Download Report

Supplier Quality Manual
Motorpal, a.s.
CONTENT
1. Motorpal, a.s. Supplier Quality Manual area of use
2. Effective range specification
3. Supplier’s responsibility
4. Quality system requirements
5. First samples requirements
6. Serial deliveries quality assurance
7. Change and deviation proceedings
8. Supplier Audit
9. Complaint procedure
10. Suppliers evaluation
11. Escalation process
12. Environment
13. Attachements : www.motorpal.cz
Compiled
by:
David Vejslík
Supplier quality dept.
Signature:
Date:
Approved
by:
Ing.Karel Jiravský
Quality vice-president
Signature:
22.04.2014
Edition:
04/2014
Revision
2
Date:
Effective:
22.04.2014
1.4.2011
Motorpal, a.s. Supplier Quality Manual
1. Motorpal, a.s. Supplier Quality Manual area of use
Quality manual defines Motorpal, a.s. suppliers requirements and sets quality assuring procedures of purchased
parts. Motorpal, a.s. expects intensive cooperation with suppliers aimed particularly on prevention and quality
assurance during all process phases, especially in the phases of planning, product realisation and product delivery.
Supplier alone is responsible for the quality assurance of purchased parts. This manual requirements are to be
transfered on the sub-supplier in full extend. Motorpal, a.s. reserves the right to audit following of the rules and
requirements of this Quality Manual. Aim is to build and develope supplier–customer relationships.
2. Effective range specification
This Quality manual revision 2 is effective since 22.4.2014 and is mandatory for all Motorpal, a.s. suppliers. Current
manual version is viable at www.motorpal.cz
3. Supplier’s responsibility
Supplier guarantees that the supplied goods is without any defects and meets agreed reguirements, technical
specifications and valid technical documentation. Supplier is fully responsible for materials and services of his subsuppliers. Warranty period of suplied goods is governed by the contract – general commercial terms (unless
specified otherwise).
4. Quality system requirements
Application of advanced quality planning and process approach are fundamental elements of quality assurance
system.
Supplier commits to plan, organize and realize his production process and quality assurance according to the Zero
Defect strategy based on APQP methods (see attachement no.10). That leads to fullfilling all product quality
requirements. Supplier is supposed to keep his quality management system updated according to latest ISO 9001
revision. Certification according to ISO/TS 16949 is a matter of agreement between supplier and Motorpal, a.s.
Supplier is supposed to have a valid certification of evironmental management according to ISO 14001 and valid
certification of Health and Safety management system according to OHSAS 18001.
5. First samples requirements
Sampling including documentation is free of charge (unless specified otherwise in the order). All sampling
documentation must be provided on Motorpal, a.s. forms. Supplier in cooperation with Supplier Quality Dept. is to
specify sampling requirements on the PPAP form (see attachement no.11).
Basic level: 05- Dimension inspection.
07 – Material inspection.
16 – Control plans.
21- Customer packaging requirements.
All first samples must undergo mutual inspection of all dimensions and parameters stated on drawings including
numerated positions marking. Supplier must properly identify the samples with label and number (see attachement
no.6).
Important: Samples must be labeled as SAMPLE (see attachement no.6)
Supplier guarantees that Sample Inspection Report and samples meet requirements stated on the first page of the
Sample Report. Sample Report must be submitted according to required level on the Motorpal, a.s. forms (on the
page 2 (from 28)
Motorpal, a.s. Supplier Quality Manual
original MS Office Excel document). Forms can be downloaded on http://www.motorpal.cz/cz/kvalita/manual-kvalitypro-dodavatele
Evaluated Sample Report will be sent back to supliers in electronic form after samples assesment in Motorpal, a.s.
Samples are placed on Incoming Inspection Dept. in Motorpal, a.s. and in case of need (for example in case of nonconformity of serial delivery) are used as reference samples.
Possible outcome of sampling:
APPROVED – Motorpal, a.s. requirements has been met and supplier can supply the parts for test series. Sampling
release does not free supplier from responsibility for delivered products quality. Requirements deviations that were
undetected during sampling process can be the subject of claim or reclamation later.
APPROVED UNDER CONDITIONS – Supplier can supply test serie according to approved documentation and
Motorpal, a.s. order. Together with the test serie the plan of corrective actions for insufficiencies discovered during
sampling must be submited for approval. In case the plan is not submited or realized the supplier is not allowed to
supply untill all requirements are met.
NOT APPROVED - Samples submited by supplier did not comfort to usage or funcion of Motorpal, a.s. products in
key parameters. Incomplete reports and documentation will automatically lead to dissaprove the sampling. Supplier
will be notified electronically and will be asked for new sampling.
.
6. Serial deliveries quality assurance
Commencement of serial deliveries follows obtaining of written or electronic Sampling Report approval. Due to assuring
the serial deliveries quality supplier must constantly prove comformity of the product with the requirements by elaborating
and recording the Preventive Quality Sheet.
6.1 Regulated documentation
Supplier always has to produce according to valid regulated documentation. Supplier receives the regulated
documentation from Motorpal, a.s. Purchase Dept. If the drawing is owned by the supplier it must be approved and
filed by Motorpal, a.s. Supplier is not allowed to pass the drawings and technical documentation to the third party
without written approval from Motorpal, a.s.
Preventive Quality Sheet
Preventive Quality Sheet is an instrument for bringing forward the customer’s requirements.
Preventive Quality Sheet contains following basic tools:
-
FMEA – Failure mode and effects analysis - a method that helps to identify potential failure modes in
advance.
SPC – statistic process control
MSA – measurement system analysis
Cmk – machines capability
Cpk – process capability
Systematic transfer of all customer requirements (important dimensions etc.)
For detailed guide to the Preventive Quality Sheet see attachement no.12
Control plan
Supplier will introduce control plan for whole part and for process defining all methods used for measurements
inspection and product testing (gauge type, measurement frequency, operations sequence etc.) – see attachement
no.4.
page 3 (from 28)
Motorpal, a.s. Supplier Quality Manual
Flowchart
Supplier will introduce process flowchart clearly describing steps and sequence of production process. The
flowchart must meet Motorpal, a.s. requirements and needs (it shall begin with incoming inspection and end with
expedition, etc.).
Packaging specification
During the sampling process supplier will introduce a proposal of packaging method that will ensure to protect the
part from corrosion and mechanical damage. In this proposal supplier will make provision for Motorpal, a.s. parts
cleanness requirements. Supplier is obliged to use this (approved) packaging method during the whole course of
deliveries.
Technical change documentation (see attachement no.9).
This document is an instrument for technical changes monitoring and it goes along with the product unless agreed
otherwise.
Inicial process study
Inicial process study defines acceptable level of preliminary process capability for all significant signs. If no
significant signs were defined customer reserves the right to request inicial process capability for another signs.
Study can be performed using long-term data from similar or alike process with explicit agreement with customer. In
case of process incapability supplier must identify, assess and if possible eliminate specific causes effects. Process
incapability must be announced to customer and corrective actions plan must be introduced unless agreed
otherwise.
6.2 Delivery documentation for incoming inspection:
Failing to introduce following documents with each delivery batch may be a reason for refusing the batch.
Material atest
Supplier must introduce required material atest according ČSN EN 10204 as stated in the order. Atest 3.1
containing chemical composition and mechanical characteristics unless agreed otherwise. Atest 2.2 must contain
chemical composition.
Heat and surface treatment protocol
Supplier is to introduce heat treatment process and quality documentation if he provides heat treatment
(cementation, hardening, annealing, etc).
In case of providing surface treatment the protocols must contain coat measurement (galvanizing, chromating etc)
Dimensions measurement record (inspection results)
Final inspection dimensions measurement record is introduced with each batch unless agreed otherwise (see
attachement no.5).
Dimensions measurement record must contain:
• Measured dimensions (drawings @)
• Visual control (corrosion, surface treatment, deburring)
• Other dimensions (measurement range extension can be required during serial production due to claims,
assembly problems, etc.)
Delivery quality and completeness declaration
Delivery quality and completeness declaration (see attachement no.7) is to be properly filled in by supplier.
7. Change and deviation proceedings
7.1. Deviation proceedings
Supplier is not eligible to supply deliberately to Motorpal, a.s. any goods that doesn’t meet quality requirements
given by mutualy agreed technical documentation and/or respective contract. In exceptional case when supllied
good contains deviation from requirements and supplier can competently suppose that Motorpal, a.s. could under
page 4 (from 28)
Motorpal, a.s. Supplier Quality Manual
specific circumstances utilize this goods supplier can (in advance before delivery) request deviation approval.
Supplier requests Motorpal, a.s. Purchasing Dept. for deviation approval electronicaly or in writing on respective
form (see attachement no.17).
Approval/Denial decision is sent to supplier by the Purchasing Dept. executive in electronic form within 14 days
from request introduction. Supplier must keep records about deviation validity end date. After validity of the
deviation expires supplier must assure conformity with original specifications. Deliveries containing deviation must
be properly labeled (see attachement no.8)
7.2. Change proceedings
-Supplier iniciated change request
Supplier requests Motorpal, a.s. Purchasing Dept. for change approval electronicaly or in writing on respective form.
Filled 8D report is to be send along with the request. Approval/Denial decision is sent to supplier by the Purchasing
Dept. executive in electronic form within 30 days from request introduction. Changes cannot be introduced into the
process without Motorpal, a.s. written approval.
Change reguest submission is required in the cases of:
• Use of different construction or material from what was used in previous approved part or product
• Production using new or modified tools or forms including tool replacement
• Production after renovation or reseting of existing tools or machines.
• Production using tools or machines moved to another place or in another facility.
• Change arts, materials or services (heat treatment, surface treatment etc.) sub-supplier.
• Production using tools that haven’t been used in serial production for longer than 12 month.
• Product or process changes connected with product components made internally or by sub-supplier that
can affect the assembly, shape, function, performance or durability of final product.
-Motorpal, a.s. iniciated change
Motorpal, a.s. reserves the right to change the design or technical specifications of the requested goods during the
contract. Supplier will receive written announcement of technical change plan from Motorpal, a.s. Purchase Dept.
Supplier will inform Motorpal, a.s. in response about goods quantity on stock and/or in process and about time
needed to implement the requested change. These information including time plan suggestion for neccessary steps
will be introduced to Motorpal, a.s. Purchase Dept. within 5 days unless agreed otherwise. After reviewing all
questions regarding technical change Motorpal, a.s. can authorize the supplier to realize the technical change.
Based on information from Motorpal, a.s. about releasing the change supplier is obliged to introduce detailed time
plan for change implementation to Motorpal, a.s. Purchase Dept. and to report weekly about the progress. Supplier
is not authorized to implement any change before obtaining information about technical change release from
Motorpal, a.s.
8. Supplier Audit
Supplier is obliged to enable Motorpal, a.s. to execute Supplier Audits. Motorpal, a.s. has a right to audit the
suppliers facility in cases of product or process quality problems appearance. Supplier is to provide Motorpal, a.s.
all necessary information and resources. Supplier has to enable Motorpal, a.s. and its customers the access to
supplier’s (and its sub-supplier’s) stocks and production premises in order to parts, processes and documentation
management quality assessment. Motorpal, a.s commits to announce the audit term in advance. Audit results are
introduced to the supplier in the form of Audit Report. Supplier is obliged to propose and (after Motorpal, a.s.
approval) realize corrective actions to eliminate insufficiencies discovered during audit in agreed schedule.
9. Complaint procedure
Supplier will be notified in writting, by e-mail or fax or in urgent cases by phone when Motorpal, a.s discovers that
purchased part, material or service does not meet defined specifications. Supplier is obliged to immediately perform
page 5 (from 28)
Motorpal, a.s. Supplier Quality Manual
suitable corrective actions according to general purchase terms and is obliged to send filled 8D report (see
attachement no.18). Unless agreed otherwise Motorpal, a.s. performs financial assessment of complaints monthly
by submiting External Failure Record Summary which is sent electronicaly and in writing together with the claimed
goods. Complaint procedure costs are contained in general purchase terms.
10. Suppliers evaluation
Motorpal, a.s. Supplier Quality Dept. evaluates suppliers‘ ppm on the basis of their deliveries. „Zero ppm“ is the
key quality indicator of each supplier. In case supplier discontinues fulfiling this key indicator he is (regardless on
evaluation of other indicators) obliged to introduce effective corrective actions that will restore the process into
agreed state.
Suppliers evaluation is based on following indicators:
•
•
•
•
•
Zero ppm
Delivering in time
System certifications
Price accommodation
Communication
11. Escalation process
After major deviations Motorpal, a.s. Supplier Quality Dept. will include supplier in escalation program „Critical
suppliers“. Deescalation will be possible after proving sustainable effectiveness of implemented actions.
Program contains four defined levels:
Level 0: Supplier with problems
Level 1: Suplier not succesful in problems solution
Level 2: Supplier in need of assistance to secure deliveries capability. Warning
Level 3: Supplier not suitable for Motorpal, a.s. quality. Evaluation
In case of repeated incidence and/or not meeting Motorpal, a.s. requirements on improvement process, terms
keeping or not reaching goals (rank „A“) following escalation principle is used:
1st escalation level:
Suppliers process audit measures verification. Suppliers Development, Incoming Control and Purchase Logistics
communicate with supplier on daily basis. Logistics and commercial representative is responsible on the supplier’s
side.
2nd escalation level:
Quality theme dialogue with competent specialised departments with management involvement. Head of Purchase
Logistics, Global Sourcing referent and Head of Supliers Quality on side of Motorpal, a.s. – Head of Production,
Suppliers Quality on supplier’s side.
3rd escalation level:
Quality theme dialogue on the level of company management including top management. Possible rank shift to „D“
category. Purchase Manager, Quality Vicepresident, Production Vicepresident on Motorpal, a.s. side. Supplier’s
side – management.
page 6 (from 28)
Motorpal, a.s. Supplier Quality Manual
12. Environment
Supplier must assure that all materials and raw materials used in production chain meet all legal requirements as
well as Motorpal, a.s. customers requirements especially concernig dangerous and forbidden materials regulations.
We expect the suplier to follow ISO 14001 environmental management system standard as well as Health and
Safety management OHSAS 18001 certification.
Suppliers oblige during first sampling to insert material data into IMDS (International Material Data System www.mdsystem.com) and guarantee inserted data correctness.
In case supplier is not able to secure this supplier is to provide all relevant data to Motorpal, a.s. to insert them to
IMDS.
page 7 (from 28)
Motorpal, a.s. Supplier Quality Manual
13. Attachements
These attachements are available on www.motorpal.cz
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
Attachement
no.1: SAMPLING – COVER SHEET
no.2: SAMPLING - INSPECTION RESULTS
no.3: SAMPLING - IMDS PROTOCOL
no.4: CONTROL PLAN
no.5: MEASUREMENTS PROTOCOL
no.6: SAMPLES LABELING
no.7: DELIVERY QUALITY AND COMPLETENESS DECLARATION
no.8: DEVIATION IDENTIFICATION LABEL
no.9: TECHNICAL CHANGES DOCUMENTATION
no.10: APQP FORM
no.11: PPAP FORM
no.12: PREVENTIVE QUALITY SHEET
no.13: FMEA COVER SHEET
no.14: TIME PLAN
no.15: DEVIATION APPROVAL REQUEST
no.16: 8D-REPORT
page 8 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.1
page 9 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.2
page 10 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.3
page 11 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.4
page 12 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.5
page 13 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.6
Attachement no.7
Attachement no.8
page 14 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.9
page 15 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.10
page 16 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.11
page 17 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.12
page 18 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.13
Attachement no.14
page 19 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.15
page 20 (from 28)
Motorpal, a.s. Supplier Quality Manual
Comments on Preventive Quality Sheet
1) Other samples:
Offer sample - „Sample for visualization and offer assessment“
Mounting sample - „Sample for mounting experiments“
Development sample - „Sample for development status control“
Note No.1: There is an option to define special development samples for certain development steps
Note No.2: Also „design samples“, „prototype“
Test samples - „Samples for function tests and reliability tests“
2) A-samples - „functional":
A-sample in priciple confirms technical functionality (design confirmation). It can be used as an information for
customer and it can be used for preliminary tests.
Note 1: Dimensions do not necessarily have to correspond with drawings.
Note 2: There can still be limits of meeting customer requirements and RB specifications, for example by
working voltage, working temperature, appearence or dimensions. A - samples are not suitable for long-term
tests.
Note 3: Definitive materials are used only partly. Production takes place in sample department (special
production) or it is only adjusted existing product.
3) B-sample - „test":
B - sample basically confirms technical functionality and can be used for first tests (also by customer) on the
vehicle and can be set to test state. It serves for product requirements verification (also for first long-term tests).
Note 1: Connecting and stopping dimensions match serial production.
Note 2: All customers requirements may not be fulfilled yet.
Note 3: B-sample is large made of final materials. Production uses test or subsidiary tools.
4) C-sample - „for release":
C - samples meet customer and RB specifications. Customer testing enables "technical release" product
releasing internaly closes development phase.
Note 1: C samples are produced with serial tools (if possible) and with manufacturing process close to serial
Note 2: Final material are used, suppliers are specified.
Note 3: Product corresponds to the drawings
5) D-samples „pre-serial":
These samples are in addition labeled with sample report number (see attachement 1,2,3). Approved sample
report is a basis for seriál production release.
Note 1: All parts of first samples must be produced using serial tools and serial processes and assembled and
inspected under serial conditions.
6) Use for series:
Product is release for serial production by Motorpal, a.s. Supplier Quality Dept.
7) Process FMEA:
Motorpal, a.s. defines deadline for Process FMEA submision and subsequently cempletes point 16 in
Preventive Quality Sheet - importance of failure consequences.
8) Parts criticality levels:
Used critical marks to be defined here (symbol + specification)
9) Parts, Functionality, critical parameters information
page 21 (from 28)
Motorpal, a.s. Supplier Quality Manual
critical (important) product functions description
10) Final product:
Final product description.
11) Important parameters:
Here are specified important paremeters according to actual drawing.
12) Critical characteristics:
S = Characteristics important in term of safety
G = Characteristics important in term of legal regulations
SG = Characteristics important in term of safety and legal regulations
K = Important characteristic of product or process that is crucial for customer or inner process satisfaction
OS = Characteristic important for operating personell safety
C = Special characters requiered by customer and marked additionally in relevant documents (ISO/TS 16949)
13) Special characteristics status:
Following critical characteristics are possible:
Fu = functionally critical
Fe = production critical
Mo = Assembly critical
14) Customer mounting dimensions:
Parameter directly connected to customer's important parameters (threads, surfaces,…)
15) Process FMEA:
Possible risks analysis that identifies points of possible failures origination, quality improvement
It is necessary to be particular about:
Failure effects importance
S (Severity)
- (point 16)
O (Occurrence)
- (point 17)
Failure appearence probability
Failure detection probability
D (Detection)
- (point 18)
Actions in stated sequence.
Costs / demand factors, terms and goal must by considered in the choice of appropriate actions. Responsible
department and implementation term is defined for each action. Customers requirements (stated in contract)
about actions in FMEA that vary from FMEA methodic standards are taken into consideration here.
Process FMEA actions specification criteria
Failure risk assessment: S x O. Goal of Product FMEA is reaching S x O < 36. Values higher than 36 indicate
that process is not optimally designed. - Deviation S x O < 36 must be reasoned in FMEA cover sheet (see
attachement no.15).
Assessment of failures that may not be discovered: O x D. Goal of Process FMEA is to O x D <15. Higher
values indicates that defective products may get to the customer. Note: - Deviations O x D <15 must be
reasoned in FMEA cover sheet (see attachement no.15).
16) Severity of failure effects
S (Severity)
Evaluation in 1-10 scale.
Our products must be without severe defects. High risks as safety risks (S = 10) or not observing legal
regulations (S = 9) must be lowered. System changes as failure detecting by detection device, diagnostics,
function backup efffect or warning/alarm can lower the severity to S < 9.
General assessment
Failure with the very high severity
affecting safety
evaluation
10
Criteria related to application method
Uawares blocked motor, uncontrolled increasing or falling of engine rpm, torsional moment
increase insufficient torsional moment flamable mixture on hot motor parts, strong
page 22 (from 28)
Motorpal, a.s. Supplier Quality Manual
Failure with the very high severity
partly affecting safety and/or braching
legal regulations
High severity failure, basic functions
failure, uncontrolable engine stop
9
Severe failure, heavily limited engine
function, imediate need of repair
7
Significant failure, important service
and comfortance systems failuire, not
imediate need of repair
Heavier failure, limitation of important
service and comfort systems function
Mild failure, minor limitation of service
and comfort system (noticable by any
operator)
6
Insignificant failure, customer lightly
limited, noticable by qualified operator
Customer unable to notice any
insufficiencies, failure can be detected
only by specialised personel with
diagnostic equipment
No failure effects
3
8
5
4
2
1
temperature rise in catalyzer, uncontrolable device function.
Engine failure during ride, engine fails to stop, diesel particulate filter cloth, fuel in
environment, Sudden power drop by >20 %, noice, legal regulations branch (branch of
emissions regulations, vehicle or operator safety threating failure.
Engine fails to start, sudden power drop by >15 %, engine jamming, impossibility of
components assembly by customer.
Unstable engine idling (engine jerking), retarded start, impossibility to start the engine
under freezing point, threat to other engine components functions (as insuficient turbo
pressure)
>10 % power loss, problematic engine start process, smell – excess components
temperature, (as contact resistance on temperature sensor connector)
increase of fuel consumption, amount of emissions, driver physical stress, noice level
(without legal regulation branch), (for expample temperature sensor failure)
Visual defect – non-readable marking, rumpled bolts, starting corrosion, shot engine power
fluctulation
Minor idle engine speed increase, minor engine power changes, minor emissions increase,
minor noice increase
Unnoticable minor effects, detectable only by technical means (as slight temperature
increase on control unit)
No failure effects
17) Failure appearance probability
O (Occurrence)
Evaluation in 1-10 scale
Basic rule: Final goal is to reach O = 1. According to assessments tables, process is sutable when O ≤ 2.
Process is thought of being stable when O < 3. Process FMEA is in faulty mode when O > 4. Further preventive
actions must be defined.
General assessment criteria
Possible
failure extend
*
ppm *
cpk ***
Assessment
points
Very high. It is almost certain that failure/cause occurs often.
1/10
1/20
100.000
50.000
- **
- **
10
9
High. Failure/cause occurs repeatedly. Inaccurate process.
1/50
1/100
20.000
10.000
- **
- **
8
7
Moderate. Failure/cause occurs occasionally. Comparable with process.
1/20
1/1.000
1/2.000
5.000
1.000
500
0,94
1,10
1,17
6
5
4
Minnor. Rare occur of failure/cause. Competent process.
1/15.000
1/150.000
≤1/1.500.000
67
6,7
≤0,67
1,33
1,50
≤1,67
3
2
Unlikely. Improbable occur of failure/cause.
* After product life cycle
**no point
1
***during Process FMEA
18) Failure detection probability D (Detection)
Assessment in 1-10 scale
This criteria serve for disclosure of failure detection probability in process. Analysis should be considered only
in combination with another activities as process effectiveness – detection failure (diagnostic function, SPC,…) ,
Probability of defect parts leak (see point no.15 OxD factor evaluation)
page 23 (from 28)
Motorpal, a.s. Supplier Quality Manual
DETECTION
PROBABILITY
CRITERIA
DETECTION METHODS SPREAD
Cannot detect or is not checked
EVALUATION
10
Almost impossible
Absolute certainty of non-detection
Very remote
Controls will probably not detect
Remote
Controls have poor chance of detection
Very low
Controls have poor chance of detection
Low
Controls may detect
Moderate
Controls may detect
Moderately high
Controls have a good chance to detect
High
Controls have a good chance to detect
Very high
Controls almost certain to detect
Error detection in-station, SPC –
measurement, automatic measurement
2
Controls certain to detect
Discrepant parts cannot be made
because item
has been error proofed by
progress/product
design.
1
Almost certain
Control is achieved with indirect or
random
checks only.
Control is achieved with visual inspection
only.
Control is achieved with double visual
inspection only
Control is achieved with
SPC (Statistical Process Control).
Calibre control of first piece after setting.
Control is based on variable gauging
after parts
have left the station, OR Go/No Go
gauging
performed on 100% of the parts after
parts have
left the station.
Error Detection in subsequent
operations, OR
gauging performed on set-up and firstpiece
check.
Error detection in-station, error detection
in subsequent operations by multiple
layers of acceptance.
9
8
7
6
5
4
3
19) Risk factor- RPN:
RPN- risk priority number. RPN exposure is counted as product of three values (S,O,D) based on
Process FMEA. If RPN≥100 points supplier must always submit corrective actions for approval
(unless stated otherwise by customer).
Severity of failure effects
Failure appearence probability
Failure appearence probability
S (Severity)
O (Occurrence)
D (Detection)
- (point 16)
- (point 17)
- (point 18)
S x O x D = RPN (max.125)
Result higher than 100 indicates unstable process.
20) Comments:
Comments on "Important parameters" column can be added here (for example A-A section; A view; RPZ or
control plan/testing instruments etc.).
Also another necessary quality assurance supplier actions os machining tests, SPC, material and structural
analysis, etc.
21) Control plans / measuring instruments:
page 24 (from 28)
Motorpal, a.s. Supplier Quality Manual
Supplier will submit part control plan that defines all control methods used for product measurement and testing
control (measuring device type, control frequency, operations sequence, …) see attachement 4.
22) Machine capability:
Machine capability - Cm/Cmk
Performing machine capability is based on customer requirement. Customer defines required sample volume
for machine capability calculation. Unless stated otherwise, machine capability is usually measured on 50 ok
successive samples without intervention into machine. Machine is capable if Cmk ≥ 1,67.
Rarely due to measurements costs required amount for Cmk can be 35pcs.
Machine is capable if Cmk from 35pcs ≥ 2,0.
23) Process capability:
Process capability Ppk ≥1,33
Preliminary process capability Cpk ≥ 1,67
Schopnost procesu se provádí na základě požadavku zákazníka.
Předběžná způsobilost procesu Cpk = krátkodobé zkoumání (méně než 30 výrobních dní, minimálně 100
naměřených výsledků z min. 25 podskupin) umožňující včasné získání informací o účinnosti (nového nebo
modifikovaného) procesu.
Postup:
Zkoumání by se mělo zakládat na co největším počtu měřených hodnot. Aby bylo získáno dostatečné množství
informací pro rozhodování, musí být k dispozici výsledky alespoň 25 výběrů tak, aby bylo celkem naměřeno
100 hodnot (při jednom výběru nutno odebrat 3 - 5 dílů vyráběných ve sledu za sebou, doporučuje se odebrat 5
dílů za sebou). Období pro zkoumání předběžné způsobilosti procesu nesmí přesáhnout 30 dnů.Trvalá
(průběžná) způsobilost procesu Ppk = dlouhodobé zkoumání (minimálně 20 výrobních dní, min. 25 podskupin,
minimálně 100 naměřených výsledků) umožňující získání informací o účinnosti procesu za delší časové období.
24) Measurement instruments capability:
Measurement system analysis;
Measuring instruments capability is evaluated by two basic procedures.
1, Measuring instrument potential / Measuring instrument capability - Cg/Cgk ≥1,33;
Measuring instrument potential (cg) – value representing influence of measurement reproductibility, that
means rate of 15% of process width (6σ - equate probability 99,73% of normal data distribution) or 15% of
tolerance field (T) width and widht of variability (reproducibility) of measuring instrument (6sm - equate
probability 99,73% of normal data distribution).
Measuring instrument capability (cgk) – value representing of influence of measuring instrument accurancy
and reproducibility. Compared to potential it can in adition record shift of median outside the etalon value.
2, Total measuring instrument variance – R&R ≤10 %
Measuring system is reproducable if different operator using same measuring instrument reach identical or
very similar results.
Measuring system is repeatable if repeated measurement of same part gives same results.
25) SPC - regulated process:
Regulated measurement process that process data obtained by measuring of monitored quality
parameter (data in numeral form).
Regulated process is automatically applied on significat/critical characteristics.
If Preliminary process capability Cpk is ≥ 1,33 supplier is required to use SPC – regulated process.
If Preliminary process capability Cpk is lower then 1,33 supplier is required to submit corrective
actions.
26) Process control/regulation:
page 25 (from 28)
Motorpal, a.s. Supplier Quality Manual
Describe the process regulation or inspection method here (for example x/s, x/R, lower value,
colection card)
27) Dokumentace Cpk :
Cpk from supplier is required here and it is to be revised and recorded monthly.
28) Batch definition
A = material batch
B = heat treatment batch
C = production batch
D = lead off batch
All yellow colored fields are filled in by supplier, white fields by customer! Cross-hatched
fields will be filled in additionally by customer in case of uding in seriál production.
page 26 (from 28)
Motorpal, a.s. Supplier Quality Manual
Attachement no.16
:
page 27 (from 28)
Motorpal, a.s. Supplier Quality Manual
8D report description
8D-Report search for problem definiton and understanding. It asks why the process works outside the target range
and gives suitable corrective action. 8D-Report is devided into 8 steps.
1) Team assembly
If a single person cannot solve the problem quickly than put together small gruop of people with good knowledge of
product/process. Share the roles in the team (leader, members). Record the team members and identify their goals,
roles and responsibilities.
2) Problem description
Describe the problem entirely, not only its symptoms. Its recommended to ask questions (who, what, where, how,
how many, why,…)
3) Short-term actions
Implement, audit and record actions leading to isolation of problem from customer until permanent corrective action
is implemented. For example sorting the N.OK parts by customers (assembly, stocks, incoming inspection). Or
immediate replacement of N.OK parts with OK parts (if you have any).
4) Analysis of reasons
Goal is to identify all possible causes of problem occurance. Use Ishikawa chart (fish-bone chart) and identify
possible problem causes. Record the most probable causes.
5) Actions for elimination
Identify possible actions that should eliminate main causes of the problem. Assess the costs and supposed
effectiveness and choose the most suitable ones.
6) Effectiveness of introduced actions
Define, apply and monitor the permanent corrective action that will eliminate the problem.
7) Preventive actions
Goal of this phase is to prevent reoccurence of the solved problem by both technical and system means, for
example by changes in FMEA and control plan of this product and of all alike products with risk of same problem
occurance.
8) Evaluation
Evaluation of introduced actions and 8D-Report closing.
page 28 (from 28)