SUPPLIER QUALITY MANAGEMENT SPECIFICATION MANUAL

Transcription

1 SUPPLIER QUALITY MANAGEMENT SPECIFICATION MANUAL 1. PURPOSE SCM 502 Issued: 02/20/06 Revision: 20 Page: 1 of 12 DISTRIBUTOR QUALITY MANAGEMENT SYSTEM REQUIREMENTS 1.1 This specification stipulates the quality management system requirements where it is necessary for organizations supplying products and materials to Howmet Castings to demonstrate conformity to contractual requirements Assurance of product quality is most significant in Howmet's contractual duties, consequently there must be adequate controls at all levels of procurement and throughout the entire supply chain. The type of product(s) or material(s) offered shall determine the extent of the structure of the organization s system. However, the quality management system must be able to demonstrate product and material conformity through effective management and diligence. 2. SCOPE 2.1 General The requirements of this document apply to all Howmet Castings purchases of products and services when so stipulated in a Howmet Castings purchase order. If the Howmet Castings purchase order requirements differ from those defined herein, the purchase order requirements shall prevail. 2.2 Application All requirements of this specification are generic and are intended to be applicable to all organizations doing business with Howmet Castings, regardless of type, size and product provided. Any exclusions and/or exceptions to these stipulated requirements must be formally presented to and accepted by the purchasing Howmet Castings facility. Requirements that cannot be applied due to the nature of an organization and its product will be considered for exclusion, providing such exclusions do not affect the organization s ability, or responsibility, to provide products and materials that meet Howmet Castings and regulatory requirements. 3. REFERENCE DOCUMENTS 3.1 ISO 9001, Quality management systems-requirements; SAE AS9100, Quality Systems Aerospace - Model for Quality Assurance in Design, Production, Installation and Servicing. 3.2 Zero Acceptance Number Sampling Plans by Nicholas L. Squeglia. Ø 3.3 Howmet Supplier Quality Management Policy and Procedures Manual 4. REQUIREMENTS 4.1 Quality Management System

2 Page 2 of 12 The organization shall establish, document, implement and maintain an effective quality management system as a means of ensuring product and material conform to contractually specified requirements. The system shall be demonstrative of process control techniques and encompass economical preventive methods, which assure consistent performance and continual improvement. The system shall provide for control and identification of product and material throughout the supply chain. It shall provide for prevention and timely detection of nonconformities. It shall encompass timely evaluations and analysis of information, which ensure the continued effectiveness of the quality management system; inventory management, repackaging and equipment decontamination processes Documentation Requirements The quality management system documentation shall include: a) Quality manual, when the size of the organization necessitates formalizing and publishing policies and procedures to ensure consistency of objectives and procedural guidance throughout the organization; b) Inventory management, repackaging and equipment decontamination process instructions, which ensure effective planning, operation, and control, where necessary; c) Quality records required of this specification (refer to paragraph 4.11, Control of Quality Records). Note: Howmet Castings reserves the right to determine the level of documentation of the quality management system, which includes but is not limited to, documentation listed in 4.1.1a, b & c. Documentation may be in any form or type of medium. 4.2 Quality Management System Administration The organization shall have on staff, a competent individual, technically qualified and administratively capable of establishing, documenting, implementing and maintaining an effective quality management system. This individual, irrespective of other responsibilities, shall have defined responsibility and authority to carry out these activities. 4.3 Quality Management System Surveillance Organizations supplying products and materials to Howmet Castings shall be subject to periodic quality management system surveillance and appraisals to ascertain the level of competency of the company to provide the desired quality. The appraisal may take the form of a self-assessment, in which a representative of your company will be requested to perform the appraisal by completing and returning quality management system and manufacturing process assessment questionnaire(s). The self-assessment appraisal may also be followed by an on-site visit in which a representative of your company will be contacted to arrange for the appraisal by a Howmet Castings or Howmet Castings contracted third party assessor. The type of appraisal and frequency shall be determined by Howmet Castings and is dependent on the products and materials provided. These appraisals shall be conducted every two years. However, Howmet Castings reserves the

3 Page 3 of 12 right to increase, decrease or waive surveillance, based on performance and third-party (i.e., ISO, Nadcap, etc.) accreditations. A failure to comply with these Howmet Castings conditions of surveillance will result in disqualification and loss of business Right of Access Howmet Castings, its customers and regulatory agencies shall be afforded the right of access to all facilities involved in the contract, and all applicable quality records within the scope of the contracted work, not withstanding ITAR and Export License requirements, to determine and verify the quality of purchased product and material. Such verification shall not be used by the organization as evidence of effective control of quality by the organization, nor shall it preclude subsequent rejection by Howmet Castings or it s customers. This surveillance does not absolve the organization or it s sources of responsibility to provide acceptable product(s) and materials Performance Reviews All active and approved organizations supplying products, materials and services that directly influence the quality of Howmet manufactured products are subject to periodic performance reviews. Performance review reports will be issued on a quarterly basis to organizations with purchase activity during the quarter being rated. Organizations with less than adequate performance will be required to take immediate corrective / preventive action. Organizations are responsible for monitoring the performance of their product and material sources and for taking timely corrective / preventive actions. A failure to adequately address Howmet Castings performance issues in a timely manner will result in disqualification and loss of business. Details on performance measurement criteria may be viewed on Howmet s Internet website at: Purchase Order / Contract Review The organization shall review each Howmet Castings purchase order to determine their ability to meet Howmet s stipulated contractual requirements. This review shall be conducted prior to the organization s commitment to supply product and/or services to a Howmet Castings facility. Reviews shall include subsequent changes, amendments to contracts or orders. Any contract or order requirements differing from those previously expressed shall be formally resolved with the procuring Howmet Castings facility procurement representative. The contract review process shall include the review of all technical and quality documents stipulated within the body of the Howmet Castings purchase order. Where product or material requirements are changed, the organization shall ensure that all relevant documents are amended and all relevant personnel and product or material sources have been appraised of the changed requirements.

4 Page 4 of 12 When the Howmet Castings purchase order does not provide a documented statement of requirement, the organization shall confirm the lack of quality and/or technical requirements with the Howmet Castings purchasing representative, prior to acceptance of the purchase order Records of the results of the purchase order, technical and quality documents review and actions arising from each review shall be maintained in accordance with paragraph 4.11, Control of Quality Records. 4.5 Infrastructure Prior to the initiation of any work, the organization shall determine, provide and maintain the infrastructure needed to achieve conformity to product requirements This shall include but is not limited to management of inventory, repackaging processes and equipment, equipment cleansing and decontamination, and related personnel skills and controls necessary for assuring conformity to product requirements. 4.6 Planning The organization shall ensure all purchase order requirements, including technical and quality requirements have been properly translated and accounted for, including sub-tier purchase orders, repackaging, inventory management (FIFO, temperature, light and date sensitive products) and equipment cleansing and decontamination where product conformity requirements may be affected. Planning activities shall consider the need to establish processes, instructions and provide resources to support the purchase and management of product and materials to meet customer expectations. The product planning shall encompass verification, validation, monitoring, inspection and test activities specific to the product and criteria for acceptance. Emphasis shall be placed on controlling the supply chain to preclude receipt of nonconformities. 4.7 Control of Documents and Configuration Management As a supplier to Howmet Castings, your organization is responsible for the timely review, incorporation, and maintenance of all current drawings, standards, specifications, planning and changes. Your organization is also responsible for flow down of applicable Howmet technical and quality documents and requirements to manufacturing sources, when product and material conformity requirements are affected. The organization is required to control all documents and data and ensure incorporation of current revisions, or incorporation of purchase order stipulated document revisions, as applicable. Your organization must prevent use of obsolete documents and ensure they are suitably identified, if retained. This requirement is applicable to all types of media such as hard copy or electronic media. The purchasing Howmet facility procurement representative will forward with the purchase order, copies of all purchase order stipulated documents, with the following exceptions: Copies of Howmet Castings SCM specifications (*), and Industry and Military Standard specifications will not be provided with purchase orders.

5 Page 5 of 12 * SCM specifications may be obtained from Howmet s Internet website at If your organization is unable to obtain these documents from the website, contact the Howmet procurement representative, listed on the purchase order, to obtain a copy of the current revision of the applicable specification(s). The organization is responsible for compliance to the current revision level of the purchase order stipulated SCM specification(s). The latest revision of the purchase order stipulated SCM specification(s) must be incorporated within 30 days from the Issued date of the specification(s) Contractually provided technical data, electronic or otherwise, may be subject to ITAR (International Traffic in Arms Regulations) or EAR (Export Administration Regulations) export restrictions, including export license requirements for any foreign national employee(s), temporary hire, or consultant. As a supplier to Howmet Castings, your organization is responsible for obtaining all necessary ITAR or EAR export approvals and for maintaining compliance with all export control requirements. If you are unsure if this provision applies, contact your Howmet Castings Procurement representative and Export Liaison representative All Howmet customer documents and/or technical data, electronic or otherwise, furnished by Howmet Castings as a provision of the purchase order shall be returned to the appropriate Howmet Castings facility upon completion or termination of the purchase order or at the purchaser s discretion The organization must incorporate the appropriate revision level of Howmet technical specification(s), stipulated in the Howmet purchase order, within 30 days from the Issued date of the related Table of Contents in which the specification(s) is listed. All product and material arriving at the Howmet Castings purchasing facility, immediately following incorporation of the specification and the organization/howmet Castings agreed upon effectivity date, must be configured to the appropriate specification revision level. The organization shall ensure all product or material is properly configured to and in compliance with the revision level of the applicable technical specification stipulated in the Howmet purchase order, or the current revision level stipulated in the related Table of Contents, which is listed and available at: as applicable. The organization shall default to the appropriate technical specification Table of Contents to determine the current specification revision level, when the purchase order technical specification(s) does not list a revision level. Improperly configured product and material is subject to immediate rejection and return, unless formally authorized by the Howmet Castings purchasing facility in accordance with paragraph 4.10, Control of Nonconforming Product.

6 Page 6 of Warehouse, Reprocessing and Source Traceability Control Distributors of raw material(s), processed material(s), or product(s) accepted by Howmet Castings shall ensure lot or batch number designation integrity and provide traceability to the manufacturing source at all times under all conditions. The method by which this is accomplished shall be formally documented, and the system of records utilized by the organization shall ensure reliable traceability of all such product or material to the manufacturing source(s) Process Changes, Product or Source Substitutions Subsequent to the acceptance of samples/prototypes, as applicable, and/or as contractually prescribed, the organization shall not make any significant changes * to the reprocessing cycle, substitute product or material(s), or change sources without notifying the purchaser (refer to Section 4.13, Organization Procurement Control). * A process or process sequence that if changed could affect design intent; may affect material structure, mechanical and/or chemical properties and cannot normally be evaluated without destructive testing Material Control The, distributor and/or manufacturer, as applicable, shall: a) notify Howmet Corporate Procurement, Quality Assurance (1600 South Warner Street, Whitehall, MI ) and the Howmet plant Procurement representative of any change in process materials critical to the chemical and physical characteristics of the applicable product; b) notify Howmet Procurement Quality Assurance and the Howmet plant Procurement representative prior to making changes in a process that may affect the chemical or physical characteristics of the product; changes in product verification sampling and test methods also shall be advised; c) notify Howmet Technical Services (1500 S. Warner St., Whitehall, MI ) and the Howmet plant Procurement representative of any known technical problem with the product, including a problem detected after product has been shipped to Howmet (reference paragraph 4.10.l, Customer Notification of Escapes) Reprocessing operations on Howmet Castings products or materials are not to be subcontracted, without prior written approval from the purchasing Howmet Castings facility. 4.9 Control of Inspection, Measurement and Test Equipment The organization shall control, calibrate and maintain metering devices, weigh scales, instrumentation and test equipment, as applicable, to the extent necessary to ensure product/material quality, volume and weight. All calibrations shall be traceable to NIST (National Institute of Standards and Technology) or other internationally recognized standards bodies. When this type of

7 Page 7 of 12 traceability is not possible, then a Standardized Laboratory Method or Consensus Standard may be used, providing the purchasing Howmet Castings facility is in concurrence Control of Nonconforming Product and Material The organization shall establish and maintain documented procedures to ensure that product that does not conform to specified requirements is prevented from unintended use, installation or shipment. This includes any customer-returned nonconforming product or material. This control shall provide for identification, documentation, evaluation and segregation (when practical). The organization shall not ship any nonconforming product or material without first submitting a Suppliers Discrepancy Action Request (SDAR) concession for review and approval by the Howmet purchasing facility. The use of an alternative method, to the methods described herein, must be formally approved by the procuring Howmet Castings facility Quality Assurance organization. a) All organizations doing business with Howmet Castings facilities, other than Howmet Prime Operations, Whitehall, MI., shall utilize procedure SCM 505, Supplier Discrepant Material, for an SDAR concession submittal. b) All organizations doing business with Howmet Prime Operations shall utilize procedure SCM 508, Howmet Prime Operations Supplier Discrepancy Action Request). A copy of the purchaser-approved SDAR concession form must accompany each affected shipment; the SDAR number and quantity affected must be referenced on the shipping invoice. A copy of SCM 505 or SCM 508, as applicable, is available from the Howmet Internet website at: Customer Notification of Escapes The organization shall promptly notify the appropriate Howmet facility(s) if it is suspected that deviant / noncompliant product has been unintentionally * or intentionally ** shipped to a Howmet facility, or other designated location as specified by the Howmet purchase order. * Unintentional is defined as being attributable to a weakness in the operating or quality management system. ** Intentional is defined as one or more employees having knowledge of a product, process or system that was not meeting customer requirements and no formal corrective action was taken despite knowing non-compliant product was being generated. Disclosure Investigation and Reporting Process a) Investigate to understand the nonconformance(s) b) Determine magnitude and impact of problem c) Explore potential for related issue on similar product(s)

8 Page 8 of 12 d) Determine the immediate actions required, establish a containment plan and respond quickly and concisely e) Immediately notify the Quality Assurance Manager of the affected Howmet Castings facility(s), providing the utmost information f) Investigate to determine root cause g) Determine magnitude of corrective action required (product process system) h) Verify corrective action(s) taken has eliminated the root cause i) Provide Disclosure Report, detailing items a - h Note: Nonconforming product submitted to the procuring Howmet Castings facility and formally approved for shipment through the established SDAR system is excluded from this requirement Records of the nature of nonconformities and any subsequent actions taken, including SDAR s, shall be maintained in accordance with paragraph 4.11, Control of Quality Records Control of Quality Records Quality records shall be maintained to demonstrate conformance to specified requirements and effective operation of the quality system. Pertinent subcontractor s quality records shall be an element of this data. Documented procedures shall exist for identification, collection, indexing, access, filing, storage maintenance and disposition (disposal) of quality records. Records may be in the form of any type of media, such as hard copy or electronic media. Record retention periods shall be established and documented. The organization shall maintain all quality records in accordance with this requirement, unless the purchase order contractually stipulates quality records be returned to the purchasing Howmet Castings facility at time of each product shipment All quality records must be legible, completed in ink and must be stored and retained in such a way that they are readily retrievable within 24 hours. They shall be stored in facilities that provide a suitable environment to prevent damage or deterioration and to prevent loss (protected from water, rodent damage, etc.). Howmet Castings, Howmet s customers and regulatory agencies reserve the right to request quality records for evaluation, within the scope of the contracted work, not withstanding ITAR and Export License requirements Part, material, product, service and related tooling records, purchase orders and amendments are to be maintained for the length of time that the contract is active plus one calendar year. Quality performance records (e.g., control charts, inspection and test results, nonconformance actions, etc.) shall be retained for one calendar year after the year in which they were created unless otherwise specified in the contract.

9 Page 9 of 12 Records of internal quality system audits shall be retained for three calendar years unless otherwise stated in the contract. Government record retention requirements shall take precedence over this requirement, as applicable. Howmet Castings customer record retention requirements when so stipulated in the Howmet purchase order shall take precedence over this requirement Handling, Storage, Packaging, Preservation and Delivery The organization shall establish and maintain documented procedures for handling, storage, packaging, preservation and delivery of product. These procedures shall cover specific requirements for the cleaning and maintenance of storage terminals; tankers; returnable and reusable drums, containers, bins, etc.; material and product transfer systems to include pumping equipment and hoses. The procedures shall also cover the use of designated storage areas, stock rooms, tanks and bins, contamination prevention and detection, special handling and storage of temperature, light and date sensitive products, identification marking and labeling including safety warnings, lot traceability identification and control, shelf life control and stock rotation, and hazardous material Product Labeling and Identification All drums, bulk containers or palletized materials shall be properly identified to include as applicable: The Product nomenclature; Name of manufacturer; Commercial and/or Howmet specification product designation identification; Lot or Batch designation numbers; Safety and/or hazardous material warning labels and Material Safety Data Sheets; Gross and tare or net weight and handling instructions; Shelf life expiration date; and any special storage / preservation, stock rotation or stacking limitation instructions or warnings. Individual product or material packaging or bagging shall be properly identified to include as applicable: The Name of manufacturer; product nomenclature; Commercial and/or Howmet specification product designation identification; Lot or Batch designation number; Gross and tare or net weight, and shelf life expiration date. This information, including the shelf life expiration date, shall be clearly visible to the end user. Limited shelf-life products being shipped to Howmet Logistics Services, LaPorte, IN and Howmet Normandy Casting, Dives sur Mer, France shall not exceed twenty percent (20%) of the manufacturer's shelf life expiration date. Limited shelf-life products being shipped to all other Howmet Castings facilities shall not exceed twenty-five percent (25%) of the manufacturer's shelf life expiration date. All deviations to this requirement must be formally authorized by the purchasing facility quality assurance department in accordance with Section 4.10 of this specification Handling

10 Page 10 of 12 The organization shall package, drum, crate, palletize and containerize product and material in a manner consistent with recognized safe practices. All product and material shipped to Howmet Castings must be capable of being handled using conventional material handling apparatus. Product and material shall not be packaged in drums, pallets, crates or containers necessitating special or unconventional material handling apparatus unless the organization has received express permission from the procuring Howmet Castings facility and the Howmet Castings Environmental Health & Safety organization. If there is any question regarding product and material packaging and/or handling, contact your Howmet Castings Procurement representative and Environmental Health & Safety representative Storage The organization shall provide adequate storage areas to prevent damage, deterioration or contamination of material(s) or product(s), pending use or delivery. The condition of stocked products and materials shall be periodically assessed at appropriate intervals to detect deterioration Packaging and Preservation The organization shall control packaging, packing, preservation, and reprocessing of products or materials to the extent necessary to ensure conformance to specified requirements and shall identify, preserve, and segregate all product from the time of receipt until the organization s responsibility ceases. Ø Wood Packaging, Crating and Pallets When stipulated in a Howmet Castings purchase order, all wood product used in packaging, crating and pallets must be in compliance with the International Standard for Phytosanitary Measures (ISPM15) guide for regulatory wood and wood packaging in international trade. To attest to compliance to the standard, wood crates and pallets must be clearly marked on two faces showing the official IPPC logo, a two-letter country code (xx), a unique number (000) assigned by the National Plant Protection Organization (NPPO), HT for heat treatment or MB for methyl bromide and BD to signify debarked. All other wood product must undergo heat treatment to a minimum core temperature of 56 C for a minimum of 30 minutes, or be fumigated using methyl bromide to the dosage and temperature prescribed in ISPM Certification of Products and Materials When required by the purchase order and/or Howmet Technical specification, a Certificate of Compliance or Certificate of Analysis, as applicable, shall accompany each shipment. The certificate shall provide all information as outlined in the Howmet Corporate Supplier Control Manual procedure SCM 104, Supplier Certification Requirements.

11 Page 11 of 12 * A copy of SCM 104 may be obtained from Howmet s Internet website at: Note: Received product and material is subject to immediate rejection and return, if information, required of SCM 104, is omitted on the required certificate Delivery The organization shall arrange for the protection of the quality of all product(s) and material(s). This protection shall be adequate to ensure material/product quality to delivery destination. The organization shall ensure that the accompanying shipping documents are enclosed in a weather-protected envelope marked Shipping Documents or facsimile. The shipping documents shall be secured to the product to prevent loss and be visibly situated for ease in locating. The organization shall ensure adherence to all U.S. Department of Transportation regulations or applicable host country transportation regulations during transit, delivery, and when discharging bulk products and materials at a Howmet Castings facility Organization Procurement Control The organization shall establish and maintain documented procurement procedures and adhere to such procedures to ensure that purchased product, material or services conforms to specified purchase requirements. Objective evidence of conformance (receiving inspection records, test reports, supplier certifications, etc.) to the purchase requirements shall be maintained. The organization shall define the type and extent of control exercised over its sub-tier sources. Control of the sub-tier source shall be dependent upon the type of product, material or service and the impact to final product or material quality. The organization shall maintain records of acceptable sub-tier sources and use only authorized sources. This shall include Howmet Castings purchase order stipulated sub-tier sources Purchasing documents shall clearly describe the product, material or service ordered, including applicable technical and quality system specifications/revision levels, test requirements and any other pertinent data or certification provisions. Howmet Castings purchase requirements shall be included in sub-tier purchase orders, including specification(s)/ revision level(s), when applicable. The organization shall ensure the review and approval of purchase orders for adequacy of the requirements prior to release. Objective evidence of these reviews shall be maintained When a sub-tier source(s) is contractually stipulated in a Howmet purchase order, the Distributor / first tier organization shall ensure only the specified sub-tier source(s) is utilized. The Howmet Castings purchase order stipulation of sub-tier source(s) only assures potential capability of the

12 Page 12 of Statistical Techniques source(s), it does not guarantee continued satisfactory performance and does not release the organization of responsibility for quality of purchased materials and services. Unless otherwise specified in a Howmet Castings purchase order, inspection sampling shall be carried out utilizing the most current revision of Zero Acceptance Number Sampling Plans by Nicholas L. Squeglia, Table No. 1-a, Index Value Corrective and Preventive Action The organization shall establish and maintain documented procedures for implementing corrective and preventive action for the effective handling of customer complaints and reports of product or material nonconformity s. The following corrective or preventive action must be taken to ensure elimination of the causes of potential nonconformities, actual nonconformities and prevention of repetitive nonconformities. The results of these investigations shall be documented. 6.1 Investigate and understand the cause of nonconformities relating to product, process and quality system. Determine the immediate interim actions necessary to control the problem until the root cause is eliminated. 6.2 Utilize appropriate sources of information such as processes, work operations which affect product quality; SDAR s; internal, customer and independent audit results; quality records; service reports; and customer complaints to detect, analyze and eliminate nonconformances. 6.3 Provide the necessary follow-up to ensure the corrective actions taken have eliminated the cause(s) to the extent necessary to prevent a recurrence. 7. Notification of Changes The organization shall notify the Howmet Castings purchasing facility procurement representative of any changes affecting the operational proficiency of a facility(s); alterations in management or organizational restructuring; alterations in the business name, location or ownership; processing capabilities, and any other pertinent changes that could hinder the reciprocal capacity to conduct customary business activities. A listing of the Howmet facility procurement representatives may be obtained at - Denotes change from previous issue