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Kiekert AG · 42577 Heiligenhaus · Germany · www.kiekert.com · Copyright 2015

6. Сomplete revised edition, Heiligenhaus, January 2015.This quality policy is protected by copyright. Any use or reproduction in whole or in part requires our permission. Located in the Internet documents and texts will be authorized for your use by our suppliers as part of your contract. The use of it by third parties without our permission is prohibited.

OF PURCHASED PARTSIN THE KIEKERTGROUP

QUALITY ASSURANCE

Supplier Quality Guideline

QR01

Supplier Quality Guideline QR01

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Contents 1. Introduction ............................................................................................................................................ 4 2. Scope .................................................................................................................................................... 5 3. Supplier Requirements .......................................................................................................................... 5 4. Selection and Approval of Suppliers ..................................................................................................... 7

4.1 Approval Procedure Process (Process Audit) ............................................................................... 7 4.2 Approval as a „Development Supplier“ .......................................................................................... 8

5. Submission of Quotation and Feasibility Assessment ........................................................................... 9 6. Project Management ........................................................................................................................... 11

6.1 Project Planning / Milestones ...................................................................................................... 11 6.2 Status Reports on Project Progress ............................................................................................ 11 6.3 Advanced Quality Planning (AQP) .............................................................................................. 12 AQP Phase 1: From Kick-Off to Tooling Go Ahead ................................................................................. 13 AQP Phase 2: From Tooling Go Ahead to PPAP readiness ................................................................... 13 AQP Phase 3: From PPAP prepared to Launch Readiness .................................................................... 14 AQP Phase 4: From Launch Readiness to Close-Off ............................................................................. 14

7. Documentation requirements for safety parts ..................................................................................... 15 8. Tool Management ............................................................................................................................... 16

8.1 Tool identification ........................................................................................................................ 16 8.2 Tool maintenance and -documentation ....................................................................................... 16 8.3 Tool revision and process innovation .......................................................................................... 16 8.4 Cavity/ Mold Identification ........................................................................................................... 17

9. Release for Series Delivery ................................................................................................................. 18 10. Testing ............................................................................................................................................. 20

10.1 Periodic Tests .............................................................................................................................. 20 10.2 Requalification Tests ................................................................................................................... 20 10.3 Deviations .................................................................................................................................... 20

11. Complaints ...................................................................................................................................... 22 11.1 8D reports / failure analysis ......................................................................................................... 22 11.2 Warranty ...................................................................................................................................... 23

12. Handling, Storage, Packaging, Labeling and Delivery .................................................................... 24 12.1 Logistical Incoming Inspection .................................................................................................... 24 12.2 Non-conforming deliveries, complaints, logistical complaint records .......................................... 24 12.3 Traceability .................................................................................................................................. 24

13. Ongoing Supplier Evaluation at the Serial Production .................................................................... 25 13.1 Quality Improvement Initiative/ Escalation .................................................................................. 25 13.2 Quality Competition ..................................................................................................................... 26

14. Continuous Improvement ................................................................................................................ 27 15. Forms and Documents .................................................................................................................... 28 16. Capability Verification Process ........................................................................................................ 29


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17. Severability Clause .......................................................................................................................... 3018. List of abbreviations/ ....................................................................................................................... 30

19. Applicable documents ..................................................................................................................... 31

20. Modification History ......................................................................................................................... 31


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1. Introduction

Kiekert is the inventor of modern central locking and servo locking. We are the world’s leader with the largest market share within the sector of automotive side-door latches. Today our customer portfolio includes more than 50 automotive manufacturers and retail brands. Our leading position in the development of locking systems is based on this comprehensive experience.

Approximately 250,000 products are shipped from our worldwide locations each day. The quality and reliability of our products are the basis of maximum comfort and safety for car drivers.

All processed components in our locking systems are purchased parts. Kiekert consumes more than 3 billion components every year. The performance and quality of our partners contributes decisively to the collaborative business success.

Our suppliers must provide excellence to our requirements. The automotive significant certifications such as ISO TS 16949, an Environmental Management systems such as ISO 14001 as well as the application of Lean Principles form the basis of their own services.

The performance and the innovation of our suppliers support Kiekert in exceeding the quality challenges of our customers worldwide.

We encourage you, our supplier and partner, to comply with the requirements defined in the quality guideline QR01, so that we may develop our products to the highest standards and can successfully produce.

Heiligenhaus, January 2015

Dr.-Ing. Guido Hanel Executive Vice President Planning, Program, Quality

Dr.-Ing. Klaus Hense Director Global Quality

Dr.-Ing. Dirk Steinebach Senior Manager Global Supplier Quality


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2. Scope

The scope refers to all production materials and components that Kiekert receives from our suppliers. Prototypes, equipment materials, supplies, consumables (if not specified in Kiekert drawings) and services are exempted and can be fulfilled by separate agreements, for example based on the QR02.

3. Supplier Requirements

For effective and purposeful collaboration between Kiekert and its suppliers, the following basic requirements to our suppliers are defined:

• The supplier is solely responsible for Quality of planning and executing work contents atmanufacturing, assembly and test work stations. The latter is always and permanentlyresponsible to Kiekert for the quality of their manufactured or supplied products including theservices and consignments of their sub-suppliers taking into consideration: drawing-requirements, technical delivery terms, engineering standards, public standards, OEMrequirements and regulative and statutory regulations. Therefore, the activities defined in thisQR 01 and in the components-specific AQP must be taken into account. Furthermore, thesupplier is solely responsible for providing and updating of the Kiekert- and customerrequirements, which are specified at the product and condition documents, as long as this isproportionate. The supplier will actively inform Kiekert, if they are unable to obtain therespective requirements documentation. The quality responsibility also comprises suitablepackaging. Details for the transport protection can be found in the Kiekert logistics guideline.

• Kiekert Quality Agents (for example Supplier Quality Engineer, SQE) are authorized to agreeto the actions necessary for reaching and holding the quality ability with the supplier.They are also authorized to check the implementing of those agreements continuously.

• The supplier shall grant the right of access to Kiekert and its customer employees. Thesupplier assures the free-of-charge onsite support by qualified personnel, at the supplier siteas well as at sub-suppliers sites.

• The supplier commits to collect, analyze and to supply the data, which is equired from theKiekert quality agent to create the quality documentation and to supply this data togetherwith the concerned consignment or following a special request. The supplier must keep thisdata available throughout the retention period.

• If additional tests or reworks are necessary due to a detected failure, which is – based on forexample incomplete data -of the shipping-documents, faulty parts, wrong deliveries and/ormissing or incomplete Quality Verifications, the failure costs shall be invoiced to the supplier.These costs can exceed the costs of the claimed parts by far.

• The supplier commits to grant Kiekert the rights concerning warranty-complaints alsoin the case, that the failure is detected only at the production process, although thefailure could be detected at an incoming inspection. The supplier receives the informationconcerned and will be requested to introduce actions to limit the effects of deviations. Thesupplier is committed to clarify the failure cost situation with their liability insurance in order toensure that the necessary product liability insurance inclusiding the product recall insuranceprovide such coverage.

• The warranty periods are defined in the Kiekert General Conditions of Purchase.• The emergency planning describes the hazard potential and the concerned safety measures

for all operating-, production- and delivery-departments at the supplier. The supplier definesunder their own responsibility, an emergency concept in order to avoid the risks of interrupteddelivery or loss of production. Fire protection, theft protection, data backup and safety, (sub-)supplier management, spare tooling, spare parts and machine capacity at different productionsites or suppliers all are to be specifically considered.


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• Insurance Coverage:o The supplier is required to contract and maintain extended product liability insurance

coverage for the following cases:§ Connecting, mixing and processing§ Secondary Processing and manufacturing§ Disassembling and installation costs including replacement of automotive parts§ Damage caused by defective machines and machine components§ Testing and sorting costs for automotive partsThe insurance shall include a recall cost insurance.The minimum coverage for each insurance shall be € 3.0 million per event andannum. The retention per claim shall not exceed 100 000 EUR. The insurance shall bedemonstrated annually over a predetermined Kiekert form.

o For claims of third parties against Kiekert due to defective delivery or performance of thesupplier, the supplier shall also conclude the Kiekert supplier liability insurance groupcontract at its own expense and beyond its own insurance coverage. By this, thesupplier will additionally be secured, unless the supplier can prove a minimum coverage of€ 7.5 million for the risks mentioned above with own coverage.

• The supplier follows the requirements of the Kiekert “Supplier Code of Conduct” whichdefines the minimum standards in the areas of environment, labor and ethics.

• The supplier uses actively and regularly the Kiekert supplier portal for among other thingsinformation about new features, for the examination of supplier evaluation (see chap. 13) andto independently update its master data (such as contact information, certification status).Other activities in the supplier portal (e.g. initial sample order and documentation, schedules,etc.) are used by the supplier depending on the Kiekert requirements.

Deviations from the requirements of this Quality Guideline shall be approved in written form by our responsible management for supplier quality.

By conclusion of a frame contract the content of this Quality Guideline will be accepted by the supplier. The Kiekert standard business conditions form the basis for the business.


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4. Selection and Approval of Suppliers

The quality management system of our suppliers has been developed according to the automotive specific requirements. To get approved as a Kiekert supplier, a certification according to ISO TS 16949 is required. Only in exceptional cases a deviating certification can be accepted. In this case, a plan to achieve ISO TS 16949 standard must be provided. An audit conducted by Kiekert is required in all cases, regardless of the level of certification.

The approval process involves the following steps:

• Information about suppliers by supplier self-assessment (annual update required)• Acceptance of an already carried out QM-system audit according to the requirements of the

automotive industry by an approved certification company• Conclusion of a confidentiality agreement• Presentation of the emergency planning / risk management• Conclusion of an eventually required Quality Assurance Agreement (QAA)• Acceptance of the Kiekert QR01 and if necessary QR02 (Prototype Delivery)• Acceptance of the Kiekert logistics guideline• Acceptance of the Kiekert Supplier Code-of-Conduct• Training of Kiekert-specific requirements, e.g. supplier portal, PPAP, IMDS, …• Providing a product liability insurance / recall cost insurance policy with a coverage

of min. € 3,0 million per event and year plus the confirmation of the Kiekert group insurance orproviding a product liability insurance / recall cost insurance policy with a coverageof min. € 7,5 million per event and year

• Passing of a Kiekert specific approval audit based on a reference serial production process.The Kiekert audit scheme is based on the VDA 6.3 standard and is enriched by additionalrequirements of Kiekert and the OEMs. Additionally, the level of production expertise and theimplementation of the Lean Philosophy is being assessed. All quality- and process-recordshave to be illustrated to the auditor of Kiekert.

A passed audit alone is not sufficient for the company to be listed as a supplier of Kiekert. All above-mentioned steps shall be fulfilled for this purpose.

4.1 Approval Procedure Process (Process Audit)

In the context of the supplier approval process Kiekert arranges an approval audit. An approval process is also required in the following cases:

• The subcontractor structure of the supplier has changed. In this case, a duty of disclosure of thesupplier is required, before changing of the subcontractor(s) takes place. The disclosure has to betransferred in written form to Kiekert.

• Changes of the production sites (organization) or the QM-System of the supplier take place. In thiscase there is the duty of disclosure in written form, before the changes are introduced.

• The quality of delivered products is poor, that means that the supplier has been assessed as achronic offender / top problem supplier location due to volume, timing or quality problems.

• When the business status “New Business Hold” shall be reset to normal.

The Kiekert SQ (Supplier Quality) organization supports the Kiekert suppliers by answering their quality questions. Kiekert will nominate a SQE (Supplier Quality Engineer) on request. The responsibility for the quality of supplied components and supplier processes remains at the supplier.

The disclosures must be forwarded to our responsible purchasing persons.

The level of compliance with the requirements will be evaluated as follows and will serve as a basic decision for the award of contract:


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Evaluation of the process

Total degree of fulfillment in %

Classification Meaning

Meets the requirements

90 - 100 A Process of the supplier meets the requirement for the serial production. For the detected minor deviations, respective actions need to be implemented prior to SOP.

Minor deviations 80 < 90 B Process of the supplier meets the requirement for the serial production only after the implementation of actions.

Major deviations < 80 C Process of the supplier is not able to meet the requirement for the serial production. Corrective actions and re-audit are required.

Table 1: Approval and audit process evaluation table

Agreed audit actions shall be executed according to the time schedule. In case of minor deviations (“B” classification), the responsible Kiekert SQE defines, if a reaudit is required or if implementation documentation is sufficient. In case of major deviations (“C” classification), a re-audit is mandatory.

If an audit is conducted during active business and the process evaluation is below 90%, Kiekert may set the business status to “New Business Hold” or downgrade the supplier evaluation.

4.2 Approval as a „Development Supplier“

Development supplier are defined as those suppliers being capable to provide significant contribution for parts design or process definition prior to the release of serial production drawings.

The status “Development Supplier“ will normally be reached due to a complementary audit, at which the previous general approval (see Chapter 4) has to be completed.

A successful supplier shall be listed in the Kiekert system as an approved development supplier.


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5. Submission of Quotation and Feasibility Assessment

Before the submission of quotation the suppliers carry out advanced quality planning based on CAD data, drawings and corresponding documents. The advanced quality planning includes in particular Feasibility Assessment. The suppliers bring in their know-how and evaluate the quality, manufacturability and compliance of the specifications in close cooperation with production, assembly, sub-suppliers, Kiekert development (PD) and Kiekert supplier quality (SQ).

Thereby the supplier ensures that the product which is to be delivered, is manufactured, assembled, packed and delivered meeting the specifications and quality instructions while also considering the manufacturing capacity.

The Feasibility Evaluation must contain the following items: • All product specifications shall be checked for completeness and ability for the serial production.• If there are definitions of impacting forces at the Single Part Drawing or such requirements are

elaborated during AQP, the supplier shall provide CT (Computer Tomography) proof, that thematerial is free of bubbles and foreign parts, and that the homogeneity (for example avoiding ofbinding lines, dispersion of glass fiber, crystallinity) is assured.

• Tool-, manufacturing and quality-assurance-concepts are defined in a written form, i.e. tool layout,type of machine, inspection equipment, process control method, sensors, hard-wired-controls(e.g. for bad parts segregation), DOE, Mold-Flow Analysis, etc.)

• The Process Equipment shall be well defined, furthermore the concept of care, of maintenanceand preventive maintenance, OEE Overall Equipment Effectiveness Analysis, Poka Yoke actions,SPC, etc. shall be defined.

• Informative process descriptions and process control equipment must be defined• Risk assessments shall be realized in accordance to the AIAG FMEA guide line• Components and processes of sub-suppliers shall be defined and the respective risks have to be

assessed according AIAG FMEA guideline• The flow of material and the transport shall be defined

The feasibility evaluation shall be performed for all new parts and shall be revised and re-confirmed for any product and process change.

During the component lifecycle, specifications can be changed (e.g. 3D data, drawings) – “engineering changes”. In case of Kiekert engineering changes, characteristics previously agreed on and not subject of change cannot be canceled or restricted by the supplier.

The supplier shall commit to Kiekert with the submission of quotation (AQP 0 milestone) via the form “Feasibility Analysis” together with the required reference and analysis documents.

Additionally, the supplier shall perform a detailed capacity analysis in terms of the Kiekert Capacity Commitment (Run at Rate planning assumptions) during submission of order. Hereby the production volume, requested by Kiekert, will be checked against all relevant supplier production process steps regarding the tool and machine capacity as well as the shift scheme and production efficiency.

For receiving the contract award, the capacity commitment and the feasibility evaluation shall be provided without constraints or in the event of minor constraints with an accompanying action plan.


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Remark: The supplier and Kiekert have a common understanding that the feasibility analysis is indicating possible risks and deviations in the series production. Therefore, the objective of this process is to proof unlimited feasibility before awarding the order. This can - under certain circumstances - only be achieved via iterative adjustments.


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6. Project Management

The supplier must have an appropriate project management. For each project a responsible person shall be nominated this person coordinates all project activities. The project responsible person has to be indicated to Kiekert by name during the complete project phase. In order to reach the technical, timing, financial and qualitative project targets a Comprehensive Project Plan with interdivisional validity has to be created. It shall clearly show all planned targets. The Project Plan shall disclose potential risks and critical project phases in order to introduce necessary Corrective Actions. The complete scope of the project planning (Project Management) depends on the complexity of the product and must defined in the context of the AQP-Process with Kiekert.

6.1 Project Planning / Milestones The supplier creates detailed project plans for tool creation and advanced quality planning, which address all items of the Kiekert AQP template. The AQP plan shall show and monitor the following five milestones (see cp. 6.3):

• AQP 0 : Kick Off • AQP 1 : Tool release (tooling go ahead) • AQP 2 : PPAP / ISIR supplying • AQP 3 : Product and process approval • AQP 4 : Close-off

The tool creation plan (detailed view between AQP 1 and AQP2) shall contain the following milestones:

• A: tool design completed • B: tool components created • C: Tool assembled • D: Tool Tryout completed • E: production of PPAP samples completed • F: PPAP submission to Kiekert

6.2 Status Reports on Project Progress The supplier must create a status report which reflects the actual state of the project progress. The report has to disclose those items evaluated as critical and when / how solutions can be realized. The project status report shall be structured according to the project plan and shall be updated at least every four weeks or in compliance with the responsible Kiekert SQE. In the context of the AQP activities the project status must be checked and evaluated by the responsible Kiekert SQE. In case of non-compliance of the planned targets or the specifications, corrective actions will be agreed to with the supplier. Only after having reached all detailed targets and having implemented all corrective actions will the progress of the project continue.


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If available at Kiekert, the supplier must submit regular status information to a tool creation monitoring system (“tool tracking system”). Details will be defined in a separate document and will be part of the QR01 after release.

6.3 Advanced Quality Planning (AQP) During the process/ product development, AQP-meetings with the Kiekert-SQE and the responsible project / quality manager of the supplier are carried out. The results are binding part-specific quality agreements. The AQP-meetings are to agree to proactive actions with the supplier and assure by using checklists that all quality activities are realized, completed and documented prior to start of serial production. If deviations are detected, applicable corrective actions must be introduced. The elimination of the deviations must to be disclosed to Kiekert in written form. Remark: During the AQP-processing (e.g. Detail P-FMEA), previously not considered risks may get disclosed. The risks may only be mitigated by possible additional costs. To achieve the quality goals, these costs must be accepted by the supplier. Open costs coverage may not result in additional risks to the start or serial production. Remark: The risk analysis at component / process level is performed according to the AIAG guidelines. Significance of failure effect as well as probability of occurrence and probability of detection of failure mode must be based on the evaluation scheme. During AQP phase 0 (prior to tooling go ahead) the risk assessment in terms of FMEA is done generically or on the basis of previous / similar products. In the course of AQP, FMEA is developed in detail and evaluated specifically in accordance with AIAG. Supplier-induced lack of cooperation or delays in AQP execution may lead to deductions in the supplier evaluation scheme. Advanced quality planning is conducted in 4 phases with 5 milestones. To monitor the progress, a checklist, structured in 11 chapters, is used. The latest version is available at the Kiekert supplier portal. The following chart provides a brief overview of the AQP project structure / phases and content; the subsequent textual description describes aim and main tasks of the respective phases.


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# AQP Elements

1 Drawing / Specifications

2 Project management & Timing

3 Traceability

4 Measurement & Testing

5 Feasibility (FA) & Process Standards

6 Capacity Planning & Run@Rate Verification

7 Sub-Supplier AQP

8 AQP Matrix special characteristics

9 Tooling / FOT => First Of Tool parts / Pre Series Tools

10 Launch Readiness Audit (LRA)

11 Safe Launch Results

ISIR Measurement Method ISIR Dim./ Dev. ReportUpdate AQP-‐Matrix / Testing

Requirements

Drawings / Nomrs / Regulations / Guidelines / Laws(SAP-‐DVS [document administration system])

Required Documents for each phase

rough Q-‐Proj. Plan Q-‐DPP updateQ-‐DPP Q-‐DPP update

inputs in drawing (see 3.1)

AQP supplied componentsGuideline & Timing Template

AQP 0:Kick off

AQP 1: Tooling go ahead

AQP Phase 1 AQP Phase 4

AQP 3: Product- & process sign off

AQP 4: AQP close off

AQP Phase 2 AQP Phase 3

AQP Phases & Milestones AQP 2: PPAPreadiness

Re ISIR documentation

signed FA FA/ AQP Action Plan

R@R header -‐ volumes

Supplier documentation and

risk matrix

R@R part I & II R@R part III launch

LRA Audit

Supplier Documentation

signed AQP Matrixand risk matrix

Detailed tooling schedule / SAP tool

tracking

Update AQP-‐Matrix

ISIR documentation

R@R partl III peak

LRA Audit

Update AQP-‐Matrix

AQP Phase 1: From Kick-‐Off to Tooling Go Ahead In the first phase, all activities concerning a quality and quantity contract awarding are made. This includes on the side of suppliers in particular the project planning, drawing review, the identification of critical characteristics, the concept of a quality and quantity capable production process including the capacity confirmation and the establishment of a traceability concept. Customer requirements (of the OEM) are taken into account. The results are included in a feasibility analysis ("HA" or "FA") and must be evaluated by Kiekert. The result of Phase 1 is the contract award for series production. The release of the feasibility analysis is mandatory prior to serial production award.

AQP Phase 2: From Tooling Go Ahead to PPAP readiness In the second phase, all activities for ensuring quality and quantity capable processes including. creation of production tools and inspection aids – are conducted. The supplier develops production and quality assurance methods for all critical characteristics. The guiding principle is that potential errors shall be avoided directly in the process by suitable design tool; in-process and downstream inspection may be required as a final protection concept. The planning is done collaboratively between supplier and Kiekert via the critical characteristics matrix. This planning includes not only the dimensional and material-technical aspects in particular, but also customer specific requirements and procedural aspects. At a minimum the stipulations made herein are to be converted into the more detailed documentation such as FMEA, control plan and instructions. In addition to the supplier-internal processes, outsourced processes and purchased parts are to be considered explicitly. The measurement alignment and methods are finalized and the sampling scope are defined with


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special regard to safe-launch activities and production capability. Another core area of Phase 2 is to monitor the progress of tools and production equipment creation. For this purpose, the supplier informs Kiekert regularly about the progress or deviations. The result of Phase 2 is the sampling of the production parts.

AQP Phase 3: From PPAP prepared to Launch Readiness The phase 3 serves to check all the planned activities with the aim of product and process approval. Core elements are the assessment of the PPAP-sampling, the Launch Readiness Audit and the Run @ Rate review. Depending on the complexity of parts and the parts supplier status these activities can be carried out either by the supplier, Kiekert or an authorized third party. The Kiekert SQE determines the release procedure. The implementation of the action plans from all previous phases will be reviewed. If Kiekert minimum process standards are applicable, the respective requirements will be checked on site. The result of Phase 3 is the release for series production in compliance with safe-launch agreements.

AQP Phase 4: From Launch Readiness to Close-‐Off In phase 4, the start of series production is monitored and the effectivity of production and quality assurance concepts is checked. In essence, the results of the specified safe-Launch activities will be evaluated. Should this reveal weaknesses of the actual mass production processes, the specifications made are re-evaluated and additive measures or corrections must be developed. Additionally, the production maximum production capacity is verified. The result of phase 4 is the unlimited production release. A mandatory pre-condition is the PPAP rating with at least UD2 or UD 1.


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7. Documentation requirements for safety parts

Safety parts with required documentation are selected by Kiekert and marked by an inverted delta-sign (triangle on top in a circle) on the respective drawing or written “DS-part” in textual form.

The supplier shall ensure that safety parts with required documentation are clearly identified at each step of the flow of material in order to avoid mixing of products. All those quality relevant documents shall be identified clearly as “required documentation”. The retention period is normally 15 years. Agreements for storage, securing and any time access are determined at the supplier’s QM-System. In case of termination of business the supplier commits to store the documents according to the prescribed documentation time or to provide it to Kiekert. The supplier guarantees that the test results and documentations of the relevant process parameters of their own production and the production of their sub-supplier are stored for each required characteristic. Safety parts with special traceability requirements underlie additional requirements, which are determined by respective Quality Assurance Agreements (QAA / QSV).


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8. Tool Management

8.1 Tool identification If the supplier is instructed to manufacture a serial/ pre-serial tool and the tool is property of Kiekert or a third party ( typically the Kiekert customer), the supplier must label those tools as properties of Kiekert or of the third party. The tool is to be labeled clearly as property of Kiekert/ third party and shall include the following items: • Owner’s sign of Kiekert and/or third party • Tool ID of Kiekert and/or third party • Part Name according to the concerned drawing • Drawing No. or Part No • Index-state • Date of manufacture • Size and weight • Additional labeling required by our customer

8.2 Tool maintenance and -‐documentation

• The supplier commits to create a tool manual / tool record that shall include the following scope: o List of all used single and spare parts (bill of material of tool components, electrodes,

wear parts, etc.) o A maintenance and repair instruction and the concerned records (maintenance

intervals, first general inspection, storage of special spare parts, etc.) o Evidence of the executed maintenance or repair over the complete period (lifetime), at

which the tool has been used. The operations must be documented in a specific manner: date, # of shots / punches, cavity ID, area/ geometry. A generic documentation like “punch exchanged” is not sufficient

o All concerned 2D/3D-drawings/data, optional pictures, photographs and documents o Progress of the production volume over lifetime o The devices and all other equipment, which are necessary to use the tool (for example,

hot runner or thread-cutting devices, cooling equipment, sensors, etc.) must be written down into the maintenance plan and to be confirmed

• The supplier is required to store, use and maintain the tool properly and professionally.

Regulations of the manufacturer must be considered.

• The tool data must be entered into the Kiekert supplier portal and to be actualized. - Baisis for that are the contents of the tool order.

The responsible Kiekert SQE checks the implementation of all mentioned requirements during AQP. With acceptance of the tool order, the supplier commits to comply with all mentioned requirements. The supplier shall maintain process records to prove the effectivity of proper tool maintenance and repair.

8.3 Tool revision and process innovation • The Supplier is required to inform Kiekert in the event of unscheduled maintenance due to tool

breakage or similar events regarding extraordinary maintenance expenses ("Tool Revision"). To


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this end, the repair cost should be presented against a new tool and the actual value of the existing tool. This information is to be sent parallel to the responsible buyer (PU) and Supplier Quality Engineer (SQE) .

• Suppliers are encouraged to practice continuous improvement. If these activities induce fundamental change concepts of tools or processes, the respective concepts have to be disclosed parallel to the responsible buyer (PU), and the Supplier Quality Engineer (SQE) in order to assess the impact to Kiekert.

8.4 Cavity/ Mold Identification One key element of the Kiekert Traceability Methodology is the physical mapping of the components to the tools used for production (see cp. 12.3). The supplier shall ensure, that the cavity / mold IDs are unique across all tool-sets. An ID assigned once may not be used for another cavity / mold. The supplier shall coordinate the identification system with Kiekert prior the creation of the cavity/ mold.


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9. Release for Series Delivery Prior to Serial shipments a Series Delivery Release for each production part number must be granted by Kiekert. For this purpose, the supplier shall perform a First Article Inspection (Production Part Approval Process) and shall confirm full compliance with all requirements in drawings, specifications, standards and regulatory requirements. The evaluation is performed with parts that were produced under series production conditions in all stages, testing and logistics processes (refer to VDA Volume 2, AIAG PPAP Directive). The supplier shall introduce initial samples in the following cases:

• New Products / Changed products (New Index)/ Changed parts • Correction of deviations at previously introduced products • Interruption of production for a longer period (more than 12 months)

Changes at Tools or Process must be carried out according the following matrix:

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Exchange of active tool parts X X Repair of tools X X Repair of Machines and equipment X X Refurbishment of tools / spare tools X X X X Relocation of core processes on same site X X X (X) Relocation of Tools to other Machines X X X X Relocation of tool to different sites X X X X Relocation of tools or processes to external service provider X X X X

Relocation of subprocesses X X X X Emergency Relocations due to acute technical or logistical reasons X X X (X)

Improvements on Tools or Processes w/o gaugeable impact on the parts characteristics (not restricted to dimensional characteristics)

X X X

Change of product creation, e.g. skip or replacement of process steps X X X X

(X): will be determined by Kiekert The responsible Kiekert SQE may determine additional validation requirements

For all other changes of the processes not stated above, the supplier shall inform Kiekert before starting serial production. In this case, the responsible Kiekert SQE decides about the scope of a necessary Initial Sampling.


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Change of material is not allowed. This needs to be officially requested via the Kiekert form “supplier change request”. The assessment does always include Kiekert PD! The details of the release for series delivery are specified in the Kiekert sampling requirements. The latest document release level must be considered. The sampling requirements are as binding as the QR-01 itself. The Kiekert Sampling requirements are available in Kiekert Partner Portal. In the event the current series deliveries are subject of deviations (in the process or at the product) the supplier is required to inform Kiekert about these deviations using the respective form (see Supplier Partner-Portal). Deliveries with deviations are only allowed with Kiekert approval. Deviations in terms of this regulation are not limited to dimensional aspects, but also include procedural changes which may affect covert component characteristics (e.g. tensile strength as a result of the closing of individual cavities in the plastic injection molding).


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10. Testing The supplier ensures that all planned tests of the complete process chain are carried out and documented corresponding to the requirements of the control plan. The results of the SPC-test-characteristics must be evaluated after determined time periods regarding the process capabilities. If the products are not manufactured by a capable process, a 100% check of the products must be carried out until the manufacturing process is optimized and the required Cpk values are met. Inspection / Testing frequency shall be adopted to the The inspection frequency must be adjusted according to the achieved cpk, ppk values and probability of occurance. Before delivering the products the supplie shall check, that all planned production and inspection steps have been carried out to assure that all parts meet all specifications. The definitions of AQP, especially regarding incoming-, process- and outgoing-inspections have to be fulfilled. Specific test reports or foreign test certificates do not disavowal the supplier of its direct quality responsibility with Kiekert.

10.1 Periodic Tests Periodic tests must be carried out in order to assure that all quality requirements are met, which exceed the regular continuous process monitoring. The periodic tests are, for example:

• Environment resistance tests, for example temperature cycling tests, and so on. • Life time tests • Strength tests • Product audits

Periodic tests are usually much more comprehensive than standard tests. Testing method and scope must be clearly defined in the control plan.

10.2 Requalification Tests Requalification tests are standard of the automotive quality management systems. Therefore the supplier must carry out the requalification in the form of an intermediate article check. In general, the requalification interval is one year, unless differently specified component-specific. Requalification tests are always under responsibility of the suppliers and do not require any special order by Kiekert. Requalification Tests may not be charged to Kiekert. Requalification test may not be excluded by the supplier; such contractual agreements are not valid under the scope of QR-01. If deviations against the Kiekert production release (PPAP) are found during requalification tests, the supplier will inform Kiekert autonomous and without prompting. Kiekert may request the Requalification reports according the form and the scope of the Kiekert sampling guideline at any time and without separate charge.

10.3 Deviations If deviations to the specification have been detected during the process monitoring, the supplier must assure, by his QM-System, that the n.o.k. parts are securely separated from the o.k. parts, and that they are clearly marked. Manual segregation systems are not allowed.


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Deviating parts can only be evaluated by a request for deviation and may not be delivered without an approval by Kiekert in written form.


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11. Complaints If deviations are detected at Kiekert due to assembly problems, laboratory tests, customer complaints or other tests, the supplier will be informed about immediately via a complaint report (CR). Following the first information by telephone, the supplier is committed to introduce the necessary actions in order to clarify and to eliminate the deviations efficiently. If a consignment is blocked, the supplier is solely responsible for the isolation of the suspicious parts in the work in process inventory. In this case, the supplier shall introduce immediate actions like replacements or rework. All delivered parts must be checked 100% against the failure mode until the permanent corrective actions are verified to be effective. The labelling must follow the requests of the Kiekert complaint report / the Kiekert SQE. If this is not possible due to deadline reasons, Kiekert and the supplier shall mutually agree about the introduction of immediate actions for production continuity at Kiekert. Production continuity is first priority in order to mitigate the financial impact of deviations. Kiekert reserves the right to implement immediate actions to protect production and outgoing quality, even if the supplier has not agreed to mitigate the risk. Kiekert reserves the right to limit the use of service providers (e.g. sorting providers) for components, that have been handed over to Kiekert. This is required to assure minimum standards for labour, quality and transparency as well as to control the access to Kiekert plants. All costs caused by complaints are basically subject to be paid by the supplier, and such costs are charged to the supplier by debit note. The following cost categories are considered and structurally displayed by complaint report:

§ Scrap disposal of parts and component assemblies § Costs invoiced to Kiekert by customer § Sorting and rework § Material handling and logistics § Testing and investigation of fault § Travel expenses § Documentation and organization of corrective actions

11.1 8D reports / failure analysis The supplier creates an 8D-Report for each Kiekert complaint report. The respective Kiekert form (see Supplier Partner-Portal) or equivalent (incl. 5-Qhy-Analysis) shall be used. Kiekert expects the first feedback within 24 hours after issuance of the Complaint Report. This first report includes at least the points 1-3 with Failure Description, Root Cause of Failure and introduced emergency measures. In addition, a time-schedule for the complete 8D shall be submitted. The supplier shall update report and schedule regularly. 8D reports must always be completed and sent to Kiekert; a 3D report does not relieve of such duty. A 5-Why-Analysis must be created by the supplier. In addition to the technical root cause, the 8D report shall additionally inform about the weaknesses of the inspection method and the quality management system. 8D reports are crucial to secure stable production quality and to derive lessons learned for Kiekert. The Kiekert suppliers are therefore required to carefully create directly case-related 8D reports and to notify to Kiekert. The findings from the 8D processing must be cascaded to the matrix of critical characteristics, the suppliers FMEA, test plans and work / test instructions (lessons learned). Kiekert evaluates the content and processing of 8D reports and will initiate deductions in the supplier evaluation in case of significant violations.


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Additionally, the regulations of the Kiekert supplier improvement initiative remain valid (see cp. 13.1). In case of enduring quality spills, special actions may be implemented and charged to the supplier. Finally, desourcing may be initiated.

11.2 Warranty

The faulty parts can cause malfunctions during longer periods in the warranty field. Because of this the complaint report will not be closed until the warranty complaint is closed.

Partial clearance of costs can be agreed to with the supplier.


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12. Handling, Storage, Packaging, Labeling and Delivery

The requirements for handling, storage, packaging, labeling and shipments are defined in the Kiekert logistics guideline. Local conditions are taken into account.

12.1 Logistical Incoming Inspection

The logistic incoming inspection at Kiekert is limited to random sampling for obvious damage, accordance to product labeling with the shipping documents and the balance of the number of loading carriers to the delivery documents. This deficiencies noted appear immediately.

Deterioration not immediately obvious can also be detected in later stages of value creation (e.g. during assembly, at final testing or at customer). This results in subsequent complaints and does not exempt the supplier from its warranty and liability.

12.2 Non-‐conforming deliveries, complaints, logistical complaint records

If deficiencies are found by Kiekert, they are disclosed to the supplier by means of a test report and the suppliers is burdened with the incurred handling costs. Other costs result from the nature and extent of the deficiency and its impact. This includes, internal sorting, Test and inspection costs, additive production labor, expenses of third parties (e.g. external sorting), travel costs, logistics costs (list is not exhaustive).

If supplier-induced late deliveries or failures against the specifications cause an interruption in production at Kiekert or its customers, the supplier must, in consultation with Kiekert, implement suitable immediate actions (replacement deliveries, sorting and rework, extra shifts, Express transportation, air freight etc.); the supplier shall bear the respective costs.

12.3 Traceability

The supplier commits to assure the traceability of the delivered products. If a failure is detected, the traceability and the containment of the faulty parts must be assured along the complete value add chain.


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13. Ongoing Supplier Evaluation at the Serial Production

Each delivery is received by Kiekert under the application of

“Zero Defects-principle as normal case”

And is available for the production without any following incoming inspection. Deviations against this “Zero defects principle’ are captured by a Complaint Report and are reflected negatively in the delivery statistic of the supplier.

The quality and reliability of supplier deliveries are evaluated continuously. At a minimum the following is included into the assessment criteria:

• Share of faulty parts in ppm• Delivery liability (time and quantity)• Quantity of critical complaints• Quantity of logistical complaints

Suppliers can obtain their actual evaluation weekly by the Kiekert supplier portal. Basic data, which flows into the supplier evaluation particularly, can be added by data into the supplier portal.

Details of our supplier evaluation can be found by the supplier portal: http://partner.Kiekert.com

13.1 Quality Improvement Initiative/ Escalation

The quality performance of suppliers is evaluated at Kiekert on a monthly basis. "Chronic Offenders" are those suppliers identified by purchasing, logistics and quality criterias, and are nominated for the Kiekert "quality improvement initiative".

Within a Kiekert "quality improvement initiative" quality targets and key characteristics as well as actions to achieve these objectives are agreed to between Kiekert and the supplier. If applicable the implementation of CSL ("Controlled Shipping Level") is required until the agreed "Exit" criteria are met.

Depending on the supplier evaluation and of the degree of achievement within a quality improvement initiative is the supplier status is set to "New Business Hold".

The quality improvement initiative is the final instrument prior to a Desourcing decision by Kiekert. Accordingly, the supplier agrees to avail themselves of all available resources for immediate and sustained improvement.

The expenses related to the quality improvement initiative can be charged to the supplier.


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13.2 Quality Competition

Annually the KieCup award ceremony takes place where the best suppliers are rewarded for their supplier performance. The performance review is based on the ongoing supplier evaluation (see above).

Supplier of Excellence KieCup – Quality award

According to the global orientation of Kiekert, global prizes as well as regional prizes will be awarded.


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14. Continuous Improvement

The supplier commits to build up a systematic management system covering their entire organization with the target being to achieve a high degree of customer satisfaction and to improve it permanently.

The complete supplier organization shall support a comprehensive philosophy of continuous improvement of quality, services, products and processes.

Representative Key Performance Indicators (KPI) shall be selected and statistically evaluated in a continuous manner to determine the need for improvement and the effectivity of improvement actions. After implementation of improvement actions, the progress shall be monitored continuously in order to check a sustainable development.

KPIs are for example:

• Costs of scrapping and rework• Number of wrong deliveries• Number of complaints• Sales Trend• Internal production rejections (ppm)• OEE (Overall Equipment Effectiveness)• Delivery performance• Tool / Machine Maintenance

If requested, the supplier must disclose the concerned data and documents to Kiekert.


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15. Forms and Documents

All above-mentioned documents are available for our suppliers as electronic data and can be downloaded at the Kiekert supplier portal at: http://partner.Kiekert.com. Access data will be shared with the supplier upon request.

The supplier is responsible for the current use of online forms.

Kiekert informs the supplier regarding changed documents and forms via the supplier portal. The supplier is then responsible for obtaining the respective documents / forms.

If the supplier does not disagree within a period of 10 days in writing, the changed documents / forms are evaluated as accepted by the supplier. Possible disagreements are to be justified in writing.


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16. Capability Verification Process

Verification, intention Potential Capability of a machine with correct alignment in order to produce normally distributed or nearly normally distributed inside of ±6s of the specification, and to make visible a quality index Cmk ≥ 2,0.

Potential Capability of a production line under influence of many working persons and parts in spite of cumulative influences normally or nearly normally distributed inside of ±6s of the specification, and to make visible a quality index Ppk ≥ 2,0.

Retention of the potential spreading and verification, that due to setting processes, trends or trends-similar influences no process-changes will occur, which endanger the minimal requirements of

+ 5s ≤ OSG - 5s ≥ USG

without a necessary 100 %-check, and to make visible a quality index Cpk ≥ 1,67.


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17. Severability Clause

If individual provisions of the contractual agreements – including the conditions of business – should prove to be impracticable, this does not affect the remaining provisions. The parties shall without delay replace the impracticable provisions by others which as closely as possible approximate the intentions of the impracticable provisions.

18. List of abbreviations/

AIAG Automotive Industry Action Group AQP Advanced Quality Planning CPK Prozess capability index CSL Controlled Shipping Level CT Kernspinn-Tomographie (Computer Tomographie) DOE Design of Experiments DS Dokumentationspflichtiges Sicherheitsteil FA Feasibility Assurance (Herstellbarkeitsnachweis) FMEA Failure Mode and Effects Analysis IMDS International Material Data System ISIR Initial Sampling Inspection Report KPI Key Performance Indicator MTTR Mean Time To Repair MTBF Mean Time Between Failure OEE Overall Equipment Efficiency OEM Original Equipment Manufacturer (BMW, Daimler, Chrysler, Ford, etc.) OSG Upper Specification Limit PD Kiekert Product Design Department PFMEA Prozess-FMEA PPAP Production Parts Approval Process PPF Produktionsprozess- und Produktfreigabe (nach VDA) PPK preliminary Process capability Index QAA Quality Assurance Agreement SPC Statistical Process Control SQ Supplier Quality SQE Supplier Quality Engineer QM Qualitymanagement UD Usage Decision USG Lower Specification Limit


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19. Applicable documents

DIN 55350 VDA book 2 AIAG PPAP guideline Kiekert sampling guideline Kiekert logistics guideline Kiekert purchase terms and conditions

20. Modification History

6. completely revised edition, in particular• Requirements to suppliers (Chapter 3)• Supplier release (Chapter 4)• Tender and Feasibility Assessment (Chapter 5)• Tool management (Chapter 8)• Production Release (Chapter 9) with reference to sampling policy• Handling, packaging, ... (Chapter 12): reference to logistics policy• Process capability (Chapter 16): separated• Salvatory clause (chapter 17): new• List of abbreviations (Chapter 18): new• Applicable documents (Chapter 19): new

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