Global Supplier Quality Manual - TRW Automotive全球供应商质量 .doc

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 Automotives 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.4New 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 Processes2C.1.Introduction2C.2.Supplier Request for Change2C.3.Concern Management2C.4.Supplier Audits供应商审核2C.5.Sub-supplier Management分供方管理2C.6.Annual Revalidation2C.7.Supplier Facility Access2C.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 - Tools2C.11.Indemnity赔偿2D. Continuous Improvement持续改进2D.1Introduction2D.2Supplier Performance Reporting供应商成绩报告2D.3Intensive Improvement Process加强的改进程序2D.4Controlled Shipping受控的运送2D.5Cost 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-fileDownload G.S.Q.M. documentThis 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 /, without any hardcopy publication.Management MessageAutomotive 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 productdevelopment 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. CarpenterMichael CharltonVice PresidentLead DirectorGlobal PurchasingEuropean PurchasingKevin GillisJohn ChueyDirectorSenior ManagerGlobal Supplier Development EngineeringEuropean Supplier Development EngineeringSection 1 Introduction1A.Policy and VisionIt 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.1B.PurposeThe 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.1C.ScopeThis 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.1D.Responsibility 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.1E.LanguageTRW Automotives 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 ProcessTRW 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. Figure 1. Global Supplier Development Management ProcessTRW Automotives 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. 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 TRWs 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.1G.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.1H.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 TRWs 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 (). Electronic submission via the Automotive Industry Action Group (AIAG) End-of-Vehicle-Life Reporting Tool (downloadable from ).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 AgreementThis agreement shall be requested, from all suppliers to TRWs European organization. It controls suppliers and TRWs 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 ProceduresTRW Product LineTRW RegionDocument NameDocument NumberDescriptionBraking, Linkage & Suspension, SteeringEurope;Asia/PacificQuality Assurance AgreementGSQM-190AQuality Assurance AgreementBraking, Linkage & Suspension, SteeringEuropeQuality Assurance Agreement Appendix EuropeGSQM-191AList of offices and facilities in Europe.Braking, Linkage & Suspension, SteeringAsia/PacificQuality Assurance Agreement Appendix Asia/PacificGSQM-192AList of offices and facilities in the Asian-Pacific region.Occupant Safety SystemsEuropeQuality Assurance Agreement GuidelineGSQM-OSS 10.40GProcedure that defines the purpose and scope of the Quality Agreement.Quality Assurance Agreement FormGSQM-OSS 10.40FQuality Assurance Agreement form.1K.GeneralThis manual is distributed only via the posting on the TRW website at /. 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 /.Section 2 - TRW Automotive RequirementsTRW 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.2A.Criteria for Selection as a TRW Automotive Supplier2A.1.ISO/TS 16949:2002 RegistrationTRW Automotives 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 /. 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 TRWs 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 .2A.2.e-Business CapabilitiesSuppliers shall have email, Internet access and Internet browser as a minimum for eBusiness capability. This is required to participate in TRWs 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 th