Professional Documents
Culture Documents
TABLE OF CONTENTS
chapter Issue 11 1. Introduction .................................................................................................................. 3 1.1. Preface ................................................................................................................. 3 1.2. Operating Principles "The Webasto Way" ............................................................ 4 1.2.1 Quality Principles .................................................................................................. 5 1.2.2 Environmental Principles ...................................................................................... 6 1.2.3 Safety Principles ................................................................................................... 7 1.3. Purpose and Scope .............................................................................................. 8 Supplier Qualification ................................................................................................... 9 2.1. Supplier Approval & Evaluation ............................................................................ 9 2.2. Supplier Selection ................................................................................................. 9 2.3. Supplier Development......................................................................................... 10 Prototype Requirements ............................................................................................ 11 3.1. Definition............................................................................................................. 11 3.2. Use of Prototype Production Data ...................................................................... 11 3.2.1. Procedure for Recording and Calculating PIST ........................................... 11 3.2.2. Procedure For Recording and Calculating of PIPC ..................................... 12 3.3. Control Plans for Prototypes ............................................................................... 13 Quality Planning ......................................................................................................... 14 4.1. Specifications and Requirements ....................................................................... 14 4.2. Process Flow Chart............................................................................................. 15 4.3. Feasibility Analysis.............................................................................................. 15 4.4. Failure Mode and Effects Analysis / FMEA......................................................... 16 4.5. Control Plans ...................................................................................................... 16 4.6. Process Instructions............................................................................................ 17 4.7. Planning of Tooling and Equipment .................................................................... 17 4.8. Gauges Measuring and Test Equipment ............................................................ 18 4.9. Preliminary Process Capability ........................................................................... 18 4.10. Packaging Planning......................................................................................... 19 4.11. Quality Assurance of Sub-contracted Parts .................................................... 19 Parts Approval & Initial Samples................................................................................ 21 5.1. Definitions ........................................................................................................... 21 5.2. Procedure ........................................................................................................... 21 5.2.1. Production Trial Run .................................................................................... 21 5.2.2. Identification of Initial Samples .................................................................... 21 5.3. Requirements...................................................................................................... 22 5.4. Approval.............................................................................................................. 23 Product & Process Quality Requirements.................................................................. 24 6.1. Suppliers Responsibility...................................................................................... 24 6.2. Process Capability Requirements ....................................................................... 24
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Non-Conformities & Corrective Actions...................................................................... 27 7.1. General ............................................................................................................... 27 7.2. Treatment of Non-Conforming Supplied Parts at Webasto ................................ 27 7.3. Reworked Parts and Problem Solving ................................................................ 28 Supplier Performance Rating ..................................................................................... 29 8.1. Quality Rating ..................................................................................................... 29 8.2. Engineering, Purchasing and Logistics Rating.................................................... 29 8.3. Non-Conformities ................................................................................................ 29 Continuous Improvement ........................................................................................... 30 9.1. General ............................................................................................................... 30 9.2. Continuous Improvement of Processes .............................................................. 30
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10. Appendix ................................................................................................................ 31 10.1. Issue and Revision Record ............................................................................. 31 10.2. Glossary .......................................................................................................... 32 10.3. Acronyms ........................................................................................................ 35 10.4. Check Lists...................................................................................................... 35
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Webasto, with its stringent Quality Management, wants to meet customers and consumers highest expectations. Therefore the most important part of suppliers give special emphasis to convert these targets. The Quality Guideline for Suppliers is fundamental to our joint partnership. It defines the quality requirements for development, production and verification of delivered parts and services. Webasto supports and develops team work with its suppliers. The clear definition of requirements and the implementation of communication at all levels generates working conditions encouraging open association with ideas and problems Webasto expects that all suppliers keep to the fixed guidelines, which are part of each agreement. Suppliers have to make sure that their subsuppliers also fulfil these specifications. As suppliers highly influence the performance of Webasto, in addition to this guideline customer requirements of automotive manufacturers are applied accordingly to them. Webasto expects its suppliers to develop their quality management systems according to the requirements of international quality standard ISO TS 16 949:2002. This will enable them not only to fulfil all governmental and safety requirements but also to reliably supply Webasto with defect free parts.
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1.2.
The operating principles and the competence slogan Feel the drive are important parts of Webastos corporate culture. Both define a philosophy that is constantly oriented to customer benefit. The intention is to give orientation for a common behavior to all members of staff and to demonstrate to our business partners that we are prepared to react on the challenge of the market in a serious and focused manner.
We are a worldwide leader of automotive products that enhance comfort and driving experience. We enhance the long-term value of our company through profitable growth that is essential for investment and innovation. We recognize market opportunities and trends early and convert them into groundbreaking and innovative products. We increase customer loyalty by providing comprehensive technology and skilled application throughout the lifecycle of our products. We apply a zero-defects strategy to all of our business processes. We respect the environment and visibly demonstrate our responsibility in our everyday activities. We encourage and support our employees to develop their skills and abilities to improve the overall strength of our company. We promote a seamless transfer of knowledge through effective communication, both internally and externally, based on the balance between centralized and decentralized responsibility. We cooperate with our worldwide customers by relying on local competencies and by transferring knowledge and synergies internationally. We build a solid network of carefully selected partners and suppliers who share our high standards, leading to our mutual success.
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10. In selecting our suppliers and contractors, we give priority to companies with a living environmental policy.
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3. 4. 5. 6. 7.
8. 9.
10. The safety of customers, suppliers, and visitors on company property is our central desire.
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1.3.
The Quality Guideline for Suppliers applies to all internal and external suppliers of prototypes, serial parts and services for Webasto. This guideline forms part of all inquiries and orders. Suppliers quality management system should be adjusted to international quality standard ISO TS 16 949:2002 and should be developed in accordance with regional requirements of customers, laws and national standards. This guideline supports the understanding of the special requirements of Webasto and helps to convert these into a successful cooperation.
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Webasto has a list of suppliers that proved their ability to meet our expectations in the past. All materials for prototypes and mass production parts and all services are only bought from the suppliers on the Approved Supplier List. Suppliers on the list are audited when circumstances make it necessary. A typical cause for a supplier audit may be insufficient performance. The kind of audit depends upon the deficiencies observed. New suppliers certified according to ISO 9001:2000 can enter the approved suppliers list if: - the evaluation carried out by purchasing is positive and - the supplier has installed an environment management system (e.g. according to ISO 14000) until 31st of December 2005 and - a Webasto short audit is successfully passed. New suppliers certified according to ISO TS 16949:2002 can enter the approved suppliers list if: - the evaluation carried out by purchasing is positive and - the supplier has installed an environment management system (e.g. according to ISO 14000) until 31st of December 2005. If instances require, Webasto audits the suppliers processes. Typical reasons may be launches of new products, start of production after engineering changes or insufficient performance of the supplier. The supplier grants Webasto as well as its customers the right to visit the suppliers to verify that sub-contracted products, the processes, and the services conform to specified requirements. 2.2. Supplier Selection
The selection of a supplier for a certain part or program is based on the Approved Supplier List only, preferred are suppliers with an approved environment management system (see above). In this case, for every project a document has to be prepared showing the suppliers name, the suppliers manufacturing facility, and the related part. Additionally, customer specific requirements are taken into consideration. This document is signed by Purchasing, Quality, Engineering and relevant plant personnel.
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Webasto develops its supply base towards ISO TS 16 949. Webasto is willing to support its suppliers by giving the necessary information, expressing clearly its expectations and arranging meetings for exchange of knowledge and experience. To monitor the suppliers' success in implementing a quality management system that fulfills the requirements of ISO TS 16 949, all suppliers are required to do a yearly internal audit according to ISO TS 16 949. To meet the requirements of Webasto, the suppliers quality management system must be based on prevention rather than detection of failures. For this reason, the use of process or design features to prevent manufacturing of non conforming products is necessary. When potential sources of non conforming units are identified by FMEAs, capability studies and service reports, these sources shall be addressed using mistake proofing methodology during the planning of processes, facilities, equipment and tooling as well as during problem resolution (see chapters 4 and 7). The employees are considered as the most important resources of the supplier. Webasto therefore requires its suppliers to develop their personnel and use motivation systems to encourage the continuous improvement.
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Prototypes are parts which, in general, are not produced from production tools. They are produced according to preliminary drawing specifications by means of all the technical and production equipment available to the manufacturer. They must be fully operational. The prototype supplier should be in close contact with Webastos designers. If requested, the prototype supplier has to provide Webasto with all prototype production data for the planning of the production process and the manufacturing of production tools. The manufacturer must consider requirements and data such as PIST and PIPC (see 3.2) stipulated for the evaluation of prototype parts. For prototype parts, the minimum requirement for PIST and PIPC is 70%. All significant and critical characteristics, however, must be manufactured according to the specifications; rework is permitted. The manufacturer shall submit evidence in writing that the required specifications have been fulfilled. If processes for PIPC evaluations are not yet available, comparable processes should be utilized. The evaluation of the prototype parts is within the responsibility of the designer and the Quality Engineer of the Webasto plant. Prototypes are to be clearly identified by tags and tapes. Deviations from the above mentioned procedure are not acceptable unless otherwise agreed upon in written form before the parts are being delivered to Webasto. 3.2. Use of Prototype Production Data
Suppliers of prototypes have to maintain a system which facilitates the recording of data as early as in the prototype stage. PIST: Percentage of Inspection points that Satisfy Tolerance PIPC: Percentage of Inspection points that are Process Capable The purpose of these factors, is to quickly get an idea as to what extent the requirements defined in the drawings and specifications have already been met during the individual stages of the development of a product. 3.2.1. Procedure for Recording and Calculating PIST a) For each cavity/tool, a measurement report must be prepared with six parts of a production step with respect to all measurements, remarks and specifications in order to be able to determine the production lot. The delivered parts should be labeled. b) PIST corresponds with the number of o.k.-positions divided by the number of requested characteristics multiplied by 100%. c) PIST is to be indicated in the measurement report as actual value. For all positions out of tolerance, the additional measurements including the corresponding deadlines
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b)
Paragraph c) - e) of the above listed PIST procedure apply accordingly. Calculation Example: For a part produced by a new process with new tooling which have 4 process variables, Ppk was determined as follows: Characteristic 1: Characteristic 2: Characteristic 3: Characteristic 4: process not stable Ppk = 1, 87 Ppk = 2, 35 Ppk = 2, 20
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70%
85%
100%
prototypes
prelaunch parts
initial samples
In order to estimate the prospective process capability and to calculate PIPC, comparable (surrogate) processes, i.e., similar tools, materials, can be applied. 3.3. Control Plans for Prototypes
Control Plans for prototypes are required. They are descriptions of the dimensional, material and functional tests that will occur during prototype built. The methodology is described in chapter four and in the QS 9000 reference manual "Advanced Product Quality Planning and Control Plan (APQP)".
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Advanced Quality Planning is the basis for the prevention of potential failures and for continuous improvement. The Advanced Quality Planning program covers the stages from development to mass production. It requires a cross functional team that includes all main departments such as Sales, Engineering, Production Engineering, Manufacturing, Purchasing and Quality Assurance. The following chapters define the planning efforts to be taken by the supplier. A plan has to be developed showing the single steps, the related completion date and the responsibilities for necessary actions. Before an order is given to a supplier, the feasibility has to be proven, without completion of the Advanced Quality Planning, the initial sample inspection reports are not valid. Catalogue and standard parts may be the exception. Usually the Advanced Quality Planning is done in cooperation with the supplier' cross s functional team and is continuously checked for progress. In the case Webasto does not participate, however, the supplier is required to do this on his own and to have it approved and signed by Webastos Quality Assurance Engineer in charge. The advanced quality planning may result in a quality agreement defining the most important characteristics and determining how they are to be checked and evaluated during mass production. For details, see also the QS 9000 Reference Manual "Advanced Product Quality Planning and Control Plan (APQP)" or supplier portal at Webasto homepage. 4.1. Specifications and Requirements
Webasto provides the necessary information and engineering data for all inquiries and orders except for standard parts. The data include this Quality Guideline, all current Webasto drawings, the Webasto specifications and technical terms of delivery (e.g. Webasto and customer standards, but not common industrial standards) as well as all other regulations and standards which describe quality characteristics to be adhered to. Additional relevant data are to be provided by the supplier, if he is responsible for engineering and design. They will be released by Webasto if necessary. During the Advanced Quality Planning stage, the supplier is to continuously check the engineering data with respect to completeness, relevance and correctness. The supplier is responsible in the event of later changes that his relevant departments have current data and that these correspond with all documents issued such as instructions for manufacturing and quality.
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A process flow chart is the schematic description of the process plan from receipt and production of goods to their shipment. It is supplemented by short descriptions of the individual production steps, lists the manufacturing equipment and the various inspection points and shows the material flow. Process flow charts are indispensable for quality planning. They are the basis for FMEAs and for Inspection and Control plans. Important processes, automatic monitoring and inspection points must be identified, rated in the process FMEA regarding the existing risk and if necessary safeguarded by appropriate methods specified in the Control plan. Material labeling and material flow must be defined in such a manner that the processing of wrong materials and parts is impossible. During the pre-launch stage, a current and detailed process flow chart is to be consulted in all meetings on FMEAs, Control Plans and capability evidence. 4.3. Feasibility Analysis
The feasibility analysis evaluates whether a requested part can be manufactured under mass production conditions per the descriptions and requirements in drawings and specifications. The feasibility analysis is to be carried out by the supplier in cooperation with Webastos departments in charge. This assessment is required for new products, in case of product and process changes and of major increases in volume. In particular, the indicated tolerances have to be evaluated statistically as well as the function and use of the component. Furthermore, a statement is required as to whether the capacity of the supplier allows for the delivery of the planned number of parts and whether the scheduled deadlines can be met. Suggestions of the supplier regarding necessary changes or supplements to drawings and specifications are expected by Webasto, carefully inspected and are implemented if they contribute to the continuous improvement of product quality, process capability and economical manufacturing. The following methods for feasibility analysis can be applied: FMEAs Process Capability Analysis Design of Experiments (D.O.E.) Check List - Feasibility Assessment (Advanced Product Quality Planning and Control Plan (APQP))
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The FMEA assists in the prevention of failures through a structured analysis of the potential failure modes. FMEAs must be used in both design and process planning. They are required for all new or changed products and processes. FMEAs are living documents which must be continuously updated with respect to design, process and usage changes throughout the product life cycle. Design FMEAs are to be prepared by the department responsible for design and engineering activities. Process FMEAs identify possible process weaknesses and help work out corresponding measures to eliminate them. The Manufacturing Engineering Department in charge is responsible for the preparation prior to the production of tools and facilities. Design FMEA should be available before a process FMEA is prepared. If Webasto, however, cannot make a design FMEA available, the supplier must proceed with the preparation of a process FMEA without delay. (For details, see QS 9000 Reference Manual FMEA (or VDA Volume 4 Part 2). Product characteristics and process parameters identified by the FMEAs as significant or "critical" become essential elements of the Control Plan. The supplier is required to make the process FMEA available to the Webasto Quality Engineer in charge at any time. The results of the FMEA are to be implemented prior to the initial sample inspection. 4.5. Control Plans
An important phase of the process for quality planning is the development of a Control Plan. A Control Plan is a written description of the system for controlling parts and processes. A single Control Plan may apply to a group or family of products that are produced by the same process at the same source. Sketches, as necessary, may be attached to the Control Plan for illustration purposes. In support of a Control Plan, process monitoring instructions and inspection plans should be defined and used continually. In effect, the Control Plan describes the actions that are required at each phase of the process including receiving, in-process, out-going, and periodic requirements to assure that all process outputs will be in a state of control. Periodic requirements may be functional tests, reliability and durability tests according to engineering specifications and product audits. The Control Plan may be required throughout the product life cycle, i.e. starting in the Prototype phase. It will be required during the Prelaunch and Production phase. It remains a living document, reflecting the current methods of control and measurement systems used. The Control Plan contains all critical and significant characteristics identified on drawings or specifications, derived from FMEA' and known from lessons learned and suppliers' s experience. Approval by Webasto may be required. For details see ISO/TS 16949 and QS 9000 reference manual "Advanced Product Quality Planning and Control Plan (APQP)".
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4.6.
Process Instructions
The Product Quality Planning Team should ensure that understandable process instructions, job instructions and operator instructions provide sufficient detail for all operating personnel who have direct responsibility for the operation of the process. Theses instructions should be developed from the following sources: FMEAs Control plan(s) Engineering drawings, performance specifications, material specifications, visual standards and industry standards Process flow chart Floor plan layout Packaging standards Process parameters Supplier expertise and knowledge of the process and products Handling requirements Operators of the process. The process instructions for standard operating procedures have to be posted to the working place and include all process relevant set-up parameters. 4.7. Planning of Tooling and Equipment
Process flow charts, Process-FMEAs, and control plans are to be inspected as to whether particular requirements imposed due to former problems have been sufficiently considered in the design of the machines, tools, gauges and facilities. Prior to the delivery of new tools/facilities, preliminary process capability studies have to be planned and carried out. The supplier has to draw up a detailed schedule for the procurement of new or changed tools, gauges and facilities. It has to be checked periodically to what extent this schedule has been fulfilled in order to guarantee that it corresponds with the Webasto schedule. Whenever the suppliers schedule does not correspond with the Webasto schedule due to technical modifications, tool problems and other reasons, the Webasto buyer in charge and the Webasto Quality Engineer have to be informed immediately. Proposals for necessary actions to keep the original due date shall be submitted in writing.
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The supplier is responsible for the development of suitable gauges as well as measuring and test equipment (incl. software) for satisfactory process monitoring. The supplier and Webasto agree on the gauging methods and the gauging equipment to be applied. In order to increase the security regarding the production and the shipment of defect free parts, all measuring and test equipment listed in the Control Plan must be certified and capability has to be proven by realizing the Reference Manual Measuring System Analysis (MSA). For details, see QS 9000 Reference Manual MSA. It is exclusively the suppliers responsibility to provide standard gauging equipment. Special tests and the procurement of the corresponding necessary gauging equipment require Webastos approval. The gauging methods and equipment suggested by the supplier and coordinated with Webasto must be recorded in the Control Plan. Gauging equipment certifications are also required for special gauging equipment and measurement programs using CNC-gauging-machines. The manufacturer is to develop and apply a plan which tests the suitability of measurement systems at sufficient intervals in order to secure the system as a whole. This plan must be documented and continuously updated. If production tools, master parts or similar devices are used as gauging equipment, they have to be checked and documented in the same way as any other gauging device. Their traceability conforming to national resp. international reference standards for calibration must be ensured also in this case. 4.9. Preliminary Process Capability
Preliminary process capability studies are short-term studies conducted to obtain early information on new or revised processes in view of customer requirements. The studies should be based on as many measurements as possible. At least 25 samples of 5 pieces are required for all significant and critical characteristics. Initial data must be gathered in production sequence by sampling and used to develop preliminary control limits. These limits are necessary for the evaluation of the process stability. Once the process has proved to be stable (no inexplicable values outside the control limits or other evidence of non-random behavior), preliminary process potential (Pp) and preliminary process capability (Ppk) can be determined. The indices Pp and Ppk are used to identify the results of preliminary process capability studies and to differentiate them from ongoing process potential and capability results indicated by the indices Cp and Cpk. The calculations of Pp and Ppk are based on the same formula as those of Cp and Cpk. After having evaluated the preliminary process capability for a longer period of time (e.g. twenty days of production), long-term process capability studies can be performed.
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Prelaunch or special sample parts are parts which, unlike prototype parts, are produced from production tools. Certain rework operations may be acceptable to meet drawing requirements as long as they are disclosed on the sample documentation. The inspection of these parts is based on a special sampling report. In this respect, parts numbered consecutively from 1 to 6 in process sequence are measured 100%. In addition, evidence of PIST and PIPC is to be provided. For special sample parts, the minimum PIST/PIPC requirement is 85%. The special samples are evaluated by the Quality Engineer in charge. Special samples and deliveries are to be clearly indicated by tags and tapes according to agreement. Initial sample parts are manufactured by the production staff at the final production site using production tools, production processes, materials, feeds, speeds and cycle times. Initial sample inspection is decisive for the acceptance of production methods and facilities, dimensional testing, materials testing and statistical analysis. With initial sample inspection, the supplier confirms with his signature that the initial samples are in accordance with all requirements determined in drawings and specifications. 5.2. Procedure
All parts, material, etc., delivered to Webasto, which fall under the following categories shall be subject to the quality evaluations noted below under "5.3. Requirements". Unapproved products that are received at Webasto shall be handled as rejected material and will be returned to the supplier at the suppliers cost through Purchasing or scraped on site if agreed on by the supplier. 5.2.1. Production Trial Run The validation of the effectiveness of the manufacturing process begins with the Production Trial Run. It must be conducted using the same production conditions as defined under "Initial Samples". In fact it can be used to produce the initial samples. The minimum quantity is usually 300, but can be agreed upon during the APQP-Process. The approval of the Production Trial Run at the suppliers premises may be required by Webasto. The output of the Production Trial Run is used for: Preliminary process capability study Measurement systems evaluation Final feasibility Production validation testing Production part approval (PSW) Packaging evaluation 5.2.2. Identification of Initial Samples
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The standard procedure for submission of a sample is defined in the QS 9000 Reference Manual Production Part Approval Process (PPAP) (if requested otherwise: e.g. PPF, according to VDA Volume 2). The procedure and Submission Level shall be determined during the APQP-process (see chapter 4). Where the product requires verification at the suppliers premises, Webasto shall undertake this function following prior arrangements and ensuring methods have been agreed with the supplier. The Production Part Approval Process (i. e. Initial Sample and Production Trial Run approval) requires at least the following to be submitted by the supplier: The quantity of parts required by the purchase order delivered on time. A part submission warrant (PSW) and a dimensional report showing complete (100%) measuring of six samples per cavity/tool of each part number to all dimensions and specifications on the drawing. The drawing showing all measured dimensions marked up and numbered according to the dimensional report. PIST and PIPC showing 100% compliance (see also Chapter 3). Preliminary process capabilities study showing Pp/Ppk for all significant and critical characteristics based on at least 25 sub groups of 5 pieces in order to obtain sufficient data for decision making. The data file i.e. paper or electronic data and the data format should be agreed upon during the APQP Process. The dimensional report of all used gauges The material data sheet (MDB) according to VDA volume 2 has to be completely established in the International Material Data System (IMDS). It additionally has to be submitted to the appropriate Webasto subsidiary and attached to the PSW. The material analysis is to be performed at an independent laboratory, certifying compliance to all drawing specifications. Engineering test data to all specifications (performance testing) which are noted on the drawing. The Control Plan that is specified for the part/material to be produced. The Process Flow Chart including checks
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Approval of Initial Samples shall be given when the following requirements are fulfilled: APQP is completed. All dimensional, material analysis related and functional as well as reliability requirements are 100% o.k.- to drawings. All required paperwork is received by Webasto
In case the functional approval cannot be completed, a deviation issued by Webasto is required before production volume delivery is due. Approval of Production Trial Run shall be given, when Initial Samples are approved and the targets for the production trial run are achieved.
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After the supplier has gained PSW approval and has received the release to ship products, systems must be in place to be sure that quality parts will continue to be received by Webasto. The supplier is responsible that all actions defined for this purpose per FMEA, Control Plan etc. are maintained throughout the supply chain. This includes sub-contractors, in house processes and packaging. Receiving, in process and final inspection shall be conducted in concurrence with Control Plans and inspection instructions. The extent of inspection and control over the suppliers processes shall be based on their stability. To minimize inspection efforts and to maximize the security that all specified requirements are met, all supplier activities should be directed towards defect prevention methods such as statistical process control (SPC) and error proofing rather than defect detection. For this reason, preferably, SPC charts such as Xbar and R charts based on preliminary capability studies shall be used to monitor process performance and product characteristics, particularly significant and critical characteristics. Process capability shall be calculated on a regular basis. In cases where variable data can not be obtained, the acceptance criteria for attribute data sampling plans shall be 0 defects. Acceptance criteria for visual standards are described in 6.4. For the control of significant characteristics by attribute data, 100% inspection is highly recommended. 6.2. Process Capability Requirements
The control of processes by SPC require that these processes are being carried out under controlled conditions. This means that they are not influenced by any systematic fluctuations. Process stability must be studied before production begins and checks must be made to ensure that the results of these studies are continuously utilized during the production stages (for background see QS 9000 Reference Manual Statistical Process Control). For new products produced by new tooling and equipment, the following capability factors are required by Webasto: Ppk 2.0 Cpk 1.67
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Identify and correct special cause ...process has gone out of control in an adverse direction. All individuals in the sample are within specification 100% inspect inspect 100% since last in-control point Accept product Continue to reduce process variation
Identify and correct special cause ...process has gone out of 100% inspect control. One or more individuals in the sample are outside specification. 100% inspect product produced since the last in-control sample
The supplier is responsible for monitoring the processes and keeping the SPC data on file. He should transmit these data to Webasto upon request or according to the quality agreement, if applicable. 6.3. Traceability
Proof of traceability is required at PSW time for all parts and characteristics affecting safety or governmental regulations, such as Federal Motor Vehicle Safety Standards (FMVSS), e.g., flammable parts and glass. In addition it is required that all parts supplied to Webasto have a method to track backwards to the specific production lot, date, etc. The supplier is required to improve and stabilize quality and facilitate quick segregation of defects by traceability. An effective traceability system will minimize costs incurred should a recall situation occur. The Traceability Plan must be submitted as part of the Quality Plan and is subject to approval by Webasto. The system must include: Production lots must be traceable back to their production line, shift, date of manufacturing and inspection records. The lot numbers/date codes must be indicated on each part. No more than (2) two lot numbers/date codes per shipping unit. Production lot number/date codes must be delivered in order of production. First In - First Out (FIFO) parts to be observed for all stocks/warehouses. Parts received at Webasto without proper traceability labeling will be subject to rejection.
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Boundary Samples define the quality of non measurable characteristics by establishing a visual acceptance standard. The characteristics to be controlled by boundary samples will be established in the Control Plan. Requirements may also be generated from pre-production evaluation or mass production line trials. The supplier is responsible to select components for consideration as boundary samples. The components must be representative of production capability and should be selected from line trial production. Samples must be submitted to Webastos responsible Quality Engineer with the quality characteristic clearly indicated on the component. It should be clearly marked, boundary sample, dated and signed where possible and a fully completed boundary sample label attached (records see appendix). The minimum number of samples required is two (2), a higher quantity may be required for the use by Webastos customer or the suppliers sub-contractor. Webastos Quality Engineer will assess all boundary samples, sign the sample tag and where applicable, sign the boundary sample for approval. The supplier is responsible to create an internal control system to monitor the issue, use and periodic inspection of boundary samples. The system should demonstrate the ability to monitor and withdraw temporary standards to prevent out of date standards remaining in use. The supplier is also responsible to ensure that sub-contractors operate similar control procedures.
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By the use of quality planning, prototype and production part approval and the suppliers system for process and production control the prerequisites to meet Webasto' quality s requirements defined in drawings and specifications are given. Thus Webasto expects the supplier to deliver only parts that are in full compliance with these requirements. If the supplier is uncertain about the standard required, he shall immediately contact the quality department of the affected Webasto Company. Webasto also expects immediate notification if the supplier detects that non conforming or suspect material may be delivered. In exceptional circumstances, where Webasto quality standards can not be met, the supplier may request a deviation. The validity of a deviation is restricted to a limited time or quantity of parts. During this time, the supplier has to work on the problem solving and if necessary stay in close contact with the affected Webasto departments. The deviation procedure must be specified in the suppliers quality system documentation. In case of eventual supply shortages, the Logistics Department or the Webasto consumer plant concerned is to be notified immediately. Webasto reserves the right to charge the supplier for additional expenses incurred. 7.2. Treatment of Non-Conforming Supplied Parts at Webasto
All supplied parts identified as being defective at the Webasto consumer plant are rejected by immediately notifying the responsible supplier. In order to avoid a shut down of Webastos production lines, the flow of defect free parts to the lines must have priority for the supplier. For this reason, containment actions such as sorting, exchange of stock, rework etc. are required within one hour unless waived by the Webasto consumer plant. If this can not be achieved by the supplier, Webasto will start the necessary work at the suppliers expense. The following actions have to be taken by the supplier: Identification and separation of non-conforming parts in the suppliers stock. Identification of the first three deliveries with good parts and of all rework parts with an appropriate label on every container / rack. An 8-D report or another comparable document upon agreement showing the completion of step 1,2,3 within 24 hours. The timing for the complete resolution of the problem and the closure of the 8-D report has to be submitted within one week. The supplier will be charged for the cost of necessary actions at the Webasto consumer plant including the retro-fitting of products already delivered to customers at the actual labor rate.
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Any rework of parts supplied to Webasto has to be authorized and approved by the Quality Department of the Webasto consumer plant and if applicable, by Engineering in writing, prior to shipment of these parts. They have to be identified appropriately and be delivered as separate shipments. The supplier must ensure that the rework parts are inspected for full compliance to the agreed upon rework standards by the suppliers Quality Department prior to shipment. Related documentation must be made available to Webasto upon request. If defective parts can not be reworked in a way that they conform to all specifications, the supplier may in exceptional cases apply for a deviation to ship those parts. Approval of the deviation request must be given in writing. The supplier shall analyze parts returned from Webastos consumer plants, engineering facilities and from Webastos customers to find root causes, establish corrective actions and prevent re-occurrence. For this reason as well as for internal non-conformances, a disciplined problem solving method should be used. Webastos preferred approach is the 8-D procedure. Comparable methods can be used upon agreement. The suppliers procedure should be defined in writing and include the following: Investigation of the root cause of non-conformities relating to product, process and quality system. Determination of short-term and final corrective actions being taken to eliminate the cause of non-conformities. Application of controls to ensure that a corrective action is taken and that it is effective. Determination of any related problem requiring preventive action. This also applies to similar parts and procedures. Initiation of preventive action and application of controls to ensure that it is effective. Definition of responsibilities for all actions and for the related documentation.
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Webastos requirements as to the suppliers quality system, its evaluation and development are described in Chapter. 2 of this guideline. However, it is recognized that an elaborate quality system does not guarantee that the supplier is consistently supplying Webasto with defect free products. The performance of the suppliers is therefore continuously monitored and evaluated by the Webasto Departments being responsible for Quality Management, Engineering, Purchasing and Logistics. 8.1. Quality Rating
Quality performance of the supplier is measured in ppm (defective parts per million). This monthly calculation takes into account the quantity of defective parts related to the quantity of delivered parts per month. The suppliers quality level is indicated as a 6-month rolling average. Targets for the ppm level are set yearly by the local Webasto companies. These targets are used only for the continuous improvement process and do not change the general zero-defect-goal. 8.2. Engineering, Purchasing and Logistics Rating
The supplier performance as to Engineering capability, services to the Webasto Purchasing Department and Logistic requirements including delivery are evaluated by the related departments on the basis of an assessment criteria check sheet. Webastos delivery requirement is 100%, targets for all other ratings will be set yearly by the local Webasto Companies. 8.3. Non-Conformities
If a supplier fails to meet the above mentioned targets, their management is required to establish a corrective action plan and present it to the local Webasto Company. The quality of this action plan determines whether the supplier is set on probation and how long the probation phase will last. If an approvement of the supplier' rating can not be s expected within a 6 month period, he will put on hold for all new orders.
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Continuous improvements is one of the basic principles of Webastos quality policy (see Chapter 1 of this guideline). It is essential to keep and ameliorate our position in the market. The high impact that our suppliers have on Webastos performance as to products and services require the deployment of the continuos improvement philosophy throughout our suppliers organization. Continuous improvement of our suppliers must include: quality of parts, service (e.g., timing, delivery, engineering capabilities and cooperation) and price. This requirement does not replace the need for innovative improvements. The supplier should develop specific action plans for continuous improvement in processes that are most important to the customer once those processes have demonstrated stability and acceptable capability. These processes can be selected and monitored using the quality operating system (QOS). Extending the continuous improvement philosophy to all business processes means to find measurables for these processes. This includes characteristics that can only be evaluated using attributes data. Here continuous improvement means perfection of process methods and comparing to measurable targets. To effectively use the continuous improvement process, the supplier shall demonstrate knowledge of the known measures and methodologies for process analysis, monitoring and rating. 9.2. Continuous Improvement of Processes
Regardless of the capability requirement for the demonstrated process capability continuous improvement is required with the highest priority on significant and critical characteristics. The supplier shall identify opportunities for quality and productivity improvements and implement appropriate improvement projects. Examples are the following points: machine downtime, machine set up, die change, machine change overtime, Excessive cycle time, Scrap, rework and repair Non value added use of floor space Excessive variation Waste of labor and materials Excessive cost of non quality Difficult assembly or installation of the product Excessive handling and storage Marginal measurement system capabilities Customer dissatisfaction
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10.1. Issue and Revision Record issue 1 2-5 change first edition (only german version) various changes in German version only date 09/93 07/94 07/96 11/98 changed by Partl Partl
new edition: reworked according to the QS 9000 requirements and agreed upon by the European Webasto subsidiaries. only German version updated
Kohlmeier
7,8
new Logo implementation of changes of German version in chapters 2.1, 2.2, and 5 Changed according to ISO TS 16 949 Changes according to international Webasto requirements and Operating Principles
10 11
02/02 10/03
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Audit Capability
Critical Characteristic
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Feasibility
Job Instructions
Lot Traceability
Nonconformity ppm
Procedures
Process Control
Process Parameter
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Quality Planning
Repeatability
Reproducibility
Rework Specification
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10.4. Check Lists you find the check lists in the section Download in the Internet at supplier portal at Webasto homepage
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