Supplier Quality Manual Quality requirements SCG-STD-006-01 10/10/2010 TRANSPORT
INTRODUCTION External parts from suppliers highly contribute to high quality products, solutions and services we have to offer our customers.to achieve this high quality level, we are determined to establish and develop close and long term relationships with our suppliers. Involvement of our suppliers is managed through this manual, describing AT standardized global approach, setting out the minimum required basics tools & requirements. This AT worldwide policy is mandatory to achieve our targets, satisfy our customers and to establish with our panel of suppliers common sustainable growth. Jean-Michel Geffriaud Valérie Gallego Senior Vice-President Sourcing & Components Sourcing Quality Vice-President P 2
Our Requirements / Our common basics Our requirements: Quality targets achieved On Time deliverables during development & execution phases Partnership behaviour Our common Basics: No Safety and Regulation concerns No issue impacting Alstom Transport premises & fields. No product/process change without AT agreements No delay in Project Quality deliverables Key product/process characteristics under control Cost Of Non Quality (CONQ) reduced year after year Customer Secure, reactivity when issues & root cause eradication Proactive quality mindset & improvement plan P 3
Our Way or Working Our Supplier Quality approach is aligned on our Sourcing processes, along the three main steps of the relationship with the supplier : Panel entrance and management : Only qualified suppliers may deliver to AT Prevention in Product & Process before deliveries : to support Quality Built-up Performance management in execution : To meet defined Quality targets This Supplier Quality Manual describes : AT requirements towards suppliers for each of these steps, Expected way of working and way of managing the activities, Associated Quality tools to be implemented, Key Performance Indicators (KPIs) that will allow to assess achievement of targets. P 4
Sourcing Quality Management Process & Quality Basics SOURCING PERFORM SUPPLIER SELECTION MANAGE SUPPLIER INTEGRATION SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT PANEL ENTRANCE QUALITY BASICS PREVENTION - SPQD PERFORMANCE in EXECUTION GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE PANEL ENTRANCE : Process leading a supplier to be introduced in the AT panel, according to a list of pre-requisites (system certifications, Co-development & industrial assessments, sustainable development criteria) PREVENTION - SPQD (Supplier Product Quality Development) MANAGEMENT: Process held during the Product & Process development phases, in order to guarantee the compliance of the Product to the Quality/Cost/Delivery targets in a sustainable way PERFORMANCE MANAGEMENT IN EXECUTION: Continuous process of assessment of the Supplier according to the Quality performance of the deliveries. GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE: Continuous process of assessment of the Supplier according to the performance in all the sectors of the relationship (Execution & Product/Process development) This performance is synthesised by a colour code. P 5
Sourcing Quality Management Process PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION PANEL ENTRANCE PROCESS CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION P 6
PANEL ENTRANCE PROCESS PANEL ENTRANCE PROCESS: A supplier will be integrated into the vendor list with a Panel status when complying with AT business criteria, as financial strength, industrial footprint, technical expertise, and has successfully passed the following items: Quality Management System ( 3 rd party certification or AT classification ) AT Sustainable development charter sign-off Process qualification on technical know-how (including special processes) Sustainable development qualification Co-development qualification (if the supplier is requested to develop the design of the part) Capacity check ( if necessary ) AT Sourcing Quality is in charge of performing these assessments and to pronounce the GO/NOGO status according to their results.. In case of NOGO, only a waiver signed-off by the Product Line Sourcing Quality Development Director can authorize a temporary panel entrance. P 7
PANEL ENTRANCE PROCESS PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION PURPOSE: To guarantee that the supplier has put in place a consistent Quality Management System able to satisfy AT requirements in the scope of the supply CONTENT The supplier shall be ISO 9001 certified. For Rolling Stock and Components, for the safety or critical parts and sub-systems, the supplier must be IRIS certified. Certified or at least shall commit to get the IRIS certification within the following year. In case of the supplier not ISO 9001 or IRIS certified, AT keep right to perform a classification audit according to its own standard. P 8
PANEL ENTRANCE PROCESS PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION SUSTAINABLE DEVELOPMENT CHARTER PURPOSE: The Sustainable Development is a core value within Alstom. It is a strong component of Alstom strategy and means responding strongly and actively to Alstom stakeholders societal needs and anticipating new environmental, social and economic developments. As key actors in the development and production processes, suppliers has to Commit to the same values, and cascade to their own suppliers. CONTENT The supplier is requested to sign-off the charter and commit to AT requirements in terms of: Labour standards Ethics Environment Occupational Health and Safety Product and services life cycle P 9
PANEL ENTRANCE PROCESS PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION INDUSTRIAL CAPABILITY QUALIFICATION PURPOSE: The Process Audit is performed to assess the capability of the supplier to manufacture and supply parts according to the AT standards and control its special processes. CONTENT This audit is divided in two main sections, one is generic whatever the processes, the other is related to the control of the special processes (a specific questionnaire per type of process ) CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION Generic 1. Process Management, control of I/0 data 2. Purchasing, Procurement 3. Production, Workstations 4. Finished products checks and tests 5. Preparation, storage, handling & shipment of product 6. Non conformities management 7. Personneel, training, skills management Sp ecial Processes Casting Cabling Electronic Board Forging Riveting Heat treatment Extrusion Brazing Rubber-Metal Machining Stratification Glazing Welding Gluing Painting Winding P 10 TARGET To be qualified, the supplier shall get: Overall score above 80% No Critical Corrective Action Request
PANEL ENTRANCE PROCESS PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION CO-DEVELOPMENT QUALIFICATION PURPOSE: The Co-Development Audit is performed to assess the capability of the supplier to perform a product & process development according to the AT standards. bring innovation through a controlled process. CONTENT This audit is divided in three main sections: Project Management Product / Process Development Innovation Management TARGET To be qualified, the supplier shall get: Overall score above 80% No Critical Corrective Action Request P 11
PANEL ENTRANCE PROCESS PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION CAPACITY CHECK PURPOSE: The Quick Supply Chain Assessment is performed to evaluate the ability of the supplier to control its supply chain and production planning. CONTENT This audit is focused on the management of all the items related to the supply Chain activity Long & Medium term planning MRP Scheduling of the production Change management Inventories In case of high risk detected, this audit shall be followed by a full Supply Chain audit. TARGET To be qualified, the supplier shall get: Overall score above 80% No Critical Corrective Action Request P 12
PANEL ENTRANCE PROCESS PERFORM SUPPLIER SELECTION SYSTEM CERTIFICATION SUSTAINABLE DEVELOPMENT CHARTER INDUSTRIAL CAPABILITY QUALIFICATION CO-DEVELOPMENT QUALIFICATON CAPACITY CHECK SUSTAINABLE DEVELOP T QUALIFICATION SUSTAINABLE DEVELOP T QUALIFICATION PURPOSE: The sustainable development audit is performed to assess the compliance of the supplier to Alstom requirements as defined in the Sustainable Development Charter. CONTENT This audit is focused on the following items: Management involvement Labour standards Ethics Environment Occupational Health and Safety Product and services life cycle TARGET To be qualified, the supplier shall get: Overall score above 80% No Critical Corrective Action Request P 13
Sourcing Quality Management Process MANAGE SUPPLIER INTEGRATION PREVENTION - SPQD PREVENTION DURING PRODUCT DEVELOPMENT (BEFORE FIRST DELIVERIES) SPQD PROCESS P 14
SPQD PROCESS SPQD PROCESS : The target of the SPQD process is to achieve product and process maturity at FAI (or FAT) stage. The supplier is requested, during the development phases of a new product, to align its development schedule on the requirements of AT regarding the Quality deliverables. The backbone of the Quality in development will be the SPQD PLAN, that will be defined jointly at the beginning of the development, and will include all the steps for the risk prevention and the Quality Assurance build-up.the schedule will be compliant with the overall Project master schedule. The AT Supplier Part Quality Development representative will be in charge of tracking and monitoring the supplier Quality performance plan on a regular basis, and ensuring the achievement of the targets, both qualitatively and on time, from the business award to the FAI (or FAT). A focus will be done on the Product & Process risk, and on the consistency & efficiency of the control plan. The performance of the supplier in the development phase (ability to achieve the targets) will be an input in the overall supplier ranking (see SUPPLIER PERFORMANCE DASHBOARD chapter). The Rolling Stock & Components Way of Working and requirements are detailed in the Appendix 1. P 15
Sourcing Quality Management Process SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT P 16
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION PERFORMANCE MANAGEMENT DURING EXECUTION : During the execution phase, the performance of the supplier by commodity is consolidated and monitored by the Supplier Quality representatives. This performance is measured through the following indicators: Non Conformities results at AT premises (e.g.:ncr rate = Non Conformity Report rate, corresponding to the number of Non Conformities over the number of deliveries), and the reactivity to solve the issues. Number of issues during the revenue service, and the reactivity to solve the issues. Number of FAI/FAT GO on time and their number of non conformities Cost Of Non Quality (CONQ) generated by the supplier non-conformities The result of this performance assessment is synthesized through a colour code: Black, Red, Yellow or Green. The rules to attribute these colours are defined hereafter. P 17
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT SUPPLIER PERFORMANCE DASHBOARD (colour status) PURPOSE: Rank the suppliers in terms of Quality targets achievements and reactivity in the Execution & Product Development phases. CONTENT The rules for ranking the suppliers is performed through a colour code (Green, Yellow, Red or Black Quality status). The following matrix describes the colour code assignment criteria, the AT owners for the supplier management; and the AT required reaction rules. QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT P 18
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION Green Yellow Red Criteria AT Owners Tools and Management Requirements Development and Execution results exceeding the target Improvement plan ongoing Proven Reactivity Punctual Quality issues Quality results at target Improvement plan ongoing Proven Reactivity Execution results at AT premises out of target or in continual degradation over the last 3 months, Safety related issue linked to a lack of process control at supplier. 2 major revenue service issues within the last 3 months. Product Development results out of target, ie: At least 2 FAI NOGO on the same product, with supplier responsibility At least 3 successive FAI NOGO on various products. AND in all cases, no proven reactivity, ineffective action plan Local Quality representative Local Sourcing representative Commodity Manager or Domain Director Sourcing Quality representative 8D managed locally CONQ recovery Management review involving Supplier management, local Quality and Sourcing representatives Improvement plan managed by local Quality and Sourcing representatives 8D managed locally Reinforced control plan managed locally. CONQ recovery. Upgrade plan managed by AT Quality and Sourcing representatives. Management review involving Supplier management, Commodity manager or Domain director, Supplier Quality Development representative. Definition of the Red status exit conditions (performance targets and due date) by Supplier Quality Development representative. NBOH (New Business On Hold) panel status preparation. E S C A L A T I O N P R O C E S S Black Ineffective action plan to exit the Red position. No involvement from supplier management Product line Sourcing Top management Sourcing Quality Top management Exit plan set-up. CONQ recovery P 19
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT CHANGES MANAGEMENT PURPOSE: Alstom requests its suppliers to inform in writing AT of any Product or Process changes that it wants to implement. AT formal acceptation is mandatory before this change request can be considered as approved. CONTENT Before applying the change, the supplier will assess the risks in terms of impact on QCD performance and contractual requirements, and submit for approval the Product and/or Process validation plan. Process modifications includes: Location of the production site (manufacturing transfer) Production process Tools Material Subcontractors. The supplier will submit the updated Product and/or Process documentation, AT keeps right to assess the modified process, either at Supplier or Subcontractor premises. P 20
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT CONTENT (ctd) CHANGES MANAGEMENT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT After validation, the modification will be formalized in the contractual documentation. The configuration management of the Product is under Supplier s responsibility. The control and monitoring of the modification will be performed using the following information: Reference(s) impacted Serial number of the first modified product (including sub-assemblies if impacted) Production date If applicable, State of hardware and software (revision level) AT modification number If applicable, reference of the AT waiver. The supplier will inform AT in case of obsolescence. P 21
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION P 22 SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT 8D MANAGEMENT PURPOSE: To guarantee an efficient problem solving approach, Alstom requires from its suppliers to implement the 8D tool in the analysis and corrections of the issues. CONTENT The 8D will at least presents the following items: Description of the problem Team in charge Problem Characterisation Containment: curative actions (within 48 hours after the problem notification) Root causes definition and validation ** Permanent corrective actions (within 30 working days after the problem notification) Preventative actions Lessons learnt ** The root causes identification will integrate the causes of non-detection and the causes of occurrence of the problem.
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT QUALITY WALL RESIDENT PURPOSE: In case of not secured control plan, reoccurrence of deliveries of defective parts detectable at supplier premises, Alstom may require the temporary implementation of a Quality Wall or a resident to secure the Quality of the delivered products CONTENT The Quality Wall is managed by a third party company, mandated to ensure the checking according to a check-list validated by Alstom Supplier Quality. The conditions to remove the Quality Wall are defined at the starting of the activity (number of parts or duration without defect found) The results of the checking are registered, and communicated to Alstom. In the meantime, the supplier commits to implement the corrective actions to tackle the internal issues.the Quality Wall is removed when the targets defined initially are reached. A resident is a person full time in charge of supporting the supplier in its management or problem solving approach. The rule to remove the permanent remains the same than for the Quality Wall. P 23
SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT SUPPLIER PERFORMANCE DASHBOARD (colour status) CHANGES MANAGEMENT 8D MANAGEMENT QUALITY WALL RESIDENT COST OF NON QUALITY (CONQ) MANAGEMENT COST OF NON QUALITY (CONQ) MANAGEMENT PURPOSE: Alstom requests its suppliers to be liable for the financial impact of a non conforming deliveries, either when detected at AT premises (S1) or in the Revenue Service (S2). CONTENT The financial impact of the non-conformities detected at AT premises will be reported in the CONQ S1 account. They will include: a fixed fee the variable cost for the non conformity management (sort-out, rework, ) the variable cost for the AT impact on production (line stoppage, ) The financial impact of the non-conformities detected during the revenue service will be reported in the CONQ S2 account. They will include: the variable cost of the non conformity management (retrofit, rework, ) the potential penalties requested by the customer. P 24
Sourcing Quality Management Process SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT GLOBAL PERFORMANCE MGT & IMPROVEMENT SUPPLIER UPGRADE GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE P 25
GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT GLOBAL PERFORMANCE MGT & IMPROVEMENT SUPPLIER UPGRADE GLOBAL PERFORMANCE MANAGEMENT & IMPROVEMENT PURPOSE: Alstom requests its supplier to develop a continuous Quality improvement plan aiming at increase their performance all along the development and production steps. CONTENT The improvement plan will be based on the analysis of the typology of the defects and the weaknesses highlighted during the development and production phases.. Besides, AT will re-assess the suppliers ability to be compliant with the AT panel criteria every 3 years at minimum according to the Panel Entrance rules. Any deviations following these audits will be managed through the improvement plan. However, in case of too high risks for deliveries highlighted during this assessment, Supplier Quality Development representative can ask for a Red status The improvement plan will be challenged by the Alstom Sourcing Quality representatives and reviewed during the management reviews held on a regular basis with the key suppliers. P 26
GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE SUSTAIN SUPPLIER QCD PERFORMANCE & CONTRACT GLOBAL PERFORMANCE MGT & IMPROVEMENT SUPPLIER UPGRADE SUPPLIER UPGRADE PURPOSE: Alstom requests its Red supplier to develop a strong upgrade Quality plan to recover yellow status and be maintained in the Alstom Panel. CONTENT ( specific Red ) For the RED SUPPLIERS, AT will request a robust action plan, aiming to leave this status within the 6 following months. AT Sourcing and Supplier Quality Development representatives will be in charge of monitoring this plan at supplier premises, and validating the effectiveness of the corrective and preventive action plans.. AT Sourcing and Supplier Quality Development representatives could support this plan through training and workshops if necessary in the supplier area. Regular meetings are required at supplier and AT management level to measure the improvement. Note : A Quality wall is mandatory for the start of production of any product manufactured at a red supplier. P 27
Sourcing Quality Management Process MANAGE SUPPLIER INTEGRATION SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE SUB-SUPPLIERS MANAGEMENT PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS PRODUCT & PROCESS CONTROL PLAN FAI APPENDIX 1 PREVENTION DURING PRODUCT DEVELOPMENT (BEFORE FIRST DELIVERIES) SPQD Plan For Rolling Stock & Components P 28
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION SPQD PLAN S P Q D P L A N SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN FAI PURPOSE: The SPQD plan (Supplier Product Quality Development plan) summarizes Way of monitoring the supplier Quality activities during the development of a new Product, in line with the project schedule CONTENT: At the early beginning of the project, the SPQD plan is defined and agreed by AT Quality representative and the supplier. SPQD plan detailed items are described on the following sheets. As a first activity, SPQD Quality specification contractualizes the project Quality targets and agreed Quality specific requirements. P 29
SPQD Plan For Rolling Stock & Components INPUT DELIVERABLES S P Q D Quality Targets per commodity Quality Targets per supplier (if any) Supplier color status and reasons why Colour status Project schedule List of the previous S1 & S2 failures and related analysis. Quality Specification sent to the Supplier (clause by clause) Quality Specification agreed between AT & Supplier (clause by clause) Supplier Quality Status analysis (Red/Yellow/Green in Development or execution) Request for concession if necessary Criticality assessment for governance Detailed SPQD plan build-up with the supplier (SPQD FU sheet) REX analysis 1 2 P L A N I T E M S Drawings / Specifications RAMS study List of Critical Product Characteristics Process flow & lay-out Sub-Suppliers CPF list List of Critical Product Characteristics List of Critical Product Characteristics List of Critical Process Characteristics P.FMEA Product validation plan results Product/Process Control Plan FAI Status Criticality assessment of the supplier NCR data Product Risk analysis (D-FMEA or other) Checking of the right implementation of the risk analysis outputs List of Critical Product Characteristics identified Process Risk analysis (P-FMEA or other) Checking of the right implementation of the risk analysis outputs List of Critical Process Characteristics identified Validation of the critical sub-suppliers bought-out parts on Product/Process. Product/Process Control Plan consistent with the Process risk analysis. Check that the design conformity files are available and validated by Engineering Product conformity to requirements Validation PRODUCT FAI STATUS (see FAI sheet) Process qualification through audit on Product specifics PROCESS FAI STATUS (see FAI sheet) Request for concession if necessary toward the PrQM Reinforced Final Inspection or Quality Wall (for red suppliers) at supplier premises Checking of the 3 first deliveries performance vs target. 8D management if any deviation 3 4 5 6 7 7 All documents related to the SPQD activity SPQD file to transfer ans handover to SQA P 30 Key suppliers SPQD activities
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION SUPPLIER PERFORMANCE FEED-BACK 1 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN FAI PURPOSE: The monitoring of the supplier Quality activities during the development of a new product will be adapted to its current and past performance during the execution phase. CONTENT According to the product & supplier criticality, 3 levels of monitoring are defined (from 1 to 3). The frequency of the follow-up will be adapted accordingly and integrated.in Product & Process Quality assurance plan. Product Risk Supplier Status G/Y Red Purple Safety A & B Class 2 1 1 Non Safety A & B+ Class 2 1 1 B- class or Safety C Class 3 1 2 NB: Suppliers with non fully qualified processes will be followed-up as the RED criticality ranking. P 31
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION RETURN OF EXPERIENCE 2 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN PURPOSE: This is the first level of the risk analysis. To guarantee the non reoccurrence of issues already happened in the past, the supplier will perform an analysis of the Product & Process Design failures and Check that the new Product concepts gets rid of the risks CONTENT The supplier will present a preliminary analysis based on the previous issues on the same type of products. Based on the root causes analysis, It will demonstrate that the previous deviations have been taken into account and will not be carried out on the new development. It will allow to define the Quality targets for the projects FAI P 32
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION PRODUCT RISK ANALYSIS 3 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN FAI PURPOSE: All along the life-cycle, prevent the risks on the product due to the design. Define the design validation activities. Determine the Critical Product Characteristics. CONTENT The supplier will give the evidence of a Product risk analysis integration in the Design activity. The supplier will be able to demonstrate its identification of the critical Product characteristics. The Product risk analysis can preferably be performed through a Design Failure Modes and Effects Analysis (D-FMEA). The activity will be performed by the supplier, and validated by AT Supplier Quality function. P 33
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION PROCESS RISK ANALYSIS 4 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN FAI PURPOSE: All along the production, prevent the risks on the product due to the manufacturing conditions.. Determine the Critical Process Characteristics. CONTENT The supplier will give the evidence of a Process risk analysis integration in the Design activity. The supplier will be able to demonstrate its identification of the critical Process characteristics. The Process risk analysis can preferably be performed through a Process Failure Modes and Effects Analysis (P-FMEA). The activity will be performed by the supplier, and validated by AT Supplier Quality function. P 34
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION SUB-SUPPLIERS MANAGEMENT 5 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PURPOSE: Insure that the supplier transmits AT Product and Process requirements to its own suppliers manages its own critical products/suppliers though a Quality Plan in line with AT expectations CONTENT Requirements of AT regarding the sub-supplier management are described on the following sheet. PRODUCT & PROCESS CONTROL PLAN FAI P 35
SPQD Plan For Rolling Stock & Components Sub-Suppliers (Tier 2) Management Requirements As a key process in the achievement of the supplier Quality targets, a special focus will be done on the management of the Tier 2 suppliers The reference to assess this activity will be the following: The list of critical Products/Suppliers is identified These critical suppliers are qualified for their process scope (focus on special processes)? A FAI process has been implemented for these products A waiver process exists in case of sub-supplier NOGO FAI (including containement too secure the deliveries) A list of required documents for each delivery exists The critical product characteristics are identified for bought-out parts? The Tier 2 product/process control plan are available and validated? The Incoming Inspection Insrtuctions are defined and consistent with the critical characteristics? The measurement means are defined and adapted? The rules for segregation of the producs according to their Quality status are defined and applied? The rules for Non Conformity management are defined and applied P 36
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION PRODUCT & PROCESS CONTROL PLAN 6 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN FAI PURPOSE: Describe the Product/Process control activities during the manufacturing of the Product, and the reaction rules in case of drift. CONTENT The Product & Process control plan is built from the Incoming Inspection to the Dispatch activities. It will detail the Product & Process control operations, their frequency, their responsible and the related registration documents. The Work-instructions and Quality instructions will be aligned on the control plan. The Product & Process Control plan will be submitted by the supplier, and validated by AT Supplier Quality function.. P 37
SPQD Plan For Rolling Stock & Components Control plan Requirements Requirements The control plan is the backbone of the operational Quality implementation all along the process steps. It must describe, from Incoming Inspection to Dispatching the prevention and detection activities, either on process or on product. The requested elements to be detailed are the following: Process Type or Operation Description Machine, device or tool Product and/or Process Characteristics to put under control Product and/or Processspecifications and tolerances Evaluation/Measurement technique Person in charge Sampling (size and frequency) Records Control Methods Reaction rules in case of N/C detection P 38
SPQD Plan For Rolling Stock & Components Control plan requested to the supplier Supplier Name: Control Plan Number Control Plan Revision Level Supplier Key Contact/Phone Written by Part Number Part Revision Level Part Name Approved by Characteristics Process Number Process Name/ Operation Description Machine, device, jig, tools, asset #, etc Class Methods Product Process Product/Process Evaluation Specification/ Tolerance Measurement Technique. (gage # if applicable) Size Sample Date of last revision Approval date Freq. Control Method Reaction Plan P 39
SPQD Plan For Rolling Stock & Components MANAGE SUPPLIER INTEGRATION FAI 7 SUPPLIER PERFORMANCE FEED-BACK (colour status) RETURN OF EXPERIENCE PRODUCT RISK ANALYSIS PROCESS RISK ANALYSIS SUB-SUPPLIERS MANAGEMENT PRODUCT & PROCESS CONTROL PLAN PURPOSE: Validate the First Article according to the product definition and requirements,and validate its manufacturing process. CONTENT Based on a Product check-list, the Product FAI will allow to check the compliance of the product to the technical & documentation requirements.fai will also be performed for carry-over parts for which the validation has been performed more than 1 year ago. The validation of the Process will be performed according to FAI Process validation check-list. The final statement of the activity will be based on the Product & Process qualification level, following a X-Y-N code, where: FAI X Y N Letter linked to the qualification level of the manufacturing process of the FAI part. Letter linked to the qualification level of the product conception validation of the FAI part. Number linked to the ownership of the corrective action plan to be deployed. P 40
SPQD Plan For Rolling Stock & Components Ranking of X can take 2 levels, given by the SPQD representative: A R "Accepted", Manufacturing process of the FAI part is qualified. "Rejected", Manufacturing process of the FAI part is not qualified. Ranking of Y can take 4 levels, given by the Engineering representative: A E I R "Accepted", Prodcut conception is able to guarantee specifications compliance "External use possible", Product conception is not able to guarantee specifications compliance on minor deviations, not jeopardizing Safety, Reliability, Fitting.Nevertheless, correction expected. "Internal use only", Product conception is not able to guarantee specifications compliance on major deviations (out of Safety) or conformity not fully demonstrated (long term test results missing). Product can be accepted under concession. "Rejected", Product conception do not guarantee the function & the compliance to specifications. Ranking of N can take 3 levels, given by the SPQD representative: 0 1 2 Product/Process FAI accepted, no need for additional action plan. Action plan needed, suppplier ownership. Action plan needed, AT ownership. P 41
SPQD Plan For Rolling Stock & Components Process Qualification status Product Concep tion validation status Resp onsab ility Criteria Commen ts Reaction rules A 0 Product conforming to the definition and specifications, complying with the usage conditions. FAI valided, no need for additional action plan. A E 1 2 Minor non conformities, not jeopardizing Safety, Relaibility or Fitting, but correction requested as soon as possible. Minor non conformities, not jeopardizing Safety, Relaibility or Fitting, but correction requested as soon as possible. Corrective action plan to be supplied by the supplier. Concession by the SPQD mgr & Engineering needeed. Corrective action plan to be supplied by AT. Concession by the SPQD mgr & Engineering needeed. I 1 2 Major non conformity, not jeorardizing Safety & Regulation items or long term test results missing Major non conformity, not jeorardizing Safety & Regulation items or long term test results missing Corrective action plan to be supplied by the supplier. Concession by the SPQD mgr, Engineering & PrQM needeed. Corrective action plan to be supplied by AT. Concession by the SPQD mgr, Engineering & PrQM needeed. P 42
SPQD Plan For Rolling Stock & Components A 1 Product conception guarantees the compliance to the specifications, but the process is not capable to guarantee the reproducibility of conforming parts. No delivery without reinforced Quality checkings & Quality Wall. Process corrective action plan to be supplied by the supplier. Concession by the SPQD mgr, TSS & PrQM needeed. P 43 R E I R 1 2 1 2 1 2 Minor non-conformities not jeopardizing safety, nor reliability nor fitting but corrections needed asap.. The process is not capable to guarantee the reproducibility of conforming parts. No delivery without reinforced Quality checkings & Quality Wall. Minor non-conformities not jeopardizing safety, nor reliability nor fitting but corrections needed asap.. The process is not capable to guarantee the reproducibility of conforming parts. No delivery without reinforced Quality checkings & Quality Wall. Major non-conformities but not jeodardizing safety or regulation, or long term test results missing. The process is not capable to guarantee the reproducibility of conforming parts. No delivery without reinforced Quality checkings & Quality Wall. Major non-conformities but not jeodardizing safety or regulation, or long term test results missing. The process is not capable to guarantee the reproducibility of conforming parts. No delivery without reinforced Quality checkings & Quality Wall. Product not conforming to the definition or the specifications (safety/regulation), and/or not complying to usage conditions. Product not conforming to the definition or the specifications (safety/regulation), and/or not complying to usage conditions. Concession by SPQD mgr, TSS & PrQM needed. Produit/Process corrective action plan to be supplied by the supplier. Concession by SPQD mgr, TSS & PrQM needed. Produit corrective action plan to be supplied by AT, Process corrective action plan to be supplied by the supplier. Concession by SPQD mgr, TSS & PrQM needed. Produit/Process corrective action plan to be supplied by the supplier. Concession by SPQD mgr, TSS & PrQM needed. Produit corrective action plan to be supplied by AT, Process corrective action plan to be supplied by the supplier. No delivery allowed No delivery allowed
SPQD Plan For Rolling Stock & Components FAI Requirements FAI is split in Product conformance on one side, and Process validation on the other side: Product conformance status, given by AT engineering representative, includes: Technical drawings & specifications. Functional tests results Configuration management Visual inspection Fire and smoke Marking and identification Process validation, given by AT Sourcing Quality representative, takes into account: Supplier documents and Implementation : Quality Control Plan, Working & Inspection instructions Dies, fixtures, jigs Special processes control in accordance with norma (including the operators training level) Packaging The final status of the FAI, including both Product & Process conformance status is given by the Sourcing Quality representative Only Product with accepted FAI can be delivered to AT. Otherwise, deviation request is needed to allow the delivery. P 44
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