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Standard Quality Plan

Oleohydraulic systems Sistemi oleodinamici


Systmes olohydrauliques Oleohydraulische Systeme
group
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1 Company Profile
2 Purpose
2.1 Quality Highlights
3 Scoda quality assurance plan
3.1 Design control
3.2 Documents and data inspection
3.3 Purchasing
3.4 Inspection of products supplied by customer
3.5 Identification and traceability
3.6 Process control
3.7 Inspections and tests
3.8 Control of metrology and testing instruments
3.9 Test conditions
3.10 Identification of products non-conformities
3.11 Corrective and preventive actions
3.12 Handling, warehousing, packaging and transport
3.13 Control of quality registrations
3.14 Quality audits
3.15 Training
3.16 Customer service
3.17 Statistical techniques
4 Application softwares used by Scoda
4.1 Design engineering
4.2 General application
General Index
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Denomination
Scoda srl
Registered office: Milan, Via Carducci, 31
VAT registration number: 07912650152
Comercial register: n. 248164
Headquarter: 21021 Angera (Va), Via San Gottardo, 14
Corporate Purpose
Design, manufacture and trade of equipments, on its own and on behalf of third parties, of machinery and industrial
equipments generally.
Share Capital: 520.000
Company Property: private, 2 shareholders
Board of Directors
Ing. Carbonatto A. - Chairman
Dott. Crespi G. - CEO
Sig.ra Perego A. - Advisor
Scoda srl - Company data
Personnel, total: 41 included temporary employees
The average age is 40 years old, 70% have high school or bachelor degrees
2012 Turnover forecast: 8,5 mio/
2011 Turnover: 7,5 mio/
The activity of the company is divided in four product lines:
Standard power units
Special power units
Customised electrohydraulics blocks and systems
Standard components and groups
Main manufacturing plants:
Angera plant - Italy
Surface under roof: 5000 m
2
1 Company Profile
Angera plant
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This Quality Plan, edited in conformity to UNI ISO 10005:2007 norm, shows the procedures carried out by Scoda
srl to comply with the quality requirements applied to the production of its products
The document has been deliberately issued in synthetic form and with general purpose contents because specific
information are just included into the Quality Manual.
Scoda manufactures two separate product lines, standard products and special products, consequently the Quality
Plan differentiates the specific activities related to both production lines
If the contents of this document do not comply with the customers requirements, they can require a registered copy
of the Quality Manual to the Scoda Quality Assurance Service.
This document is considered under not controlled distribution.
2 Purpose
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Entrance Exit
MANAGEMENT
RESPONSABILITIES
Quality policy
Definition of developments
strategies
Assigning of responsibility and
authority
Management audit
Communication & Marketing
RESOURCES MANAGEMENT
Identifying needs
Management of staff involvement
and training
Implementation of optimization
measures and improvements in
plants, machineries and
equipments efficiency
MEASUREMENT of ANALYSIS AND
IMPROVEMENTS
Collection and punctual + statistical
analysis of data in all
stages of the process
Management of non-conformities,
returns, complaints and delays
Internal audits
Definition and monitoring of
corrective and preventive actions
PRODUCT/SERVICE
REALIZATION
Offers preparation
Orders acquisition
Design & Development
Purchases
Production
Products Quality assurance
Quality Management system
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Quality Policy
The main targets that Scoda aims to achieve and maintain, are linked to the
philosophy of continuous Improvement, to be implemented as working style for
growth of the companys activities.
Through the constant support and motivation of mother Company Atos spa, the
company has set-up the following guidelines in order to achieve the a.m. targets.
Guidance to the Customer Satisfaction, namely the development of effective
and proactive relationships providing a Quality Service based on product
conformity starting from technical and commercial requirements
Cost reduction of quality defects caused by the incorrect application of the
Quality System; reduction of scraps and improvement of the efficiency of all
activities in any Organization level by optimizing working methods and times
Strict collaboration with suppliers to get progressive and constant
improvements of the range of purchased products and services by increasing
the Quality level and the competitiveness of overall costs
Improvement of the sensibility, the team work attitude and the care of Quality
targets in every level of personnel. It is taken good care of human resources
management by qualifying the personnel through specific training courses
Computerization of the production process and individual workstation
throughout the company, in order to comply with requirements of traceability
and production control
Quality and production requirements, design capabilities, Marketing activities
and staff aspirations have to merge into a wide corporate project making persons
aware of their responsibilities and more and more involved in a continuous
growth of Scoda.
Quality System conforming to ISO 9001:2008 supplemented with
applications and methods of ISO TS 16949 Technical Specification
In a more and more competitive global market, the Quality of product plays a
basic role in customers satisfaction and therefore in having a successful
business. In continuous improvement perspective, Scoda has decided to
integrate the Quality Management System conforming to ISO 9001:2008 norm
with applications and methods of ISO TS 16949 technical specification mainly
applied in the Automotive market. The most significant methods used by Scoda
are: DFMEA, PFMEA, CONTROL PLAN.
2.1 Quality Highlights
ISO 9001:2008 Certificate
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Sharing of quality policy with all corporate levels
The Quality policy and the most significant trend indexes are shared with all
operating services and departments. The main goal is to maximize the
involvement and participation of all company personnel in regards to Quality
subjects. Everyone has the right and duty to notify possible inefficiencies or
nonconformities both of product and service. Each report will be always checked
by services in charge; appropriate and corrective actions will be targeted and put
in the field.
Strong partnership with customers and suppliers
Scoda policy promotes strong partnership with customers and suppliers; close
technical relationships with customers enable a thorough knowledge of products
and applications, thus developing products able to meet all the requirements
and suitable for the relevant application. The partnership with suppliers builds up
and promotes their involvement in the company policy of continuous
improvement; therefore the supplier becomes an active partner in the process
of growth and improvement of Quality standards.
Personnel with high competence
Scoda, together with mother Company, invests a lot of resources in staff training
at all corporate levels; the competence of staff plays a fundamental role to reach
and maintain high quality standards over time and, in addition, to promote the
policy of continuous improvement.
The training courses are planned with reference to the Skills Matrices, that point
out and relate the individual skill to the running working activity, so any possible
gap can be easily filled. In addition specific training are scheduled and focused
on new methodologies learning (see ISO TS) or on using of new working tools.
Suppliers with certified Quality System
All suppliers are approved through joint Audit carried out by Quality and
Purchasing specialists and their status of Scoda supplier is maintained by
continuous monitoring of their trend indexes particularly the PPM (Parts-Per-
Million) not-conformities. The evaluation of suppliers by Vendor Rating is issued
every six months. Suppliers with underperforming VR index respect to Scoda
target are called to jointly define proper countermeasures to restore the targeted
quality rating.
Punctual Analysis of Not-conformities, for a continuous improvement
The nonconformities are split in three main groups:
External not-conformities, reported by customers
Internal not-conformities, reported by departments or services
Not-conformities in material entrance, dependent on suppliers and detected
in acceptance
Each not-conformity is promptly investigated, checked and solved by applying
corrective actions according to the methodology of the Problem Solving. The
Quality service draws up the analysis of not-conformities half-yearly; it is shared
with all the company departments in charge, to jointly define and implement
necessary and resolving actions.
Partnership with Customers & Suppliers
Technical session
PPM Graphics - Not-conformities
Not-conformities analysis
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Significant equipments at the R&D department
Scoda works together with Atos R&D, which is equipped with the necessary instruments to catty out functional and
performance tests on products and components, moreover also specific machinery are available in order to simulate
the most critical applications to which the components may be exposed. The functional tests are performed both
during the feasibility study of a new product and on large serial production. The R&D plays a fundamental role in
identifying functional limits and weak points of the product, allowing designers to work and focus on the improvement
of Quality, Reliability and Performance standards.






































































































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Salt fog test
IP protection degree test
Temperature test chamber
Infrared camera
Electrodynamic shaker
Fatigue test
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Significant equipments at Quality Assurance department
Scoda is equipped with an own division for control of incoming material, and it works together with ATOS for checking
critical components, using their advanced control equipments that permit to check in automatic or semi-automatic way
the conformity of components realised internally or purchased at suppliers.
The controls are defined according to the critical points of each component, and according to the suppliers VR.
The quality and sampling plans are managed dynamically according to the number of conformed supplies and they
are set on three levels: low, normal or intensive. Suppliers having high quality level maintained over the years, work
under Free Pass; however all suppliers are required to prove and state the results of their own inspections and tests.
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3D coordinate measuring machine
Roundness tester
Roughness measuring station
Spring testing instrument
Optical measurement system
Universal length measuring machine
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Products 100 % tested
All Scoda products are 100 % tested, this permits to detect possible functional
non-conformities before the delivery to the final customers. The automatic testing
benches, using CNC programmable electronic sequencers, enable the check of
all functionalities and the recording of the tested performances.
Eventual products that are identified as not-conforming during the test are
immediately sent to the involved divisions, for checking and repairing. The used
fluid is properly thermostated and filtered, in order to ensure continuous
monitored cleaning and alarm signals if contamination exceeds 20/18/15
according to ISO 4406.
Traceability of the testing and product data
All Scoda products are identified with serial numbers through a specific marking.
This procedure permits a full traceability of each single product, enabling to
manage and to monitor it from the phases of definition of the basic requirements
of the series prototype and for the after-sales assistance.
Documentation for product use
All Scoda products are integrated with assembling Instructions and their
respective declarations of incorporation, in accordance with Machine Directive
2006/42/CE. The documentation is also available in several languages and
supplied also in electronic format, with Assembly 3D models, hydraulic and
electric schemes, digital bills of materials (BOM) usable for being integrated into
the technical book and final customer documentation.
Risk analysis and product safety
All Scoda products are properly developed taking into account the regulations in
force and supplying all required information about possible residual risks, general
warnings, inspections, etc.
An example of the above mentioned regulations compliance is the accordance
with ISO 4413 for:
Flexible pipes equipped with safety cables
Reduction of noise pollution sources in order to bring plants into compliance
with regulations through soundproof cabins, vibrating structures and balanced
thickness carpentries
Structures equipped with appropriate indications and with lifting and handling
devices.
Automatic testing benches
Indentificative label
Assembly Instruction
Pressure equipment directive 97/23/CE
Machinery Directive 2006/42/CE
Oleohydraulic systems Sistemi oleodinamici
Systmes olohydrauliques Oleohydraulische Systeme
group
Product documentation
Example of ISO 4413 application
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Paint inspections
OTO-MELARA testing bench
PED Certificate
2
Systems & Power units
CE decIaration of incorporation
PED certification for preaaure expIoaion riak
ATEX execution for hazardoua environmenta
fuIIy teated and preaet
Scoda srl
headquartera: Angera, Vareae, ItaIy
turnover: 10 miIIion 6
pIant aurface: 5000 m2
yearIy production over 2.000 unita
Systems & power units
The quality managements system certified since 98 in conformity with UNI EN
ISO 9001:94, has been checked with positive results in 2010, according to UNI
EN ISO 9001:08, through the certification body IMQ. To pursue the objective of
continuous improvement, plans to control the productive processes have been
established, to allow monitoring all the production phases.
The welding, qualified under Section IX of ASME norm since 1997 through RINA
certification body, guarantees the quality levels required by current Scoda
standards.
The painting processes are scheduled and executed according to ISO 12944, in
order to ensure an expected durability independently of the operating
environment corrosion classification.
The processes carried out are monitored through a series of checks such as the
thickness test according to ISO 2178, the adhesion test according to ISO 2409
and environment resistance tests carried out in cooperation with Atos according
to ISO 92227 and ISO 6270-2. Quality has been always a key point for Scoda,
specifically matured by managing orders according to quality assurance
requirements according to military provisions NATO AQAP-1 and UNI EN 29001
for civil, naval and military applications.
The ongoing target to improve the company quality standard leads Scoda to
align its own quality management system according to ISO TS 16949 standards,
introducing important activities mainly focused on customer satisfaction.
Certificates and qualifications achieved in Quality system
Quality system:
Dedicated Quality Plans to manufacture components in compliance with Atex
and PED directives
Registration into vendor lists of important groups operating in automotive,
energy, steel industry and mining
Product certifications:
electrohydraulic power packs certified according to 97/23/CE
safety blocks certified according to 97/23/CE
accumulators groups certified according to 97/23/CE
All above mentioned certifications are available on our web site www.scoda.it
on-line catalogue;
Main supplies:
Customer: OTO-MELARA LA Spezia
Role: sub-supplier Atos Spa
Supply: power packs to control stabilizing and balancing cylinders for SKY
GUARD launching system
Reference Norm: NATO AQAP-1
Customer: Fiat Ferroviaria Savigliano (CN)
Role: sub-supplier Atos Spa
Supply: handling and lifting systems for EUROTUNNEL shuttle trains
Reference Norm: UNI EN 29001
Main supply programs, managed according to the Quality Plan:
Cameron - Voghera Flexa - Milano
ZF Marine - Padova Enel - Pisa
Alstom Power Italia - Milano Voith-Siemens - Milano
Nuovo Pignone - Firenze CMD Transmissions - Cambrai Francia
Tetra Pack - Luno Svezia BHS - Weiherhammer Germania
Beijing Power - Pechino Cina Bystronic - Niederoenz Germania
3 Scoda quality assurance plan
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3.1 Design control
The design activity follows distinct operative lines in relation to the different product
types. The design of a power unit, of a component or of a standard group (as per
catalogue) is made through the issuance of a "Management Specification" prepared
by the Technical Department and approved by marketing and general management.
The design activity foresees, during its development, several stages of
documented review, where the conformity of the activities developments is
verified. The main review is extended to all the involved business divisions, and
customer approval is required.
The control and validation of the standard design are always carried out by testing
one or more prototypes according to a qualification trial program.
Test and verifications reports are always registered into the Management
Specification.
3.2 Documents and data inspection
All Scoda documents are identified according to qualified criteria of codification.
The code is always provided by the index of revision.
The data management is done both on paper (less and less used) and on data
processing supports according to the ongoing softwares for management,
design and usual practice. The external documents (norms, technical
specifications of customer) are registered into special lists issued and
periodically updated by quality assurance.
3.3 Purchasing
The purchases are managed by the purchasing department in cooperation with
technical services. The Scoda suppliers are preliminarily verified by the quality
assurance dept. in order to analyse their features and suitability.
Scoda do not ask their suppliers for the achievement of the ISO 9000 certification,
but Scoda checks if they comply with the relevant operating prescriptions and
requirements through dedicated inspection audits.
The vendor rating is set up and delivered to the suppliers twice a year in order to
monitor their performances in terms of quality of supplying and also their reliability
in terms of delivery time, flexibility and technical support forwarded to Scoda.
Scoda call suppliers having a quality index not aligned to a fixed benchmark in
order to agree on necessary corrective actions and to restore a quality standard
suitable for the needs of Scoda.
Scoda carried out specific frame agreements with suppliers having a quality
index higher than a fixed benchmark; this agreement includes self-certification
and free pass. The purchase orders are formalized on specific numbered forms,
including the contract terms fixed in the relevant suppliers contracts.
3.4 Inspection of products supplied by customer
The products supplied by customer are handled separately respect to Scoda
standards ones. Their storage is managed in separated warehouse areas.
Order management
specification
Project approval
Acceptance label
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12 group
3.5 Identification and traceability
The identification of parts and products is usually carried out by affixing the
identification labels on the components themselves.
The critical parts are marked by punching marking (special items, subplates for
blocks, others...)
The finished products identification is carried out by affixing a metal lable on
which the Machine Directive required data are printed, in order to have a unique
product code, the serial number identification, etc.
The finished products traceability, applied on all Scoda products, allows to
identify the name of the inspector, the time and the testing procedures that have
been applied.
3.6 Process control
The process control is usually carried out directly by the operative personnel
according to structured control plans.
The control of the manufacturing processes executed in the Company is carried
out in accordance with the working and control cycles, in which the operations
sequence and the working parameters are registered.
The control of the mounting activities is carried out both through visual
instructions finalized to describe and represent the execution procedures and
through the indications contained in the reference documents, in which the
operative guidelines and reference documentations are required.
3.7 Inspections and tests
Inspections and tests concern three different phases.
Acceptance sampling: is done by the acceptance control department according
to a sampling plan. Drawings and, where necessary, operative and visual
instructions are adopted as reference documents. The sampling results are
registered on a specific form.
On line controls: performed by the production workers and by the production
manager according to sampling plans. The on-line controls are performed in
accordance with the constructive design and with the production technical
specifications; the results are registered on the specifications for order
management.
Final functional tests: are performed on all components by testing personnel,
according to products test specification, and are registered on both the
specifications for order management and related forms.
The objective proof of the functional tests execution is granted by the presence
of the product traceability code marked directly on the body components and
by the data matrix code printed into the identification label.
3.8 Control of metrology and testing instruments
All the instruments used to control and test components are encoded and
registered on specific master registration cards. Their suitability is constantly
verified by the QA personnel through the relevant controls established in the
same master registration cards. The instruments verifications are carried out by
relying on Atos SpA laboratories or by external accredited laboratories by using
primary samples SIT, DKD, NAMAS
3.9 Test conditions
The status of trials, controls and tests of components is realized by marking or
punching of parts and, whenever not applicable, through identification labels.
Operative instructions
Test module
Product identification label
group 5
Productive structure
modern faciIitiea
quaIified peraonneI, for an efficient
production with QuaIity aaaurance
automatic teating benchea for beat
reIiabiIity and aafety
exceIIent cIeaneIeaa IeveI thanka to
vigoroua waahing and conatant oiI
contamination monitoring
Quality policy
8coda exceIIence ia featured through
high apeciaIization and conatant
improvement phiIoaophy.
QuaIity activitiea are managed to
enaure ayatema' beat reIiabiIity,
targeted to obtain fuII cuatomera
aatiafaction
Production policy
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3.10 Identification of products non-conformities
The products not-conformities both for simple part faults as well as finished
product defects are always identified with coloured labels.
The not-conformity is always registered by the quality personnel on a specific form.
The analysis of not-conformity management procedures are in charge to the
acceptance control dept. in cooperation with purchase dept., for what concerns
not-conformities issued at the acceptance of materials delivered by suppliers,
while they are in charge to the staff responsible for quality in cooperation with the
technical dept. for not-conformities issued during production phases.
For not-conforming parts that can be repaired or accepted in derogation, the
management procedures are defined exclusively by the technical dept.
The management of not-conformities highlighted by customers is usually
managed according to 8D reporting method, according to ISO TS 16949 norm.
3.11 Corrective and preventive actions
Corrective and preventive actions start from the analysis of product or system
not-conformities and they are registered through the internal and external not-
quality complains.
The relevant areas interested in such an analysis are: not-conformities in
acceptance and production, customers claims, not-conformities found in the
product overhaul, internal and external quality audits.
3.12 Handling, warehousing, packaging and transport
All the parts managed in the Company are handled, stocked and preserved
through specific equipment and protections. The preservation against ambient
decay is granted by coating protective products.
Packing for the shipment is realised by using different protections related to the
package weight, the selected way of transport and particular customer
requirements.
3.13 Control of quality registrations
Quality documents are registered and managed by the same departments in
charge of the specific activities.
Documentation of the quality will not be disclosed to entities outside the company
unless agreed in the review of the contract with the end customer.
These documents are stored for 10 years.
3.14 Quality audits
Quality audits are constantly carried out by the QA personnel both within the
Company structure and organisation as well as at the external suppliers.
The results of the inspections are always registered on specific forms, that are
integral part of the quality system documentation.
3.15 Training
The personnel training involves the analysis of the job description that identifies,
for any activity, the required preparation level.
The required skills are compared to the effective knowledge of the employee
responsible of the activities, highlighting the need to start training courses held
both by Scoda staff and external staff.
Training programs are registered and verified periodically by QA people.
Packing machine
Components warehouse
Not-conforming product
Training
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3.16 Customer service
Scoda customer service is composed by qualified personnel usually involved in
the R&D activities.
Each service intervention is registered into specific forms and service reports
are always forwarded to the customers.
3.17 Statistical techniques
Statistical techniques are applied to check quality problems that can be verified
through the analysis of Quality registration documents.
Particularly, the following company areas are analysed:
Controls and tests at material entry and in production
Not-conformities generated by customers claims or by companys departments
Customers claims
Delivery delays
Missing parts in production
4 Application software used by Scoda
4.1 Design engineering
Workstation Platform
ONE SPACE DESIGNER for 2D and 3D design
X-PIPING for piping advanced design
E3 workstation for hydraulic schematics
4.2 General application
UNIX Server Platform
Software for factory management Asco, including:
General accounting
Assets accounting
Balance analysis management
Production (stock, cost analysis, etc.)
ACT (configurator of codes, price lists and product part lists)
Microsoft PC Platform
Applications (WORD, EXCEL, ACCESS, POWER POINT)
Applications Adobe Illustrator, Quark Express
Web services and e-mails are self-managed
Customer service
Documentation and technical support
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