Tokai Eastern Rubber (Thailand), Ltd. - er.sumiriko.com · This guide to Technical Supplier Manual is defined a standard of quality assurance for new or changed product as supplied

Supplier Quality Improvement Manual

Tokai Eastern Rubber (Thailand), Ltd.

Issued by Checked by

Revision 11

Effective date : 01 April 2012

Approved by

Technical Section

Technical Supplier Manual


ContentsItem Page

1. Quality assurance ideality 1

2. Purpose 1

3. Scope 1

4. Requests for supplier4.1 Initial Control Organization 2

4 2 Approval Initial Part of Supplier 34.2 Approval Initial Part of Supplier 3

4.2.1 Production Preparation Schedule 4

4.2.2 SPTT Audit 4

4.2.3 Inspection Standard 5

4.2.4 SBSC 7

4.3 Initial Delivery Control 8

4.4 PPAP Activity 8

4.4.1 Reason to submit PPAP 8

4.4.2 PPAP Retention / Submission Requirement for Supplier 9

4.4.3 TER PPAP Status 23

4.4.4 Record Retention 23

4 5 P Ch R i t 244.5 Process Change Requirement 24

4.5.1 Reason to information of process change 24

Submission requirement for supplier

4.5.2 Delivery requirement after PCN approved 25

4.5.3 Change Control Flow 26

4.5.4 Record Retention 27

4.6 Guideline for Environmental Hazardous Substance Management 27

4.7 Control of initial nonconforming products(NC) 32

5. Attachment List 33

Technical Supplier Manual Change Notification

Technical Supplier Manual


1. Quality assurance ideality10

1.1 Supplier shall produce parts that meet to TER satisfaction as purchasing agreement.

TER would approve parts that shall be controlled quality continuously.

1.2 Supplier shall improve production process to achieve condition and requirement and

prepare quality assurance of part have not problem after delivery Especially for problems in TER

shall be corrected and prevented immediately.

1.3 TER shall audit QA system of supplier including monitoring and advising in order to

assure quality of supplier efficiently and continuously.

1.4 To conduct coordination between TER and supplier.

1.5 Supplier shall apply ISO9000 or ISO/TS16949 to implement in Quality Assurance

system.

1.6 Initial part of supplier shall approved by TER before start Mass production.

2. Purpose

This guide to Technical Supplier Manual is defined a standard of quality assurance for new or

changed product as supplied to "Tokai Eastern Rubber (Thailand),Ltd."

3. Scope

This manual applies to the quality assuarance activities of suppliers for new or change, which

related to TER in assembly product. If it difficult to carry out them please contact to Technical section,

QA&Technical department of TER

Page 1 of 34 Technical Supplier Manual


4. Requests for supplier

4 1 I iti l C t l O i ti4.1 Initial Control Organization

Establish and maintain the quality assurance system. The supplier shall assign a person

who responsible in quality and delivery for initial part. This assignment has aimed to ensure an establishment

of a consistent quality assurance and delivery system to cover all processes of each supplied product

for TER and response in our satisfaction of requirements. Supplier shall submit to Technical section within

11

7 days after received New Part Notice from Purchasing / TER. <for 1st SPTT activity>

** If Contact person change. Please Review /Revise this organization and submit to Technical

section within 7 days.

TER Engineering Div

Project Organization Chart

Project LeaderProject Name

RT-50Supplier Name

Factory ManagerName : Mr.N. YoshidaE-mail : [email protected]

Tel : (038) 893-557-61 ext.162Mobile Phone : 081-9496355

< Manager > < Staff >Project Leader (Department): Project Leader (Department):

TER Engineering Div.

Engineering Div. Engineering Div.

Core team4Marketing Div. Quality Div. Production Div. PE Div. PC Div. WH Div.

Core team6Core team1 Core team2 Core team3

RT 50

Core team5

j ( p ) j ( p )Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :

Core Team # 1 (Department): Core Team # 1 (Department):Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :081-629-4615

Mr.W.CherdpanMkt.Mgr.

[email protected]

02-685-3557-60 ext.110

Mr.T.Makino

Marketing Div. Marketing Div.

02-685-3557-60 ext.112084-084-6660

[email protected]

[email protected]

(038) 893-557-61 ext.210081-664-9426 085-436-4241

[email protected]

(038) 893-557-61 ext.112

Mr.T.SuppachaiMkt.Staff

QA & Technical GMMr.T.Chawalit

Technical Dept.Supv.

Mobile Phone : Mobile Phone :

Core Team # 2 (Department): Core Team # 2 (Department):Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :

Core Team # 3 (Department): Core Team # 3 (Department):Name : Name :Position : Position :E il E il

081 629 4615

Production Mgr.

Production Div. Production Div.

Quality Div. Quality Div.

(038) 893-557-61 ext.116

084 084 6660

Mr.C.AtthayaProduction Supv.

h @ h

Mr.K.Projob

j b@ h

089-939-5191

Mr.S.EkkaratQA Supv.

[email protected]

(038) 893-557-61 ext.117081-377-8504

Ms.S.SaranyaQA & Technical Dept.Mgr.

[email protected]

E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :


Core Team # 5 (Department): Core Team # 5 (Department):Production Control Production Control

Production EngineerProduction Engineer

081-663-6295

[email protected]

(038) 893-557-61 ext.175081-723-2936

[email protected]

081-663-6295

Mr.M.YoothasisthProduction Engineer Supv.

[email protected]

(038) 893-557-61 ext.175081-750-7738

Mr.K.ProjobProduction [email protected]

(038) 893-557-61 ext.175

(038) 893-557-61 ext.175

Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :


(038) 893-557-61 ext.125 (038) 893-557-61 ext.125081-865-2072 081-330-4431

PC Asst.Mgr. [email protected] [email protected]

Production Engineer Production EngineerMr.W.Prapan Mr.K.Narest

Mr.W.Prapan Mr.P.Sakdinan

081-865-2072 081-7825986(038) 893-557-61 ext.125 (038) 893-557-61 ext.189

[email protected] [email protected]

PC Asst.Mgr. Supv.


Mobile Phone : Mobile Phone :

Rev.01

081 865 2072 081 330 4431


4.2 Approval Initial Part of Supplier

T h i l ti t fl f l i iti l t t t f li i d PO tilTechnical section set flow for approval initial part start from supplier received PO until mass

production(MP). In each stage technical will check/audit document and process of supplier.



4.2.1 Production Preparation Schedule(PPS)

S li i PPS hi h t i N P t N ti TER t l11

Supplier issue PPS which contains New Part Notice, TER master plan

(TD0, TM0, TM1, MP), SPTT stage and detail of part preparation. After received plan Supplier shall issue

Supplier plan submit to TER within 2 week and update supplier plan in PPS submit to Technical every

month. Technical will check progressive of part from PPS.

Supplier shall issue supplier's PPS to Technical / TER after received New Part Notice for

1st SPTT audit activity. Supplier shall update progressive of PPS by 25th of every month

Supplier : XXXXXXXXXXXXXXXX 3Part No. : XXXXXXXXXXXXXXXX 2 Approved Approved Checked Checked Approved Checked IssuedPart Name: XXXXXXXXXXXXXXXX 1Mfg.No.: XXXXXXXXXXXXXXXX PLAN 0 dd/mm/yy xxxx

ACTUAL Rev. Date PIC President Manager Advisor Engineer President Manager Engineer

7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1

sign sign sign

20112010

CUSTOMER Plan

Tokai Eastern Rubber(Thailand),Ltd.

History Recordnew issue sign sign sign sign

Production Preparation Schedule

ResponsibilityActivities

Supplier:________________

S-Lot ET PT1 PT2 SOP

Raw Material& CKD XXXComponent Local parts XXX

Process planning XXXXXXXXXxProd. Of Tooling/Equipment XXXXXXXXXxProd. Of Checking Fixture XXXXXXXXXxTry-out XXXXXXXXXxTurning & Modilication XXXXXXXXXxTooling & Equipment Transfer XXXXXXXXXxProd Of Tooling/Equipment XXXXXXXXXx

Supplier Plan

TER Plan

CUSTOMER Plan

Master Schedule

epar

ation

JAPAN

TM1TM0TD0 MP

TM1TM0TD0 MP1stSPTT 3rdSPTT2ndSPTT

Prod. Of Tooling/Equipment XXXXXXXXXxProd. Of Checking Fixlure XXXXXXXXXxInstallation XXXXXXXXXxTry-out XXXXXXXXXxTuning & Modification XXXXXXXXXxLow Volume Production Trial (LVPT) XXXXXXXXXxHigh Volume Production Trial (HVPT) XXXXXXXXXxStart of Vulume Production XXXXXXXXXxDimension & Appearance XXXXXXXXXxMaterial Evaluation XXXXXXXXXxPerformance Evaluation(Sample part) XXXXXXXXXxPerformance Evaluation XXXXXXXXXx(Re-comfirmation of Local Prod. Part) XXXXXXXXXxInspection Standard XXXXXXXXXx

THAI

Evalution

Proc

ess P

re

4.2.2 SPTT Audit

T h i l t SPTT ti it f

Inspection Standard XXXXXXXXXxQC Process Chart XXXXXXXXXxProcess Standard (WI,QCS,etc.) XXXXXXXXXxPPAP Submit (SPSW Submit) XXXXXXXXXxEducation & Training XXXXXXXXXx

Quality Document

Technical set SPTT activity for

1. 100% Quality meet to TER requirement

2. 100% On time delivery in each stage

3. Close communication between TER and Supplier

SPTT activity has 3 steps and criteria as list below.



SPTT

1st Audit

ReferenceActivity

Check tooling plan/status

Stage Part Quality Quantity

TD0 Part Off Tool n=3 pcs/shots SPTT audit check sheet

11

1st Audit

2nd Audit

-Check tooling plan/status

-Co-check dimension of part

TD0 Part Off Tool n=3 pcs/shots SPTT audit check sheet

-Co-check dimension of part

(Trial Dimension) (CKD or Local) -Inspection std.approval

TM0 Part Off Tool Refer to Pilot PO

-Check production process

Can rework

SPTT audit check sheet

Off Process

TM1 Part Off Tool Refer to PO

(Trial mold at JP)

3rd Audit

Supplier shall control part follow Approval Initial Part of Supplier schedule.

MP Part Off Tool Refer to PO

(Trial mold at THA)

Can not rework

-Check capacityOff Process

Off Process -Confirm capacity PPAP Approved

-Confirm part before shipping

-Confirm production process

Can not rework -Supplier PPAP Approve

SPTT audit check sheet

(Mass Production)

4.2.3 Supplier shall issue Inspection standard and record which identify all measuring items

and specification for supplier product testing and submit to TER after received drawing within 2 weeks

Supplier shall maintain inspection item which TER approved. (TER form)

Doc. No. TES-IY- DCR No. Rev. 0 PAGE OF

(DATE)

MFG. NO PART NO PART NAME

MODEL ROUTE MATERIAL RANK

INSPECTION INSPECTION SAMPLING INSPECTIONCRITERION INSTRUMENT PLAN METHOD

①

②

Dimen-sion

THREAD ACCURACY

LENGTH

B

B

THREAD GAUGEM10 X 1.25

xxxxxx

ITEM

TSB1001G-11.9

NO INSPECTION ITEM RANK

xxxxxx

INSPECTION STANDARD

xxxxxxxxxxxxx

( 1 / 2 )

HEIGHT GAUGE / CMM

SAFETY PART

xxxxxxxx

FINISHEDUNFINISHEDMETAL

20-May-10

40 + 0.5

n = 5, c = 0 / METAL LOT

※ n = 5, c = 0 / LOT②

③

④

⑤ ※

⑥ ※

⑦

⑧

RADIUS B

CALIPERB 14 -0.25

B

OUTER DIAMETER

LENGTH B

DIMENSION B

DIAMETER B

B

DIMENSION

26 0 HEIGHT GAUGE / CMM

CALIPER / CMM9.5 ( MAX )

CMM40 0.5 ,SUPPLIER DATA

CHECK ONLY

1.35 ( MIN ) HEIGHT GAUGE / CMM

PROFILE

∅ 21.5 ( MAX )

R0.5 ( MIN )

CALIPER

+2.5

0

⑨

⑩ ※

⑪

⑫

⑬

⑭

DIMENSION

DIAMETER CALIPER

15.5 (MIN) CALIPER

A TSB1001G-11.9 EVIDENCE

B

B

ALL METAL LOT MATERIAL CERTIFICATE

MATERIAL CERTIFICATE

∅ 9.5 -0.15

n = 1, c = 0 / INITIAL OR PROCESS CHANGE

/ IF NECESSARY

BALANCER n = 5, c = 0 / METAL LOT

EVIDENCE

33 g

MATERIAL OF PART

NO USE OF 4ENVIRONMENTAL SOCs A CONFORM TO

TSZ0001G

VISUAL n=10%,c=0 / METAL LOTALL(SUPPLIER)

TSH7903GTSH6524G-B

Appea-rance

SURFACE TREATMENT B ZINC COATING

Charac-teristic

WEIGHT Ref

0

CUSTOMER QA DEPT

CHECK ISSUE

SUPPLIER QA DEPT (TER)

APPROVE CHECK CHECK CUSTOMER TOKAI EASTERN RUBBER (THAILAND) LTD APPROVE CHECK

ISSUE DATE REVISION RECORD


CHECK ISSUEAPPROVE CHECK CHECK CUSTOMER TOKAI EASTERN RUBBER (THAILAND),LTD. APPROVE CHECK

SUPPLIER XXXXXXXXXXXXXXXXXX


INSPECTION RECORD ( METAL PART )

NO. 1 2 3 4 5 X JUDGE TESTEQUIPMENT NO. 1 2 3 4 5 X JUDGE

THREAD ACCURACYM10 X 1.25

Due

LENGTH40 ± 0.5

( 39.50 ~ 40.50 ) Due

LENGTH + 2.526 - 0

( 26.0 ~ 28.5 ) Due

DIMENSION

Due

RADIUS

Due

DIMETER

DueDIM

ENSI

ON

⑤ R 0.5 ( MIN )

⑥

③

④ 9.5 ( MAX )

1.35 ( MIN )

PROFILE

HEIGHT GAUGE / CMM

CALIPER/CMM

HEIGHT GAUGE / CMM

SPEC. INSTRUMENT SAMPLING PLAN

②HEIGHT

GAUGE / CMM

①THREAD GAUGE

n=5,c=0/METAL LOT

CUSTOMER NAME

PART NAME

SHIPPING QT'Y

SKETCHPART NO.

MFG NO.

MODEL

TER 's DATA

INSPECTION DATE

INSPECTION QTY

SUPPLIER 's DATA

SHIPPING DATE

QAINSPECTION RECORD ( METAL PART )

NG QTY

RECEIVING LOT

SUPPLIER NAME

SHIPPING LOT

QAINSPECTION RECORD ( METAL PART )

xx-xxxxxx-xxxxxxxxxxxxxxxTERxxxxx

xxxxx

OUTER DIMETER

Due

DIMENSION 014 - 0.25

( 13.8 ~ 14.0 ) Due

DIMENSION

Due

DIMETER 0∅ 9.50 - 0.15

( 9.35 ~ 9.50 ) Due

⑫

⑭

APPE

ARAN

CE

CALIPER

⑨ CALIPER 15.5 ( MIN )

PCS

∅ 21.5 ( MAX )

⑩

⑧

CALIPER

PCSGOODGOOD

CALIPER

PCS NG PCS

CHECKED BY

INSPECTED BY

NG

n=1 , c =0 / INITIAL OR PROCESS CHANGE &

IF NECESSARY

ALL SUPPLIERn=10%,c=0/LOT

TER⑪

SURFACE TREATMENT

VISUAL

n=5,c=0/METAL LOT

MATERIAL OF PART (TSB1001G-11.9)

NO USE OF 4 ENVIRONMENTAL SOCs (CONFORM TO TSZ0001G) EVIDENCE

⑦

EVIDENCE ※ SUPPLIER DATA CHECK ONLY

CHAR

ACTE

RIST

IC

⑬ WEIGHT: 33 g. (REF.)*VICKER

HARDNESSTESTER

ZINC COATING

(TSH7903G, TSH6524G-B)

RECEIVING LOT

INSPECTION QTY

QASKETCH

MFG NO. SUPPLIER 's DATA TER 's DATA

PART NO. INSPECTION DATESUPPLIER NAME

SHIPPING DATE

SHIPPING LOTPART NAME

MODEL

CUSTOMER NAME

SHIPPING QT'Y NG QTY

xx-xxxxxx-xxxxxxxxxxxxxxxTERxxxxx

xxxxx

Keep period : EFFECTIVE DATE :

CHECKED BY

(GM)

APPROVE

History Record

Rev. Date Revisior Record PIC

TER

CHECKED

(SUPV.)

SUPPLI

ISSUED CHECKED

APPROVE

(MGR.)

APPROVE APPROVE

Inspection Rank List Control

Keep period :

IER

(ENGINEER) (SUPV.) (MGR.) (MGR.)

RankControl Method

Dimension Appearance Characteristic RemarkDimension Appearance Characteristic Remark

Control method

-Visual 100% Inspection

-Test before shipping part to TER

- Test before start production evey lot - Use SPC control

-Test before shipping part to TER

A

B

- Test before shipping part to - Test before start

-Sampling check

and frequencyrefer to TER'srequirement

whichagree togetherC

R

For (Safety) (Regulation) (Emission)

S S TER evey lot- Use SPC control

-Visual 100% Inspection production evey lot - Use SPC control

S R ES

E

S S



4.2.4 SBSC

SBSC i S li B d S b t Ch k Sh tSBSC is Supplier Banned Substance Check Sheet

Suppliers shall

check your material and reply to Technical by attach with TM0 Data. Concentration of banned substances

calculate from MSDS or Chemical ingredient. (Attach sheet No. 18)

SBSCTech Tech Mgr Tech SupplierSupplier Tech Tech Mgr. Tech Supplier

Supplier Name :

Address :

Responsible person :

Reason for submission

Supplier

Supplier Banned Substance Check Sheet (SBSC)

New model New Materials / Chemical Change ECN no. … … … Current material Correction for previous discrepancy with Mfg.No. ……...………….Change Process ……………..to……………….

Please fill form of your material or chemical name and concentation if it don't have these chemical Substanced, Pleases fill in that column.

No.Material Concentration of Banned Substances (ppm)

Ch i l N

7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1

2

3

4

5

6

7

Chemical Name

7

8

1 Cadmium and cadmium compounds 11 Polybrominated diphenylethers (PBDE) 21 Trinuvin 3202 L d d l d d 12 O h b i d i d 22 Di h lf ( DMF )

Remark7

72 Lead and lead compounds 12 Other brominated organic compounds 22 Dimethylfumarate ( DMF )3 Mercury and mercury compounds 13 Organic tin compounds 23 REACH (SVHC)4 Hexavalent chromium compounds 14 Asbestos 24 Other5 Polychlorinated biphenyls (PCB) 15 Azo compounds6 Polychlorinated naphthalenes (PCN) 16 Formaldehyde7 Polychlorinated terphenyl (PCT) 17 Polyvinyl chloride (PVC) and PVC blends8 Chlorinated paraffins (CP) 18 Perfluorooctane sulfonate anion (PFOS)9 Other chlorinated organic compounds 19 Recycled Meterial

10 Polybrominated bihenyls (PBB) 20 Polycyclic Aromatic Hydrocarbon(PAHs)

* For specification refer to Sony Technical Standards SS-00259 Yano standards and Green Procurement

7

7

7

For specification refer to Sony Technical Standards SS 00259, Yano standards and Green Procurement Standard of Matsushita group and GGP-001 of Pioneer Group *For REACH refer to the European Chemical Agency has announced the latest SVHC Candidate List - please see information from UK. The summary of the obligations is available on ECHA's website.

For Supplier

Approved by: ………………………… Checked by …………………………Checked by …………………… Approved by ………………………(Mgr) (Technical Engineer) (Technical SoC) (Tech Mgr.)

Date : ……../……../……… Date : ……../……../……… Date : ……../……../……… Date : ……../……../………

For TER


Page 1 of 1


4.3 Initial Delivery Control

P t d li i h t h ll tt h d Shi i T f ll thi lPart delivery in each stage shall attached Shipping Tag follow this manual.

4.3.1 TD0 Stage (White color tag) 4.3.6 Last Lot (PCR Old Part)

4.3.2 TM0 Stage (Orange color tag) 4.3.7 First Lot (PCR New Part)

4.3.3 TM1 Stage (Sky blue color tag)

4.3.4 MP Stage (Green color tag)

4.3.5 Special Stage (Pink color tag)

TO: ARRIVAL DATE : dd/mm/yySUPPLIER : XXX MODEL: XXX

TOKAI EASTERN RUBBER (THAILAND), LTD.Technical

SUPPLIER : XXX MODEL: XXX

PART NO. : XX-XXXXX MFG. NO. : XX-XXXPART NAME.: XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

Q'TY (Pcs.) XXX P/O NO. XXX

PART FOR TD0 TM0 TM1 MP Other

Change PCN No.

DELIVERY BY MR.XXXXXXXX PHONE XXX-XXXXXX

Supplier shall attach delivery tag to every box and invoice.

Technical Contact Person IPP Name ESIE MR.XXXXXXXXXX

4.4 PPAP activity

PPAP: Production Part Approval Process is a activity for preparation of part and document to

control process and inspection to reach TER requirement before part approval process in TER. Refer to

Production Part Approval Process : PPAP 4th edition

4.4.1 Reason to submit PPAP

4.4.1.1 New part or product (e.g., a specific part, material, or color not previously

supplied to TER).

4.4.1.2 Correction of a discrepancy on a previously submitted part.

4.4.1.3 Product modified by an engineering change to design records, specifications,

or materials.

4.4.1.4 Any situation required by TER example 4M Change (Man, Machine, Method and

Material)



4.4.2 PPAP Retention/Submission Requirement for Supplier

S li h ll b it d t f ll thi i t t t li i dSupplier shall submit document follow this requirement separate to supplier group or any required

by TER (supplier shall to use TER format some requirement at symbol is )

Metal part, Plastic part, Rubber part

Rubber CompoundPlastic Material

ChemicalOther

Requirement Fix TER format

Production Matetial

1 Design Record S - S

-For proprietary components/ details R - R

-For all other components/ details S - R

2 Engineering Change Documents S - S

(List of engineering standard and drawing) -

3 Customer Engineering Approval S - S

4 Process Flow Diagrams S S S -5 Process FMEA S - R -6 Control Plan S S S -7 Measurement System Analysis Studies S - - -8 Dimensional Results S - S

9 Material, Performance Test Results, Supply Chain S S S

10 Initial Process Studies S - - -11 Qualified Laboratory Documentation S - S -12 Master Sample S - S -13 Checking Aids R - - -14 Records of Compliance with Customer-

Specific Requirements S - S -15 Part Submission Warrant (PSW) S S S

16 SBSC, Certification of Non-Use of the S S S16 ,Controlled Substances S S S

17 Cover sheet and Test report S S S

18 Material Data Sheet S S S

19 Declaration of no use of PFOS S S S

20 SVHC survey S S S

S = Supplier shall submit to TER and retain a copy of records or documentation items at appropriate locations.

R = Supplier shall retain at appropriate location and make available to TER upon request.



4.4.2.1 PPAP Retention/Submission Requirement for Supplier

TER i "S li PPAP R t Sh t" t li ft TM1 t S li h ll11

TER issue "Supplier PPAP Request Sheet" to supplier after TM1 stage. Supplier shall

submit document/PPAP folow the request sheet

Supplier PPAP Request Sheet Model : _______________

Supplier Name : Submit Criteria: Production Matetial

Part No. : ❒ Metal part, Plastic part, Rubber part

Part Name : ❒ Rubber Compound, Plastic Material, Chemical

Revision : E.C.I. No. : ❒ Other

Due Date of Submission : _______________________ Received Date from Supplier : _____________________

1

2

3

4

5

Customer Engineering Approval (Inspection std.)

Process Flow Diagrams

Process FMEA

Design Record

-For proprietary components/ details

-For all other components/ details

Engineering Change Documents(List of engineering standard and drawing)

Requirement

❒

TER Judge❒ Not Accept❒ Accept

Remark

❒ Accept ❒ Not Accept

TER's Request



❒❒

❒ A t ❒ N t A t



❒

❒❒❒5

6

Process FMEA

Control Plan



❒❒

19

20

Supplier PPAP Result

❒ Approved ❒ Interim ❒ RejectedResubmit within ________________ Resubmit within ________________

Detail of document (Not Accept item)

Declaration of no use of PFOS

SVHC survey



❒❒

Remark : TER will control Supplier PPAP by Supplier PPAP Request Sheet

Distribution Flow : TER(Technical) Supplier TER(Technical)

Request Submit Approve

SupplierTechnical

SupplierApprove Check Incharge Approve Check

TER

4.4.2.2 Design Record (List of Engineering Record)

Supplier shall have the design record for the saleable product/part, including design

records for components or details of the saleable product/parts which approved and distributed by TER.

Where the design record is in electronic format, e.g., CAD/CAM math data, the supplier shall produce

h d ( i t i l t i di i i & t l i [GD&T] h t d i ) t id tifa hard copy (e.g.pictorial, geometric dimensioning & tolerancing[GD&T] sheets, drawing) to identify

measurements taken.



4.4.2.2(a) When supplier received "List of Engineering Drawing to Supplier" shall reply to

TER within 3 days for convenient date to receive new engineering drawing by supplier must to receive y g g g y pp

drawing within 7 days

4.4.2.2(b) In receive date supplier must return "Old Engineer Drawing" to TER

4.4.2.2(c) Supplier must review new engineering drawing by record date of "First Lot,

Last Lot" in List of Engineering Drawing to Supplier document and reply to TER within 7 days after supplier

have received drawing by result are reviewedhave received drawing by result are reviewed

Issued date : dd/mm/yyyyTo : From : Tokai Eastern Rubber (Thailand), Ltd.

Attn : Ms. Suthasri Suwannasri

Position : Position : Technical Staff

Dept. Dept. Technical

Tel. No.: CC : Ms. Maneerat / Technical Dept. Senior Staff

Model :

List of Engineering Drawing to Supplier

xxxxxxxxxxxxxMr. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx(0xx)xx-xxxx

xxxxxxxxxxxxxxxxxxxx

① 　Supplier Confirm Sheet

วนัทเีขา้มารับ ………………………………………….……... เวลา 09.30 - 16.00 น. สถานท ี TER / ESIE

กรุณาเซ็นตร์บัทราบ และตอบกลบัเอกสารมายงั Fax: (038)-927594 หรอื E-mail: [email protected]

ภายในวนัท.ี.......................................... โดย Supplier จะตอ้งกรอกขอ้มูลในสว่นท ี2 ใหค้รบถว้น

รับทราบ ……………………………………………….

วนัท ี………………………………………………......

② 　List Engineering Drawing / Confirm Submittion Date

Inspection Standard** Supplier จะตอ้งกรอกขอ้มลูใหค้รบถว้น

** 1st Lot

dd/mm/yyyy

dd/mm/yyyySupplier Confirm

Receive date

S li C fi Fi1 XXXXX-XXXXX XXXXXXXXXXXXXXX XX-XXX A T-XXXX dd/mm/yyyy dd/mm/yyy

2 XXXXX-XXXXX XXXXXXXXXXXXXXX XX-XXX A T-XXXX dd/mm/yyyy dd/mm/yyy

No. Part No. Part Name MFG.No

dd/mm/yyyy

dd/mm/yyyy

Submittion Due DateDrawing Effective Date

Level ECI.No.** 1st Lot

(กรณุาระบวัุนทสํีาหรับ 1st Lot)

Supplier Confirm Firt Old ECI

หมายเหต:ุ Supplier จะตอ้งทําการยนืเอกสาร Inspection Standard ภายในวนัเวลาทกํีาหนด

หากมขีอ้สงสยัประการใด กรุณาตดิตอ่ : คณุนลิบุล เจยีมประสตูร / คณุมณีรัตน ์ แสงสงัข ์/ คณุสธุาส ี สวุรรณศร ีเบอร ์038-927-500 ตอ่ 601, 602, 630 E-mail: [email protected], [email protected], [email protected]

โดยสง่ถงึคณุนลิบุล เจยีมประสตูร แผนกเทคนคิคอล

TER Supplier

( ) ( )


ผูรั้บคนื/ผูส้ง่ ผูรั้บ

วนัที วนัที


4.4.2.3 Engineering Change Documents (ECR, PCR and Deviation)

Supplier shall have any authorized engineering change documents for those changes

11

not yet recorded in the design record but incorporated in the product, part or tooling. * ECR (Engineering Change Reques)* PCR (Process Change Request)

4.4.2.4 Customer Engineering Approval (Inspection Standard and Record)

Where specified by TER, supplier shall have evidence of TER engineering approval. (TER's format )

<Engineering Standard> <Engineering Recorder>

TER's signature

4.4.2.5 Process Flow Diagrams

Supplier shall have a process flow diagram in a supplier-specified format that clearly

d ib th d ti t d i t d d ifi d TER d

TER's signature

describes the production process steps and sequence, as appropriate, and need specified TER needs,

(e.g., Advanced Product Quality Planning and Control Plan reference manual).



Note: Process flow diagrams for "families" of similar parts are acceptable if the new parts have

b i d f lit b th li been reviewed for commonality by the supplier.

4.4.2.6 Process FMEA

Suplier shall develop a Process FMEA in accordance with, and compliant to, TER-p p p

specified requirements, (e.g., Potential Failure Mode and Effects Analysis referance manual).

Supplier must undertake efforts to reduce this calculated risk through corrective action

and preventive action

1. RPN more than 128

or 2. The highest RPN

After action will evaluate RPN again

Remark : Refer to Potential Failure Mode and Effects Analysis Manual 4th editionRemark : Refer to Potential Failure Mode and Effects Analysis Manual 4th edition



4.4.2.7 Control Plan

S li h ll h C t l Pl th t d fi ll th d d f t l dSupplier shall have a Control Plan that defines all methods used for process control and

complies with TER-specified requirements, (e.g., Advanced Product Quality Planning and Control

Plan reference manual). Use TER format

Note: Control Plan for "families" of similar parts are acceptable if the new parts have been

reviewed for commonality by the supplier.

4.4.2.8 Measurement System Analysis Studies

Supplier shall have applicable Measurement System Analysis studies, e.g. gage R&R,

bi li it t bilit f ll idifi d t d t t i t (M t

11

bias, linearity, stability, for all new or midified gages, measurement, and test equipment.(Measurement

Systems Analysis reference manual)

G.R&R technique and/ or Hypothesis test use to analyze measurement system.

Guideline for acceptance of G.R&R

% R&R Value Judge

Under 10% Measurement system is acceptable

10% to 30% Acceptable based upon importance of application,

cast gage, cost of repairs.

Needs comment in result and approve by QA Mgr.

Over 30% Measurement system needs improvement.



※ D4 = 3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limited individual R's.Circle those that arc beyond this limited.Identify thecause and correct.Repeat these reading using the same appraisers and unit as originally used for discard value and re-average and recomputeR and the limiting value from the remaining observation.% R&R Value Judge Recomment Action Supplier :

Under 10% Measurement system is acceptable Detail Due PIC

10% to 30% Acceptable based upon importance of application, 1

cast gage, cost of repairs. 2

Needs comment in result and approve by QA Mgr. 3

Over 30% Measurement system needs improvement. 4

CheckedApproved

4.4.2.9 Dimensional Results

Supplier shall provide evidence that dimensional verifications required by the design

record and the control plan have been completed and result indicate compliance with specified

requirements. The supplier shall have dimensional results for each unique manufacturing process, e.g.,

ll d ti li d ll iti ld tt di Th li h ll d ith thcells or production lines and all cavities, molds, patterns or dies. The supplier shall record, with the

actual results: all dimensions (except reference dimensions), characteristics, and specifications as noted

on the design record and control plan.

Supplier shall indicate the date of design record, change level, and any authorized

engineering change document not yet incorperated in the design record to which the part was made. The

supplier shall record the change level, drawing date, supplier name and part number on all auxiliary

documents (e.g., supplementary layout results sheets, sketches, tracings, cross sections, CMM

inspection point results, geometric dimensioning and tolerancing sheets, or other auxiliary drawings used

in conjunction with the part drawing).



The supplier shall identify one of the parts measured as the master sample.

Dimension ResultsSupplier Name : Part No. : Revision :

Part Name : E.C.I. No. :

Stage : Test Date : Test Quantity :

1 2 3 4 5 X R 1 2 3 4 5 X R

①

Judge Judge

Supplier Measure TER Measure

ResultTestEquipment

ResultSpecificationTest Item

①

②

③

④

⑤

⑥

⑦

⑧

⑨

4.4.2.10 Material, Performance Test Results, Supplier Chain

The supplier shall have records of material and/or performance test results for tests

specified on the design record or control plan

Material test results shall indicate and include :

-the design record change level of the parts tested;

-any authorized engineering change documents that have not yet been incorporated in the

design record;

-the number, date, and change level of the specifications to which the part was tested;

-the date on which the testing took place; the date on which the testing took place;

-the quantity tested;

-the actual results (Attach with test result from laboratory) ;

-Mill sheet

-Supply chain check sheet

M t i l Li t & C t P t -Material List & Component Parts



Mill Sheet

Supply Chain Check Sheet

Material List & Component Parts



Performance test results shall indicate and include :

th d i d h l l f th t t t d -the design record change level of the parts tested;

-any authorized engineering change documents that have not yet been incorporated in the

design record;

-the number, date, and change level of the specifications to which the part was tested;

-the date on which the testing took place;

-the quantity tested;

-the actual results (Attach with test result from laboratory);

4.4.2.11 Initial Process Studies and Control

The level of initial process capability or performance shall be determined to be acceptable

prior to submission for all special characteristics designated by TER or supplier The supplier shall obtain

10

prior to submission for all special characteristics designated by TER or supplier. The supplier shall obtain

TER concurrence on the index for estimating initial process capability prior to submission.

The supplier shall perform measurement system analysis to understand how

measurement error affects the study measurements.

Note: For characteristics that can be study using X-bar and R charts, a short term study should

b b d i i f 25 b t i i t l t 100 di f ti be based on a minimum of 25 subgroups containing at least 100 readings from consecutive

parts of the significant product run.

Acceptance Criteria for Initial Study

Index > 1.67 The process currently meets the acceptance criteria.

1.33 < Index > 1.67 The process maybe acceptable. Contact the authorize TER

representative for a review of the study results.

Index < 1.33 The process does not currently meet the acceptance criteria.

Contact the authorize TER representative for a review of the study

results.



After 2nd SPTT audit, supplier will launch to intial process control. Supplier shall record

k h t i ti d k d t h t i ti SPC d t Th d h ll t t TERkey process characteristic and key product characteristic as SPC data. The record shall report to TER

for 3 months or 30 production lots by 1 time per month or appropriate period which accept by TER.

4.4.2.12 Qualified Laboratory Documentation

The qualified laboratory (internal or external to the supplier) shall have a laboratory scope

and documentation showing that the laboratory is qualified for the type of measurements or tests

conducted.

When an external/commercial laboratory is used, the supplier shall submit the test

results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that

performed the tests, the date(s) of the tests, and the standards used to run the tests shall be identified.

4.4.2.13 Master Sample

Th li h ll b it l d t 3 3 h t d t i t lThe supplier shall submit sample product 3 pcs. or 3 shots and retain a master sample

for the same period as the production part approval records, or

-until a new master sample is produced for the same part number for TER approval

-where a master sample is required by the design record, control plan or inspection

criteria, as a reference and standard. The master sample shall be identified as such, and shall show TER

approval date on the sample. The supplier shall retain a master sample for each position of a multiple

cavity die,mold,tool or pattern,or production process.The master sample will attached with full lay out data.



MASTER SAMPLE TAGSUPPLIER XXXXXXXXXXXXXXXXXXXXXXXXXXX

MFG.NO. XXXXXXXXXPART NAME XXXXXXXXXXXXX

PART NO. XXXXXXXXXX NEW

MODEL XXXXXXXX CHANGE

DATE XXXXXXXX RENEWAL

DESCRIPTION & SKETCH : LOT NO. :XXXXXX

MASTER SAMPLE TAG

MAKER : TOKAI EASTERN RUBBER (THAILAND) , LTD.APPROVED CHECKED

SUPPLIER : XXXXXXXXXXXXXXXXXXAPPROVED APPROVED CHECKED ISSUED

FRONT VIEW SIDE VIEW

4.4.2.14 Checking Aids

The supplier shall submit any part-specific assembly or component checking aids. The

supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The

supplier shall document all released engineering design changes that have been incorporated in the pp g g g g p

checking aid at the time of submission. The supplier shall provide for preventive maintenance of any

checking aids for the life of the part.

4.4.2.15 Records of Compliance with Customer-Specific Requirements

The supplier shall have records of compliance to all applicable TER-specific requirement.

4 4 2 16 Part Submission Warrant (PSW)4.4.2.16 Part Submission Warrant (PSW)

Upon completion of all PPAP requirements, the supplier shall complete the Part

Submission Warrant(PSW).

If production parts will be produced from more than one cavity, mold, tool,die, pattern,

or production process, the supplier shall complete a dimensional evaluation on one part from each.

Th ifi iti ld li t h ll th b id tifi d i th "M ld/C it / d ti P "The specific cavities, molds, line, etc., shall then be identified in the "Mold/Cavity/production Process"

line on a PSW, or in a PSW attachment

Note: One warrant per customer part number



4.4.2.17 Certification of Non-Use of the controlled substances.

C tifi ti f N U f th t ll d b t i th d t f li tif10

Certification of Non-Use of the controlled substances is the document for supplier certify

the non-use of the controlled substances in process of supplier which produce production material to TER.

Certified with test report or ICP data.

Certification of Non-Use of the controlled substances

TOKAI EASTERN RUBBER (THAILAND), LTD.

Supplier name :

Supplier code :

Responsible person name :

Responsible Division/Dept. :

Certification of non-use of the controlled substances(for initial parts)

Part no./ Part name:

This is to certify that , these material/ products which were delivered to TER did not contains ;

1. Cadmium and cadmium compounds 13. Organic tin compounds

2. Lead and lead compounds 14. Asbestos

3. Mercury and mercury compounds 15. Azo compounds

4. Hexavalent chromium compounds 16. Formaldehyde

5 Polychlorinated biphenyls (PCB) 17 Polyvinyl chloride (PVC) and PVC blends5. Polychlorinated biphenyls (PCB) 17. Polyvinyl chloride (PVC) and PVC blends

6. Polychlorinated naphthalenes (PCN) 18. Perfluorooctane sulfonate anion (PFOS)

7. Polychlorinated terphenyl (PCT) 19. Recycled material

8. Chlorinated paraffins (CP) 20.Polycyclic Aromatic Hydrocarbon(PAHs)

9. Other chlorinated organic compounds 21.Trinuvin 320

10. Polybrominated biphenyls (PBB) 22.Dimethylfumarate ( DMF )

11. Polybrominated diphenylethers (PBDE) 23.REACH(SVHC)

12. Other brominated organic compounds 24. Other

* Remark:For REACH refer to the European Chemical Agenc has announced the latest SVHC Candidate List

334

334

334

* Remark:For REACH refer to the European Chemical Agency has announced the latest SVHC Candidate List -

please see information from UK. The summary of the obligations is available on ECHA's website.

Put a check in this box if applicable chemical substances are used are no used

If use that substances, what item do you use (1 to 24) ?

If use that substances, when change to no use ?

(date/ month/ year)

Approved by

(Manager or higher)

For Technical of TER

Received by Approved by

Date Date

Supplier Tech (TER) Tech Manager <Attached Sheet 19>Remark : Supplier shall submit this format together with PPAP

Date



4.4.2.18 Cover sheet and Test report

Cover sheet Test report

4.4.2.19 Material Data Sheet

Material Data Sheet is the document which show and calculate ingredient or

use of substance. Supplier Name :

Contact Person : Tel :TOKAI EASTERN RUBBER (THAILAND), LTD.

Material Data Sheet

Measured Component Component Part Component Material Name Material No. / Symbol Material Norms/Standard Material Weight (g) Material Classification Basic Substance Percentage of SoC/ EHS SoC/ EHS Substance Weight Part/Item No. Measured Weight Part Or Or Inhouse Norm Surface Treatment (Select from sheet of Name Basic Substance Substance Name Purpose of Use

per Items (g) per Item (g) Quantity Surface Treat. Name Surface Treat. Code Surface Treat. Standard Weight (mg) Material Classification) %

Delivery Part Material SoC/ EHS

Part No. Part Name Component Part Name

Component Part

Position : Fax :

Dept. : Mobile :

Email:

TOKAI EASTERN RUBBER (THAILAND), LTD.

Issued byChecked byApproved by

Supplier

4.4.2.20 SVHC Survey

To survey substances of very high concern (SVHC) in product to comply with REACH

regulation. Accompanying Document Exhibit 2 : SVHC Questionnaire Supplier codeComponents that contain any of the proposed substances listed in Accompanying Document Supplier name in a concentration of 0.1% or more in a homogeneous material or not ? Authority's name

Company Stamp

11

( Please add your answer mark in the blank ) PositionPhone no.

If yes please fill in the following table regarding components that contain any of the proposed substances listed in Accompanying Document in a concentration of 0.1%

or more in a homogeneous material. ※If more lines are needed, please add lines as necessary.

a b c d e f

Material Name

Material Standard

Weight of basic material

(homogeneous material)

Concentration of SVHC in homegenious

material (%)Total weight of SVHC Weight of component

12

No.SVHC-containing part of component

Part name./Component name.

Part no./Component No.

Name of SVHC

Have

Not have

2345678910111213



4.4.3 TER PPAP Status

4 4 3 1 A d4.4.3.1 Approved

Approved indicates that the part or material meet all TER requirements. The supplier is

therefore authorized to ship production quantities of the product, subject to releases from TER schedule.

4.4.3.2 Interim Approval

Interim Approval permits shipment of material for production requirements on a limited

time or piece quantity basis. The supplier shall re-submission to TER for status of "Approved" within

7 days after TER reply to supplier.

4.4.3.3 Rejected

Rejected means that the PPAP of supplier does not meet TER requirement. Supplier

shall be corrected to meet TER requirement then submit to TER within 15 days.

4.4.4 Record Retention

PPAP shall be maintained for the length of time that the part is active plus one calendar year.

Supplier shall ensure that the appropriate PPAP records from a superseded part PPAP file are included,

or referenced in the new pat PPAP file.

11

p

For (Safety) (Regulation) (Emission) Supplier shall keep the PPAP 11 years

after moldle run out.

Supplier shall keep approved PPAP in paper file and/or Electronic file (PDF file).

Electronic file shall submit to TER by 7 working days after received PPAP from TER.

S R E



4.5 Process Change Requirement

4 5 1 R t i f ti f h d b i i i t f li4.5.1 Reason to information of process change and submission requirement for supplier

Type

PCN

PPA

P

Proc

ess

Flow

Cha

rt

and

cont

rol p

lan

MSA

Dim

ensi

on R

esul

t

Perf

orm

ance

Res

ult

Supp

ly C

hain

Initi

al P

roce

ss s

tudy

PSW

Sam

ple

Engineering Change from customer O O - - - - - - - -Shape Change O O

Item Cange

ct Shape Change O O - - - - - - - -Add/Change Tolerance O O - - - - - - - -Characteristic O O - - - - - - - -Material (Design Change) O O - - - - - - - -

MAN Subcontractor use O - - - - - - O - -Machine add to up capacity (same specification with current machine) O - - - O - - O O O

Machine change (change specification with current machine) O - - - O - - O O O

Process flow chart O O O O

Prod

uc(E

CN

)

MACHINE

Process flow chart O - O - - - - O - OControl item I control plan change O - O - - - - O - -Sub-supplier production (Tier3) O - O O O O O O OAdd material sourcing O O - - - - - - - -Change material sourcing O O - - - - - - - -Add mold/die/tooling to up capacity O O - - - - - O - -Change mold/die/tooling O - - - O O - O O OUse tooling which stop production over 12 months O - - - O O - O O O

Mold

MATERIAL

METHOD

Proc

ess

Cha

nge

4.5.1.1 Process Change Notice

Process Change Notice to define change previous process compare with new process for

months

Checking figure/inspection gauge add O - - O - - - - - OChacking figure/inspection gauge change (design change) O - - O - - - - - O

OTHERS Location change O - - - O - - O - O

MEASUREMENT

Process Change Notice to define change previous process compare with new process for

TER approve. The supplier shall submit Process Change Notice before

change 1 month. (N-1)

4.5.1.2 Sample production parts

The supplier shall provide sample product 3 pcs./shots or all cavity for TER evaluation.

d d t ld ith b f t P Ch N ti (B f 2 th )and compare data old with new before approve to Process Change Notice (Before 2 months)

4.5.1.3 Balance Stock Control

Supplier shall to confirm implement timing of change to TER below

N

N-2 -Submit Process Change Notice before 2 months

Confirm Item Remark

- Implement timing by forecast

N-1 - Co-Check the Sample production parts before 1 month

D-9 -Stock balance information to TER before 9 days

D-3 -Stock balance information to TER before 3 days

D-1 - Last & First Lot Confirm & Information before 1 day

D - First Lot arrive to TER Implement date



4.5.2 Delivery requirement after PCN approved.

S li h ll i iti l t f t l hi i t h t TER f ll11

Supplier shall use initial tag for control shipping parts change to TER follow

Delivery requirement table

Deliver requirement

RemarkReason / identifyPurposeColor Tag

Last Lot Confirm Change is "Old Part in Last - Attach with Invoice and Part

(Old Parts) ECI" at " Others - Confirm by telephoen / e-mail

First Lot Confirm Change is "New Part Lot - Attach with Invoice and Part

(New Parts) ECI" at " Others - After PSW approved is 1 lot

- Confirm by telephone / e-mail

Red

Yellow

<Old Part in last ECI tag> < New Part Lot ECI tag>

TO: ARRIVAL DATE : dd/mm/yySUPPLIER : XXX MODEL: XXXX

PART NO. : XX-XXXX-XX MFG. NO. : XX-XXX

TOKAI EASTERN RUBBER (THAILAND), LTD.Technical TO: ARRIVAL DATE : dd/mm/yy

SUPPLIER : XXX MODEL: XXXX

PART NO. : XX-XXXX-XX MFG. NO. : XX-XXX

TOKAI EASTERN RUBBER (THAILAND), LTD.Technical

PART NAME.: XXXXXXXXXXXXXXXXXXXXXXXXXXXXX

Q'TY (Pcs.) XX P/O NO. XX


Change XXXXXXXXX PCN No. XXXX

DELIVERY BY MR.XXXXX PHONE XXX-XXX


PART NAME.: XXXXXXXXXXXXXXXXXXXXXXXXXXXXX

Q'TY (Pcs.) XX P/O NO. XX


Change XXXXXXXXX PCN No. XXXX

DELIVERY BY MR.XXXXX PHONE XXX-XXX




4.5.3 Change Control Flow11

ItemQA &TC ‐ Issue ECR from supplier ‐ ECR

TC ‐ Issue ECR to TRI ‐ ECR

TC & TRI ‐ Review ECR from TER ‐ ECR

Customer ‐ Review & Approve ECI/ ECN from TER ‐ ECN / ECIPlanning I

P.I.C.CUSTOMER Concerned Doc.DetailTRI SUPPLIERTER

Review

ECR Issue

ECR Issue

Review

ECR Issue

Reject

Review

Reject

Reject

Accept

Accept

‐Received ECI from customer ECN/ECI/customer

part drawing

‐ Issue RFD ‐Doc.no.TES‐IZ‐6127

‐ Revise Internal drawing and send to TER ‐ Drawing

TC ‐ Revise and Register drawing ‐ Drawing

‐ Receive drawing ‐Drawning

( )

P

l

TRI Designer

Supplier

MKT

MKT

Review

ECI/ECN Issue

Drawing Release

Receive ECI

Issue RFD

Receive /Register Receive drawing

‐ Set up plan (Plan approved)

Core Team ‐ Review and set up trial plan ‐ TPCR

‐ Issue TPCR ‐ PCR

QA&TC ‐ Submit to customer approve(plan) ‐ PCR

Customer ‐ Review / Approve PCR plan ‐ PCR

‐Making sample part for evalaution

‐Trial Confirm Change point follow ‐Doc.no.TES‐PZ‐6513

Working step 6M ‐Scat Sheet issue

Planning II

Supplier

SupplierPE

Set up master plan&Issue PCR

(Target = 45 days)

APQP meeting & Issue PCR & TPCR

Trial

Sample

Approve

Reject

AcceptSubmission PCR

Supplier ‐ Prepare process (6M) support TER trial ‐S‐PPAP package

‐ Summary S‐PPAP submit to TER

QA &TC ‐Test confirm Chagne point ‐Scat sheet result

‐Compare Result with current condition ‐Compare data

‐Technical Supplier Manual

‐Submit OTS to customer for evaluation ‐ Part data (OTS)

QA&TC&PC ‐Audit supplier process ‐ SPTT Activity

Customer ‐Trial confirm part approve

‐ Tooling & Equipment preparation ‐ Working stepPE & QA

QA&TC

Scat sheet & Evaluation

Production preparation

Reject

Accept

Submit Off tool sample to customer

Part EvaluationAccept

Reject

Supplier Process audit


Accept

Reject

S-PPAP submission

‐ Process preparation ‐ Process control std.

‐ Work standard preparation ‐ I will check this

QA & TC ‐ Approve PCR and S‐PPAP ‐PCR

‐SPPAP approved

QA ‐ Process & Product confirmation ‐ TPCR

‐ Audit report

‐ First delivery to TER ‐ Firs lot data

MD ‐ Approved TPCR ‐ TPCR

Process capability monitoring RecordQA & PD

Verification

Supplier


Process audit

TPCR Approval

Reject

RejectAccept

Accept

Start mass productionat supplier

Supplier PCR & S‐PPAP approve

Accept

Reject

‐ Process capability monitoring ‐ Record

‐ % NG summary

QA ‐ Process capability monitoring ‐ Record

‐ % NG summary

‐ Submission concern document ‐PPAP pacakge

of PPAP to customer approve

‐ Approved process before start mass ‐PCR & PPAP

production

S d i i st l d l dApproval

QA & PD

QA & TC

Customer

Monitoring & Special control

Process capability evaluation

Submission PPAP

Approval

Accept

Reject

(Target = 15 days)

Reject

4.5.4 Record Retention

PCN or ECR shall be maintained for the length of time that the part is active plus one

calendar year. Supplier shall ensure that the appropriate PCN and ECI records are included,

11

‐ Start production continue ‐ 1st lot delivery record ‐ Balance stock & run out old part

‐ 1st lot delivery confirm to customer

A

PD, QAPC, TC

(Target = 7 days)Start mass production

Accept

or referenced in the past PPAP file.



[Responsible to QA department]4.6 Guideline for Environmental Hazardous Substance Management

4.6.1. Introduction

4.6.1.1 Introduction

According to automotive parts and electronic equipment are commerced to EU market, it is

enforced by ELV, RoHS Directive and REACH regulation. The ELV concept is about "Do not use Lead

Mercury, Cadmium and Hexavalent Chromium for automotive parts (some material / parts are exempted

by Annex II). For RoHS (Restriction of the use of certain Hazardous Substances in electrical and

electronic equipment) is about "Do not use Lead, Mercury, Cadmium, Hexavalent Chromium, PBBs

(Polybrominated Biphenyl) and PBDEs (Polybrominated Diphenyl Ether) for electronic part.

REACH concept is to survey use of SVHC in product.Tokai Eastern Rubber (Thailand), Ltd. have many

supplier that manufacture and deliver raw material / part. It will be finished goods which send to OEM

customer who export the goods to EU market. Then we would like to coorperate with our

supplier in order to establish Environmental Hazardous Substance Management System and protect

contamination of these substances in raw material and product.

4.6.1.2 Purpose

*1 *2 *3

*4

11

This document is a guideline of quality management for our supplier to comply with it.

4.6.1.3 Scope

This document can apply for all suppliers to prevent Environmental Hazardous Substances

contamination in raw material, part and solution include in-direct material. Supplier will be considered

by supply chain.

4.6.2. Implement

4.6.2.1 Policy/ Objective & Target / Action Plan

(1) Policy/ Objective & Target/ Action Plan is issued by top management. The detail shall

concern activity to decrease Environmental Hazardous Substances. These document shall implement

and review cover organization.

(2) Shall set up training program about Environmental Hazardous Substances for employee.

4.6.2.2 Organization

Shall set up responsible person or team to support management of Environmental Hazardous

Substances in organization. The purpose is to achieve the target.

Note

1 ELV: Directive of End-of-Life vehicles (2000/53/EC)

2 RoHS: Directive of Retriction of the use of certain hazardous substances in electrical and electrinic equipment

(2002/95/EC)

3 REACH: Registration, Evaluation, Authorization and Restriction of Chemicals (Regulation 2006/1907/EC)

4 SVHC: Substance of Very High Concern

Page 27 of 34 Environmental Supplier Manual


4.6.2.3 Communication

(1) Shall set up communication route and information method inside and outside company

about Environmental Hazardous Substances.

(2) Shall have procedure for report to top management and customer when Environmental

Hazardous Substances are found in raw material, part and product.

4.6.2.4 Internal audit

(1) Shall have internal audit and audit report that contain Environmental Hazardous Substances

item.

(2) Shall set up skill and/ or training of internal auditor.

(3) Shall set up procedure for corrective action from internal audit result.

(4) Shall present internal audit result to top management for review performance.

4.6.2.5 Supplier selection

(1) Shall set up supplier selection standard and activity of top management about Environmental

Hazardous Substances with supplier.

(2) Shall set up / inform analysis method of Environmental Hazardous Substancess to supplier.( ) p y pp

4.6.2.6 Supplier management

(1) Shall set up plan to monitor Environmental Hazardous Substances at supplier

manufacturing site.

(2) Shall inform supplier about Environmental hazardous Substances control and standard.

4.6.2.7 Receiving raw material

(1) Shall have standard for raw material and part receiving. The standard have to contain

Environmental Hazardous Substances item in check sheet and keep record of it.

(2) Shall have standard for material receiving / distribution from Warehouse and record it

such as lot number.

(3) Shall have analysis result of Environmental Hazardous Substances of raw material.

(4) Shall have method to prevent contamination of Environmental Hazardous Substances in

receiving area.

4.6.2.8 Production

(1) In case of using same equipment/ machine with other customer, production shall have

method to prevent Environmental Hazardous Substances contamination when change raw material.

(2) Shall have procedure for protection of wrong material using.

(3) Shall not use recycled material.



4.6.2.9 Shipping

(1) Shall have supplier history record about lot no.

(2) Shall have procedure for stop shipping raw material when Environmental Hazardous

Substances are found.

(3) Shall have procedure for protection of product mixing.

4.6.2.10 Prevention of re-occurrence

(1) Shall have preparation to protect Environmental Hazardous Substances contamination.

It shall find root cause to protect re-occurrence.

Reference TER's customer requirements

Requirement

The Environmental Hazardous Substances shall not be used for material/part, in-direct & sub-material

which are delivered to TER according to EU Directive 2000/53/EC.The amendment on a regular basis

shall be obeyed, regarding Annex II (2005/673/EC) for automotive part and RoHS Directive 2002/95/EC

for electronic part. All products must be free from Perfluorooctane Sulfonates in accordance

with laws and regulation Directive 2006/122/EC, and REACH Regulation (Regulation 2006/1907/EC)

for chemical.for chemical.

Supplier' s Responsibility

(1) Supplier shall fulfill all requirements that contained in this manual regardless if is mentioned

in the drawing or not.

(2) Supplier shall fulfill the latest version for amending of the related directives, laws regulations etc.

(3) In case of use of Environmental Hazardous Substance can not be avoided, supplier shall

report to Technical and Purchasing of TER.

Standard of environmental hazardous substances control

Environmental Hazardous Substance Control Flow

TER Supplier

Technical

Technical

Technical

Technical

QA

In case of change : When supplier have change, shall consider environmental hazardous substance which may be effect to

Flow In charge Document

Request new material/part

Trial new material/part

Approve PPAP

Start Mass Production

New Part Notice

SBSC (at TM0stage)

- Test report (ICP Data) + Cover sheet - Certificate of non-use of the controlled substances- Declaration of no use of PFOS- Material Data Sheet + Mill sheet/certificate- SVHC survey sheet- PPAP

PPAP

- Certificate of non-use of the controlled substances- Mill sheet- Test report (ICP Data) + Cover sheet (annual) (when request)

11

Submit PPAP

g pp g , y

material/part which are sent to TER. Supplier shall submit test report of environmental hazardous substance to Technical section of TER.



Standard for environmental hazardous substances control

In case of found environmental hazardous substances

intentional use unintentional use

inform top management and customercompare with criteria at Table 1, 2

And Annex II

acceptover than criteria

inform top management and customer

Corrective action such aschange raw material, change chemical

change process

re-submit PPAP to TER Corrective action such aschange raw material, change chemical

change process

submit PPAP to TER

In case of unintentional using

Table 1 Criteria of environmental hazardous substances for metal, rubber, chemical which use for

automotive parts

100 100 100 50 1000

ppm max ppm max ppm max ppm max ppm max

Table 2 Criteria of environmental hazardous substances for rubber, chemical which use for

electronic parts

100 None None 5 None

ppm max ppm max ppm max less than ppm max

Remark: Cr6+ Criteria for rust preventive plating part (for TM, JT, DR, DT part) and criteria for reference

is less than 300 ppm by use method prEN 15025 for testing.

: Preparation of PFOS must be less than 50 ppm .

Reference

Chiorinated Paraffin

None

ppm max

Cd PBBs, PBDEs

None

Pb Hg Cr6+

Criteria for reference

Criteria for reference

ppm max

CdCr6+HgPb

PFOS

PFOS

TER' s customer requirements



Analytical method of Environmental Hazardous Substances

There are 2 types of analysis methods, having different purposes.

(1) Qualitative analysis

The qualitative analysis is the method for determining with each whether a substance of

environmental concern is contained. Basically, the methods specified in Table 1 shall be used.

The main purpose of this analysis is to examine whether there is a content of a substance of

environmental concern in production materials, production trial materials and products. If no such

substances are detected, it means that there is no substances of environmental concern.

Table 1 Qualitative Method and Lower Limit if Detection Level

Cadmium - Fluorescent X-ray method - when measured with magnified

Lead/ Mercury (ED-XRF) detection ability, a signal

intensity level of the concerned

element shall be approximately

Controlled elements Analysis method Lower limit of detection level

3 times the fluctuation of

background intensity (S/B ration

shall be approximately 1/1)

Hexavalent chromium - Colorimetric testing paper(1) - The lower limit of the detection

(Colourometric analysis using level when using a colorimetric

diphenyl carbazide) testing paper shall be such that

the color corresponding to the

corresponding to the color that

indicates the minimum

concentration on the testing

paper can be visually identified.

Note (1); Pack test: KYORITSU CHEMICAL-CHECK Lab., Corp.

(2) Quantitative analysis

The quantitative analysis is the method for accurately determining the amount of a substance, in

order to quantitatively prove that the amount of the substance is equal to or less than the threshold value.

Table 2 shows the analysis method and the lower limit of determination amount for each substance.

However, other quantitative methods may be used instead as long as the method assures the

accuracy of measured value with use of a standard sample and a standard substance, and satisfies

a lower limit determination amount as specified in Table 2a lower-limit determination amount as specified in Table 2.



Table 2 Quantitative Method and Lower Limit of Determination Amount

amount (ppm)

Cadmium - Inductively coupled plasma atomic

Lead/ Mercury emission spectrometry (ICP-AES)

- Atomic absorption

spectrophotometry (AAS)

Hexavalent chromium - Colourometric analyses using

diphenyl carbazide

Outline of Analysis

The outline of the analyses shall be as shown.

50

Controlled elements Analysis method Lower limit of determination

10

Materials/ parts

Qualitative analysis

Reporting of nodetection

Quantitative analysis

Reporting measured value

Controldivision

Not detected

Detected

Analytical Instruments

(1) ICP - AES analytical instrument

An instrument comprising an excitation power supply unit, sample injection unit, atomic

emitting unit , spectrometer, device control system, and recorder. It is desirable to use an

instrument equipped with a device for producing atomic vapor by reduction (for Mercury) as an

auxiliary instrument.

(2) AAS analytical instrument

An instrument comprising a light source unit, sample atomization unit, wavelength selection

unit, measuring unit, and data display / recording unit. It is desirable to use an instrument equipped

with auxiliary instruments such as device for producing atomic vapor by reduction (for Mercury)

and electrothermal type furnace.

(3) Absorption photometer

An instrument comprising a light source unit, wavelength selection unit, sample chamber,

measuring unit, and data display/ recording unit.

(4) Fluorescent X-ray spectrometer

An analytical instrument comprising an X-ray generation unit , spectrometer / detector /

proportional counter, data processing unit. Basically, for qualitative analysis, an energy dispersive

type instrument with less restrictions on sample surface shapes shall be used. Further , the

instrument shall be capacle of exciting targeted elements by means of X-ray that prevents detection.



4.7 Control of Initial Nonconforming Products(NC)

To determine supplier responsibility for control and make corrective action in initial nonconforming

product. Nonconforming product is the production part from supplier which their specifications do not

reach engineering drawing and related standard.

Nonconforming Product divided to 2 cases

-Major NC : NC effect to part functional

-Minor NC : NC not effect to part functional

When Technical found NC which occur in supplier process, Technical and supplier shall action

follow this step.

Control of Initial Nonconforming Products(NC) Flow Chart

Technical/TER found NC part

Issue Quality Information(QI)

Judgement

Major NC Minor NC

TER Problem Follow Up Sheet

Note: When Technical found NC may effect to quality score in TER Initial Technical Control(TITC) refer

to TITC criteria.

For special control of initial part, supplier shall take activity QRE (Quality Resident Engineering)

3 months or 30 supplier's production lot. Supplier shall inspect part whice supplied to TER before use

in TER's production process, record for inspection result and identified on delivery tag is "QRE Passed"

Criteria for QRE Approve No major case in part function

Minor case in appearance less than 0.05 ppm

QA/TER issue CAR Technical/TER issue Problem follow up sheet

Supplier analyze and report CAR within 7 days

QA and Technical follow up CAR in

process of supplier

Technical follow up Problem follow up sheet

in process of supplier

Supplier analyze and report Problem follow up sheet within 7 days

CAR closing Problem follow up sheet closing

Accept Accept

Not accept Not accept



5. Attachment list

Att h d Sh t N 1 P j t O i ti Ch tAttached Sheet No.1 : Project Organization Chart

Attached Sheet No.2 : Production Preparation Schedule : PPS

Attached Sheet No.3 : List of Engineering drawing of supplier

Attached Sheet No.4 : SPTT Audit Report

Attached Sheet No.5 : MSA format

Attached Sheet No.6 : Shipping Tag

Attached Sheet No.7 : List of Engineering Change

Attached Sheet No.8 : Process Flow Diagram

11

Attached Sheet No.9 : Control Plan

Attached Sheet No.10 : Dimension Results

Attached Sheet No.11 : Material Test Results

Attached Sheet No.12 : Supply Chain Database List

Attached Sheet No.13 : Material List & Component Parts

Attached Sheet No.14 : Performance Test Results

Attached Sheet No.15 : Initial Master Sample Tag Format

Attached Sheet No.16 : Supplier PPAP request sheet11

Attached Sheet No.17 : Part Submission Warrant(PSW)

Attached Sheet No.18 : Supplier Banned Substance Check Sheet (SBSC)

Attached Sheet No.19 : Certification of Non-Use of the Controlled Substances

Attached Sheet No.20 : Process Change Notice

Attached Sheet No.21 : Quality Problem follow up sheet

Attached Sheet No.22 : Environmental test report cover

Attached Sheet No.23 : Material Data Sheet

Attached Sheet No 24 : Declaration of no use of PFOS11 Attached Sheet No.24 : Declaration of no use of PFOS

Attached Sheet No.25 : SVHC Survey:

Attached Sheet No.26 : Inspection Standard and Inspection Record:

Attached Sheet No.27 : Allowed maker <Making paint list free SoC>:

Attached Sheet No 28 : Engineering Change Request (ECR)

11

Attached Sheet No.28 : Engineering Change Request (ECR)


11

Technical Supplier Manual Change Notification

1 Quality assurance ideality 1 Quality assurance ideality

2 Purpose 2 Purpose

3 Scope 3 Scope

4 Requests to supplier 4 Requests to supplier

4.1 Initial Control Organization 4.1 Initial Control Organization

Purchasing / TER. <for 1st SPTT activity>4.2 Approval Initial Part for Supplier 4.2 Approval Initial Part for Supplier

4.2.1 Production Preparation Schedule (PPS) 4.2.1 Production Preparation Schedule (PPS)

For 1st SPTT audit activity

4.2.2 SPTT activity 4.2.2 SPTT activity

Activity of each stage

4.2.3 Supplier Inspection standard 4.2.3 Supplier Inspection standard

4.2.4 SBSC 4.2.4 SBSC

4.3 Initial Delivery Control 4.3 Initial Delivery Control

4.4 PPAP Activity 4.4 PPAP Activity

4.4.1 Reason to submit PPAP 4.4.1 Reason to submit PPAP

4 4 2 PPAP Retention/S bmission Req irement for 4 4 2 PPAP Retention/S bmission Req irement for

New Technical Supplier Manual (Rev.10) New Technical Supplier Manual (Rev.11)

4.4.2 PPAP Retention/Submission Requirement forSupplier

4.4.2 PPAP Retention/Submission Requirement forSupplier

Production material type Inspection standard

4.4.2.1 Supplier PPAP request sheet 4.4.2.1 Supplier PPAP request sheet

Submit Criterial : Production Material

4.4.2.2 Design Record 4.4.2.2 Design Record

extend the detail and format

4.4.2.3 Engineering Change Documents 4.4.2.3 Engineering Change Documents

extend the detail and example Engineering Change Request Form

4.4.2.4 Customer Engineering Approval 4.4.2.4 Customer Engineering Approval

extend the detail and format

4.4.2.5 Process Flow Diagrams 4.4.2.5 Process Flow Diagrams

4.4.2.6 Process FMEA 4.4.2.6 Process FMEA

Established standard for preventive/corrective action

4.4.2.7 Control Plan 4.4.2.7 Control Plan

4.4.2.8 Measurement System Analysis Studies 4.4.2.8 Measurement System Analysis Studies

Signature of TER change to Supplier

4.4.2.9 Dimensional Results 4.4.2.9 Dimensional Results

4.4.2.10 Material, Performance Test Results,Supply Chain 4.4.2.10 Material, Performance Test Results,Supply Chain

4.4.2.11 Initial Process Studies 4.4.2.11 Initial Process Studies

4.4.2.12 Qualified Laboratory Documentation 4.4.2.12 Qualified Laboratory Documentation

4.4.2.13 Master Sample 4.4.2.13 Master Sample

4.4.2.14 Checking Aids 4.4.2.14 Checking Aids

4.4.2.15 Records of Compliance with Customer-SpecificRequirements

4.4.2.15 Records of Compliance with Customer-SpecificRequirements

4.4.2.16 Part Submission Warrant (PSW) 4.4.2.16 Part Submission Warrant (PSW)

Technical Supplier Manual Change NotificationNew Technical Supplier Manual (Rev.10) New Technical Supplier Manual (Rev.11)

4.4.2.17 SBSC, Certification of Non-Use of the ControlledSubstances

4.4.2.17 SBSC, Certification of Non-Use of the ControlledSubstances

format change by not separate initial /mass production4.4.2.18 Cover sheet and test report 4.4.2.18 Cover sheet and test report4.4.2.19 Material data sheet 4.4.2.19 Material data sheet

4.4.2.20 Declaration of no use of PFOS 4.4.2.20 SVHC survey4.4.2.21 SVHC survey 4.4.2.21 -

4.4.3 PPAP Status 4.4.3 PPAP Status

4.4.3.1 Approved 4.4.3.1 Approved

4.4.3.2 Interim Approval 4.4.3.2 Interim Approval

4.4.3.3 Rejected 4.4.3.3 Rejected

4.4.4 Record Retention 4.4.4 Record Retention

keed the PPAP by PDF file and/or

4.5 Process Change Requirement 4.5 Process Change Requirement

4.5.1 Reason to information of process change and 4.5.1 Reason to information of process change and

submission requirement for supplier submission requirement for supplier

4.5.1.1 Process Change Notice 4.5.1.1 Process Change Notice

4.5.1.2 Sample Product parts 4.5.1.2 Sample Product parts

4.5.1.3 Balance Stock Control 4.5.1.3 Balance Stock Control

remark remark

4.5.2 Delivery requirement after PCN approved 4.5.2 Delivery requirement after PCN approved

technical control person in tag Mistake "Invoise" to "Invoice"

SRE

4.5.3 Change Control Flow 4.5.3 Change Control Flow

Balance Stock Control flow change

4.5.4 Record Retention 4.5.4 Record Retention

4.5.5 - 4.5.5 -

4.6 Guideline for Environmental Hazardous Substance Management 4.6 Guideline for Environmental Hazardous Substance Management

[Responsible to QA department]

cancel certificate of non-use the controlled substancestest report (when request)

4.7 Control of Initial Nonconforming Products (NC) 4.7 Control of Initial Nonconforming Products (NC)

5 Attachment list 5 Attachment list

format change format change

5 Technical Supplier Manual Change Notification 5 Technical Supplier Manual Change Notification