QAD 7.4.1B Rev.A 8/09/2013 1

Copy Exact Training For SMC Suppliers

Created by: SMC Corporation of America – Noblesville 10100 SMC BlvdNoblesville, IN 46060

Marc Godwin

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To: SMC Suppliers The following information is presented to provide

suppliers the understanding and the need for a strict process and design control for products purchased by SMC under “Copy Exact” requirements.

The “Copy Exact” requirement has been driven by SMC’s customers and the flow down of this requirement to sub-tier supplier is mandatory for eliminating quality excursions.

SMC’s Copy Exact Requirements are defined in the SMC Quality Assurance Supplier Manual.

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What Is Copy Exact?

• It ensures that identical tools perform identically upon installation for our customers without the need for any additional adjustment or tuning.

• Parts are “Build to Print” - any deviations from the drawing or process changes must be approved in advance.

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Supplier Compliance

Approach: Design Control and Change Management focus Reiterate existing Supply Agreement expectations as

defined in SMC’s Quality Assurance Supplier Manual Establish communication for all Copy Exact issues Emphasize accountability Training

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How do I know if the products I supply to SMC require Copy Exact compliance?

If your company have been sent this training material, your company has been confirmed as supplying product to SMC that falls under the Copy Exact requirements.

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When does Copy Exact Take Effect?

When SMC receives and accepts your first article report with your accompanying certification of compliance or first shipment where applicable.

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Why is Copy Exact Critical? Many of SMC’s customers are in the

medical equipment and microelectronic wafer processing industries.

Defective components can cost our customers losses in the millions of dollars with effect of the potential of loss of business to SMC.

Our customers demand this.

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What is a Copy Exact What is a Copy Exact “Violation”?“Violation”?

When a supplier makes an uncontrolled and/or undocumented change from the drawing or to the manufacturing process of a part without prior SMC/Customer approval, a Copy Exact VIOLATIONVIOLATION is deemed to occur.

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Copy Exact Violation (cont.):Supplier’s Subcontract Change

A supplier shall not change the established subcontractor for components, processes or completed / substantially completed items supplied to SMC without prior notification and approval.

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Manufacturing Process Elements5M’s + 1 E:

The “5 M’s”.• Methods.• Machines.• Material.• Manpower (Untrained personnel). • Measurement.

1 E• Environment.

No changes are to be made to these elements without prior approval.

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How to ensure products delivered are Copy Exact?

Establish series of well defined steps that repeatedly produce a part within an agreed to specificationAny uncontrolled process step is inadequate and will have impact on copy

exact product. “Copy exact” in everything that is produced, do not change anything (5M+E)

without prior notification and approval. Key parameters (on the part, on the tool set,..) are routinely measured and SPC

maintained (if required by SMC).The parts produced are within the UCL and LCL (upper & lower control

limits)There are well defined responses when there is any deviation in an SPC

parameter Parameter impacts are understood for control parameter changes

Measurement tools are calibrated according to set standardsAdequate preventive maintenance is determined. Determine tool wear behavior and identify yield improvements.

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How does a supplier notify SMC of a proposed Copy Exact change?

The instructions and form are included in your SMC Quality Assurance Supplier Manual.

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Copy Exact Non-compliance Examples

Some Actual Case Examples……

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Non-compliance ExampleNon-compliance Example

Machine Change:

Supplier changed from milling machine A to another milling machine B in order to meet a production schedule.

Resulting Impact:

The components which arrived had numerous leak/sealing issues on the manufacturing floor and upon closer inspection it was noted that machine B was a different make/model than machine A. Once the specs for the milling machines were compared, it was noted machine B could not produce to the same tolerances as A, resulting in the original leak/sealing issue.

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Non-compliance example – Material Change

Problem Statement

Windows failed at several customers for high particles

Root Cause

Supplier used wrong material

Material shortage of as specified material resulted in substitution of a different higher grade material. Not approved prior to implementation.

Short-Term Containment■ All windows were screened for correct material.■ World wide purge/recall of all effected parts.

Long-Term Containment

Supplier improved their material tracking process. All parts are now traceable to boule number and original raw material supplier P.O.

100% secondary inspection performed at final clean prior to delivery.

Liability Cost

Supplier ~$100K

Customer $1.3M+

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Non-compliance example – Design ChangeProblem Statement

High particle count in chamber

Root Cause

Supplier increase chamfer around Helicoil in improve manufacturing yield.

Increased chamfer allows gasses to flow past fasteners transporting loose particles to the wafer.

Notification submitted after implementation and rejected.

Short-Term Containment

Deviation OK to build ”as is” until DOE is complete

Long-Term Containment

New part number created to evaluate tools requiring small chamfer.

Add a picture

Liability Cost

$140,000 investigation, including DOE 2 months

Customer could have lost $$ and chargeback to supplier.

Thermal Control plate, side A

Thermal Control plate, side B

Large chamfer allows gas to flow between side A and side B transporting trapped particles from the helicoil

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In summary, Copy Exact means:

No changes are to be made to the established process or subcontract supplier without SMC approval once the First Article or first shipment has been accepted by SMC.

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The Bottom Line...

Copy Exact requires coherent change management.

Copy Exact violations can cost any one of our customers millions of dollars $$$.

Conformance to Copy Exact standards enhances SMC’s customers’ business results, productivity & satisfaction, and therefore our FUTURE BUSINESS.

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Copy Exact In ReviewCopy Exact In Review

Copy Exact is a change control process that provides for advance notification and/or approval prior to making a change.

Copy Exact applies to all SMC products where a business decision has been made to do so.

Copy Exact is based on the unambiguous and maintained reference configurations.

Copy Exact is affected by process controls and the 5M+E.

A “violation” occurs when a supplier makes an uncontrolled and/or undocumented change.

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Thank-you for reviewing this training.

Please document all personnel who have reviewed this training in your company and keep in your training records. SMC may periodically request documented evidence of the training completion as necessary.

If you have any questions or concerns, please contact:

Craig Nagahori – Purchasing Manager Noblesville - (317) 688-0556

Terry Moody – Quality Engineer Noblesville - (317) 688-0625

Mark Miller – Quality Manager Noblesville - (317) 688-0525