Brakes Manual - KNOTT GmbH8 8 9 9 KNOTT Supplier Manual July 2016, revision number: 004/2016 KNOTT...

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KNOTT Supplier Manual July 2016, revision number: 004/2016

www.knott.de We make your brake

TYPE ERG

KNOTT Electromagnetic Release Spring-Applied Dual-Surface Spring applied Brakes

B r a k e sELECTROMAGNETIC

Delivery terms and conditions of KNOTT GmbH Revision date: July 2016

ManualFOR OUR SUPPLIERS

The Supplier Manual from KNOTT Our requirements for mutual success

1. Introduction 5

1.1 Foreword 5

1.2 Confidentiality 7

1.3 Objectives 7

1.4 Continuous improvement process 7

1.5 Target motto 7

2. General information/purpose 8

2.1 Purpose and scope 8

2.2 Delivery form 8

2.3 Distribution list 8

2.4 Delivery date 9

2.5 Information behavior 9

2.6 Selection and qualification process 10

2.7 Initial meeting with supplier 11

2.8 Supplier evaluation 11

2.9 Performance agreement with supplier 14

2.10 Reasons for blocking a supplier 14

2.11 Supplier audits 14

2.12 Consent declaration from supplier 14

2.13 Continuous improvement process 15

3. Overview of Knott factories in Germany 16

3.1 Knott Eggstätt 16

3.2 Knott Regenstauf 16

3.3 Description of goods receiving /

acceptance process 18

3.4 Delivered quality 18

3.5 Load carriers 19

3.5.1 EURO pallet 19

3.5.2 Pallet crates 19

3.5.3 Pallet carton 19

3.6 Rated transportation weight 19

3.7 Miscellaneous packaging requirements 20

3.8 Non-conforming packaging 22

4. Identification 23

4.1 Labeling 23

4.1.1 Shipment identification 23

4.1.2 Part identification 23

4.1.3 Labeling in accordance 24

with VDA Standard 4902

4.2 Product support documents 25

4.2.1 Shipping ticket 25

4.2.2 Miscellaneous documents 26

4.3 Additional requirements 26

4.4 Forwarding 26

5. Quality assurance process 27

5.1 Requirements for product quality

and the production process 27

5.2 First article inspection

(quality assurance prior to series production) 27

5.2.1 Reasons for first article inspection 28

5.2.2 Submission milestone (VDA Volume 2) 28

5.2.3 Non-conformances on first article samples 28

5.3 FMEA 29

5.4 As-built variances / customer variance approvals 29

5.5 Quality assurance during series production 29

5.6 Incoming inspection 29

6. Claim procedure 30

7. Handling of incurred costs 30

8. Miscellaneous 32

9. Invoicing / payment 32

10. General information - terms /

concluding comments 32

11. Contact 33

12. Schedule of figures 34

The Supplier Manual from KNOTT Our requirements for mutual success

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Knott is active world-wide as a module supplier for high-profile customers. The quality of your products and services has a profound impact on our performance with customers.

This supplier manual describes the logistics and quality requirements of Knott Werke

Germany for suppliers and also represents an integral contractual component.

Our position on the world market is materially determined by our product quality.

The specifications in this document represent requirements intended to ensure smooth

processes between Knott GmbH (hereinafter called KNOTT) and its suppliers.

Rapidly changing and escalating customer requirements imposed on KNOTT also

require a maximum of flexibility from our suppliers, along with the willingness to

quickly and creatively contribute solutions to problems.

The contractor‘s deliverables must fully comply with all statutory requirements.

Systematic advance quality planning is essential for achieving objectives with zero

defects.

It is equally important that the supplier is fully accountable forensuring that its sub-contractors comply with all aspects in these guidelines.

1.1

1 INTRODUCTION

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Confidentiality 1.2

The content of the supplier manual is the intellectual property of KNOTT. Its use for

purposes other than those described therein or forwarding to persons not associated

with KNOTT is only permitted based on written approval from the QM representative

of the Procurement department. The German text shall be definitive in the event that

translations are prepared.

Objectives 1.3

We expect our suppliers to observe and comply with the laws and mandates applicable

in their countries of origin.

Our objective is to achieve complete defect avoidance and to implement the following

objectives:

• complete documentation

• minimized warehousing and transportation expenses to the benefit of both sides

• securing the competitive position of both parties

• compliance with technical specifications

• the best possible communication with KNOTT

• on-going protection of product quality

• process capability during production

Continuous improvement process 1.4

KNOTT and its suppliers jointly work toward optimizing the logistics and manufacturing

process. Changes are implemented with the objective of achieving sustainable and

enduring improvements.

Target motto 1.5

The supplier‘s role in production to provide and/or to allocate the material resources

needed to produce the goods.

The right materials, in the right quantity, at the right quality, at the right time, at the

right location, and at the right price.

“The right materials, in the right quantity, at the right quality, at the right time, at the right location, and at the right price!”

1 INTRODUCTION

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KNOTT Supplier Manual July 2016, revision number: 004/2016 KNOTT Supplier Manual July 2016, revision number: 004/2016

2.1 Purpose and scope

The purpose of this supplier manual is to describe all requirements for the delivered

and packaged state to KNOTT, including the proper identification of load carriers.

The supplier manual is valid for shipments to Knott Werke Germany. This manual shall

remain valid unless specified otherwise in separate written agreements.

We require KNOTT suppliers to inspect their products prior to shipment based on

generally accepted industry practices so that any form of damage prior to and during

transport and upon delivery are avoided.

The purpose of this manual is to ensure the product quality and to simplify the

acceptance process at KNOTT.

If damaged packaging is identified during acceptance, this indicates potential product

damage and the shipment may under certain circumstances not be accepted. In

addition, the quality of your delivery also has a direct impact on our products. It is

therefore of the utmost importance that you incorporate all aspects of the specific QA

activities from KNOTT - as described in this policy -

within your quality assurance system.

2.2 Delivery form

The parts must be delivered ready for assembly, e.g. no dismantling

or repackaging work must be required after delivery.

2.3 Distribution list

Every purchase order refers to the supplemental validity of the supplier manual,

the purchasing terms and conditions, and other applicable contractual documents.

The supplier is directly responsible for ensuring that it is using the latest revision of

the supplier manual. The revision is printed in thepurchase order text.

Delivery date 2.4

The supplier is responsible for compliance with delivery dates.

All purchase order dates are specified as receiving dates at KNOTT.

Inconsistencies with, and deviations from the specification must be addressed in

advance with the employees of the Procurement department at KNOTT.

Information behavior 2.5

Information requestsThe supplier must respond immediately to information requests / follow-up questions

concerning the delivery date, the facility, and quantity of the goods to be shipped or

shall address these by a deadline agreed-to with the respective procurement dispatcher.

ResponsivenessAny anticipated delivery bottleneck resulting in due date or quantity non-conformances

for the end customer delivery must be immediately - e.g. on the same day - reported to

the assigned procurement dispatcher.

CollaborationFor the purpose of processing purchase orders and shipments, the supplier shall

identify contacts to KNOTT who have the authority to make competent, reliable

decisions and to take appropriate actions.

2 GENERAL INFORMATION / PURPOSE 2 GENERAL INFORMATION / PURPOSE

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2.6 General information / purpose

In order to engage in a business relationship with KNOTT, suppliers are initially required

to undergo a defined process.

KNOTT reviews and evaluates all collected information. Suppliers are classified in

accordance with the results of the evaluation.

Upon reaching a positive classification, the process ends with the supplier‘s certification

for a business relationship with KNOTT. The certification is open-ended. Suppliers are

required to request a recertification with sufficient advance notice if they intend to

change the circumstances. For purposes of safeguarding products and processes, the

following items need to be addressed with suppliers prior to series purchase orders.

Supplier checklist items:• Supplier‘s QM planning approved

• Supplier‘s process safeguards approved

• First article inspection completed

Supplier rating, continuous improvement

Approval of first articles

Series delivery

KNOTT approval process

Agreements with suppliers

Supplier selection

Fig 1: Supplier process

Initial meeting with supplier 2.7

When requested by KNOTT, the supplier must report the following minimum facts,

either verbally or in writing:

• Information about the company

• Information about the production range

• Information about development and design-engineering

• Information about quality assurance

• Information about logistics

• General information

The official form „Supplier-provided information“ - which can be downloaded from the

homepage or is made available to the supplier directly by the procurement department

- shall be used for this purpose.

Supplier evaluation 2.8

Suppliers are evaluated based on performance indicators from the logistics,

procurement, development, and quality management functions. A rating is determined

for each of the functions, which are then consolidated at different weights into an

overall rating. Supplier criteria are largely evaluated automatically, and in certain cases

also manually.

On-time deliveryOn-time delivery is an automated rating criterion that is determined based on the

receiving transaction by comparing the target and actual delivery date; the result is

then recorded in the on-time delivery column.

The number of days is converted into a percentage entered into the weighting rows

and is then multiplied with the determined downgrading factor.

The total is 100% of the total performance.

Overall performance 96

> = -5 days Accurate > = 5 days > = 10 days > = 20 days

4 56 18 9 9

On-time delivery

> = -5 days 4,2 0,25

Accurate 58,3 0,00

> = 5 days 18,8 0,50

> = 10 days 9,4 0,75

> = 20 days 9,4 1,00

100 %

Result

CriterionMaximum

scoreAchieved

score

On-time delivery 105 78

Example

4,2 x 0,25 = 1,05

18,5 x 0,50 = 9,25

9,4 x 0,75 = 7,05

9,4 x 1,00 = 9,40

= 26,75

105

-26,75

= 78,25Maximum score: 105

2 ALLGEMEINES / ZWECK 2 GENERAL INFORMATION / PURPOSE

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QualityQuality is measured in PPM (parts per million).

Claims data is recorded from our general CAQ

system, and the part count is the delivered

quantity recorded by the receiving system.

Different weight factors were determined for

various manufacturing processes to accurately

account for manufacturing-specific circumstances

and difficulties. PPM is determined by dividing the

defective and delivered quantities; the result is

then multiplied by one million.

Maximum score: 135

Soft FactsSoft facts are determined by the

assigned procurement staff.

Pricing behavior

The pricing behavior fact is determined based on:

• Pricing stability

• Quotation behavior

Maximum score: 45

Cooperation

The following is rated under the „Cooperation“ fact“

• Willingness to perform

• Friendliness

• Willingness to assist

• Flexibility

• Joint projects

• Responsiveness

Maximum score: 15

Our objectives are:• Reviewing the overall performance of the supplier

• Classifying suppliers (ABC supplier)

• Identifying and tracking weaknesses

• Introducing a continuous improvement process

• Assessing the direction of the supplier relationship

Supplier classification

Weighting

15.000 PPM = 135 points

20.000 PPM = 110 points

25.000 PPM = 95 points








Gewichtung 2











Pricing behavior

5 Deficient 0

4 Adequate 15

3 Satisfactory 25

2 Good 40

1 Very good 50

Cooperation

5 Deficient 0

4 Adequate 15

3 Satisfactory 25

2 Good 40

1 Very good 50

Quality

Parts per Million

5.371x 1.000.000

112.541

Quality

PPM1 47.725

Defect claims

Number of defect claims2 30

Defective quantity 5.371

Delivered quantity 112.541

Revision date : 08.06.20153

A Supplier “Preferred Supplier“

100 – 83.3 % attained rating score

Preferred partner for new projects

B Supplier “Supplier to be developed“

83.3 – 50 % attained rating score

Improvement potential

C Supplier “Prohibited Supplier“

less than 49 % attained rating score

Significant improvement potential

The supplier is blocked without evidence

for improvements

A B C


Fig 2: Supplier classification

1 The top row shows the PPM reading 2 The number of defect claims is used as information about how many non-conformance reports were prepared

based on packaging damage and defective products during the indicated timeframe.3 The revision date indicates when the data were last updated.

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2.9 Performance agreement with supplier

The supplier rating mentioned under Section 2.8 is performed regularly with the

supplier every six months or in response to special events.

The supplier agrees to make a statement after having received a supplier rating of “B“

or “C“ and to present appropriate countermeasures and improvement options for the

individual issues, and to implement these by an agreed-to deadline. The objective is to

improve the product and process quality and in doing so to bring the supplier rating to

the A Supplier status.

The planned measures must be reported in writing to the Procurement

department for review.

2.10 Reasons for blocking a supplier

Reasons for the complete or partial block of a supplier can be:

• Degradation of product quality and logistics requirements

• Deficient implementation of system requirements

• Inadequate response times

• Significant degradation of transaction processing

2.11 Supplier audits

KNOTT reserves the right to conduct supplier audits on-site at its partner locations at

any time. The frequency of audits depends on the business volume, supplier ratings,

the quality indicators, and on special events and/or incidents.

2.12 Consent declaration from supplier

This supplier manual is an integral component of the contractual relationship between

KNOTT and its suppliers. A confirmation about receipt of the supplier manual and

agreements with its contents must be confirmed once in a separate letter and shall be

valid for all business transactions with KNOTT.

Continuous improvement process 2.13

Continuous improvements must be part of any supplier quality strategy. The supplier

has implemented a structured process of continuous improvement for its business

concerning all products, processes (also applicable for outsourced processes),

operational procedures and services, and demonstrably uses these for the products

supplied to KNOTT and for the activities related to the business relationship.

The supplier demonstrates the effectiveness based on continuously improving quality

performance, delivery performance, flexibility, and collaboration. The corresponding

programs and measures for continuous improvement are submitted to KNOTT on

demand.


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3.1 Knott Eggstätt

Unloading schedule & contact informationKnott GmbH

Brakes – Axles

Obinger Straße 15

D-83125 Eggstätt

Unloading schedule & contact informationKnott GmbH

Brakes – Axles

Gutenbergstraße 21

D-93128 Regenstauf

Knott Regenstauf 3.2

Unloading schedule / Eggstätt facility

Monday

7:00 a.m. – 3:00 p.m.Tuesday

Wednesday

Thursday

Friday 7:00 a.m. – 12:30 p.m.

Unloading schedule / Regenstauf facility

Monday

7:00 a.m. – 3:00 p.m.Tuesday

Wednesday

Thursday

Friday 7:00 a.m. – 12:30 p.m.

In order to avoid unnecessary time spent searching / waiting at receiving, shipping tickets and any other required support documentation must be included in a clearly visible location for both facilities

without being prompted.

RECEIVING

RECEIVING

SHIPPING

SHIPPING

EXITEXIT

3 KNOTT WERKE GERMANY / RECEIVING 3 KNOTT WERKE GERMANY / RECEIVING

ENTRANCE

ENTRANCE

Fig 4: KNOTT RegenstaufFig 3: KNOTT EggstättG

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sisd

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© B

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3.3 Description of receiving/acceptance process

In addition to the transportation containers, packing units are inspected for visible

damage. If non-conformances are identified, goods may be received with restrictions.

Acceptance shall under no circumstances be construed as a waiver of warranty rights

by KNOTT.

A quality defect notice is entered into the system, and the supplier is required to

submit remedial and corrective measures, and is invoiced for any resulting additional

costs associated with inspecting and repackaging the goods. The documentation is

filed with the supplier rating.

3.4 Delivered quality

In order to ensure the quality of the delivered products, the supplier agrees to comply

with all necessary guidelines.

These specifically include:

• Compliance with all manufacturer regulations applicable for the relevant products.

• The driver must immediately inform the KNOTT receiving department if the

packaging is damaged.

Load carriers 3.5

Suppliers to KNOTT are required to deliver their products

in one of the following containers:

EURO pallet 3.5.1

Unless agreed otherwise with KNOTT, goods must only be

delivered on pallets (Fig. 4) in accordance with DIN EN 13698 Part 1

(standardized, returnable transportation pallets with dimensions

1200 x 800 x 144 mm and an empty weight of 20 - 24 kg).

Pallet crates 3.5.2

Goods can be delivered in EURO pallet crates in accordance with. DIN EN 13626 and

UIC 435-3 (Fig. 5). The dimensions of a pallet crate are standardized and are 835 mm

in width, 1,240 mm in length, and 970 mm in height, the empty weight is approx.

70 kg (until 2011 the empty weight of pallet crates was

approx. 85 kg), the usable capacity is approx. 0.8 m3.

The load capacity (1,000 - 1,500 kg), the stacking

capacity (4,400 - 6,000 kg) and therefore the number

of stackable units (three to five units) differs by

manufacturer and quality.

Pallet carton 3.5.3

Due to their design, pallet cartons (Fig. 6) are 4-way

compatible. Pallet cartons are suited as transport

pallets for roller conveyors and pallet racks.

Rack load up to 500 kg.

Rated transportation weight 3.6If the goods do not comply with these quality

specifications, KNOTT reserves the right to refuse acceptance.

Fig 4: EURO pallet

Fig 6: Pallet carton

Fig 5: EURO pallet crate

EURO pallets ≤ 1.000 kg Pallet crates ≤ 1.000 kg Pallet cartons ≤ 500 kg


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3.7 Miscellaneous packaging requirements

• Product parts located inside must also be secured against sliding

during transport. The supplier shall ensure

uniform weight distribution. Small parts can be

prevented from sliding through by placing a foil

(Fig. 7) between layers. Sensitive products must be

protected against moisture by using shrink wrap.

• Dunnage must be used to fill cavities in transportation containers as a means to

protect products against mechanical damage. Materials compatible for recycling

must be used in this case. All packaging materials (polystyrene, FillAir, Packtiger, ...)

must be recyclable and free of hazardous substances of any kind. The respectively

valid IPPC standard must also be adhered to.

• The technically compliant condition of flat EURO pallets must be verified in accordance

with the exchange criteria of the EURO European Pallet Association EPAL.

• Edge protectors (Fig. 12) or alternative reinforcements can be used in certain cases

to prevent carton failure.

• Cartons should be secured to pallets with at least 4 but no more than 8 nails.

• The carton width must not exceed the width of a pallet (Fig. 13). Protruding cartons

(Fig. 14) cause malfunctions in material handling and warehouse systems.

They also represent an elevated safety risk.

• The requirements specified in the above section also apply for pallet crates.

This requires protection between the inside wall of the load carrier and the individual

parts (e.g by placing corrugated cardboard between layers, Fig. 15). This is intended

to prevent damage on surfaces caused by shocks, scratches, etc. - primarily during

transport.

Fig 7: Packaging foil

Fig 9: Filler material - Fill Air system

Fig 11: Filler material - foam packaging

Fig 8: Filler material - polystyrene

Fig 10: Filler material - Packtiger

Fig 12: Edge protectors

Fig 13: Cartons - correct

Fig 15: Corrugated cardboard

Fig 14: Cartons - incorrect


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Type ERG• Returnable packaging is generally preferred.

• All shipments must be delivered sorted by materials. A variance from the

specification is only possible following prior request and approval by the assigned

Procurement department. If this is cost-prohibitive for transportation reasons, this

must be coordinated and approved in advance.

Mixed load units can only be formed when KNOTT has first approved this in writing

or verbally, and additional steps are taken to ensure that the part numbers are clearly

labeled (e.g. labeled with the note „Mixed Pallet“ and the relevant, different part

numbers shown with staggered labeling).

• The supplier is immediately invoiced for any resulting costs for internal special

processes (e.g. repackaging).

• Fixed identification for labels / information applies for pallet crates (Fig.16) / cartons

(Fig.17); these must be attached to the outside in a clearly visible location. See 4.1.1

for more information.

• The ability to stack pallets must be ensured. Ability to stack means that the load

carrier must be delivered with sufficient strength that cracks, bends, damaged pallets

are avoided and the goods survive any form of transportation without damage.

This also includes avoidance of malfunctions in material handling systems and

minimizing safety risks, as specified in Section 3.7.

• Parts identified in accordance with KNOTT Standard 836 “Technical Surface

Specifications“ in the purchase order must be inspected, packaged, and delivered in

accordance with with the referenced standard.

3.8 Non-conforming packaging

Goods acceptance is rejected if the goods were damaged because of inadequate

packaging. In this case, a non-conformance report with photograph is prepared that

references the inadequate packaging. The damage to the goods is additionally noted

on the bill of lading / shipping ticket.

Fig 17: Carton identificationFig 16: Pallet crate identification

Labeling 4.1

Shipment identification 4.1.1The shipment must be visibly identified with a label (Fig. 18). This label must show the

number of packages and the numbering of the load carriers.

Part identification 4.1.2The part must be visibly identified on the label (Fig. 19).

The following minimum data must be shown on this label:

• Part identifier with Knott part number and/or barcode

• Drawing number and revision level / index

• The serial number of a product must be attached on the packaging in a location

visible from the outside

• Quantity (or packaging unit) or weight of the particular part

Fig 18: Example for shipment identification

Fig 19: Example part identifier

Number of packages

Quantity

Serial number

Barcode

3 KNOTT WERKE GERMANY / RECEIVING 4 IDENTIFICATION

Weight

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Knott GmbH

(5) Gewicht netto (kg)

736,5000

(1) Warenempfänger

Kessler Handels-GmbH & Co. KGWerk I

(2) Abladestelle - Lagerort

Hüttlinger Straße 18-2073453 Abtsgmünd

(3) Lieferschein-Nr. (N)

322239

(4) Lieferant

(8) Sach-Nr. Kunde (P)

(9) Füllmenge (Q)

15 Stk(10) Bezeichnung Lieferung, Leistung

Hydr. Festsattel 4x85 (mineraloelbestaendig)(11) Sach-Nr. Lieferant (30S)

101845.02(12) Lieferanten-Nr. (V) 34 500

(13) Datum (D)

D151027

(6) Gewicht brutto (kg) (7) Anzahl Packstücke

1

(15) Spez. Info Kunde

Obinger Str. 15, D-83125 Eggstätt

2159693(14) Auftrag (A)

The shipping ticket must be attached on the outside of each load carrier.

Acceptance can be rejected if the shipping ticket is missing.

4.1.3 Labeling in accordance with VDA Standard 4902

Each load unit must be equipped with a machine-readable goods tag (Fig. 22) in

accordance with VDA standard 4902. For each goods transfer (receiving, etc.), the

objective is to automatically read all warehouse-relevant data by scanning the barcode

on the VDA goods tag. Individual packages should be identified with the VDA label

4902 revision 4 (210 mm x 74 mm for single and 210 mm x 148 mm for complete

loads).

Fig 22: Goods tag

Product travelers 4.2

Each shipment must be accompanied by the required goods supporting documentation

(shipping ticket, factory certificates, etc.). Supporting documentation must be attached

to the package in a clearly visible location using a shipping ticket pouch. The shipping

ticket pouch is designed to protect the documents located inside against dirt and

moisture.

Shipping ticket 4.2.1

The following details must be indicated on the shipping ticket in the format in

accordance with DIN 4991 and content in accordance with VDA 4913. The shipping

ticket number should be additionally indicated as a barcode in the Code 39 format.

Shipping ticket elements

✔ KNOTT Purchase order number ✔ Shipping ticket number

✔ KNOTT Part number ✔ Supplier number

✔ KNOTT Part identifier ✔ Internal supplier part number

✔ KNOTT Drawing number ✔ Gross and net weight

✔ KNOTT Drawing index ✔ Drop-off location

✔ Shipped quantity ✔ Contact person

Fig. 24: Example SupplierFig 23: Example KNOTT Purchase Order

4 IDENTIFICATION 4 IDENTIFICATION

Fig 20: Shipping ticket in the pallet crate Fig 21: Shipping ticket in the package

Goods receiver Net weight Drop-off location - warehouse location

Shipping ticket No.Supplier

Fill volume

Number of packages

Supplier No.

Identifier for shipment, deliverable

Purchase order

Acceptance can be rejected if the shipment is not accompanied by a shipping ticket. This regulation also

applies to freight carriers who work on behalf of the supplier or KNOTT. All documents and identifiers shall be

preferably written in German in a clearly legible format. The shipping and freight documentation intended to

identify the shipment must at all times be written in German and / or English. A German or English translation

must be included if a different language is required by law (e.g. customs regulations).

Mailing address

Purchase order No.

Supplier / KNOTT part

number

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4.2.2 Miscellaneous documents

• First article inspection reports must be delivered together with the segregated

and clearly marked inspected parts, labeled as „FIRST ARTICLES“.

• Factory or acceptance testing certificates must be included

with the shipping ticket when the goods are delivered.

• As-built variance requests approved by KNOTT must be included

with the shipping ticket.

• Exceptions must be obtained in advance from the assigned Procurement

department.

• Acceptance of the goods can be rejected if documentation is missing or defective.

4.3 Additional requirements

• Parts must be packaged so that they are protected against any form of damage.

This should be accomplished by minimizing the use of disposable packaging.

• Products must be packaged so that they are protected against moisture /

condensation water ingress.

4.4 Forwarding

If a shipment is delivered to KNOTT Germany that needs to be forwarded to another

INTERNATIONAL KNOTT factory, this intent must be approved by the relevant

Procurement departments of the factories before the goods are shipped.

Without the approval of the relevant buyer, the shipment will not be accepted and

will be returned at the sender‘s expense. If approval is granted, the shipment must

be specifically identified for forwarding on the outside of the load carrier and in the

shipping tickets.

Requirements for product quality 5.1

and the production process

All delivered products must comply with EU standards and the relevant applicable

directives, certificates, etc.

If the delivered goods were produced on the basis of design-engineering documentation

from KNOTT, the supplier is required to immediately report these in writing.

The supplier also agrees to deliver the goods in compliance with the latest design-

engineering documentation, and to produce said documentation on request.

The supplier is required to keep gap-free records of

quality inspections during production, and also agrees to produce these records at any

time when requested by KNOTT.

New products must be planned jointly together with KNOTT Procurement according

to the relevant requirements. Where required, the supplier shall assign appropriately

qualified employees for the planning phase.

First article inspection 5.2

(quality assurance prior to series production)

The purpose of the first article inspection is for the supplier to demonstrate the

required quality-related capabilities and to verify that the requirements in the drawing

and other specifications have been met.

First articles are products manufactured and inspected under series conditions

(machinery, production lines, process and inspection tools, operating conditions).

The inspection results for all features shall be documented in a first article inspection

report. The number of parts to be documented must be agreed with KNOTT, but is at

least 1 per cavity.

The first articles must be delivered together with the first article inspection report and

the documentation in accordance with the submission milestones by the agreed-upon

deadline and to the agreed-to facility (Eggstätt, Regenstauf). The materials must be

clearly identified as first articles.

For purposes of identifying features, the same numbers shown in the latest drawing

approved by KNOTT (to be included in the delivery) must also be used in the first

article inspection report. Modules manufactured in accordance with a KNOTT design

must undergo a first article inspection (including for their constituent parts) and must

be submitted to KNOTT. For products designed by the supplier in-house, the supplier

is required to supply the modules to KNOTT for sampling purposes. First article

inspections are also required for constituent components and any applicable sub-

assemblies. When requested, KNOTT must be granted access to this documentation.

Variances from KNOTT specifications not identified during the production process

and the product approval phase entitle KNOTT to claim these as instances of non-

conformance at a later point in time.

4 IDENTIFICATION 5 QUALITY ASSURANCE PROCESS

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5.2.1 Reasons for first article inspections

Based on the indicated set of regulations, first articles are required:

• following a product revision on all affected features

• following a drawing revision level change on all affected features

• following a change in the supplier‘s sub-contractor

• following changes in the production methods / processes

• following the commissioning of new / modified forming tools (e.g. casting,

punching, rolling, forging, press tooling, for several dies and / or for each

cavity on multi-cavity dies)

• following production facility relocations or use of new or relocated machinery

and / or operating equipment

• following use of alternative materials and designs

Exceptions in the procedure and scope are only permitted following approval from the

KNOTT quality representative.

5.2.2 Submission milestone (VDA Volume 2)

The regulations in VDA Volume Submission Milestone 3 applies for first article

inspections, unless KNOTT has specified otherwise or other written agreements have

been made.

The first article documentation in accordance with the required submission milestones

(VDA Volume 2 para. 4) must be submitted together with the first articles.

Missing, incomplete, or deficient first article documentation results in a negative

supplier rating and will not be processed. The supplier can be invoiced for

consequential costs from this.

5.2.3 Non-conformances on first article samples

Documentation, records, and first article parts can only be submitted when all

specifications have been met.

Any identified non-conformances must first be approved by KNOTT in writing based on

the “As-built variance request“, which must then be included with the submission.

KNOTT will not process first articles with non-conformances for which there is no

variance request.

FMEA 5.3(Failure Mode and Effects Analysis)

This is a method for conducting an front-end analysis and assessment of potential

defects during the development phase, the manufacturing and assembly of the

products, or for changes in the current manufacturing process. The scope of the FMEA

must be approved by the relevant quality representatives & product developers at

KNOTT.

The FMEA is a „living document“ that is continuously updated based on complaints

from KNOTT. The FMEA must be presented for review by KNOTT when requested.

As-built variances / customer variance approvals 5.4

Without exception, as-built variances require prior approval from KNOTT.

Variances must be declared in writing to the respectively assigned product owner at

KNOTT. A first article inspection is not possible without such a form of the as-built

variance approval. As-built variance requests must be included with the product

support documentation.

Quality assurance during series production 5.5

For purposes of series deliveries, the supplier must take into account the processing

time for the first article inspection. Since the approval process is product-dependent,

the supplier is required to obtain information about the timeframe required for the

particular first article inspection from the Procurement department. The supplier runs

any series production without an approved first article inspection at its own risk.

Incoming inspection 5.6

Independently of the outgoing inspections conducted by the supplier, KNOTT conducts

the following inspections on a random basis:

• identification check

• visual inspection for directly evident transportation damage

• quantity checks

KNOTT will notify the supplier in writing about identified defects.

Defects that were not evident and / or not identified during the receiving inspection are

reported to the supplier immediately after these become known.

5 QUALITY ASSURANCE PROCESS 5 QUALITY ASSURANCE PROCESS

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7 HANDLING OF INCURRED COSTS

6 DEFECT CLAIMS PROCESS

• All non-conformances from technical and other specifications for the product

and the approved first article parts are classified to be non-compliant and are

immediately reported to the supplier.

• The supplier is required to supply KNOTT with information in the form of stop-gap

measures within 24 hours after having received the defect claim.

• The corresponding statement from the supplier must be submitted as an 8-D report

to the Quality Assurance and Procurement departments within 10 days.

• If the analysis of the incident requires more time or the supplier‘s statement is

required on short notice due to the urgency of the situation, said statement must be

promptly submitted informally to the function that reported the defect.

KNOTT is entitled to charge back to the supplier any costs incurred due to

defects caused by any deficient quality performance attributable to the

supplier. Depending on the resulting labor (regional hourly rates, scope,

duration), KNOTT in particular charges back the following cost types:

• sorting actions

• rework

• production downtime

• tied-up warehouse space

• analysis activities

• resubmitted first article inspections following a rejection

• claim-related process acceptance testing

• processing costs for customer claims (caused by supplier)

• costs for production capacity - e.g. machining costs for recurring casting defects

“Reliable logistics form the basis for efficient processes“.

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8 MISCELLANEOUS

9 INVOICING / PAYMENT

10 GENERAL TERMS / CONCLUDING COMMENTS

Knott GmbHObinger Straße 15

83125 Eggstätt, Germany

Phone: +49 8056 906-0

Fax: +49 8056 906-103

E-mail: [email protected]

Internet: www.knott.de

Knott GmbH, Branch FactoryGutenbergstraße 21

93128 Regenstauf

Phone: +49 9402 9317-0

Fax: +49 9402 9317-20

E-mail: [email protected]

Internet: www.knott.de

11 CONTACT

Fig 25: Regenstauf facility

• Before entering the KNOTT facility grounds, freight operators are required to

comply with all occupational safety regulations (e.g. by wearing safety shoes

and safety vests)

• A shipping ticket and / or alternative freight documentation must be presented prior

to any unloading. Non-compliance with this regulation may result in the shipment

being returned.

• Non-compliance with these regulations generally results in internal, costly add-on

processes. The supplier can be invoiced for these costs. Any changes to agreed-

to transport costs must first be approved by the Procurement department of the

relevant facility.

Invoices are approved in digital or hardcopy format.

For invoicing purposes, we ask that you only send invoices directly from your invoicing

software as a PDF to the following email address:

[email protected].

PDF invoices that were scanned are not approved.

Please contact your assigned Procurement staff with any

questions you may have about this.

The supplier manual can also be downloaded in German and English from our

homepage www.knott.de.

This document is binding and applies to all business partners of Knott GmbH.

The standard business terms & conditions are the basis for business transactions

processed with our supplier and partners.

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12 INDEX OF FIGURES

Figure 1: Supplier process 10

Figure 2: Supplier classification 13

Figure 3: KNOTT Eggstätt aerial photograph 16

Figure 4: KNOTT Regenstauf aerial photograph 17

Figure 4: EURO pallet 19

Figure 5: EURO pallet crate 19

Figure 6: Pallet carton 19

Figure 7: Shrink wrap 20

Figure 8: Fillers - polystyrol 20

Figure 9: Fillers - Fill Air System 20

Figure 10: Fillers - Packtiger 20

Figure 11: Filler materials - foam packaging 20

Figure 12: Edge protectors 21

Figure 13: Carton - correct 21

Figure 14: Carton - incorrect 21

Figure 15: Corrugated cardboard 21

Figure 16: Pallet crate identifier 22

Figure 17: Carton identifier 22

Figure 18: Example for shipment identifier 23

Figure 19: Example for part identifier 23

Figure 20: Shipping pouch in the pallet crate 24

Figure 21: Shipping pouch on the package 24

Figure 22: Goods tag 24

Figure 23: Example of KNOTT purchase order 25

Figure 24: Example supplier 25

Figure 25: Regenstauf facility 33

We make your brake

Knott GmbH

Obinger Strasse 15

83125 Eggstätt

Germany

Phone: +49 8056 906-0

Fax: +49 8056 906-103

[email protected]

www.knott-group.com

KNOTT subsidiaries

KNOTT representatives

BRAKE AND TRAILER TECHNOLOGY

GROUP

The Knott Group –global competency

The member companies of the Knott Group design, develop, produce

and market braking systems for commercial and off-highway vehicles

together with running gear components for trailers.

Competent, one-to-one consulting and outstanding product quality

are characteristic of all the companies within the Group.

KNOTT’s own production plants and branch offices are supported by

a world-wide dealership network.

Brakes Manual - KNOTT GmbH8 8 9 9 KNOTT Supplier Manual July 2016, revision number: 004/2016 KNOTT...

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Transcript of Brakes Manual - KNOTT GmbH8 8 9 9 KNOTT Supplier Manual July 2016, revision number: 004/2016 KNOTT...