Gate Management of supplier

1、Gate Management System Work InstructionsGate 1:Request For Quote Ready31.01Appoint Team Members31.02Lotting of Products31.03Production Demand Requirements31.04Determine Bid Scenario31.05Bidder Selection31.06Tool/Part Supplier Transfer Checklist31.07Determine Plant Assets Transfer and Value31.08Map E

2、xisting Process Procedures41.09Print Review, Changes, and Statistical Features41.10Engineering/Reliability Test Acceptance Plan41.11Production Part Approval Process (PPAP)/First Part Approval (FPA) Requirements Established4Gate 2:Supplier Selection Decision52.01Self-Survey52.02 Line Item Detail Assu

3、mptions52.03Quality Survey52.04Manufacturing Process Review52.05Technical Assessment52.06Business Assessment52.07Preliminary Capital and Expense Requirements52.08Project Plan52.09Commodity Strategy Evaluation62.10Decision Matrix6Gate 3:PPAP Interim Approval (FPA-Approved with Exceptions)73.01Final P

4、rint Review73.01.01Statistical Features73.01.02Engineering Specifications73.02LTA Approved73.03A/R Approved73.04Process Documents73.04.01Operator Methods/Process Sheets73.04.02Training Records73.04.03Maintenance Record73.04.04Process Flow Diagram Including Sub-Tier Suppliers73.05Process Failure Mode

5、 & Effect Analysis73.06Process Capability83.06.01Pre-Move Capability Studies83.06.02Statistical Capability Studies83.07Quality Control Plan83.08First Part Layout83.08.01Dimensional Certification83.08.02Material Certification83.09Supplier Quality Requirements83.09.01Supplier Gage R&Rs83.09.02Gage Cal

6、ibration Schedule83.09.03Maintain Lot Traceablity83.10Plant Quality Requirements83.10.01Receiving Inspection Plan83.10.02RMA Gage R&Rs93.10.03Gage Calibration Schedule Implemented93.11Gage Correlation93.12Chemicals Approved93.13Initial Packaging and Labeling93.14PPAP Interim Approval (FPA-Approved w

7、ith Exceptions)9Gate 4:Production Release Approved104.01Engineering/Reliability Testing104.01.01CFM Testing104.01.02Other Engineering Testing104.02Copeland Plant Pilot104.03Final Packaging Approved104.03.01Packaging Specifications104.04Production Plan Approved104.04.01Ramp-Up104.04.02Seasonal Demand

8、104.05PPAP/FPA Approval11Gate 5:Production Stability Audit125.01Receiving Inspection Historical Data125.02Achieve the Planned PPM Level125.03Capacity at 80% and on Ramp Plan125.04Re-Audit Supplier PPAP Approval Criteria125.04.01Process Audit125.04.02Part Audit12Gate 1:Request For Quote ReadyThe goal

9、 of Gate One is to clarify procurement strategy, define project scope, and identify implementation resource requirements.1.01Appoint Team MembersThe Project Team Members should be made from functional positions that are primarily responsible or affected by the change. The team should consist of a Pr

10、oject Leader, Commodity Manager, Project Engineer, Supplier Quality Engineer (SQE), Primary Plant SQE, Primary Product Engineer, and others as appropriate. The Project Leader should be a Commodity Manager, an assigned Project Engineer, or a Commodity SQE.1.02Lotting of ProductsThe Commodity Manager

11、with input from the Project Team should lot the commodity by looking at their business strategy.1.03Production Demand RequirementsUsing forecast data, the Commodity Manager should be able to provide the Estimated Annual Usage (EAU), peak seasonal demand requirements, and expected change of demand fo

12、r each lot.1.04Determine Bid ScenarioBidders are determined differently for the three different bid scenarios.Full Source Reverse Auction: In this scenario, the Commodity Manager will work with the reverse auctioneer to determine the bidders. Using physical properties of the part, the geographical l

13、ocation of supplier and/or plant to be supplied, and travel constraints, the Commodity Manager and the reverse auctioneer work together to create a viable bidder list.Quick Source Reverse Auction: In this scenario, the Commodity Manager will present the reverse auctioneer with a list of possible bid

14、ders. These are usually suppliers that Emerson Climate Technologies has worked with or has had contact with in the past.Request for Quote (RFQ): In this scenario, the Commodity Manager chooses the suppliers he/she would like to bid on the part. This scenario does not require an auction.1.05 Bidder S

15、electionThe Project Team should decide which bidders are to participate in the bid event based on the requirements that the Project Team decided.1.06Tool/Part Supplier Transfer ChecklistThe Commodity Manager will determine if any tooling, gages, or dies that are property of Copeland Corporation can

16、be transferred from a current supplier to a new supplier. The Commodity Manager should refer to the Tooling/Part Supplier Transfer Checklist in a location that will be updated. The current user of the equipment should inspect the condition of the equipment being transferred.1.07Determine Plant Asset

17、s Transfer and ValueThe Project Engineer with assistance of the Project Team should determine what equipment would be included in the package that the supplier will bid on and the net book value of that equipment. This is used when a process is to be outsourced that was previously done in-house by C

18、opeland.1.08Map Existing Process ProceduresThe Project Team should make a flow chart for the process, including every operation and transfer. The Project Team should try to provide as much information as possible to help insure a more seamless transfer of the process to the company. Although, be cau

19、tious about sharing proprietary information of incumbent suppliers processes to the bidders.1.09Print Review, Changes, and Statistical FeaturesThe Project Team should review the prints of the parts to be quoted. The Project Team should confirm that the prints specify all aspects of the part to be qu

20、oted, mark statistical features to monitor the consistency of the part in production, and recommend any changes to help clarify the print. All prints of parts that are alike should have consistent format for each drawing with globally accepted standards and specifications. They should have similar w

21、ays of measuring features and referencing dimensions so that they are all consistent. This print review should also assess the specifications of the parts and see whether they are consistent and up-to-date.1.10Engineering/Reliability Test Acceptance PlanThe Product Engineer decides the testing neede

22、d to qualify the parts for production. The plan should include the number of parts needed for testing and a schedule of events to estimate the duration of the testing. Engineering testing concurrent with production should be considered.1.11Production Part Approval Process (PPAP)/First Part Approval

23、(FPA) Requirements EstablishedThe Project Engineer, with input from the Commodity SQE, determines what documentation is needed from the supplier to qualify the part. Refer to CC-955 for list of available requirements.Gate 2:Supplier Selection DecisionGate Two outlines the activities recommended to f

24、acilitate the supplier selection decision. This is also an opportunity to solidify the project plan and schedule relative to the original procurement strategy.2.01Self-SurveyOnce bidders are determined through one of the three methods, the Commodity Manager will then send the self-survey form to the

25、 bidders. The bidders will then submit form back to the Commodity Manager. The purpose of the Supplier Self-Survey is to provide a company profile for a preliminary look at their overall capability to manufacture the lotted parts. The Project Leader summarizes and reports areas of significant weakne

26、ss from the self-survey. Refer to F:FormsQualitySurvey Folder to find the actual self-survey that is sent out to the suppliers.2.02 Line Item Detail AssumptionsThe bidder may have processes that are not the same as what is agreed upon in the bid event. The new processes are to be reviewed to verify

27、that it is cost and time effective. The new processes could include new technology in manufacturing, using different material, packaging, and using a different rust preventative.2.03Quality SurveyThe perspective suppliers that are not ISO Certified should have a Quality Survey conducted. Survey shou

28、ld be comparable to Level Four Document 6.01.06.01. The Project Leader summarizes and reports areas of significant weakness from the Quality Survey.2.04Manufacturing Process ReviewThis review is to ensure that the supplier understands all of our print specifications regarding the product in the bid

29、event. Also, this review includes the suppliers process for production. The supplier can present their new process and it should be reviewed with an open mind to new methods. The new methods can be studied to ensure that they are capable.2.05Technical AssessmentThe purpose of this on-site assessment

30、 is to match supplier capability with part requirements. The secondary purpose is to highlight areas of weakness and identify resource requirements to develop the supplier. Reference to form number #.2.06 Business AssessmentThe purpose is to assess the bidders ability to execute the project on our s

31、chedule. The assessment should include capacity expansion, capital, current asset utilization, and infrastructure to support implementation.2.07Preliminary Capital and Expense RequirementsCapital and expenses that Copeland Corporation will sponsor to include tooling, gages, travel cost, engineering

32、cost, engineering test cost, pilot, etc. This will lead to an Appropriation Request (AR) that includes the cost to manage the entire project all the way to completion.2.08 Project PlanThe key critical path elements should be defined in the project plan. The time of implementation is compared between

33、 the perspective suppliers.2.09 Commodity Strategy EvaluationThe Commodity Manager should compare the bid proposals with the global commodity strategy, which includes geographic location proximity, cost, logistics, and supplier characteristics.2.10 Decision MatrixWeigh all factors in Gate 2 in order

34、 to make a recommendation for a Supplier Selection.Gate 3:PPAP Interim Approval (FPA-Approved with Exceptions)Completing the Gate Three elements qualifies the supplier production process. This gate authorizes the supplier to submit CFM test and plant pilot parts, as required.3.01Final Print ReviewTh

35、e Project Team with the supplier will review the Engineering Drawings and Specifications.3.01.01Statistical FeaturesPrint features requiring statistical analysis during qualification and/or statistical process control should be identified on the print by the SQE and product engineer.3.01.02Engineeri

36、ng SpecificationsEngineering specifications should be reviewed with the supplier. Any changes must be mutually agreed to and the engineering specification formally revised.3.02LTA ApprovedThe Commodity Manager will make a contract for the new supplier to sign. This contract will include the agreemen

37、ts that are to be held between both companies.3.03A/R ApprovedThe Commodity Manager is responsible for having the Appropriation Request (AR) approved. For more information about AR Approval, refer to the Procurement Quality Manual.3.04Process Documents3.04.01Operator Methods/Process SheetsOperator W

38、ork Instructions should be written and accessible for every work station. They should include operator instructions as well as process parameters.3.04.02Training RecordsThe supplier is expected to maintain a qualified workforce. Training plans and records should be available for review.3.04.03Mainte

39、nance RecordThe supplier is expected to maintain equipment, tooling and gaging in good condition. The supplier indicating the maintenance schedules and activities should maintain records.3.04.04Process Flow Diagram Including Sub-Tier SuppliersA process flow diagram should be completed which includes

40、 sub-tier supplier processes. Changes to that process flow should require prior approval by the SQE. 3.05Process Failure Mode & Effect AnalysisThe new supplier is responsible for making a PFMEA, which is a procedure that has a list of many possible failures during the production process. It has the

41、severity of the failure, how often it may occur, and the actions required to fix the problem that resulted in the failure. This will help the development of the Suppliers Quality Control Plan. Refer to industry standards for conducting a Process FMEA.3.06Process Capability3.06.01Pre-Move Capability

42、StudiesUsed Machinery or Tooling to be transferred to a new supplier should be studied to document current capability. This applies to Outsourcing Projects as well as Transferred Supplier Tools.3.06.02Statistical Capability StudiesItems designated as Statistical Features should be studied statistica

43、lly. Minimum acceptance results should be 1.33 Cpk. Exceptions need approval of the SQE.3.07Quality Control PlanThe Quality Control Plan should be available at each operation that indicates dimensions to check, gaging method, and gaging frequency. This should also include a containment plan.3.08Firs

44、t Part Layout3.08.01Dimensional CertificationRepresentative samples should be verified (dimensions, notes, and specifications) by the supplier and results submitted to Copeland. All features measured should be approved by the SQE.3.08.02Material CertificationRepresentative samples should be checked

45、for compliance to the engineering specification. The SQE should approve the test facility and results.3.09Supplier Quality Requirements3.09.01Supplier Gage R&RsGage R&R studies should be completed for print dimension gages. Refer to Industry Standards for conducting a Gage R&R Study. Correlation bel

46、ow 10% is good, 10%-30% can be approved at the discretion of the SQE, and above 30% needs an exception approval.3.09.02Gage Calibration ScheduleEvidence that gages are included in a gage calibration schedule should be available for review.3.09.03Maintain Lot TraceablityAbility to maintain lot integr

47、ity throughout the supply chain should be reviewed. Decisions on record and sample part retention should be agreed to between the supplier and SQE.3.10Plant Quality Requirements3.10.01Receiving Inspection PlanCopeland RMA plans should be reviewed and communicated to the supplier. One of the goals is

48、 to have all of the plants consistent in their RMA Plans.3.10.02RMA Gage R&RsGage R&R studies should be completed for print dimension gages. Refer to Industry Standards for conducting a Gage R&R Study. Correlation below 10% is good, 10%-30% can be approved at the discretion of the SQE, and above 30%

49、 needs an exception approval.3.10.03Gage Calibration Schedule ImplementedEvidence that gages are included in a gage calibration schedule should be available for review.3.11Gage CorrelationCorrelation studies between Copeland RMA and supplier gages should be conducted. Measurements that fail to meet

50、expectations should be corrected. The R2 value should be 0.7 or higher.3.12Chemicals ApprovedChemicals used for cutting fluids, cleaning agents, or rust inhibitors should be approved by the SQE and documented on the work instruction. Chemical changes should be approved by the SQE prior to incorporat

51、ion. Compatibility with plant processes should be considered.3.13Initial Packaging and LabelingPackage design should be representative of final production design. Exceptions can be approved for pilot parts shipment.3.14PPAP Interim Approval (FPA-Approved with Exceptions)Interim Approval is expected

52、prior to approving parts for use in a plant pilot or CFM build.Gate 4:Production Release ApprovedCompletion of the Gate 4 requirements leads to PPAP/FPA approval. Authority to ship production parts to Copeland requires PPAP/FPA approval or a deviation to release parts with discrepancies.4.01Engineer

53、ing/Reliability Testing4.01.01CFM TestingThe purpose of the CFM (Copeland Failure Mode) testing is to evaluate component reliability of parts manufactured under production conditions. Product Engineering is responsible for designing and conducting the CFM test plan. Scroll Compressor CFM guidelines

54、are defined in ES81-#.4.01.02Other Engineering TestingThere may be other engineering testing conducted, as defined by 1.10.4.02Copeland Plant PilotThe purpose of the Plant Pilot is to evaluate component compatibility to plant machining and/or assembly processes. The Receiving Plant determines the qu

55、antity of parts needed for these tests. When multiple plants are involved efforts should be made to leverage results from a lead plant allowing subsequent pilots to be less comprehensive. Plant Pilot Parts should be inspected per the RMA Plan.4.03Final Packaging ApprovedPackaging should be evaluated

56、 during the plant pilot. Compatibility with plant material handling equipment and work station layouts should be reviewed. When multiple using plants are involved priority should be given to standardized package design. Exceptions can be made for unique situations such as international shipments or

57、extended storage requirements.4.03.01Packaging SpecificationsPackaging specifications should be defined and documented by the supplier as part of the PPAP/FPA submittal.4.04Production Plan Approved4.04.01Ramp-UpThe ability of the supplier to improve production efficiency and add equipment to meet demand should be reviewed. The team should be comfortable that the plan is reasonable based on both supplier and Copeland resource requirements. 4.04.02Seasonal DemandThe Supplier should understand the seasonal nature of