Tecumseh Products Company

Transcription

1 Tecumseh Products Company Supplier Quality Development Requirements SQD-9000 Original Issue: September 28,

2 Foreword Tecumseh Products Company is committed to continually improving its products and services to maintain our position as a world leader in our industry. An important part of this commitment is the development of a supply base capable of providing excellence in quality, value, delivery, technology, and service. SQD-9000 is the cornerstone of this development process. This Supplier Quality Development document was developed to communicate our requirements while maintaining consistency with our customer s requirements. Suggestions for improvements to this document are encouraged and should be directed to your Tecumseh Products Company Purchasing contact. Upon Supplier agreement to furnish production parts or services to Tecumseh Products Company (TPC), it is understood the supplier agrees to and understands the requirements set forth in the SQD-9000 document. Suppliers will be given preference based on achievement of quality system certification by an accredited thirty party registrar. Gregg Neumeyer VP Global Customer Quality Assurance Dave Reeves VP Procurement 2

3 Table of Contents 1.0 Introduction Goal Purpose Applicability Implementation Quality Systems Requirements Quality System Quality System Assessment Verification of Purchased Product General Requirements Approved Supplier List Request for Quotations Purchase Order Receipt & Verification (P.O.) Classification of Characteristics Statistical Process Control (SPC) Data Process Certification Material Certification Restricted Materials Regulatory Conformity (EPA/DOT/Safety) Packing Lists &Shipping Labels Lot Traceability Bar-Code Label Instruction Packaging Transportation FIFO Processing Requirement % On-Time Delivery Label Requirement Metal Bar Stock Suppliers Manufactured Component Production Process Suppliers (Heat Treat, Plating, Grinding, etc.) Nonconforming Material Nonconforming Material Prior Approval of Non-Conforming Product Nonconforming Material Reports (NMR) and Corrective Action Requests (CAR) NMRs and CARs Initial Response Corrective Action Response D Approach to Corrective Action Certified Product Escalation Process for Supplier of Nonconforming Material Expectation Escalation Process Escalation Process Steps for Repeat Nonconformance Part and Process Development Advanced Product Quality Planning Quality Planning Tools Production Part Approval Process (FAA/PPAP) Purpose PPAP Requirements When PPAP is Required PPAP Submission Level PPAP Level and Document Submission Requirement Where to Submit PPAP TPC PPAP Approval. 17 3

4 10.0 Supplier Rating System Supplier Rating Quality Rating Delivery Rating CAR Demerits Supplier Ranking Based on Supplier Rating Appendix C=0 SAMPLING PLAN BAR CODE LABEL INSTRUCTION NONCONFORMING MATERIAL (NMR) D Corrective Action Report (CAR) Level 1 Controlled Shipment Level 2 Controlled Shipment 31 4

5 1.0 Introduction: 1.1 Goal The goal for Supplier Quality Development SQD-9000 is supplier registration to ISO 9000 (2000) or TS (2002) by an accredited third-party certification body. Conformity with ISO 9001 (2000) is the first step in achieving this goal. The supplier is required to be registered to at least one of these standards or at least, in the beginning, have conformity to either one so long as it is confirmed by Tecumseh Products (No self-assessments will be accepted). 1.2 Purpose This document defines the fundamental quality system expectations of Tecumseh Products Company for external suppliers of production and service parts, components, services, and materials. The term supplier used in this document is synonymous with the term subcontractor as defined in the ISO 9000 (2000) or TS (2002) terms and definitions and refers to providers of production and service parts, components, services and materials directly to Tecumseh Products Company. 1.3 Applicability This system applies to all external suppliers of production and service parts, components, services and materials to any Tecumseh Products Company location. 1.4 Implementation Tecumseh Products Company requires that the supplier establish, document, and implement an effective quality system based on ISO 9000 (2000) or TS (2002). All applicable requirements of ISO 9000 (2000) or TS (2002) are to be incorporated in the supplier s quality system and described in the supplier s/subcontractor s quality manual. I ISO 9000 (2000) or TS (2002) is an input document for the development of a quality manual. ISO 9000 (2000) and TS (2002) is copyright protected property of the International Organization for Standardization, Geneva, Switzerland. ISO 9000 (2000)/TS (2002) was prepared by the International Automotive Task Force (IATC) and Japan Automobile Manufacturers Association, Inc. (JAMA), with support from ISO/TC, quality management and quality assurance. Only those third party certification bodies/registrars qualified for ISO 9000 (2000) or TS (2002) by the International Automotive Task Force (IATF) are permitted to issue a registration certificate with the term ISO 9000 (2000) or TS (2002). The related ISO 9000 (2000) or TS (2002) manuals are available from the Automotive Industry Action Group (248)

6 2.0 Quality System Requirements: 2.1 Quality System The supplier, as a fundamental principle in its quality system, shall: Establish, document, and implement an effective quality system, based upon compliance to all applicable elements of ISO 9000 (2000) OR TS (2002) Incorporate all requirements of Tecumseh Products Company s SQD-9000 into the supplier s quality system. Prepare a quality manual that addresses all requirements of ISO 9000 (2000) OR TS (2002). The manual must include or reference documented procedures to support the specified requirements within the quality manual. 2.2 Quality System Assessment Supplier quality system assessments to ISO 9000 (2000) or TS (2002) by an accredited third party certification body/registrar are the only acceptable method. If the supplier is ISO 9001 (2000), or TS (2002) certified, the supplier is required to send a copy of their registration certificate to the Tecumseh Products Company local Purchasing Office upon the issuance of a Tecumseh Products Company purchase order and at each recertification thereafter. If a change in the supplier s registration status occurs, the supplier shall notify the appropriate Tecumseh Products Company purchasing contact. Suppliers will be given preference based on achievement of quality system certification by an accredited thirty party registrar. 2.3 Verification of Purchased Product Tecumseh Products Company shall be afforded the right to verify at the supplier s premises that product conforms to specified requirements. This right shall also be afforded to Tecumseh Products Company s customers. The supplier shall not use such verification as evidence of effective control of quality. Verification by the customer shall not absolve the supplier of the responsibility to provide acceptable product/service, nor shall it preclude subsequent rejection by the customer. 3.0 General Requirements: 3.1 Approved Supplier List Production parts/materials/processes and services will only be purchased from suppliers on Tecumseh Products Company s "Approved Supplier" lists. Tecumseh Products Company evaluates and selects suppliers based upon their ability to supply product/services in accordance with the specified requirements. Requirements include an approved Confidentiality Agreement, pass a Supplier Capability Assessment, which will include a financial review, self-assessment or an on site audit if applicable. The self-assessment and on-site audit documents are available on line at the Tecumseh Products website. 3.2 Request for Quotations Engineering drawings, required specifications, expected annual quantities, delivery quantities, or other special requirements normally accompany a Request for Quotation (RFQ), or equivalent local document. The RFQ or equivalent local document must specify the material or services to be provided. Suppliers are encouraged to question any RFQ or equivalent local document they feel does not clearly describe all requirements and terms. 6

7 Quotations submitted to Tecumseh Products Company must include pricing for each quantity break specified, FOB/freight information, and any other anticipated costs to provide the product as requested. 3.3 Purchase Order Receipt & Verification (P.O.) The supplier shall verify all Purchase Orders (P.O.) issued by Tecumseh Products Company upon receipt. Any discrepancies in price, quantity, specifications, packaging, or delivery requirements must be communicated to and resolved with Tecumseh Products Company Purchasing before taking action on the purchase order. The supplier accepts responsibility for compliance with the current Tecumseh Products Company Purchase Order terms and conditions by accepting and acting upon the P.O. The current P.O. terms and conditions are specified on the back of the Tecumseh Products Company purchase order. 3.4 Classification of Characteristics Tecumseh Products Company classifies the characteristics on the blue print. Classification of characteristics is a method of assigning importance to each characteristic. The symbol on the drawing is representative of the seriousness Tecumseh Products places on the characteristic. When a Tecumseh Products Company customer special characteristic is shown on the drawing or referenced in the specification, the supplier is required to comply with the Tecumseh Products Company customer s requirement. It is the supplier s responsibility to understand all requirements shown on drawings or specifications. Please contact your TPC Purchasing contact if you do not understand the requirements. Associated Inspection Characteristic Symbol A.Q.L. Plan Category I % Category II.25 Control Plan Category III 1.0 Control Plan Category IV No Symbol N/A N/A The Categories are defined as follows: Category I - Any characteristic in which a nonconformance could result in an unreasonable risk of personal injury to one or more persons using, maintaining or depending on the product. Category II - Any characteristic in which a nonconformance could render the product unusable, reduce its usefulness, reduce its life, cause the product to be rejected by the customer or fail to meet government regulations or industry standards. Category III - A characteristic in which a nonconformance could cause internal failure (scrap, rework, added operations or reprocess) or cause significant downtime at subsequent operations. Category IV - A characteristic in which a nonconformance could not affect the usability of the product, be noticed by the customer or user, cause any reduction in reliability or life of the product, or result in any external or internal failure costs. 7

8 In Receiving Inspection, the inspector will utilize a C=0 sample plan and will check the category characteristics features as noted, to the associated (A.Q.L.) Accepted Quality Level that is utilized for each classification. See Appendix 11.1 C=0 Sampling Plan 3.5 Statistical Process Control (SPC) Data The supplier shall provide appropriate SPC data demonstrating statistical control of a capable process for each Category I, II and III feature as required in the FAA/PPAP. For these characteristics, SPC data verifying a minimum 1.67 C pk or 1.33 P pk acceptance level shall be furnished at any time upon request. 3.6 Process Certification The supplier has the responsibility to ensure that production processes supplied to Tecumseh Products Company are in compliance with all specifications shown on the drawing and/or purchase order Process certification containing actual measured results with a minimum 1.67 C pk or 1.33 P pk acceptance level must be maintained at the processing location and be made available upon request. 3.7 Material Certification The supplier is responsible to ensure that production materials supplied to Tecumseh Products Company are in compliance with all material specifications as shown on the drawing or purchase order. When requested on our P.O., material certification must accompany the shipment of product when delivered, unless otherwise arranged. Material Certifications must have lot test data attached specifically showing the specification requirements and results of the tested lots. Certifications must refer to the manufactures name and address, part number, lot number, manufacture date, results measured, signature and title of individual approving certificate, order number, and the name of the specification the product is being certified to. Copies of lab accreditation are required if materials are being tested and certified by commercial laboratories. Suppliers must maintain material certifications records for all product produced. 3.8 Restricted Materials Supplier of components and materials is responsible for ensuring that their supplied products do not conflict with Tecumseh Products Company s restricted materials list. If an issue is present, contact the Tecumseh Product Purchasing Department for approval prior to manufacture of parts. 3.9 Regulatory Conformity All supplied products or materials used in the supplier s process must comply with current governmental safety and environmental standards and laws regarding restricted, toxic, and hazardous materials. Hazardous materials must be marked clearly as such, and packaged appropriately. Compliance Certificate for Restriction of Hazardous Substances (RoHS), per Directive 2002/95/EC, must be provided for new items, prior to delivery of samples or production materials into the European market. An authorized third-party laboratory must provide the certificate. The supplier must provide further auditor certificates, upon Tecumseh Products Company request. 8

9 Material Safety Data Sheets (MSDS) must be provided for new items prior to delivery of samples or production materials. An updated version of the MSDS will be forwarded to Tecumseh Products Company whenever it is revised. If an MSDS sheet cannot be submitted, an Engineering Technical Data sheet must be submitted. The supplier shall have a form of documented compliance for this type of material on site, and make available upon request Packing Lists & Shipping Labels Packing lists must contain: Tecumseh Products Company s part number, manufacturer s part number, all lot numbers in the shipment with quantities per lot, P.O. number, number of cartons and quantity per carton and total quantity shipped, unless otherwise authorized in writing by the local purchasing entity. Shipping labels shall be formatted and located according to Tecumseh Products Company s standard label See Appendix 11.2 Bar Code Label Instruction. Labels must contain Tecumseh Products Company s part number, drawing revision level, part description, supplier number and location, manufacture date, number & quantities of lots, total quantity shipped, P.O. number and all requirements identified on the part drawing and specification Lot Traceability The supplier is responsible for maintaining lot traceability while the product is at the supplier s location. Lots are not to be mixed together Bar-Code Label Instruction Tecumseh Products will accept bar code labeling in accordance with AIAG (Automotive Industry Action Group) shipping/parts Identification Label Standard AIAG-B-3, unless otherwise authorized in writing by the local purchasing entity. See Appendix 11.2 Bar Code Label Instruction Packaging Transportation Weight per container must be limited to 40 pounds or less, unless otherwise authorized in writing by the local purchasing entity. Unless packaging and/or mode of transportation are specified, it is the responsibility of the supplier to determine the appropriate means to ensure product arrives on time and undamaged. Tecumseh Products Company works off the premise that the supplier knows their product and process best and should have the expertise necessary to determine the most appropriate packaging and transportation at the time of quotation. Unless otherwise specified, corrosive un-plated/un-painted metal components will be delivered with a light rust preventative coating. The protective coating shall be applied per TPC Spec H122 or approved local specification. The supplier is expected to ensure that product received at the Tecumseh facility is undamaged, uncontaminated, corrosion free and suitable for use FIFO Processing Requirement The supplier is responsible for utilizing the FIFO (first in, first out) concept when processing Tecumseh Products Company parts. This concept should be used for each part number processed. The lot traceability number is the number that each supplier shall use for following the FIFO concept. 9

10 % On-Time Delivery 100% on-time delivery is required of all suppliers. Appropriate planning information and purchase commitments to enable suppliers to meet this expectation, is provided by the Tecumseh Products Company Purchasing function. Subcontractor delivery performance is monitored and is an element of the supplier rating. Appropriate corrective actions are to be taken in the event of failure to meet delivery requirements. Deliveries are considered on time if the required product, as specified on the P.O. or release, is received on the due date or up to 2 days early. In some cases early delivery will not be accepted. The supplier will be notified in writing of that delivery requirement. Suppliers are expected to notify Tecumseh Products Company Purchasing prior to the due date whenever a delivery date will not be met. Applicable documents, such as packing lists, material certifications of conformance, certificates of analysis, material safety data sheets, etc., must arrive with or prior to receipt of the shipment 4.0 Label Requirements: Below are minimum label requirements. Additional label requirements from individual TPC business units may be required. 4.1 Metal Bar Stock Suppliers The minimum information to be shown on labels for bar stock is supplier s name, material type and grade and a supplier initiated unique traceability number that can be used to trace the material to its manufacturing process. 4.2 Manufactured Component Suppliers The minimum information to be shown on labels for component parts is the supplier s name, purchased part number and a supplier initiated unique traceability number that can be used to trace components to their manufacturing process and raw material used. Date Coding or Lot Coding can be used in lieu of traceability. 4.3 Production Process Suppliers (Heat Treat, Plating Grinding, etc.) It is the supplier s responsibility for marking the Lot Process Traveler label (tracking label) on each container of parts that passes in-process inspection. Preferably, this marking will be the operator s initials and the date. This label, when initialed, signifies accepted product. It also identifies the last process completed. If the parts have to be put in trays after the process has been completed, it is the responsibility of the supplier to transfer the information from the lot Process Traveler to a label attached to each pallet of trays. 5.0 Nonconforming Material: 5.1 Nonconforming Material In cases where nonconforming material is discovered at a Tecumseh Products Company or its customer, it is the supplier s responsibility to replace or 100% sort the nonconforming material at the supplier s expense and to reimburse Tecumseh Products Company for all associated costs incurred as a direct result of nonconforming product or service. There may be an additional defined cost per rejected lot of material to cover administrative costs. These costs generally run in the range of $ $ USD, but will be defined by the individual TPC organization. 10

11 Normally, rejected material will be returned to the supplier. If this is the case, the supplier will be issued a Debit Memo and will then the supplier will need to re-invoice Tecumseh Products Company once the material is re-shipped. The supplier can be charged for any and all costs that are incurred due to the receipt of non-conforming material. These costs include: rework, sorting, shipping, warranty, down time, freight, administrative costs, and customer charges. These costs are defined as shown below: Type 1: Sorting or Rework As a Separate Operation Under certain circumstances, it will be necessary for Tecumseh Products Company to sort product in-house so that scheduling requirements are not compromised. In such a circumstance, the sorting may take place at the supplier s expense. The charge for this sort or rework generally runs in the range of $ $50.00 USD per man-hour, but will be defined by the individual TPC organization. Type 2: Sorting Included With Packaging Under certain circumstances, it will be necessary for Tecumseh Products Company to sort for a defect as part of the normal packaging operations so that scheduling requirements are not compromised. In such a circumstance, the sorting may take place at the supplier s expense. The charge for this sort generally runs in the range of $ $ USD per lot, but will be defined by the individual TPC organization. Type 3: Sorting as Provided By a Third Party Under certain circumstances it will be necessary for Tecumseh Products Company to hire the services of a third party sorting company for sorting at its own facility or at a customer s facility. In such a circumstance, the cost of such sorting will be at the supplier s expense. Type 4: Cost of Nonconforming Material The total cost of nonconforming material sorted and scrapped from any particular lot will be charged to the supplier at the cost in the part up to that point. Type 5: Excess Freight The supplier will be held responsible for excess freight costs incurred because of supplier s lack of performance. This includes premium freight charges from the supplier facility to the receiving Tecumseh Products Company facility as well as any premium freight charges passed on by Tecumseh Products Company s customer. Type 6: Customer Warranty Claims If a non-conformity of a supplier s part is determined to be the root cause of a Tecumseh Products Company s customer warranty claim, all costs resulting from Tecumseh Products Company s customer warranty claims will be passed back to the responsible supplier. 11

12 5.2 Prior Approval of Non-Conforming Material In some rare cases, a supplier may need to make a delivery of material that contains nonconformities. If this occurs, the supplier shall formally request a deviation through the local Tecumseh Products Company purchasing department for that material prior to shipment. All material supplied under that deviation will be identified with the approved ECO (Engineering Change Order) Deviation number. If for some reason the ECO is rejected after Tecumseh Products Company receives the material, the non-conforming material will be returned to the supplier 6.0 Nonconforming Material Reports (NMR) and Corrective Action Requests (CARs) 6.1 NMRs and CARs Tecumseh Products Company uses the Nonconforming Material Report (NMR) and Corrective Action Request (CAR) system to communicate quality concerns to the supplier. (Nonconforming Material Reports may still be referred to as NCRs in some local organizations.) These quality concerns may originate at a TPC facility or from a customer concern. These documents are communicated electronically. 6.2 Initial Response Upon receiving an NMR See Appendix 11.3 NONCONFORMING MATERIAL (NMR), the supplier is required to respond within 24 hours. The initial response must include at a minimum: Nonconforming Report (NMR) number and problem description. If different than originally reported by issuing TPC organization: Name, Title, telephone and fax number for the individual with the responsibility to resolve the issue. Containment action initiated by the supplier to prevent additional product from affecting Tecumseh Products Company or its customer. This can include shipments in transit, supplier on-hand quantities, customer on-hand quantities, and consigned quantities. 6.3 Corrective Action Response Root Cause Analysis is integral to quality improvement, corrective action, and nonconformance elimination. The supplier shall submit a timely and effective corrective action response within 30 days of receipt of the CAR. Failure to respond to an NMR within the designated time could lead to the removal of the supplier from the Approved Supplier List. When additional time is required for completion of an investigation for root cause and implementation of corrective action the supplier may request an extension from the issuing Quality Manager. Under certain circumstances, which may be unique to the product, the issuing Quality Manager may grant additional time. The corrective action response must contain at a minimum: Problem Description. Containment Action including the Target and the Effective Date Root Cause of the problem 12

13 Escape Cause; how did this nonconformance go undetected within the supplier s Quality System Interim corrective action taken to eliminate the causes of the existing nonconformity or undesirable situation in order to prevent a reoccurrence, including Target and Effective Dates. Verification that corrective action resolves the existing nonconformity or undesirable situation and that it will not cause undesirable side effects, including control method used to ensure that interim corrective action remains in place until permanent action is in place. Permanent corrective action taken to eliminate the causes of the existing nonconformity or undesirable situation in order to prevent reoccurrence, including Target and Effective Dates. Verification that corrective action resolves the existing nonconformity or undesirable situation and that it will not cause undesirable side effects, including control method used to ensure that corrective action remains in place. Preventive action taken to eliminate the causes of potential nonconformity or other undesirable situation in order to prevent recurrence or occurrence in other similar product D Approach to Corrective Action The preferred format for responding to Corrective Action Requests is the 8D (8-Disciplined Steps) Approach described below. See Appendix D Corrective Action Report: 1. FORM TEAM: Establish a small group of people with the process/product knowledge, allocated time, authority, and skill in the required technical disciplines to solve the problem and implement corrective actions. 2. DESCRIBE THE PROBLEM: Define the out-of-specification condition and identify the specific operation that caused the defect. Identify in quantifiable terms (who, what, when, where, why, how many) for the problem. 3. CONTAINMENT ACTION: What actions were taken to contain suspect material from entering the customers process, i.e., recall of shipments in transit, supplier in-house stock, customer in-house stock, consignment stock. Include sorting results in all cases. List the immediate action taken to segregate, sort, control and identify all nonconforming materials. Provide the target and effective dates and identification method of first shipment of conforming material. 4. ROOT CAUSE: Identify all potential causes, which explain why the problem occurred. Isolate and verify the root cause by testing each potential cause against the problem description and test data. Identify alternative corrective actions to eliminate root cause. Include the ESCAPE CAUSE, identifying how the nonconformance escaped detection within the supplier s Quality system. 5. INTERIM ACTION, TARGET and EFFECTIVE DATE: List the interim action taken to correct or modify the identified process such as tooling/machining set up or instructional /procedural changes with implementation dates. Methods should include root cause analysis and FMEA review. PERMANENT ACTION, TARGET and EFFECTIVE DATE: List the permanent action taken to correct or modify the identified process such as tooling/machining set up or instructional /procedural changes with implementation dates. Methods should include root cause analysis and 13

14 FMEA review. If implementation dates are in excess of ten days, then indicate in response so future follow up and final closure can occur 6. VERIFICATION: Define current and revised inspection/operating processing procedures with documented results, which should include dimensional layout, and testing (if applicable) results. 7. PREVENTION: Identify action taken to eliminate the causes of potential nonconformity or other undesirable situation in order to prevent recurrence or occurrence in other similar product. This usually entails changing management systems, operating systems, practices, and/or procedures. Methods such as error proofing should be considered to assure conformance to specification. Include the CONTROL method, identifying the controls, such as; increased inspection at failed or similar/like operations, implementation of ongoing statistical controls and finished product audits. 8. SUPPLIER TEAM: Names of individuals who were instrumental in the solution(s). 6.5 Certified Product Upon receiving an NMR, all affected material awaiting shipment or that has been returned for rework or sorting shall: 1. Be 100% sorted and/or reworked, as applicable. 2. Label each container as CERTIFIED PRODUCT after the sort/rework has been done. 3. Identify the NMR number on the label 4. Identify what work was performed, i.e.: SORTED FOR (specify condition) REWORKED FOR (specify condition) Note: If trays are being used, identify the entire pallet of trays with several certified labels. 5. Indicate on the return shipper the NMR number and that it is certified product. 6. Certify, at a minimum, the next three (3) consecutive shipments to be defect free. This requirement may be altered by the receiving plant s Quality Manager or by a Supplier Quality Engineer Following is an example of the information to be on the CERTIFIED PRODUCT label: CERTIFIED PRODUCT NMR # XXXXXX 100% SORTED FOR (Specify condition, i.e., Nonconformity) Attention: Name of person at Customer 7.0 Escalation Process for Supplier of Nonconforming Material 7.1 Expectation Tecumseh Products Company requires suppliers to assure that all material, services, and processes are in conformance to all specifications and requirements and delivered within the defined delivery schedule. Repeated shipment of nonconforming material will invoke an escalation process designed to elevate management review and involvement to urgently identify and resolve the problem cause. 14

15 7.2 Escalation Process Tecumseh Products Company escalation process for repeated receipt of nonconforming material is initiated through the NMR process (See Section 6.0). A supplier failing to insulate Tecumseh Products Company from repeated nonconforming product or services will be subject to the escalation process, up to and including re-sourcing. 7.3 Escalation Process Steps for Repeat Nonconformance Step One: 1 st Nonconformance Nonconforming Material Report (NMR) is issued with a request for Corrective Action (CAR) (see Section 6.0) Step Two: 2 nd Repeat Nonconformance Level One Containment: Supplier implements 100% offline inspection. Tecumseh Products Plant Quality will initiate Level One activities by ing a Level One letter to the Supplier's Quality Manager. The letter will specify the non-compliance, required actions and exit criteria. See Appendix 11.4 Level 1 Controlled Shipment. The supplier will be required to fill out a Containment Confirmation reply and back to the Tecumseh Products initiator within 24 hours. Step Three: 3 rd Repeat Non-conformance Level Two Containment: Tecumseh Products considers Level Two Containment a serious breach in the supplier's quality management system. See Appendix 11.5 Level 2 Controlled Shipment. Level Two Containment may be imposed to mitigate the risk of receipt of further non-conforming material. Supplier contracts 100% third party certification (Level Two Containment) in addition to Level One Containment. Tecumseh Products will initiate Level 2 activities by phone call and confirm by ing a Level 2 letter to the Supplier's Quality Manager. The letter will specify the noncompliance, required actions and exit criteria. The supplier will be required to fill out a Containment Confirmation reply and back to Tecumseh Products initiator within 24 hours. Supplier will assume all cost for Level 2 Containment Step Four: 4 th Repeat Non-conformance Re-sourcing: If steps one through three in the escalation process are not sufficient to insulate Tecumseh Products from receiving nonconforming material, Tecumseh Products management may elect to re-source the job. This process is shown graphically is the following diagram SUPPLIER ESCALATION PROCESS LEVELS Increasing expectations and product restrictions. NMR 100% off-line Inspection Third party product Inspection & 100% Inspection Potential for Re-sourcing STEP 1 STEP 2 STEP 3 STEP 4 15

16 8.0 Part and Process Development 8.1 Advanced Product Quality Planning (APQP) Supplier shall use some form of systematic planning for new products/process changes. The preferred method is described in the Advanced Product Quality Planning and Control Plan reference manual available from AIAG. Other methods may be used if they achieve the same results. 8.2 Quality Planning Tools The following quality planning methods and documentation are required as a minimum for all production parts, materials and processes: Process Flow Chart Process Failure Mode and Effects Analysis (PFMEA) Control Plan Measurement System Analysis for all equipment listed in the control plan. 9.0 Production Part Approval Process (PPAP) 9.1 Purpose The purpose of the Production Part Approval Process is to determine if all customer specification and requirements are properly understood and validated with documentation. The process equally must have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. 9.2 PPAP Requirements The supplier shall comply with all requirements set forth in the latest release of the Production Part Approval Process (PPAP) reference manual available from AIAG. The AIAG website ( may be accessed for ordering the reference manual, if needed. Production part approval is granted for a part number, engineering change level, manufacturing location, material supplier(s) and production process environment. Changes to any of these require approval from the Tecumseh Products Company receiving facility prior to supplying production parts. Re-submission per PPAP may be required. The quality office of the Tecumseh Products Company facility receiving the product or service or a Supplier Quality Engineer are the approving authorities for PPAP submissions. 9.3 When PPAP is required The supplier should utilize a part approval process for their suppliers where applicable. Unless waived in writing, production part approval is always required prior to the first production shipment of product in the following situations. 1. A new part or product (i.e., a specific part, material, or process not previously supplied to the specific customer). 2. Correction of a discrepancy on a previously submitted part. 3. Product modified by an engineering change to design records, specifications, or materials. 4. Additionally, the supplier must notify Tecumseh Products Company and submit for part approval prior to the first production shipment in the following situations unless the responsible part approval activity has specifically waived in writing this requirement for the subject part. If a formal submission is waived, all items of the PPAP file must be reviewed and updated by the supplier, as necessary to reflect the current process. The 16

17 PPAP file must contain the name of the responsible part approval activity person granting the waiver and the date. a. Use of optional construction, material, or process than was used in the previously approved part. b. Production from new or modified tools (except perishable tools), dies, molds, patterns, etc., including additional or replacement tooling or equipment. c. Production following refurbishment or rearrangement of existing tooling or equipment d. Production following any change in process or methods of manufacture e. Production from tooling and equipment transferred to a different plant location or from an additional plant location. f. Change of source for subcontracted parts, materials or services (e.g.: heat-treating, plating, etc.). g. Product re-released after the tooling has been inactive for volume production for twelve months or more. h. Following a customer request to suspend shipment due to a supplier quality problem. IF THERE IS ANY QUESTION CONCERNING THE NEED FOR PRODUCTION PART APPROVAL, CONTACT THE Tecumseh Products Company PURCHASING DEPARTMENT. 9.4 PPAP Submission Level The Tecumseh Products Company receiving facility will identify the submission level that will be used with each supplier. Tecumseh Products Company s choice of levels for a supplier will be determined by such factors as supplier compliance to ISO 9000 (2000) OR TS (2002) requirements, supplier quality recognition status, part criticality, experience with prior part submissions, and the supplier s expertise with the specific commodity. Default submission level is AIAG Level 3, unless otherwise communicated to the supplier by the receiving facility or facilities Quality Manager(s) and Supplier Quality Engineer. 9.5 PPAP Level and Document Submission Requirement Submit the following documents to Tecumseh Products Company s Receiving facility at the requested level: Level 1 Warrant only Level 2 Warrant, Parts, Drawings, Inspection Results, Laboratory and Performance Results Level 3 Warrant, Parts, Drawings, Inspection Results, Laboratory and Performance Results, Product Capability Results, Process Flow Chart, PFMEA, Control Plan, and Measurement System Studies Level 4 Per Level 3, but without parts Level 5 Review at supplier location: Warrant, Parts, Drawings, Inspection Results, Laboratory and Performance Results, Process Capability Results, Process Flow Chart, PFMEA, Control Plan and Measurement System Studies. 9.6 Where to Submit PPAP Unless otherwise notified, the supplier shall submit PPAP to the quality office of the Tecumseh Products Company facility that will receive the product shipment. 9.7 TPC PPAP Approval The supplier must receive Tecumseh Products Company s approval prior to shipping production product. The Quality Assurance Manager at the Tecumseh Products Company 17

18 receiving facility or a Supplier Quality Engineer is the approving authority for PPAP submissions. Simply receiving a material release or a purchase order does not constitute PPAP approval nor does it imply authorization to ship product without PPAP approval Supplier Rating System 10.1 Supplier Rating The supplier rating is based on quality, delivery, cost reduction, and responsiveness to customer concerns. The supplier rating (SR) is calculated as 70% of the Quality Rating (QR) plus 30% of the Delivery Rating (DR) less CAR demerits. The formula for determining the Supplier Rating is shown as follows: SR = 0.7 x QR x DR CAR demerits 10.2 Quality Rating Quality Rating = 50 x (.02 qty rejected/total qty received) x 100 No points awarded if rejection rate is above 2% (20,000 PPM) 100 points max Delivery Rating Delivery Rating = quantity received on time/total quantity received x points max CAR Demerits The Supplier Rating will be reduced by subtracting Corrective Action Response (CAR) demerits per the following table. Demerits are carried over each month until an acceptable Corrective Action is received. These demerits will apply for each outstanding late Corrective Action Response Demerits Late<=10 days 1 <= 20 days 3 <= 30 days 5 <= 45 days 7 <= 60 days 9 Over 60 days 10 A Corrective Action may be rejected if it does not appear that it effectively addresses the root cause, permanent action, valid verification methods, or positive preventive action Supplier Ranking Based on Supplier Rating: Overall Supplier Ranking, where as each supplier s overall Time Period Total (TPT) SR, is compared against each other supplier s TPT SR, for a defined time period of 1-month, up to 12-month history. The Supplier Ranking Number is a number from 1 to the total number of suppliers in the Time Period, ranking each supplier based upon their collective TPT SR value, and reported out as either Top 10 Worst Suppliers, or Top 10 Best Suppliers. 18

19 11.0 Appendix 11.1 C=0 SAMPLING PLAN (Table No. 1) C=0 SAMPLING PLAN TABLE NO. 1 REVISION B CATEGORY CHAR. I II III IV ASSOCIATED AQLS LOT SIZE S A M P L E S I Z E 2 TO 8 * * * * * * * * * * * * TO 15 * * * * * * * * * * TO 25 * * * * * * * * * TO 50 * * * * * * * * TO 90 * * * * * * TO 150 * * * * * TO 280 * * * * TO 500 * * * TO 1200 * TO TO 10, ,000 TO 35, , 000 TO 150, , 000 TO 500, ,000 TO OVER * INDICATES ENTIRE LOT MUST BE INSPECTED NOTE: THE ACCEPTANCE NUMBER IN ALL CASES IS ZERO. EXPLANATION 1). IN THE LEFT HAND COLUMN, FIND THE SIZE OF THE LOT WHICH IS TO BE INSPECTED. 2). FIND THE COLUMN FOR THE APPROPRIATE CATEGORY CHARACTERISTICS (SHOWN IN THE TOP ROW). 3). THE SIZE OF THE SAMPLE TO BE INSPECTED IS FOUND AT THE INTERSECTION OF THE LOT SIZE ROW AND THE CATEGORY CHARACTERISTIC COLUMN. 4). IF AN "*" IS FOUND, THE ENTIRE LOT MUST BE INSPECTED. 5). RANDOMLY SELECT THE SAMPLE AND INSPECT THEM FOR EACH CHARACTERISTIC. 6). IF ANY NONCONFORMANCE IS FOUND IN THE SAMPLE, REJECT THE ENTIRE LOT. 7). SAMPLE PLAN FOR MULTIPLE PACK SHIPMENTS Number of Containers Sample Size More 8 19

20 11.2 BAR CODE LABEL INSTRUCTION Tecumseh Products Company will accept bar code labeling in accordance with AIAG (Automotive Industry Action Group) Shipping/Parts Identification Label Standard AIAG-B-3. DEFINITIONS: Part Label: A label used to identify the contents of an individual shipping pack. Each container, whether expandable or returnable, requires a minimum of two Part Labels. Master Label: A label used to identify and summarize the total contents of the same part number in a multiple pack. A multiple pack (Pallet, Trailer, etc.) is a pack containing more than one individual shipping container of the same part number or different part numbers. Mixed Load Identifier: A Label used to identify mixed part numbers in a multiple pack or pallet. LABEL CHARACTERISTICS: Label Height Width Part 4.0 (102 mm) 6.0 (152 mm) Master 6.0 (152 mm) 8.0 (203 mm) Mixed Load 4.0 (102 mm) 6.0 (152 mm) Quality: Symbology: Material: Label Protection: Labels are to be wrinkle free and durable to ensure readability at destination. A sample label must be tested to ensure accuracy of readability, print contrast and all other specifications prior to use. Bar codes must be 3 of 9 (Code39) type and conform to the AIAG Standard. Labels can be pressure sensitive or dry gummed type. Adherence to the package must be ensured. Labels must be protected against moisture, weathering, and abrasion. Laminates, sprays, window envelopes and clear plastic pouches are examples of possible protection methods. In selecting a protection method, care must be taken to ensure that labels meet reflectivity and contrast requirements and can be scanned with contact and noncontact devices. PART LABEL AND LOCATION: Part labels are required on adjacent corners of each shipping container as illustrated. The label must be parallel to the container base. If parts are shipped in returnable containers that cannot be labeled, tags are to be used. The serial numbers of the two labels on a container must be the same. There is only one unique serial number per container. 20

21 PART LABEL AND LOCATION: SINGLE CARTONS Part labels are to be located on two adjacent sides. A wrap around label is acceptable. CARTON ON A PALLET Part labels are required on each carton as shown below. Master label and Mixed Load ID is required on each pallet. Must be placed on the most visible area of the pack. DRUMS OR BARRELS BASKETS Part Labels are required on two sides, or a attached to side and top of the container. HIGH-BOYS, WIRE Part Labels are to be adjacent sides of container. PALLET BOX/GAYLORD Labels are to be attached to adjacent side of container. Labels are to be attached to adjacent side of container. One label must be attached to the bottom half of the container. METAL BIN OR TUB 21

22 PART LABEL SAMPLE: Data Identifier Code The first position, after the start code of the bar code symbol must be used to identify the information to follow. This character is not to be included in the human readable line, but must be shown in human readable characters under the title for the appropriate data area. Identification Manufacturer (AIM) and listed in US National Identifier Standard ANSI/FACT-1. (1) Part Number (P) This is the part number as assigned by Tecumseh Products Company. The human readable characters and bar code symbols must be a minimum of 0.5 in. (13mm). The maximum character allowance for part field is character for the data identifier P. (2) Quantity (Q) The unit of measure is number of pieces. If the unit of measure is not pieces, (e.g. gallons, pounds, etc.), it must be noted in human readable characters to the right of the human readable quantity. The unit of measure is NOT to be included in the bar code. Human readable characters and bar code symbols must be a minimum if 0.5 in. (13 mm) high. The maximum characters allowance for the quantity number field is characters for the data identifier Q. (3) Purchase Order number (K) This is the purchase order number assigned by Tecumseh Products Company. Supplier must use only current purchase order numbers. The human readable characters must be a minimum of 0.3 in. (8mm) high. The bar code symbol must be a minimum of 0.5 in. (13mm) high. The maximum character allowance for the purchase order field is 6 characters + 1 character for the data identifier K. 22

23 (4) Supplier number (V) This is the vendor no. (Supplier code) assigned by Tecumseh Products Company. The maximum characters allowance for the supplier number is 5 characters + 1 character for the data identifier V. (5) Revision level This is the drawing revision assigned by Tecumseh Products Company, which is usually a letter, in human readable characters only. It cannot be left blank. The human readable characters must be a minimum of 0.2 in. (5mm) high. (6) Serial Number (S) The serial number is a unique number for both the Part and master Label assigned by the supplier for each shipping container (e.g. carton, pallet, box, etc.) having identification labels. Serial numbers cannot be duplicated with the calendar year for the same supplier number. The human readable characters must be a minimum of 0.2 in. (5mm) high. The bar code symbol must be a minimum of 0.5 in. (13mm) high. The maximum character allowance for the serial number field is 9 characters + 1 character for the data identifier S. (7) Supplier Location Supplier name, country of origin, city, state (or province) and postal code must be shown in the lower left hand corner of the bar code label. Character size is 0.1 in. (2.5 mm) high. (8) Description This is the product description specified on the part print in human readable characters only. Minimum character size is 0.2 in. (5mm) high. (9) Manufacture Date and Lot Number The manufacture date and manufacture lot of final production or assembly of all the parts in the container in human readable characters only. Minimum character size is 0.2 in (5mm) high. 23

24 PART MASTER LABEL SAMPLE: The Master Label Contents must conform to the same specifications as the Part label content specified in Section II-B above. All pallets containing multiple containers or cartons of the same or different part numbers require a Master Label for each part number. The only exception would be one container on a pallet such as a Gaylord. 1. The heading MASTER LABEL must be printed in bold 1.0 in. (25mm) high letters. Recommended label size is 6.0 in (152mm) high by 8.0 in (203mm) wide. (An optional label size of 4.0 in high by 6.0 in wide can be used if all required information is contained in the label and is identified by the words MASTER LABEL). 2. The Data Identifier for the serial number of a Master Label is M. 3. S Unique Tracking Serial Number Master Label, like items. 4. The maximum character allowance for the serial number field is 9 characters for the data identifier S. 5. The serial number is a unique number for both the Part and Master Label assigned by the supplier for each shipping container (e.g. carton, pallet, box, etc.) having identification labels. Serial numbers cannot be duplicated within the calendar year for the same supplier number. The human readable characters must be a minimum of 0.2 in. (5mm) high. The bar code symbol must be a minimum of 0.5 in. (13mm) high. 6. Placement of Master Label will be determined by the type of shipment see diagram. 7. The Master Label quantity must be the total quantity for each part number on a pallet. 8. Mixed Load Labels are required, in addition to Part Labels and Master Labels, when there is more than one part number on the same multiple pack. This label is shown below with bold 1.0 in. (25mm) high letters. 24