Global Supplier Quality Manual - TRW Automotive 全球供应商质量手册――天合（TRW）汽车
Controlled only when viewed online at TRW Automotive's Website 只有在天合汽车网站上发布的观点是受控的
Revision History (Current revision: E0; Last revised: June 2004) 修订历史记录（当前版本：E0；最近一次 修订：2004 年 6 月） Management Message 经营讯息 Section 1 - Introduction 第一章 介绍
1A. Policy and Vision 方针和远景目标 1B. Purpose 目的 1C. Scope 范围 1D. Responsibility 职责 1E. Language 语言 1F. Supplier Development Template 供应商发展模板 1G. Government Regulatory Compliance 政府调整顺从 IH. End-of Life Vehicle (ELV)/International Material Data System (IMDS) Reporting IJ. European Quality Assurance Agreements 欧洲质量保证协议 1K. General 概要 Section 2 - TRW Automotive Requirements 第二章 天台汽车需求 2A. Supplier Selection Process 供应商选择程序 2A.1. ISO/TS16949:2002 Registration ISO/TS16949:2002 注册 2A.2. e-Business Capabilities 电子商务能力 2A.3. New Supplier/Location Qualification 新供应商/地理条件 2A.4 New Supplier Assessment Criteria 新供应商评估标准 2B. New Product Launch 新产品投放市场 2B.1. Introduction 介绍 2B.2. Advanced Product Quality Planning (APQP)产品质量先期策划 2B.3. Production Part Approval Process (PPAP/ISR)生产件批准程序 2B.4. Lot Traceability 可追溯性 2B.5. Special Characteristics 特殊特性 2B.6. Prototype Fabrication and Quality Evaluation 原型制作和质量评估 2C. Serial Production Processes 2C.1. Introduction
2C.2. Supplier Request for Change 2C.3. Concern Management 2C.4. Supplier Audits 供应商审核 2C.5. Sub-supplier Management 分供方管理 2C.6. Annual Revalidation 2C.7. Supplier Facility Access 2C.8. Contingency Plan 应急计划 2C.9. Document and Product Sample Retention 文件和产品样件保持 2C.10. TRW Property - Tools 2C.11. Indemnity 赔偿 2D. Continuous Improvement 持续改进 2D.1 Introduction 2D.2 Supplier Performance Reporting 供应商成绩报告 2D.3 Intensive Improvement Process 加强的改进程序 2D.4 Controlled Shipping 受控的运送 2D.5 Cost Recovery 成本控制 Documents Table 文件表格 Glossary 术语表 Revisions 修订
Download all documents as self extracting ZIP-file Download G.S.Q.M. document
This manual supersedes the previous TRW Automotive Supplier Development Manual Revision C1, June 2003, LucasVarity Global Supplier Quality Manual (GSQM-001), and any Product Line specific manuals. This manual includes both the TRW Automotive and the TRW Automotive Product Line Specific Requirements. This manual is released electronically on the TRW Vendor Information Network website http://vin.livmi.trw.com/, without any hardcopy publication. Management Message Automotive market expectations continue to be high, requiring extreme business fitness for survival and profitable growth. TRW Automotive plans to maintain its business strength and create exceptional value for its customers via four strategic priorities of: Best Quality, Lowest Cost, Global Reach and Innovative Technology. A robust and adaptable supply base that understands TRW requirements, and acts with similar urgency demanded by our customers, is key to achieving these priorities. Purchasing focus areas integrated into these initiatives are detailed supplier commodity strategies, sourcing excellence and cost reduction plans, superior new program development and flawless product launch. Additionally, to support achievement of Operations Excellence of the supply base TRW operating units will participate in and input into supplier sourcing decisions and status (New Business Hold, Bid Suspension, Quality Improvement Plan & Top Focus). The Purchasing organizational support of the focus areas is driven by a matrix of Global Commodity management. This group is responsible for sourcing excellence and commodity strategies coupled with Product Line specific Purchasing and Supplier Development. They are responsible for the deployment of new program/product introduction, flawless launch execution and supplier APQP and continuous improvement. The Purchasing focus and TRW Global Supplier Development Process are supported by major e-Business initiatives that require, besides Internet based commerce, collaborative engagement with our suppliers in early sourcing, new product development, launch and on-going continuous improvement. This collaboration will enable TRW Automotive and its supply base to meet the OEM market demands of shorter product development cycles, flawless launches and exceptional quality. To assist our suppliers in helping us achieve our priorities and focus areas, TRW Automotive Global Purchasing will deploy, the necessary Lean/Sigma, Quality Product Engineering, Operations, Supplier Quality
Assurance and Supplier Development Engineering personnel. We recognize that TRW cannot succeed without the superior quality, cost, service and technology offered by its supply base. Edward L. Carpenter Vice President Global Purchasing Michael Charlton Lead Director European Purchasing
Kevin Gillis John Chuey Director Senior Manager Global Supplier Development Engineering European Supplier Development Engineering
Section 1 – Introduction
Policy and Vision
It is the policy of TRW to achieve a clear competitive advantage through continuous improvement in quality, service, delivery and cost from our suppliers in the total supply chain. It is the vision of TRW that suppliers shall:
Do it Right the First Time by planning, preparing, and being trained to supply quality products and services.
Do it Right Every Time by assuring consistent quality products and services through addressing all concerns.
Continually Improve by proactively improving the quality and value of products and services.
The purpose of this Global Supplier Quality Manual (GSQM) is to specify TRW Automotive quality system requirements for our suppliers. These requirements extend from supplier qualification, to new product development, to production.
This manual applies to all Direct material/service suppliers. This manual applies to Indirect material/service suppliers only when it is required by a TRW Purchase Order.
Suppliers are responsible for meeting the GSQM requirements. Failure to meet these requirements may result in the loss of existing and/or future TRW business, in addition to
reimbursement of the cost to TRW resulting from those failures.
Suppliers shall ensure that their direct material/service suppliers comply with the requirements of ISO/TS 16949:2002.
Suppliers shall adopt the standards of Zero Defects and 100% On Time Delivery to TRW. Suppliers shall understand that any established PPM target is not an Accepted Quality Level, but represents an intermediate continuous improvement step toward shipment of components/materials meeting the Zero Defects requirement.
TRW Automotive?s official language is English. All official communication with TRW will be done in English. Documents may display the native language when integrated in parallel translation. In this instance, the English is the only valid version.
1F. Global Supplier Development Process TRW Automotive Global Supplier Development follows a series of processes/procedures that have been defined as the TRW Automotive Supplier Development Management Processes. This details the methods and tools used by Supplier Development and Supplier Quality from the initial assessment at a potential new supplier through launch and into intensive supplier improvement and tactical monitoring within operations. The horizontal axis of the figure follows the product development stages, starting with Concept Validation.
TRW AUTOMOTIVE SUPPLIER DEVELOPMENT PROCESS
CONCEPT VALIDATION DESIGN VALIDATION PRODUCT AND PROCESS DEVELOPMENT LAUNCH START OF PRODUCTION CONTINUOUS IMPROVEMENT
GDPIM Gate 6
D30.200 Scorecard D30.100 Part and Process Audit D20.600 Supplier PPAP (Change Management)
GDPIM Gate 5
Safe Launch Plan D20.600 Supplier PPAP D20.500 Supplier Run at Rate D20.400 Supplier Launch Readiness Review
GDPIM Gate 4
D20.100 Advanced Product Quality Planning D20.200 Component Design Review (Production) D20.100 Advanced Quality Planning.
Component Criticality Assessment
D20.507 Preliminary Capacity Study D10.100 Supplier Initial Assessment Audit
Figure 1. Global Supplier Development Management Process
TRW Automotive?s product development process, Global Development Product Introduction Management (GDPIM), initiates with the quoting process to our customers. Once a program is awarded, engineering works on concepts to meet the customers? specifications and requirements. The process continues on to validation of the design. Design Validation (DV) builds take place during this stage.
GDPIM Gate 7
D30.100 Part and Process Audit
Next is the development of the product and the process. TRW facilities are installing the assembly equipment, engineering is working together with the customer to assure the product meets all performance and appearance, where applicable, requirements. During this stage suppliers are developing their tooling and processes to provide material for future serial production. Also during this period, many suppliers will be required to supply components/materials for equipment tryouts and product validation (PV) builds and testing. Supplier should also be constructing ramp-up plans to meet initial production requirements and creating contingency plans to address catastrophic events that would prevent the supply of materials under normal production conditions. After the approval of the Production Part Approval Process (PPAP) package, and with the start of serial production, many suppliers will participate in Safe Launch Planning. For a pre-determined period of time or number of components, the supplier and the TRW facilities will employ an expanded inspection process on key characteristics. Once the program transitions from Launch into Production, the supplier shall continue to use the validated process. Any changes to that process, see Supplier Request for Change (2C.2), requires TRW?s approval before the change is implemented. Suppliers whose performance during this phase does not meet agreed upon goals and metrics will be subject to one or more intensive improvement tools.
Government Regulatory Compliance
Suppliers shall comply with all applicable governmental regulations. These regulations relate to the health and safety of the workers, environment protection, toxic and hazardous materials, and free trade. Suppliers should recognize that the applicable government regulations might include those in the country of manufacture, as well the country of sale. Registration to ISO14001 is strongly recommended.
End-of-Life Vehicle (ELV)/International Material Data System (IMDS) Reporting
The End-of-Life Vehicle (ELV) Directive, 2000/53/EC, was enacted by the European Commission "to minimize the impact of end-of-life vehicles on the environment." The use of lead, mercury, cadmium, and hexavalent chromium are prohibited in vehicles and their components, except for certain exemptions published in Annex II of the Directive. This is a mandated requirement for European Union (EU) Member States and also required by North American, and some Japanese, vehicle manufacturers. Additionally, other legal requirements, such as EU Directives 2002/95/EC, 2002/96/EC, and 2003/11/EC restrict the use of certain flame retardant substances: polybrominated biphenyls (PBBs) and polybrominated diphenyl ethers (PBDEs). PBBs or PBDEs shall not be present in components or materials supplied to TRW Automotive. Suppliers in all regions shall ensure that all components and materials supplied to any TRW Automotive facility comply with the above-mentioned legal requirements. TRW Automotive has developed new lead-free specifications to define the materials, processing and performance of lead-free components that are purchased for use in lead-free soldering environments (refer to TRW Lead-Free Performance Requirements). Suppliers of affected components shall meet the lead-free specifications.
To ensure compliance with the various legal and customer requirements, TRW Automotive requires its suppliers to report information on materials within their respective components. The International Material Data System (IMDS) has been developed by vehicle manufacturers to collect and manage this data. Suppliers shall submit the required ELV data to TRW Automotive as soon as possible upon award of new business, but in any case prior to the PPAP submission. The supplier as part of the PPAP submission shall provide confirmation to TRW?s acceptance of the ELV data. Refer to section 2B.4, Production Part Approval Process (PPAP) for further explanation of the submission requirements. TRW Automotive accepts two formats for suppliers to submit ELV data: ? ? Direct entry into IMDS via the Internet (www.mdsystem.com). ? ? Electronic submission via the Automotive Industry Action Group (AIAG) End-of-Vehicle-Life Reporting Tool (downloadable from www.aiag.org). For suppliers located within the Asian-Pacific region, please contact your SDE for specific ELV requirements. Suppliers to TRW-Commercial Steering Systems are exempt from the ELV initiative due to the classification of CSS product per the ELV directive. IJ. European Quality Assurance Agreement
This agreement shall be requested, from all suppliers to TRW?s European organization. It controls suppliers? and TRW?s responsibilities and tasks for the key quality processes in respect to the Global Supplier Quality Manual and the legal requirements of specific countries. The supplier is responsible for review of the Quality Assurance Agreement, when provided.
Product Line Specific Processes and Procedures TRW Product Line Braking, Linkage & Suspension, Steering Braking, Linkage & Suspension, Steering Braking, Linkage & Suspension, TRW Region Document Number GSQM-190A
Description Quality Assurance Agreement List of offices and facilities in Europe. List of offices and facilities in the Asian-Pacific
Europe; Quality Assurance Asia/Pacific Agreement
Quality Assurance Agreement – Appendix Europe
Asia/Pacific Quality Assurance Agreement – Appendix
Steering Occupant Safety Systems
Asia/Pacific Quality Assurance Agreement Guideline
Quality Assurance Agreement Form
region. Procedure that defines the purpose and scope of the Quality Agreement. Quality Assurance Agreement form.
This manual is 'distributed' only via the posting on the TRW website at http://vin.livmi.trw.com/. Printed copies are uncontrolled documents. While TRW will communicate to the suppliers major revisions to this manual, the suppliers are expected to remain up to date on TRW requirements by frequently visiting the TRW website. Visiting this website should become a business routine as TRW shifts to web based communications and applications. Questions regarding this manual should be directed to the TRW contacts listed on the TRW website http://vin.livmi.trw.com/.
Section 2 - TRW Automotive Requirements
TRW Automotive bases its supply management requirements on four key processes. These are the supplier selection process, new product launch, continuous improvement, and supplier intensive improvement. These key processes are global in nature, as are any of their referenced procedures. In some instances, because of unique system configurations, product lines and regions may have specific processes, procedures, and/or forms that may only pertain to conducting business with them. These unique requirements will be found in a table at the end of each section.
Criteria for Selection as a TRW Automotive Supplier
2A.1. ISO/TS 16949:2002 Registration
TRW Automotive's goal for all suppliers of materials and services affecting production material is to demonstrate compliance to ISO/TS 16949:2002. Suppliers shall also comply with TRW Automotive specific requirements defined in the Global Supplier Quality Manual
(GSQM), found at http://vin.livmi.trw.com/.
Suppliers to TRW Automotive shall be third party certified to ISO9001:2000 or ISO/TS 16949:2002 by June 1, 2004. This is consistent with TRW's customer expectations, and ISO9001: 2000 is seen as the first step in becoming ISO/TS 16949:2002 certified. The scope of this requirement affects subassembly, sequencing, sorting, rework and calibration services in addition to direct material suppliers.
Suppliers, with manufacturing capability, shall continue on to ISO/TS 16949:2002 third party registration by submitting a plan with details including internal self-appraisals and the name of the third party registrar body. A plan to achieve certification shall be submitted to your respective commodity buyer and Supplier Development Engineer. Third party certification to ISO/TS 16949:2002 shall be completed no later than July 1, 2006.
TRW Automotive recommends for its suppliers to continue using the latest Automotive Industry Action Group (AIAG) versions of the Advanced Product Quality Planning and Control Plan (APQP), Potential Failure Mode and Effects Analysis (FMEA), Measurement System Analysis (MSA), Production Part Approval Process (PPAP), and Statistical Process Control (SPC) manuals as guidelines for their system development.
For these publications, visit http://www.aiag.org.
2A.2. e-Business Capabilities
Suppliers shall have email, Internet access and Internet browser as a minimum for eBusiness capability. This is required to participate in TRW's web based applications and communications such as:
? ? ? ? ? ? ? ? ? ? ? ?
Measure of Performance System (MOPS)/Supplier Scorecard, Concern Tracking System, Program Tracking System, Supply Web, EDI & ASNs, Supplier Audit Database (SAD), Global Supplier Quality Manual.
Suppliers are responsible for maintaining contact information in the VIN Supplier Master. These contacts include the top management representatives, and the required information includes phone numbers and email addresses. Additionally, suppliers shall, at minimum,
maintain and update their certification status, once per year. Any change in certification or status must immediately be communicated to your respective commodity manager and SDE. Certification status is also accessible to suppliers through their scorecard. This information is updated monthly.
2A.3. New Supplier/Location Qualification
New suppliers who wish to be added, as a supplier, to TRW Automotive shall:
Demonstrate compliance at a minimum to ISO9001: 2000 with a plan to achieve ISO/TS 16949:2002 upon approval,
Meet all commercial and financial requirements of the relevant TRW product line,
Complete the New Supplier Questionnaire (D10.200).
Successfully pass a TRW New Supplier Audit (D10.105) with a minimum score of 80%. Guidelines for this audit can be found in the Supplier Assessment Protocol (D10.104).
Suppliers directed for use by TRW's customers shall meet all the criteria defined by this document.
New Supplier Assessment Criteria
During supplier selection and assessment, TRW will perform various audits to confirm supplier capability, beyond the certification level. The primary focus areas are depicted in Figure 2 below. Each area requires a minimum score of 80 and overall of 80, or greater, to be considered for sourcing. Suppliers that initially do not score acceptably will be allowed to develop action plans and timelines to correct any deficiencies and then request a re-audit to verify implementation of these actions.
Figure 2.Planning Supplier Audit cover page. New 78 80 60 Product
Supplier Management 66 80 60 Quality Control 73 80 60 Manufacturing 80 60 Specific 86 Questions relating to Commoditycommodity process parameters 87 80 60 and learned lessons
Quality Mgmt. 100 80 60
Quality Management Management Responsibility ? Document Management ? Resource Management
Commodity 40 20
Identification and Traceability Production Control ? Manufacturing Monitoring ? Inventory and Storage ? Preventive Maintenance
Product Realization Design and Development ? Advanced Quality Planning
Supply Chain Management (with a focus on sub-tier supplier management) ? Incoming Inspection and Layout
Quality Control Statistical Process Control ? Control of Monitoring Devices Quality Control ? Non-Conforming Product ? Process Improvement
Section Score Points for Green
Quality Management Systems 82.00 80
Product Planning 77.96 80
Supplier Management 66.43 80
Quality Control 72.75 80
Manufacturing 86.17 80
Commodity Specific 86.67 80
Overvall 78.79 80
Supplier: New Supplier Audit
Audit Date: TRW SDE:
Systems unable to meet requirements (High Risk)
Systems acceptable, but ? 60, requires action plan < 80 (Intermediate Risk) Systems meet or exceed ? 80 requirements. (Minimum Risk)
Figure 2. New Supplier Audit cover page.
New Product Launch
New Product Launch initiates at design concept and runs through a production launch of a new component. When specified by the TRW SDE, suppliers shall use the TRW Global Supplier Development Management Process (Figure 1) when launching new product for TRW Automotive. TRW Automotive New Product Introduction teams will define component criticality during the product development cycle. This designation determines the involvement of TRW Supplier Development in the APQP and launch process of suppliers.
All suppliers, regardless of component criticality, shall use a disciplined launch and APQP process.
2B.2. Advanced Product Quality Planning (APQP)
Suppliers shall provide APQP status reports for a new product with regard to meeting the Program objectives of quality, cost, performance and timing. TRW will provide the format, frequency, and the required content of these reports. TRW prefers for their suppliers to use the forms included in this document. Suppliers whose components/materials that TRW has designated as Critical A shall use the TRW Automotive forms available through this manual, and shall complete those forms in English. Suppliers whose components/materials are designated as other than Critical A, and who wish to use an alternative format shall contact their Supplier Development Engineer and demonstrate equivalency between the forms before any submission is made. When required, suppliers shall use TRW's online reporting system for Program tracking.
Suppliers to TRW are responsible for managing their new product introduction process to the guidelines provided in this document. TRW?s APQP process consists of five phases as shown below. Deliverables for the five phases are defined in Figure 3.
Supplier Management – APQP Key Elements
Phase Description APQP-1 Initial APQP Kick-off
? Initial Supplier Program Plan & Timing ? APQP Requirements Review ? Process Flow Diagram, PFMEA, and Control Plan
APQP-2 Design Review
? Component Design Update ? Supplier Schedule Review ? APQP Progress Review ? Updated Process Flow Diagram, PFMEA, and Control Plan review ? Equipment, Tooling, & Gage Plan Review ? Open Issues Update ? Sub-Contractor Supply Plan ? Product Char. Matrix Update
? Component Design Review ? Initiate APQP Progress Report ? Theoretical Capacity Study ? Initiate Open issues Document ? Product Characteristic Matrix
APQP-3 Process Design Review
? Component Design Update ? Supplier Schedule Review ? APQP Progress Review ? Updated Process Flow Diagram, PFMEA, and Control Plan review ? Equipment, Tooling, & Gage Plan Review ? Open Issues Update ? Capacity study ? Sub-Contractor Supply Plan ? Product Char. Matrix Update
? Component Design Update ? Supplier Schedule Review ? APQP Progress Review ? Updated Process Flow Diagram, PFMEA, and Control Plan review ? Equipment, Tooling, & Gage Plan Review ? Open Issues Update ? Develop Safe Launch Plan ? Sub-Contractor Supply Plan ? Product Char. Matrix Update
APQP-5 Prod/Proc Validation & Launch
? Launch Readiness Review ? Part & Process Audit ? PPAP ? Lot Traceability ? Run at Rate / Capacity Verification ? Open Issue Closure Verification ? Initiate Safe Launch Plan
Figure 3. Key APQP elements by phase.
This is the “Kick-off” phase. It begins with the award of work to the supplier. During this period TRW defines the key milestones, deliverables and expectations of the supplier for the given component and program. Suppliers? input to this phase include: ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? Initial timing plan, Process Flow diagram, Initial PFMEA and Control Plan, Manufacturing Feasibility Sign-off, Project schedule, Tooling & Capital Equipment plan, and Preliminary Capacity Study (D20.507) Product Characteristic Matrix (D20.205) Component Design Review (D20.202) APQP Progress Report (D20.105) APQP Tracking Report (D20.102)
Tools used during this, and all other, phases include:
APQP-2 During this period the supplier completes their tooling and equipment design and start on building/assembling the process. Meetings may be held to review the progress of APQP items and resolution of open actions. Supplier input includes: ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? Updated schedule, Updated Flow Diagram, PFMEA and Control Plan, Updated Tooling & Equipment plan, Updated APQP Progress Report, Updated Capacity Study, Updated Product Characteristic Matrix, Measurement/Test Equipment plan, and A Sub-contractor Supply plan.
APQP-3 This segment reviews the results of the APQP-2 phase. Meetings may be held to review the progress of APQP items and resolution of open actions. Supplier input includes an update to the APQP-2 deliverables. APQP-4 This is the Pre-PPAP or Pre-Validation phase. This phase is defined by the process development and validation activity. During this phase open issues generated by the previous phases are tracked to their resolution. In addition to updates of the APQP-2 deliverables, the supplier input includes: ? ? ? ? Ramp plan and Safe Launch Plan (Product Characteristic Matrix).
APQP-5 This segment is the Product and Process Validation, and Launch, stage of the process. It is during this segment that the supplier completes a validation run on the production process, submits a Production Product Approval Process (PPAP) package. Suppliers shall conduct, during this segment ? ? ? ? ? ? A Run at Rate on the process, Complete a Launch Readiness Review, and A Part and Process Audit.
Depending on the component criticality, the SDE may either be present for these events, require submission of the results, or may review at the supplier?s facility during a future visit. As stated previously, regardless of component/material complexity, every supplier is required to conduct and execute the APQP process. Suppliers who wish to use other reporting formats than defined in this document shall have written approval from their SDE. Determination of Manufacturing Feasibility and/or Preliminary Capacity Study may be required for every new or modified product design or manufacturing process based on engineering changes. These are completed, and submitted, just after the Request for Quotation (RFQ) has been accepted and prior to any commitment for facilities or tool development. TRW Product Line Automotive TRW Region Global Document Name Manufacturing Feasibility Manufacturing Feasibility Sign-off Guideline Document Number D20.152 Description Manufacturing Feasibility Sign-off form. Defines purpose and procedure for completing the Manufacturing Feasibility form. Manufacturing Feasibility Sign-off form.
Occupant Safety Systems
Manufacturing Feasibility Sign-off form
Key TRW Automotive global APQP events/forms include: ? ? Supplier Component/Process Design Review - a formal drawing and validation plan review involving a TRW cross-functional team and the supplier. This is a key event in the APQP process. Suppliers are expected to conduct an internal design review before attending any held by TRW. It is also beneficial for suppliers to invite representatives from their sub-tier suppliers to join their team for this meeting. An
action plan will be generated from the open issues discussed during the review and there will be follow-up to assure timely closure of those issues.
? The Product Characterization Matrix (PCM) is a document that is generated at the Design Review and evolves as the process develops. For those components and materials that do not require a Design Review, the supplier shall generate this document and shall submit it as part of their PPAP package. This document ties together designated and high Risk Priority Number (RPN) ranked features with the identified controls. Beyond this, it also drives the identification of sub-tier suppliers who have an impact on these features and documents the controls they will use. This document will be used to formulate the Safe Launch Plan, when required (see Figure 4).
? ? ? ?
Figure 4. Example of extended supply chain linkage.
? Supplier Run at Rate - a formalized production capacity study that verifies proper cycle times, quality expectations and yields. ? Launch and Production Readiness Review - a review of the production process status and the supplier's plan to meet new production ramp-up. ? Safe Launch Plan (Dual Launch Netting, GP12, Pre-Launch Control Plan, etc.) - a joint effort between the supplier and TRW to have similar Pre-Launch Control Plans at both the shipping and receiving facilities. Safe Launch Plan requires the creation of a Pre-Launch Control Plan, an enhancement to the supplier's Production Control Plan. The implementation of an elevated, short-term Quality Inspection process is required. Safe
Launch Plan plans will be signed-off by the Supplier, the TRW SDE and the plant SQA representative. Supplier will be required to submit data to the using plant(s) as part of this process. Suppliers shipping parts under Safe Launch Plan shall create a separate label, placed on each container, showing “SLP” to indicating the nature of the parts.
See Figure 5 for an example.
Figure 5. Example of Safe Launch Plan label.
? Exit criteria for the Safe Launch Plan is shipment of zero defect parts that meet either the defined period of time or number of pieces. Any defect discovered during the SLP period restarts the event a “0” pieces shipped.
Three key documents that are also associated with advanced quality planning are the Process Flow Diagram, PFMEA, and Control Plan. TRW has definitive expectations, for these documents, that suppliers shall comply with. Process Flow Diagram ? ? Shall define the entire process flow starting with Receiving Inspection and finishing with Packaging and Shipping. ? ? ? Shall include any sub-tier, or outside, suppliers, along with the names of those suppliers. ? Shall include machine numbers or unique identifiers that reflect what has been approved as part of the process. Suppliers shall identify those operations linked to the manufacturing of features identified by special characteristics.
Process Potential Failure Modes & Effects Analysis (PFMEA) ? ? Unless otherwise specified, suppliers shall use the AIAG Potential Failure Mode & Effects Analysis (PFMEA) manual as the basis for creating this document. ? ? ? ? Shall follow flow established in Process Flow Diagram. ? Failure modes shall include designated characteristics from the TRW drawing in addition to the process and tooling based items. ? Suppliers shall have a process in place to report on their highest RPN numbers. This report may be in the form of a Pareto chart, displaying the RPNs from highest to lowest. This system shall include documentation of recommended actions and verification of their implementation.
? The PFMEA shall be used as a continuous improvement tool. Suppliers shall be able to document continuous improvement efforts derived from RPN rankings below their target value for improvement actions. Suppliers can prioritize their activities based on Number of RPNs vs. current performance, as shown in Figure 6. Control Plan ? ? The Control Plan shall appropriately reflect the same steps and flow established by the Process Flow diagram and PFMEA. ? ? The Control Plan shall include all features denoted in the Product Characteristic Matrix, characteristics and notes that are designated as special characteristics. Each product line and/or region uses a unique set of special characteristics. Please see your SDE for those that affect your components. If a supplier ships to multiple regions or product lines, contact your SDE for each product line/region to get all of the special characteristics affecting the components/materials your company supplies. ? The Control Plan shall include those features, characteristics and notes that are used to create the annual revalidation package. ? The control plan shall include the Safe Launch Plan controls, when used based on the Product Characterization Matrix.
PFMEA RPN Rankings
# of RPNs Incidents
30 25 20 15 10 5 0 21
7 3 2 1 0
RPN Range Initial Results Current Status
Figure 6. Example of graphing the number of RPNs per defined range.
Packaging & Labeling
TRW and suppliers shall agree upon the packaging plan during APQP, including the following requirements.
? ? ? ?
There shall be only one part number in a box or packaging unit. All packaging units shall be labeled and the label shall include: o o o TRW part number with engineering level and part name. Quantity. Supplier name and TRW supplier code.
o o o o
o Lot traceability number and date. This number shall have a direct relationship with Delivery Note supplied. Starting with the Delivery Note, the supplier shall be able to trace all the documents and record. TRW, at its discretion, may specify additional traceability requirements. o Raw material Heat number, if requested. o A Bar Coded label applied to each packaging unit. TRW facilities may specify their own bar coding formats. Suppliers shall meet the bar code requirements of the TRW location they are shipping to.
Suppliers shipping to TRW?s North American facilities shall meet the requirements found in the North American Labeling Requirements.
Suppliers providing product to multiple operating units, on a global scale, shall work with each of the locations to assure that the packaging is sufficiently robust to withstand shipment by sea and arrive on time, without damage. TRW Automotive expects their suppliers to conduct, periodically, dock audits on packaged materials. Evidence of these audits shall be retained with other lot inspection documentation. Product Line Specific Processes and Procedures TRW Product Line Automotive TRW Region North America
Document Name North American Labeling Requirements Keep Separate Label
WA.D20.001 Specification for bar coded labels. GSQM-150 Rev. A12 Label to segregate material not for production. Packaging instruction PPAP form.
Braking, Global Linkage & Suspension, Steering Braking, Europe Linkage &
Packaging Instruction Form
Occupant Safety Systems – Airbag
Packaging Instruction Form Example Guideline for Barcode and Labeling
Example of Packaging instruction PPAP form. Instructions for effective labeling of supplier?s components.
2B.3. Production Part Approval Process (PPAP)
Suppliers shall ensure that the PPAP document and sample submissions are in accordance with the requirements of the Automotive Industry Action Group (AIAG) PPAP Manual. Suppliers shall only submit PPAP packages for production-released drawings, and a copy of this drawing shall be included in the submission package. They shall also ensure that all these requirements are met before submission to TRW, including obtaining TRW approvals for any change requests. TRW has established a global PPAP validation requirement that further defines submission levels, including what the supplier submits and/or retains (see Figure 7). The order that the package is to be organized is indicated in the TRW Number column. Suppliers are required to use the forms identified in the AIAG PPAP manual. Suppliers may use their forms only if they are equivalent to the AIAG forms and if they have the written approval of the TRW SDE. TRW requires their suppliers to submit a validation package that contains additional documents and forms beyond those required by AIAG. In addition, the supplier is responsible for all sub-tier PPAP submissions and approvals, including those suppliers TRW has directed for use. For all new components and materials, suppliers shall submit with the validation package a copy of ELV/IMDS Reporting Form C. This form verifies the submission of End-of-Life Vehicle component content. Based on the absence of this document, TRW will not approve the PPAP submission. Supplier submission of a non-conforming PPAP package may be recorded as a supplier performance failure and could affect the supplier's performance rating. TRW will determine the Level of PPAP submission, and any special requirements if applicable. When applicable, suppliers shall include in the PPAP submission the Engineering Specification (ES) test plan and the ES test results. An approved/accredited laboratory shall conduct the ES tests. For standard catalog purchased components, i.e., diodes, resistors, etc., that do not go through the PPAP process, based on a product line decision, are to be considered as approved components.
Part Validation Package Submission Requirements
AIAG PPAP Manual TRW TRW / AIAG No. Form No. CFG-1001 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14.1 14.2 15 16 17 18 19 20 21 22 23 24 CFG-1003 6 CFG-1004 6 CFG-1005 6 ----D20.205 CFG-1002 6 ----see Product Line Reporting Form C --------D20.152 D20.252 D20.503 D20.402 ------------GSQM-150 A11 GSQM-150 A12 ------------see Product Line
Production Part Approval Process (PPAP)
No. 13 7 8 8 11 9 14 1 2 19 10 18 ----------------5 4/6 12 ----16 -----------------
Documents Part Submission Warrant Dimensional Layout Material Test Results Performance Test Results Qualified Laboratory Certification Product Characterization Matrix Appearance Approval Report Drawings(s) Change Request Documents3 ELV/IMDS Confirmation Gauge R & R Study Checking Aids (Product related) Manufacturing Feasibility Sign-Off Capacity Verification Run @ Rate Results 7 Launch Readiness Review 7 Process Flow Diagram Design and/or Process FMEA Process Control Plan Certification of APQP Document Review Sample Parts (when requested, keep separate) Subtier PPAP Approvals Master Sample Other5 Packaging Instructions, if required
1 S R R R R R R R2 R2 R R S S S S R R R ----S R8 R S5 R
TRW PPAP Submission Level 2 3 4 S S S S S S S S2 S2 R R S S S S S R R ----S S8 R S5 S S S S S S S S S2 S2 S S S S S S S S4 S4 S4 S S8 R S5 S SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD SD
5 OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS OS
R = Retain at supplier; S = Submit to TRW Automotive, SD = Defined by SDE, OS = On-site, at supplier, PPAP review/approval. Shaded boxes are required to be submitted as part of the validation package to TRW
1 2 3 4
Include actual data along with capability report. For designated appearance items only. Includes deviations (concessions), requests to change the drawing and process change requests. In a situation where the supplier does not attach, to the PPAP/ISIR folder, the DFMEA and/or PFMEA and/or Control Plan for components/assembly, in general, due to confidentiality issues, they must arrange a review date with the TRW Supplier Development Engineer or Plant SQE. In this case PPAP submission must contain Certfication of Reveiw according item 19/ GSQM-150-A11. Supplier must submit both DFMEA and PFMEA if they have design responsibility, otherwise only the PFMEA is required. Any other information, forms or documents formally requested by either the TRW SDE or Plant SQA as part of the validation package submission. Templates according AIAG PPAP- Manual Has to be submitted in case component has been ranked by TRW as category A or B component (Category A conducted by TRW representative, Category B conducted by supplier) Level 1, Warrant Letter, at minimum. A full Level 3 sub-tier PPAP may be requested by a TRW representative as part of the supplier's validation package.
Figure 7. TRW PPAP Submission levels.
Product Line Specific Processes and Procedures
TRW Product Line Steering
TRW Region North America
Document Name Supplier Drawing and PPAP Requirements Notification Supplier Drawing and PPAP Requirements Notification Certificate of Review
Document Number GSQM-135
Description PPAP requirements notification form.
Occupant Safety Systems
PPAP requirements notification form.
Braking, Europe; Linkage & Asia/Pacific Suspension, Steering Occupant Europe Guideline for PPAP Safety Richtlinie Zum Systems Produktionsteil – Abnahmeverfahren PPAP
GSQM-151 Rev. A11
Form certifying the review of the supplier?s PMFEA and Control Plan. GSQM-OSS Guideline for PPAP 20.60GA Submissions
2B.4. Lot Traceability
All suppliers to TRW Automotive shall have an effective lot definition and traceability procedure. The shipper number will be linked to the lot traceability procedure in such a way that the delivered product can be traced back to the raw material. Unless otherwise approved in writing by the TRW Supplier Development Engineer a lot shall consist of one shift, or eight hours of production, whichever is smaller. TRW reserves the right to specify a maximum batch size. Each lot shall be traceable back to the raw material used. The lot definition shall reflect all significant processes influencing the component/material, with the shipping lot number reflecting the last value added operation. Suppliers shall ensure that their lot traceability system maintains its integrity throughout entire extended supply chain, including not only raw material, but also purchased components/products. Many components lifeline begins and ends within the facility of the supplier. There are those components, however, that do require processing by outside companies to finish the process stream. These may include heat treat, coining, grinding, coating, and other various processes. If the original lot were batch processed through the different secondary processes, then there would be no need to change the original lot number. However, if the batches are split at a secondary processor, then the lot number for each of the batches should be unique. Once manufacturing/assembly begins a lot number would be changed if:
? ? ? ?
? One shift of production or eight hours is reached. ? The lot number changes on the raw material being used. ? When the components undergo another value added process and the original lot is divided during processing. ? The lot number changes on any one of the components being used.
When required the supplier may need: ? ? ? To implement Serialized (maintains a one-to-one relationship between the finished good serial number and the components? serial number) lot traceability, or ? Specific Lot (maintains a one-to-one relationship between the finished good serial number and the components? lot numbers) traceability for certain programs. To clarify the difference between this and general traceability, consider a supplier who stamps a given component. After stamping, two fasteners are pressed into the stamping. General traceability is where there is no lot traceability between the stamped component and the assembled parts. Specific traceability would be where the lot numbers of the assembled components are traceable through the lot number of the stamped component.
For safety/critical parts, the required retention time for Lot Traceability records shall be found in Section 2C.8.
2B.5. Special Characteristics
At a minimum, suppliers shall implement process controls for Special Characteristics as designated on TRW drawings. Additional characteristics deemed germane to be ?predictors of process stability and feedback? should also be identified in the supplier?s Control Plan. These relate to product safety, government regulation, product performance, and the ability to assemble product or customer satisfaction features. These are identified by various symbols, requiring specific levels of special controls and process capability. Unless otherwise specified by a product line and/or region, for characteristics/features designated as significant or critical, during launch, the supplier must calculate and report the process capability as Ppk. For those characteristics/features showing a Ppk of less than 1.67, the supplier must create an action plan that both defines containment and process improvements. Process capability can be conducted with both variable and attribute data. The minimum acceptable sample size for variable data is 100 pieces, and for attribute is 300 pieces. Containment must effectively separate non-conforming material from the population. Containment, generally either 100% sort or some form of mistake proofing, must continue until such time that the process Cpk demonstrates capability greater than, or equal to, 1.33, unless specified by a product line designation.
Product Line Specific Processes and Procedures TRW Product Line Braking, Linkage, Suspension, Steering TRW Region Global Document Name Designated Characteristics List
Identifica? o de ? Desenhos (Informativo)
Document Number GSQM-100
Description Defines special characteristics used on drawings.
Occupant Safety Systems
Safety & Security (North America) Europe
Designated Characteristics Standard Procedure Designated Characteristics
Defines special characteristics used on drawings. Designates symbols used in additional to WA.C45.001 Defines purpose and procedure for implementing special characteristics used on drawings. Special characteristics classifications and labeling. Defines critical and significant characteristics used on drawings.
Special GSQM-OSS 20.30G Characteristics Implementation Procedure
Commercial North Steering America Systems
Special Characteristics Classification, Labeling of Characteristics Designated Characteristics Standard Procedure
2B.6. Prototype Fabrication, Quality Evaluation, Pre-Production Process Changes
For the fabrication of prototype or pre-production parts, suppliers shall imitate the planned production process as closely as feasible. For these prototypes, TRW may require that the suppliers provide material, dimensional, performance, or process data. If the prototype and
production suppliers are different, the prototype supplier shall share with the production supplier the process knowledge gathered in prototype fabrication. Proprietary information may be withheld by prior agreement with TRW. Once a supplier starts providing parts, as part of the process development and validation stage, any changes to the process require notification to TRW of those changes. These changes may include: ? ? ? ? ? ? ? ? ? ? To outside or sub-tier suppliers, Addition/deletion of capital equipment, Tooling and/or gages, To manufacturing methodology, and To internal secondary processing.
Suppliers of proto-type parts, when required, shall respond to material concerns.
Serial Production Processes
2C.1 Introduction Once the manufacturing process for producing a component is successfully validated, the next phase encountered is that of serial production. During this stage there are a number of requirements each supplier should be fully aware of and follow. Key areas include change management, concern management, sub-tier supplier management and annual revalidation. Additional expectations are also detailed in the following sections. 2C.2. Supplier Request for Change
Suppliers shall submit a written request for product or process change and obtain TRW approval prior to implementing the change. See TRW Product Line Specific Processes and Procedures, at the end of this section, for further details and forms. Change approval may take an extended period when TRW customer approval is required. Changes shall not be implemented prior to the receipt of written approval from TRW. VERBAL REQUESTS WILL NOT BE ACCEPTED. This written approval from TRW is to be considered authorization to implement the process/product change. Authorization to ship production material after the change is communicated through a signed Part Submission Warrant after TRW has approved the PPAP for the requested change, and that change is coordinated through the using TRW facility or facilities.
Off-Line rework, not included in the original Control Plan, is considered a process change and suppliers shall obtain TRW approval for it as specified above. Rework shall be supported by operating and inspection instructions. The inspection instructions shall be consistent with an updated production process control plan. TRW will require special identification and segregation of the reworked product. Suppliers shall request, in writing, a deviation (or concession) before shipping non-conforming material to TRW. A plan to return to normal production and the time required to do so shall be submitted at same time as the written request. Material shipped under an approved deviation shall be labeled with the Deviation Number and its expiration date. For an example, see Figure 8.
Figure 8. An example of a Deviation label.
Product Line Specific Processes and Procedures TRW Product Line Braking TRW Region North America Document Name Manufacturing/ Purchasing Changes Request Change Request Form Supplier Request for Change Document Number GSQM-130
Description Describes methodology for changing a specification. Change Request form Form for requesting a Deviation, Drawing Change or Process Change
Chassis Occupant Safety Systems
Global North America
Manufacturing/ Purchasing Change Request (MPCR) – Deviation Application Manufacturing/ Purchasing Change Request (MPCR) – Deviation form
Defines purpose and procedure for suppliers to request a change/deviation from TRW.
Form for suppliers to request change/deviation from TRW.
2C.3. Concern Management
Upon receiving a TRW concern for quality or delivery, suppliers shall implement a containment action within 24 hours. Within 10 working days, unless otherwise specified, the suppliers shall submit a corrective action plan or a reasonable approach to developing one in case of complex issues. These targets are standard, but the concern creator can establish other target dates, if needed. Suppliers shall use a systematic problem solving method such as 8D, 5 Phase, 7-Step, etc. Concern issuance, response and tracking are all online, and the suppliers shall participate in the TRW online system. Suppliers shall immediately notify TRW upon discovery that they might have shipped nonconforming or suspect product to TRW. Notification shall go to the Quality Manager and the Materials Manager, or in their absence, the Operations Manager of the TRW facility. The suppliers shall notify all TRW facilities receiving the same or similar affected product. Suppliers are responsible for all costs and expenses created by any defect on the material supplied and TRW will recover these costs from the responsible supplier.
The Materials Rejection Reports process involves five procedures: 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. TRW - Identification and definition of problem. TRW - Reporting and notification process. Supplier - Response and corrective action. TRW - PPM defects and rate of occurrence. TRW - Supplier Charge backs for quality related expenses
Each step lists required and recommended elements for each procedure. Unless otherwise noted, the procedures that follow will be used by TRW. Suppliers are obligatory to use or develop their own systems that comply with TRW?s materials rejection reports and corrective actions procedures.
TRW - Identification and Definition of Problem
Required Procedures a. a. Will contain sufficient information to ensure understanding by the supplier of the problem. b. b. Will contain sufficient information to ensure proper and quick containment by supplier and user plant. Information may include lot number, traceability or quantity. d. d. Will have representative samples available for review and supplier evaluation. e. e. Will have defined severity and/or classification of problems. f. f. Will contain quantitative information to define the extent of the problem. g. g. Will have a method to distinguish “fit and function” (critical) issues from “nonfunctional” (nuisance) issues. 2. 2. TRW - Reporting and notification Process
Required Procedures a. Will include proper identification and definition of problem.Will use a Concern Tracking System (VIN CTS) for reporting and status tracking.Will have established time frame for reporting and notification.Will include initiator or contact person at the issuing plant.Will ensure supplier acknowledgment of receipt of notice or report (CTS automated process).Will identify status of material and current disposition.g. Will request a return material authorization (RMA.) Recommended Procedures a. a. Should identify status of material and current disposition. b. b. Should include request for return material authorization (RMA.) 3. 3. Supplier - Response and Corrective Action
Required Procedures a. a. Will have well-defined procedure for corrective action and response. b. b. Will have well-defined time frame for corrective action and response. c. c. Will have formal approval, closure and tracking process.
d. d. Will require 8D Process or a similar problem-resolution process for documenting and verifying corrective action. e. e. Will utilize VIN CTS for tracking and maintaining corrective action and response. f. Will define specific steps for disposition of material.Will have a process for rescinding invalid corrective action requests, which are not needed or were generated in error by TRW. Recommended Procedures a. a. Should have method or process for rescinding invalid or incorrect corrective action requests where 8D or a similar problem resolution process is not needed or error was made by initiator. 4. 4. TRW - PPM Defective and Rate of Occurrence.
Required Procedures a. a. TRW will have well-defined procedure for TRW to adjust PPM to verified parts defective. b. b. The supplier must acknowledging receipt of returned parts within the time frame dictated by the user plant. c. c. The Supplier, within a the time frame dictated by the user plant, as part of the 8D or a similar problem-resolution process must supply to user plant a minimum of the following information: d. d. Segregation/containment actions 1) 1) Sort results 2) 2) Rework plan 3) 3) Interim actions 4) 4) Root causes PPM will include the following: 1. 1. Quantity of VERIFIED nonconforming production parts, 2. 2. Quantity reworked (on-site or off-site) and used, and 3. 3. Initial PPM will include total quantity of suspect parts returned to supplier. This amount will be adjusted later to reflect actual defect quantity if all adjustment policy criteria are met. PPM will not include the following: 1. 2. 3. 4. 1. 2. 3. 4. Part that have not been PPAP approved and prototypes, Parts used under authorized deviation, Warranty returns, and Parts “used as is.”
Bulk Rejections - For example: labeling, plastic resin, steel, etc... 1. 1. First occurrence - bulk rejection shall be counted as 1 quantity nonconforming accompanied by a well-documented QCCAR.
2. 2. Second occurrence - bulk rejection Actual number of defects NOT rejects shall be included in PPM calculation and supplier to be placed on Controlled Shipping Level I. 3. 3. Third occurrence - bulk rejection, all parts shall be counted against the supplier, included in the PPM calculation, and the supplier inducted into Controlled Shipping Level II. The rate of occurrence offence will be tracked and reported within the VIN CTS system. All occurrences are counted regardless of severity with the exception of those that are rescinded.
TRW Procedure for Supplier Chargebacks for Quality-Related Expenses
Required Procedures 1. 1. Will have well-defined procedure capturing all associated costs for defective material and related expenses using TRW standard form. 2. 2. Will include detailed explanation of components for the charges, including hours, rework, cause and cost. 3. 3. Will be traceable to applicable CTS and RMA report. 4. 4. Will have well-defined authorization and review levels and will be cross-functional including the following company disciplines: quality, purchasing, finance and plant management. 5. 5. Will include detailed scope and timing. 6. 6. Will capture all associated costs.
2C.4. Supplier Audits
TRW Automotive employs a number of audit tools in its Supplier Development Process. This starts with the assessment of a potential new supplier who desires to enter a business relationship with TRW to 2nd Party compliance audits to the latest version of ISO/TS 16949. See Figure 9.
Figure 9. The TRW Automotive audit hierarchy.
Any supplier of production material to TRW may be requested to participate in one, or more, of the audit types defined in Figure 9. When notified of a future scheduled audit the supplier, to best prepare, should conduct an internal audit before the TRW audit team arrives. TRW may, at its discretion, utilize independent auditors. These individuals represent TRW Automotive and will audit the supplier's processes to establish conformance to validated quality systems. TRW has a web-based audit tool, the Supplier Audit Database (SAD), located in VIN. This system hosts all audit related activities, for all levels of audit. Suppliers will be notified, via email, of audit dates, completed audits will be posted and accessible to all TRW facilities. Suppliers will submit corrective plans through SAD and will have closure of action items tracked through the system.
Product Line Specific Processes and Procedures TRW Product Line Automotive TRW Region Global Document Name ISO/TS Compliance Audit ISO/TS Audit Instructions New Supplier Audit New Supplier Audit Instruction Part and Process Audit Product Audit Line Walk Document Number D10.105
Description System audit for ISO/TS16949 Compliance System audit instructions Audit to assess risks with potential new suppliers New supplier audit instructions Part and Process audit Product audit Line Walk Checklist
Automotive Automotive Automotive
Global Global Global
D30.104 VDA 6.5 G54-F02
2C.5. Sub-Supplier Management
Suppliers of TRW Automotive shall have capabilities to manage their respective suppliers including APQP disciplines and periodic auditing. TRW Automotive, when it deems necessary, will audit the critical processes of the sub-tier suppliers to assure that proper controls are in place throughout the entire supply stream. Suppliers of TRW shall ensure critical processes such as heat treating and plating are audited and managed and, when directed, use the designated format. An example of such a format is the TRW Heat Treat System Survey. Sub-tier suppliers have a tremendous impact on the quality of the final component. Whether they provide raw materials, services or sub-components their influence is so profound that it is critical for each of TRW?s suppliers to have a supplier management system in place. This system shall include a function that tracks and reports on their supply base quality and delivery performance. Supplier shall be able to demonstrate that they manage their suppliers? issues through documented corrective actions and verification activities.
2C.6. Annual Revalidation
Unless otherwise specified, a complete annual layout inspection, including all sub-components, is required for all parts. All suppliers shall annually revalidate their respective production components, and be able to provide the results to TRW within 48 hours of the request. Revalidation submission requirements are a product line specific criteria based on supplier performance and PPAP process flow. Suppliers shall compile revalidations and document this requirement in the Production Control Plan for all parts supplied regardless of the product line/region. Those features/characteristics/notes that will be part of the revalidation package need to be designated such at the time of initial PPAP. TRW shall review changes to the revalidation package content before any changes are made.
2C.7. Supplier Facility Access
By prior notice, suppliers shall allow TRW and TRW customers' access to both their facilities and those of their suppliers, for the purpose of evaluating parts, processes, documents (i.e., FMEA, Control Plan, Instructions, records....), methodologies and systems used in manufacturing of TRW products. TRW may, at its discretion, use 3rd Party independent auditors. These individuals represent TRW Automotive and will audit the supplier's processes to establish conformance to validated quality systems.
2C.8. Contingency Plan
Suppliers shall develop a contingency plan for potential catastrophes disrupting product flow to TRW, and advise TRW at the earliest in the event of an actual disaster. In an actual catastrophe, suppliers shall provide TRW access to TRW's tools and/or their replacements.
2C.9. Document and Product Sample Retention
Suppliers shall retain documents and product samples for the time the part is active (a part is active as long as it is being supplied to the customer for original or service applications) in production plus a minimum period of 15 years. Parts used on multiple programs may require an exceptionally long retention period. The supplier shall retain a master sample from each cavity, die, pattern … for the same period as production part approval records or until a new master sample is produced for the same part number subject to TRW PPAP approval. The master sample shall be identified as such and shall show PPAP submission reference and TRW approval date.
2C.10. TRW Property – Tools
All tools, manufacturing, test or inspection equipment belonging to TRW, or their customers, will be permanently marked to clearly show that they are Property of TRW (ISO/TS
16949-220.127.116.11), or the customer. These tools will only be used for TRW products unless an authorization in writing exists. Contact your Product Line buyer for information on regarding this subject.
Without prejudice to TRW's rights under any conditions, the supplier will be liable to TRW on demand for any indemnity and hold TRW harmless against any loss, damage, liability, claims, costs or expenses caused by any breach by the supplier or by any defect in any goods supply. Supplier shall have an insurance covering those risks.
TRW Automotive defines supplier continuous improvement as a holistic approach to overall quality management system improvement. Suppliers should, at a minimum, during the Annual Purchasing Planning Process (APPP), develop and present plans that improve internal systems that support flawlessly launching of new products/components/sub-systems, value enhancements and cost competitiveness, and achievement of agreed upon quality targets, with a plan to achieve zero defects in support of on-going operational excellence. This plan should include lessons learned from previous launch, cost and quality issues, and how these lessons have been incorporated into respective continuous improvement proposals. Suppliers should also be prepared to discuss their intent to maintain (or achieve) strategic status including a plan to ?grow? with TRW globally, if applicable. TRW recommends suppliers use the fundamentals outlined in ISO/TS 16949:2002 as a platform for organizing continuous improvement plans.
2D.2. Supplier Performance Reporting
Where provided, suppliers shall access their performance through the TRW Vendor Information Network (VIN) website at http://vin.livmi.trw.com/. Zero defects and 100% On-time Delivery are the TRW expectations for purchased material. TRW will update supplier performance monthly, and provide suppliers an access to their performance scorecard. The scorecard includes Overall Score, Quality Score, PPM, Concerns, On Time Delivery data, Quality Status, and Quality Certification. A poor performance score is used both as part of future sourcing decisions and also to focus continuous improvement efforts. Note: Regions/suppliers not linked to the VIN system - contact your Purchasing representative regarding this topic.
Supplier Performance Scorecard
These codes have a direct impact on whether a supplier may be sourced new business or even be available to quote that work. The categories are: ? ? ? Good Standing (GS) – a supplier that meets TRW?s requirements and goals. ? Quality Improvement Plan (QIP) – a supplier with ongoing quality issues requiring a formalized improvement process. Suppliers may still be able to quote for and receive new business. ? Top Focus (TF) – a nominated supplier that is under intensive corrective action. Once nominated, the supplier shall be placed on new business hold (NBH). ? New Business Hold (NBH) – a supplier that can quote new business, but cannot be awarded any new work. ? Bid Suspension (BS) – a supplier that cannot bid on new or transfer business and cannot be awarded any new work.
Displays the current Quality Certification listed in the TRW VIN system. Suppliers are responsible for updating this information, and attaching a copy of the certification, whenever it changes. Suppliers can do this in the same area where they maintain their contact information.
This score shows the overall global ranking of the supplier. At this time this score is equal to the Quality Score. The value for a supplier?s quality performance is based on both rejected material and the number of concerns generated against that supplier. The formula is: QS = 0.6 QPC + 0.4 QPR, where QPC, or Quality Performance Concerns, is a weighted value based on the severity of the concern combined with the number of concerns for each of the severities. In addition, the score is normalized creating an equalized evaluation across all suppliers regardless of the number of components shipped. The formula is:
ACx10 ? BCx5 ? CCx1 ? DCx0 x100 Total# ofshipments QPC = 1,
where AC = A concerns, BC = B concerns, CC = C concerns, and DC = D concerns. Two additional rules apply: 1. 1. If the number of A Concerns = 1 per month (for the reporting period) and the QPC is greater than 89%, then the QPC = 89%. 2. 2. If the number of A Concerns >1 per month (for the reporting period) and the QPC is less than 65%, then the QPC = 65%. Every supplier is automatically assigned an annual target for Concern Score for each region and product line they ship to. This is based on the total score for the preceding year for the combination of region, product line and commodity. The target is the higher number of either the mid-point between 100 and the commodity Q-Score or the mid-point of the supplier Q-Score and 100. QPR, or Quality Performance Rejects, is a weighted value that normalizes the PPM. The formula is: QPR = 100 PPM
The method by which the supplier?s quality performance is calculated, using the following formula:
PPM = (No. of Defective Parts ? Total number of parts received) x 1,000,000.
The number of defective parts is derived entirely from the concerns written in the Concern Tracking System (CTS). # of Concerns
This is the count of concerns issued against rejected material by a TRW location. Concerns are ranked A, B, C, and D. ? ? An “A” concern is any component defect that o o Is raised by the customer. o o Causes TRW line downtime in excess of ten (10) minutes. o o Affects a defined critical or significant characteristic. ? ? A “B” concern is any component defect that does not conform to the drawing and cannot be used in production. ? ? A “C” is any component defect that does not conform to the drawing and requires rework or a deviation to use in production. ? ? A “D” concern is for informational purposes only. PPM is affected, but Concern score is not. ? ? A “W” concern is used to document warranty related issues. Operations will generate Delivery Concerns, which will affect the MOPS Delivery score. These concerns are weighted by severity and used to calculate a Delivery Score similar to the current Quality Concern Score. A concern is immediately communicated to suppliers via email, and corrective action reports may be requested. Delivery Score = [1-(AC*10 +BC*5+CC*0)/TS]*100
AC: “A Concerns” – most critical, BC: “B Concerns” – somewhat critical, CC: “C Concerns” – minor issues with little impact on the plant, TS: Total number of shipments.
Most Critical Concerns. Any variances for release-based delivery: early delivery, late delivery, over-delivery, and under-delivery.
Somewhat Critical Concerns. Caused significant scheduling changes within TRW; Chronic severe premium freight issues; Chronic failure to communicate appropriately. Informational Concerns such as incorrectly located labels. Recurring C concerns can be escalated to a B concerníby the plant at their discretion.
Peer ranking is displayed in Quality Score, PPM and Delivery. It is done among suppliers in the same region, product line and commodity. The prior calendar year from the report date. A period of time spanning the last 6 months from the report date. Year-to-date. This is a period of time, starting in January of the current year, and running through the month prior to the report month. The trend is based on the slope of the best-fit line applied to a 6-month rolling period. If the trend is positive for PPM, or negative for Overall Score, Quality Score, and Delivery the scorecard shows Red. If the trend is positive for the Overall Score, Quality Score, and Delivery, or negative for PPM, the scorecard displays Green. Performance targets are established for all suppliers annually. The VIN system will automatically generate the next year?s targets based on a 50% improvement to the current performance. In support of the Advanced Purchasing Procurement Process (APPP), targets use July of the previous year through June of the current year to establish the initial set of goals. These goals are then re-evaluated by Purchasing and Supplier Quality, using QOS analysis, to assure that the proper targets are being set.
Prior Year 6 Months YTD
Intensive Improvement Process
The Intensive Improvement process involves four steps (see Figure 11). It starts with one of the TRW facilities writing a complaint against a supplier for a quality performance issue. The corrective action process can escalate from a written corrective action to certified stock, or controlled shipping, to one of the intensive improvement disciplines (see Figure 11).
Figure 11. Intensive Improvement Process
Controlled Shipping (CS) Level I and II will be levied against the supplier when the TRW Automotive plant has determined that the supplier does not have the necessary safeguards preventing non-conforming products from reaching TRW manufacturing location or its customers. Controlled Shipping, Level I initiated by TRW and performed at the supplier location by supplier employees. Controlled Shipping Inspection process must be performed in a controlled area of the plant. Secondary Inspection data must be collected, and inspected product must be certified and data provided to TRW receiving plant. Controlled Shipping, Level II includes all of Level I, with an added inspection by a TRW approved 3rd party. Third party is selected by the supplier and approved by TRW, and paid by the Supplier. In some instances TRW may require that the 3rd party inspection to be performed outside the supplier facility. Based on the severity of the incident, TRW may elect to go directly to CSII. TRW SQA will review irreversible corrective action and authorize removal or renewal of Controlled Shipping when appropriate. CS shall be maintained for 12 month period on the Supplier Scorecard. NOTE: minimum of 30 days Corrective Actions verification period with no re-occurrences is mandatory.
2D.5 Cost Recovery Supplier Cost Recovery (CR) will be initiated by TRW Automotive when it has been determined that the supplier is responsible for quality and or delivery shortcomings. Cost Recovery will be communicated using Vendor
Information Network. Cost Recovery process will include, but is not limited to: contaminated stock at TRWA plant, product in transit, OEM assembly plant, non-conforming received goods, assembly line downtime due to delivery or quality related issues, and warranty returns. Cost Recovery Concerns will be a significant factor in TRW Automotive sourcing decisions.
APQP Progress Report
Detailed plan for all critical APQP elements. fundamental Most Advanced
Quality Planning document. APQP Tracking Report Bar Code and Labeling Guideline Certificate of Review GSQM-151 Rev. A11 D20.102 Management level report of key APQP elements Software for effective Occupant Safety Systems Airbag Systems Form signed by the SDE, and submitted with the PPAP package, documenting the review of a supplier?s PFMEA. Change Request Form GSQM-130A Form for suppliers to Braking; Linkage Suspension; Steering Component Review Designated Characteristics List GSQM-100A Design D20.202 Checklist and launch Defines characteristics drawings. Identifica? o de Desenhos ? (Informativo) Designated Characteristics Standard Procedure Designated Characteristics Standard Procedure Designated Characteristics ELV/IMDS Form C Reporting Form C GSQM-101 WA.C45.001 WA.C45.001 Defines characteristics drawings Defines critical and significant characteristics used on drawings. Designates symbols used in additional to WA.C45.001 Confirmation form for acceptance of an ELV data OSS-Safety & Security Systems Automotive Global North America Commercial Steering Systems North America special used on Occupant Safety Systems North America special used on Braking; Linkage Suspension; Steering (Portuguese) & Global for focused Automotive Global review of drawing, APQP, & Global request approval for change Chassis Europe; Asia/Pacific – Europe labeling by suppliers. Automotive Global
GSQM-150 Rev. A12
Keep Separate Label
Label to segregate material not for use in production.
Braking; Linkage Suspension; Steering &
Launch and Production Readiness Review Line Walk
Checklist used to assess a supplier?s state used of by preparedness for launch.
suppliers to audit their own components. Manufacturing/ Purchasing Change Request (MPCR) – Deviation Application Manufacturing/ Purchasing Change Request (MPCR) – Deviation form Manufacturing Feasibility Sign-off D20.152 Form documenting that the supplier has reviewed the drawing and is capable of manufacturing component Manufacturing Feasibility Guidelines Manufacturing Feasibility Sign-off Form Manufacturing Feasibility Sign-off Form (Herstellbarkeitsanallyse) Manufacturing/ Purchasing Request New Supplier Audit D10.105 Changes GSQM-130 A form used by North American suppliers changes. Audit suppliers used on new to Automotive Global registered Braking to for request Braking North America GSQM-OSS 20.10Fe GSQM-OSS 20.10Fd Sign-off GSQM-OSS 20.10G Defines procedure Manufacturing Sign-off form. Manufacturing Manufacturing Feasibility Feasibility Sign-off form. (English) Sign-off form. (Deutsch) purpose and for Feasibility Occupant Safety Systems Europe the Automotive Global GSQM-OSS 30.20F GSQM-OSS 30.20G Defines purpose and procedure for suppliers to request a change/deviation from TRW. Form for suppliers to request change/deviation from TRW. Occupant Safety Systems Europe Occupant Safety Systems Europe
New Supplier Audit – Protocol North American Labeling Specification
Rules and guidelines for conducting a New Supplier Audit
Bar coding specification for labels used to ship product to TRW facilities in North America.
Packaging Form Packaging
Braking; Linkage Suspension Braking; Linkage Suspension Automotive & &
instruction PPAP form Instruction GSMCE-002 Example form of European
Form – Example Part and Process Audit D30.104
packaging instruction PPAP Audit form used for audits conducted at suppliers for during serial production
PPAP Guideline – OSS Europe
Guide for PPAP submission for OSS Europe Richtlinie Produktionsteil Abnahmeverfahren PPAP Zum –
Occupant Safety Systems
Run at rate study filled out by supplier after the award of new business
Product Characterization Matrix
bridging the PFMEA to Control Plan; Basis for Safe Launch Plan
Quality & Supplier
Braking, Linkage Suspension, Steering &
Agreement between TRW
Quality Europe Quality
Quality & Supplier
Braking, Linkage Suspension, Steering &
Agreement – Appendix
Agreement between TRW
Braking, Linkage &
Agreement – Appendix
Agreement between TRW
Asia/Pacific Quality Assurance
Suspension, Steering Occupant Safety Systems Occupant Safety Systems Automotive Automotive
GSQM-OSS 10.40G GSQM-OSS 10.40F D20.502 D20.503
Defines purpose and scope of Quality Assurance Assurance Agreement
Agreement Guideline Quality Assurance
Quality Agreement form
Europe Global Global
Agreement Form Run at Rate – Guidelines Run at Rate – Form
Rules and guidelines for conducting the Run at Rate Form for data collection and analysis for Run at Rate
Instructions for filling out the Run at Rate form Description of Safe Launch Plan and Dual Launch Netting activities.
Instructions Safe Launch Plan and Dual Launch Netting Special Characteristics Implementation Procedure Special Characteristics Classification, Labeling of Characteristics Supplier Drawing and PPAP Requirements QF0680-01 Notification Supplier Drawing and PPAP Requirements D10.200 QF0650-01 Notification Supplier Questionnaire Supplier Change Request for GSQM-135 GSQM-OSS 20.30F GSQM-OSS 20.30G
Defines purpose and procedure for implementing special characteristics used on drawings. Special characteristics classifications and labeling. Form detailing the level and submission for a PPAP Form detailing the level and submission for a PPAP Supplier package. Form for supplier to submit request change for deviation, process change or drawing information requirements requirements
Occupant Safety Systems
Occupant Safety Systems Automotive Occupant Safety Systems; Safety & Systems Security
Global North America
TRW Heat Treat System Survey
auditing the Heat Treaters
TRW Performance Requirements
Establishes of purchased
requirements for all types electronic that to are verify to Automotive Global Automotive Global components
specified for lead free use. TS16949 Audit TS16949 Compliance D10.107 Compliance D10.106 Audit used compliance ISO/TS16949 Rules and guidelines for conducting System Audit a Supplier Audit – Protocol
Download all documents as self extracting ZIP-file Download G.S.Q.M. document
Definition Advanced Product Quality Planning. A structure activity that plans, tracks and reports the development of a process to manufacture a component/material/assembly to meet customer requirements. Automotive Industry Action Group. A North American automotive organization, which publishes standards. Advance Shipping Notice Action Group. A North American. The capability index for a stable process. Cost Recovery. Controlled Shipping. Concern Tracking System. An internet based material rejection reporting
ASN Cpk CR CS CTS
system used by TRW Automotive to notify their supply base of non-conforming material/components affecting a TRW facility. DCTS Delivery Concern Tracking System. An internet based delivery performance reporting system used by TRW Automotive to notify their supply base of non-conforming material/components affecting a TRW facility. Design Failure Modes Effect Analysis. A document generated during the design phase that identifies and establishes controls for potential failures in a component/material/assembly. Design Validation. Testing that assures that a component/ material/ assembly meets the users requirements. GDPIM is the business process used to manage product development and customer application programs. The process consists of defined phases and reviews that cover the product development cycle from concept to production. The process employs cross-functional program management and a defined set of tools & techniques and Measures of Performance (MOPs) for executing and monitoring the programs. A key element is the use of cross-functional teams in both the core and customer application development programs. Electronic Data Interchange. End-of-Vehicle-Life/International Materials Data System. ELV is a regulatory requirement to eliminate hazardous materials from current production components. IMDS is the data system used to collect and report on the materials that make up components and assemblies. Measure of Performance Systems. The TRW Automotive system that collects and reports supplier quality and delivery performance data. Manufacturing/Purchasing Changes Request. A form only used by TRW Braking in North America for suppliers to request changes from that product line and region. Original Equipment Manufacturer. Applies to automotive corporations, i.e., BMW, Ford, Daimler-Chrysler, GM, Volkswagen, etc. Process Failure Modes Effects Analysis. A team process that identifies and controls potential failures before the product goes into production.
GDPIM (Global Development and Product Introduction Management)
Production Part Approval Process. A defined process for the validation of new materials and subsequent process changes. The performance index of a process. Normally used as part of the PPAP process. Program Tracking System. A internet based launch tracking system used by TRW Automotive to monitor and report on component status? affecting new program launches. Suppliers will be able to report progress toward key milestones affecting their APQP deliverables. Production Validation. Testing that assures that the manufacturing process produces product that meets the customers requirements. Quality Improvement Plan. A supplier intensive improvement tool used by SQA. Supplier Audit Database. An Internet application the stores supplier audits and tracks closure of identified issues. A joint effort between the supplier and TRW to have similar Pre-Launch Control Plans at both the shipping and receiving facilities. Supplier Development Engineer. A quality engineer who is primarily responsible for APQP activity and development of a supplier?s systems. Supplier Quality Assurance. A quality engineer who is primarily responsible for suppliers? quality after the start of production. Top Focus. A supplier intensive improvement tool used by SDE. TRW Automotive Vendor Information Network. This is a suite of applications that includes MOPs, SAD and supplier contact information.
Safe Launch Plan
TF TRWA VIN
Revision Date 25-Sep-2002 Revision Level B ? ? ? ? Changes Updated Management Team. Added Item 9 End of Life Vehicle (ELV) Reporting. Responsible Person K. Gillis
? 17-Feb-2003 01-May-2003 B1 C ? ? ? 12-Jun-2003 01-Nov-2003 C1 D0 ? ? ? ? ? ? ? 01-Jun-2004 E0 ?
Added Item 15 Sub-supplier Management. Updated Management Team. K. Gillis
? Revised entire document to follow Business Policy K. Gillis Manual flow. ? Revised certification requirement to reflect ISO/TS 16949:2002. ? Revised supplier certification requirements. K. Gillis K. Gillis ? Changed all “must” to “shall…” ? Section 2, Paragraph A.2 - added D20.100 hyperlink. ? Section 2, Paragraph A.3 - added Dual Netting requirements. ? Section 2, Paragraph A.7 – add requirement for lot traceability. ? Section 2, Paragraph D.2 – replaced “VIN/MOPS” with “Vendor Information Network.” ? Section 3 - added tables for global procedures and product line/regional specific requirements. ? Major rewrite and restructure. K. Gillis
copyright ©right 2010-2020。