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TABLE OF CONTENTS
Quality/Environmental Manual ......... 4 Documentation Requirements .......... 93 Control of Documents ...................... 96 Control of Records ......................... 100 Management Review ...................... 103 Competence Awareness & Training 111 Control of Nonconforming Product . 116 Corrective and Preventive Action .... 120 Work Instructions ......................... 124 Work Instructions ......................... 127 Management Review FC-MR-5.6 .... 131

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and explanations. to smooth the progress of continual improvement by emphasizing defect prevention and the reduction of variation and waste: y International Automotive Task Force (IATF) Guidance to ISO 9001 and all related documents Page: 4 Page: 133 . The Company has based the Quality Environmental Management System described in this manual to demonstrate our capability (see Section 5) to provide products and services that meet customer and applicable regulatory requirements.QUALITY/ENVIRONMENTAL MANUAL SOP 4.2. Our products (name your market here) and therefore the quality and environmental management system adhere to the current ISO/TS 16949 and ISO 14001 standards. We developed Quality/Environmental Systems in accordance with the following four additional types of documents containing recommended automotive industry practices.2 1. Scope General The Company is a design-responsible supplier of (name your product here). examples. illustrations. and The Company·s quality and environmental policies. and to operate with increased effectiveness and efficiency with the overall aim of enhancing customer satisfaction consistently.

The Company currently supplies to the following manufacturers: y y XXXX. State. XXXX Where possible we integrated the quality system and the environmental management system to ensure that operations are cost effective and environmentally responsible. safety.y Status reports on actions from previous Management Reveiws Identification of any stratigic or operations changes that could affect the System Identification of any policy issues requiring review Status reports on progress towards meeting specific improvement objectives: y Customer Satisfaction y Supplier Performance y Overall System effectiveness including evidence of repeat audit findings or other repeat problems y Overall operational effedciency including an evaluation of the cost of poor quality y Manufacturing process effectivness and efficiency including performance against customer specified (or other targets for productivity. zip. on-the-job training. and employee awareness and effectiveness of employee motivation Recommendations for improvement and plans y Quality System Assessment Checklist to ISO 9001 and all related documents ISO/TS 16949 Automotive Certification SchemeRules for Achieving IATF Recognition and all related documents y y ISO 14001 Environmental Management Systems Requirements and all related documents Customer-specific requirements and guidance documents y Company Background The Company. process capability and cost y Overall product performance including an analysis of actual and potential field failures and their impacton on quality. The Company·s· Quality and Environmental Policy are available upon request. established in XXXX. City. and the headquarters is located at XXX Some Street. y Page: 132 Page: 5 . or the environment y Oerall product qualtiy including performance against customer spcified (or other) targets related to product quality Overall effectiveness of training completed including skills training.

covers the design and provision of all company products. through reference in this manual. Quality management systems ² Fundamentals and vocabulary ISO 9001:2000. Quality management systems ² Guidelines for performance improvements Issue Management Review Agenda Prepare Management Review Inputs Issue Management Rewview Minutes Review Inputs & Develop Outputs Action to improve Effectiveness of the System & its processes Monitor Implementation of Actions Resulting from Management Review Actionss to improve products Actions to provide nedded resources New or revised improment of objectives Assess Process for Effectiveness Page: 6 Page: 131 . constitute provisions of our Quality/Environmental Systems: y y y ISO 9000:2005. Quality management systems ² Requirements ISO 9004:2000. Reference Documents The following external documents contain provisions. and encompasses all operations at both of our facilities.6 Assess Overall System Effectiveness Monitor Objedctives and Operations Plan & Schedule Managament Review Meeting Significant Impact on System Exclusion Table Clause Exclusion Justification Analyze Results & Trends 2. which. The following table identifies the requirements not applicable to our organization and provides a brief narrative justifying their exclusion from the scope of our Quality/Environmental Systems: MANAGEMENT REVIEW FC-MR-5.Application Our Quality/Environmental Systems comply with all applicable requirements contained in ISO/TS 16949:2002.

Ford Motor Company CustomerSpecific Requirements for Use with ISO/TS 16949:2002 CSR-GM. Second Edition. Reinforces the need for a systemic approach to analysis of variation in data Page: 130 Page: 7 . Quality management systems ² particular requirements for the application of ISO 9001:2000 for automotive production and relevant service part organizations CSR-Ford. Rework the part by manually punching the holes using correct size punch 3/16 for the two holes on each side of the release trunk slot and 5/16 for the remaining holes. Potential Failure Mode and Effects Analysis (FMEA Third Edition) PPAP-4.ISO/TS 16949:2002 CSR-DC. The SPC Reference Manual. Production Part Approval Process (PPAP Fourth Edition) SPC-3. DaimlerChrysler (Chrysler Group) Customer-Specific Requirements for Use with ISO/TS 16949:2002 y y y  Customer Reference Manuals: y y y y APQP-2. General Motors Customer Specific Requirements .Rework Instructions: If the tool in the press does not punch the required holes in the S197 Deck Lid remove the part to designated rework area. Advanced Product Quality Planning & Control Plan (APQP) FMEA-3. Revision History  Customer Specific Requirements: y ISO/TS 16949:2002. has an improved flow and 2. Statistical Process Control (SPC) Note: 1.

The quality inspector performs part inspection and looks for (see boundary sample): y y y y y y Correct Color No Forming Flaws (I. Quality System Assessment Checklist. When the container is full. communicated. Terms and Definitions Our Quality/Environmental Systems uses the same internationally recognized terms.3 ² Nonconforming product). include the Quality and Environmental policies and objectives for continuing suitability. The operator then places the finished parts into a shipping container to packaging specifications 11. customers. and definitions unique to our organization. Carpet Wrinkles) Clean Trim Edge ² No Fuzz Or Debris Hole Clean ² No Slugs Slots and additional cutouts are cut or punched clean. vocabulary. The quality inspector also checks for container quantity and correct label Page: 129 . the operator has the material handler to remove the container and bring an empty one as needed 12. 4.. Excess Carpet. Overall Appearance Good 3. industry.E.3 ² Nonconforming product) 15. Terms and Definitions. Acronyms. and definitions given in ISO 9000 as supplemented by terms defined in ISO/TS 16949:2002. IATF Guidance to ISO/TS 16949:2002 9. terms. The quality inspector performs 1st piece inspection at beginning of shift (If needed follow SOP 8. The quality inspector records the findings (If needed follow SOP 8. The material handler puts a shipping label on container and moves the container to the inspection holding area 13. Quality Management System General Requirements Top Management is responsible to define the organization·s quality and environmental policy and ensure that it is documented.y y 3. Checklist to ISO/TS 16949:2002 TS-GS. and region and referenced throughout our Quality/Environmental Systems are contained in Appendix A. Measurement Systems Analysis (MSA) TS-QSA2. Section 3. vocabulary. Page: 8 14. and understood throughout the organization. Management review meetings. and records the information 10. Addresses additional control chart methods and tools MSA-3.

including all SOPs and other key Quality/Environmental Systems documents. When the press finishes its· cycle. or cutouts are not punched clean. slots. and satisfies Quality/ Environmental Systems requirements of ISO9001/ 14001. and 3 additional cutouts are clean with no slugs or fabric strings or debris. The operator raises the carpet to the cutter and cuts the carpet just above the tenor frame 3. which meet or exceed customer requirements. Specific responsibilities for and the sequence and interaction of our key Quality/Environmental Systems processes are detailed in the Standard Operating Procedures (SOPs). and related processes for providing products and services. The operator then places the waste material into the compactor 7. by defining and managing: y Process inputs. The operator cycles the press by pressing the two black palm buttons simultaneously 5. The operator inspects the part to verify 15 holes. The operator uses pre-cut carpet and the operator attaches the tenor frame to the carpet 2. one slot. many of which contain or reference deployment flow charts depicting the process or procedure described in the narrative SOP. Page: 128 desired results are achieved. We have adopted the process approach advocated by ISO 9000. follow Rework Instruction.The material handler: y Brings carpet to the press and helps the operator to load the carpet onto carpet feeder Provides shipping containers as required during the shift y Process: Our Quality/Environmental Systems is part of our overall management system. Appendix A contains a List of Key Quality/ Environmental Systems Documents. the operator removes the parts and the left over material 6. If holes. and y Interfaces between interrelated processes to ensure system effectiveness is achieved. controls. 8. General requirements ² Supplemental We also recognize the significant role that subcontractors play in achieving desired results and recognize that we must ensure proper control over Page: 9 . and outputs to ensure 1. which establishes documents and implements our quality policy. The operator then places the tenor frame central over the tool 4. The operator burnishes the part edges of extra fuzz (if necessary).

is responsible to implement and maintain a quality and environmental management system.2 General Safety Notes PPE: y y y y Safety Glasses Kevlar Gloves Kevlar Sleeves Knife General Notes Setup includes: y y y y Press (See Setup Sheet) Check Fixture Burnishing Table Final Pack Container Material Needed: y Carpet ² Milliken -62 µ roll Stage Material for production: The team leader ensures that the proper tenor frames are available at the beginning of the shift and will check throughout the shift.2. and continually improve its effectiveness. Outsourced processes are also depicted in our flowcharts. monitoring. measuring. Management reviews the identified and documented indicators for measurement and analysis to assure effectiveness and efficiency. Quality/Environmental Management System processes. The Management ensures that adequate resources and information necessary to support the operation. procedures governing their management are described in documents referenced in applicable SOPs.outsourced Quality/ Environmental Systems processes (Section 7). WORK INSTRUCTIONS WI-DL-6. Documentation requirements General The Management. and are managed in accordance with ISO and customer requirements. have been identified and documented in this Quality/ Environmental Manual. Page: 127 Page: 10 . including their sequence and interaction with other processes. through the Management Team. and analysis of these processes is made available and actions necessary to achieve planned results and support continuous improvement.

When the container is full. and processes needed to implement our quality policy and achieve our quality Page: 126 Page: 11 . Quality manual This manual is that part of our Quality/Environmental Systems defines the scope of our Quality/Environmental Systems and documents the policy. and other internal and external documents and data needed to manage. Quality/Environmental Systems documents and data may be in hard copy or electronic media. We also issue and control work instructions. The Company recognizes that control of any outsourced processes is necessary in order to ensure the product conforms to customer requirements. This quality manual. including the implementation and control of the Environmental Management System. Pack and label Revision History Each Department Manager is responsible for evaluating and adjusting resource requirements to efficiently execute assignments and accomplish goals defined in the business plan. the operator calls the material handler to remove the container and bring an empty one 12. SOPs. job descriptions. Management gives individuals total support and the necessary authority to perform the assigned tasks. We use SOPs and flow charts to document and define the key Quality/Environmental Systems processes. The material handler puts a shipping label on container and moves the container to the inspection holding area 13. perform. and other internal and external documents and data as appropriate and needed to manage our systems (Section 4).11. Part inspection 14. procedures. or verify work affecting product quality.

objectives. at beginning of shift. The information Quality Manager has overall responsibility for ensuring that all Quality/Environmental Systems documents. Control of documents Quality/Environmental records represent information that demonstrates conformity to Quality/Environmental Systems requirements and effective operation of The Company·s· Quality and Environmental system. as well as ISO/TS requirements. the operator removes the parts and the left over material 8. retrieval. Attach both tenor frames to the carpet and cut the carpet between them 4. records should be disposed of accordingly. Raise carpet to the cutter and cut the carpet just above the tenor frames 5. Once retention time is met. protection. The operator cycles the press by pressing the two black palm buttons simultaneously 7. below includes forms used to create controlled quality records as detailed in procedure SOP 4. The material is automatically loaded onto conveyor and into oven while the operator prepares the carpet for insertion into the press 2. The operator then places the part on over bend fixture and the waste material into the compactor and presses the green palm buttons simultaneously 9. This manual also shows our justification for any exclusion from ISO/TS 16949:2002 requirements (Section 1) and defines the overall sequence of between our key Quality/Environmental Systems processes. Pertinent records from our subcontractors are an element of this. readily available and retained for a specified period in Quality Record Matrix. When the press finishes its· cycle. and the retention and disposition of these records Quality/Environmental records are legible.3: Page: 12 Process: 1.2. Each Process Owner is responsible for identifying which records they consider quality/environmental records and for collection. Record retention must satisfy both regulatory and customer requirements. and after the removal of the part from the over bend fixture 10. The operator then places the finished parts into a shipping container Page: 125 . storage. The operator uses the controls to roll out the carpet long enough to place the tenor frames on the carpet 3. The quality inspector performs 1st piece inspection. Place the both tenor frames central over the cavities (one tenor frame per two cavities) 6.

readily identifiable. b) Review. The Company uses a Product Data Management system to manage and control engineering records and data (see SOP 4. e) Ensure that documents remain legible. Material handler brings material to conveyor and setup in proper position for conveyor load 2. and implementation of all customer-engineering standards/ specifications and changes based on customer-required schedule. Material handler brings carpet to the press to be loaded onto carpet cutter 3. WI-SB-5. Engineering specifications The Program Manager oversees our process for assuring the timely review. Two frames are required Page: 124 Page: 13 . Provide shipping container 4.2. and retrievable f) Ensure that identified external documents (including customer-engineering standards/specifications) have controlled distribution g) Prevent the unintended the use of obsolete documents.WORK INSTRUCTIONS a) Approve documents for adequacy prior to issue.2 Important General Safety Notes PPE: y y Safety glasses Gloves d) Ensure that relevant versions of applicable documents are available at points of use.2. Important General Notes Setup includes: y y y y y Press Carpet Cutter Over Bend fixture Check Fixture Final Pack Container Stage Material for production: 1. distribution. and re-approve documents. c) Identify the current revision status of documents. and to apply suitable identification to them if they are retained for any purpose. update as necessary.3).

2. or they affect PPAP documents. b) Product/process evaluation/acceptance criteria Work Instructions This booklet contains sample Work Instructions.The Company considers reviews timely if performed within two working weeks of receipt. including identification of the individual performing the activity. Pertinent Records from our sub-contractors are an element of this. we submit an updated PPAP. (Section 7) Master Lists Requirements for the establishment and maintenance of Master Lists of internal and external Quality/Environmental Systems documents are defined in SOP 4. Control of records Quality/Environmental records represent information that demonstrates conformity to Quality/Environmental Systems requirements and effective operation of The Company·s· Quality and Environmental system. They are very generic in nature and would need to be added to or changed for a real company. are prepared to document: a) Results of processes performed. When a change involves standards or specs that are reference on design records. Page: 14 Page: 123 .3.4 details procedures necessary to control Quality/Environmental Systems records that.2. SOP 4. as a minimum. Records may be in the form of hard copy or electronic media.

Management Responsibility Management commitment The Managing Director. Preventive actions will be reviewed during regular management review meetings. implementation. and improvement of our Quality/ Environmental Systems in very tangible ways: Page: 122 Page: 15 .) are updated to permanently implement the changes required by the corrective or preventive action. All corrective actions are to be reviewed during management review meeting. material or equipment qualifications f) Pertinent technical records from sub-contractors Records Retention SOP 4.2. drawings. is responsible to communicate the importance of meeting customer as well as statutory and regulatory requirements. including revision or date of document. Records of the analysis will be made available upon request. We provide evidence of commitment to the development.The corrective action is monitored for thirty days to assure that the action taken has been successful.e. Disposition of records also includes their disposal. etc. parts. along with the management team. diagrams. etc. Revision History c) Procedures. Records controlled include customer-specified records. Preventive Actions may be initiated because of. lessons learned follow up. the APQP process. x-bar and r charts. appropriate documents (procedures. Analysis of customer returned rejects will begin upon receipt of the defective material. All forms used in the corrective and preventive action procedure are retained for active life of the product for reference to prevent reoccurrence.4 contains related procedures and responsibilities to ensure: y y y y y Record controls established satisfy all regulatory and customer requirements. work instructions. or equipment used in the making of the product e) Personnel. If a corrective action is initiated because of the analysis will be tracked through the corrective action format. d) Identification of material.) are used when applicable. If the action is successful. or instructions used to perform an activity. Preventive actions will be tracked on the Preventive Action Log. TPM activities. Statistical methods (i. Lean activities or technology changes.

3 FOPARLOG 6. Permanent corrective action is to be determined by the team within 7 days of issuance. and maintenance of our quality policy at all levels of the organization through widespread printed distribution of our quality policy statement. and disposition of stock are determined and recorded. and through their proactive involvement in our continual improvement activities (Section 8). regulatory and legal requirements) through continual improvement of our processes. Emphasis is placed on improving both effectiveness and efficiency of our key Quality/Environmental Systems processes. The team will utilize mistake-proofing methodology to the degree appropriate to the magnitude of the problems and commensurate with the risks encountered. through their involvement in the internal audit process. SOP 8.0 Procedure Control of Nonconforming Product Procedure Preventative Action Log An immediate (possibly temporary) fix is developed and implemented with documentation. within twenty-four hours of the receipt of the notice of concern.Our quality policy statement (Section 5) documents and communicates the importance of meeting or exceeding all applicable requirements (including customer. through periodic management review of the quality policy statement. and services. y All managers demonstrate their commitment to the development and improvement of the Quality/ Environmental Systems through the provision of necessary resources (Section 6). Quality. The time frame to verify the effectiveness of the corrective action is to be determined by the corrective action team. We ensure understanding. We communicate and deploy our quality policy and objectives throughout the organization through individual performance objectives established and reviewed during employee performance reviews (Section 5 and 6). All suspect parts are inspected and inventoried. the quantity defective. The root cause of the problem is established and documented after the initial write up. implementation. Page: 16 Page: 121 . and corporate level improvement objectives. products.If future shipments are to be certified a method and duration must be established by Manufacturing. The quantity checked. and the customer (if applicable). Corrective/Preventative action reports must be complete through interim corrective action within three days of issuance.

5. explicit customer requirements and expectations in the form of a contractual agreement or customer order. and it prescribes the method by which we accomplish this: by continually improving Page: 17 SOP 8. The format utilized will be an 8D. 2.0 Definitions Not applicable 4. Top Management ensures that we meet these requirements with the aim of enhancing Customer Satisfaction.2/8.0 Responsibility y The Quality Manager is responsible for ensuring that the corrective/preventative action is managed effectively. and converted into requirements (Section 7). the Managing Director has overall responsibility for ensuring that specified and unspecified requirements are determined. understood. These customer focused communications and interactions ultimately yield clear.0 Associated Materials FOCAR 8. problems from subcontractors and customer complaints. 3. 5.CORRECTIVE AND PREVENTIVE ACTION Process efficiency Top management reviews product realization and support processes to assure both effectiveness and efficiency during management reviews (Section 5). The Top Management Team is responsible for analysis of customer rejected material. Our quality policy statement indicates our commitment and focuses on what is important to us as an organization: achieving customer satisfaction.5.2 FOMCRLOG Concern Report (MCR) Material Concern Report Tracking Log Page: 120 y .0 Purpose This procedure provides a systematic means in which quality problems will be eliminated. unless otherwise directed by the customer. including internal rejections. through Customer feedback and the following activities: y The Company continually monitors and measures customer complaints and other customer input/ feedback to identify opportunities for improvement (Section 8).5. Customer focus Customer requirements are determined during Quoting and Contract review processes.0 Application This procedure applies to all quality problems.3 1.

Quality Objective Our objective is to satisfy all of our customers with quality products and services.some rework necessary with written instructions & records. Scrapped material is recorded in the Scrap Log and the Material Concern Report. (Section 5) y We ensure that our quality policy is communicated and understood at all levels of the organization through documented training. Revision History y Quality/Environmental Policy Management review meetings checks the Quality and Environmental policies and objectives for continuing suitability. date. Our quality policy statement is controlled by inclusion in this manual. Conforming materials are removed from the container and returned to production flow. etc. A Quality representative records the results of the inspection and rework on the Material Concern Report listing the method of rework. Page: 18 Page: 119 . All material shipped under a customer concession or deviation will be identified as required by the customer. The material is re-inspected by the designated Quality Representative. our quality policy statement acts as a compass in providing the direction and a framework for establishing key corporate level performance measures and related improvement objectives. and reinforcement during annual employee performance reviews (Section 6). Nonconforming materials are scrapped or reworked accordingly. products. is reviewed for continuing suitability during management review meetings (Section 5). regular communication. and services to ensure they consistently meet or exceed requirements. employee responsible for reprocessing. Records of the quantity and expiration date shall be maintained.processes. number of acceptable/ unacceptable parts. and along with all policies contained in this manual. Unacceptable Product (placed in red ´SCRAPµ container / on rack) Questionable Product (QA disposition required) Quality disposes of questionable product and records the final counts and outcomes. y y y Acceptable Product . Moreover. No rework shall be visible on the exterior of the product.

as appropriate.3 FO 8.2 FO 8.SOP 8. There are four possible determinations of inspected product: y Acceptable Product ² green check mark Page: 118 Page: 19 . to encourage customer satisfaction and overall growth of the organization. The Production Supervision and Quality Manager determine the disposition of the non-conforming material and record it on the Quarantine Area Record. We also have methods to track update and revise fall under the Continuous Improvement Process. Make statement 2. Quality or a member of management will provide written instructions to the employee conducting these activities. The Company·s Management Team annually reviews business plan and revises. Production personnel complete sort or rework. the container(s) is identified by a Quality representative or production supervisor with an initial Material Concern Report. and defines timeframes to achieve each goal. including those needed to meet product requirements. a Material Concern Report will be issued at the time of occurrence) The non-conforming material is moved to the Quarantine Area and a member of the quality department or Production Supervision. Make another statement Planning Quality objectives The Managing Director and Operations Manager ensures (established at relevant functions and levels within the organization) that quality and environmental objectives and measures are documented in a business plan. The business plan includes short and longterm goals relating to quality and environmental policy objectives.0 Procedure Corrective/Preventive Action Procedure Quarantine Area Record Scrap Log Quality Policy Our Objective Will Be Accomplished Through Customer Satisfaction by Providing: 1.5. (If material is part of an accumulation.3 6. completes the Quarantine Area Record. up to the disposition section. The quality manual documents the necessary processes that define the planning process for quality/environmental management system and objectives. When material is found to be nonconforming.

and charting of performance measures (Section 6). This managing includes the procurement of a deviation or concession from the customer if changes to the product differ.The Company benchmarks trends in quality. (Section 6) Product Performance: Program Manager. reading material. including materials and services provided by vendors. The Program Manager/Production is responsible for managing the customer authorization of products or processes and the procurement of a deviation or concession. 4. Material is reviewed and disposition is determined by management and quality.0 Associated Materials FO 8. and effectiveness are. We accomplished Benchmarking formally and informally via trade shows. The Quality Department is responsible for maintaining and analyzing data from NC material activities. efficiency. 5.3 The Quality Manager is responsible for notifying the customer if non-conforming material is detected after shipment has been made or use has started. productivity. customer feedback. that differ from those currently approved according to the Production Part Approval Process Manual.3 NCMR Material Concern Report y y y y y y y Page: 117 . It is clearly (visually) identified and quarantined or segregated to prevent inadvertent use or installation. Actions will be taken such as stock returns and replacement. sorting or even sending a company representative to their site to protect their interests. (Section 7) Effectiveness of Manufacturing Processes: Production Manager (Section 7) Product Quality: Quality Manager (Section 8) Page: 20 product which does not conform to specified requirements. Objectives may include the following possible measures (Section 5): y Customer Satisfaction: Managing Director (Section 8) Supplier Performance: Materials Manage (Section 7) Quality/Environmental Systems Effectiveness: ISO Management Representative. as information is available. (Section 8) Overall Operational Efficiency and Manufacturing Process Efficiency (Section 5 and 6) Training Effectiveness and Employee Awareness: Human Resource Director (HRD) with input from the Training Manager.

(Section 7) d) Provide objective evidence that all supplied products and services satisfy all AIAG Production Part Approval Process (PPAP) requirements. PPAP-4¸ (Section 7) as required including acceptable process capabilities for all Special/Control Characteristics that have been established.. Note: In the absence of any specific Page: 21 . unidentified or suspect material. quality systems and personnel to consistently and cost effectively produce products and furnish services that meet customer needs (Section 7). dimensions. c) Develop and implement Advanced Product Quality Planning (APQP) practices and procedures in accordance with ISO/TS 16949:2002. 2.0 Application This procedure applies to. 3.3 1.0 Definitions Nonconforming Product: Material (e. in-house rejections. driven by the following objectives we strive to achieve as a Full Service Supplier (FSS) to the automotive industry: a) Achievement of Zero Defects and 100% on time delivery performance. melt flow.0 Responsibility The Production Supervision and Quality Department are responsible for following documented procedures and work instructions for Page: 116 Quality objectives ² Supplemental: Top management utilizes the management review process (Section 5) to define quality objectives and measurements to include in our Business Plan and used to deploy our quality policy. and associated customer specific requirements documents. processes. including the AIAG ´Advanced Product Quality Planning and Control Planµ reference manual. but is not limited to.g. We base specific measurable objectives on achievable performance within a specified period. work-in-progress. APQP-2. purchased components. customer rejection / returns or material received from a supplier.0 Purpose This procedure provides a method to control nonconforming material at any location in the S Group and to eliminate its potential for unintended use or delivery.) Suspect Product: All material having the same lot number as known nonconforming product. etc. visual.g. etc.CONTROL OF NONCONFORMING PRODUCT SOP 8.) that does not meet established parameters (e. 4. (Section 7 and 8) b) Manage and control facilities.. resin.

instructions. and associated customer specific requirements documents. maintaining. (Section 7). SPC-3. (Section 7) e) Utilize appropriate statistical techniques for ongoing process control and improvement as established in the AIAG ´Statistical Process Control (SPC)µ reference manual. and through the provision of resources needed for its effective implementation. (Section 8) g) Conduct operations in conformance with. h) Meet customer requirements by controlling and using returnable packaging. of. Quality management system planning The Quality/Environmental Systems planning process involves the establishment and communication of our quality policy and objectives through issuance of this manual and its associated procedures. we will default to a level 3 PPAP submission. or to exceed. This manual constitutes our overall plan for establishing. Determine Effectiveness of Training One or more of the following determines training effectiveness: y y y Review of Salaried and Hourly Evaluations Post-training tests. (Section 8) f) Be committed to continuous process improvement by emphasising reduction of part-to-part variation and the elimination of all waste. all applicable environmental laws and regulations of the jurisdictions in which we do business (Section 6). and improving systems. when applicable Employee on the job performance Revision History Page: 22 Page: 115 .

The Company employees and their manager/supervisor shall review the employees training status to determine training needs. including contract or service personnel. authority. and 8) The Quality Manager develops appropriate quality planning documents for specific products.0 Associated Materials Orientation Manual Job Descriptions Our management review process and internal audit process ensure the integrity of our System is maintained when significant changes are planned and implemented that affect our key Systems. in any new or modified job. This review occurs concurrently with the employee·s performance evaluation or upon need. and communication Responsibility and authority 6. or contracts whenever customer requirements exceed the capability or intent of the product/service realization and support processes described in our Quality/Environmental Systems (Section 7). Provide Training One or more of the following provides formal training: y y Identified The Company Trainers Professional / Industry Organizations or Societies Local Community and Trade Schools College and University Sponsored Classes On-The-Job training is provided for all personnel. The Managing Director (MD). projects. Other members of Top Management include: y y The Operations Managing and The Human Resource Director y y y The interrelationship of Top Management and other key personnel is depicted our Organization Chart. with the help of department managers.0 Procedure Identify training needs. (Sections 5. Responsibility for quality Overall Quality/Environmental Systems responsibility and authority is as follows: Page: 114 Page: 23 . Responsibility. 6. sets direction and ensures the success of our business through the clear definition and communication of Quality/Environmental Systems responsibilities and authorities.5.

It is the responsibility of the TS-16949 Management Representative to measure the extent to which our personnel are aware of the relevance and importance of their activities and how they contribute to the achievement of the quality objectives. Management All managers are responsible for execution of the Business Plan and implementation of the policy. and the provision of resources needed to implement and improve these processes. and an assessment test (if applicable) is given upon completion of the course. Management with responsibility and authority for corrective action promptly notifies employees of non-conformities (Section 8). including the establishment and deployment of operational level objectives (Section 5). and systems described in this manual. Management ensures the staffing of all production shifts with personnel in charge of. or delegated responsibility for product quality (Section 7). Quality/Environmental Systems Planning including the establishment and deployment of objectives (Section 5). employee·s manager/supervisor in the performance review process determines individual training needs. It is the responsibility of the Manufacturing Supervisor to inform personnel whose work affect quality of the consequences to the customer of nonconformity to quality requirements. Top Management is responsible for Business Planning. Managers also conduct employee performance reviews (Section 6). All managers are responsible for planning and controlling Quality/ Environmental Systems processes within their area(s) of responsibility. The content of the courses are evaluated through a training feedback and evaluation form. processes. Safety Training All employees receive safety training Specialized Training Employees requiring specialized training in areas affecting quality shall receive the training needed per job description. Page: 113 Page: 24 . development and communication of our quality policy.Top Management Members of Top Management are ultimately responsible for the quality of The Company·s· products and services since they control the systems and processes accomplished work. Evaluating Training The training courses offered internally are continually assessed by the Human Resource Department. the provision of resources needed to implement and improve Quality/Environmental Systems and management reviews (Sections 5 and 6).

work instructions. The management representatives have the responsibility and authority to: y Ensuring that the ISO/TS 16949:2002 processes needed for quality and environmental management systems are established. Evaluating Training Needs Employees All employees are responsible for the quality of their work and implementation of the policy and procedures applicable to processes they perform. Ensuring the promotion of awareness of customer and environmental requirements throughout the organization (Section 5) Page: 25 All employees (salaried and hourly) must complete the specific orientation program administered by the Human Resource Department. These records include. The Page: 112 y . implemented. Each hourly employee has an individual training record. but are not limited to. which is maintained by the Human Resource Department. Each salary employee has an individual training record.Training Records Hourly Employees: Records of hourly training needs and training received by active employees performing activities affecting quality shall be maintained by the Human Resource Department. Personnel responsible for product quality have the authority to stop production to correct quality problems (Section 8). All employees have training in awareness. Detailed responsibilities and authorities for Quality/ Environmental Systems implementation and improvement are contained in lower level documents referenced throughout this manual and other Quality/Environmental Systems documents including procedures. Personnel whose work affects quality are informed about the consequences to the customer of nonconformity to quality requirements. job descriptions. but are not limited to. training matrices and copies of training certificates. which is maintained by the Human Resource Department. relevance. flow charts. training matrices and copies of training certificates. etc. These records include. and maintained in accordance with their respective standards (Section 5). Salary Employees: Records of salary training needs and training received by active employees performing activities affecting quality shall be maintained by the Human Resource Department. and importance of their activities and how they contribute to the achievement of our overall quality objectives. Management representative The Company has appointed Quality and Environmental Management representatives for each system.

and the status and importance of quality activities.2. and specific training sessions to communicate internal information about the effectiveness of our quality and environmental management system. objectives and significant environmental aspects. and its policies. and regular formal and informal communications as follows: y The ISO Management Representative posts information on quality bulletin boards throughout the facility to convey information regarding customer requirements. including but not limited to workplace meetings.0 Responsibility Job Description Each position has a written job description maintained by the Human Resources Department. skills appropriate required for the position. continual improvement. 3.y The Environmental Management Representative is responsible for documenting and responding to relevant communication from external parties. the internal audit process (Section 8). as appropriate. new employee orientation.0 Purpose The system described in this section is used to ensure that all personnel performing activities affecting quality shall have their training needs identified and. and corrective/ preventive action processes (Section 8). memos. Page: 26 Page: 111 . Each job description identifies the competence level/ education.0 Definitions Not applicable 4. from contract review through production Internal communication The Company uses a variety of tools. the training provided. bulletins.0 Application The scope of this procedure incorporates the training of all employees performing quality related activities. 2.2 1. COMPETENCE AWARENESS & TRAINING SOP 6. We communicate information regarding Quality/ Environmental Systems processes and their effectiveness through documented training (Section 6). Customer representative The Program Manager will ensure and address customer requirements and will represent the needs of the customer internal functions.

and effectiveness of our Quality/Environmental Systems in accordance with procedures detailed in SOP 5. which we convey and reinforce during employee performance.0 Associated Records Management Review Report: Record of the management review meeting. Quality Objectives Matrix: Record of established quality objectives. All managers and supervisors. and related statutory/regulatory requirements. to include presented and discussed topics and issues. Communications regarding how employees contribute to the achievement of objectives.1. The Managing Director Page: 110 Page: 27 . programs. are responsible for establishing internal communications as needed to convey to their employees the relevance and importance of their activities. Documented using form FO-MRR-5.9. Management review Top Management conducts formal review meetings at least quarterly to ensure the continuing suitability. The Human Resources Department posts information on employee bulletin boards throughout the facility to convey information regarding employee benefits. conclusions. Documented on the title page of the Management Review Report (MRR 5. and applicable statutory/regulatory requirements. reviews (Section 6).6). involvement opportunities. Revision History The Operations Manager posts information on safety bulletin boards throughout the facility to convey information regarding the status of the Safety and Environmental Management Program.6.6. policies and changes. adequacy. typically this information is conveyed through production team meetings and cross-functional improvement projects (Section 8). and any actions initiated to implement the conclusions and policies. Management Review Report. y The Company uses internal audits (Section 8) to reinforce or communicate appropriate information to employees.

time frame.or designee chairs the corporate reviews and top management from all relevant functions attends. We retain meeting records. 7. and environment. Corrective and Preventive Action Page: 109 .6.4 Operational Procedure.2 Operational Procedure. Page: 28 Resource needs for implementing improvement actions are identified.2. safety.4. (Section 5) The Quality Manager ensures that review includes analysis of actual and potential field failure and their impact on quality. The primary output of management review meetings are management actions taken (Section 8) to make changes or improvements to our Quality/Environmental Systems and the provision of resources needed to implement these actions.e. evidence of achievement of quality/environmental objectives and customer satisfaction. identifying opportunities for improvement and corrective and preventative actions.0 Referenced Documents 5. Quality system performance Each management review includes all requirements of the Quality/Environmental Systems including monitoring of quality objectives (Section 5). These include assignment of responsibility. if any. regular evaluation of the cost of poor quality (Section 8) . equipment. Control of Records SOP 8. The location and retention period for management review records are specified in Operational Procedure SOP 4.1. and an assessment of the suitability and effective of support processes (i.2.5.1 Management Review Report Form SOP 4. and allocation of human.0 Records Management review records must be as comprehensive as possible. (Section 8) The Company record review results provide at a minimum. The Company holds review meetings at least monthly to review plant specific data and process effectiveness indicators.6. Section 6) as an essential part of our continual improvement process (Section 8). absent participants. 8. Control of Records. They will be the sole evidence that the agenda of the review was completely covered. plant. facility and equipment. and that the review was concluded with appropriate decisions and actions. Management review output is documented in the Management Review Report based on form MRR 5. The report is prepared by the Quality Manager and is distributed to the attending and. and other necessary resources. technical knowledge.

effectiveness and/or efficiency improvement objectives (Section 5) documented in prior management reviews (and/or specified in our Business Plan) and reviewed for status and continuing suitability. CARs are normally used for improvements related to specific actual or potential product or process nonconformities. outputs from management review meetings include new/revised corporate level improvement objectives and any related actions required for improvement of the Quality/Environmental Systems and its processes. and Improvement of products and/or services to better meet customer requirements and increase customer satisfaction At a minimum. Improvement of quality performance.6. The Program Manager provides an analysis of actual and potential field-failures and their impact on quality. and Due Date columns.2. and opportunities for improvement. Quality objectives Documented on the title page of the Management Review Report (refer to Section 6 of this procedure). related performance trends. Corrective and Preventive Actions. follow-up actions from earlier management reviews. At a minimum. we use these results to demonstrate achievement of the quality objectives in our Business Plan and customer satisfaction with supplied product. all applicable requirements of the QEMS. Page: 108 At a minimum. Assigned to. This type of action is most suitable for minor improvements that can be quickly implemented. In addition. and which are not directly related to product or process conformity.1) in the Actions. and strategic or operational changes that could affect the QEMS.0 y y y Management review output Improvement of the quality management system. This method is most suitable for implementing long-term improvement goals. Corrective or preventive actions Documented in the Corrective Action Request (CAR) form (FO-NCCAR-8.3) and processed in accordance with procedure SOP 8. corporate level. results of self-assessments (Section 8). Review input The management review meeting includes a review of our quality policy (Section 5).5. Review output These improvement actions are defined implemented as: Management review actions Documented in the Management Review Report (FO-MRR-5.2. improvement of product related to Page: 29 .6. Review input ² Supplemental. safety or the environment as an input to the management review process.

Quality presents the status of quality objectives established by the previous review (those objectives are documented on the title page of the Management Review Report). the participants decide whether to drop the objective. we record the results of management review meetings and the ISO Management Representative maintains the records. or when changes within or outside the company render the policy inadequate or inappropriate. and advanced Quality/ Environmental Planning. Per SOP 5. Objectives that have been achieved may be discontinued or be retained with a higher target value. Any quality objectives that are carried on into the next period and any new objectives established by the review meeting are documented in the Quality Objectives Matrix on the title page of the Management Review Report. and records their status in the Status Next Management Review column. and to enhance customer satisfaction by meeting customer requirements. We accomplish verification of work through budget comparisons. When an objective is not achieved.customer requirements. Quoting process. as well as through the results of internal audits of the quality and environmental provided through our budgeting and other business management processes including: and thus fulfill the quality policy and other organizational goals and aspirations. The policy is changed when the goals expressed in the policy have been achieved. Page: 30 Page: 107 . through the Management team. and provision of resource needs. The principal quality policy is reviewed to ensure its continuing suitability. At the end of the meeting. 5. Resource requirements identified during the Business Plan Process. or extend the target due date.6. reduce its target value. performance measurements. Resource Management Provision of resources The Company. determines its resource needs and provides the resources to implement and maintain the quality management system and continually improve its effectiveness. capital expenditure review.

Quality objectives are established to improve performance and/or the quality system Subject y y y y y y y y y y y y y y y y Quality/Environmental Planning Business Planning Human Resource Planning Plant. market and customer response to the quality effort. with input from other responsible managers. and Improvement Planning (including the use of SPC) Organizational Continual Improvement Planning Manufacturing Process Continual Improvement Planning The MD.Changes and quality system planning Quality highlights any product. and any other such issues related to the quality management system. integration of the quality system with other operations and activities. Facility. the management review may also consider such issues as cost of quality and non-quality. capacity. Recommendations for improvement Quality concludes the input phase of the review with recommendations for improvement. and Service Provision Planning Measurement Systems Planning (including the conduct of MSA) Measurement. Analysis. and identify areas where improvement is required. In addition to the topics listed above. and Safety Planning Product Quality Planning (including Advance Product Quality Planning) Planning of Customer-related Processes Product and Manufacturing Process Design and Development Planning Planning of Purchased Product (Materials. compare their status and performance with preceding periods. the participants discuss the issues. 5. process. Page: 31 Page: 106 . Equipment and other Infrastructure Planning Contingency Planning Work Environment. or other operational or organizational changes that affect the quality system and proposes specific actions to update or modify the system in response to these changing circumstances. monitors and measures overall operational efficiency (including the cost of poor quality) and provides related input and recommendations that may affect Quality/ Environmental Systems effectiveness to Top Management for review and action (Section 5). Services and Vendors) Production.0 Quality objectives and quality policy An important role of management reviews is to establish quality objectives and to review progress toward achieving the objectives and fulfilling the quality policy. Following each presentation.

Human resources General The Company ensures that all employees who perform activities that may affect product quality or have significant impact on the environment have the appropriate training. experience and competence. Some persons may move on to the fourth stage and we deem them an ´expertµ allowing them to train others or assume other responsibilities. Awareness. In the third phase. It is which visually displays the capabilities of the person according to which of the quadrants have been achieved. on-time delivery performance. This includes rates of process and product nonconformities.Analysis of Data. In the second phase. Page: 105 Page: 32 . and Training The Company maintains a Training/Competence Matrix for personnel by job description. Edit the scope of the quality performance data as appropriate. Competence. Process performance and product conformity Quality presents quality performance data. and coordinate with ISO/TS 16949 Element 8. the frequency of audit findings against particular elements of the quality system and discussion of significant findings. we deem the new person ´competentµ to work on his or her own. Customer feedback and complaints Customer Service presents summaries of customer feedback and customer complaints. Corrective and preventive actions: Quality presents the most important corrective and preventive actions implemented through the period. the experienced person or member of management continues to observe the new person. skills. This includes summaries of results for the cycle. (SOP 6) abandoned. Internal quality audits Quality presents results of internal quality system audits. and the status of pending actions. supplier quality performance. This Competency Matrix is available to persons assigning work. including analysis of trends. It is a four-quadrant system. Reasons for the failure to implement the action and any decisions regarding continuation of the action are recorded in the Management Review Report. All personnel understand the importance of their activities and their contribution to the achievement of the quality and environmental objectives. We utilize a ´mentorµ system for the first of four phases with an experienced operator working with a new person and the work instructions of the particular process. and productivity data.4.

changed. Management review input At a minimum. evaluates and qualifies applicants for specific job openings based on documented or demonstrated competencies. Actions which are not completed may be extended with a new due date. these include: Product design skills The Program Manager ensures that personnel with product or manufacturing process design responsibility (Section 7) are competent to achieve design requirements and are skilled in design methods (Section 7) needed to achieve desired results. Attendance Management reviews are chaired by the Quality Manager and are attended by Management. as Page: 33 . may submit their input and comments to the Quality Manager. after reviewing the minutes. Where possible. Agenda The agenda for management review meetings covers at least all items listed in Section 4 of this procedure. The Operations Manager and Quality Manager must always attend. Production. and Purchasing. we help existing employees qualify for new/changed jobs through the provision of appropriate education and training. or Page: 104 Need Determination Department managers and supervisors are responsible to identify required training and competency for personnel in their respective areas and to coordinate training and follow through with evaluations for competencies. and update of hourly employee Training/Competence Matrix records. reassigned to another person/function. including on-the-job-training (OJT). with input from responsible managers. Personnel performing specific assigned tasks are qualified. At a minimum.Manager may call for unscheduled extraordinary reviews. The Human Resource Department. Those managers who are unable to attend shall receive minutes of the review meeting and. Engineering. the following information and data are presented for review: Follow-up actions from previous reviews Quality reports on the status of action items from the previous meetings. Our Training Coordinator is responsible to analyze effectiveness of training and competence. The agenda is documented on the cover page of the Management Review Report. No more than one manager may be absent from the meeting. Training Responsible managers identify training needs for their employees and achieve competence of all personnel performing activities affecting product quality.

with particular attention to the satisfaction of customer requirements (application of digitized mathematically based data. The additional review is conducted in September.. through the maturation phase of the quality system).).6 1.0 Application This procedure applies to all activities comprising the quality system.required. Employee motivation and empowerment The management team is responsible to motivate employees to achieve quality objectives. The Company carries out periodic audits with employees to determine their awareness of the relevance and importance of their activities and contribute to the achievement of the quality and environmental objectives. e. MANAGEMENT REVIEW SOP 5. 3. and to assign responsibilities for scheduling.0 Purpose The purpose of this procedure is to provide for a system and instructions. to make continual improvements and to create an environment to promote innovation. In response to changing or special conditions and events. We conduct Annual employee reviews to give one on one interaction of communication employee with The Company Management. conducting.g. the Operations Page: 103 Page: 34 . and in particular those named in Section 4. The annual review is conducted in March.e. For the first two years (i. including agency or contract employees.0 Definitions None 4. Review Input. 2.0 Procedure Frequency and Scheduling Quality performance and the quality management system are reviewed at least once a year. of this procedure. Responsible managers ensure that employees are aware of the relevance and importance of their activities and contributions to the achievement of our objectives. On-the-job-training Responsible managers ensure on the job training (OJT) is provided for personnel in any new or modified job affecting product quality. management reviews are conducted twice a year. and recording management reviews of the quality management system.

We use employee performance reviews and the internal audit process (Section 8) to promote and assess the extent of quality and technological awareness throughout our organization. and supervisors reevaluate employee competencies and evaluate employee performance against established objectives through our employee performance review process. Obsolete documents. Responsible managers. Provision. we ensure that our employees are aware of customer requirements (Section 5 and Section 5). and determines the filing and storage method (for retrievability and preventing damage) and the retention duration (conforming to TS-16949 requirements) for quality records. Effectiveness The Company evaluates the effectiveness of all actions taken to meet competency needs. purchase orders and amendments. The records may be retained longer for reference at the discretion of the responsible party. The Quality Department retains superseded part documents used for new part qualification. officers. We evaluate provided training through immediate feedback from the employee and the manager. or supervisor who identified the training requirement. We utilize the ´employee performance review processµ to motivate employees to achieve individual or functional performance objectives that support achievement of our corporate objectives (Section 5). shall be maintained for the length of time established by the corresponding Department Manager and in accordance with minimum customer requirements. Responsible managers monitor and measure the overall training effectiveness and to meet competency needs and provides related recommendations to Top Management for review and action (Section 5). The retention duration listed is a minimum retention. tooling records.6. The status of archived records is determined and appropriate records are disposed of annually. The Quality Department ensures quality records are available for evaluation by the customer for the stated period. and importance Page: 102 Page: 35 Revision History . the relevance. Employee Awareness Through their activities and contributions. The responsible manager collects the documents for each training event. other than production part approvals.0 Procedure The responsible personnel and/or departments ensures the validity and completeness.

workspace and associated utilities. we detail methods to evaluate and monitor the effectiveness of existing operations in SOP 7. In addition. skills. and equipment. including buildings. The Materials Manager and Accounting department are responsible for ensuring the proper retention of customer related purchase orders and amendments. employee performance reviews (Section 6). Employee qualification/competency review records and annual performance review results are maintained by the Human Resources Department.2 SOP 8.4 DD FO 4.4 and SOP 5.4 QR Advanced Product Quality Planning Manual Failure Mode Effect Analysis Manual Measurement Systems Analysis Manual Statistical Process Control Manual Production Part Approval Process Management Review Procedure Contract Review Procedure Internal Audit Procedure Destroyed Documents List Quality Records List Page: 36 Page: 101 . and employee participation in our internal audit (Section 8) and improvement (Section 8) processes. and experience in accordance with provision of Section 4.0 Accounting department and the Materials Manager are responsible for ensuring the proper retention of subcontractor purchase orders and amendments.2 FO 4. This is accomplished through awareness training. training.6. Infrastructure The Company provides and maintains the infrastructure needed to achieve conformity to product requirements.1. processes.achieving our quality policy (Section 5) and objectives (Section 5). such as transportation or communication.6 SOP 7.2. We use a multi-disciplinary approach to develop plant. The Company prepared contingency plans to satisfy customer requirements in event of an emergency such as 5. process equipment (hardware and software as necessary). Records We maintain appropriate records of education.5. facility.2.2. The Training Manager maintains records of all training completed. Associated Materials AIAG APQP AIAG FMEA AIAG MSA AIAG SPC AIAG PPAP SOP 5. and any supporting services that are needed.

facility. The Quality Manager is responsible for ensuring the proper retention of production part approvals. 2. maintenance and repair Housekeeping/custodial services management Process equipment management. and disposal. 3.CONTROL OF RECORDS utility interruptions. indexing.2) The Plant Supervisor has overall responsibility for managing our Facilities and Equipment Maintenance programs in accordance with SOP 6. storage.0 Responsibility Each Department Manager is responsible for records their department creates and for their maintenance. and equipment planning The MD uses a multidisciplinary approach for developing plant. (SOP 6.0 Definitions None 4. Page: 100 Facilities management. quality performance records. and disposal. filing.3. The Plant Supervisor develops and implements an effective preventive maintenance program utilizing predictive maintenance methods (Section 7) as appropriate. and equipment plans. maintenance and repair Production tooling management. availability. The Information Systems Manager has Page: 37 . internal quality system audits. and management review. and repair y y Plant.4 1. facility. and Transportation and material handling equipment management.0 Purpose This procedure provides a method of maintaining quality records consisting of identification. maintenance. labor shortages. these programs include: y y y SOP 4. collection. and key equipment failure and quality issues. This is inclusive of all prints. protection.3.0 Application This procedure applies to all departments responsible for the maintenance of quality records. The Program Manager and/or designee is responsible for ensuring the proper retention of appropriate tooling records.2. handling and value-added use of floor space and facilitate synchronous material flow. The Program Manager ensures plant layouts are designed and continually evaluated through the application of lean manufacturing principles (state your approach here) to minimize material travel.

5. The Quality Manager.2.3 WI 4. The Human Resources Department has overall responsibility for identifying. Contingency plans. implementing. and maintaining safety and environmental management systems. and maintaining effective employee benefit and workforce involvement programs. Management reviews the effectiveness of these efforts during management review meetings (Section 5). The Operations Manager has overall responsibility for identifying.4 Control of Quality Records Procedure SOP 7. job and schedule flexibility. ensures contingency plans are documented in the Business Plan and implemented as needed to satisfy customer requirements in the event of an emergency such as utility interruptions. and key equipment failure and field returns. and involvement of our employees in an empowered environment of continual improvement (Section 6). We engender total participation by involving employees in internal audit (Section 8) and improvement (Section 8) activities.0 Associated Materials SOP 4. in conjunction with the Information Systems Manager and other appropriate managers. Page: 38 Department Managers are responsible for reviewing all of their applicable documents within their departments at a minimum of annually to insure relevance and conformance.2. processes and controls needed to ensure product conformance and meet customer. implementing. Work environment We provide employee benefits.3 Advanced Quality Planning Procedure Documentation ² Writing Procedures and Work Instructions Revision History Page: 99 . labor shortages.overall responsibility for managing our automated data processing and communications systems. interesting work. statutory or regulatory requirements. We monitor and improve workplace safety. health. and ergonomics by following proper manufacturing practices.

reviewing and retaining CAD/ Math data. Department Managers are responsible for creating. approving. Personnel safety to achieve product quality: We design and carry out production processes to ensure product safety and minimize potential risks to employees as may be identified during development of design FMEAs (Section 7) and/or process FMEAs (Section 7) and documented in work instructions located in process areas (Section 7). but not limited to. The Plant Supervisor is responsible for ensuring records of Total Preventive Maintenance activities are maintained. The Program Manager is responsible for ensuring all levels of documents and subordinate documents (such as control plan. Product Realization Planning of product realization 1. Both the person receiving a copy of a new or revised document and the person distributing the document are responsible for ensuring that obsolete copies are identified and/or disposed of. Cleanliness of premises We provide and maintain a work environment in a state of order. and repair consistent with the product and manufacturing process needs (Section 6) 6.2). Instructions and Test Procedures are available. and in-process and operator instructions) are in agreement. The Company has implemented a Quality and Environmental-planning process to define and document how the respective requirements will be met (See SOP 7. the following: Page: 39 Page: 98 . 2. a cross functional team plans the processes with consideration given to. For new projects. first piece. and maintaining their individual department work instructions.Control Procedure and Engineering Change Process. All Department Managers listed above are also responsible for making sure distributed and or obsolete copies are retrieved and replaced with the latest revision. The Program Manager is responsible for receiving. and through safety team meetings and training (Section 6). The Plant Supervisor is responsible for ensuring current instructions are available at all work instructions. cleanliness.1 & SOP 7. This planning process is consistent with the requirements of the ISO/ TS16949 standard and sets the framework for all Company processes of the quality/environmental management systems.

MSA. including the prevention of pollution f. Error proofing for processes. monitoring. The PM has 10 business days of receipt to document the receipt of drawings and maintain the engineering standards according to the Drawing Page: 97 Page: 40 . equipment. training and skills needed to achieve the required quality and environmental objectives and targets. 4. fixtures. ISO 14001 y y y y y y The Program Manager is responsible for a timely review of customer drawings and specifications. Identification of required verification. The identification of any controls. and Control Plan manuals as required. measuring. The Quality Manager and/or designee is responsible for retaining master copies and assuring current revision level of the AIAG reference manuals: y Advanced Product Quality Planning & Control Plan Fundamental Statistical Process Control Measurement Systems Analysis Potential Failure Mode and Effects Analysis Product Part Approval Process Quality System Requirements TS 16949 Environmental Mgmt. Environmental aspects/impacts c.a. Customer requirements and references to technical specifications are to be included in the quality plan 3. processes. Records are identified and kept as evidence that the realization processes and resulting product meet company and customer requirements per the quality and environmental plans h. The Company uses the methods in the APQP. facilities.0 Responsibility The Department Managers are responsible for ensuring that the Quality System Procedures have the appropriate controls in place to ensure that current issues are available in all locations as required. PPAP. equipment (including inspection and test equipment). and tooling e. Product special characteristics. inspection and test activities g. documentation. including safety characteristics d. System. The quality/environmental objectives and requirements for the product b. SPC PFMEA.

manufacturing processes.2. test procedures..1 provides a consistent advanced product quality planning process acceptable to all of our customers. clearly define acceptance criteria and approved by the customer. Planning of product realization ² Supplemental We review proprietary designs. Purpose This procedure describes the responsibilities for receipt. etc. The Company assesses product and manufacturing process changes that affect product realization. 6. assembly methods. work instructions and inspection instructions related to deliverable goods and our processes. Tooling. including electronic data. When we receive the approval for any changes affecting customer requirements.3 1. and related product information. We maintain customer confidentiality for all products and projects under development.e. 5. and distribution of drawings and documents. 2. impact use with the customer. Control Plans. as detailed in SOP 7. Application This procedure applies to statutory & regulatory requirements the drawings specifications and documents that explain the engineering requirements. including documents of external origin.CONTROL OF DOCUMENTS SOP 4. Run @ Rate. We confirm defined activities to ensure compliance with customer requirements. Definitions y y Quality Manager is the Document Control Specialist Controlled Customer owned product related prints & specifications are located on the ´Xµ drive and are available to Engineering Quality &Manufacturing personnel AIAG ² Automotive Industry Action Group 4. we notify the customer and validate changes before implementation. Fixtures. PPAP. PFMEA. The APQP Team uses the APQP process: y y y y Develop a control plan Develop/review failure modes and effects analysis Setup actions to reduce potential failure modes with high risk Report required deliverables (i.) Page: 41 y Page: 96 . (Section 7) Our APQP/PPAP process. review. 3. The quality plan and relevant work instructions.

materials. or instruction according to the Quality Policy Manual. Page: 42 Revision History Page: 95 .Special Characteristics for inclusion in the control plan comply with customer specifications (including drawings. Procedure Manual. to determine the type of quality re-certification required (PPAP documentation. Where practical. we will default to a level 3 PPAP submission. y y y Acceptance criteria Acceptance criteria is approved by the customer. For attribute data sampling. through their department manager. where required. If a Quality System procedure needs to be changed. Upon receipt of the new or revised policy.) that affect product characteristics and process parameters. the request form gives an explanation and a copy returned to the originator. 6. PPAP-4. or services (e. Production Part Approval Process (PPAP) (Section 7). the recipient updates the manual. operator instructions. the revision history identifies the changes. may request document changes. The quality department distributes a copy of the new or revised policy. or forms generated before the revision process shall be considered ¶grandfathered·. procedure. If not approved. see SOP 7.g. All documents used during. etc. procedure. The Quality Department files original form. FMEAs. the acceptance level is zero defects (Section 8). heat treating or plating) Product re-released after the tooling has been inactive from volume production for twelve months or more. acceptable to use ¶as is· due to unavailability of revised forms or unacceptable costs which would be incurred by disposing of unused forms. and Operator Instructions Distribution List.0 Procedure Any member of staff. PPAP approval is obtained prior to the first production shipment of product (unless specifically waived by the customer). The APQP Team Leader implements the PPAP recognized by our customers. The APQP Team Leader ensures: y Submissions for part approval prior to the implementation of changes. The changes become part of the revision history. send a Quality Manual Change Request Form to the Quality Manager describing the proposed change. or instruction.) Production following any change in process or method of manufacture Change of source for subcontracted parts.1) in the absence of any specific instructions.

and customer feedback.0. inquiries. contract or order handling and related changes.2. including complaints. understand. such as required for new product introduction. and SOP 7. Reference 6. and consistently meet or exceed our customers· requirements and expectations. initial issue. and for the recall of obsolete documents. impact of form. and amendments of all documents and data relating to the requirements of the quality system. Department/Plant Supervisor are responsible for controlling issuance and maintenance of associated manuals and data within their area of responsibility as required.3 SOP4. For propriety designs. The responsible Department ensures availability of appropriate documents at all locations where the performance of operations affect the quality system.4 FO 4.The Program Manager and/or designee are responsible for controlling issuance and maintenance of drawings. and function (including performance and durability) are reviewed with the customer. additional verification and identification requirements are performed. (Section 8) Page: 94 Page: 43 . 5. fit. Change control The Quality Manager obtains necessary customer approval of quality plans. product. so all effects can be properly.3 Document Control Control of Quality/Environmental Records Quality Manual Change Request Department Specific Manuals Confidentiality We ensure the confidentiality of customer-contracted products and projects under development and related product information (Section 7).2. and that we establish effective communication systems with our customers with regards to product information. validation. and all related changes that may affect product realization. (Section 7) Customer-related processes Achieving our quality policy ´to meet or exceed customer requirementsµ requires that we determine. The Administrator will maintain a master list of quality-related documents.0 Associated Materials SOP 4. and/or manufacturing process.2. When required by the customer. The responsible Department ensures that designated personnel receive approval.1. acceptance criteria.

0 Purpose This procedure addresses the maintenance of quality documents pertaining to customer requirements. and any additional requirements determined by the Company. procedures. Page: 93 . Requirements include those specified by the customer (including delivery and post delivery requirements).0 Application To maintain designated secured locations for original policy. requirements related to the product are reviewed to ensure that product requirements are defined. and systematically issues documents in a controlled manner. handling. elimination. procedure. and instruction elements. and identified characteristics (Section 7). safety and environmental regulations and requirements. and operator instructions for original release and the release of changes. and control of special characteristics that are indentified during the planning phase. approves.2 1. contract or order requirements Page: 44 DOCUMENTATION REQUIREMENTS SOP 4. applicable statutory. Quality receives. and operator instructions. it is processed according to the Quoting Process to ensure that quality and environmental requirements adequately define and document considerations for recycling.0 Responsibility The Process Owners/Area Managers are responsible for controlling issuance and maintenance of quality/and environmental-related policies. safety. Review of requirements related to the product During Quoting and Contract Review. recycling. storage. government. When a request for quote is received. procedures. 2. and specifications. revises. reviews. drawings. and environmental regulations applied to the acquisition.0 Definitions Not applicable 4. environmental impact. requirements not stated by customer but are necessary for specified or intended use. prepares. or disposal of materials. All applicable government. 3. documentation. One level above the author will be an approver for reviewing and approving company wide policies. The Company conforms to customer requirements for designation.Determination of requirements related to the product The Company maintains documented procedures for quoting and contract review and the coordination of these activities.

and The Company can meet the defined requirements. and validation that are appropriate to each design and development stage and the responsibilities and authorities for design and development. During Quoting. Organization manufacturing feasibility The Program Manager confirms and documents the manufacturing feasibility of proposed automotive products. feasibility reviews and risk analysis are carried out and documented to determine the manufacturing feasibility of the product.2. review. and product design input and manufacturing process design input in accordance with customer-specific requirements governing the APQP/PPAP process detailed in SOP 7. This review is conducted before the purchase contract is accepted. Page: 92 Page: 45 . Procedures This booklet contains sample procedures. Records of feasibility reviews are maintained as in noted in the Quality and Environmental Records. unless customer waives review requirement. (Section 7).2) Customer communication During the design and development planning the following are determined and controlled: the design and development stages. Where product requirements are changed. including risk analysis. verification.differing from those previously expressed are resolved.1 in accordance with APQP. They are very generic in nature and would need to be added to or changed for a real company. we ensure relevant documents are amended and relevant personnel are made aware of the changed requirements (SOP 7.

Electronic Data Interchange (EDI) The Company believes that the most effective and efficient way to communicate throughout our supply chain is to utilize a common industry practice for EDI. The Program Manager maintains a list of products for which The Company has design responsibility. the authority to establish a new. in a customer specified language and format. including data. processes. and review of FMEAs and control plans. products. and conformance with objectives and targets. policies. i. on a regular basis. or systems. and transaction sets comply with the guidelines set forth by the AIAG and our key suppliers are mandated to have the capability to interface with us electronically. the key characteristics of the operations and activities that can have significant impact on the environment. including but not limited to computer-aided design (CAD) data and electronic data interchange (EDI). The Company and our customers require EDI methods to be employed by all partner suppliers throughout the supply chain. or Page: 46 Monitoring and Measurement The Company shall establish and maintain documented procedures to monitor and measure. This will include the recording of information to track performance.To prepare for product realization. Page: 91 . Customer communication ² Supplemental The Information Systems Manager establishes/maintains an ability to communicate necessary information. All of our EDI initiatives. development. Design and development Design and development processes for tooling is employed by The Company to transform customer requirements into specifications. activities are carried out using a multidisciplinary approach including identification and monitoring of special characteristics. relevant operations controls.e.

this responsibility includes testing and verification of design performance within customer specified applications. tooling specification. The Quality Manager has overall responsibility for managing manufacturing process design and development activities (for automotive products) in accordance with our APQP/PPAP process detailed in SOP 7.Environmental objectives and targets are consistent with The Company environmental policy.1 in accordance with customer specific requirements (see APQP and serves as the overall APQP Team Leader (as referenced throughout this section). fixed design reviews. See Procedure The Company Supplier Manual located on The Company website. specific emergency response instructions are prepared to allow rapid and effective response to environmental incidents. as a minimum. The Quality Manager assigns a qualified Quality Engineer to service as APQP Team Leader for design projects involving new/changed automotive products and related manufacturing processes. including its commitment to the prevention of pollution. scheduled verification and validation activities. The Company has also established procedures related to the identifiable significant environmental aspects of the goods and services used by the company. annually. Emergency response drills are conducted. and targets. Environmental Operational Control The Company has identified those operations and activities that are associated with the identified significant environmental aspects in line with its policy. Page: 47 . The Design (or APQP) Team Leader uses project management planning tools (available software etc. Procedures and instructions are reviewed and revised after drills and after the occurrence of accidents or emergencies. Procedures provide general guidelines to follow in the event of an environmental accident or incident and references appropriate emergency response instructions.3.) to establish a Design Plan that identifies design stages. Emergency Response When appropriate. The Company shall document procedures to cover situations where the absence of such procedures could adversely affect quality or have a significant environmental impact. where they exist. The Program Manager has overall responsibility for managing tooling design and development activities in accordance with SOP 7. and communicates relevant procedures and requirements to suppliers and contractors. (Section 7) Design planning The Program Manager serves as Design Team Leader for tooling design projects for new/changed non-automotive products. objectives. Page: 90 change an existing.

These inputs include functional and performance requirements. and has access to. and business requirements. as well as the views of interested parties. The Product Engineer or Program Manager is responsible for ensuring that all valid design inputs are identified. as described in the Objectives. The Environmental Laws and Regulations are maintained by the Corporate EMS Coordinator thru periodic contact with local. documented and reviewed. production and other appropriate qualified personnel to prepare for product realization. and Action Plans. and federal agencies and review of environmental publications. These inputs include functional performance requirements. products. A list of applicable Environmental Requirements has been developed and is maintained by the EMS Department. its technological options and its financial. and services. (See APQP Workbook Master) (Section 7). operational. quality. Page: 89 Development/finalization and monitoring of special characteristics Development and review of Potential Failure Mode Effects Analysis (FMEA) including actions to reduce potential risks per customer guidance. Objectives/Targets and Environmental Management Programs The Company identifies environmental objectives and targets. its significant environmental aspects. through: y The Company considers these significant environmental impacts and aspects when establishing environmental objectives as described in Environmental Objectives. associated work instructions. manufacturing. targets and action plans are established at each relevant function and level within the organization. Customer environmental requirements are identified during the Quoting Process and are documented in specific contracts. The Company considers it·s legal and other voluntary requirements. and requirements Development and review of control plans y y Design inputs The Product Engineer or Program Manager is responsible for ensuring that all applicable design inputs are identified. FMEA. legal and other voluntary equirements that are applicable to its activities.Multidisciplinary approach The Design (or APQP) Team Leader forms a Design (or APQP) Team composed of design. and production documents. applicable legal and regulatory requirements and other requirements essential for design and development. Legal and Other Requirements The Company has identified. when establishing its environmental objectives and targets. engineering. state. Page: 48 . Targets. applicable statutory and regulatory requirements and other requirements essential for design and development. and establishes action plans and programs for achieving these objectives. documented and reviewed for adequacy.

products and services that it can control and influence and has determined those that have. These significant environmental aspects and their associated impacts were identified during the Initial Environmental Aspects Review. Customer requirements d. timing and cost Process design inputs are identified. life reliability. or conflicting requirements are resolved prior to the release of the final design.review and action during management reviews. Ongoing determination of environmental aspects and impacts is conducted during Advanced Quality/ Environmental Planning As designs and processes are developed.e. customer feedback. Information from similar product experience including field data and internal input and Competitor Analysis c. identification. Incomplete. maintainability. Product design inputs are identified. (Section 5) Preventive action Data from internal audits. Customer requirements such as special characteristics. Process design includes the use of error-proofing Page: 88 Page: 49 . process capability and cost c. and reviewed including: a. employee suggestions. documented. a document for lessons learned is maintained which documents information derived from previous similar designs. Targets for productivity. Results of this analysis and related recommendations are presented to Top Management for review and action during management reviews. Environmental Management System Environmental Aspects The Company has identified the environmental aspects of its activities. traceability and packaging b. or could have. Investigating and eliminating the root cause of potential failures is a critical part of our continual improvement process. including: a. unclear. a significant environmental impact. Product design output data (i. DFMEA) b. This information is also reviewed as an input to new designs. durability. Targets for product quality. documented. and other appropriate data is collected and analyzed (Section 8) to identify the actions needed to eliminate the causes of potential problems and thereby prevent their occurrence. The preventive action system is considered effective if potential losses were avoided. and reviewed. where applicable.. (Section 5) 8.

Control Plans. y Non-conformities relating to customer returns from assembly plants. Design outputs The Design (or APQP) Team Leader ensures that design outputs comply with the design input requirements.5. When external non-conformances occur. Corrective action procedures are followed to prevent recurrence. Results of this analysis and related recommendations are presented to Top Management for y Page: 50 Page: 87 . include information needed for production and service provision.2. and other process documents as appropriate. These records are available to the customer upon request. when appropriate. and dealerships are analyzed in a timely manner and the results are. engineering facilities. including error proofing Documenting results of action taken and reviewing action taken SOP 8. Corrective actions and controls are applied to similar processes and products. and diagnostic guidelines y Determining and implementing action needed. Follow-ups are conducted (through the internal audit process (Section 8) to ensure that effective corrective action is taken appropriate to the impact of the problem encountered. Product error-proofing Product definition including drawings or mathematically based data Product design review results. and are approved before issuance: Product Design Outputs ² Supplemental Product design requirements outputs can be verified and validated against product design input using: y y y y Design FMEAs and reliability results Product special characteristics and specifications. policies.Advanced Product Quality Planning is used to indentify Customer product and process special characteristics and symbols to be included on FMEAS. The Company responds in the problem-solving format prescribed by the customer. procedures. include or reference acceptance criteria. indicate design characteristics critical to the safe and proper operation of the product. There is a defined problem-solving process used in all plants. and work instructions are changed as appropriate. The size and effects of the nonconformities are considered when corrective/preventative actions are taken. When a process change is implemented.

analysis. including external party communications. If a customer requires another format. y Page: 86 Page: 51 .2 which describes the 8D methodology we use internally. internal. and environmental non-conformities. the Design (or APQP) Team Leader conducts design reviews as planned and records results and any necessary actions. work instructions Manufacturing process FMEAs Specifications and drawings Tool designs y y y y y y y y Design review During the evolution of each design project. we do as they wish.5) which includes improvement actions and corrective and preventive actions as outlined in Section 8. The Company maintains a corrective action system that provides for the identification. Corrective action It is the policy of The Company to strive to prevent problems before they occur. nonconforming material from suppliers. which define requirements for the review and handling of customer complaints. The procedures also define requirements for determining: y The causes of non-conformities and potential nonconformities Evaluating the need for action to prevent occurrence or recurrence Manufacturing Process Design Output Manufacturing process design outputs expressed in terms that can be verified against manufacturing process design input requirements and validated (Section 7).5. The Design (or APQP) Team Leader uses input from those involved in the review to propose a remedy for each identified problem. The corrective/preventive action system utilizes documented procedures. and elimination of the cause of quality and environmental problems in order to prevent recurrence. including: y Methods of rapid detection and feedback of product/mfg process nonconformities Manufacturing process flow chart/layout Process approval acceptance criteria Maintainability and Measurability Results of error-proofing activities Control plans. customer or third Party Audit non-conformities. See SOP 8. internally recognized product or process nonconformities or potential non-conformities.improvement system (SOP 8. returned products.

Validation is performed in accordance with customer requirements. or where product characteristics are predictable and meet customer requirements. product monitoring and measurement activities (Section 8). (Section 5). analyzing and recording measurements at specified stages of design and reports summary results as an input to management review (Section 5). As warranted. Inputs to the management review process are used to establish new or changed improvement objectives and to initiate/prioritize additional improvement actions. potential problems identified do not occur. including program timing. Essentially. We identify such opportunities through analysis of manufacturing process monitoring. The Quality Manager has overall responsibility for establishing and implementing an effective continual Page: 52 Page: 85 . and process. Wherever practicable. Measurements may include quality risks. Final validation testing is conducted to validate the final product.Monitoring The Design (or APQP) Team Leader monitors the design project by defining. The overall objective of manufacturing process improvement is to reduce part-to-part variation and eliminate all waste. Production Part Approval Process (PPAP) for customers requiring this program or other sample submission programs as required. Design Validation includes a review of field reports for similar products. such actions are effective if the problems corrected do not reoccur. costs. and other improvement actions accomplish the desired results or objectives. Records of verification results and any necessary actions are recorded on the DVP & R and Program Open Issues. improved controls and/or to methods to reduce variation in product characteristics and manufacturing process parameters are instituted using the same methodology as prescribed for manufacturing process design and validation (Section 7). Design verification Design verification is conducted to ensure that the design and development outputs have met the specified input requirements. and process-oriented audits (Section 8) of key manufacturing processes at least once annually. validation is completed prior to the delivery or implementation of the product. lead-times. Validation records and any necessary actions are documented and maintained per Quality Record. if applicable. (Section 5) Manufacturing process improvement The Program Manager plans and implements continual improvement of manufacturing processes that are capable and stable. and critical paths. design. The Program Manager summarizes and reports results of manufacturing process improvement activities to Management for review.

Suppliers are required to follow The Company product and manufacturing process approval procedures and requirements. audit results. All management actions are prioritized and implemented on the basis of data analysis (Section 8) and perform cost/ benefit analyses to identify and prioritize improvement actions. Our Management Review Process assesses the overall effectiveness of continual improvement program. and appearance specifications as required by the customer. these are documented as changes and kept in the ECN documentation. (Section 5). Design validation is performed to ensure the product or service resulting from design efforts performs as intended for all specified or known uses/applications. Records of required tests are kept in the APQP documentation by the Program Manager. Design validation The Design (or APQP) Team Leader ensures design validation is carried out as planned (per the Design Plan) and records results and any necessary actions. Form 8. including program timing. (Section 5) Product approval is submitted after process verification. Page: 84 Page: 53 . corrective and preventive actions and management review. It is the responsibility of the Program Manager in cooperation with the Quality Manager to ensure The Company submissions meet functional. Design validation is performed on products that have been produced from production equipment and tooling wherever and to the extent possible. the Design (or APQP) Team Leader plans and carries out or oversees design validation to ensure it is performed in accordance with customer requirements.Computerized information systems are implemented for timely reporting of data related to product usage. analysis of data. quality and environmental objectives. material. customer feedback. Management Action Requests (MARs). (Section 5) Continual improvement Continual Improvement is implemented with the goal of continually improving the quality/environmental management system using the quality policy. is used to document improvement. Analysis and Use of Data: Trends in quality and operational performance are compared with progress toward objectives and related recommendations for improvement are developed and are presented to Top Management for review and action during management reviews. corrective and preventive actions.5-1. If there needs to be corrective actions. As applicable.

Product Approval Process Detailed in SOP 7.1, per PPAP, through the APQP Team Leader, to ensure all customer engineering design record and specification requirements are properly understood and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. Note: In the absence of any specific instructions, we will default to a level 3 PPAP submission (Section 7). Control of design changes Design changes throughout the life of the program are reviewed, verified, validated, and approved, as appropriate, by Engineering, Sales, and Manufacturing before their implementation. The review of a change includes an evaluation of the effect of the changes on component parts and product already delivered. The customer will authorize design changes before implementation. Records of the review and any necessary actions are maintained. An internal work order is distributed for changes as is detailed in the Design Release and Change Procedure. The Company will validate all production-engineering changes to PPAP requirements.

Non-conformance reports requested by the customer (usually if/when a customer receives material or service that fails to conform to applicable quality and delivery specifications) are processed per customer requirements and the procedures defined in SOP 8.3. If placed on ´containment statusµ (due to continued poor performance and/or failure to achieve goals and objectives), The Company will take all actions required by the customer, and guidelines contained in SOP 8.3. Analysis of data Data from quality and environmental system processes is collected and analyzed to evaluate the effectiveness of the quality/environmental management system, and to find opportunities for continual improvement of the effectiveness of the quality/environmental management system. Analysis of this data provides information relating to customer satisfaction, product conformity; characteristics and trends of processes and products, and suppliers. During Business Planning and Management Review processes, trends in data and information is reported and compared with progress towards the overall business objectives. This information is used to develop priorities for prompt solutions to customer-related problems, support status review, decision-making, and longer term planning, and is compared with competitors and/or appropriate benchmarks. When negative trends are noticed during data analysis, corrective/preventative action may be initiated.

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Control of nonconforming product ² Supplemental Product with unidentified (Section 7) or suspect status is classified and processed as nonconforming. Any material or product that is suspect or does not conform to the appropriate specifications will be reworked or segregated, and disposed of as is detailed in the Nonconforming Product Procedure. Because rework/repair is only performed for minor defect problems, the operations are a repetition of one or more original production processes. Therefore, original process instructions are used and reworked material is verified by the verification activities specified on the control plan. Customer Information It is the responsibility of the Quality Control Manager to ensure that the customer is promptly informed in the event that nonconforming product has been shipped. Customer Waiver According to the production Part Approval Process (PPAP) manual, prior written customer approval is obtained whenever the product or process is different from that which is currently approved. Engineering Approved Product Authorization (EAPA) records would be maintained, including expiration date or quantity authorized, and authorization is labeled on the carton of such parts. The original or superseding specs and requirements are complied with when the authorization expires.
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Purchasing We work in partnership with our suppliers to ensure that purchased products and services meet all applicable requirements. The processes applicable to the planning, acquisition and verification of all products and services that affect customer requirements (such as sub-assembly, sequencing, sorting, and rework and calibration services) are defined in accordance with the policies outlined in this section. Purchasing process The type and extent of control applied to our suppliers and purchased product is dependent upon the effect on subsequent realization processes and their output, as well as consideration of other characteristics including the type of product; the potential impact of the product on our processes, products, or services; the results of supplier evaluations; and past performance. Purchased products are verified (Section 7 and 8) to ensure conformity to specified purchase requirements. Regulatory conformity Purchased products or materials are also verified to ensure conformity to applicable regulatory requirements. Purchasing, Quality Control, and Engineering work together to ensure purchased products and /or services conform to all specified requirements, including those

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from the customer. Purchasing procedures are documented. Supplier Quality Management System Development Essentially, the same requirements imposed on The Company are cascaded down to our supply base. In order to ensure the quality of the parts shipped by The Company, we have established systems to manage the parts and materials received from our supply base and initiate supplier development based on importance of the supplied product and supplier quality performance in accordance with supplier expectations and monitoring procedures defined in SOP 7.4.1. Customer-approved sources Where specified (by contract, customer engineering drawing, or specification) we purchase products, materials, or services from customer-approved sources. A master list of approved suppliers is maintained to ensure we only purchase product from The Company qualified sources or customer-approved sources. The results of evaluations and follow/up actions are recorded. The Materials Manager monitors Supplier performance per SOP 7.4.1 through one or more of the following indicators: delivered product quality; customer disruptions including field returns; delivery schedule performance (including incidents of premium freight); and special status customer notifications related to quality or delivery issues.
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Disposition The results of the evaluation and resultant disposition determinations are documented. Dispositions resulting from the evaluation of nonconforming product may include rework to meet specified requirements; re-grade for an alternative application; use as is (under customer concession or other required approval authority); obtain (from relevant authority) a waiver of or deviation from requirements; return to supplier; scrap or other disposal. Suspect or rejected material is either clearly identified with yellow Quality Hold tape or is stored in clearly marked designated areas, depending on the nonconformity. The Quality Control Manager is responsible to ensure disposition of all suspect or nonconforming material is made within an appropriate timeframe. Product Recall In the event nonconforming product is detected after delivery or use has started, the Quality Manager notifies the customer and initiates action appropriate to the effects, or potential effects, of the nonconformity. Where appropriate, product recall is initiated based on trace and recall data and records (Section 7) Nonconformance Reporting Records of the nature of nonconformities and any subsequent actions taken, including concessions obtained, is maintained in accordance with SOP applicable inspection and test procedures, and Section 4.
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the Quality Manager documents and communicates the intended verification arrangements and method of Page: 57 Page: 80 . (Section 8) Segregation Nonconforming product is segregated pending evaluation and disposition. Where needed.Identification Identification of nonconforming product originates from inspection. and quality management system requirements. The Quality Manager plans and implements appropriate sampling plans and other statistical techniques to verify purchased product per Section 8. requirements for approval/qualification of product. As applicable. product audits or customer complaints. Evaluation The Quality Manager through authorized Quality Control personnel. description of nonconformance. Verification of purchased product The Quality Manager ensures that purchased product is verified prior to use or release in accordance with provision of this section. and location where the nonconforming product is being held pending further review or disposition. Purchasing information The Materials Planning and Logistics ensure the adequacy of specified purchase requirements prior to communication to the supplier per procedures defined in SOP 7. equipment.4.2 and the following policies. perform the initial evaluation of nonconforming product in accordance with approved test and inspection procedures. Production and other technical personnel may become involved in the evaluation and recommendation for disposition. Incoming Product Quality Quality Control is responsible for conducting verification inspections to ensure incoming materials meet customer specifications. processes/systems. Engineering. Inspection procedures are documented in the Receiving Inspection Process and on Incoming Inspection Form. Documentation The Quality Manager or authorized Quality Control personnel enter the nonconformance into the corrective action system identifying the nonconforming product and lot number if applicable. qualification of personnel. procedures. including. where appropriate. Purchasing information communicated to our suppliers contains the appropriate data needed to clearly and fully describe requirements for purchased materials and services. Employees clearly mark or otherwise identify nonconforming product or suspect material. internal testing.

that is. training. the applicable control plan and design records (i. grain. and processes must be measured. as well as parts. Page: 58 Page: 79 . (Section 7): y For pre-launch and production that takes into account the design FMEA and manufacturing process FMEA outputs Layout inspection and functional testing Layout Inspection and Functional Testing is the responsibility of the Test Technician and Submissions Coordinator and is conducted according to customer requirements. stored. Documented procedures are available for the control of non-conforming materials and product. and properly utilized The suitability of the fundamental process inputs must be assured. gloss. which is product with unidentified status. employees.2. and certification. and issued. and material level for the product supplied. and methods. including performance of color eyesight testing. subsystem. accurate.4) Results are retained and available for customer review. are provided for evaluation areas for appearance items.product release related to verification activities performed at our suppliers· premises. so that they are not used or delivered to the customer (SOP 8. Personnel responsible for making appearance evaluations are qualified and competent to do so. Equipment and facilities must be adequate. (Section 6) Control of nonconforming product The Company procures raw materials and manufacture products that are defect free. Production and service provision Control of production and service provision We use a process-focused approach to plan and control operations and support services related to production and service provision. Employees must be equipped to perform the process properly through appropriate education. Material must meet specified requirements and be properly identified. Control plan The Quality Manager develops control plans at the system. Appearance Items For parts designated by the customer as ´appearance itemsµ The Company provides. including lighting. Our initial focus is to assure the quality of process inputs . Masters for color. including processes producing bulk materials. (SOP 8. is considered non-conforming product until status can be confirmed. and controlled to assure effectiveness and/or to identify opportunities for improvement. appropriate resources. material. facilities and equipment. available. drawings).3). Suspect product.e. including suspect products. & texture and evaluation equipment are maintained in the QC laboratory. component. monitored.

2. and records have been maintained providing evidence of conformity with acceptance criteria and identifying the person(s) authorizing release. These records include final inspection authority. This is responsibility if Program Manager. measurement logistics. Additionally. Release Products are not released for further processing or delivery until we have objective evidence that all requirements have been met. product samples are stored for a minimum of 3 years. (Section 8) y y Ensures that productions across all shifts are staffed with personnel in charge of. Product Release and Delivery: Product is not normally released or delivered until all planned inspections and tests have been completed. The instructions are derived from sources such as the control plan and the product realization process and are accessible to the work areas where they are needed. The Quality Manager further ensures that control plans: List the controls used for manufacturing process control y Include methods for monitoring of control exercised over special characteristics defined by both The Company and the customer y Include customer-required information.4. manufacturing process. or delegated responsibility for product quality Tooling Management: The Company personnel maintain control over any work that is outsourced. Nonconforming (or suspect) product is identified and controlled to prevent its inadvertent use. if any y Initiate the specified reaction plan when the process becomes unstable or not statistically capable y Are reviewed and updated when any change occurs affecting product. and confirm that all critical parameters are in accordance with established requirements and specifications.Final Inspection and Test: All finished products and completed services are verified by final inspections/tests specified in the control plan and SOP 8. Page: 78 Page: 59 . supply sources or FMEA Work instructions y The Production Manager prepares appropriate work instructions for all employees having responsibility for processes that impact product quality and employee safety (Section 6). identify. Evidence of Conformity Test and inspection records are maintained for a minimum of three years.

4. measurement means. In-process Inspection Formal in-process inspections are performed by Quality Control personnel in accordance with the control plan and SOP 8. the Program Manager provides resources and oversees efforts related to tool and gauge design. layout inspection and functional test.4) includes receiving inspection. provides resources for their maintenance. evaluating. such as receiving inspection or (SOP 8.2.4 prior to commencing each new production run and/or when process changes are made. and improving maintenance objectives.2. and the required capability and inspection/test skills needed.4). and verification activities. and develops an effective total preventive maintenance system that at a minimum includes: y y Planned maintenance activities Packaging and preservation of equipment. Preventive and predictive maintenance Per Section 6. The Production Manager establishes and implements a system for production Page: 60 . Work instructions governing set ups and related verifications are developed and available. job set up verification.2.Verification of job set-ups Job set ups are verified prior to commencing each new production runs and when process changes are made. in-process inspection. Production personnel in accordance with the applicable control plan perform manufacturing process monitoring (Section 7 and 8). Methods used to verify incoming product from the supplier. (Section 7). and use statistical methods of verification where applicable. final inspection and test. tooling. (Section 7) The scope of our product monitoring and measurement system (SOP 8. (Section 7) Job Set Up Verification Job set ups are verified per SOP 8. Page: 77 y y Management of production tooling As part of manufacturing process design. Availability of replacement parts for key manufacturing equipment Documenting. fabrication. Receiving Inspection Incoming product is not used or processed until it has been inspected or otherwise verified as conforming to specified requirements in accordance with the control plan and/or documented procedures. evaluation by accredited laboratories. and gauging. the Plant Supervisor identifies key process equipment. and special consideration regarding monitoring and measurement of appearance items. (Section 8). or source inspections.2.

For attribute data sampling. Monitoring and measurement of product The Company has overall responsibility for planning and implementing inspection and test activities needed to verify product requirements are met at appropriate stages of the product realization process in accordance with the applicable control plan. Control plans and process flow diagrams are implemented to ensure adherence to the specified measurement techniques. product characteristics are determined leading to the types of measurement. acceptance criteria. such as production. and reaction plans when acceptance criteria is not met. sampling plans. preventive or other improvement action. The Quality Manager then initiates a corrective action plan indicating the timing and assigned responsibilities to assure the process becomes stable and capable. including: y y y y y Setup Storage and recovery Maintenance and repair facilities and personnel Tool changing programs for perishable tools Tool design modification documentation. Manufacturing and other appropriate personnel for the purpose of initiating appropriate corrective.control plans and/or job packs. the acceptance level shall be Zero Defects. When selecting product parameters to monitor compliance to internal and external requirements. and requires application of a customer recognized or approved problem-solving approach (Section 8). or disposal y Production scheduling The Production Manager schedules production to meet customer requirements and our goal to achieve 100% ontime delivery performance through a just in-time production control.(Section 8) Page: 61 . repair. suitable Page: 76 tooling management (or monitors these activities if any work is outsourced). including engineering change level Tool identification. defining the status. (Section 7) Process Monitoring Processes are monitored by process operators per applicable instructions. (Section 7 and 8) Production personnel follow documented reaction plans when processes become unstable or no longer capable. The corrective action plan is reviewed with and approved by the customer. Feedback on information from services The Managing Director collects and communicates servicing concerns to Engineering.

Acceptance criteria (as well as objectives for process capability. ensures process studies are performed on all new product realization processes to verify process capability and provide additional input for process control. we monitor and measure-manufacturing processes to ensure to ensure continuing process capability and suitable performance as specified by the customer part approval process (PPAP) requirements (Section 7). and carried out in accordance with procedures detailed in SOP 7. where applicable. raw material characteristics and the required product parameters. team meetings. and specifications (including methods of production. 8) to ensure they are effective and efficient (i. work instructions posted in areas where they are needed. Process capability study results. measure the quality and environmental management system process. achieve desired results) and to identify opportunities for improvement. scheduled. the Program Manager. plans. where applicable. and maintenance instructions) are documented. The Production Manager ensures that all appropriate information including final product specifications. At a minimum. managers with overall responsibility for carrying out a Quality/Environmental Systems process. reliability. Corrective action is taken. is provided to production personnel throughout the product and service provision process. Such information is provided through job schedules. analyzes process performance (Section 8) and takes appropriate improvement. Information Information inputs to the process include both product characteristics and appropriate work instructions containing specific work methods and other pertinent information. when planned results are not achieved. corrective or preventive action (Section 8). as appropriate. and through job specific information included in individual job packs. measurement and test. including process monitoring and verification instructions and criteria developed during product quality planning and manufacturing process development (Section 7).e. In addition.Service Agreements with customer If there is a service agreement with the customer. Monitoring and measurement of manufacturing processes As part of manufacturing process design. Process audits (Section 8) are carried out to monitor and. the Quality Manager will establish and implement a plan to verify the effectiveness The Production Manager ensures that production and service jobs are planned. maintainability and availability) and appropriate reaction plans are included in Page: 75 Page: 62 . through our APQP/PPAP process.

( SOP 7. including internal auditor training records. Qualified personnel who do not have direct responsibility for the activity being audited carry out audits. results of internal audits and related follow-ups. facilities and tooling used for production and service operations-(Section 6) Monitoring and Measurement Devices The Quality Manager ensures that monitoring and measurement devices capable of meeting requirements are available for use during production and service provision (Section 7) Monitoring Activities The Production Manager. ensures that production personnel monitor the quality of the work and that employees understand the procedures for reporting related problems and suspected nonconforming conditions. Audit checklists are prepared and used to aid in ensuring audit consistency and comprehensiveness. skills. Quality/Environmental Systems processes are documented measured. through Production Shift Supervisors. controlled and evaluated (Section Page: 74 Work Instructions The need for work instructions is dependent upon the knowledge. Management is responsible for the area audited implement and timely corrective action to eliminate detected non-conformances and their causes. Engineering.1) The Quality Manager is responsible for planning and Page: 63 .Auditor qualification Internal auditors are qualified to audit to ISO/TS 16949:2002 requirements (Section 6). and initiate other appropriate action in response to opportunities for improvement identified by process participants or managers. Equipment The Plant Supervisor ensures the suitability and availability of all equipment. periodically reviews internal audit results as well as progress towards achievement of corporate level objectives aimed at improving overall Quality/Environmental Systems effectiveness and provides related recommendations for review by Top Management. Follow-ups are conducted to verify timely and effective implementation of the proposed action. The ISO Management Representative maintains all internal audit records. and abilities of our employees and the complexity of the work process they are assigned to perform. (Section 5) Monitoring and measurement of processes We apply suitable methods for monitoring and measuring all Quality/Environmental Systems processes. Quality and other technical personnel identify critical production and service work will provide process sheets included in the job pack or other information included in work instructions posted in areas where they are needed.5.

or quality system element under review is effective if it is achieving the desired results or established objectives. (Section 8) The Quality/Environmental Systems process. Responsible managers may also request that the audit be used to gather ´value addedµ data serving as input to aid in monitoring. and for reporting results and maintaining records. as identified in the contract. arrangements are established: y Defining criteria for review and approval of the processes Approval of equipment and qualification of personnel Page: 64 Product audit Product audits are conducted at appropriate stages of production and delivery to verify conformance to all specified requirements contained in the control plan (Section 8). frequency and methods used for internal audits and define the responsibilities and requirements for planning and conducting audits. with a special emphasis on our ¶core· customer oriented processes and our unique product realization processes. (Section 8) SOP 8. (Section 7) The Managing Director periodically reviews operational data and progress towards achieving of corporate level performance objectives and provides recommendations for review by Top Management.2. function. and delivery. As applicable.5. shipping. measurement. this includes any processes where deficiencies may become apparent only after the product is in use or the service has been delivered.2 defines the criteria. y Page: 73 . Internal Audit Plans Each of our key Quality/Environmental Systems processes.implementing in-process inspections needed to ensure process control and product quality. (Section 5) Validation of processes for production and service provision The Company defines processes in which results cannot be verified by subsequent monitoring or measurement as ´Special Processesµ. and improvement of Quality/Environmental Systems processes and systems. Delivery. scope.2. and Post-Delivery Processes Release of product is dependent on its compliance with all specifications and its ability to meet customer requirements including packaging. The Program Manager has overall responsibility for ensuring ¶Special Processesµ are validated in accordance with procedures detailed in SOP 7. (Section 8) Release. and is reviewed at least once annually to determine effectiveness.

The Company identifies the product by suitable means throughout product realization. as well as progress towards achievement of corporate level customer satisfaction improvement objectives (Section 5) and provides related recommendations for review by Top Management. in identifying any opportunity for improvement. The propose of these audits is to verify that the quality/environmental system conforms to product realization arrangements and to the requirements of ISO/TS16949. The Managing Director periodically reviews customer satisfaction survey data and other customer feedback (including complaints).3. Identification and traceability The Program Manager has overall responsibility for establishing and maintaining product identification throughout all stages of design. and delivery in accord with procedures defined in SOP 7. installation. Quality/Environmental Management System Audit The Company conducts system audits. Identification and traceability ² Supplemental The identification and status of product is established and maintained during all product and service provision processes. production. Page: 65 Page: 72 .1.Manufacturing process performance is monitored to demonstrate compliance with customer requirements for product quality and efficiency of the process. and in promoting awareness of customer requirements and effectiveness of the Quality/ Environmental Systems. and revalidation Use of specific methods and procedures Validation of process for production and service provision ² Supplemental Process validation applies to all processes for production and service provision (Section 7) related to our products. Manufacturing process audit Audits of our key product realization processes are conducted annually to determine their effectiveness and performance and to identify opportunities for improvement (Section 8) y y Requirements for records.5. appropriate controls and records are established. The APQP Team Leader uses a production part approval process acceptable to our customer to validate that product realization processes are capable of achieving desired results in accordance with the APQP/ PPAP process detailed in SOP 7. ISO 14001. Where product traceability is a customer-specified requirement. (Section 5) Internal audit The Company·s internal audit results are critical inputs to aid in assessing the effectiveness of our QEMS. including inspection and testing activities.

verify. and intellectual property.2. returned goods. This drives our quality policy ´to meet or exceed customer requirementsµ. (Section 7) Customer-owned production tooling All customer-owned production tooling is permanently marked so the ownership of each item is visible and can be determined. See Management Review Process. (Section 6) Monitoring and measurement Customer Satisfaction Customer satisfaction is the reason we exist. Measurements of customer satisfaction include evaluation of Customer feedback such as complaints. tools (including returnable packaging). The Managing Director has overall responsibility for identifying and reviewing customer requirements (Section 7) and for monitoring and measuring customer satisfaction per procedures contained in SOP 8. damaged. QC Receiving personnel are responsible for verifying incoming material part numbers and date coding as detailed in the Receiving and Inspection Process. and maintains appropriate traceability records in accordance with customer requirements. The Quality Manager ensures that lost. Incoming product received without part numbers is tagged or labeled in Receiving.Incoming material is assigned a part number. or unsuitable customer property is recorded and immediately reported to the customer. by applying the same process controls as we do to purchased product. Overadjustments will be understood and utilized throughout the organization. warranty reviews. Where contractually required.1: Customer Satisfaction ² Supplemental Customer Satisfaction is a critical measurement of the performance of the quality management system. or perform work will attend a Basic Statistics course containing an overview on basic concepts such as variation. The Company identifies. (Section 7) Customer property Customer property includes customer-owned material. (Section 8) Knowledge of Basic Statistical Concepts Employees using statistical tools to manage. protects. verifies. establishes. Customer satisfaction data is analyzed and reported in management review meetings. the Quality Manager plans for. and maintains customer property provided for use or incorporation into the product. tooling (including test/inspection tooling and equipment). Incoming material is received with labels indicating the assigned part numbers. customer performance ratings and delivered part quality. control (stability) process capability. Page: 71 Page: 66 .

Identification of Statistical Tools The Quality Manager ensures that statistical tools used to monitor Quality/ Environmental Systems processes are identified during quality planning and included control plans. analysis. and preservation of product pending use or delivery. as applicable.6 for calibration laboratories) 7. packaging. and implement the monitoring. e.g. Obsolete product is treated the same as nonconforming product and is appropriately identified and segregated to avoid using it for production. Designated storage areas are designed to prevent damage. (See SOP 7. Analysis and Improvement General These sections describes how we define. Statistical techniques for on-going process control and improvement are established per SOP 8. handling. measurement. and improvement activities needed to assure product and Quality/Environmental Systems conformity and achieve continual Quality/Environmental Systems improvement.) is controlled as nonconforming product. and protection. or calibration services are either acceptable to the customer or accredited to ISO 17025.1 and the AIAG ´Statistical Process Controlµ (SPC) reference manual. and product monitoring and measurement. obsolete product (including expired age dated material. (Section 8) Advanced Shipping Notification (ASN) The Company utilizes an ASN to facilitate the electronic transfer of data utilized by our customers to: Page: 67 . process monitoring and measurement. storage. test. deterioration. (Section 7) Page: 70 Preservation of product The Plant Supervisor is responsible for preserving the conformity of the product during internal processing and delivery to the intended destination including identification.Laboratory Requirements ² Internal Laboratory The Company does not have an internal laboratory. Measurement. Inventory turns and levels are goals defined within the business plan. The Company uses an automated inventory management system to optimize inventory turns over time and assure stock rotation on a ¶first-infirst-out· (FIFO) basis. Further. A FIFO inventory system is used and regular tracking of inventory turns is reported at the management meeting. Storage and inventory In order to detect deterioration. the condition of stock is periodically assessed. External Laboratory The Quality Manager ensures external laboratories used for inspection. These activities include assessment of customer satisfaction. conduct of internal audits. plan. SPC.

uses/acceptance criteria and the action to be taken when results are unsatisfactory. frequency/method of checks. they are adjusted or re-adjusted as necessary and the validity of previous measuring results is documented. measuring. including the measurement standard against which the equipment is calibrated Revisions following engineering changes Statements of conformance to specification after calibration/verification Control of monitoring and measuring devices We determine the measurements to be made and the accuracy required to assure conformity of our product to specified requirements. All monitoring and measuring devices that can affect product quality are identified and calibrated at prescribed intervals against certified equipment having a known valid relationship to internationally or nationally known standards. and maintenance of monitoring and measuring devices including their identification. We identify and select monitoring and measuring devices and verify their capability of meeting such requirements prior to use. (Section 4 & 7) Measurement systems analysis The Quality Manager is responsible for selecting appropriate analytical methods and acceptance criteria which conform to the Measurement Systems Analysis manual. Verify and receive products into their system. A number or other identifier is used to provide traceability to the device calibration record. such as gage R & R studies. In addition.y y y Determine and confirm goods in transit. and test equipment needed to provide evidence of product conformity to determined requirements. location. Create an electronic invoice that will generate payment. control. the Program Manager documents the method for confirming the ability of software to satisfy the intended application (Section 7) We define the processes employed for the on-going calibration. including employee and customer owned equipment. corrective actions to remedy the situation and preclude its recurrence. When monitoring and measuring devices are found to be out of calibration (or when calibration status is not known). including appropriate Page: 68 y y Page: 69 . (Section 8) Appropriate calibration records are maintained to document results of calibration activities and suitable indicators are used to show current calibration status. include: y Equipment identification. Calibration/verification records Records of the calibration verification activity for all gauges. actions taken are documented.

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