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TITLE: PAGE OF SEC. 1.0, TITLE PAGE 1 1 PROCEDURE # L-PUR-25
REV. G
DATE: 05/09/06
PREPARED BY: STEVE FELLOWS
APPROVED BY: CRAIG BENSON
MANUAL REVISION G
SUPPLIER QUALITY
MANAGEMENT GUIDELINES
Hi-Stat a Stoneridge Company Lexington Division 345 South Mill St.
Lexington, Ohio 44904 Phone: (419) 884-1219
Fax: (419) 884-4196
TITLE: PAGE OF SEC. 2.0, TABLE OF CONTENTS 1 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 G 05/09/06 STEVE FELLOWS CRAIG BENSON
Quality SystemRequirem ents
Section 3.0
Supplier Self Survey
Section 5.0
Hi-Stat Supplier
Assessm entSection 6.0
PPAPSection 8.0
Packaging, Identification,
Visual ConditionsSection 9.0
Form sSection 15.0
Purchase Order Term sSection 16.0
Q .C.SpecificationSection 13.0
M aintaining Approved
StatusSection 7.0
Non-Conform ing
M aterialSection 11.0
Dock to Point Of UseSection 14.0
Continuous Im provem entSection 12.0
M aterial CertificationSection 10.0
Supplier Quality M anagem ent Guidelines
Supplier Selection
Section 4.0
TITLE: PAGE OF SEC. 2.0, TABLE OF CONTENTS 2 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 G 05/09/06 STEVE FELLOWS CRAIG BENSON
Quality SystemRequirements
Supplier Self Survey
Hi-Stat Supplier
Assessment
PPAP
Packaging, Identification,
Visual Conditions
Forms
Purchase Order Terms
Q.C.Specification
Maintaining Approved
Status
Non-Conforming
Material
Dock to Point Of
Use
Continuous Improvement
Material Certification
Supplier Quality Management Guidelines
Quality System Mgr. Supplier Quality Agent
Quality EngineerAPQP Engineer
Purchasing AgentSupplier Quality Agent
Quality EngineeringAPQP Engineer
Product EngineerManufacturing Operations
Purchasing AgentSupplier Quality Agent
APQP Engineer
Purchasing AgentSupplier Quality Agent
Purchasing AgentSupplier Quality Agent
APQP EngineerQuality Engineer
Supplier Selection Process
TITLE: PAGE OF SEC. 2.0, TABLE OF CONTENTS 3 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 G 05/09/06 STEVE FELLOWS CRAIG BENSON
Table of Contents
Section # Title Revision Page 1.0 TITLE PAGE G 1 of 1 2.0 TABLE OF CONTENTS G 1 of 3 3.0 QUALITY SYSTEM REQUIREMENTS D 1 of 7 4.0 SUPPLIER SELECTION PROCESS B 1 of 3 5.0 SUPPLIER SELF-SURVEY B 1 of 2 6.0 SUPPLIER ON-SITE QUALITY SYSTEM C 1 of 3 ASSESSMENT 7.0 MAINTAINING APPROVED STATUS D 1 of 6 8.0 PRODUCTION PART APPROVAL PROCESS B 1 of 5 9.0 PACKAGING, IDENTIFICATION, AND B 1 of 6 VISUAL CONDITIONS 10.0 MATERIAL CERTIFICATION B 1 of 2 11.0 NON-CONFORMING MATERIAL D 1 of 5 12.0 CONTINUAL IMPROVEMENT B 1 of 3 13.0 Q.C. SPECIFICATION QO1-0001 C 1 of 5 14.0 DOCK TO POINT OF USE PROCEDURE C 1 of 3 15.0 FORMS B 1 of 1 16.0 PURCHASE ORDER TERMS, CONDITIONS B 1 of 2 AND TOOLING NOTES 17.0 REVISION HISTORY G 1 of 1
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 1 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
Quality System Requirem ents
Third party registration
Are you registered by a
third party? YesNo
Present form al registration plan
to Hi-Stat’s Supplier
Developm ent Engineer or
becom e certified by Hi-Stat
Supply Hi-Stat’s Supplier
Developm ent Engineer with your
currentTS-16949
ISO -9001/2000 certification
Quality Requirements
Attend design reviews at Hi-Sat
or via teleconference
Maintain a system to use only current drawings,
and perform inspections to the critical dim ensions
on those drawings
Use statistical m ethods to control and evaluate
processes variability and continual im provem ent
Subm it statistical data upon request,
report low Cpk values
Be fam iliar w ith the use of “Core Tools”, for
Docum enting Control Plans, PFMEA’s
W ork Instructions, and subm itting PPAP’s
100% On Time Delivery
Respond prom ptly to all
“Supplier Corrective Action
Reports”
Assure all sub-contractors are approved and are
operating under a controlled system
Achieve Dock-to-Stock status
Subm it “Annual Validation Reports”
Reporting of Restricted
Substances(IM DS)
Supplier shall subm it data
for all restricted and
controlled substances
Re-Source
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 2 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define the quality requirements of Hi-Stat's suppliers. SCOPE: These quality requirements are applicable to suppliers of materials, processes,
components and/or services used in the manufacture of Hi-Stat's products. Exception: Commercially available items are excluded from this scope and
may include, but are not limited to the following examples: standard fasteners, lubricants, sealants, compounds, inks, MRO supplies, and etc. Commercially available items are defined as those products that are not produced to a Hi-Stat drawing, but have been designed and produced by the manufacturer for any/all customers. These items can be purchased using the manufacturers’ part number from various suppliers (distributors) and may be used in the manufacture of Hi-Stat’s products.
DEFINITIONS: MRO - Maintenance, Repair and Operating
PPAP - Production Part Approval Process SCAR - Supplier Corrective Action Report NAFTA - North American Free Trade Agreement QSA - Quality System Assessment IMDS – International Material Data System QE – Quality Engineer PE – Product Engineer PA – Purchasing Agent DO – Director Operations SDE – Supplier Development Engineer
PROCEDURE: RASI: Responsible: Supplier Development Engineer Accountable: Customer Reliability / Quality Systems Manager Support: Purchasing Agent Inform: Director Materials & Logistics Management 1. GENERAL
1.1 The TS-16949 Quality Management System has been adopted by Hi-Stat in compliance with our OEM customer requirements. At this time, suppliers to Hi-Stat are required to obtain third party registration to a minimum of ISO 9001/2000, or present a formal registration plan.
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 3 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
NOTE: THE TS-16949 SELF SURVEY (L-PUR-F31), AND THE QSA (L-PUR-
F15) WILL BE USED TO MONITOR THE QUALITY MANAGEMENT SYSTEM AND HELP DETERMINE THE STRENGTHS AND DEVELOPMENT NEEDS OF OUR SUBCONTRACTORS. THE QSA WILL BE CONDUCTED ONCE IN A FIVE YEAR PERIOD FOR SUPPLIERS CERTIFIED TO TS-16494 OR ISO 9000/2000.
1.2 All current suppliers that do not have certification to TS-16949 or ISO-9001/2000, will be reviewed by the Supplier Development Engineer at a minimum of once a year using the Supplier Quality System Assessment (L-PUR-F15). Paragraphs 1.3 through 1.7 are the action plan to be followed for the suppliers who are not certified.
1.3 The SDE shall conduct the assessment at the time Hi-Stat product is being
produced, and shall be directed to the Hi-Stat processes. 1.4 The SDE will compile the assessment report. The report shall contain as much
hard copy evidence for team review. 1.5 The SDE completes a “Supplier Selection Approval” form (LQCP-F41) noting
the supplier’s strengths, weaknesses (development needs), and recommendations.
1.6 The SDE e-mails a meeting notice with the assessment attached to the cross-
functional team. (QE, PE, PA, DO) 1.7 The cross-functional team shall discuss the scoring, extent of development,
needed, and make one of the following decisions and complete the necessary actions.
A) Certify Supplier – The supplier must score the following and have no
development needs within their Hi-Stat related processes in order to become Hi-Stat certified.
95% - 100% “Preferred” Business Candidate 80% - 94% “Acceptable” Business Candidate
The “Supplier Selection Approval” form (L-QCP-F41) will be signed by
the cross-functional team as “Approved” A certificate will be signed by each of the cross-functional team
members and presented to the supplier, approving them and their processes for Hi-Stat use.
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 4 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
B) Develop – Supplier’s scoring in the following range will have a
development action plan put in place.
70% -79% “Potential” Business Candidate (Due to moderate development needs)
The cross-functional team will decide the extent of the development and create a plan. Development may be conducted by the SDE or may require the assistance of the Hi-Stat TQM team. This shall be determined when considering the extent of development needed and resources available to complete. The ‘Supplier Selection Approval” form (L-QCP-F41) will be signed by the cross-functional team as “Denied”. The supplier’s status on the “ASL” will be “Conditional” until development is complete. Once the development is complete the SDE will begin the process with an assessment, which will then have cross-functional team review and sign-off.
C) Re-Source – Supplier’s scoring in the following ranges will be placed on a re-source schedule immediately. The progress towards re-sourcing will be tracked by the SDE through the “Supplier’s Top 10” list.
70% – 79% “Potential” Business Candidate (Due to
extensive Development) 69% – and below “Not Viable” For Business (No systems in
place)
The “Supplier Selection Approval” form (L-QCP-F41) shall be signed by the cross-functional team as “Denied”. The supplier shall be placed on “Restricted” status on the “ASL”. The re-source process shall begin immediately by the purchasing department. The Purchasing Agent must follow the “Supplier Selection Process” as outlined in Section 4.0 of this manual.
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 5 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
2. QUALITY REQUIREMENTS FOR SUPPLIERS OF MATERIALS, COMPONENTS
AND/OR PROCESSES
2.1 Hi-Stat will accept only purchased material, components, or processes which meet the agreed upon Hi-Stat drawings and/or specifications. The acceptance criteria are ZERO defects. (See SEC. 13.0, QC SPECIFICATION QO1-0001). In order to obtain the above it will be mandatory that the supplier attend a APQP design review meeting at Hi-Stat prior to the making of any tooling and release of product. Hi-Stat personnel should consist of Product Engineer, Manufacturing Engineer, Quality Engineer, APQP Engineer, Purchasing Representative, and Supplier Development Engineer.
2.2 The supplier is expected to perform the inspections and tests required to
substantiate conformance to the applicable drawing and/or specifications. The supplier shall establish and maintain a system to assure that only the latest applicable drawings/specifications are used.
2.3 The supplier is expected to use statistical methods to control and evaluate
process variability and track continual improvement as well as its effectiveness.
2.4 The supplier is expected to submit, upon request, evidence of statistical control for all drawings/specifications with designated quality symbols noted on Hi-Stat's drawings. The supplier is expected to contact Hi-Stat’s Supplier Development Engineer in the event of a Cpk value decreasing below the value reported at time of PPAP as well as submit a documented plan to bring the Cpk value back up to PPAP value level or higher.
2.5 The supplier is expected to have documented Control Plans and Work
Instructions that will provide control of quality throughout the manufacturing process. Hi-Stat Supplier Development Engineer and APQP Engineer, in conjunction with the supplier, will develop the Control Plans and Work Instructions. Hi-Stat's Supplier Development Engineer, APQP Engineer and/or Quality Engineer for that specific product are responsible for issuing final approval of the Control Plan and Work Instructions.
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 6 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
2.6 The supplier is expected to maintain 100% on time delivery performance, which will be communicated in writing to them on a quarterly basis. In order to minimize the amount of inventory at Hi-Stat, Suppliers are expected to meet delivery requirements, reduce lead times and react effectively to schedule changes. A Purchasing Representative will evaluate shipments for timely delivery and may issue a Supplier Corrective Action Report (SCAR) as deemed necessary.
NOTE: If the supplier is unable to meet Hi-Stat's delivery requirements
and the production schedules dictate that the product must be expedited using alternate transportation, the supplier will have the following options:
A. Ship the product via expedited transportation at the supplier's expense. B. Immediately reimburse Hi-Stat for the difference in cost between the
original specified method and the expedited method.
2.7 Suppliers who are certified to TS16949, ISO 9001/ISO 9002, or ISO14001 are expected to submit a copy of the current and appropriate registration certificate to Hi-Stat’s Supplier Development Engineer. Any change in status (loss, updated, new standard, etc.) must be reported to Hi-Stat’s Supplier Development Engineer immediately
2.8 The supplier is expected to be familiar with the Automotive Industry Action
Group (A.I.A.G.) Production Part Approval Process (PPAP). Included within this Supplier Quality Management Guidelines are Hi-Stat's PPAP Requirements.
2.9 The supplier is expected to respond to all Supplier Corrective Action Reports
(See SEC. 11.0, Non-Conforming Material for response times) submitted for all non-conforming product or material received by Hi-Stat.
2.10 The supplier has the responsibility of ensuring that its sub-contractors have
been approved and are under a controlled system of evaluation and review.
2.11 The goal of this Supplier Quality Management Guidelines is to select, development, and maintain our suppliers in accordance with the TS-16949 requirements.
2.1.2 The supplier shall submit an “Annual Validation Report”. (per procedure L-
QCP-32) This report will be submitted in the form of a PPAP, and follow the guidelines set in section 8 of this manual.
TITLE: PAGE OF SEC. 3.0, QUALITY SYSTEM REQUIREMENTS 7 7 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 06/02/05 STEVE FELLOWS DARREL GEORGE
3. QUALITY REQUIREMENTS FOR SUPPLIERS OF SERVICES
3.1 Suppliers of services include those companies that provide repair and maintenance parts and/or services, calibration services for inspection, measuring and test equipment, test labs, common carrier transportation services, consulting services, and tooling and equipment suppliers.
3.2 The specific quality requirements are provided by the requestor for these
services and will be documented on or attached to the purchase order. 4. RESTRICTED SUBSTANCES / IMDS REQUIREMENTS
4.1 All suppliers of materials, components, processes, and/or services shall have a process to assure that governmental and safety constraints on restricted, toxic, and hazardous substances are complied with relative to purchased products and the manufacturing process.In order for Hi-Stat to develop products which are compliant to current Regulated/Restricted Substances policies of both governmental agencies and our Customers, the supplier shall submit at the time of PPAP all data information for reporting all restricted and controlled substances. This information shall be submitted through the IMDS system or on form L-ENG-F57 (see forms in section 15.0 of this manual).
5. HI-STAT'S CUSTOMER SPECIFIC REQUIREMENTS
5.1 Hi-Stat's customer specific requirements will be specified in the Production Part Approval Process (PPAP) as it applies to each of Hi-Stat's suppliers.
6. NAFTA REQUIREMENTS
6.1 Where applicable, Suppliers are required to provide the appropriate NAFTA documentation.
TITLE: PAGE OF SEC. 4.0, SUPPLIER SELECTION PROCESS 1 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
Purchasing Agent will review existing supply
base for capable supplier
No
Yes
Purchasing Agent will
deliver returned survey to Suppler
Developm ent Engineer
Does the supplier m eet the m inim um
qualifications?
1
Yes
Supplier Developm ent Eng . will contact potential supplier and arrange
an on-site assessment
Supplier Development Eng. with select m em ber
conducts on-site assessm ent
Supplier Developm ent
Eng. com piles audit results
Supplier Development Eng. arranges cross-functional team
m eeting to review data
Does the cross-functional team agree
to add potential supplier?
2
YesAdd to
Approved supplier List
No
Supplier SelectionProduct Design,
Com ponent Design Definition
1 ISO 9001 / TS 16949 Certified
Supplier to other divisions
Quality Capabilities
Does the CPAC “Approved Supplier List”
have a capable Supplier?
2
Quality Standards Registration
Current Stoneridge Supplier
Capability and Perform ance Records
Capacity Lim itations
Financial Stability
Decreasing Rating Trend
Ability to meet “On Time Deliveries”
Ability to m eet Quality and Engineering Requirem ents
Assessm ent Score
Attitude and Market Place Reputation
Does the existing supply base contain a
capable supplier?
Request m inim um quotes and use
selected supplier3
Yes
No
Seek potential supplier via alternate sources
(Purchasing Files, Thom as Registry, etc.)
No
Purchasing Agent will
send survey to potential supplier
Request m inim um quotes
3
3
Minim um Quote Requirem ents
2 Dom estic1 Global
TITLE: PAGE OF SEC. 4.0, SUPPLIER SELECTION PROCESS 2 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define the selection process for placing a Supplier on the "Approved Supplier List". SCOPE: This procedure is applicable to all current and potential suppliers of materials,
processes, components and/or services used in the manufacture of Hi-Stat's products.
DEFINITIONS: N/A PROCEDURE: RASI: Responsible: Purchasing Agent / Supplier Development Engineer Accountable: Purchasing Agent Support: Director Materials & Logistics Management / Customer Reliability/Quality
Systems Manager Inform: Project Engineering 1. SELECTION PROCESS FOR SUPPLIERS OF MATERIALS, COMPONENTS,
EQUIPMENT, TOOLING, ANDPROCESSES
1.1 Supplier sourcing decisions require cross-functional approval of Purchasing, Supplier Development Engineer, Quality Engineer, APQP Engineer, Product Engineering, and Manufacturing Operations.
1.2 Purchasing agent will make initial contact with potential suppliers by
requesting the minimum required quotes (2 domestic and 1 global). 1.3 Once the quotes are obtained the Purchasing Agent will request the
completion of the TS-16949 Self-Survey (L-PUR-F31) from suppliers that were not chosen from either the “Approved Supplier List” or the “Corporate Approved Supplier List”. The potential supplier will have five (5) working days to complete and return. Purchasing will also advise them to review the Supplier Quality Management Guidelines found at www.histat.com.
1.3.1 Minimum requirements must be met for consideration as a new
supplier to Hi-Stat.
• TS-16949 or ISO-9001/2000 Registration • Ability to meet Hi-Stat’s engineering and quality
requirements
TITLE: PAGE OF SEC. 4.0, SUPPLIER SELECTION PROCESS 3 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
1.4 Purchasing will submit the self-survey to Stat’s Supplier Development
Engineer. 1.5 The Supplier Development Engineer will conduct an on-site Quality System
Assessment at the potential supplier facility providing the supplier has submitted an acceptable TS-16949 Self-Survey.
NOTE: On sight surveys are only necessary if there is not a current survey
available from another Stoneridge Division. Supplier Development Engineer may conduct on-site surveys with the APQP or Quality Engineer or the Manager of Customer Reliability and Quality Systems.
1.6 Hi-Stat’s cross-functional team will meet and review all information provided
for final approval. All comments will be documented and all members of the team will sign-off. (form L-QCP-F41)
1.6.1 The following will be used but not limited to in the decision making
process.
• Quality Standards Registration • Current Supplier to a Stoneridge Division • Records of previously demonstrated capability and
performance • Capacity limitations • Financial stability • Decreasing rating trend • Ability to meet on time delivery requirements • Ability to meet Hi-Stat engineering and quality
requirements • TS-16949 Self-Survey • On-site Quality System Assessment • Supplier attitude and market place reputation
1.7 The supplier will be notified within thirty (30) days of the results of the cross-functional team meeting by the Supplier Development Engineer. At this time the Purchasing agent may or may not place the supplier on the Approved Supplier List.
TITLE: PAGE OF SEC. 5.0, SUPPLIER SELF SURVEY 1 2 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
Purchasing Agent sends survey to
the potential supplier
Supplier completes the
survey and returns to
Purchasing Agent.
Do we assess this supplier?
1
Supplier Development
Engineer reviews survey
NO
Seek another supplier.
YE
S
Supplier Development Engineer will contact supplier to set-up the internal assessment.
1
ISO 9001 / TS 16949
Supplier to other Divisions
Quality Capabilities
Supplier Self-Survey
TITLE: PAGE OF SEC. 5.0, SUPPLIER SELF SURVEY 2 2 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define Hi-Stat's Supplier Self Survey process. SCOPE: This procedure is applicable to suppliers of materials, components and/or
processes used in the manufacture of Hi-Stat's products. DEFINITIONS: N/A PROCEDURE: RASI: Responsible: Purchasing Agent Accountable: Director Materials & Logistics Management Support: Supplier Development Engineer Inform: Supplier Development Engineer
1. GENERAL
1.1 Hi-Stat requires each supplier to complete and submit a self-survey. This self-survey is comprised of the TS-16949 Supplier Self-Survey. The TS-16949 Supplier Self-Survey is required to be returned within 5 days of request to Hi-Stat's Purchasing Department. Failure to return within the time limit will result in a five point reduction on the onsite assessment.
2. TS-16949 SUPPLIER SELF-SURVEY
2.1 The TS-16949 Supplier Self-Survey (See SEC. 15.0, Forms) will be sent to the supplier by a purchasing Agent. This survey allows Hi-Stat to evaluate and understand the suppliers current position and intentions in complying with the TS-16949 quality standard.
2.2 The completed survey will be reviewed by Hi-Stats Supplier Development
Engineer. 2.3 If the survey is acceptable then the Supplier Development Engineer will
contact the potential supplier to set-up a date and time for the on-site assessment.
TITLE: PAGE OF SEC. 6.0, SUPPLIER ON-SITE QUALITY SYSTEM
ASSESSMENT BY HI-STAT 1 3
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 06/02/05 STEVE FELLOWS DARREL GEORGE
S u p p lie r D e v e lo p m e n t
E n g in e e r c o n ta c ts th e s u p p lie r to
a r ra n g e th e a s s e s s m e n t d a te .
S u p p lie r D e v e lo p m e n t E n g in e e r a n d s e le c te d
te a m m e m b e r w il l a s s e s s th e s u p p lie r
S u p p lie r D e v e lo p m e n t
E n g in e e r c o m p ile s d a ta .
Is th e s c o r in g in th e “ A c c e p ta b le ” a n d /o r
“ P re fe r re d ” le v e l?
1
Y E S
N O Is th e s c o r in g in th e “ P o te n t ia l” le v e l?
2
YE
S
N O
S u p p lie r D e v e lo p m e n t E n g in e e r w il l
a r ra n g e c ro s s -fu n c t io n a l te a m
m e e t in g
1
S u p p lie r h a s a s c o re f ro m 3 4 8 to
5 8 0 p o in ts .
R e q u ir in g l i t t le to n o d e v e lo p m e n t
2
S u p p lie r h a s a s c o re 2 3 3 to 3 4 7
p o in ts .
R e q u ir in g m o d e ra te to
e x te n s iv e d e v e lo p m e n t .
Q u a lity S y s te m A s s e s s m e n t
Is th e s c o r in g in th e “ N o t V ia b le ”
le v e l?
3
Y E S
3
S u p p lie r h a s a s c o re 2 3 2 o r
b e lo w .
N o t re c o m m e n d e d fo r
b u s in e s s c a n d id a te .
C ro s s -F u n c t io n a l
te a m re v ie w s
d a ta .
A p p ro v e to a d d a s a s u p p lie r to H i - S ta t?
4
N O
YE
S
S u p p lie r D e v e lo p m e n t E n g in e e r w il l
n o t ify s u p p lie r o f re s u lts
S u p p lie r D e v e lo p m e n t E n g in e e r w il l n o t ify
s u p p lie r o f a s s e s s m e n t re s u lts
4
Q u a lity S ta n d a rd R e g is tr a tio n
C u r re n t S u p p lie r to S to n e r id g e
C a p a b i l i ty a n d P e r fo rm a n c e
F in a n c ia l S ta b il i ty
D e c re a s in g ra t in g t re n d
A b il ity to m e e t o n t im e d e liv e ry
A b il i ty to m e e t e n g in e e r in g a n d
q u a lity re q u ire m e n ts
S e lf S u rv e y
A s s e s s m e n t s c o re
A tt itu d e a n d M a rk e t P la c e
S u p p lie r s u b m its m o re e v id e n c e a n d /o r m a k e s c o r re c t iv e a c t io n s , a n d
s u b m its to H i -S ta t ’s S u p p lie r D e v e lo p m e n t
E n g in e e r
TITLE: PAGE OF SEC. 6.0, SUPPLIER ON-SITE QUALITY SYSTEM
ASSESSMENT BY HI-STAT 2 3
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 06/02/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define the method by which Hi-Stat will conduct a Quality System
Assessment at the supplier’s location. SCOPE: This procedure is applicable to suppliers of materials, components and/or
processes used in the manufacture of Hi-Stat's products. DEFINITIONS: QSA - Quality Systems Assessment PROCEDURE: RASI: Responsible: Supplier Development Engineer Accountable: Director Total Quality Management & Organizational Effectiveness Support: Customer Reliability / Quality Systems Manager Inform: Cross Functional Team (Supplier Development Engineer, APQP Eng., Quality Engineer, Purchasing Agent, Product Project Engineer, and Director of Operations and Order Fulfillment)
1. GENERAL
1.1 An on-site TS-16949 QSA is required to be conducted by Hi-Stat’s Supplier Development Engineer, an APQP Engineer or Quality Engineer, or the Manager of Customer Reliability and Quality Systems. One of the above must be a TS-16949 certified lead auditor (See SEC. 4.0, Supplier Selection Process, paragraph 1.5).
1.2 The QSA is intended to inform Hi-Stat's suppliers of their conformance to
the TS-16949 Quality Systems Requirements. This QSA is used to promote consistency in evaluating each supplier.
1.3 This phase of the supplier selection process determines the degree and
effectiveness of the implementation of the quality system at the suppliers manufacturing and support locations.
TITLE: PAGE OF SEC. 6.0, SUPPLIER ON-SITE QUALITY SYSTEM
ASSESSMENT BY HI-STAT 3 3
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 06/02/05 STEVE FELLOWS DARREL GEORGE
2. ON-SITE ASSESSMENT
2.1 The supplier will be notified in advance by the Supplier Development
Engineer of the following:
a. Assessment Date (on-site). b. Scope, Purpose and Objective of Assessment. c. List of Hi-Stat Auditor(s). d. Supplier personnel required to assist during Assessment.
e. Audit Plan (QSA).
3. ASSESSMENT SUMMARY
3.1 The supplier will be notified of the results of their assessment within 30 days from the on-site assessment date.
3.2 The assessment can be revisited at anytime, as long as evidence of
improvements have been submitted by the supplier
3.3 The supplier will have 30 days from the report date to respond to any non-conformances listed. These responses must be in the form of an 8D.
3.4 Random on-site audits to all suppliers will be performed using this survey.
This will be for auditing the system as well as follow-up to corrective actions.
4. Scoring
4.1 95% – 100%“Preferred” World class system. 80% – 94%“Acceptable” Minor development needed. 70% – 79%“Potential” Moderate to extensive development needed. 69% – 0% “Not Viable” Extensive development needed.
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 1 6 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 05/09/06 STEVE FELLOWS CRAIG BENSON
S u p p lie r is o n th e “ A p p ro v e d S u p p lie r L is t”
S u p p lie r m u s t m a in ta in th e ir q u a lity s y s te m
P ro d u c t s p e c if ic
re q u ire m e n ts m u s t b e
m a in ta in e d
P a s s o n s ite s p o t a u d its
1 0 0 % o n t im e d e liv e ry , a t
a g re e d p r ic e s
N o P la n t d is ru p tio n s
R a tin g m u s t n o t fa ll b e lo w
8 0 %
S u p p lie rs a re n o tif ie d q u a r te r ly ,u n le s s
d e fic ie n t th e n m o n th ly
P e r fo rm a n c e b a s e o n : P P M . O T D , P ro c e s s C o n tro l , P P A P /P S W T im e lin e s s , P la n t D is ru p tio n s /C o rre c tiv e A c tio n s , IS O /T S C e r t if ic a tio n , L e a d T im e R e d u c tio n ,
a n d C o s t Im p ro v e m e n t P a r t ic ip a tio n
S u p p lie rs o f s e rv ic e s m u s t
a d h e re to re q u ire m e n ts
o n P O
M a in ta in in g A p p ro v e dS ta tu s
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 2 6 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 05/09/06 STEVE FELLOWS CRAIG BENSON
PURPOSE: To define the level of performance the Supplier must maintain for an
approved status. SCOPE: This procedure is applicable to Hi-Stat's suppliers of materials, processes,
components and/or services used in the manufacture of Hi-Stat's products. DEFINITIONS: MDR - Material Discrepancy Report
SCAR - Supplier Corrective Action Report PPAP – Production Part Approval Process
PPM – Parts Per Million SREA – Supplier Request for Engineering Approval PROCEDURE: RASI: Responsible: Buyer/Supplier Quality Agent Accountable: Strategic Supply Chain Manager Support: Purchasing Agents, Director of Operations & Order Fulfillment, Inform: Director of Operations & Order Fulfillment
1. SUPPLIERS OF MATERIALS, COMPONENTS AND/OR PROCESSES
1.1 Once the approved Supplier begins supplying goods to Hi-Stat, they must adhere to the following requirements to remain on Hi-Stat's Approved Supplier List with an "Approved" status:
a. Maintain their quality system to the fundamentals of the TS-16949
Quality System requirements. b. At the Supplier's facility, product specific requirements must be
implemented and maintained as approved during the PPAP. c. Pass on-site spot audits by Hi-Stat auditors.
d. 100% on-time delivery is expected. Delivery performance is based on the due date +3/-0 days.
e. No more than two Supplier SCAR’s and/or Supplier Concerns per month
f. Material delivered at agreed upon prices. g. The Supplier’s Performance Rating cannot drop below 80% for three
consecutive months of shipments.
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 3 6 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 05/09/06 STEVE FELLOWS CRAIG BENSON
2. SUPPLIERS OF SERVICES
2.1 For Suppliers of services to maintain their approved status they must adhere
to the requirements specified on the purchase order.
3. PERFORMANCE REPORT 3.1 Hi-Stat maintains performance records for each active Supplier of production
materials, which includes the following information:
a. PPM Data b. Delivery
c. Process Control d. PPAP/PSW Timeliness e. Plant Disruptions/Corrective Actions f. ISO9000/TS16949 Certification g. Lead Time Reductions h. Cost Improvement Participation
. 3.2 Suppliers will be advised of their performance scores on the Hi-Stat
Supplier Performance Rating Form, L-PUR-F29 (See SEC. 15.0, FORMS), at the end of each calendar quarter. Suppliers that fall into the unacceptable threshold (below 80%) will be notified in the month of their deficiency. Suppliers are expected to use this document as a performance metric in striving for continual improvement.
4. Performance Scoring
4.1 PPM a. This value is calculated using incoming supplier data from customer
key characteristics as defined on Hi-Stat drawings generating a defect per million value.
1 = > 5000 for the current month 2 = < 5000 for the current month or 0 for less than 3 months running 3 = 0 for running 3 month period 4 = 0 for running 6 month period 5 = 0 for running 12 month period
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 4 6 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 05/09/06 STEVE FELLOWS CRAIG BENSON
4.2 On Time Delivery
a. On time delivery is calculated using a +3 / -0 days.
1 = < 100% OTD for 2 or more consecutive months 2 = < 100% OTD for current month of 100% OTD for < 3 months 3 = 100% OTD for running 3 month period 4 = 100% OTD for running 6 month period 5 = 100% OTD for running 12 month period
4.3 Process Control
a. Process Control is evaluated by comparing the received Cpk value against the PPAP Cpk level for each component received for the month.
1 = < 100% of critical product characteristics meet PPAP Cpk with no
approved SREA 2 = < 100% of critical product characteristics meet PPAP Cpk with a
approved SREA 3 = Critical product characteristics meet PPAP Cpk for running 6
month period 4 = Critical product characteristics meet PPAP Cpk for running 12
month period 5 = Critical product characteristics exceed PPAP Cpk for running 12
month period
4.4 PPAP / PSW Timeliness
a. Timeliness is evaluated on all PPAP submission for the current month. If no PPAP submitted default is a 3.
1 = YTD < 100% on time and < 100% accepted 2 = YTD 100% on time but < 100% accepted 3 = No PPAP or PSW submitted YTD 4 = YTD < 100% on time but 100% accepted 5 = YTD 100% on time and accepted
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 5 6 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 05/09/06 STEVE FELLOWS CRAIG BENSON
4.5 Plant Disruptions / Corrective Actions
a. Plant disruptions are evaluated as any time Hi-Stat is required to sort prior to use, any time Hi-Stat is required to rework prior to use, and any time an MDR is created and requires engineering/quality services to disposition. Each corrective action is considered one disruption.
1 = 1 disruption for the current month 2 = 1 disruption for current month or 0 for < than 3 months running 3 = 0 plant disruptions for 3 month running total 4 = 0 plant disruptions for 6 month running total 5 = 0 plant disruptions for 12 month running total
4.6 ISO 9001 / TS 16949 Certification
a. Evaluated by month for compliance to one of the above quality system certifications.
1 = System nit certified, not compliant, and no plans 2 = ISO 9001 / TS 16949 compliant system in place for certification
but required additional form or product/process certification 3 = ISO 9001 / TS 16949 compliant system in place with plans for
certification within 60 days 4 = ISO 9001 / TS 16949 compliant system in place with plans for
certification within 30 days 5 = Certified to either ISO 9001 / TS 16949
4.7 Lead Time Reduction
1 = No formal proposal submitted 2 = 20% improved YTD 3 = 30% improved YTD 4 = 40% improved YTD 5 = 50% improved YTD
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 6 6 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 05/09/06 STEVE FELLOWS CRAIG BENSON
4.8 Cost Improvement Participation
1 = No cost improvement plans submitted 2 = Cost improvement plans rejected 3 = Cost improvement plans submitted, to be realized within the next
six months 4 = Cost improvement plans submitted, to be realized within the next
three months 5 = Cost improvement plans submitted and realized within the
current month 5. REGAINING APPROVED STATUS
5.1 Once a Supplier is removed from the Approved Supplier List, they must become re-qualified per the Supplier Selection Process (See SEC. 4.0, SUPPLIER SELECTION PROCESS).
STATUS DESIGNATIONS 5.2 Status A (Preferred & Approved) – Supplier’s who have earned a
performance rating of > 80% or received an assessment score > 348. Suppliers with this status are the only sources considered for Dock-To-Stock shipments.
5.3 Status C (Conditional) – Supplier’s who earned a performance rating
between 70% and 80% or an assessment score of 233 to 347. If a supplier earns this status, a corrective action and/or a development plan will be initiated. These supplier’s are considered to be on new business hold.
5.4 Status R (Restricted) – These suppliers have earned a performance rating <
70% or an assessment score < 347. A re-sourcing plan will be considered if appropriate.
NOTE: STATUS DESIGNATIONS ARE COLORED CODED FOR EASY
REFERNCE ON THE APPROVED SUPPLIER LIST.
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 7 9 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/31/05 STEVE FELLOWS DARREL GEORGE
DELIVERY PERFORMANCE:
a. On-time delivery data: Total Quantity Early/Late = D% Total Quantity Received
The percent shown on the Rating form is derived from locating the corresponding D% on the Supplier Delivery Matrix (Figure 4)
SUPPLIER DELIVERY MATRIX
PERFORMANCE RATING
% EARNED % LATE / EARLY
25 0 - 4 24 5 - 8 23 9 - 11 22 12 - 15 21 16 - 19 20 20 - 23 19 24 - 27 18 28 - 31 17 32 - 35 16 36 - 39 15 40 - 43 14 44 - 47 13 48 - 51 12 52 - 55 11 56 - 59 10 60 - 63 9 64 - 67 8 68 - 71 7 72 - 75 6 76 - 79 5 80 - 83 4 84 - 87 3 88 - 91 2 92 - 95 1 96 - 99 0 100
Hi-Stat
A Stoneridge Company
Figure 4
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 8 9 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/31/05 STEVE FELLOWS DARREL GEORGE
b. Packaging Issues – deduction of one point for each
damaged shipment resulting from the Supplier’s packaging.
c. Premium Freight – deduction of one point for each shipment resulting in premium charges that are Supplier related.
If a supplier knows in advance that they are unable to meet the requested
due date, a call shall be placed to the appropriate Hi-Stat Purchasing Agent advising him/her of a new delivery date. The Purchasing Agent may approve the new due date provided that the production schedule is unaffected by the change. If approved, the shipment may not be considered an early/late delivery.
SERVICE PERFORMANCE:
a. Responsiveness − Purchasing/Quality Issues: (Purchasing issues include: RFQ’s, P.O.’s, contracts, pricing, expediting, and paperwork). (Quality issues include: MDR’s, SCAR/Concerns, problem resolution, submission of IMDS data, and continual improvement).
NOTE: SUPPLIERS THAT ELECT NOT TO RESPOND TO QUALITY
ISSUES WITHIN THE TIME PERIOD GIVEN WILL RESULT IN AN AUTOMATIC DOWNGRADE TO CONDITIONAL STATUS AND A LOSS OF 25 POINTS FROM THE CURRENT MONTHLY SUPPLIER RATING.
b. The Service Performance Rating is based on a scale of 0-10
(0 = No response; 10 = Excellent response) with a number being assigned by each contact Purchasing Agent and Expediter. If more than one person has communication with a Supplier, the average of the numbers assigned will be the rating.
3.4 Overall Performance Levels:
90 - 100% PREFERRED 85 - 89% ACCEPTABLE 80 - 84% NEEDS IMPROVEMENT 0 - 79% UNACCEPTABLE
TITLE: PAGE OF SEC. 7.0, MAINTAINING APPROVED STATUS 9 9 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/31/05 STEVE FELLOWS DARREL GEORGE
4. REGAINING APPROVED STATUS
4.1 Once a Supplier is removed from the Approved Supplier List, they must become re-qualified per the Supplier Selection Process (See SEC. 4.0, SUPPLIER SELECTION PROCESS).
STATUS DESIGNATIONS
5.1 Status A (Preferred & Approved) – Supplier’s who have earned a
performance rating of > 85% or received an assessment score > 348. Suppliers with this status are the only sources considered for Dock-To-Stock shipments.
5.2 Status C (Conditional) – Supplier’s who earned a performance rating
between 79% and 84% or an assessment score of 233 to 347. If a supplier earns this status, a corrective action and/or a development plan will be initiated. These supplier’s are considered to be on new business hold.
5.3 Status R (Restricted) – These suppliers have earned a performance rating <
79% or an assessment score < 347. A re-sourcing plan will be considered if appropriate.
NOTE: STATUS DESIGNATIONS ARE COLORED CODED FOR
EASY REFERNCE ON THE APPROVED SUPPLIER LIST.
6. Dock-To-Stock Reporting 6.1 Dock-To-Stock (DTS) is reported as percentage of total shipments received.
TITLE: PAGE OF SEC. 8.0, PRODUCTION PART APPROVAL PROCESS 1 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
Supplier is “Production”
ready
Samples run in the
production setting
Samples for PPAP pulled from this run
Submission
Tooling completed
Same machinery, equipment,
environment setting, etc.
Process should run at a minimum of one hour to
one shift
Samples selected randomly
Samples should be representative to each position
of a multiple cavity die, mold, tool, or pattern
Supplier to complete
dimensional layout on
above samples
Supplier submits PPAP
to Supplier Development
Engineer
Quality / APQP
Engineer “Approves”
PPAP
Production Part Approval Process
Supplier Development
Engineer reviews PPAP
for completeness
TITLE: PAGE OF SEC. 8.0, PRODUCTION PART APPROVAL PROCESS 2 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define Hi-Stat's Production Part Approval Process (PPAP) for Suppliers. SCOPE: This procedure is applicable to all suppliers of materials, components and/or
processes used in the manufacture of Hi-Stat's products. DEFINITIONS: PPAP - Production Part Approval Process PROCEDURE: RASI: Responsible: Purchasing Agent Accountable: Director Materials & Logistics Management Support: Supplier Development Engineer Inform: Quality or APQP Engineer
1. GENERAL 1.1 The PPAP is used to determine if all Hi-Stat drawings and/or specifications
are properly understood by the Supplier; and that the process has the potential to produce product meeting these requirements during an actual production run at the quoted production rate.
2. DEFINITION
2.1 Production parts are manufactured at the production site using the production tooling, gauging, process, materials, operators, environment, and process settings, e.g., feeds/speeds/cycle times/pressures/temperatures.
2.2 Parts for PPAP must be taken from a significant production run. This run
would typically be from one hour to one shifts production. Parts from each position of a multiple cavity die, mold, tool or pattern are to be measured and representative parts tested.
2.3 Production part review and approval are required for each part prior to the
first production shipment.
TITLE: PAGE OF SEC. 8.0, PRODUCTION PART APPROVAL PROCESS 3 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
3. WHEN SUBMISSION IS REQUIRED
3.1 Submission is always required in the following situations: a. New part or product. b. Correction of a discrepancy on a previously submitted part. c. Engineering Change Notice (ECN). d. Any change (i.e., materials, tooling, processes, change of source for sub-
contracted parts, etc.) to the current approved PPAP. e. Product re-released after the tooling has been inactive for volume
production for twelve months or more. EXCEPTION: Service requirements (i.e. small volume) produced by the original Supplier do not require PPAP submission, but will require 100% inspection by the supplier for each lot or shipment received. Shipments must be labeled as certified material.
f. Following Hi-Stat's request to suspend shipment due to a Supplier quality concern.
g. Anytime the supplier location is changed. h. Merges, acquisitions, or affiliations can not be used until section 4.0 of
this manual is completed. PPAP will then follow.
3.2 Primary Suppliers are responsible for sub-contracted material and/or services.
4. REQUIREMENTS FOR PART APPROVAL
4.1 The following documents and items must be completed and/or submitted by the Supplier for each part when any of the situations in paragraph 3 above occur:
a. Part Submission Warrant (A.I.A.G. format required). b. First Piece Approval (dimensional layout results). A minimum of two
sample parts (per cavity for molded components) or as agreed to in the Control Plan and/or Work Instruction with complete dimensional layout. Master samples to be retained by the supplier.
c. All Hi-Stat detailed drawings. d. Any authorized ECN documents not yet incorporated in the design record
but incorporated in the part. e. Checking aids specific to the part being submitted, used in inspecting and
testing.
TITLE: PAGE OF SEC. 8.0, PRODUCTION PART APPROVAL PROCESS 4 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
f. Control Plans and/or Work Instructions which include all product and
process-related Significant or Key characteristics. Control Plans and/or Work Instructions for "families" of similar parts are acceptable if the new parts have been reviewed for commonality.
g. Process Capability results showing conformance to Hi-Stat's requirements for Key, Significant, Safety, Critical, and compliance-related characteristics, with supporting data such as Control Charts. (Refer back to paragraph 2.2 and the AIAG PPAP manual).
h. Gage R & R studies. i. PFMEA with all potential failure modes for each process identified. j. Material certifications for all raw materials used. k. A minimum of a 300 piece sample, or the amount agreed upon on the
original purchase order. l. IMDS required information. (See section 3.0 Quality Expectations) m. Pass through characteristic identified and verified. n. All PPAP samples shall be shipped to Hi-Stat with specific label L-PUR-
F52, which will be supplied to the supplier by the purchasing agent.
NOTE: ALL DATA SHEETS, STUDIES, AND CERTIFICATIONS MUST DISPLAY THE CURRENT DATE. FAILURE TO COMPLY WILL RESULT IN REJECTION OF THE PPAP.
4.2 If a customer of Hi-Stat has specific requirements, they will be specified in the
PPAP as it applies to each of Hi-Stat's suppliers.
5. CONTROL OF QUALITY RECORDS
5.1 Quality records shall be maintained to demonstrate conformance to specified requirements and the effective operation of the quality system. These quality records are to be maintained for the length of time that the part is active for production and service requirements plus one calendar year.
5.2 Documentation required in the quality records includes copies of:
a. Inspection results b. Laboratory test reports specified for the material and/or part c. Gage R & R Studies d. Production Part Approval Process records
TITLE: PAGE OF SEC. 8.0, PRODUCTION PART APPROVAL PROCESS 5 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
6. MASTER SAMPLES RETENTION
6.1 Master samples are to be retained for the same period as the production part approval records or until a new master sample is produced for the same part number for the purpose of Hi-Stat's approval. Master samples are to be identified as such and are to show Hi-Stat's approval date.
7. PARTS SUBMISSION STATUS 7.1 Suppliers will be notified by Hi-Stat's Supplier Development Engineer as to
the disposition of the submission. The appropriate Hi-Stat Quality Engineer is responsible for disposition. If the Part Submission Warrant is rejected, the Quality Engineer must indicate the reason for rejection. After sample approval, suppliers are responsible for assuring that future production continues to meet all of Hi-Stat's requirements.
7.2 Suppliers must NEVER ship production quantities of their products before
receiving Hi-Stat's approval.
TITLE: PAGE OF SEC. 9.0, PACKAGING, IDENTIFICATION, AND VISUAL
CONDITIONS
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Proper Packaging
IdentificationVisual
Condition
Proper PreservativesBar Code Labeling
Sealed Containers
Identification easily located
Containers do not overhang
on pallets
Containers secure to
pallet
Containers not to exceed
40 lbs.
Pallet in good shape, and not to exceed 48 inches in length and width
(preferred 30" x 30" or 45" x 45")
Hi-Stat Format
A.I.A.G. Specifications
No surface defects,No obvious discrepant material,
Damaged material,No foreign material,No contamination
Packaging, Identification, and Visual Condition
See procedure for
layout and Specifications
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PURPOSE: To define Hi-Stat's requirements for packaging, identification and the visual
condition of material shipped by our suppliers. SCOPE: This procedure is applicable to suppliers of materials, components, and/or
processes used in the manufacture of Hi-Stat's products. DEFINITIONS: N/A PROCEDURE: RASI: Responsible: Purchasing Agent Accountable: Director Materials & Logistics Management Support: Process Engineering Inform: Sustaining Business Unit Manager
1. PROPER PACKAGING
NOTE: ALL INFORMATION LISTED IN THIS PROCEDURE MUST BE IDENTIFIED AND ADDRESSED DURING THE APQP DESIGN REVIEW.
1.1 Materials must contain proper preservatives applicable to the material
composition, (ie: desiccants, vanishing oil, PAVCO treatment, sealed plastic bags, etc.).
1.2 Containers must be adequately sealed. 1.3 Containers must be placed so identification is easily located and readable. 1.4 Containers must not overhang pallets. 1.5 Containers must be secure to limit shifting in transit. 1.6 A 40-pound maximum weight limit must be observed. This limit includes the
combined weight of the containers and their contents. Larger packaging, such as tri-wall containers, metal tubs, etc., requires pre-approval from Hi-Stat's Purchasing Department.
TITLE: PAGE OF SEC. 9.0, PACKAGING, IDENTIFICATION, AND VISUAL
CONDITIONS
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1.7 Pallets must be in good repair and not broken. 1.8 Pallets must not exceed 48" in length or width unless approved by the
appropriate Hi-Stat personnel. Preferred sizes are 30" X 30" or 45" X 45".
2. PROPER IDENTIFICATION
2.1 Containers must be clearly identified with a bar code label (See Hi-Stat Bar Code Label Questionnaire in SEC. 15.0, FORMS).
2.2 Labels should be a minimum of 4 inches by 6 inches in size and exposed on
the outside of each container (Figure 1).
Figure 1
TITLE: PAGE OF SEC. 9.0, PACKAGING, IDENTIFICATION, AND VISUAL
CONDITIONS
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2.3 Labels must be formatted as shown on the examples in figure 1, and contain the following information: a. Hi-Stat part number b. Revision level c. Lot quantity d. Hi-Stat purchase order number e. Supplier Code
f. Mfg. Date 2.4 Bar coding must comply with A.I.A.G. specifications and as required by Hi-
Stat. Bar Code Label Specifications:
1. Data Area Characters
The part number, quantity, purchase order number, supplier code, revision, serial number, and mfg. date shall be included on each label in the designated areas and shall be displayed in both bar code symbols and human readable characters.
2. Bar Code Symbology
The bar codes shall be of the 3-of-9 type (Code 39) and shall conform to the AIAG “Bar Code Symbology Standard for 3-of-9 Codes.” The bar heights shall be a minimum of 0.5 inches and the average width of the narrow elements shall be within a range of 0.013 to 0.017 inches. The ratio of the average width of the wide elements to the average width of the narrow elements shall be 3:1 (2.8:1 to 3.2:1 allowable). A minimum 0.25 inches of leading and trailing quiet zone shall be provided for each symbol.
The four characters ($, /, +, %) of the 3-of-9 symbology shall not be used on the shipping /parts identification label. Check digits shall not be used in the bar codes.
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CONDITIONS
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3. Titles
Titles should be 0.1 inches high and are to be shown as follows: PART NO., QUANTITY, PURCHASE ORDER NO., SUPPLIER, SERIAL, REVISION, and MFG. DATE.
4. Data Identifier Codes
An identifier code starting in the first position following the start code symbol shall be used to identify the information to follow. This character is not to be included in the human readable line, but is shown in human readable characters under the title for the appropriate data field. The identifier codes are assigned as follows:
(P) – Part Number (Q) – Quantity (V) – Supplier (K) – Purchase Order Number (E) – Revision (S) – Unique Serial Number – Individual Label (4S) – Unique Serial Number – Master Label (D) – Mfg. Date
5. Part Number Area
The human readable part number shall be bold and a minimum of 0.5 inches high. The bar code symbol for the part number shall be directly below the human readable characters. It shall be a minimum of 0.5 inches high and shall contain the data identifier (P for customer part number). The part number (in both human readable characters and bar code symbols) shall be printed exactly as it appears on the purchase order.
6. Quantity Field
The human readable quantity characters shall be a minimum of 0.5 inches high. The bar code symbol for the quantity shall be directly below the human readable characters. This bar code shall be a minimum of 0.5 inches high and shall contain the data identifier (Q for quantity). The maximum length for the quantity field is six numeric characters plus the data identifier (Q).
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Note: When the unit of measure is pieces, no notation is required. When the unit of measure is pounds, feet, gallons, and etc., it shall be noted in human readable form only (no bar code). This unit of measure shall be directly to the right of the human readable quantity and shall be a minimum of 0.2 inches high.
7. Purchase Order Number
The bar code for the purchase order number shall be a minimum of 0.5 inches high and shall contain the data identifier (K). The human readable purchase order number shall be directly above the bar code and shall be a minimum of 0.2 inches high. The maximum length for the purchase order number is nine alphanumeric characters plus the data identifier (K).
8. Supplier Code
The human readable supplier code characters shall be a minimum of 0.2 inches high. The bar code symbol for the supplier code shall be directly below the human readable characters. This bar code shall be a minimum of 0.5 inches high and shall contain the data identifier (V). The maximum length for the supplier code is nine numeric characters plus the data identifier (V).
9. Serial Number
The human readable serial number shall be bold and a minimum of 0.2 inches high. The bar code symbol shall be directly below the human readable characters. This bar code shall be a minimum of 0.5 inches high and shall contain the data identifier (S). The serial number shall be a unique number assigned by the supplier. The supplier shall avoid repeating serial numbers within a given calendar year.
10. Supplier Name
The supplier name, city, state, and zip code shall be directly below the serial number bar code symbol and should be a minimum of 0.1 inches high.
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11. Revision Level
The human readable revision level shall be a minimum of 0.2 inches high. The bar code symbol shall be directly below the human readable characters. This bar code shall be a minimum of 0.5 inches high and shall contain the data identifier (E). The maximum length for the revision level is four alphanumeric characters.
12. Manufacture Date
The human readable manufacture date is shown in this field as MMDDYY with a minimum height of 0.2 inches. The bar code symbol for the manufacture date shall be directly below the human readable characters. This bar code shall be a minimum of 0.5 inches high and shall contain the data identifier (D). The maximum length for the manufacture date is nine numeric characters plus the data identifier (D).
13. Extra Fields
If extra fields are available, they may be used by the supplier for any type of information necessary providing there are no bar codes.
14. MASTER LABEL
A master label shall be used when the pack contains multiple sub-packs of the same part number and purchase order number. Each sub-pack of the multiple pack should be identified with an Individual Label. The total contents of a common, multiple, item pack shall be identified with a master label. At the top of this label, the heading MASTER LABEL should be printed in bold 1.0 inch letters. The balance of the label should conform to the specifications for the individual label except that the data identifier for the serial number shall be 4S instead of S. The serial number, preceded by a 4S in the bar coded form only, shall be a unique number, not to be repeated over the course of a year. The quantity on the master label shall be the total in all of the sub-packs.
TITLE: PAGE OF SEC. 9.0, PACKAGING, IDENTIFICATION, AND VISUAL
CONDITIONS
8
8 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
15. MIXED LOAD LABEL
A mixed load label shall be used when the pack contains multiple sub packs of different part numbers and/or purchase order numbers. Each sub pack shall be identified with an Individual Label and the pack should be identified with a Mixed Load Label. The label for mixed loads should have the heading MIXED LOAD printed in bold 1.0 inch letters. The data identifier for the serial number shall be a 5S.
3. VISUAL CONDITION OF MATERIAL
3.1 Shipments received must not have: a. Surface defects b. Obviously discrepant materials enclosed c. Damaged materials d. Any foreign materials or contamination
TITLE: PAGE OF SEC. 10.0, MATERIAL CERTIFICATION 1 2 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
YE
S
Is material certification required?
1
NO
Send Shipment to
Hi-Stat
Supplier shall sample raw
material and have analyzed for
property composition
1
Requirement is designated on drawing with appropriate
symbol.
If it is to be sent, it will be communicated
thru PO or Design Review.
If not needed Supplier to keep on file available for
review.
Material Certification
Material certification to be sent with the
shipment
Supplier shall identify all material with a lot number, and include actual readings of the
composition properties
TITLE: PAGE OF SEC. 10.0, MATERIAL CERTIFICATION 2 2 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define Hi-Stat's Material Certification requirements. SCOPE: This procedure is applicable to all new and current Suppliers of materials,
components, and/or processes used in the manufacture of Hi-Stat's products. DEFINITIONS: Material Certification: Contains actual readings of material properties. MDR – Material Discrepancy Report PROCEDURE: RASI: Responsible: Supplier Development Engineer Accountable: Customer Reliability / Quality Systems Manager Support: Purchasing Agent Inform: Director Materials & Logistics Management
1. MATERIAL CERTIFICATION 1.1 When a Material Certification is required, a sample must be obtained from each
shipment of raw material received, and used for analyzing the property composition of the material. Material certifications must be identify with a lot number and include the actual readings of the properties (chemical composition, physical properties, hardness, etc.) of the raw material. A copy of the Material Certification from the raw material supplier is sufficient.
1.2 Material Certification requirements are determined by the Product Engineer and
designated on the drawing with the appropriate symbol. If the certification is required to be sent with each shipment, it may be stated on the Purchase Order or communicated at design review. Material Certifications are required to be on file at the Supplier's location at all times and subject to review or recall (in the form of a copy) as needed or demanded by Hi-Stat or its Customers. When Material Certifications are requested, a copy of the most recent lot processed is required.
1.3 Shipments received without the required material certification are considered a
non-conformance requiring a MDR be processed.
TITLE: PAGE OF SEC. 11.0, NON-CONFORMING MATERIAL 1 5
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 07/29/05 STEVE FELLOWS DARREL GEORGE
Production finds Non-
Conformance
Production notifies Quality
Engineer
Was this a minor issue?
1
YES
Use per Quality
Engineer instructions
Quality Engineer notifies Supplier Development
Engineer
Suppliers product goes
on containment
Supplier sends certified shipments
until corrective action is
implemented
Supplier elects to pay Hi-Stat to sort, or Hi-Stat has no choice to keep
production moving
Quality Engineer
writes TPC and requests sort charges
Production continues
Supplier or supplier contacted firm comes to Hi-
Stat and sorts When sort is complete sort charge forms are delivered to purchasing for
cost recovery
Production Continues
Non-Conforming Material
Hi-Stat in conjunction with the Supplier selects
sort option
1A minor non-
conformance is one that will not
increase the percentage of
line scrap, cause any rework, or
affect a Pass through
CharacteristicQE provides samples to
SDE
Inspect all component Inventory and Finished
Goods for potential non-conformance and contain as
appropriate per L-QCP-12
TITLE: PAGE OF SEC. 11.0, NON-CONFORMING MATERIAL 2 5
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 07/29/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define what Hi-Stat considers to be non-conforming material and the
method to be used to disposition the non-conforming material. SCOPE: This procedure is applicable to all Suppliers of materials, components,
services and/or processes used in the manufacture of Hi-Stat's products. DEFINITIONS: SREA – Supplier Request for Engineering Approval SDE – Supplier Development Engineer PROCEDURE: RASI: Responsible: Supplier Development Engineer, Quality Engineer Accountable: Customer Reliability / Quality Systems Manager, Sustaining Business Unit Manager Support: Purchasing Agents Inform: Director of Operations & Order Fulfillment, Director Materials & Logistics Management.
1. GENERAL 1.1 Hi-Stat defines non-conforming material as the following:
a. Parts that are not to drawing specifications (physical, visual, or dimensional).
b. Mixed parts. c. Contamination (i.e. plastic runners, metal blanks, cleanliness, etc.). d. Lack of required Quality Control Documentation. e. Damaged parts. f. Parts that are not delivered on time. g. Not meeting purchase order requirements.
1.2 If a Supplier has a known non-conformance in a lot that is ready for
shipment to Hi-Stat, they must receive documented approval from Hi-Stat's Purchasing Department prior to shipment. The Supplier must obtain from Hi-Stat or from the Hi-Stat web site a "Supplier Request for Engineering Approval" form (See SEC. 15.0 FORMS). This form must be completed and returned to Hi-Stat for disposition. An approved SREA will serve as a record of Hi-Stat's authorization for the Supplier to ship the specified non-conforming lot or to implement the requested change(s).
TITLE: PAGE OF SEC. 11.0, NON-CONFORMING MATERIAL 3 5
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 07/29/05 STEVE FELLOWS DARREL GEORGE
1.3 If a minor non-conformance is found at Hi-Stat and the lot could be used
"AS IS," a small sample will be returned with a copy of Hi-Stat's "Material Discrepancy Report" (MDR) or Supplier Concern form to the Supplier (See SEC. 15.0 FORMS). This is to prompt the Supplier's awareness of the non-conformance in order for them to take appropriate action. A minor non-conformance is defined as a non-conformance that did not increase the percentage of line scrap, cause un-necessary rework, and/or affect a pass through characteristic. Supplier’s ratings are affected even though it’s a minor non-conformance.
1.4 If the non-conforming lot is discovered by Hi-Stat’s Metrology Lab and is
determined to be not useable, it will be necessary for the Supplier to take appropriate corrective action. Hi-Stat, in conjunction with the Supplier, will choose one of the following actions to address the problem: a. The Supplier can sort/rework the lot at Hi-Stat. b. The Supplier may have the lot returned at Supplier cost, if replacement
stock is available. c. The Supplier may choose to contact and hire at their cost, a sorting firm
to sort/rework the lot at Hi-Stat. (See approved sources below) d. The Supplier may choose to have Hi-Stat scrap the lot at Supplier cost. Approved Sorting Firm:
• Spherion, 2282 Village Mall Drive Suite #2, Mansfeild, OH 44906
Phone – 419-747-7479, Fax – 419-747-3874. Contact person will be Beth Delaney
1.5 If the non-conforming lot is found on Hi-Stat’s production line (See Note 1
below) and is determined to be unusable (See Note 2 below), the Supplier will have three possible options. Those options (listed in order of Hi-Stat’s preference) are: 1. Expedite “certified” product to Hi-Stat. 2. Provide “qualified” personnel to sort at Hi-Stat. 3. Supplier compensates Hi-Stat to sort. This is not an elective for the
supplier. This is to keep production flowing until other arrangements are made.
Note 1: All time accumulated by Hi-Stat per this procedure will be documented on Form L-PUR-F30, Supplier Sort Charges (See SEC. 15.0, FORMS).
TITLE: PAGE OF SEC. 11.0, NON-CONFORMING MATERIAL 4 5
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 07/29/05 STEVE FELLOWS DARREL GEORGE
Note 2: If there are no other acceptable lots available in Hi-Stat’s inventory, the Supplier will be required to act immediately in order to allow Hi-Stat to maintain production requirements and minimize the costs associated with non-conforming product for both parties.
1.6 In order to prevent the problem from recurring, Hi-Stat's Supplier
Development Engineer will send the Supplier a "Supplier Corrective Action Report" (SCAR). This form (See SEC. 15.0, FORMS) will be attached to a copy of the "MDR", which is required to be completed by the Supplier and returned to Hi-Stat's Supplier Development Engineer within 10 working days of the origination date. Initial response must be given within 24 hours. This will serve as a written record to Hi-Stat showing how the Supplier corrected the problem to prevent future recurrences. Consequences for failure to respond see section 7.0 Maintaining Approved Status.
NOTE: THE FOLLOWING IS WHEN A SCAR SHALL BE ISSUED, BUT
NOT LIMITED TO:
A) If the disposition of the MDR creates a line shutdown. B) If the disposition of the MDR creates an increase in the
percentage of line scrap. C) If there is an addition of rework or a secondary operation
in order to use the components. D) If the product is to be sorted prior to use. E) Supplier Concerns have previously been issued within
the last 30 days for this non-conformance.
NOTE: THE FOLLOWING IS WHEN A QUALITY OF SERVICE CHARGE SHALL BE APPLIED TO A MDR, BUT NOT LIMITED TO:
A) Anytime the Quality Engineer has issued a SCAR. B) Anytime the on time delivery date is not met.
1.7 In the event of a product problem discovered at Hi-Stat, the Supplier will be
responsible for taking the appropriate immediate containment action on their current inventory to prevent further shipments of non-conforming product. Maintaining containment of in transit shipments will be the responsibility of the supplier. Containment action should be reported to Hi-Stat within 24 hours. All shipments to Hi-Stat until corrective action is obtained must be 100% sorted and labeled as certified product.
TITLE: PAGE OF SEC. 11.0, NON-CONFORMING MATERIAL 5 5
PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 D 07/29/05 STEVE FELLOWS DARREL GEORGE
2. RECOVERY COSTS ASSOCIATED WITH UNACCEPTABLE QUALITY
2.1 Hi-Stat’s Suppliers are expected to be responsible for costs incurred by Hi-Stat as a result of supplier quality related issues. These costs include: added production costs (i.e., sorting, rework, scrap, etc.) and freight costs. The recovery process for the incurred costs will be through the issuance of debits.
Hi-Stat’s intent is to be fair in the settlement of costs associated with supplier quality problems. The assessment of accountability and evaluation of costs will be based on justifiable reasoning in order to establish mutual consideration. Any questions and/or concerns related to the associated costs should be directed to the appropriate Purchasing Agent or the Director Materials & Logistics Management.
TITLE: PAGE OF SEC. 12.0, CONTINUAL IMPROVEMENT 1 4 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
C o n t in u a l Im p ro v e m e n t
C o n t in u a l Im p r o v e m e n t
G e n e r a l
Q u a lity a n d P r o d u c t iv ity
Im p r o v e m e n ts
T e c h n iq u e s fo r C o n t in u a l Im p r o v e m e n t
C o m p r e h e n s iv e c o n t in u a l
im p r o v e m e n t p r o g r a m a t
s u p p l ie r fa c i l i ty
U n s c h e d u le d d o w n t im e , s e t -u p , d ie
c h a n g e s , a n d c h a n g e o v e r s
C a p a b i l i ty S tu d ie s
(C p , C p k )
C o n t in u a l im p r o v e m e n ts
in q u a li ty , s e r v ic e , a n d
p r ic e
A c t io n p la n s fo r c o n t in u a l
im p r o v e m e n ts to H i -S ta t p r o c e s s e s
T a r g e t n o m in a l a n d
r e d u c e v a r ia t io n
E x te n d c o n t in u a l
im p r o v e m e n t p h ilo s o p h y to s u b -s u p p lie r s
E x c e s s iv e c y c le t im e
S c r a p , r e w o r k , a n d
r e p a ir
E x c e s s v a r ia t io n ,
ta r g e ts n o t a t n o m in a l , le s s
th a n 1 0 0 % f ir s t r u n y e i ld
R e s u lts n o t d a ta b a s e d ,
m a r g in a l m e a s u r e m e n t
s y s te m s
W a s te o f la b o r a n d m a te r ia ls , e x c e s s iv e
h a n d lin g a n d s to r a g e
E x c e s s iv e c o s t o f n o n -
c o n fo r m a n c e s ,
H i-S ta t d is s a t is fa c t io n th r o u g h c o m p la in ts , r e p a ir s , r e tu r n s , m is -
s h ip m e n ts , a n d in c o m p le te o r d e r s
C o n tr o l C h a r ts ( V a r ia b le a n d a t tr ib u te )
D e s ig n o f E x p ir e m e n ts
C o s t o f Q u a li ty
P P M A n a ly s is
V a lu e A n a ly s is , P r o b le m S o lv in g ,
a n d B e n c h m a r k in g
A n a ly s is o f M o t io n /
E r g o n o m ic s
M is ta k e P r o o fin g
L e a n M a n u fa c tu r in g
(5 S , K a n B a n , a n d J IT
F o r m a l C o s t R e d u c t io n
P r o g r a m
TITLE: PAGE OF SEC. 12.0, CONTINUAL IMPROVEMENT 2 4 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define Hi-Stat's continual improvement expectations required by each
Supplier. SCOPE: This procedure is applicable to Suppliers of materials, components, services,
and/or processes used in the manufacture of our products, production, and shipping supplies.
DEFINITIONS: N/A PROCEDURE: RASI: Responsible: Supplier Development Engineer Accountable: Customer Reliability / Quality Systems Manager Support: Purchasing Agents Inform: Business Unit Managers, Director of Operations & Order Fulfillment Consultant: APQP Engineer, Quality Engineer, Director Total Quality Management & Organizational Effectiveness
1.0 GENERAL
1.1 A comprehensive continual improvement philosophy shall be fully implemented throughout the Supplier's organization.
1.2 Hi-Stat Suppliers shall continually improve in quality, service, and price. This
requirement does not replace the need for innovative improvements. 1.3 Action plans for continual improvement must be developed for processes
important to Hi-Stat once those processes have demonstrated stability and acceptable capability.
1.4 For product characteristics and process parameters that can be evaluated
using variables data, continual improvement means optimizing to a target or mean value and reducing variation around that value.
1.5 Hi-Stat Suppliers should extend the continual improvement philosophy to all
of their sub-contractors.
TITLE: PAGE OF SEC. 12.0, CONTINUAL IMPROVEMENT 3 4 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
2.0 QUALITY AND PRODUCTIVITY IMPROVEMENTS
2.1 Hi-Stat Suppliers shall identify opportunities for quality and productivity
improvements and implement appropriate improvement projects. Examples may include the following: a. Unscheduled machine downtime. b. Machine set-up, die change & machine changeover times. c. Excessive cycle time. d. Scrap, rework, and repair. e. Non-value added use of floor space. f. Excessive variation. g. Less than 100% first run capability. h. Process averages not centered on target values. i. Testing requirements not justified by results. j. Waste of labor and/or materials. k. Excessive cost of non-conformances. l. Excessive handling and storage. m. Marginal measurement system capability. n. Hi-Stat dissatisfaction, e.g. complaints, repairs, returns, mis-
shipments, incomplete orders, etc.
3.0 TECHNIQUES FOR CONTINUAL IMPROVEMENT
3.1 Hi-Stat Suppliers are required to demonstrate knowledge of the following measures and methodologies and use those that are appropriate:
a. Capability Indices (Cp, Cpk). b. Control Charts (Variables, Attributes). c. Design of Experiments (DOE). d. Cost of Quality. e. Parts per million (PPM) analysis. f. Value Analysis. g. Problem Solving. h. Benchmarking. i. Analysis of Motion/Ergonomics. j. Mistake proofing. k. Lean Manufacturing (5S, Kan Ban, JIT, etc.)
TITLE: PAGE OF SEC. 12.0, CONTINUAL IMPROVEMENT 4 4 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
4.0 SUPPLIER COST REDUCTION EFFORT
4.1 Hi-Stat's Suppliers are expected to evaluate and submit for approval,
proposals that reduce cost, eliminate waste, and improve quality. A well defined total cost reduction program shall be implemented at the Supplier's facility so that component costs are reduced as the component matures along the learning curve. Any cost savings realized would be shared between Hi-Stat and the Supplier.
TITLE: PAGE OF SEC. 13.0, Q.C. SPECIFICATION Q01-0001 1 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/24/06 STEVE FELLOWS CRAIG BENSON
C r it ic a l C h a r a c te r is t ic s
U n - M a r k e d C h a r a c te r is t ic s
P a s s - T h r o u g h C h a r a c te r is t ic s
D e s ig n a te d o n d r a w in g s w i th a f la g s y m b o l
c o n ta in in g C p k le v e l r e q u ir e d
D e te r m in e d b y H i -S ta t ’s A P Q P a n d /o r Q u a l i ty
E n g in e e r d u r in g d e s ig n r e v ie w
S u p p lie r a d d s to P F M E A a n d
C o n t r o l P la n
S u p p l ie r s u b m its d a ta to H i -S ta t w ith
s h ip m e n ts p e r r e q u ir e m e n ts in
p r o c e d u r e
Is th e d a ta a c c e p ta b le to p r in t r e q u ir e m e n ts
a n d to c r i te r ia in p r o c e d u r e ?
N O
YES
C o m p o n e n ts a r e a p p r o v e d
fo r p r o d u c t io n
M a te r ia l D is c r e p a n c y R e p o r t F i le d
M D R p r o c e d u r e
fo l lo w e d a n d C o r r e c t iv e
a c t io n is s u e d
S u p p lie r C o r r e c ts P r o c e s s
S u p p lie r a n s w e r s
c o r r e c t iv e a c t io n
H i- S ta t ’s S u p p l ie r Q u a l i ty A g e n t fo l lo w s -
u p o n c o r r e c t iv e
a c t io n
Q C S p e c if ic a t io n s
S u p p lie r m o n ito r s a n d c o l le c ts d a ta
fo r e a c h d e s ig n a te d c h a r a c te r is t ic p e r th e p a r a m e te r s o n
th e p r o c e d u r e
M a r k e d C h a r a c te r is t ic s
TITLE: PAGE OF SEC. 13.0, Q.C. SPECIFICATION Q01-0001 2 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/24/06 STEVE FELLOWS CRAIG BENSON
PURPOSE: To define the application of Q.C. Specification QO1-0001 noted on Hi-Stat
drawings. SCOPE: Use of this procedure applies to Suppliers and all internal Hi-Stat functions
verifying conformance of component parts, materials or processes to drawing specifications.
DEFINITIONS: Cpk: Capability Index for a stable process. PROCEDURE: RASI: Responsible: Project Engineer Accountable: Business Unit Manager Support: Purchasing Agent Inform: Buyer/Supplier Quality Agent
Any parameter or dimension not meeting specified requirements on the drawing is considered a non-conformance. Parameters and/or dimensions (characteristics) shown on Hi-Stat drawings are classified according to their seriousness by application of the appropriate Cpk level requirement inside the flag symbol.
Suppliers of materials, components and/or processes are required to produce components which are centered about the target or nominal value. Documentation (ie: control charts, Cpk, etc.) must be maintained by the supplier demonstrating statistical control of the process for the appropriate Cpk level noted on Hi-Stat's drawing.
1. CRITICAL CHARACTERISTICS
a. Critical characteristics are designated on Hi-Stat drawings by the flag symbol ( ), which will be located next to the dimension with the requirement. Inside this symbol will be the Cpk level requirement for that dimension. The Supplier's manufacturing process is required to produce a normal curve per the designation equal to a minimum of +/- 4 sigma (8 standard deviations) within specification which is equal to a 1.33 Cpk, or a normal curve of +/- 3 sigma within specification, which is equal to a 1.00 Cpk. Appropriate control charts (Xbar-R) must be used with a minimum of 100 samples to prove stability.
⌂
TITLE: PAGE OF SEC. 13.0, Q.C. SPECIFICATION Q01-0001 3 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/24/06 STEVE FELLOWS CRAIG BENSON
NOTE: Cpk provides a combined measure of the amount of part-to-part variability within a process and the relationship of process average to the specification limits. A Cpk value is calculated when variable data are used to evaluate product quality. The process must be stable or in "statistical control" before a valid Cpk value can be determined.
Cpk = distance from process average to nearest spec limit
3 (process standard deviation)
The higher the Cpk value the more capable a process is to repeatedly produce parts that are within specifications.
b. A critical characteristic is one that judgement and experience indicate can affect:
- safe vehicle/product function. - product life. - meeting customer specifications. - assembly. - use requiring additional operations to make the part operational or functional. - compliance with government regulations.
2. MARKED CHARACTERISTICS
a. Marked characteristics are designated on Hi-Stat drawings by the flag symbol ( ) with the letter “M” inside, this symbol will be located next to the dimension with the requirement. All marked characteristics are declared as “Zero Defects” The Supplier must use "Zero Defects" sampling methods for marked characteristics.
⌂
b. Marked characteristics on Hi-Stat drawings are designated as requiring ongoing process monitoring after an approved First Piece Dimensional Layout. Hi-Stat's Control Plan and/or Work Instruction to the Supplier will dictate the ongoing process control requirements for marked characteristics.
3. UNMARKED CHARACTERISTICS
a. All unmarked characteristics are declared as “Zero Defects” The Supplier must use "Zero Defects" sampling methods for unmarked characteristics.
b. Unmarked characteristics on Hi-Stat drawings are not designated as requiring
ongoing process monitoring after an approved First Piece Dimensional Layout
TITLE: PAGE OF SEC. 13.0, Q.C. SPECIFICATION Q01-0001 4 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/24/06 STEVE FELLOWS CRAIG BENSON
4. PASS THROUGH CHARACTERISTICS
4.1 Pass through characteristics are those that will have potential fit and/or functional issues that will not be detected within the customer’s manufacturing process. Proper fit assures the mating part(s) will assemble properly. Functionality assures the part(s) are 100% functional over the entire operating range.
4.2 Pre-Production
a. Pass through characteristics will be developed from the customer’s top level
print and documented during the design review process. This will be done by the APQP or Quality Engineer.
b. The supplier shall submit evidence of an acceptable capability process for
each pass through characteristic identified at the time of PPAP. Failure to do so or submitting an unacceptable Cpk level will result in rejection of the PPAP.
c. The supplier will be required to add the pass through characteristics to their
PFMEA and control plan. d. 100% in-process inspection (go/no go gages, vision system, etc.) prior to
shipping may be required for any process that is not controlled and stable. e. The supplier is required to submit data with every shipment to comply with Hi-
Stat’s Dock-to-Point-of-Use program. This data will be monitored by Hi-Stat’s Metrology Lab and any non-conformances will result in the processing of a Material Discrepancy Report.
f. The supplier will be notified by Hi-Stat’s Supplier Quality Agent of the non-
conformance and a Supplier Corrective Action will be issued. 5. POST PPAP
a. Supplier will be required to submit data as required by the APQP Engineer. This data may be reviewed by Hi-Stat’s Metrology Lab or the APQP Engineer, and any non-conformance will result in a material discrepancy report being filed.
b. Supplier Corrective Action will be issued by the Supplier Quality Agent. The
supplier will then have to submit data with every shipment until process stability is regained and corrective action is closed.
TITLE: PAGE OF SEC. 13.0, Q.C. SPECIFICATION Q01-0001 5 5 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 03/24/06 STEVE FELLOWS CRAIG BENSON
6. LOT SAMPLING USED AT HI-STAT'S RECEIVING INSPECTION DEPARTMENT
All Hi-Stat Customers expect their product to be delivered with zero defects. Conformance to drawing specifications will be evaluated by Hi-Stat using the following plan and procedures.
a. In support of this Customer expectation, Hi-Stat's Metrology Lab utilizes the following
sample size:
Diamond Symbol: n=30 Square Symbol: n=30 Circle Symbol: n=30 No Symbol: n=10
b. Selection of the sample from the lot received from the Supplier must be a random
selection where each part in the shipment has equal opportunity in being selected. The acceptance number in all cases is zero. The Metrologist only accepts the shipment if zero non-conformances are found in the sample.
c. Sample sizes for variables/attribute data collected by Hi-Stat's Metrology Lab may be
reduced to 10 parts per shipment after 5 consecutive manufacturing production lots have been received with no non-conformances found and all stated Cpk requirements on the drawing (evaluated as Ppk) were met or exceeded. This reduced sampling does not require the Supplier to have an "Approved" rating or be qualified for "Dock to Point of Use" status.
TITLE: PAGE OF SEC. 14.0, DOCK TO POINT OF USE 1 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 05/09/06 STEVE FELLOWS CRAIG BENSON
Storeroom M aterial Coordinator receives
com ponents
Storeroom M aterial
Coordinator verifies
inspection data was delivered
w ith the shipm ent
W as data delivered? NO
YES
Notify M etrology to
begin the M DR process
and place shipm ent on
hold
Storeroom M aterial Coordinator w ill not re -
label w ith Hi-Stat bar code labels
M etrology w ill enter the data
into the Infinity
program
YES
Storeroom M aterial
Coordinator w ill stam p
and place one m aster label
on each pallet of m aterial
Storeroom M aterial
Coordinator w ill m ove the
m aterial to the line
M etrology w ill process M DR for any non-
conform ances
Dock to Point of Use
TITLE: PAGE OF SEC. 14.0, DOCK TO POINT OF USE 2 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 05/09/06 STEVE FELLOWS CRAIG BENSON
PURPOSE: To define the "Dock to Point of Use" procedure and its application. SCOPE: This procedure is applicable to Suppliers of materials, processes, and
components and Hi-Stat's Metrology Lab Process. DEFINITION: PPAP - Production Part Approval Process DPU – Dock to Point of Use PROCEDURE: RASI: Responsible; Buyer/Supplier Quality Agent Accountable: Strategic Supply Chain Manager Support: Purchasing Agent Inform: Director of Operations
Hi-Stat's goal in developing its Suppliers is for every Supplier with an "Approved" status to also meet the "Dock to Point of Use" requirements for each part number they supply. Dock to Point of Use (DPU) is a status that is applied on a per part basis that allows Hi-Stat's Metrology Department to only verify the certification and data provided by the supplier for the shipment while sending the components to stock (Dock to Point of Use). Variables/attribute data collection is not required by Hi-Stat's Metrology Department with this status.
1. DPU status for each part number is earned by achieving the following items:
a. "Approved" Supplier status.
b. Maintaining "Approved" Supplier status.
c. Approved PPAP (where required) on file for the part number.
NOTE: See SEC. 3.0 (Quality System Expectations) and SEC. 8.0 (Production Part Approval Process) that define PPAP requirements.
TITLE: PAGE OF SEC. 14.0, DOCK TO POINT OF USE 3 3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 C 05/09/06 STEVE FELLOWS CRAIG BENSON
d. Required inspection data as defined on the Work Instruction for 5 shipments or until
sufficient evidence of a stable process can be proven. Then required data / certification is received from the Supplier or evidence that the Supplier is retaining required inspection data for the part number.
e. Five (5) consecutive shipments received for the part number without any Supplier
fault non-conformances found during inspection and/or during the assembly process.
f. The Metrology Lab Supervisor will maintain a list for the Receiving Dock of all
suppliers that DO NOT have DPU Status
2. The DPU status for a part number is removed if any items in paragraph 1 above are not met and requires returning to full inspection as described in the work instruction for that part number.
3. If DPU status for a part number is lost, it can be obtained again by achieving the items
outlined in paragraph 1 above.
4. If a part number loses Dock to Point of Use status (for quality related issues only) more than two (2) times within a 12 month period, it will require a new PPAP submission from the Supplier to regain the DPU status. Once the new PPAP is approved, the DPU status can once again be obtained providing all requirements in paragraph 1 have been met.
5. Hi-Stat's Metrology personnel are required to accurately record Supplier performance to
assure Dock to Point of Use requirements are met and utilized as much as possible.
6. Hi-Stat’s Metrology Lab personnel are required to enter supplier data (until full DPU status is obtained) into the infinity system and notify the Buyer/Supplier Quality Agent of any trends in the data that could potentially move to a non-conformance.
7. A shipment received without certification and data as required will be considered a non-conformance and a MDR will be processed. Supplier will lose DPU status.
8. Any non-conformance found on the line will result in the components being returned to the
Met lab for a MDR to be processed. Supplier will lose DPU status.
TITLE: PAGE OF SEC. 15.0, FORMS 1 1 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To define form(s) disclaimer. SCOPE: This procedure is applicable to all Suppliers of materials, components, services
and/or processes used in the manufacture of Hi-Stat's products. DEFINITIONS: N/A PROCEDURE:
1.0 FORMS
All forms outlined in each section of the Supplier Quality Management Guidelines can be obtained using the “FORMS” link located at www.histat.com. To assure proper form and current revision level is used, be sure to check the “FORMS” link at www.histat.com for any updates. If you have any questions, please contact the Supplier Development Engineer.
Supplier: If you are IMDS registered, do not fill out this form. Submit data to our Co. ID # 9348.
Contact Name: Please use the Hi-Stat ordered part number and description in the IMDS submission.
Phone Number: E-Mail:
Component Part Number
(Hi-Stat)
Part Name / Description
Part Rev. Level
Piece Gram
Weight
Weight Tolerance
(%)Material Name Material
Number
Material Trade Name &
SupplierClassification
Polymeric part(s)
marked? Yes / No /
Not Applicable
Does Material contain
Recyclate? Amount?
Norms / Standards
% of Component
Substance Name
CAS # % of Material
Declarable / Prohibited
(D/P)
Prohibited Substance Application
* IF MATERIAL USED IN A COMPONENT IS A STANDARD MATERIAL (i.e. : 12L14 STEEL, 1010 STEEL, 260 BRASS, etc.), SUBSTANCES DO NOT NEED TO BE LISTED. PLEASE PLACE IN SUBSTANCE COLUMN: "STANDARD IMDS MATERIAL"
If not IMDS registered, please provide the following information for each product you supply to Hi-Stat Mfg., Lexington Division
DISCLAIMER OR REMARKS TO ADD TO THE IMDS DATA:
Component Data Substance DataMaterial Data
Hi-Stat
A Stoneridge Company
Material Data Information for the Reporting of Restricted and Controlled SubstancesTo be provided to Hi-Stat Manufacturing
If you have any questions, please contact:Darrel D. George, Quality Systems Manager, at 419-884-4176 or [email protected] Jen Conover, IMDS Coordinator, at 419-884-4179 or [email protected] L-QAP-F7 REV. C
QUALITY MANAGEMENT SYSTEM SELF-SURVEY
PAGE: 1 OF: 5
L-PUR-F31 REV. B
DESCRIPTION OF REQUIREMENT YES NO EVIDENCE EXAMINED-REMARKS
QUALITY MANAGEMENT SYSTEM
1) Is there evidence of an implementedadvanced product quality planning process?
2) Do process FMEA's consider all Special Characteristics?
3) Are control plans developed, in accordance with the AIAG PPAP Manual by a multidisciplinary approach to the system, subsystem, component, and/or material level, and list all controls used for process control?
4) Does the supplier utilize a part approval process for subcontractors?
5) Is there evidence of continuous improvement in quality (extending to product characteristics), service (timing and delivery) and price that benefit all customers?
6) Are methods developed for evaluating the effectiveness of existing operations and processes which consider the overall work plan, appropriate automation, ergonomics and human factors, operator and line balance, storage and buffer inventory levels, and value added labor content?
QUALITY MANAGEMENT SYSTEM SELF-SURVEY
PAGE: 2 OF: 5
L-PUR-F31 REV. B
DESCRIPTION OF REQUIREMENT YES NO EVIDENCE EXAMINED-REMARKS
7) Has the supplier established and implemented a system for tool management that includes maintenance and repair facilities and personnel, storage and recovery, set-up and tool change programs for perishable tools, tool modification including tool design modification?
8) Are appropriate technical resources available for tool and gage design, fabrication and full dimensional inspection or if tooling activities are subcontracted, is there a system to track and follow-up these activities?
PROCESS CONTROL 9) Does the supplier have contingency
plans to reasonably protect the customer's supply of product in the event of emergency?
10) Do controlled conditions include the monitoring and control of suitable process parameters and product characteristics, including designation and documentation of Special Characteristics?
QUALITY MANAGEMENT SYSTEM SELF-SURVEY
PAGE: 3 OF: 5
L-PUR-F31 REV. B
DESCRIPTION OF REQUIREMENT YES NO EVIDENCE EXAMINED-REMARKS
11) Have documented process monitoring and operator instructions derived from the sources listed in the Advanced Product Quality Planning and Control Plan referencemanual, or equivalent sources, beenprepared for all employees having responsibilities for operation of processes and are they accessible at the workstation?
12) Do process monitoring and operator instructions include or reference, as appropriate:
• Operation name and number keyed to process flow diagram?
• Part name and part number? • Current engineering level/date? • Required tools, gages and other
equipment? • Material identification and
disposition instructions? • Customer and supplier designated
Special Characteristics? • SPC requirements? • Relevant engineering and
manufacturing standards? • Inspections and test instructions? • Reaction plan • Revision date and approvals? • Visual aids? • Tool change intervals and set-up
instructions?
QUALITY MANAGEMENT SYSTEM SELF-SURVEY
PAGE: 4 OF: 5
L-PUR-F31 REV. B
DESCRIPTION OF REQUIREMENT YES NO EVIDENCE EXAMINED-REMARKS
12) Does the supplier maintain or exceed the process capability or performance as approved by PPAP through the implementation and adherence to the Control Plan, Process Flow Diagram, measurement technique, sampling plans, and reaction plans when acceptance criteria is not met?
INSPECTION & TESTING 13) Does the supplier ensure that
incoming product is not used or processed (except for urgent production purposes), until it has been inspected or otherwise verified as conforming to specified requirements in accordance with the quality plan and/or documented procedures?
14) Does the quality plan (Control Plan) mandate that all specified inspections and tests, incoming, in process, and final, must be performed and that they meet specified requirements?
15) Does the supplier maintain records which provide evidence that the product has been inspected and/or tested clearly showing whether the product has passed or failed inspection based on the defined acceptance criteria, and identifying the authority responsible for the product release?
QUALITY MANAGEMENT SYSTEM SELF-SURVEY
PAGE: 5 OF: 5
L-PUR-F31 REV. B
DESCRIPTION OF REQUIREMENT YES NO EVIDENCE EXAMINED-REMARKS
16) When the supplier uses independent/commercial laboratories are they accredited?
CONTROL OF NONCONFORMING PRODUCT 17) Does the control of nonconforming
product and suspect material or product provide for identification, documentation, evaluation, segregation (when practical), disposition, and for notification of all appropriate functions?
18) Does the supplier quantify and analyze nonconforming product, establish a prioritized reduction plan and track progress?
19) Does the supplier obtain customer authorization prior to shipment whenever product or process is different from the current PPAP approval?
CORRECTIVE & PREVENTIVE ACTION 20) Does the supplier use a disciplined
problem solving method to address internal or external nonconformances?
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
President:
Vice President Sales:
V.P. Manufacturing:
Sales Manager:
Q.A. Manager:
Engineering Manager:
NAME OF PRINCIPLE OFFICERS
Page 2 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
$ of Total Sales
Is the work force unionized:
Years with YouType of Business References
List the top 4 customers according to their share(s) of gross sales:
Yes No
Number of Manufacturing Locations:
Company Name
Page 3 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
Yes or No:
2003: 2001:
2002: 2000:
Sales To Stoneridge Last 4 Years:
2003: 2001:
2002: 2000:
Estimated Sales: 2004: 2005:
If yes, describe below (e.g.; ethnicity, sex, disabled, veteran, etc…):
FINANCIAL INFORMATION
Ownership:
Sales – Last 4 Years:
Do you have Minority Owned Business Enterprise Status?
Publicly Held Privately Held
Page 4 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
If the financial data requested is not available to Stoneridge please explain:
Yes No
Rating
Financial Statement Available? Yes No
Any Outward Sign of Financial Weakness? Yes No
Financial Statement Attached? Yes No
Additional Comments:
Is company rated by Dunn and Bradstreet?
Page 5 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
Screw Machine Thread Coating Connectors
Metal Stamping Precious Metal Plating Fasteners
Metal Drawing PC Boards IPC training/Level
Welding Cables & Wire Electro-Plating
Molding Sorting Annealing
Plastics Cleaning Ryton
Polyimide Extrusion RTD
Teflon Castings Thermocouples
Tooling Inspection Services Heaters
Kapton Film Engineering Testing
COMPETENCIES
Page 6 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
Facilities List:
Page 7 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
Page 8 L-PUR-F15 Rev. B
Assessment Date:
Supplier Address:
Supplier Phone/Fax:Supplier Contact:
Supplier Quality System Assessment
Supplier Name:
Supplier Commodity:
Hi-Stat
A Stoneridge Company
15. What is the RFQ Capture Ratio?
16. Is a Facility List Attached?
4. Square Footage of Facilities:
5. Number of Employees:
6. Number of Shifts:
13. What is the PPAP First Pass % ?
14. What is the RFQ Response Time?
11. What is the On-Time Delivery % ?
12. What is the PPAP On-Time % ?
7. Manufacturing Capacity:
Manufacturing:
8. In-House Tooling Capabilities:
Direct Labor:Office:
9. Organizational Chart Attached:10. What % of Stoneridge Business Would Make the Business Un-Comfortable?
MISCELLANEOUS
Indirect Labor:
1. Other Automotive Customers:
2. Other Major Customers:
3. Awards Received:
Page 9 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Quality1. Parts Per Million External PPM’s < 100 PPM 4.4 0
Internal PPM’s < 1000 PPMHow are internal PPM’s addressed for continuous improvement?Are customer PPM’s monitored and if so is the trend positive. Is there a metric to reduce PPM level plant wide? Are supplier PPM’s monitored? Is there a formal review process with the entire management team that includes the PPM metric?
2. Corrective Action Disciplined Corrective action implemented & verified effectively. (Internal & External)
4.4 0
Few/No repeats.Are repeats tracked and addressed in a formal fashion using the Pareto principle to prioritize activities.
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
Page 10 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
2. Corrective Action Continued
Are all actions tracked for timeliness, is there a formal tacking mechanism to monitor and report out performance?Are there performance expectations with respect to timing?Do all customer complaints have management review?
3. QS-9000 / ISO 14001 / TS16949 / ISO 9001 2000
QS-9000/TS16949 Alignment/Certification, ISO 14001 certification or implementation plan.
4.4 0
Knowledge of industry specific standards that are being developed or are developed that will replace the current standards such as TS 16949 and IS0 9001 2000. Does the organization have an AIAG membership or an equivalent system for getting the latest information on available standards and updates?Are there plans in place to get certification to the latest industry standards if not currently in compliance?
Page 11 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
4. Lean Manufacturing / Six Sigma
Lean Manufacturing Knowledge and implementation of basic tools. (Inventory levels, visual factory, P.M., Employee Involvement)
4.4 0
Are P.M. systems linked to a database for tracking?Are P.M.s effective (planned vs. unplanned)?Is OEE , Takt time FTT, being measured? Is the Lean program linked to Six Sigma or cost reduction activities?Six Sigma methodologies understood and practiced throughout the facility.Is the infrastructure in place to support a Lean/Sigma activity?Though not formalized is there an understanding of the concepts with some implementation?
5. Continuous Improvement
Is there evidence available to support a formal continuous improvement program?
4.4 0
Is the Management team involved in the program?
Page 12 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
5. Continuous Improvement Continued
Is the program inclusive of the entire organization?
Are projects or continual improvement items derived from a corporate perspective or independently established by teams, section, or product etc?
Is there evidence of organizational improvement goals?Are there ramifications for not meeting improvement goals?Is the improvement program tied to employee performance, compensation, gain sharing, profit sharing etc?
6. PPAP Methodology Control Plan Methodology actively deployed and understood. (FMEA’s, GR&R’s, SPC, Process Flow with Controls etc.)
4.4 0
Is the PPAP process a standard part of the business process.Are AIAG guides (PPAP, MSA, SPC etc.) available and to the latest revision?
Page 13 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
6. PPAP Methodology Continued
Is there a industry specific APQP package available to produce PPAP documentation, or is home grown software being used.Is there a formal system in place with respect to record & sample retention?Has the supplier demonstrated the capability to produce a PPAP package capable of meeting the AIAG and Stoneridge requirements?Is the evidence available to support the capability to produce a PPAP package.Is the entire process defined and is it a team approach?
7. Measurement Capability
Can the sub-contractor demonstrate the ability and does the equipment exist to meet AIAG & Stoneridge requirements.
4.4 0
Is there a sound understanding of GD&T as well as basic dimensioning techniques?
Page 14 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
7. Measurement Capability Continued
Is the Equipment (CMM, Vision Systems, Comparator) available to support the measurement requirements?
List all equipment.Does the organization have qualified resources to support the measurement requirements and organizational needs?Does the organization have the ability to perform GR&R’s to the AIAG MSA guide?
Is the latest MSA guide available and is there evidence available to support the claim? Does the measurement competency support the technology requirements, and if not is an approved certified outside source available?Does the organization have a measurement capability or competency that they would consider a competitive advantage in their industry?
Page 15 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
8. Calibration What is the current calibration software being used?
4.4 0
Are calibrations done in-house or outsourced?Were there any devices observed to be past due for calibration?If outsourced, are only certifed labes used?Are all personnel trained for technician status?
9. APQP/PPAP Output Is there a formal process defining the APQP process?
4.4 0
Does the process meet the AIAG requirements?Is the process cross-functional?Does the process take the cradle to grave approach?Is there a tracking system available to monitor the stages of the process?
Page 16 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
If the deadlines are not being met are there recovery plans or corrective action plans in place?
Page 17 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
9. APQP/PPAP Output Continued
Is this a standard part of the business or automotive specific?Who is the process owner?Is the APQP process visible on a set interval to senior management?Is there evidence of the process deliverables available to support the execution of the APQP process?
10. Supply Management Is there a system in place to select, develop, monitor and improve the key production supply base?
4.4 0
Does the supplier selection process include benchmarking or is it exclusively system surveys.
Does the selection process include a system for corrective action in areas that are not meeting requirements?Are these actions tracked and implemented prior to new business award? Is there a formal system in place to track supplier performance?
Page 18 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
10. Supply Management Continued
Are performance expectations communicated and acted on?
Does the supplier do any form of development and if so is it formalized?Has the supplier conducted on-site workshops?Is there a formal system in place for tracking a suppliers status (Qualified Supplier List)Is there a formal supplier requirements manual.Who is responsible for supplier selection?
11. Process Control Is there evidence of process monitoring?
4.4 0
Are operator instructions, special characteristics posted?Is a process change system with a process change procedure and tracking available?
Is a 1st piece set-up procedure in effect?Is the process control element linked to initiatives such as lean/six sigma?
Page 19 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
11. Process Control Continued
Are process controls derived from the APQP process (Process Flow, PFMEA, Control Plan etc.)? Are the appropriate resources in place to execute all process control requirements?Is evidence available to confirm out of control conditions are addressed real time and that all personnel are capable of shutting down out of control processes?Is there any evidence of real time data collection systems designed to present immediate feedback to operations with respect to key process control elements?If these systems exist, are they designed to automatically control line flow and process output?Are control plan elements studied for Gage repeatability & reproducibility and are special operations qualified with masters or standards?
Page 20 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
12. Document Control Is there evidence of an engineering change control system for internal & external purposes?
4.4 0
Does the system include a recall process for all obsolete documentation?
Does the change process include provisions to assure that financial, regulatory, contractual & customer requirements are addressed at the appropriate levels?
Is the change process linked to a database for performance tracking purposes and if so are there performance measurables associated with the system?
Total this section. 0264Points Possible this section
Page 21 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
Delivery1. Delivery Performance Is there a system to monitor
delivery for all elements of the business (supplier, customer)?
4.29 0
What is the delivery number for incoming and outgoing?
Is 100% on-time delivery the goal?Is delivery part of the plant core measurable system?Does the supplier have access to the customer reporting systems or reports?
Does delivery information get reported back to the management team?
Is production order driven?Does the supplier have access to systems such as EDI & ASN acknowledgement?Are actual numbers readily available and to world class criteria?
Page 22 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
2. Dock to Stock Does a formal Dock to stock or skip lot inspection program exist?
4.29 0
Is criteria identified to support the program?How is product removed from Dock To Stock?Who is responsible for the designation of DTS and is the system electronic or linked to the ERP system?Is Dock to Stock percentage tracked?Are other programs designed at reducing non value added activities being utilized in place of DTS?
3. Premium Shipments Are premium shipments tracked on both ends of the business?
4.29 0
What percentage of shipments is related to premium deliveries (should be below 5%)?
Who is responsible for tracking, reporting and correcting issues related t premium shipments?
Page 23 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
3. Premium Shipments Continued
Are component requirements and customer shipments tied to electronic systems?
Are schedules firm on both ends of the business and what window of requirements is available on both ends?
Is senior management aware of premium shipments and associated expenses?
Are formal corrective actions taken when and where required to address premium shipments?
4. Line Shutdowns Look for history of line shutdowns (due to delivery issues) and reasons for the actions.
4.29 0
Page 24 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
4. Line Shutdowns Continued
Are line shutdowns related to component parts or process downtime?Is there a visual inventory system or Kan Ban system in place to highlight potential issues?Does the organization have a formal planning department responsible for incoming component and outgoing components?Is end of line yields in line with industry standards or can they potentially impact shipping schedules?Has the supplier identified qualified sources (land, sea and air) to expedite freight when necessary?
5. Production Systems Shipping capabilities and understanding of common systems (JIT, Level Scheduling, Kanban etc.)
4.29 0
Does the supplier ship daily, weekly, monthly etc?Is the production schedule forecast driven?
Page 25 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
6. Electronic Planning & Scheduling
Is production building to demand using concepts such as one-piece flow, Dock to Dock time and optimum inventory to meet the schedule?
4.29 0
Does the supplier have a computerized system for executing the order fulfillment process?
What system is used for production planning and scheduling?
Is the system still supported by the manufacturer or the internal IT function?
Do scheduling capabilities include current systems such as EDI using ERP systems?
Are ASN’s used if not is the system capable of generating ASN’s?
7. Barcoding Does the supplier utilize Bar-coding throughout the order fulfillment process?
4.29 0
What type of equipment is available?
Page 26 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
7. Barcoding Continued Are ample back-up units in place and is technology current? Is there a system in place and is it capable of verifying content vs. label?Are AIAG standard label formats in use or available?
Is the barcode system verified using the ERP system to confirm the order matches the printed code?
Total this section. 0150Points Possible this section
Page 27 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
Capabilities1. Computer Aided Design
CAD systems available such as: Pro-Engineering, Catia, IDEAS, SDRC, Autocad
3.75 0
2. Electronic Communication
Electronic Communication available such as: FTP site, e-mail, high speed modem, EDI, Internet access, Web site, barcode, Y2K compliance.
3.75 0
3. Analytical Capabilities
Laboratory/Analytical services available internally or externally. Capable of providing the necessary scientific independent evaluation required for the specific industry. (egs. include but are not limited to, mold flow analysis, x-ray technology, IR analysis, material composition etc.)
3.75 0
4. Tooling/Fixturing/ Development Capabilities
Capabilities such as: In-house prototyping, tool design, tool machining, EDM, tool maintenance programs, rapid prototyping, soft tooling, tooling with automation, gauging etc.
3.75 0
Page 28 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
5. Material Experience /Intellectual Property
Materials used to support the commodity being provided. Does the supplying facility have experience with many different types of alternative materials that have similar properties and multiple application opportunities. Can the supplier demonstrate a competency in material experience that may differentiate them and provide competitive advantage over the competition. Has the supplier developed a niche application, material or product that provides a competitive advantage in the supplying industry.
3.75 0
6. Cost Reduction Cost reduction programs including full organizational participation, management driven, % of business goals, measured and monitored for performance.
3.75 0
Page 29 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
7. Serviceability Serviceability as a measure of the suppliers ability to have a flexible operation, #of shifts, weekend, flex. Scheduling etc. Most important is the ability to have a cross-trained workforce that is capable of job sharing throughout the entire organization. Established back ups at all levels, with competency gained from training initiatives.
3.75 0
8. Quick Turn Around A defined business process that is capable of providing conceptual or early prototype components. This process should be based on speed to market and provide high value prior to the production award. Examples in plastic would be, SLS (Selective Laser Sintering), SLA (Stereo Lithography) etc.
3.75 0
Total this section. 0150Points Possible this section
Page 30 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
Commercial1. LTA’s Are Long Term Agreements
with customers available?0.34 0
Are Long Term Agreements with suppliers available?
Do the contracts include provisions for sharing tooling cost (prototypes, production)?Do the contracts include provisions for rebate programs based on duration & quantities?Are cost penalties included for quality, delivery and warranty issues?
2. Cost Reduction Is there a formal cost reduction program?
0.34 0
Are cost reduction activities inclusive of the entire organization?Is cost reduction directed to customer rebates and price reductions and if so is the link obvious?
Page 31 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
2. Cost Reduction Continued
Reduction can come in many fashions, product/process improvements, new materials etc. The key here is how these programs are linked to the end customer.
Are cost reduction activities part of the business planning process and if so what are the expectations?
3. Serviceability Serviceability inclusive of shift flexibility, weekend hours, overnight shipping.
0.34 0
The ability to flex the entire operation in a manner that is not detrimental to the quality or cost of the product.
Look for the ability to meet fluctuating requirements without having to look for price concessions. Must be able to flex with customer demand without incurring financial penalty.
4. Strategic Alliances Does the supplier subscribe to any industry associations or cooperatives?
0.34 0
Page 32 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
4. Strategic Alliances Continued
Can the supplier demonstrate strategic advantage do to material volume agreements?Can the supplier demonstrate technical advantages based on strategic posturing with key resources?Can the supplier demonstrate a strategic advantage based on alliances and posturing with key resources?
5. Cost Drivers Review of cost drivers vs. cost structures, try to determine reasonable level of profit margin with respect to Stoneridge cost structures.
0.34 0
Are cost models in line with Stoneridge models? List cost drivers.What are the marketing/sales cost models for bid activity?
6. Capture Rate Is capture rate tracked? 0.34 0
Page 33 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
6. Capture Rate Continued
Review of competitive pricing, capture rate, lead times, quote responsiveness etc.
Total this section. 012Points Possible this section
Page 34 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
Training1. Training Schedule & Planning
Is training part of the business planning process?
0.4 0
Is there a formal training plan in place for all personnel?
Does the organization provide for internal training as part of a compensation program?Is a master training schedule available for all disciplines?
Does the entire organization have input in identify the individual training needs?
How are the training needs identified if not part of the planning process?How is training effectiveness evaluated?
2. Continuing Education Is tuition reimbursement offered?
0.4 0
Page 35 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
2. Continuing Education Continued
Do training activities coincide with specific industry recognized programs such as (Lean Manufacturing, Six Sigma, GD&T, CAD/CAE etc.)?Are employees encouraged to participate in training programs internal & external?Are employees compensated and promoted based on acquired knowledge?
3. Operator Training Is there a formal training schedule for all operators?
0.4 0
Is training tied to advancements in position and or salary?Is operator training geared toward procedural issues on day to day functions?Are operators cross-trained on multiple product/processes?Are records available as evidence to support the training activities?Are new employees trained prior to actual job assignment?
Page 36 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
3. Operator Training Continued
Does training include provisions for systems, safety and housekeeping (5S)?
4. Cross Training Is there a formal cross training program?
0.4 0
Are all operators part of the cross training program?
Is cross training limited to the operators?How are non English speaking people trained?
5. Customer Workshops Has the supplier benefited from customer workshops or specific customer driven programs?
0.4 0
Is there evidence available to support a good strong supplier/customer information sharing process?
Are certificates of completion or records of attendance available to support attendance at the workshops?
6. Workshops Has the supplier held any workshops on site with their supply base to trickle down the acquired knowledge?
0.4 0
Page 37 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
6. Workshops Continued Are certificates of completion or records of attendance available to support attendance at the workshops? Is course or topic material available and are other workshops planned?
Total this section. 012Points Possible this section
Page 38 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
Facility1. Facility Planning Is a facility layout available? 0.48 0
Does the layout include the entire facility?Is evidence available to support the use of these layouts for planning of new & future business?Do facility plans take into account lean principles?Are efforts made to minimize wasted space & travel?
Is the facility well organized and does material flow fluidly throughout?Does the facility show sign of decay or neglect internally and externally?
2. Facility Expansion The facility layout should include provisions for growth and should not be at or over capacity.
0.48 0
Is the property owned or leased?Can the current site be expanded without the need to purchase properties from abutting owners?Has expansion been considered and if so is a suggested layout available?
Page 39 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
2. Facility Expansion Continued
Is the current property a single site location?
3. Safety Environmental Look for any visible signs of neglect and or safety related issues that may jeopardize worker/ building preservation which could directly affect material flow and operating costs (workman’s comp, lost days etc.)
0.48 0
Does the supplier have programs and policies geared to an environmentally friendly facility, modeled or certified to ISO 14001.
Are lost work days tracked?
Does the facility handle any materials that would be considered hazardous?Are there provisions to properly handle the hazardous materials internally and externally?Is there an active safety committee or program?Who oversees the committee?
Page 40 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
4. Contingency Planning Contingency planning should be included in the operating systems and should include provisions for key equipment/resources necessary to ensure uninterrupted product flow in cases where reasonable emergency planning is required.
0.48 0
Is a contingency planning procedure available?Does the plan cover items such as utilities, labor & key equipment?
5. Location Is the facility located in an area that allows for easy access to all modes of transportation?
0.48 0
List the closest airports and railway in terms of general proximity to the facility.Is the facility located in a community that enables the organization to attract employees with the background & education necessary to run the business effectively?
Page 41 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
Category Requirements Results (Evidence Obtained) Weight Value
Scoring Total Score
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
0
0
Hi-Stat
A Stoneridge Company
5. Location Continued Are there any inherent dangers related to the location of the site, either environmental or climatic.
Total this section. 012
TOTAL 0 Points Possible this section
Page 42 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
WeightingQuality
Delivery
Capabilities
Commercial
Training
Facility
Scoring1
2
3
4
5
Overall Rating
232 – Under (400 - under 69% - under)
Systems not Evolved at this timeExtensive Development Required
233 – 347 (406 - 458 70% - 79%)
Systems are in Evolutionary StagesModerate to Extensive Development Required“Potential” Future Business Candidate
348 – 464 (464 - 545 80%-94%)
System Evidence ApparentMinor Development Required“Acceptable” Business Candidate
There is enough evidence available to meet the minimum requirements.
This requirement is implemented and understood at some levels of the organization, additional training and education would help to engrain this requirement into the organizational culture. This requirement is part of the organizational culture, this facility could train others on this requirement.
465 – 580 (551 - 580 95%- 100%)
World Class SystemsBest in Class Practices“Preferred” Business Candidate
25% of the total points possible are within the Delivery Category
25% of the total points possible are within the Capabilties Category
There is no evidence of this requirement at this time, corrective action is required.
There is little evidence of this requirement, further documentation is required, corrective action is required.
2% of the total points possible are within the Commercial Category
2% of the total points possible are within the Training Category
2% of the total points possible are within the Facility Category
44% of the total points possible are within the Quality Category
0
0
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
Hi-Stat
A Stoneridge Company
Page 43 L-PUR-F15 Rev. B
Supplier Name: 0 Assessment Date:
0
0
Supplier Quality System Assessment
01/00/000
0Supplier Address:
Supplier Phone/Fax:
0
0
Supplier Commodity:
Supplier Contact:
Hi-Stat
A Stoneridge Company
- under 69% - under)“Not Viable” Business Candidate at this time
Page 44 L-PUR-F15 Rev. B
TITLE: PAGE OF SEC. 16.0, PURCHASE ORDER TERMS, CONDITIONS AND
TOOLING NOTES
1
3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
Purchasing Agent informs suppliers of terms and
conditions for purchase order
Is the purchase order a blanket order?
YES
NO
Is the purchase order for tooling?
Note on the PO that the order qty. is for reference only and that
obligation is limited to release qty.
YES
NO
Note on purchase order terms of tooling including: tool maintenance, PPAP submission, and tool identification.
No additional notes required on purchase order.
Release Purchase Order
Purchase Order Terms & Conditions
TITLE: PAGE OF SEC. 16.0, PURCHASE ORDER TERMS, CONDITIONS AND
TOOLING NOTES
2
3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
PURPOSE: To inform Hi-Stat Suppliers of our Purchase Order terms and conditions and tooling
notes that may or may not appear in the body of a Purchase Order. SCOPE: Use of this procedure applies to Suppliers of component parts, materials or
processes to Hi-Stat. DEFINITIONS: N/A PROCEDURE: RASI: Responsible: Purchasing Agent Accountable: Director Materials & Logistics Management Support: Director of Operations & Order Fulfillment Inform: Business Unit Manager
1. PURCHASE ORDER TERMS & CONDITIONS
The terms and conditions attached to this section obligates the Supplier when accepting the Purchase Order to agree to the terms stated. See succeeding pages of this section.
1.1 Blanket Purchase Order Note The total quantity stated on this Blanket Purchase Order is for reference only. The Buyer intends to purchase the quantity shown, but the Buyer’s obligation is limited to ONLY the quantity specified in each individual authorized release.
1.2 Price Increase Justification
Any Supplier requesting a price increase must provide detailed, itemized data verifying the requested increase. Only material increases accompanied with the appropriate justification will be considered. Labor and overhead increases are excluded from consideration since these areas should be offset with productivity improvements. All requested price increases by a Supplier must be submitted and approved by the respective Hi-Stat Purchasing Agent sixty days prior to becoming effective. Any price increases may warrant re-quoting of the affected part(s) with competitive sources.
TITLE: PAGE OF SEC. 16.0, PURCHASE ORDER TERMS, CONDITIONS AND
TOOLING NOTES
3
3 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 B 01/12/05 STEVE FELLOWS DARREL GEORGE
2. TOOLING NOTES
Included in this section are examples of notes that may be printed in the body of purchase orders (when applicable) for production tooling, dies, and molds.
Notes:
1. Any / all maintenance / replacement charge(s) for this tooling during the life of this program is the complete responsibility of the supplier.
2. Please refer to the Supplier Quality Management Guidelines, Sec. 8.0,
Supplier Production Part Approval Process (PPAP) for part submission.
3. Obtain the proper tooling identification number from the purchasing agent and stamp this number on the base of the subject die/mold.
L-PUR-F32 REV. A
ADDITIONAL TERMS AND CONDITIONS WHEN QUOTING OR
ACCEPTING A TOOLING PURCHASE ORDER FROM HI-STAT MFG.
1. To supply a complete set of drawings to Hi-Stat Mfg. which accurately convey the details of the tool(s) built. Hi-Stat will not send the final payment until the drawings are received. 2. Upon Production Part Approval (PPAP) and full payment of tooling, tool(s) become sole property of Hi-Stat Mfg. and can be removed from the supplier at Hi-Stat’s request. 3. The tool(s) are to be permanently marked “Property of Hi-Stat Mfg. Co.” followed with Hi-Stat’s part number and tool identification number. 4. Supplier agrees to use the tool(s) exclusively to produce parts for Hi-Stat Mfg. unless given written authorization to indicate otherwise. 5. Supplier agrees to submit parts per Sec. 8.0, Production Part Approval Process (PPAP)
of the Hi-Stat Supplier Quality Management Guidelines. (Note: If there are any exceptions to Sec. 8.0, they must be documented on the PPAP.)
6. The supplier will provide material certifications as specified in the Hi-Stat Supplier
Quality Management Guidelines, Sec. 10.0, Material Certification.
I have read the above statements and agree to comply with all of the listed terms and conditions.
Name of Company Authorized Signature Date
Hi-Stat Part Number:
Request for Quotation Number:
Return completed form to: Hi-Stat Manufacturing Company Lexington Division 345 South Mill Street Lexington, OH 44904
Attn:
TITLE: PAGE OF SEC. 17.0, REVISION HISTORY 1 1 PROCEDURE # REV. DATE: PREPARED BY: APPROVED BY: L-PUR-25 G 05/09/06 STEVE FELLOWS CRAIG BENSON
REVISION HISTORY
REV. DATE CHANGE PREPARED REVIEWED AND BY: APPROVED BY: G 05/09/06 S. Fellows C. Benson Rewrite section 7.0 to show new evaluation criteria, change section 14.0 from Dock to Stock
to Dock to Point of Use. F 03/24/06 S. Fellows C. Benson In section 13.0 removed symbols and added symbol with Cpk level requirement. Changed
Supplier Development Engineer to Buyer/Supplier Quality Agent. E 07/29/05 S. Fellows D. George Changed sort firm in section 11.0; updated title page and table of contents. D 06/02/05 S. Fellows D. George Revised section 3 and 6 to reflect the assessment score as a percentage. Updated title
page and table of contents. C 03/31/05 S. Fellows D. George Updated Title Page and Table of Contents to reflect changes within the manual. Sec. 3.0 –
Added the process for certifying, developing and re-sourcing non-certified suppliers (paragraphs 1.2 – 1.7); updated flowchart. Sec. 7.0 – Re-write of paragraphs 5.1 – 5.3. Sec. 11.0 – Re-write of paragraph 1.4.
B 01/12/05 Re-write of all sections. S. Fellows D. George A 08/01/01 Replaces C-PUR-1 B. Culler D. George Manual Rev. F.