Supplier Quality

Manual

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

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

2
 Revision History

REV Description of Change Author Effective Date

A Initial Release M. Rodgers 1/1/10
B Modified scorecard requirements J. Brewster 8/1/11
C Update Problem Report / Costs J. Brewster 12/8/13
D Updated to Include Aerospace Supplier Requirements L. Murden 12/5/2014
E Added IATF Requirements L. Murden 10/14/2017
F Added requirements for ISO 9001 certifications to bear mark of L. Murden 11/14/2017
IATF certification body
Aligned PLEX Scouring with requirements
G Added Requirements for suppliers with embedded software L. Murden 3/28/2018

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 Supplier Quality Manual
Introduction

Commitment to Our Suppliers

OUR SUPPLIER RELATIONSHIPS ARE THE KEY TO OUR

SUCCESS; CONTINUED SUCCESS WILL RELY ON
EFFECTIVE COMMUNICATION WITH OUR SUPPLIERS TO
MEET OR EXCEED OUR CUSTOMER EXPECTATIONS.

IT IS OUR COMMITTMENT TO COMMUNICATE TO OUR

SUPPLY BASE OUR CONTINUAL IMPROVEMENT
PHILOSOPHY AND THAT THIS INFORMATION WILL BE
BENEFICIAL IN DEFINING THE EXPECTATION’S OF AGM
AUTOMOTIVE AND OUR VALUED CUSTOMERS.

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 Supplier Quality Manual

Supplier Certification Requirements

(bearing the accreditation mark of a recognized IAF MLA)

Automotive suppliers with embedded software are required to implement and maintain a process for quality
assurance. Based on risk and potential impact to the customer, AGM may require a software capability
assessment.

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 Supplier Quality Manual

Subcontractor Development
With the increasing demands for higher quality at a lower cost, the entire supply chain is
responsible for increasing quality and contribution to a lower overall cost. It is AGM’s
expectation that all AGM production suppliers work closely with their supply base to
ensure that the quality level of received product meets AGM and its customers’
requirements and expectations. The primary area of focus is in the communication and
documentation of customer requirements, which is achieved through APQP (Advanced
Product Quality Planning). Through the APQP process, the subcontractor is informed of
customer requirements and expectations and develops the process foundation.

Certification of Conformance
When required by AGM, each shipment shall include a Certification of Conformance. The
Certificate of Conformance must contain a statement that all inspections, processing, and
tests have been performed as required by the drawing requirements and/or Purchase Order.
Products controlled by heat numbers, certification numbers, batch numbers, or cure dates
must be linked to the Certificate of Conformance by the controlling number, and show
physical and chemical values when applicable.

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 Supplier Quality Manual

Engineering & Process Changes

AGM’s continuous improvement philosophy encourages process improvements both

internally and at supplier facilities. However, prior to any engineering and or process
changes being implemented, the effects of the change are required to be assessed, verified
and validated to ensure compliance to AGM requirements and AGM’s customer
requirements. PPAP approval is required for any process changes including change of the
manufacturing location. The supplier is also responsible to complete Early Launch
Containment, per page 17 of this manual.

When an Engineering Change Notice (ECN) is issued by AGM the supplier is required to
provide AGM with breakpoint and obsolescence information. The supplier is required to
identify the next 2 shipments, unless otherwise specified by AGM, with the ECN
Breakpoint Label, see page 37. The label (6” x 6” minimum) is required on all boxes. If
product is not properly identified with the breakpoint label and the correct information
the supplier will be issued another QI and their scorecard will be negatively impacted.

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 Supplier Quality Manual
Material Labeling
All product shipping into any AGM facility must be bar code labeled. All labels must
follow the AIAG format and contain the follow information at a minimum, whne
specified by AGM. Additional requirements may be required based on AGM customer
requirements.
• Part Number
• Quantity
• Part Description
• Date of Manufacture
• Part Revision Level
• Lot Number

IMDS Requirements- Automotive Product

In 2000, the European Union established the End of Life Vehicle (EVL) Directive, which
states that “All OEMs & Suppliers must account for prohibited, restricted and reportable
substances for all components. International Material Data Sheets (IMDS) provide
substance breakdowns necessary to safely recycle vehicle at the end of their useful life.

AGM Automotive requires IMDS to be submitted to AGM’s site code 34118 through the
MDS system, which can be accessed at http://www.mdsystem.com and observe the
requirement of the IMDS Recommendation 001.

Suppliers must include IMDS data with their PPAP submissions. If the data is not
received with the PPAP submission, AGM Automotive reserves the right to refuse PPAP
sign-off. Additionally, AGM may issue a QI and the supplier score card may be
negatively affected by late or non-submittal of IMDS.

Right of Access
Supplier shall provide AGM, its customer(s), and/or a specified third party
(statutory/regulatory agency) right of access to the facility and all records related to
product ordered by AGM or its customers. AGM, its customer(s) representative(s), and/or
a specified third party reserves the right to perform an audit or inspection at the supplier’s
facility to verify that supplied product conforms to specified requirements. This
verification does not absolve the supplier of the responsibility to provide acceptable
product and does not preclude subsequent rejection by AGM or its customer.
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 Supplier Quality Manual
Scoring Criteria and
Performance Tracking
➢ Suppliers performance is tracked by five categories
totaling 100 points on a rolling 12 month calendar according
to the following categories:

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

➢ At the end of each month supplier scorecards will be

available and the scores are determined according to the
below ranking chart. Any category score or overall score
in the red or NBH the supplier is required to submit
corrective action.
On‐Time Written
Ranking PPM Communications Total
Delivery Concerns
Gold 30 30 20 20 98‐100
Green 27‐29 27‐29 12‐13 8‐9 86‐97
Yellow 21‐26 21‐26 9‐11 6‐7 66‐85
Red 11‐20 11‐20 5‐8 4‐5 36‐65
NBH 10 or less 10 or less 4 or less 3 or less 35 or less

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 Supplier Quality Manual
Quality - PPM
➢ At the end of the calendar year below are the required
actions based on the yearly performance results:

➢ Gold – No actions required.

➢ Green – No actions required.

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

➢ NBH (New Business Hold)

➢ Improvement plan required to be removed from
new business hold.
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 Supplier Quality Manual
Quality - PPM
Quality -PPM
The PPM category accounts for 30 points of the overall scorecard rating. Supplier PPM (parts per
million) is calculated on the basis of the amount of non-conforming materials versus the total
amount processed through production in the fiscal month, which includes any AGM customer field
returns. This calculation is then normalized to reflect a constant basis of one million units received.

Non-conforming material identified as the responsibility of the supplier will be noted as PPM,
except;

• If a supplier shows diligence and immediately notifies AGM of a potential problem

• When there is mutual agreement between AGM quality and the supplier that the part
rejection was unjustified.

The AGM plant affected by the non-conforming parts will decide whether of not the supplier should
sort product on location at AGM facility. A supplier must report all non-conforming product found
in sorting. AGM quality will decide whether all non-conforming products will be classified as PPM,
or only those parts which were found by AGM.

A supplier must give AGM Quality team an RMA (Return Material Authorization) within 24
hours of the time the PPM was reported. AGM reserves the right to claim compensation from
a supplier for any sort activities ($50 per hour USD) or downtime resulting from supplier PPM

PPM calculation and EXAMPLE:

A supplier ships 100,000 parts to a plant, 10 of which are non-conforming. The scorecard’s
calculation will be (10/100,000) x 1,000,000 = 100 PPM’s.

(REFER TO THE TABLE BELOW FOR THE RATING RANGE.)

PPM SCORE PPM SCORE

0-25 30 326-350 17
26-50 29 351-375 16
51-75 28 376-400 15
76-100 27 401-425 14
101-125 26 426-450 13
126-150 25 451-475 12
151-175 24 476-500 11
176-200 23 501-525 10
201-225 22 526-550 9
226-250 21 551-575 8
251-275 20 576-600 7
276-300 19 601-625 6
301-325 18 626 or Higher 5

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Supplier Quality Manual
Quality – Written Concerns
Supplier Quality Incident Tracking
AGM issues a Problem Report (PR) for reporting and resolving supplier quality, delivery,
customer satisfaction and warranty issues. Suppliers must formally respond to a Quality
incident with a systemic countermeasure process (See page 30 for the required formats).

• PR(s) created for supplier issues are considered written complaints and are part of
the supplier’s scorecard.

Suppliers must give an initial respond within 24 hours with containment actions,
48 hours for oversees suppliers.

Permanent corrective action implementation and verification of effectiveness is

required within 30 days. AGM approval is required in the event that permanent
actions cannot be achieved in 30 days.

Quality –Written Concerns (PR)

The written concern category accounts for 10 points of the overall scorecard rating. The
written concern category is calculated on the basis of the quantity of Problem Reports
issued through production in the fiscal month. See the table below for the scoring
breakdown.

QI Quantity SCORE
0 10
1-2 9
3-4 8
5-6 7
7-8 6
9 5
12 4
11 3
12 2
13 1
14 or more 0

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 Supplier Quality Manual
Delivery Performance

Delivery
The delivery score accounts for 30 points of the overall scorecard. Delivery ratings are calculated
on the basis of the amount of shipments that have errors versus the total amount of shipments in a
given fiscal month. This information is then calculated into a percentage.

Delivery ratings are based on the number of occurrences when it is determined to be the supplier’s
responsibility:

EXAMPLE: During one month, a supplier sends 36 shipments. Out of the total 36, 1 shipment is
late and 1 shipment is short of the quantity ordered.

The delivery percentage calculation will be (36-2)/36 x 100= 94.4%

DELIVERY OCCURRENCE
Shipments Count % Points
Late Deliveries- 1
Early Deliveries-
Premium Freight-
Damaged Parts-
Over Shipment-
Short Shipment- 1
Incorrect Quantity-
Reference Wrong Purchase Order -
Missing Paperwork -
Incorrect Freight Carrier -
Referencing Incorrect Part Number-

Other:
Delivery Total: 36 2 94.4 28

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Supplier Quality Manual
Delivery Performance
(continued)
The potential for more than one occurrence, per shipment does exist.

The system automatically calculates the delivery percentage and associated points based
on the following formula:

(TOTAL SHIPMENTS - NUMBER OF OCCURENCES)/TOTAL SHIPMENTS) X 100

Delivery Rating Range Chart

DELIVERY OCCURRENCE PERCENTAGE SCORE

100 30
99.0 29
98.6 - 98.9 28
98.3 – 98.5 27
98.0 – 98.2 26
97.6 – 97.9 25
97.3 - 97.5 24
97.0 – 97.2 23
96.7 – 96.9 22
96.4 – 96.6 21
96.1 – 96.3 20
95.8 – 96.0 19
95.5 – 95.7 18
95.2 – 95.4 17
94.9 – 95.1 16
94.6 – 94.8 15
94.3 – 94.5 14
94.0 – 94.2 13
93.7 – 93.9 12
93.4 – 93.6 11
93.1 – 93.3 10
92.0 - 93.0 9
90.0 – 91.9 8
89.0 – 89.9 7
88.0 – 88.9 6
86.0 – 87.9 5
84.0 – 85.9 4
82.0 – 83.9 3
80.0 – 81.9 2
75.0 - 79.9 1
Less than 75.0 0

THE GOAL FOR DELIVERY FOR EACH MONTH IS 100%

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 Supplier Quality Manual
Communication

Communication
Communication Accuracy category accounts for 15 points of the overall scorecard and is based
on the following criteria:
Occurrence Description
No Release Acknowledgement Returned
Signed Purchase Order Not Returned
Lack of Response (E-Mail/Phone calls)/ Late Quality Incidents (QI)
Other:

Total Score for Communication 10

Communication SCORE
Occurrence
0 20
1 19
2 18
3 17
4 16
5 15
6 14
7 13
8 12
9 11
10 or more 10

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 Supplier Quality Manual

Containment Requirements
Containment Requirements
All suppliers are required to have a documented containment process, which must include
methods of identifying corrective action and containing suspect material in order to
prevent non-conforming material from entering back into production or being received by
an AGM facility.

If a supplier’s containment process fails and non-conforming parts are delivered to an

AGM facility, we may require containment depending on the severity of the rejection.
Containment is 100% inspection of all parts at the supplier’s facility and is required in
addition to any current quality checks. A sort of ALL material for the specified defect
must be performed at the supplier’s facility under the following guidelines:
The product acceptance standards and measurement/testing processes must be
agreed upon by AGM Quality.
Data must be collected for all non-conformances and corrective actions. If
required by AGM the results must be reported.
• Problem solving must be formal, data driven, and documented. AGM prefers
it’s suppliers to use the 5 Phase, 8-D or 3 X 5 Why problem solving method.

The supplier is required to provide AGM with breakpoint information and identify the
next 2 shipments, unless otherwise specified by AGM Quality, with the Breakpoint Label
(6” x 6” minimum) on page 36. The label is required on all boxes.

In addition to setting up containment at its own facility, a supplier must also manage
containment activities of parts at all AGM Automotive facilities and all material that is in
transit to AGM Automotive. AGM Quality department will notify the supplier by
e-mail using the Problem Report. In the Problem Report AGM Automotive will request
corrective action. Corrective action updates will be required through out the containment
process.

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 Supplier Quality Manual
Containment Requirements
(continued)

Containment - Continued
If the supplier’s containment is ineffective and AGM Automotive receives defected
material after the breakpoint, or during the breakpoint requirement (including labeling)
are not met, a third party containment may be required. If this occurs the supplier will be
issued another Problem Report and their scorecard will be negatively impacted. The
presence of the third party sorting company does not relieve the supplier of Containment
Activities.

Early Launch Containment

New launches and product or process changes may require containment based on the
supplier readiness and the risk of the product. Requirement for Early Launch
Containment (ELC) will be communicated on the P.O. or by AGM Quality. To be
released from Early Launch Containment the following criteria must be met. You must
maintain containment through the pre established ELC date, 30 days or 3 lots of material
with zero defects.

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 Supplier Quality Manual

Cost Recovery
Cost Recovery Policy
Suppliers to AGM Automotive are liable for all costs incurred by AGM Automotive
during containment activities when the cause is the supplier responsibility. The “Cost
Recovery Report” will be submitted monthly to each supplier. The guide lines are
outlined as such:

External Cost Recovery: Charges incurred at an AGM Customer by an outside

sorting company and found to be the responsibility of the supplier will be charged back.
This cost is at the rate billed by the outside sorting company. In this case a cop y of the
invoice will be available upon request.

Internal Cost Recovery: When a sorting activity is performed at an AGM Plant by

AGM personnel a minimum charge of 50.00 per hour per person on the sort will apply.
The supplier will be charged for all rejected parts associated with the sort. Copies of the
sorting activities will be made available upon request.

Administrative Cost Recovery: Each Problem Report has an administrative charge

of $250.00 USD covering the collection of data and documentation and m anagement of
containment activities.

Non Responsive Cost Recovery: A Cost Recovery Charge may be assessed if

failure to submit an approved Corrective Action by the due date listed on the PR and a
new PR will be issued. The amount of this charge may vary based on severity of the
quality concern, the number of late Corrective Actions and the number of days late. To
avoid Non Responsive Cost Recovery plan to submit corrective Actions on time. You
can also avoid this charge if you contact AGM Quality requestin g additional time for
your Corrective Action. Non Responsiveness negatively impacts your Supplier Score
Card in the communication section.

EXAMPLES OF COSTS THAT CAN BE CHARGED BACK TO THE SUPPLIER:

- Rework / Repair (Supplier Fault)
- Premium Freight Costs including Air Charter, if required
- Overtime to Avoid Production Interruption
- Disposition of Scrap (Supplier Fault)
- Production Downtime for AGM and End Customer
- Sorting of Suspect Material In-House, at Customer Location or Third Party Warehouse
- On-Line Containment
- Outside Lab Testing
- Customer Returns including hourly charges,
- Receiving Inspection, Material Handling and Freight transportation
-on-site inspections associated with Scrap and Replacement Material
- Delays in Customer PPAP or other approvals
-Late submission of IMDS

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Supplier Quality Manual

Supplier PPAP
Documentation
Requirements

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 Supplier Quality Manual
PPAP Performance
PPAP On-Time Submission and Acceptability
PPAP approval is required for new product. AGM identifies the supplier PPAP
documentation requirements on the PPAP Request Form.

Occurrence Description
Late Submission
Unacceptable Paperwork
Missing Paperwork
Other:

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 Supplier Quality Manual
PPAP Requirements
All production suppliers are required to obtain full PPAP
approval from AGM Automotive per the current revision of
the requirements of the AIAG Production Part Approval
Process (PPAP) Manual and any additional requirements of
the AGM Automotive Supplier Requirements Manual.

➢ PPAP approval is required for new product. AGM

identifies the supplier PPAP documentation
requirements on the PPAP Request Form.

➢ PPAP approval is required for any changes to the

product and/or process,
including change in location or supplier.
All submissions are to be at Level 3 unless otherwise
specified in writing from AGM.

AGM may request an updated PPAP if the PPAP on

file is over one year old.

Annual validation testing is required to verify

continuing conformance on all parts and components,
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unless otherwise QF-SQR001 /
 Supplier Quality Manual
Documentation Links

Process
Flow
Design
FMEA
Process
FMEA
Control
Plan
Operator
Instructions

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 Supplier Quality Manual
PPAP Submission Request

SUPPLIER PPAP SUBMISSION REQUEST

QF-063
1000 E. Whitcomb Avenue
Madison Heights, MI 48071

PART #: SUBMISSION DUE DATE:

If submission is
PRINT REV. LEVEL:
NEW PART #: after the due date
(If Applicable)
PART NAME/DESCRIPTION: PPAP LEVEL REQUESTED:
the supplier will be
SAMPLE SIZE: issued a Quality
APPLICATION: Incident
QUALITY CONTACT:

TEL #: (248) 776-0600

FAX #: (248) 776-0601

SUPPLIER MANUFACTURING INFORMATION PPAP Submit to Information:

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 QF-07 7

Process Sign Off Check List

Supplier Program
Mfg Location Supplier Code
Part Number(s) Part Name(s)
Change Level PSO Date

Completed Document
Yes No
1 Part Number, Description and Change Level
Part Print
Any alerts or deviations

2 Design FMEA
DFMEA including AIAG checklist A-1

Process Sign Off Checklist

Supplier Quality Manual
3 Test Sample Sizes and Frequencies
DVP& R

4 Process FMEA
PFMEA including AIAG checklist A-7

5 Process Flow Diagram and Manufacturing Floor Plan

Process Flow Diagram
Facility Floor Plan
Cell Material Layout

6 Control Plan
Control Plan including AIAG checklist A-8

7 Quality Planning
Quality Org Chart w/Plant Responsible Personnel Highlighted
Risk analysis of subcomponent suppliers
Evidence of problem solving methods (e.g. Blank 8D form)

8 Incoming Material Qualif/Cert Plans

Certificate of analysis
Copies of sub-tier PSWs
Plan for lot control
Plan for lot tracebility

9 Parts Handling Plan

Nonconforming product procedure
Container maintenance plan
Routing/Traveler cards

10 Operating Instructions
Set-up Sheets
Operator Instructions
Gage Instructions
Rework/Repair Instructions
Evidence of operator training

11 Tooling, Equipment and Gages Identified

Tool List

12 Special Product/Process Characteristics Identified

List of SCs/CCs/KP Cs/KQCs

13 Process Monitoring
Control charts
1st piece approval procedure

14 Error and Mistake Proofing

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

15 Layered Process Audit Plan

Acceptable LPA plan with frequency and structure chart

16 Evidence of Product Specifications

Compliance Report Indentifying Charactersitics to be Checked during PSO

17 Line Speed Demonstration

Evidence of a production demonstration run (See PSO PDR log)
Evidence that the supplier can meet quoted capacity

18 Outgoing Material Qualif/Cert Plans

Outgoing inspection plan including early launch containment

19 Parts Packaging and Shipping Specifications

Shipping Procedure
Packaging Instructions
Final Dunnage Matrix
Copy of Shipping Label

20 Gage and Test Equipment Evaluation

Gage R&R
Calibration Records
Checking Fixture Layout

21 Preventative Maintenance Plans

PM Plans for all machinery

22 Initial Process Study

Cpk/Ppk or Control Charts from PDR (build pre PSO)
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 Supplier Quality Manual
Process Flow Requirements

QF-010

Product Program Issue Date ECL ECL

Supplier Name SUPPLIER Part Name NAME
Supplier Location CITY STATE Part Number NUMBER

Legend:
Operation Transportation Inspection Delay Storage

Operation or Event Description of Evaluation

Operation or Event and Analysis Methods

Develop and flow the

sequential work
activities or steps

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 Supplier Quality Manual
Process FMEA Requirements

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:

Item: Process Responsibility uto Prepared by:

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

Core Team: Date (Rev.)

C Potential O Current Current D
Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results
Step Failure Ef fect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P.
s r c Date v c t N.

Process Step - Manner in which Special product or process

Function and the process could characteristics
Number must be fail
same as the See AIAG
process flow severity
The effects of a
evaluation
failure mode as
criteria
perceived by the
List the requirements for customer
each process function

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 Supplier Quality Manual
Process FMEA Requirements
(cont.)

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:

Item: Process Responsibility uto Prepared by:

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

Core Team: Date (Rev.)

C Potential O Current Current D
Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results
Step Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P.
s r c Date v c t N.

Indication of how the See AIAG

failure could occur occurrence Description of
evaluation controls to identify
the cause of the
failure See AIAG
detection
eliminate the
cause of the
failure on
Description of controls to criteria
eliminate the cause of the
failure

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 Supplier Quality Manual
Process FMEA Requirements
(cont.)

POTENTIAL

FAILURE MODE AND EFFECTS ANALYSIS

Print # Rev. (PROCESS FMEA) FMEA Number:

Item: Process Responsibility uto Prepared by:

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

Core Team: Date (Rev.)

C Potential O Current Current D
Process Requirement Potential Potential S l Cause(s)/ c Process Process e R. Recommended Responsibility Action Results
Step Failure Effect(s) of e a Mechanism(s) c Controls Controls t P. Action(s) & Target Actions S O D R.
Function Mode Failure v s of Failure u Prevention Detection e N. Completion Taken e c e P.
s r c Date v c t N.

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

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

Name and organization

responsible and target and
completion date

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 Supplier Quality Manual
Control Plan Requirements

CONTROL PLAN
Protot ype Pre-La unch Produ ction
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
NUMBER ECL
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
NAME
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
SUPPLIER CODE
MACHINE,
CHARACTERISTICS METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD

Must be
same as the
process
flow and Must match
PFMEA print, FMEA
and process

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 Supplier Quality Manual
Control Plan Requirements
(cont.)

CONTROL PLAN
Protot ype Pre-La unch Production
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
NUMBER ECL
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
NAME
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
SUPPLIER CODE
MACHINE,
CHARACTERISTICS METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
NUMBER DESCRIPTION FOR MFG. NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. CONTROL PLAN
TOLERANCE TECHNIQUE METHOD

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 Supplier Quality Manual
First Article Inspection Documents
First
(Aerospace)
Along with the PPAP submission products for Aerospace must have the
completed First Article Inspection forms per the latest version of AS9102.

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 Supplier Quality Manual
First Article Inspection Documents
(Aerospace continued)
Along with the PPAP submission products for Aerospace must have the
completed First Article Inspection forms per the latest version of AS9102.

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 Supplier Quality Manual
Operator Instruction Example

Part No:
Description:
Customer:
Customer Part #:
Operation:

Revision: Approvals:
Rev. Level Date Quality Engineering Production

Procedure:
1 2 3 4

6 7 9

Describe the
Process Step

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 Supplier Quality Manual

Supplier Corrective
Action
Requirements

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 Supplier Quality Manual
8 – D Example
8-D Analysis
AGM AUTOMOTIVE, INC.
1000 E. W hitcomb Avenue
Madison Heights, MI 48071
Phone: 248-776-0600 Fax: 248-776-0601

Problem Status
Prog ram Na me: Part Num ber:
Dave Opened: Part Name:
Date Revise d: Customer:
Date Closed: Contact:
CCIR # RMA # :

8-D Report
D1. Form the Team (List team membe rs name and titles)

D2. Desc ribe the Problem (objec t, concern, qualification)

D3. Implemen t and Ve rify Inte rim Containment Actions (Co ntainmen t)

D4. Find an d Verify Ro ot Ca use

D5. Co rrective Actio ns

D6. Verify Co rrective Action

D7. Actions to Prevent Recu rrence of the Proble ms

D8. Co ngratulate the Tea m

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

35
 Supplier Quality Manual
3 x 5 Why Example
3 x 5 Why

Date:

Issue title:

Problem on part:

5 Why Corrective Action Owner Due Date

P1
Why did the planning process
not predict the defect?
P2

P3
Predict
P4
Planning process -
informational content P5
in FMEAs and CPs
P-RC

M1
Why did the manufacturing
process not prevent the defect?
M2

M3

Prevent M4

Manufacturing process -
standardized work and M5
error proofing

M-RC

Q1
Why did the quality process not
protect GM from the defect?
Q2

Q3

Prot ect Q4
Qualit y process -
cont ainment & Q5
Responsiveness

Q-RC

Based on the above 5 why C1

analysis, what are the common
system deficiencies? C2

C3

C4

C5

C-RC

36
 Supplier Quality Manual
Breakpoint Label
BREAK POINT NOTICE (REQUIRED ON EVERY BOX) QF-012

PART
NUMBER
SUBMITTED BY
1
QUANTITY
QI
NUMBER 2
REASON FOR CONTAINMENT

3
ATTENTION TO

4 6 7
BREAK POINT DATE

5
ENGINEERING CHANGE NOTICE
PART ECN
NUMBER NUMBER
SUBMITTED BY QUANTITY DETAIL OF CHANGE

ATTENTION TO

DRAWING LEVEL

SU PP LIER

8
USE FOR QUALITY INCIDENTS (Blue Paper)
1) PART NUMBER (number for which the Breakpoint is written)
2) QI NUMBER (quality incident number)
3) SUBMITTED BY (person who fills out break point label)
4) ATTENTION TO (whom the break point is directed to
5) BREAKPOINTE
(Material is
Certified)
 Supplier Quality Manual
Engineering Change Notice
Label
BREAK POINT NOTICE (REQUIRED ON EVERY BOX) QF-012

PART QI
NUMBER NUMBER
SUBMITTED BY QUANTITY REASON FOR CONTAINMENT

ATTENTION TO

BREAK POINT DATE

ENGINEERING CHANGE NOTICE

PART
NUMBER
SUBMITTED BY
1
QUANTITY
ECN
NUMBER 2
DETAIL OF CHANGE

3
ATTENTION TO
5 6
4 DRAWING LEVEL

SUPPLIER 7
8
Rev: Da te : 8 -01 -11

USE FOR ENGINEERING CHANGE

(Orange NOTICE
Paper)
1) PART NUMBER (number for which the Breakpoint is
written)
2) ECN NUMBER (quality incident number)
3) SUBMITTED BY (person who fills out break point
label)
4) ATTENTION TO (whom the break point is directed to)
5) QUANTITY (number of parts in box) 38
6 DETAIL OF CHANGE (what changed on the part