受控发运操作规范(DM-SGMW0502B12-2009)OK

1、上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册SGMW Purchase. & Supply Chain Center management manualDM/SGMW 05.2B.12-2009版本号Version #:A 受控发运操作规范 Controlled Shipment Operation Procedure2009-12-1发布 2010-1-1实施Issued on Dec 1st, 2009 Implemented on Jan 1st, 2010上汽通用五菱汽车股份有限公司采购及供应链管理中心发布Issued by SAIC GM Wuling Autom

2、obile Co. Ltd Pur. & Supply Chain Center.前 言Forward本文件是上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册支持性文件,目的在于防止不合格品流向公司和最终用户，并对供应商限时实施永久性的整改措施。 It is a supporting document for management manual of Pur. & Supply Chain Dept., it is purpose to stop unqualified products flowing into company and end user, and ex

3、ecute time-limited permanent containment measure to supplier.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心提出。Suggested by SGMW WWP& Supply Chain Center.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心归口。Supervised by SGMW WWP& Supply Chain Center.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心负责组织起草。Drafted by SGMW WWP& Supply Chain Center.本程

4、序主要起草人：汪杰强Main drafter: Wang Jieqiang本程序如出现文字理解歧义，以中文为准。If there is any different understanding to the words of this process, please refer to its Chinese version.审核Auditing： 会签Subscribe ：批准Approval：上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册SGMW Pur.& Supply Chain Center. management manual受控发运操作规范 DM/SGMW05.2B

5、.12-2009（0/A）1 编制与适用范围本文件由采购及供应链管理中心负责编制，规定了实施受控发运的条件及退出准则；适用于批量生产时不合格品、PPM值较高或有重复PRR单的供应商。2 术语/缩写PPM：百万分之不合格品数。PRR：问题报告与处理。一级受控发运（CSL1）：由供应商在供应商现场独立于生产线以外的遏制区域对零件实施额外检查的一种遏制不合格品程序，以确保不合格品不送到SGMW。二级受控发运（CSL2）：由SGMW或SGMW认可的第三方对供应商零件实施额外检查的一种不合格品遏制程序，以确保不合格品不送到SGMW。3 一级受控发运规定3.1 一级受控发运进入条件1） SGMW发布PR&

6、amp;R后，供应商采取短期和长期措施实施后仍无法遏制问题的发生，重复发生相同的问题和类似的问题。2）发生重大质量问题（涉及国家法规/安全/环保）。3）由于零件质量问题对SGMW造成重大影响或损失（如：SGMW停线60min或以上，出现须对库存整车进行返工50辆或以上，50分的GCA问题等）。4）供应商违反PPAP程序（如擅自更改设计、原材料、分供方、工艺、检验标准等）。5)零件实物抽检不合格（性能、材料）。6）供应商产品存在质量高风险时，SQE可发布CSL13.2 职责3.2.1 SQE职责1）确认供应商质量问题是否满足进入一级受控发运的条件，完成供应商进入一级受控发运审批（SQE提出，SQ

7、E经理审核，SQ总监批准）。2） SQE发布SGMW一级受控发运通知，同时通11 Develop and ScopeThis Process initiated by Purchasing & Supply Chain Center regulates controlled shipment entry and exit criteria, for un-conforming parts, high PPM or repeated PRRs of mass production.2 Terms /AbbreviationsPPM: parts per millionPRR: probl

8、em reporting and resolutionControlled shipment level-1 (CSL1): is a containment procedure to protect SGMW from non-confirmation that a supplier implements extra inspection in additional to normal production.Controlled shipment level-2 (CSL2): is a containment procedure to protect SGMW from non-confi

9、rmation that an SGMW-approved third party implements extra inspection in additional to normal production.3 CSL13.1 Entry criterion 1) Suppliers short/long term action cannot containment same or similar problems happening after a PRR has been issued.2) Major disruption (related to Nation regulation/

10、safety / environment protecting).3) Severe impact or loss to SGMW due to quality problem (i.e. over 60 mins downtime, more than 50 vehicles rework, upwards of 50 points GCA deduction).4) Supplier offending against PPAP procedure. (i.e. Changing product design, raw material, sub-suppliers, process or

11、 inspection criterion without SGMW approval )5) Non-conformance of normal parts actual check (performance, material)6) High- quality-risk of the supplier products 3.2 Responsibility3.2.1 SQE responsibility1) Review supplier non-confirmation to confirm whether or not it complies with the entry criter

12、ion. If applicable, accomplish the approval for the CSL1(Proposed by SQE, confirmed by SQE manager, approved by SQ DM/SGMW05.2B.12-2009（0/A）知生产采购科、计划科、物流科及SQA。3） 通过会议方式，使供应商理解一级受控发运要求（包括退出标准）。4） 审核、批准供应商一级受控发运计划/流程。5） 审核供应商的根本原因分析及纠正措施。6） 监控供应商的遏制活动数据。7） 审核供应商过程控制改进成效。8） 对供应商进行控制计划审核（PCPA）。9） 审核供应商是

13、否满足供应商进入一级受控发运确定的退出标准，完成供应商退出一级受控发运审批（供应商提出，SQE同意，SQE经理审核，SQ总监批准）。10）向供应商发布SGMW一级受控发运退出通知，同时通知生产采购科、计划科、物流科及SQA。3.2.2 采购员职责1） 如果供应商不配合执行SGMW一级受控发运要求时，采购员必须介入并通知采购总监，同时支持SQE开展一级受控发运。2） 会同SQE就进入受控发运状态的供应商受控发运产品的具体问题及改进情况提出是否停止该供应商该类产品或全部产品的新业务开展的建议。3.2.3 供应商职责1) 立刻针对具体的质量问题，建立与现有生产、检查区域独立的遏制区域。2) 通知其他

14、使用相同零件的顾客，告知该不合格情况，并且根据需要制定、采用遏制活动。3) 跟踪不合格品断点，并向SGMW通报断点信息。1） 4) 在产品最小单元的包装上或料架上贴上经供应商主管质量的最高领导签字的绿色圆形一级受控发运标签。5) 提供执行一级受控发运所需的平面布局图、作业指导书、检验指导书，工装（含检验工具）。Director.)2) Send CSL1 notice to supplier and inform Purchasing Section, Planning section and SC, SQA.3 Communicate CSL1 requirements to supplie

15、rs (including exit criteria) via meeting.4) Verify and approve suppliers CSL1 plan/process.5) Verify supplier root cause analysis and corrective actions.6) Monitor supplier containment activity data7) Verify supplier process control improvement effectiveness.8) Conduct PCPA at suppliers plant9) Chec

16、k if supplier meets all exit criteria of CSL1, if applicable, complete exit approval, (proposed by supplier, admitted by SQE, verified by SQE Manager, approved by SQE Director.).10) Send exit notice to supplier and inform Purchasing section, Planning section, SC and SQA.3.2.2 Buyer responsibility1)

17、If required, inform Purchasing Director and support SQE, when the supplier is not cooperative in conducting CSL1 per SGMW requirements. 2) Together with SQE to advise whether or not implement New Business Hold on the CSL1-product or all products of the supplier depending on the CSL1 problem and impr

18、ovement status.3.2.3 Supplier responsibility1) Immediately establish a additional containment activity area focusing this specific quality problem.2) Notify the nonconformance to other customers using the same part, and take containment activities if necessary.3) Track breakpoints of nonconforming m

19、aterial and inform breakpoint information to SGMW. 4) Mark CSL1 label, a green-round tag with signature of the highest quality leader, on the smallest package unit or rack. 5) Provide layout, instruction sheet, inspection sheet, tooling (including checking tool) used in CSL1.DM/SGMW05.2B.12-2009（0/A

20、）6) 发运前100%检验行动，并在遏制区域公布检验结果。7) 每日组织会议来评审相关质量数据和结果，确认纠正措施有效性。8）查找问题的根本原因,制定、实施长期纠正措施。9）更新相关的质量文件（例如但不限于：过程流程图，PFMEA，控制计划，作业指导书，检验指导书等）。10）满足退出一级受控发运的标准时，提出退出申请，并提供相关的支持性文件/证据。3.3 一级受控发运退出准则SQE根据实际情况，在供应商进入一级受控发运的同时，与供应商确定适用的退出准则。原则上供应商应在两个月内退出一级受控发运。1） 对售后重大问题，受控发运开始后经市场验证有效且没有重复出现。2） 对违反PPAP流程，立即恢复

21、PPAP原状态或新状态申请并获得批准。3）需进行控制计划审核的，控制计划审核结果在70分或以上，并制定有不合格项进一步的整改计划。4）对实物抽检不合格的，进行第二次抽检应合格。5）该问题从CSL1实施开始20个工作日内在SGMW内部缺陷数量为0。SQE根据问题的实际情况，可以制定相应的其他退出标准，但需经SQ总监批准。4 二级受控发运规定4.1 二级受控发运进入条件1） 处于一级受控发运的供应商，仍无法遏制问题的发生。2） 由于零件质量问题对SGMW造成重大影响或损失（如：SGMW 停线120min或以上，出现须对库存整车进行返工100辆或以上等）。6) 100% check and disp

22、lay the results in CSL1 area.7) Conduct a daily meeting to review quality data and the results, ensure the corrective actions taken are effective.8) Find out root cause, develop, and implement the permanent corrective actions,9) Update all applicable documentation, (such as but not limited. Flow Dia

23、gram, PFMEA, Process Control Plan and SOS, inspection Instructions etc.)10) Request exit from CSL1 and provide supporting documentation when exit criteria is met.3.3 Exit criteria for CSL1SQE discuss and confirm the applicable exit criteria with supplier when supplier entering CSL1.In principle, sup

24、plier shall exit CSL1 in the two months since entry.1) For market issue, no repeated issue happened after implement as per market validation.2) For offending-PPAP procedure issue, immediate get back to initial status or new status requisition approved.3) PCPA result is more than 70 points with furth

25、er improvement plan for non-conforming if applicable.4) The result of the second sample taken check should be conformance when the actual sample taken is NOK.5) There should be no defect found in SGMW since the entry of CSL1.6) SQE can define other exiting criteria but SQ Director approval is essent

26、ial.4.0 Controlled shipment level-24.1 Entering condition of CSL21) In CSL1, but the same problem or similar problem re-happen again.2) Severe impact or loss to SGMW due to parts quality (such as; more than 120 minutes downtime, more than 100 vehicles rework).DM/SGMW05.2B.12-2009（0/A）3） 导致产品召回或采取市场活

27、动的重大质量问题；4） 供应商违反PPAP流程并对SGMW造成重大质量问题（如擅自更改设计、原材料、分供方、工艺、检验标准等）。5） 实施GP-12的零件在SGMW仍然发现不合格品。6）供应商产品存在质量高风险时，SQE经SQ总监批准可发布CSL24.2 职责4.2.1 SQE职责1） 确认供应商质量问题是否满足进入二级受控发运的条件，完成供应商进入二级受控发运审批（SQE提出，SQE经理确认，SQ总监批准）。2） 向供应商发布SGMW二级受控发运通知，同时通知生产采购科、计划科、物流科及SQA。3） 审核并批准供应商对二级受控发运第三方的选择（SQE经理审核，SQ总监批准）。4） 主持与第三

28、方及供应商的二级受控发运启动会议。5） 审核、批准供应商二级受控发运计划/流程。6） 审核供应商的根本原因分析及纠正措施。7） 监控供应商的遏制活动数据。8） 审核供应商过程控制改进成效。9） 对供应商进行控制计划审核（PCPA）。10) 审核供应商是否满足供应商进入二级受控发运确定的退出准则，完成供应商退出二级受控发运审批（二级受控发运第三方建议，SQE审核、SQE经理确认、SQ总监批）。11) 向供应商发布SGMW二级受控发运退出通知，同时通知生产采购科、计划科、物流科、SQA及第三方机构。4.2.2 采购员职责1） 如果供应商不配合执行SGMW二级受控发运要求时，采购员必须介入并支持SQ

29、E开展二级受控发运。3) Severe market quality issues such as recall or field action adopted.4) Supplier offend against PPAP procedure and give quality problem to SGMW (such as: change design, raw material, sub-supplier, engineering, check standard with notification to SGMW)5）Implement GP12 or parts still be NO

30、K at SGMW after mass production delivery check.6) High- quality-risk of the supplier products 4.2 Responsibility4.2.1 SQE responsibility1) Confirm supplier to meet the entering condition or not, complete CSL2 entering approval.( SQE released, SQE manager confirmed, SQ Director approval).2) Issue SGM

31、W CSL2 notice to supplier and inform SGMW PSC Purchasing section, planning section and SC, SQA.3) Audit and approve the CSL2 provider selection of supplier( SQE manager confirmed, SQ Director approval).4) Hold a CSL2 kick off meeting with supplier and the provider.5) Audit, approve suppliers CSL2 pl

32、anning process.6) Audit supplier root cause analysis and corrective action.7) Monitoring supplier containment activity data.8) Audit supplier process control improvement effect.9) Conduct PCPA at supplier plant.10) Audit exiting criteria of CSL2, complete exiting criteria approval,(The provider sugg

33、ested SQE agreed, SQE manager audit, SQ Director approval).11) Issue exiting notice to supplier and inform SGMW purchasing section, planning section, SC and SQA, CSL2 provider.4.2.2 Buyer responsibility1）If SGMW does not assort to implement CSL1 buyer should involve to support SQE.DM/SGMW05.2B.12-20

34、09（0/A）2） 通知采购总监，如果需要采购员介入二级受控发运。3）会同SQE就进入受控发运状态的供应商受控发运产品的具体问题及改进情况提出是否停止该供应商该类产品或全部产品的新业务开展的建议。4.2.3二级受控发运第三方职责1） 在供应商制造地或其它指定的地点做SGMW的代表，根据零件缺陷和重要程度确定检查项目，实施发运前100%检查，费用由供应商承担。2）跟踪不合格品断点，并向SGMW通报断点信息。3）在产品最小单元的包装上或料架上贴上绿色圆形标签，由第三方检查人员签名，并印有“二级受控发运”字样。4）满足二级受控发运退出标准时，提出退出建议，并提供相关的支持性文件/证据。4.2.4 供

35、应商职责1）确保理解不合格，立刻针对具体的质量问题，建立与现有生产、检查区域独立的遏制活动区域。2） 通知其他使用相同零件的顾客，告知该不合格情况，并且根据需要制定、采用遏制活动。3） 在第三方检验前，需进行100%自检。4） 分析问题的根本原因，制订、实施长期纠正措施。更新相关的质量文件（例如但不限于：过程流程图，PFMEA，控制计划，作业指导书，检验指导书等）。5） 通知质量体系认证机构与其他顾客。4.3 二级受控发运退出准则SQE根据实际情况，在供应商进入二级受控发运的同时，与供应商确定适用的退出准则。原则上供应商应在60天内退出二级受控发运。2）Inform purchasing Di

36、rector if buyer involved3）With SQE conducting Control shipment for supplier.According to product issues and improvement status, release the suggestion of new business hold for one kind of part or all, get approval of SQ Director and Purchasing Director. the supplier can get new business again after

37、it exit from CSL.4.2.3 The CSL2 provider responsibility1）Act as GM representative on site at the Suppliers manufacturing site or other designated location, decide check item base on part defect and severe degree, implement 100% inspection before shipment , charge is beard by supplier.2）Track breakpo

38、ints of nonconforming material and inform breakpoint information to SGMW.3）Mark individual parts(or parts label) or rack with a Green round label sign by supplier top quality management.4) Request exit from CSL2 and provide supporting documentation when meet exiting criteria.4.2.4 Supplier responsib

39、ility1）Ensure understanding of the nonconformance., Immediately establish a separate containment activity area focusing this specific quality problem2）Notify additional customer facilities that use the same part, inform them of the nonconformance, and provide containment activities as necessary3）Con

40、duct 100% self-inspection before the provider s activity.4) Find out root cause, develop, and implement the permanent corrective actions, update all applicable documentation, (such as but not limited. Flow Diagram, PFMEA, Process Control Plan and SOS, inspection Instructions etc)5） Notify quality sy

41、stem attestation organization and other customers4.3 Exit criteria of CSL2SQE discuss and confirm the applicable exit criteria with supplier when entering CSL2In principle, supplier shall exit CSL2 within two months after entry.DM/SGMW05.2B.12-2009（0/A）1）对售后重大问题，受控发运开始后经市场验证有效且没有重复出现。2） 对违反PPAP流程，立即

42、恢复PPAP原状态或新状态申请并获得批准。3） 控制计划审核结果在70分或以上，并制定有不合格项进一步的整改计划。4） 该问题在第三方检查期间连续20个工作日缺陷数量为0，期间若问题重复出现，则跟踪日期重新计算。5） 通过TS16949质量体系认证机构的追加审核。SQE根据问题的实际情况，可以制定相应的其他退出标准 ，但需经SQ总监批准。5 一级/二级受控发运退出说明1） 供应商提出书面退出受控发运申请给SQE。2） 供应商满足在进入受控发运时确定的退出标准。3） 提供更新的质量文件，包括整改措施计划、PFMEA、控制计划、作业指导书、检验指导书等。4） 受控发运期间内的质量数据。5） 经SQ

43、总监批准有效。6 一级/二级受控发运启动会应明确以下内容：1） 阐述会议目的；2） 描述问题；3） 定义各方职责；4） 评审过程流程图/PFMEA/控制计划/作业（检验）指导书；5） 建立详细计划；6） 定义退出准则；7） 信息沟通（人员沟通方式，信息记录格式（至少纠正措施和遏制状态）/频次/方法和反馈）。与会人员至少包括：SGMW SQE、采购员（按需），供应商质量经理/工厂经理，第三方（二级受控发运）。1) For market issue, validate to be effective by market and no repeated issue happened after im

44、plementing CSL22) For offend PPAP procedure issue, immediate back to PPAP initial status or new status requisition approved, no same or similar problem happened at least 60 days after implementing CSL23) PCPA result is more than 70 score and supplier develops a deeper improvement plan for non-confor

45、ming. 4） No defect found by the CSL2 provider for at least 20 days continually since the implement day. If not, the count will restart.5) Pass addition auditing of TS16949 certification organization.6) SQE can develop related other exiting criteria but SQ Director approval is essential.5.CSL1, 2 exi

46、ting condition1）Supplier release requisition of exiting to SQE in letter.2）Supplier meet exiting criteria decided when entering CSL.3）Provide updated quality document, including improvement action plan, PFMEA, control plan4）Quality data during CSL.5）Approved by SQ Director6. CSL1,2 Kick off meeting

47、content:1）Clarify meeting purpose2）Description problem3）Define al shock holders responsibility4）audit Process diagram / PFMEA/ Control plan / Operation(inspection) instruction.5）Set up detailed plan6）Define exiting criteria7）Information communication( people communicating method, information record

48、format(at least including corrective action and containment status) / frequency / method and feed back).DM/SGMW05.2B.12-2009（0/A）7. 对遏制区域的要求1）遏制区域必须做到目视化（与其他区域明确区分），并且有充分的照明和设施，必须明确物流线路和区域。2）遏制区域内不能对零件进行返工。3）遏制区域必须独立于供应商的生产线之外。4）在信息墙或遏制区域其他显著的地方公布不合格情况、措施、行动计划和状态、以及遏制行为的结果。5）相关的图表、数据必须每天及时更新，并由供应商质量

49、管理层进行评审。6）制定出现问题的解决流程的反应计划，并记录相关的数据和信息。7）必须对遏制区域相关操作人员进行充分培训，在工作现场应有工作指导书、质量标准、边界样本（如适用）、相关工具和设备等。8）适用时，应进行预防性维护。8 受控发运标签（见附件1）9 流程图 (见附件2)10 相关文件DM/SGMW05.02B.11-2009 问题报告与解决管理规范11 相关表式11.1表05.02B.12-01 一级受控发运通知单11.2表05.02B.12-02 二级受控发运通知单11.3表05.02B.12-03 受控发运提交资料清单7 Requirement for containment ar

50、ea1）This area must be visible (separated from other areas),with enough light and equipment, logistic route and area must be clear.2） No rework activity in containment area.3）Separated from suppliers normal production area4）Display the non-conforming status, action, action plan and status, containmen

51、t activity result on the information wall or other marked location of containment area 5）Related diagram and data must be updated every day, supplier quality management must review it.6）Develop reactive plan for problem resolution process and record related data and information7）The related operator

52、s must get related training within containment area, there are operating instruction, quality standard, boundary sample(if applicable), related work and equipment.8）Conduct preventive maintenance if applicable8.0 Control shipment label (see appendix 1)9.0 Flow chart (see appendix 2)10. Related docum

53、entDM/SGMW05B.09-2009 Problem reporting and resolution11. Related terms11.1 05.2B.12-01 CSL1 notice11.2 05.2B.12-02 CSL2 notice11.3 05.2B.12-03 CSL document submission listDM/SGMW05.2B.12-2009（0/A）附件1Appendix 1：受控发运标签Controlled shipment label一级受控发运标签 CSL1 label检验员checker:出厂日期Date of leaving factory：

54、供应商质量代表Supplier quality delegate：二级受控发运标签CSL2 label检验员checker:出厂日期Date of leaving factory：第三方代表Delegate of the Provider：DM/SGMW05.2B.12-2009（0/A）附件二Appendix 2：受控发运流程图 CSL flow chart采购零件发生质量问题Purchased parts quality problemSQE判断是否满足受控发运条件？SQE judge YSQE办理受控发运审批手续 SQE deal with approvalSQE通知供应商进入受控发运S

55、QE inform supplier to enter CSL供应商与第三方（指CSL2）实施受控发运 conduct CS供应商申请退出受控发运supplier request to exit（二级受控可由第三方建议） (provider request for CSL2)SQE与第三方（指CSL2）评估供应商是否满足退出条件？Evaluate exit or not N 退出受控发运审批 exit approval Y N YSQE发布受控发运退出通知 SQE issue exit notice资料归档 AchievementDM/SGMW05.2B.12-2009（0/A）表05.02B.12-01（0/A） 上汽通用五菱一级受控发运进入/退出通知单 Controlled shipment notice No：供应商Supplier联系人Contact电话Tel:零件号Part No.零件名称 Part Name问题描述Description受控发运条件Term1） SGMW发布PR&R后，供应商采取短