SQAP第二版供应商质量保证程序.doc

Supplier Quality Assurance ProcessEdition 2, April 2006DaimlerChryslerSUPPLIER QUALITY ASSURANCE PROCESS(SQAP)April 2006 EDITION 2Confidential and Proprietary to DaimlerChrysler CorporationReproduction is not permittedSQAP Version 1.0 Issued September 2004SQAP Version 1.1 - Issued July 2005SQAP Edition 2 - Issued April 2006Copyright 2004, 2005, 2006 by DaimlerChryslerEndorsed by DaimlerChrysler Global Supplier Quality Council James Gajda DaimlerChrysler International QualityJoseph Nguyen DaimlerChrysler International, China Project供应商质量保证程序(SQAP)2006年4月第二版版权归戴姆勒克莱斯勒公司所有，侵权必究未经允许，不得翻印SQAP 版本 1.0 2004年9月出版SQAP 版本 1.1 - 2005年7月出版SQAP 版本 2 - 2006年4月出版版权 2004, 2005, 2006 属于戴姆勒克莱斯勒戴姆勒克莱斯勒全球供应商质量委员会认可James Gajda 戴姆勒克莱斯勒国际质量部Joseph Nguyen 戴姆勒克莱斯勒国际部 - 中国项目FOREWORD MISSION:Implement Best in Class quality processes to ensure process performance improvements in the supply Base. Our goal was to develop a comprehensive manual FAST, SIMPLE and LEAN to ensure world-class quality to “Be the Best in class by 2007”.SCOPE: This SQAP specifies the minimum suppliers activities to satisfy the Quality Assurance requirements of production parts for DaimlerChrysler.OBJECTIVE & TARGET:The objective of this SQAP (Supplier Quality Assurance Process) is to define the requirements of the Advanced Quality Planning.By implementing this process, we and suppliers will strive for zero defects.GUIDING PRINCIPLES:l Clearly define customer expectations. l Communicate clearly and consistently with our suppliersl Work with our suppliers as a one teaml Pay attention to detailsl Concentrate on processl Reduce process variation l Focus on problem preventionl Be Proactivel Have flawless pilots and launchesPROCESS:This SQAP consists of 20 key elements; this process is based on benchmark against the best practices in the industry. Some of the elements are divided in the SQAS (Supplier Quality Assurance Schedule) as “a” and “b” (Plan vs Implemented/Approved) see page 5a and #5bThe SQAP timing is structured such that it begins after the supplier selection, however, elements of GPMA (Global Procurement Market Analysis), Source Evaluation and Quote Packages (RFQs) are integral to the quality planning processes at both DaimlerChrysler and the supply base. Purchase orders should be issued for SQAP to be initiated.Source Evaluations are conducted to ensure that suppliers possess the necessary engineering, development, facility, manufacturing, quality and logistic capabilities to supply world class product to DaimlerChrysler. New buildings, building expansions and capital equipment that are specific to a new product shall be managed and monitored within the SQAP process with updates provided at DaimlerChryslers request. Reference element 12The Quote Process (RFQs) ensures that the best source is chosen with regards to the source evaluation criteria, unit pricing and the strategy for the particular product and commodity.Potential volume and mix changes may affect tooling, production, capacity and logistics after the initial quote and business placement. The supplier shall manage the capacity/delivery risks and program requirements and alert DaimlerChrysler to any program timing risks these changes may affect. Reference element 17前 言 使命:通过运行同行最佳的质量过程来实现对供应基础过程绩效的改进。 我们希望借助于本手册，确保以“快速，简洁，精益”的方式 “于2007年实现同行最佳”的世界级质量。范围: 本SQAP手册明确了供应商为满足戴姆勒克莱斯勒对零部件生产的质量保证要求所需采取的最基本的行动。目的和目标:SQAP（供应商质量保证程序）的目的是确定先期质量策划的要求。通过实施本程序，我们和供应商共同争取实现零缺陷。指导方针:l 明确顾客期望值l 与供应商保持顺畅与和谐的沟通l 与供应商同心协力l 注重细节l 以过程为核心l 减少过程变差l 重心放在问题的预防l 具有前瞻性l 试装和投产无缺陷程序:SQAP包含了20个关键要素，本程序的制订借鉴了行业标杆企业的最佳实践经验。SQAS（供应商质量保证 计划进度）中的某些要素被拆分为“a”和“b”（计划已实施/已批准）详见第 5a页和第5b页。SQAP在供应商选定后开始启动，然而，全球采购市场分析GPMA 的要素包括货源评估（SE）及报价文件包（RFQs）也是戴姆勒克莱斯勒和供应基础质量策划过程的组成部分。采购订单发出SQAP即同时启动。开展货源评估以确保供应商具有必要的工程 、开发、 设备、生产、质量和物流能力从而为戴姆勒克莱斯勒提供世界级的产品。如戴姆勒克莱斯勒有要求，为新产品而投入的新厂房， 厂房扩充，资产设备也应被纳入SQAP过程进行监控，管理和更新。参考要素#12报价过程（RFQs）确保以货源评估(SE)准则，单价及特殊产品商品的战略为依据从而选择最好的货源。潜在的产量和混合变化可能影响初始报价和业务给予后的工装、生产、产能以及物流。供应商应管理产能/交付风险和项目要求并警示戴姆勒克莱斯勒这些变化可能影响的项目进度风险。 参考要素#17SUPPLIER QUALITY ASSURANCE PROCESS (SQAP) April 2006All customer reference manuals shall comply with:AIAG manuals -MSA, FMEA, SPC and PPAP.ORGANIZATION:Authors: James Gajda and Joseph Nguyen Version 1.0, 1.1 and Edition 2The authors gratefully acknowledge the contributions of individuals for edition 2 from: DaimlerChrysler GP&S NEA (North East Asia Office), GP&S BBDCA (Beijing Benz DaimlerChrysler Automotive)FORMS, AND EXAMPLES FOR SOME OF THE SQAP ELEMENTS ARE INCLUDED ON THE CD, ATTACHED TO THE LAST PAGE (COVER) OF THIS MANUAL. SQAP edition 2 includes the following changes:- Revised SQAP cover page- Revised page 5a and page 5b to meet CDS ( Chrysler Development System ) Quality Gates v5.1 timing- Incorporated two new Quality Gates: “G2” and ”S2 start”- Elements 8, 10, 11, 16 and 18 were split into a and b segments ( see page 5a and 5b) due to the CDS Gate timing changes. - Modified page #33aThe attached CD for SQAP edition 2 includes the following changes:- New Forms: SES (SQAP Executive Summary) MSR (Meeting Structure Requirements)- Divided elements into folders- New Customer SpecificsPREPARED AND ISSUED BY:James Gajda Joseph C. NguyenDaimlerChrysler International Quality DaimlerChrysler International China Project供应商质量保证程序(SQAP)2006年4月所有顾客参考手册应符合:AIAG手册-MSA, FMEA, SPC 和PPAP.组织:作者: James Gajda 及 Joseph Nguyen 第 1.0, 1.1版及第 二版作者感谢以下团队为第二版所作出的贡献：l 戴姆勒克莱斯勒全球采购与供应（GP&S）l 全球采购与供应 东北亚采购中心（GP&S NEA）l 北京奔驰戴姆勒克莱斯勒汽车有限公司（BBDCA）手册最后一页（封底）附带CD，含SQAP其中一些要素的表格和举例。SQAP第二版中的修改之处有：- 修改了SQAP 封面- 修改了第5a页和第5b页, 使其符合CDS（克莱斯勒开发体系）质量门v5.1的时间节点- 引入了两个新的质量门“G2”和“S2 开始”- 由于CDS质量门时间节点变化，要素8, 10, 11, 16 和 18被拆分为a 和 b 两部分 ( 参见第5a页和第5b页)- 修改了第33a页SQAP第二版附带的CD有以下变更：- 新增表格：SES (SQAP执行概要) MSR (会议组织要求)- 将要素按文件夹分类- 新版的顾客特殊要求筹备发行人:James Gajda Joseph C. Nguyen戴姆勒克莱斯勒国际质量部 戴姆勒克莱斯勒国际部 - 中国项目 iiiTable of Contents page #MANAGEMENT:ELEMENT “1” DESIGNATE SUPPLIER REPRESENTATIVES AND QUALITY GATE PART RISK ASSESSMENT. . . 1ELEMENT “2” SUPPLIER QUALITY ASSURANCE SCHEDULE (SQAS) 3ELEMENT “3” QUALITY ASSURANCE FOR TIER II & III SUPPLIERS . 6STANDARDS:ELEMENT “4” ENGINEERING STANDARDS . 7 ELEMENT “5” DFMEA . 8ELEMENT “6” PARTS IDENTIFICATION, TRACEABILITY, PACKAGING & SHIPPING SPECIFICATIONS . 9ELEMENT “7” KEY PROCESS & PRODUCT CHARACTERISTICS 11ELEMENT “8” PARTS INSPECTION STANDARD . 12ELEMENT “9” BOUNDARY SAMPLES AND APPEARANCE APPROVAL 13PROCESS QUALITY ASSURANCE:ELEMENT “10” PROCESS FLOW & PFMEA; OPERATOR WORK INSTRUCTIONS AND OPERATOR TRAINING . 14 ELEMENT “11” ERROR MISTAKE PROOFING 18ELEMENT “12” TOOLING, EQUIPMENT AND GAGES; PREVENTIVE MAINTENANCE . 20ELEMENT “13” PROCESS CAPABILITY STUDY . 22ELEMENT “14” CONTROL PLAN: INCOMING AND OUTGOING MATERIAL PLAN; SAMPLES SIZES AND TEST FREQUENCIES . 24ELEMENT “15” CORRECTIVE ACTION PROCESS . 28ELEMENT “16” PROCESS MONITORING AND LAYERED PROCESS AUDIT (LPA) . 29ELEMENT “17” PROCESS CHANGE REQUEST APPROVAL . 31PRODUCT QUALITY ASSURANCE:ELEMENT “18” LINE SPEED DEMONSTRATION, PRODUCT VALIDATION (PV) TESTING AND PART SUBMISSION WARRANT (PSW) . 33ELEMENT “19” FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC) . 37FIELD:ELEMENT “20” SUPPLIER WARRANTY PARTS . 38 Index . 39Attached CD- FORMS- EXAMPLES目录 页码管理:要素 “1” 供应商代表指派及质量门零件风险评估 1要素 “2” 供应商质量保证进度计划 (SQAS) . 3要素 “3” 二三级供应商的质量保证 . 6标准要素 “4” 工程标准 . 7 要素 “5” 设计失效模式及后果分析DFMEA. 8要素 “6” 零件标识、可追溯性和包装及发运规范. 9要素 “7” 关键过程与产品特性 .11要素 “8” 零件检验标准. .12要素 “9” 边界样品和外观批准. 13过程质量保证:要素 “10”过程流程和过程失效模式及后果分析PFMEA; 操作者作业指导书和操作者培训. 14 要素 “11” 防误防错 18要素 “12” 工装、设备与量检具；预防性维护保养.20要素 “13” 过程能力研究.22要素 “14” 控制计划：进出料计划；样本大小和试验频次.24要素 “15” 纠正措施程序 28要素 “16” 过程监控和逐层过程审核 (LPA) . 29要素 “17” 过程更改申请. . . 31产品质量保证:要素 “18” 生产线节拍演示、产品验证试验 (PV) 和零件提交保证 (PSW) 33要素 “19” 首次生产发运鉴定 (FPSC) . 37售后服务:要素 “20” 供应商保修件. . 38 索引 . 39附带CD- 表格- 举例SUPPLIER QUALITY ASSURANCE PROCESS (SQAP)ELEMENT “1” DESIGNATE SUPPLIER REPRESENTATIVES AND QUALITY GATE PART RISK ASSESSMENT PURPOSE: To define the roles and responsibilities of the Supplier Representative and other personneland to explain the procedure for notifying the customer operation of the individuals names/titles/phone #, and e-mails addresses.SCOPE: Applies to all suppliers.A. DESIGNATE SUPPLIER REPRESENTATIVESSUPPLIER RESPONSIBILITIES:The supplier shall provide the following information (names, titles, mailing address, telephone #, fax# and e-mail), to the Customer Supplier Quality and to Quality organization.NOTE: Customers Supplier Quality Engineer is the primary contacts for quality issues.A1. Supplier Representative:This person is the primary contacted for all quality matters. It is Quality Engineer or/and Quality Manager. Responsibilities include: Maintaining operating system Reporting and providing Problem Resolution Coordinating of containment Representing the supplier during meetings/pilots/launch with the customer personnelA2. Supplier Quality Manager or equivalentA3. First, Second and Third shift contact:The production quality control staff personnel that can be contact directly by the customer. They are responsible for preventing the non-conformances and to provide corrective action to the customer within a few hours. A4. Non-conformances contact:This individual is the primary contact point for returning non-conforming product.A5. New Project Quality contact:This person is responsible for coordinating new projects for pilot and Launch.A6. Warranty contact: This individual is responsible for receiving, investigating and providing reports for Warrantyreturn parts sent from the customer. - 1 -供应商质量保证程序 (SQAP)要素 “1” 供应商代表指派及质量门零件风险评估目的: 规定供应商代表和其他人员的角色和职责，解释如何通知顾客每个人的姓名/职务/电话号码和邮箱地址的程序。范围:适用于所有供应商。A.供应商代表指派供应商职责:供应商应给顾客供应商质量和质量部提供以下信息(姓名、职务、通信地址、电话号码、传真号码和邮箱地址)。注: 顾客的供应商质量工程师是质量问题的第一联系人。A1.供应商代表：此人是质量工程师或/和质量部经理，他是所有质量问题的第一联系人。职责包括: 保持运行系统 报告并提出解决方案 协调遏制问题 在与顾客进行的会议/试装/投产过程中代表供应商A2. 供应商质量经理或同等职务人员A3. 一班，二班，和三班的联系人:顾客可直接联系生产质量控制人员。他们负责防止不合格产品并在几个小时内向顾客提交纠正措施。 A4. 不合格产品联系人:此人为不合格产品退货的第一联系人。A5. 新项目质量联系人:此人负责协调新项目的试装和投产。A6. 保修联系人:此人负责接收、调查顾客退还的保修零部件，并作出报告。 - 1 - It is acceptable for the same contact name to appear more than once but there shall be at least two contacts. The supplier shall provide quality contact information to the customer with names, titles, office phone numbers, pager numbers, home phones numbers and e-mail addresses. The contact list shall be provided to the customer within one week of being informed that have been selected to provide the parts/components. The supplier shall create and maintain an organization chart and provide copy to the customer. The supplier shall notify the customer within three working days of any changes to contact information.B. QUALITY GATE PART RISK ASSESSMENT B1. At each Quality Gate and as requested, Supplier Representative will submit a Status Summary of the required SQAP elements for each part or family of parts. At a minimum the supplier shall complete the elements listed for each quality gate, to support the vehicle program schedule.PART Green, YELLOW and Red Risk Assessment“G” - Green Pass: Complete fulfillment of all deliverables. Continue to next gate as planned “Y” Yellow All requirements/objectives not met and issues exist. A corrective action plan is secured and have confidence toward a successful outcome. X “R” - Red Does not pass: The current status of the Deliverable does not fulfill the target Need a detail Action Plan for each Red” deliverable.For “Does not Pass”, identify root cause of process failures, identify systemic process issues, and review with the Customer the action plan.REPORTS:Supplier shall develop status reports listing each of the elements for the regular team and management assessment meetings.Some of the report assessment questions are listed in the key elements that includes (Part Inspection Standard, PFMEA, Error Mistake Proofing, Control Plan, Layered Process Audit, Line Speed Demonstration and Part Submission Warrant.At the minimum, there shall be a Management Status Review at each of the Quality Gates.In addition, the Customer will prepare reports for the Quality Gates Review using the appropriate TIP LEVELS applied to the CDS v5.1 Quality Gate Criteria.FORMS:Supplier Contact form is included in the attached CD- 2 -2 同一个联系人可以出现一次以上，但应至少指派两个联系人。 供应商应为顾客提供质量联系人的各种信息，包括姓名、职务、办公室电话、呼机号码、家庭电话和邮箱地址。供应商在被选中后一周内应向顾客提供联系人信息。 供应商应制作并保存组织机构图，并提供复印件给顾客。 若联系人信息有任何变动，供应商应在三个工作日内通知顾客。B. 质量门零件风险评估B1. 当位于每个质量门上，供应商代表将按照要求提交每个零件或每套零件的SQAP要素状态概要。供应商应至少完成每一质量门包含的要素以支持整车项目进度。零件 绿色、黄色和红色风险评估 “G” 绿色 通过：完全实现所有输出要求，按计划向下一个质量门推进。 “Y” 黄色 所有要求/目标未满足且存在问题。 纠正行动计划被引入并有信心产生成功的输出。 X “R” 红色 未通过：目前输出未达到既定要求，需要为每个“红色”输出制定详细的措施计划。对于“未通过”项，将识别过程失效的根本原因，识别系统性的过程问题并与顾客一起评审措施计划。报告:供应商应向定期举行的小组及管理评估会议提交各要素进展状态报告。报告中所应评估的某些问题已在一些关键要素中列出，这些要素包括零件检验标准、PFMEA、防误防错、控制计划、逐层过程审核、生产线节拍演示和零件提交保证。至少，在每个质量门应进行管理状况评审。此外，顾客将用CDS 5.1版质量门标准所应用的适当可接受水平为质量门评审准备报告。表格:供应商联络清单在附带CD中- 2 -SUPPLIER QUALITY ASSURANCE PROCESS (SQAP)ELEMENT “2” SUPPLIER QUALITY ASSURANCE SCHEDULE (SQAS)PURPOSE: The purpose of the (SQAS) is to provide a schedule of the manufacturing and quality control activities necessary to assure the quality of parts for Volume Production. This schedule shall show the relationship of the supplier production preparation activities to the customers master schedule. This schedule should be prepared by a cross-functional team that includes at minimum Supplier, Supplier Quality and Engineering organizations. SCOPE: Applies to all suppliers.The schedule should span the time between the issuance of the production drawing to three months after the start of volume production or Part Approval, whichever occurs later. For parts manufactured for export from China the time schedule may be differentSUPPLIER RESPONSIBILITIES:Suppliers are required to prepare a Supplier Quality Assurance Schedule (SQAS) for each Tier I, as well asdirect supply sub-components. The SQAS shall include the following:AHeader: Includes:Supplier Information (Supplier name, Supplier Code, Part Number, Contact name, Model Code and Revision Record). This information except Revision record will be provided by the Customer.B Build Phase and MRD (Material Required Date) dates and includes the following:Name of build (S-0, S-1, S-2, and V1), Build Dates, MRD (Material Required Date), # of vehicles that will be built during the build phase, and # of days of the build. This information will be provided by the Customer.CCustomer Master Schedule:Build Phases and the Quality Gates and includes the following:Timing for S0, S1, S2, V1 and the Quality Gates. This information will be provided by the Customer.DSQAP Divisions:The divisions are: Management, Standards, Process Quality Assurance, Product Quality Assurance and Field.ELegend: Includes Customer Lead and Customer phase. - 3 -供应商质量保证程序 (SQAP)要素 “2” 供应商质量保证进度计划(SQAS)目的: SQAS即为供应商制定的必要的生产及质量控制活动的进度计划，以此来确保批量生产中的零件质量。此进度计划应体现供应商生产准备活动与顾客总计划的相互关系。它由横向跨部门职能小组制定，该小组至少由供应商、供应商质量管理部门和产品工程部门组成。 范围: 适用于所有供应商。此进度计划应包括自生产图纸发放到批量生产或零件批准后三个月，以两者中的较迟者为准。对中国生产的出口零件