRECTIVE ACTION REQUIREMENTS 32 - 34 BREAK POINT LABEL 35 ENGINEERING CHANGE NOTICE LABEL 36 ACKNOWLEDGEMENT AND ACCEPTANCE 37

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Revision History

REV Description of Change Author Effective Date A Initial Release M. Rodgers 1/1/10 B Modified scorecard requirements J. Brewster 8/1/11 C Update Problem Report / Costs J. Brewster 12/8/13 D Updated to Include Aerospace Supplier Requirements L. Murden 12/5/2014 E Added IATF Requirements L. Murden 10/14/2017 F Added requirements for ISO 9001 certifications to bear mark of

IATF certification body

Aligned PLEX Scouring with requirements

L. Murden 11/14/2017

G Added Requirements for suppliers with embedded software L. Murden 3/28/2018

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Supplier Quality Manual

Introduction

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

Automotive suppliers with embedded software are required to implement and maintain a process for quality

assurance. Based on risk and potential impact to the customer, AGM may require a software capability

assessment.

(bearing the accreditation mark of a recognized IAF MLA)

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Supplier Quality Manual

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

ensure 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 Purchase Order.

Products controlled by heat numbers, certification numbers, batch numbers, or cure dates

must be linked to the Certificate of Conformance by the controlling number, and show

physical and chemical values when applicable.

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Supplier Quality Manual

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

Containment, 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.

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Supplier Quality Manual

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 Product In 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 MDS system, 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 to

product 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 the supplier’s facility to verify that supplied product conforms to specified requirements. This

verification does not absolve the supplier of the responsibility to provide acceptable

product and does not preclude subsequent rejection by AGM or its customer.

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Supplier Quality Manual

Scoring Criteria and Performance Tracking

➢ Suppliers performance is tracked by five categories totaling 100 points on a rolling 12 month calendar according to the following categories:

➢ PPM = 30 points. ➢ Written Concern Quantity = 20 points. ➢ On-Time Delivery Percentage = 30 points. ➢ Communication = 20 points.

➢ At the end of each month supplier scorecards will be available and the scores are determined according to the below ranking chart. Any category score or overall score in the red or NBH the supplier is required to submit corrective action.

Ranking On‐Time

Delivery PPM Communications

Written

Concerns Total

Gold 30 30 20 20 98‐100

Green 27‐29 27‐29 12‐13 8‐9 86‐97

Yellow 21‐26 21‐26 9‐11 6‐7 66‐85

Red 11‐20 11‐20 5‐8 4‐5 36‐65

NBH 10 or less 10 or less 4 or less 3 or less 35 or less

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Supplier Quality Manual

Quality - PPM

11

➢ At the end of the calendar year below are the required actions based on the yearly performance results:

➢ Gold – No actions required.

➢ Green – No actions required.

➢ Yellow ➢ Corrective action recommended for any category in yellow. ➢ Improvement Plan Recommended.

➢ Red ➢ Corrective action required for any one category in red. ➢ Improvement plan required if total score is in red. ➢ AGM supplier audit may be required (AGM travel cost will be supplier responsibility).

➢ NBH (New Business Hold) ➢ Improvement plan required to be removed from new business hold.

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Supplier Quality Manual

Quality - PPM

12

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 SCORE

0-25 30 326-350 17

26-50 29 351-375 16

51-75 28 376-400 15

76-100 27 401-425 14

101-125 26 426-450 13

126-150 25 451-475 12

151-175 24 476-500 11

176-200 23 501-525 10

201-225 22 526-550 9

226-250 21 551-575 8

251-275 20 576-600 7

276-300 19 601-625 6

301-325 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 of

the supplier’s scorecard.

Suppliers must give an initial respond within 24 hours with containment actions,

48 hours for oversees suppliers.

Permanent corrective action implementation and verification of effectiveness is

required within 30 days. AGM approval is required in the event that permanent

actions 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 category is calculated on the basis of the quantity of Problem Reports

issued through production in the fiscal month. See the table below for the scoring

breakdown.

QI Quantity SCORE

0 10

1-2 9

3-4 8

5-6 7

7-8 6

9 5

12 4

11 3

12 2

13 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 30

99.0 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 11 93.1 – 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 Occurrence

SCORE

0 20

1 19

2 18 3 17 4 16 5 15 6 14

7 13

8 12 9 11

10 or more 10

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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 supplier’s 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 be

agreed upon by AGM Quality.

Data must be collected for all non-conformances and corrective actions. If required by AGM the results must be reported.

• Problem solving must be formal, data driven, and documented. AGM prefers it’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 in

transit to AGM Automotive. AGM Quality department will notify the supplier by

e-mail using the Problem Report. In the Problem Report AGM Automotive will request

corrective action. Corrective action updates will be required through out the containment

process.

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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 Manual

Cost 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:

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Supplier Quality Manual

PPAP Requirements

All production suppliers are required to obtain full PPAP approval from AGM Automotive per the current revision of the requirements of the AIAG Production Part Approval Process (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 documentation requirements on the PPAP Request Form.

➢ PPAP approval is required for any changes to the product and/or process,

including change in location or supplier.

All submissions are to be at Level 3 unless otherwise specified in writing from AGM.

AGM may request an updated PPAP if the PPAP on file is over one year old.

Annual validation testing is required to verify continuing conformance on all parts and components,

unless otherwise 21

QF-SQR001 /

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Supplier Quality Manual

Documentation Links

Process Flow

Design FMEA

Process FMEA

Control Plan

Operator Instructions

22

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Supplier Quality Manual

PPAP Submission Request

If submission is after the due date the supplier will be issued a Quality Incident

23

SUPPLIER PPAP SUBMISSION REQUEST QF-063

1000 E. Whitcomb Avenue

Madison Heights, MI 48071

PART #: SUBMISSION DUE DATE:

PRINT REV. LEVEL:

NEW PART #:

(If Applicable)

PART NAME/DESCRIPTION:

PPAP LEVEL REQUESTED:

SAMPLE SIZE:

APPLICATION:

QUALITY CONTACT:

TEL #: (248) 776-0600

FAX #: (248) 776-0601

SUPPLIER MANUFACTURING INFORMATION

PPAP Submit to Information:

Supplier:

Submit PPAP to:

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QF-077

Process Sign Off Check List

Supplier Program

Mfg Location Supplier Code

Part Number(s) Part Name(s)

Change Level PSO Date

Completed Document

Yes No

1 Part Number, Description and Change Level

Part Print

Any alerts or deviations

2 Design FMEA

DFMEA including AIAG checklist A-1

3 Test Sample Sizes and Frequencies

DVP&R

4 Process FMEA

PFMEA including AIAG checklist A-7

5 Process Flow Diagram and Manufacturing Floor Plan

Process Flow Diagram

Facility Floor Plan

Cell Material Layout

6 Control Plan

Control Plan including AIAG checklist A-8

7 Quality Planning

Quality Org Chart w/Plant Responsible Personnel Highlighted

Risk analysis of subcomponent suppliers

Evidence of problem solving methods (e.g. Blank 8D form)

8 Incoming Material Qualif/Cert Plans

Certificate of analysis

Copies of sub-tier PSWs

Plan for lot control

Plan for lot tracebility

9 Parts Handling Plan

Nonconforming product procedure

Container maintenance plan

Routing/Traveler cards

10 Operating Instructions

Set-up Sheets

Operator Instructions

Gage Instructions

Rework/Repair Instructions

Evidence of operator training

11 Tooling, Equipment and Gages Identified

Tool List

12 Special Product/Process Characteristics Identified

List of SCs/CCs/KPCs/KQCs

13 Process Monitoring

Control charts

1st piece approval procedure

14 Error and Mistake Proofing

List of Error Proofing Methods by Operation including destinction between prevention and detection

15 Layered Process Audit Plan

Acceptable LPA plan with frequency and structure chart

16 Evidence of Product Specifications

Compliance Report Indentifying Charactersitics to be Checked during PSO

17 Line Speed Demonstration

Evidence of a production demonstration run (See PSO PDR log)

Evidence that the supplier can meet quoted capacity

18 Outgoing Material Qualif/Cert Plans

Outgoing inspection plan including early launch containment

19 Parts Packaging and Shipping Specifications

Shipping Procedure

Packaging Instructions

Final Dunnage Matrix

Copy of Shipping Label

20 Gage and Test Equipment Evaluation

Gage R&R

Calibration Records

Checking Fixture Layout

21 Preventative Maintenance Plans

PM Plans for all machinery

22 Initial Process Study

Cpk/Ppk or Control Charts from PDR (build pre PSO)

D

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Supplier Quality Manual

Process Flow Requirements

QF-010

Product Program Issue Date ECL ECL

Supplier Name SUPPLIER Part Name NAME

Supplier Location CITY STATE Part Number NUMBER

Legend:

Operation Transportation Inspection Delay Storage

Operation or Event Description of Evaluation

Operation or Event and Analysis Methods

Develop and flow the sequential work activities or steps

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Supplier Quality Manual

Process FMEA Requirements

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:

Item: Process Responsibility uto Prepared by:

Model Year(s)/Vehicle(s) Key Date Date (Orig.)

Core Team: Date (Rev.)

C Potential O Current Current D

Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results

Step Failure Ef fect(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.

Process Step -

Function and

Number must be

same as the

process flow

Manner in which

the process could

fail

List the requirements for

each process function

The effects of a

failure mode as

perceived by the

customer

See AIAG

severity

evaluation

criteria

Special product or process

characteristics

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Supplier Quality Manual

Process FMEA Requirements (cont.)

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:

Item: Process Responsibility uto Prepared by:

Model Year(s)/Vehicle(s) Key Date Date (Orig.)

Core Team: Date (Rev.)

C Potential O Current Current D Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results

Step 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.

Indication of how the failure could occur

See AIAG occurrence evaluation

Description of controls to identify the cause of the failure

See AIAG detection eliminate the cause of the failure on criteria Description of controls to

eliminate the cause of the failure

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Supplier Quality Manual

Process FMEA Requirements (cont.)

28

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:

Item: Process Responsibility uto Prepared by:

Model Year(s)/Vehicle(s) Key Date Date (Orig.)

Core Team: Date (Rev.)

C Potential O Current Current D Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results

Step 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.

RPN= severity x occurrence x detection

Preventive / Corrective actions to reduce rankings of severity, occurrence and detection

Completed Actions

After completed actions determine and record the resulting severity, occurrence and detection rankings

Name and organization responsible and target and completion date

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Supplier Quality Manual

Control Plan Requirements

29

CONTROL PLAN

Protot ype Pre-La unch Produ ction

Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

NUMBER ECL

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)

NAME

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

SUPPLIER CODE

MACHINE, CHARACTERISTICS

METHODS

PART/ PROCESS NAME/ DEVICE, SPECIAL

PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN

TOLERANCE TECHNIQUE METHOD

Must be same as the process flow and PFMEA

Must match print, FMEA and process

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Supplier Quality Manual

Control Plan Requirements

30

(cont.)

CONTROL PLAN

Protot ype Pre-La unch Produ ction

Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

NUMBER ECL

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)

NAME

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

SUPPLIER CODE

MACHINE, CHARACTERISTICS

METHODS

PART/ PROCESS NAME/ DEVICE, SPECIAL

PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN

TOLERANCE TECHNIQUE METHOD

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Supplier Quality Manual

First 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.

31

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Supplier Quality Manual

First 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.

32

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Supplier Quality Manual

33

Operator Instruction Example

Describe the Process Step

Part No:

Description:

Customer:

Customer Part #:

Operation:

Revision: Approvals:

Rev. Level Date Quality Engineering Production

Procedure:

1 2 3 4

6 7 9

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Supplier Quality Manual

Supplier Corrective

Action

Requirements

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Supplier Quality Manual

8 – D Example

8-D Analysis AGM AUTOMOTIVE, INC. 1000 E. Whitcomb Avenue Madison Heights, MI 48071 Phone: 248-776-0600 Fax: 248-776-0601

Problem Status

Program Name: Part Number:

Dave Opened: Part Name:

Date Revised: Customer:

Date Closed: Contact:

CCIR # RMA #:

8-D Report

D1. Form the Team (List team members name and titles)

D2. Describe the Problem (object, concern, qualification)

D3. Implement and Verify Interim Containment Actions (Containment)

D4. Find and Verify Root Cause

D5. Corrective Actions

D6. Verify Corrective Action

D7. Actions to Prevent Recurrence of the Problems

D8. Congratulate the Team

QF-058 Rev. Date : 1-11-08

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36

Supplier Quality Manual

3 x 5 Why Example

3 x 5 Why

Date:

Issue title:

Problem on part:

5 Why Corrective Action Owner Due Date

Why did the planning process

not predict the defect?

Predict

Planning process -

informational content

in FMEAs and CPs

P1

P2

P3

P4

P5

P-RC

Why did the manufacturing

process not prevent the defect?

Prevent Manufacturing process -

standardized work and

error proofing

M1

M2

M3

M4

M5

M-RC

Why did the quality process not

protect GM from the defect?

Prot ect Qualit y process -

cont ainment &

Responsiveness

Q1

Q2

Q3

Q4

Q5

Q-RC

Based on the above 5 why

analysis, what are the common

system deficiencies?

C1

C2

C3

C4

C5

C-RC

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Supplier Quality Manual

Breakpoint Label

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) BREAKPOINTE (Material is Certified)

BREAK POINT NOTICE (REQUIRED ON EVERY BOX) QF-012

PART

NUMBER 1 QI

NUMBER 2 SUBMITTED BY QUANTITY REASON FOR CONTAINMENT

3 6 7

ATTENTION TO

4 BREAK POINT DATE

5 ENGINEERING CHANGE NOTICE

PART

NUMBER ECN NUMBER

SUBMITTED BY QUANTITY DETAIL OF CHANGE

ATTENTION TO

DRAWING LEVEL

SUPP

8LIER

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Supplier Quality Manual

Engineering Change Notice Label

DRAWING

7LEVEL

USE FOR ENGINEERING CHANGE NORev

T: Da

Ite

C: 8-01

E-11

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) 38

6 DETAIL OF CHANGE (what changed on the part

BREAK POINT NOTICE (REQUIRED ON EVERY BOX) QF-012

PART

NUMBER QI

NUMBER

SUBMITTED BY QUANTITY REASON FOR CONTAINMENT

ATTENTION TO

BREAK POINT DATE

ENGINEERING CHANGE NOTICE

PART

NUMBER 1 ECN NUMBER 2

SUBMITTED BY QUANTITY DETAIL OF CHANGE

3 5 6 ATTENTION TO

4

SUPPLIER

8

(Orange Paper)

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