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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 The Company·s quality and environmental policies. 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. 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.2.2 1. and to operate with increased effectiveness and efficiency with the overall aim of enhancing customer satisfaction consistently.QUALITY/ENVIRONMENTAL MANUAL SOP 4. 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 . We developed Quality/Environmental Systems in accordance with the following four additional types of documents containing recommended automotive industry practices. and explanations. Scope General The Company is a design-responsible supplier of (name your product here). examples. illustrations.

y Page: 132 Page: 5 . The Company·s· Quality and Environmental Policy are available upon request. safety. 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. 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. process capability and cost y Overall product performance including an analysis of actual and potential field failures and their impacton on quality. The Company currently supplies to the following manufacturers: y y XXXX.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. City. XXXX Where possible we integrated the quality system and the environmental management system to ensure that operations are cost effective and environmentally responsible. and the headquarters is located at XXX Some Street. State. zip. established in XXXX.

through reference in this manual. Quality management systems ² Requirements ISO 9004:2000.6 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. Reference Documents The following external documents contain provisions. 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 .Application Our Quality/Environmental Systems comply with all applicable requirements contained in ISO/TS 16949:2002. constitute provisions of our Quality/Environmental Systems: y y y ISO 9000:2005. and encompasses all operations at both of our facilities. covers the design and provision of all company products. 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. which.

Ford Motor Company CustomerSpecific Requirements for Use with ISO/TS 16949:2002 CSR-GM. has an improved flow and 2. The SPC Reference Manual. Potential Failure Mode and Effects Analysis (FMEA Third Edition) PPAP-4. Revision History  Customer Specific Requirements: y ISO/TS 16949:2002. Quality management systems ² particular requirements for the application of ISO 9001:2000 for automotive production and relevant service part organizations CSR-Ford. Advanced Product Quality Planning & Control Plan (APQP) FMEA-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. Statistical Process Control (SPC) Note: 1.ISO/TS 16949:2002 CSR-DC.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. Second Edition. General Motors Customer Specific Requirements . 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. Reinforces the need for a systemic approach to analysis of variation in data Page: 130 Page: 7 . Production Part Approval Process (PPAP Fourth Edition) SPC-3.

Management review meetings. Excess Carpet. When the container is full.3 ² Nonconforming product). and understood throughout the organization. Terms and Definitions Our Quality/Environmental Systems uses the same internationally recognized terms. and records the information 10. Quality System Assessment Checklist. and region and referenced throughout our Quality/Environmental Systems are contained in Appendix A. Checklist to ISO/TS 16949:2002 TS-GS. Section 3. communicated. the operator has the material handler to remove the container and bring an empty one as needed 12. include the Quality and Environmental policies and objectives for continuing suitability. Carpet Wrinkles) Clean Trim Edge ² No Fuzz Or Debris Hole Clean ² No Slugs Slots and additional cutouts are cut or punched clean. Terms and Definitions. vocabulary. The quality inspector also checks for container quantity and correct label Page: 129 . industry. Quality Management System General Requirements Top Management is responsible to define the organization·s quality and environmental policy and ensure that it is documented. and definitions unique to our organization. customers. Page: 8 14. Measurement Systems Analysis (MSA) TS-QSA2. IATF Guidance to ISO/TS 16949:2002 9. vocabulary. The quality inspector records the findings (If needed follow SOP 8. Addresses additional control chart methods and tools MSA-3.y y 3. 4. Acronyms. and definitions given in ISO 9000 as supplemented by terms defined in ISO/TS 16949:2002.3 ² Nonconforming product) 15. Overall Appearance Good 3. The material handler puts a shipping label on container and moves the container to the inspection holding area 13. The operator then places the finished parts into a shipping container to packaging specifications 11. The quality inspector performs 1st piece inspection at beginning of shift (If needed follow SOP 8. The quality inspector performs part inspection and looks for (see boundary sample): y y y y y y Correct Color No Forming Flaws (I.E.. terms.

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

Page: 127 Page: 10 . and continually improve its effectiveness. Quality/Environmental Management System processes.outsourced Quality/ Environmental Systems processes (Section 7). procedures governing their management are described in documents referenced in applicable SOPs. WORK INSTRUCTIONS WI-DL-6. and are managed in accordance with ISO and customer requirements. Outsourced processes are also depicted in our flowcharts. monitoring.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. through the Management Team. Management reviews the identified and documented indicators for measurement and analysis to assure effectiveness and efficiency. measuring. The Management ensures that adequate resources and information necessary to support the operation. and analysis of these processes is made available and actions necessary to achieve planned results and support continuous improvement. is responsible to implement and maintain a quality and environmental management system. have been identified and documented in this Quality/ Environmental Manual. Documentation requirements General The Management. including their sequence and interaction with other processes.

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

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

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. distribution. Provide shipping container 4. update as necessary. and to apply suitable identification to them if they are retained for any purpose.2. Material handler brings carpet to the press to be loaded onto carpet cutter 3. The Company uses a Product Data Management system to manage and control engineering records and data (see SOP 4.WORK INSTRUCTIONS a) Approve documents for adequacy prior to issue. WI-SB-5.2. c) Identify the current revision status of documents. and implementation of all customer-engineering standards/ specifications and changes based on customer-required schedule.3). e) Ensure that documents remain legible. Material handler brings material to conveyor and setup in proper position for conveyor load 2. and re-approve documents. 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. b) Review. readily identifiable. Two frames are required Page: 124 Page: 13 . Engineering specifications The Program Manager oversees our process for assuring the timely review. 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.

or they affect PPAP documents. are prepared to document: a) Results of processes performed. Pertinent Records from our sub-contractors are an element of this.2. They are very generic in nature and would need to be added to or changed for a real company. b) Product/process evaluation/acceptance criteria Work Instructions This booklet contains sample Work Instructions. SOP 4.The Company considers reviews timely if performed within two working weeks of receipt. When a change involves standards or specs that are reference on design records.4 details procedures necessary to control Quality/Environmental Systems records that.2.3. Records may be in the form of hard copy or electronic media. 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. including identification of the individual performing the activity. Page: 14 Page: 123 . (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. we submit an updated PPAP. as a minimum.

e. appropriate documents (procedures. work instructions. Records of the analysis will be made available upon request. material or equipment qualifications f) Pertinent technical records from sub-contractors Records Retention SOP 4. Lean activities or technology changes.4 contains related procedures and responsibilities to ensure: y y y y y Record controls established satisfy all regulatory and customer requirements. If the action is successful.2. If a corrective action is initiated because of the analysis will be tracked through the corrective action format. implementation. etc. and improvement of our Quality/ Environmental Systems in very tangible ways: Page: 122 Page: 15 . Preventive actions will be tracked on the Preventive Action Log. parts. Disposition of records also includes their disposal. Statistical methods (i. diagrams. Management Responsibility Management commitment The Managing Director. is responsible to communicate the importance of meeting customer as well as statutory and regulatory requirements. etc. d) Identification of material. the APQP process. lessons learned follow up. drawings. All forms used in the corrective and preventive action procedure are retained for active life of the product for reference to prevent reoccurrence.) are used when applicable.) are updated to permanently implement the changes required by the corrective or preventive action. TPM activities. Records controlled include customer-specified records. or instructions used to perform an activity. All corrective actions are to be reviewed during management review meeting. along with the management team. including revision or date of document.The corrective action is monitored for thirty days to assure that the action taken has been successful. or equipment used in the making of the product e) Personnel. Analysis of customer returned rejects will begin upon receipt of the defective material. Revision History c) Procedures. Preventive Actions may be initiated because of. Preventive actions will be reviewed during regular management review meetings. x-bar and r charts. We provide evidence of commitment to the development.

regulatory and legal requirements) through continual improvement of our processes. The time frame to verify the effectiveness of the corrective action is to be determined by the corrective action team. Corrective/Preventative action reports must be complete through interim corrective action within three days of issuance. SOP 8. Emphasis is placed on improving both effectiveness and efficiency of our key Quality/Environmental Systems processes. through their involvement in the internal audit process. and services. The team will utilize mistake-proofing methodology to the degree appropriate to the magnitude of the problems and commensurate with the risks encountered. and the customer (if applicable). Permanent corrective action is to be determined by the team within 7 days of issuance.3 FOPARLOG 6.0 Procedure Control of Nonconforming Product Procedure Preventative Action Log An immediate (possibly temporary) fix is developed and implemented with documentation. The root cause of the problem is established and documented after the initial write up. products. through periodic management review of the quality policy statement. within twenty-four hours of the receipt of the notice of concern. and disposition of stock are determined and recorded. The quantity checked. All suspect parts are inspected and inventoried.If future shipments are to be certified a method and duration must be established by Manufacturing. the quantity defective. and maintenance of our quality policy at all levels of the organization through widespread printed distribution of our quality policy statement. We ensure understanding. Quality. implementation. and through their proactive involvement in our continual improvement activities (Section 8).Our quality policy statement (Section 5) documents and communicates the importance of meeting or exceeding all applicable requirements (including customer. y All managers demonstrate their commitment to the development and improvement of the Quality/ Environmental Systems through the provision of necessary resources (Section 6). 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). and corporate level improvement objectives. Page: 16 Page: 121 .

3.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). problems from subcontractors and customer complaints.0 Definitions Not applicable 4.2/8. and it prescribes the method by which we accomplish this: by continually improving Page: 17 SOP 8. 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).0 Purpose This procedure provides a systematic means in which quality problems will be eliminated. explicit customer requirements and expectations in the form of a contractual agreement or customer order.5.0 Associated Materials FOCAR 8. unless otherwise directed by the customer. The format utilized will be an 8D. including internal rejections.2 FOMCRLOG Concern Report (MCR) Material Concern Report Tracking Log Page: 120 y .5.0 Application This procedure applies to all quality problems. These customer focused communications and interactions ultimately yield clear. 2. Customer focus Customer requirements are determined during Quoting and Contract review processes. the Managing Director has overall responsibility for ensuring that specified and unspecified requirements are determined. and converted into requirements (Section 7). Top Management ensures that we meet these requirements with the aim of enhancing Customer Satisfaction.3 1. understood. 5.0 Responsibility y The Quality Manager is responsible for ensuring that the corrective/preventative action is managed effectively.5. Our quality policy statement indicates our commitment and focuses on what is important to us as an organization: achieving customer satisfaction. The Top Management Team is responsible for analysis of customer rejected material.

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

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. including those needed to meet product requirements. The business plan includes short and longterm goals relating to quality and environmental policy objectives. The Production Supervision and Quality Manager determine the disposition of the non-conforming material and record it on the Quarantine Area Record.3 FO 8. (If material is part of an accumulation. The quality manual documents the necessary processes that define the planning process for quality/environmental management system and objectives.2 FO 8. The Company·s Management Team annually reviews business plan and revises. the container(s) is identified by a Quality representative or production supervisor with an initial Material Concern Report. Quality or a member of management will provide written instructions to the employee conducting these activities.5. completes the Quarantine Area Record. When material is found to be nonconforming. as appropriate.SOP 8. 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.0 Procedure Corrective/Preventive Action Procedure Quarantine Area Record Scrap Log Quality Policy Our Objective Will Be Accomplished Through Customer Satisfaction by Providing: 1. to encourage customer satisfaction and overall growth of the organization.3 6. and defines timeframes to achieve each goal. Make statement 2. There are four possible determinations of inspected product: y Acceptable Product ² green check mark Page: 118 Page: 19 . We also have methods to track update and revise fall under the Continuous Improvement Process. up to the disposition section. Production personnel complete sort or rework.

efficiency. customer feedback. including materials and services provided by vendors. reading material. sorting or even sending a company representative to their site to protect their interests. and effectiveness are. productivity. 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. This managing includes the procurement of a deviation or concession from the customer if changes to the product differ. 4. Actions will be taken such as stock returns and replacement.The Company benchmarks trends in quality. Material is reviewed and disposition is determined by management and quality.3 NCMR Material Concern Report y y y y y y y Page: 117 . (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. that differ from those currently approved according to the Production Part Approval Process Manual. (Section 6) Product Performance: Program Manager. (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. The Quality Department is responsible for maintaining and analyzing data from NC material activities.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.0 Associated Materials FO 8. as information is available. We accomplished Benchmarking formally and informally via trade shows. It is clearly (visually) identified and quarantined or segregated to prevent inadvertent use or installation. The Program Manager/Production is responsible for managing the customer authorization of products or processes and the procurement of a deviation or concession. 5. and charting of performance measures (Section 6).

(Section 7 and 8) b) Manage and control facilities.0 Definitions Nonconforming Product: Material (e.g. purchased components. APQP-2.g.) Suspect Product: All material having the same lot number as known nonconforming product. We base specific measurable objectives on achievable performance within a specified period. customer rejection / returns or material received from a supplier. resin. visual. quality systems and personnel to consistently and cost effectively produce products and furnish services that meet customer needs (Section 7). and associated customer specific requirements documents. melt flow. (Section 7) d) Provide objective evidence that all supplied products and services satisfy all AIAG Production Part Approval Process (PPAP) requirements.CONTROL OF NONCONFORMING PRODUCT SOP 8. 2.0 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. work-in-progress.) that does not meet established parameters (e.0 Application This procedure applies to.. etc.3 1.. etc. PPAP-4¸ (Section 7) as required including acceptable process capabilities for all Special/Control Characteristics that have been established. processes. 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. Note: In the absence of any specific Page: 21 . but is not limited to. in-house rejections. dimensions. including the AIAG ´Advanced Product Quality Planning and Control Planµ reference manual. 4. c) Develop and implement Advanced Product Quality Planning (APQP) practices and procedures in accordance with ISO/TS 16949:2002. unidentified or suspect material.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. 3.

when applicable Employee on the job performance Revision History Page: 22 Page: 115 . 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. h) Meet customer requirements by controlling and using returnable packaging. 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. and improving systems. all applicable environmental laws and regulations of the jurisdictions in which we do business (Section 6). (Section 7). or to exceed.instructions. of. we will default to a level 3 PPAP submission. This manual constitutes our overall plan for establishing. (Section 8) g) Conduct operations in conformance with. maintaining. (Section 8) f) Be committed to continuous process improvement by emphasising reduction of part-to-part variation and the elimination of all waste. and associated customer specific requirements documents. and through the provision of resources needed for its effective implementation. 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.

The Managing Director (MD). 6. authority. This review occurs concurrently with the employee·s performance evaluation or upon need. Responsibility for quality Overall Quality/Environmental Systems responsibility and authority is as follows: Page: 114 Page: 23 . in any new or modified job. Responsibility. with the help of department managers.0 Procedure Identify training needs. (Sections 5. 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).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. The Company employees and their manager/supervisor shall review the employees training status to determine training needs. and communication Responsibility and authority 6. 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. and 8) The Quality Manager develops appropriate quality planning documents for specific products. sets direction and ensures the success of our business through the clear definition and communication of Quality/Environmental Systems responsibilities and authorities.5. including contract or service personnel. projects. 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.

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. or delegated responsibility for product quality (Section 7). the provision of resources needed to implement and improve Quality/Environmental Systems and management reviews (Sections 5 and 6). The content of the courses are evaluated through a training feedback and evaluation form. Management with responsibility and authority for corrective action promptly notifies employees of non-conformities (Section 8). 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. and systems described in this manual. and an assessment test (if applicable) is given upon completion of the course. Management All managers are responsible for execution of the Business Plan and implementation of the policy. development and communication of our quality policy. 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. Page: 113 Page: 24 . employee·s manager/supervisor in the performance review process determines individual training needs. Quality/Environmental Systems Planning including the establishment and deployment of objectives (Section 5). Evaluating Training The training courses offered internally are continually assessed by the Human Resource Department. Top Management is responsible for Business Planning. Managers also conduct employee performance reviews (Section 6). 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. including the establishment and deployment of operational level objectives (Section 5). and the provision of resources needed to implement and improve these processes. All managers are responsible for planning and controlling Quality/ Environmental Systems processes within their area(s) of responsibility. processes. Management ensures the staffing of all production shifts with personnel in charge of.

Each salary employee has an individual training record. which is maintained by the Human Resource Department. All employees have training in awareness. Personnel responsible for product quality have the authority to stop production to correct quality problems (Section 8). but are not limited to. but are not limited to. 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. etc. These records include. 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. training matrices and copies of training certificates. job descriptions. The Page: 112 y . work instructions. Management representative The Company has appointed Quality and Environmental Management representatives for each system. and maintained in accordance with their respective standards (Section 5). and importance of their activities and how they contribute to the achievement of our overall quality objectives. 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. 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. Personnel whose work affects quality are informed about the consequences to the customer of nonconformity to quality requirements.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. training matrices and copies of training certificates. which is maintained by the Human Resource Department. 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. relevance. flow charts. Each hourly employee has an individual training record. implemented. These records include.

skills appropriate required for the position. Each job description identifies the competence level/ education.2. Customer representative The Program Manager will ensure and address customer requirements and will represent the needs of the customer internal functions. new employee orientation.0 Application The scope of this procedure incorporates the training of all employees performing quality related activities. bulletins. and specific training sessions to communicate internal information about the effectiveness of our quality and environmental management system. and the status and importance of quality activities. 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.0 Definitions Not applicable 4. as appropriate. objectives and significant environmental aspects. COMPETENCE AWARENESS & TRAINING SOP 6. the training provided. including but not limited to workplace meetings. 2.0 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). Page: 26 Page: 111 . We communicate information regarding Quality/ Environmental Systems processes and their effectiveness through documented training (Section 6). from contract review through production Internal communication The Company uses a variety of tools. the internal audit process (Section 8). 3.0 Responsibility Job Description Each position has a written job description maintained by the Human Resources Department.2 1. memos.y The Environmental Management Representative is responsible for documenting and responding to relevant communication from external parties. continual improvement. and its policies.

Quality Objectives Matrix: Record of established quality objectives. Documented on the title page of the Management Review Report (MRR 5. and effectiveness of our Quality/Environmental Systems in accordance with procedures detailed in SOP 5. programs. Communications regarding how employees contribute to the achievement of objectives.6). All managers and supervisors.0 Associated Records Management Review Report: Record of the management review meeting. Management review Top Management conducts formal review meetings at least quarterly to ensure the continuing suitability. which we convey and reinforce during employee performance. policies and changes.9. to include presented and discussed topics and issues. and applicable statutory/regulatory requirements. Documented using form FO-MRR-5. and related statutory/regulatory requirements. conclusions.1. involvement opportunities. typically this information is conveyed through production team meetings and cross-functional improvement projects (Section 8). 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. The Human Resources Department posts information on employee bulletin boards throughout the facility to convey information regarding employee benefits. The Managing Director Page: 110 Page: 27 . are responsible for establishing internal communications as needed to convey to their employees the relevance and importance of their activities.6. y The Company uses internal audits (Section 8) to reinforce or communicate appropriate information to employees. reviews (Section 6). adequacy.6. and any actions initiated to implement the conclusions and policies. Management Review Report.

4. The Company holds review meetings at least monthly to review plant specific data and process effectiveness indicators.4 Operational Procedure. evidence of achievement of quality/environmental objectives and customer satisfaction.e.0 Records Management review records must be as comprehensive as possible. These include assignment of responsibility. if any. time frame. (Section 8) The Company record review results provide at a minimum. safety. (Section 5) The Quality Manager ensures that review includes analysis of actual and potential field failure and their impact on quality. Section 6) as an essential part of our continual improvement process (Section 8).0 Referenced Documents 5.2 Operational Procedure. We retain meeting records. Management review output is documented in the Management Review Report based on form MRR 5. regular evaluation of the cost of poor quality (Section 8) . Control of Records. The report is prepared by the Quality Manager and is distributed to the attending and. technical knowledge.5. Corrective and Preventive Action Page: 109 .2. Page: 28 Resource needs for implementing improvement actions are identified. The location and retention period for management review records are specified in Operational Procedure SOP 4.6. They will be the sole evidence that the agenda of the review was completely covered. 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. Quality system performance Each management review includes all requirements of the Quality/Environmental Systems including monitoring of quality objectives (Section 5). Control of Records SOP 8.2. and environment.1. plant. equipment. and allocation of human.6. identifying opportunities for improvement and corrective and preventative actions.1 Management Review Report Form SOP 4. and that the review was concluded with appropriate decisions and actions. and an assessment of the suitability and effective of support processes (i. facility and equipment. 8. absent participants. 7.or designee chairs the corporate reviews and top management from all relevant functions attends. and other necessary resources.

In addition. follow-up actions from earlier management reviews.1) in the Actions. This type of action is most suitable for minor improvements that can be quickly implemented. and strategic or operational changes that could affect the QEMS. related performance trends. CARs are normally used for improvements related to specific actual or potential product or process nonconformities. and Improvement of products and/or services to better meet customer requirements and increase customer satisfaction At a minimum. and which are not directly related to product or process conformity. 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. all applicable requirements of the QEMS. Review input ² Supplemental. The Program Manager provides an analysis of actual and potential field-failures and their impact on quality. At a minimum.2. we use these results to demonstrate achievement of the quality objectives in our Business Plan and customer satisfaction with supplied product. Quality objectives Documented on the title page of the Management Review Report (refer to Section 6 of this procedure). 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. Corrective or preventive actions Documented in the Corrective Action Request (CAR) form (FO-NCCAR-8. results of self-assessments (Section 8). Improvement of quality performance. safety or the environment as an input to the management review process.0 y y y Management review output Improvement of the quality management system.6. Page: 108 At a minimum. and Due Date columns. corporate level. Review input The management review meeting includes a review of our quality policy (Section 5). and opportunities for improvement. improvement of product related to Page: 29 .2. Assigned to.3) and processed in accordance with procedure SOP 8.5. This method is most suitable for implementing long-term improvement goals. Review output These improvement actions are defined implemented as: Management review actions Documented in the Management Review Report (FO-MRR-5.6. Corrective and Preventive Actions.

customer requirements. 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. 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).6. determines its resource needs and provides the resources to implement and maintain the quality management system and continually improve its effectiveness. Per SOP 5. and to enhance customer satisfaction by meeting customer requirements. we record the results of management review meetings and the ISO Management Representative maintains the records. Quoting process. Resource Management Provision of resources The Company. The principal quality policy is reviewed to ensure its continuing suitability. Resource requirements identified during the Business Plan Process. and records their status in the Status Next Management Review column. reduce its target value. Objectives that have been achieved may be discontinued or be retained with a higher target value. capital expenditure review. and provision of resource needs. We accomplish verification of work through budget comparisons. Page: 30 Page: 107 . the participants decide whether to drop the objective. and advanced Quality/ Environmental Planning. performance measurements. 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. through the Management team. or extend the target due date. or when changes within or outside the company render the policy inadequate or inappropriate. 5. The policy is changed when the goals expressed in the policy have been achieved. When an objective is not achieved. At the end of the meeting.

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. process. Following each presentation. and Service Provision Planning Measurement Systems Planning (including the conduct of MSA) Measurement. 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. market and customer response to the quality effort.Changes and quality system planning Quality highlights any product. the participants discuss the issues. and any other such issues related to the quality management system. and identify areas where improvement is required. Page: 31 Page: 106 . 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). capacity. and Improvement Planning (including the use of SPC) Organizational Continual Improvement Planning Manufacturing Process Continual Improvement Planning The MD. Analysis. 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. Facility. In addition to the topics listed above. Equipment and other Infrastructure Planning Contingency Planning Work Environment. integration of the quality system with other operations and activities. with input from other responsible managers. the management review may also consider such issues as cost of quality and non-quality. 5. compare their status and performance with preceding periods. Services and Vendors) Production. Recommendations for improvement Quality concludes the input phase of the review with recommendations for improvement. 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.

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. on-time delivery performance. It is a four-quadrant system. the experienced person or member of management continues to observe the new person. Page: 105 Page: 32 . supplier quality performance. This includes summaries of results for the cycle. experience and competence. Process performance and product conformity Quality presents quality performance data. Internal quality audits Quality presents results of internal quality system audits. In the second phase. we deem the new person ´competentµ to work on his or her own. 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. Corrective and preventive actions: Quality presents the most important corrective and preventive actions implemented through the period. Some persons may move on to the fourth stage and we deem them an ´expertµ allowing them to train others or assume other responsibilities. (SOP 6) abandoned. It is which visually displays the capabilities of the person according to which of the quadrants have been achieved. Customer feedback and complaints Customer Service presents summaries of customer feedback and customer complaints. Awareness.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. In the third phase. This Competency Matrix is available to persons assigning work.4.Analysis of Data. including analysis of trends. and Training The Company maintains a Training/Competence Matrix for personnel by job description. and the status of pending actions. skills. the frequency of audit findings against particular elements of the quality system and discussion of significant findings. Edit the scope of the quality performance data as appropriate. Competence. This includes rates of process and product nonconformities. and coordinate with ISO/TS 16949 Element 8.

At a minimum. Training Responsible managers identify training needs for their employees and achieve competence of all personnel performing activities affecting product quality. after reviewing the minutes. Those managers who are unable to attend shall receive minutes of the review meeting and. Actions which are not completed may be extended with a new due date. Personnel performing specific assigned tasks are qualified. with input from responsible managers. Where possible. Production. including on-the-job-training (OJT). 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. may submit their input and comments to the Quality Manager. No more than one manager may be absent from the meeting.Manager may call for unscheduled extraordinary reviews. The Operations Manager and Quality Manager must always attend. reassigned to another person/function. evaluates and qualifies applicants for specific job openings based on documented or demonstrated competencies. changed. The agenda is documented on the cover page of the Management Review Report. 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. we help existing employees qualify for new/changed jobs through the provision of appropriate education and training. The Human Resource Department. Our Training Coordinator is responsible to analyze effectiveness of training and competence. 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. Agenda The agenda for management review meetings covers at least all items listed in Section 4 of this procedure. Attendance Management reviews are chaired by the Quality Manager and are attended by Management. as Page: 33 . Engineering. Management review input At a minimum. and update of hourly employee Training/Competence Matrix records. and Purchasing.

MANAGEMENT REVIEW SOP 5.g. 2.). including agency or contract employees. to make continual improvements and to create an environment to promote innovation. Review Input. The annual review is conducted in March.0 Definitions None 4.0 Procedure Frequency and Scheduling Quality performance and the quality management system are reviewed at least once a year. the Operations Page: 103 Page: 34 .e. and to assign responsibilities for scheduling. and in particular those named in Section 4.0 Application This procedure applies to all activities comprising the quality system.. with particular attention to the satisfaction of customer requirements (application of digitized mathematically based data. e. In response to changing or special conditions and events. For the first two years (i. management reviews are conducted twice a year.0 Purpose The purpose of this procedure is to provide for a system and instructions. 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.required. through the maturation phase of the quality system). Responsible managers ensure that employees are aware of the relevance and importance of their activities and contributions to the achievement of our objectives. of this procedure. 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. We conduct Annual employee reviews to give one on one interaction of communication employee with The Company Management. 3. conducting. and recording management reviews of the quality management system. The additional review is conducted in September.6 1. Employee motivation and empowerment The management team is responsible to motivate employees to achieve quality objectives.

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. or supervisor who identified the training requirement. we ensure that our employees are aware of customer requirements (Section 5 and Section 5). Employee Awareness Through their activities and contributions. Effectiveness The Company evaluates the effectiveness of all actions taken to meet competency needs. 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). other than production part approvals. 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. The retention duration listed is a minimum retention. Provision.0 Procedure The responsible personnel and/or departments ensures the validity and completeness. tooling records. We evaluate provided training through immediate feedback from the employee and the manager. the relevance. purchase orders and amendments. officers. The responsible manager collects the documents for each training event. Obsolete documents. The records may be retained longer for reference at the discretion of the responsible party. and importance Page: 102 Page: 35 Revision History . and determines the filing and storage method (for retrievability and preventing damage) and the retention duration (conforming to TS-16949 requirements) for quality records. The Quality Department retains superseded part documents used for new part qualification. The status of archived records is determined and appropriate records are disposed of annually. Responsible managers. and supervisors reevaluate employee competencies and evaluate employee performance against established objectives through our employee performance review process.6. The Quality Department ensures quality records are available for evaluation by the customer for the stated period.

4 and SOP 5. such as transportation or communication. skills.2.2 SOP 8. This is accomplished through awareness training. Infrastructure The Company provides and maintains the infrastructure needed to achieve conformity to product requirements.4 DD FO 4.1. The Materials Manager and Accounting department are responsible for ensuring the proper retention of customer related purchase orders and amendments.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 . Associated Materials AIAG APQP AIAG FMEA AIAG MSA AIAG SPC AIAG PPAP SOP 5. employee performance reviews (Section 6).2 FO 4. training. In addition. and experience in accordance with provision of Section 4. processes. and employee participation in our internal audit (Section 8) and improvement (Section 8) processes. facility. process equipment (hardware and software as necessary). We use a multi-disciplinary approach to develop plant. and any supporting services that are needed.6. The Company prepared contingency plans to satisfy customer requirements in event of an emergency such as we detail methods to evaluate and monitor the effectiveness of existing operations in SOP 7. workspace and associated utilities.6 SOP 7. Employee qualification/competency review records and annual performance review results are maintained by the Human Resources Department.0 Accounting department and the Materials Manager are responsible for ensuring the proper retention of subcontractor purchase orders and amendments.achieving our quality policy (Section 5) and objectives (Section 5). and equipment. including buildings. The Training Manager maintains records of all training completed. Records We maintain appropriate records of education.

0 Definitions None 4. and equipment plans. and key equipment failure and quality issues. quality performance records. Page: 100 Facilities management.0 Purpose This procedure provides a method of maintaining quality records consisting of identification. maintenance and repair Housekeeping/custodial services management Process equipment management.2) The Plant Supervisor has overall responsibility for managing our Facilities and Equipment Maintenance programs in accordance with SOP 6. indexing. 3. maintenance and repair Production tooling management. labor shortages. these programs include: y y y SOP 4. and management review. storage. and equipment planning The MD uses a multidisciplinary approach for developing plant. and Transportation and material handling equipment management. protection. collection. maintenance.0 Responsibility Each Department Manager is responsible for records their department creates and for their maintenance. This is inclusive of all prints. The Plant Supervisor develops and implements an effective preventive maintenance program utilizing predictive maintenance methods (Section 7) as appropriate. 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. and disposal. The Quality Manager is responsible for ensuring the proper retention of production part approvals. and repair y y Plant. facility. and disposal. 2.4 1. The Information Systems Manager has Page: 37 .3. facility.3. (SOP 6. filing.0 Application This procedure applies to all departments responsible for the maintenance of quality records.2. handling and value-added use of floor space and facilitate synchronous material flow. internal quality system audits. The Program Manager and/or designee is responsible for ensuring the proper retention of appropriate tooling records.CONTROL OF RECORDS utility interruptions. availability.

statutory or regulatory requirements. 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. and maintaining effective employee benefit and workforce involvement programs. labor shortages. The Operations Manager has overall responsibility for identifying.4 Control of Quality Records Procedure SOP 7.3 Advanced Quality Planning Procedure Documentation ² Writing Procedures and Work Instructions Revision History Page: 99 . We monitor and improve workplace safety. 5. Work environment We provide employee benefits.3 WI 4. Contingency plans. and ergonomics by following proper manufacturing practices.overall responsibility for managing our automated data processing and communications systems. Management reviews the effectiveness of these efforts during management review meetings (Section 5). 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.2. and involvement of our employees in an empowered environment of continual improvement (Section 6). processes and controls needed to ensure product conformance and meet customer. The Human Resources Department has overall responsibility for identifying. interesting work. We engender total participation by involving employees in internal audit (Section 8) and improvement (Section 8) activities.2. implementing. The Quality Manager. in conjunction with the Information Systems Manager and other appropriate managers. and key equipment failure and field returns. and maintaining safety and environmental management systems. job and schedule flexibility.0 Associated Materials SOP 4. health. implementing.

a cross functional team plans the processes with consideration given to.2). and maintaining their individual department work instructions. The Program Manager is responsible for receiving. 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). the following: Page: 39 Page: 98 . approving. and repair consistent with the product and manufacturing process needs (Section 6) 6.Control Procedure and Engineering Change Process. Department Managers are responsible for creating. cleanliness. Instructions and Test Procedures are available. The Company has implemented a Quality and Environmental-planning process to define and document how the respective requirements will be met (See SOP 7. and through safety team meetings and training (Section 6). For new projects. 2. The Plant Supervisor is responsible for ensuring records of Total Preventive Maintenance activities are maintained. All Department Managers listed above are also responsible for making sure distributed and or obsolete copies are retrieved and replaced with the latest revision. 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.1 & SOP 7. first piece. but not limited to. 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. Product Realization Planning of product realization 1. The Plant Supervisor is responsible for ensuring current instructions are available at all work instructions. reviewing and retaining CAD/ Math data. and in-process and operator instructions) are in agreement. The Program Manager is responsible for ensuring all levels of documents and subordinate documents (such as control plan.

documentation. including the prevention of pollution f. SPC PFMEA. measuring. and tooling e. 4. and Control Plan manuals as required. facilities. MSA.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. inspection and test activities g.a. monitoring. PPAP. fixtures. 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. equipment. Environmental aspects/impacts c. Customer requirements and references to technical specifications are to be included in the quality plan 3. processes. training and skills needed to achieve the required quality and environmental objectives and targets. Identification of required verification. equipment (including inspection and test equipment). Error proofing for processes. The quality/environmental objectives and requirements for the product b. The identification of any controls. ISO 14001 y y y y y y The Program Manager is responsible for a timely review of customer drawings and specifications. Product special characteristics. System. 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 . including safety characteristics d. 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.

PPAP. manufacturing processes. Control Plans. 6. test procedures. Fixtures. review. we notify the customer and validate changes before implementation. Application This procedure applies to statutory & regulatory requirements the drawings specifications and documents that explain the engineering requirements. (Section 7) Our APQP/PPAP process. Purpose This procedure describes the responsibilities for receipt.e. assembly methods. The quality plan and relevant work instructions. 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. The Company assesses product and manufacturing process changes that affect product realization. Run @ Rate. 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. Tooling. 3. including electronic data.3 1.1 provides a consistent advanced product quality planning process acceptable to all of our customers. Planning of product realization ² Supplemental We review proprietary designs. etc. impact use with the customer. PFMEA. We confirm defined activities to ensure compliance with customer requirements. including documents of external origin. clearly define acceptance criteria and approved by the customer.. 5.) Page: 41 y Page: 96 . When we receive the approval for any changes affecting customer requirements. 2. and related product information. as detailed in SOP 7. We maintain customer confidentiality for all products and projects under development.CONTROL OF DOCUMENTS SOP 4.2. and distribution of drawings and documents. work instructions and inspection instructions related to deliverable goods and our processes.

g. The quality department distributes a copy of the new or revised policy. and Operator Instructions Distribution List. operator instructions. The Quality Department files original form. Upon receipt of the new or revised policy. may request document changes. Where practical. PPAP-4. etc. The APQP Team Leader implements the PPAP recognized by our customers. Page: 42 Revision History Page: 95 . we will default to a level 3 PPAP submission. 6.0 Procedure Any member of staff. or instruction according to the Quality Policy Manual. The changes become part of the revision history. or instruction.) Production following any change in process or method of manufacture Change of source for subcontracted parts. If not approved. FMEAs.Special Characteristics for inclusion in the control plan comply with customer specifications (including drawings. acceptable to use ¶as is· due to unavailability of revised forms or unacceptable costs which would be incurred by disposing of unused forms. The APQP Team Leader ensures: y Submissions for part approval prior to the implementation of changes. where required. Production Part Approval Process (PPAP) (Section 7). see SOP 7. or services (e. heat treating or plating) Product re-released after the tooling has been inactive from volume production for twelve months or more. the revision history identifies the changes. the recipient updates the manual. If a Quality System procedure needs to be changed.) that affect product characteristics and process parameters. send a Quality Manual Change Request Form to the Quality Manager describing the proposed change. For attribute data sampling. PPAP approval is obtained prior to the first production shipment of product (unless specifically waived by the customer). y y y Acceptance criteria Acceptance criteria is approved by the customer. to determine the type of quality re-certification required (PPAP documentation. procedure. Procedure Manual. through their department manager. the acceptance level is zero defects (Section 8). All documents used during. the request form gives an explanation and a copy returned to the originator. procedure.1) in the absence of any specific instructions. materials. or forms generated before the revision process shall be considered ¶grandfathered·.

(Section 7) Customer-related processes Achieving our quality policy ´to meet or exceed customer requirementsµ requires that we determine. inquiries.2. acceptance criteria.2. and SOP 7. product.3 SOP4. including complaints. understand. impact of form. For propriety designs.0.3 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). contract or order handling and related changes.4 FO 4. and customer feedback. The responsible Department ensures availability of appropriate documents at all locations where the performance of operations affect the quality system. and all related changes that may affect product realization. such as required for new product introduction.0 Associated Materials SOP 4. and for the recall of obsolete documents. and amendments of all documents and data relating to the requirements of the quality system. The responsible Department ensures that designated personnel receive approval. and that we establish effective communication systems with our customers with regards to product information. The Administrator will maintain a master list of quality-related documents. fit. Department/Plant Supervisor are responsible for controlling issuance and maintenance of associated manuals and data within their area of responsibility as required. Change control The Quality Manager obtains necessary customer approval of quality plans. and function (including performance and durability) are reviewed with the customer. 5. When required by the customer.1. additional verification and identification requirements are performed. and/or manufacturing process. validation. and consistently meet or exceed our customers· requirements and expectations. so all effects can be properly. initial issue. (Section 8) Page: 94 Page: 43 .2. Reference 6.The Program Manager and/or designee are responsible for controlling issuance and maintenance of drawings.

elimination. environmental impact. 3. 2. documentation. Quality receives. or disposal of materials. requirements related to the product are reviewed to ensure that product requirements are defined. Requirements include those specified by the customer (including delivery and post delivery requirements). and instruction elements.Determination of requirements related to the product The Company maintains documented procedures for quoting and contract review and the coordination of these activities. applicable statutory. procedures. The Company conforms to customer requirements for designation. prepares. storage. revises. and specifications. approves.2 1. handling. and identified characteristics (Section 7). Review of requirements related to the product During Quoting and Contract Review. When a request for quote is received. All applicable government.0 Application To maintain designated secured locations for original policy. and environmental regulations applied to the acquisition. it is processed according to the Quoting Process to ensure that quality and environmental requirements adequately define and document considerations for recycling. and systematically issues documents in a controlled manner. Page: 93 . safety. recycling.0 Responsibility The Process Owners/Area Managers are responsible for controlling issuance and maintenance of quality/and environmental-related policies.0 Definitions Not applicable 4.0 Purpose This procedure addresses the maintenance of quality documents pertaining to customer requirements. and operator instructions. government. and operator instructions for original release and the release of changes. safety and environmental regulations and requirements. and any additional requirements determined by the Company. One level above the author will be an approver for reviewing and approving company wide policies. procedure. requirements not stated by customer but are necessary for specified or intended use. drawings. reviews. and control of special characteristics that are indentified during the planning phase. contract or order requirements Page: 44 DOCUMENTATION REQUIREMENTS SOP 4. procedures.

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

policies. the authority to establish a new. 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. including data. including but not limited to computer-aided design (CAD) data and electronic data interchange (EDI). activities are carried out using a multidisciplinary approach including identification and monitoring of special characteristics. and review of FMEAs and control plans. the key characteristics of the operations and activities that can have significant impact on the environment. 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. Design and development Design and development processes for tooling is employed by The Company to transform customer requirements into specifications. 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. Page: 91 . i. The Program Manager maintains a list of products for which The Company has design responsibility. in a customer specified language and format. relevant operations controls. Customer communication ² Supplemental The Information Systems Manager establishes/maintains an ability to communicate necessary information.e. processes. products. All of our EDI initiatives. development. This will include the recording of information to track performance. or systems.To prepare for product realization. and conformance with objectives and targets. on a regular basis.

Environmental objectives and targets are consistent with The Company environmental policy.) to establish a Design Plan that identifies design stages. The Company has also established procedures related to the identifiable significant environmental aspects of the goods and services used by the company. this responsibility includes testing and verification of design performance within customer specified applications. objectives. fixed design reviews. 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. 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. where they exist. (Section 7) Design planning The Program Manager serves as Design Team Leader for tooling design projects for new/changed non-automotive products. See Procedure The Company Supplier Manual located on The Company website. The Company shall document procedures to cover situations where the absence of such procedures could adversely affect quality or have a significant environmental impact.3. and targets. The Design (or APQP) Team Leader uses project management planning tools (available software etc. 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 7.1 in accordance with customer specific requirements (see APQP and serves as the overall APQP Team Leader (as referenced throughout this section). The Program Manager has overall responsibility for managing tooling design and development activities in accordance with SOP 7. Page: 90 change an existing. Emergency response drills are conducted. and communicates relevant procedures and requirements to suppliers and contractors. as a minimum. scheduled verification and validation activities. Page: 47 . Emergency Response When appropriate. Procedures and instructions are reviewed and revised after drills and after the occurrence of accidents or emergencies. annually. Procedures provide general guidelines to follow in the event of an environmental accident or incident and references appropriate emergency response instructions. specific emergency response instructions are prepared to allow rapid and effective response to environmental incidents. tooling specification.

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

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

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

2 which describes the 8D methodology we use internally. 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). The Design (or APQP) Team Leader uses input from those involved in the review to propose a remedy for each identified problem. including external party communications. internally recognized product or process nonconformities or potential non-conformities. we do as they wish. See SOP 8. y Page: 86 Page: 51 . Corrective action It is the policy of The Company to strive to prevent problems before they occur. and elimination of the cause of quality and environmental problems in order to prevent recurrence. customer or third Party Audit non-conformities.5. returned products. the Design (or APQP) Team Leader conducts design reviews as planned and records results and any necessary actions.improvement system (SOP 8. and environmental non-conformities. internal. If a customer requires another format.5) which includes improvement actions and corrective and preventive actions as outlined in Section 8. 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. The corrective/preventive action system utilizes documented procedures. which define requirements for the review and handling of customer complaints. nonconforming material from suppliers. analysis. 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. The Company maintains a corrective action system that provides for the identification.

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

corrective and preventive actions. corrective and preventive actions and management review.Computerized information systems are implemented for timely reporting of data related to product usage. Our Management Review Process assesses the overall effectiveness of continual improvement program. 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. Design validation is performed on products that have been produced from production equipment and tooling wherever and to the extent possible. including program timing. (Section 5) Product approval is submitted after process verification. these are documented as changes and kept in the ECN documentation. customer feedback. Page: 84 Page: 53 . 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. Records of required tests are kept in the APQP documentation by the Program Manager. is used to document improvement. Suppliers are required to follow The Company product and manufacturing process approval procedures and requirements. material. As applicable. and appearance specifications as required by the customer. Form 8. Design validation is performed to ensure the product or service resulting from design efforts performs as intended for all specified or known uses/applications.5-1. the Design (or APQP) Team Leader plans and carries out or oversees design validation to ensure it is performed in accordance with customer requirements. 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. If there needs to be corrective actions. (Section 5). analysis of data. It is the responsibility of the Program Manager in cooperation with the Quality Manager to ensure The Company submissions meet functional. audit results. quality and environmental objectives. 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.

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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4. (Section 8) Segregation Nonconforming product is segregated pending evaluation and disposition. Incoming Product Quality Quality Control is responsible for conducting verification inspections to ensure incoming materials meet customer specifications. procedures. product audits or customer complaints. the Quality Manager documents and communicates the intended verification arrangements and method of Page: 57 Page: 80 . requirements for approval/qualification of product. perform the initial evaluation of nonconforming product in accordance with approved test and inspection procedures. processes/systems. Employees clearly mark or otherwise identify nonconforming product or suspect material. Engineering. 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. The Quality Manager plans and implements appropriate sampling plans and other statistical techniques to verify purchased product per Section 8. and location where the nonconforming product is being held pending further review or disposition.Identification Identification of nonconforming product originates from inspection. Inspection procedures are documented in the Receiving Inspection Process and on Incoming Inspection Form. Purchasing information communicated to our suppliers contains the appropriate data needed to clearly and fully describe requirements for purchased materials and services. and quality management system requirements. internal testing. As applicable. Where needed. including. description of nonconformance.2 and the following policies. equipment. where appropriate. Production and other technical personnel may become involved in the evaluation and recommendation for 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. Evaluation The Quality Manager through authorized Quality Control personnel. qualification of personnel. 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.

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

manufacturing process.4. Nonconforming (or suspect) product is identified and controlled to prevent its inadvertent use. Evidence of Conformity Test and inspection records are maintained for a minimum of three years. identify. 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). product samples are stored for a minimum of 3 years. Page: 78 Page: 59 . or delegated responsibility for product quality Tooling Management: The Company personnel maintain control over any work that is outsourced. Additionally. 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. Product Release and Delivery: Product is not normally released or delivered until all planned inspections and tests have been completed. and confirm that all critical parameters are in accordance with established requirements and specifications. This is responsibility if Program Manager. 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. and records have been maintained providing evidence of conformity with acceptance criteria and identifying the person(s) authorizing release. 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.2. measurement logistics. Release Products are not released for further processing or delivery until we have objective evidence that all requirements have been met.Final Inspection and Test: All finished products and completed services are verified by final inspections/tests specified in the control plan and SOP 8. (Section 8) y y Ensures that productions across all shifts are staffed with personnel in charge of. These records include final inspection authority.

the Plant Supervisor identifies key process equipment. and develops an effective total preventive maintenance system that at a minimum includes: y y Planned maintenance activities Packaging and preservation of equipment. and gauging. Methods used to verify incoming product from the supplier. The Production Manager establishes and implements a system for production Page: 60 . provides resources for their maintenance. 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.2. such as receiving inspection or (SOP 8. evaluation by accredited laboratories. Work instructions governing set ups and related verifications are developed and available. and verification activities. job set up verification. tooling. and the required capability and inspection/test skills needed. layout inspection and functional test.Verification of job set-ups Job set ups are verified prior to commencing each new production runs and when process changes are made. Production personnel in accordance with the applicable control plan perform manufacturing process monitoring (Section 7 and 8). in-process inspection. or source inspections. Page: 77 y y Management of production tooling As part of manufacturing process design. and improving maintenance objectives.4). (Section 7) The scope of our product monitoring and measurement system (SOP 8. and use statistical methods of verification where applicable. Availability of replacement parts for key manufacturing equipment Documenting. and special consideration regarding monitoring and measurement of appearance items.2. the Program Manager provides resources and oversees efforts related to tool and gauge design. (Section 8). In-process Inspection Formal in-process inspections are performed by Quality Control personnel in accordance with the control plan and SOP 8.2.4 prior to commencing each new production run and/or when process changes are made. Preventive and predictive maintenance Per Section 6. (Section 7). final inspection and test. measurement means.4) includes receiving inspection.4.2. fabrication. (Section 7) Job Set Up Verification Job set ups are verified per SOP 8. evaluating.

(Section 7 and 8) Production personnel follow documented reaction plans when processes become unstable or no longer capable.(Section 8) Page: 61 . (Section 7) Process Monitoring Processes are monitored by process operators per applicable instructions. acceptance criteria. sampling plans. and reaction plans when acceptance criteria is not met. For attribute data sampling. 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. suitable Page: 76 tooling management (or monitors these activities if any work is outsourced). 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. such as production. including engineering change level Tool identification. Manufacturing and other appropriate personnel for the purpose of initiating appropriate corrective. Control plans and process flow diagrams are implemented to ensure adherence to the specified measurement techniques. and requires application of a customer recognized or approved problem-solving approach (Section 8). product characteristics are determined leading to the types of measurement. The Quality Manager then initiates a corrective action plan indicating the timing and assigned responsibilities to assure the process becomes stable and capable. the acceptance level shall be Zero Defects. Feedback on information from services The Managing Director collects and communicates servicing concerns to Engineering. defining the status. preventive or other improvement action. When selecting product parameters to monitor compliance to internal and external requirements. repair. 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. The corrective action plan is reviewed with and approved by the customer.control plans and/or job packs.

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

and abilities of our employees and the complexity of the work process they are assigned to perform. including internal auditor training records.( SOP 7. Management is responsible for the area audited implement and timely corrective action to eliminate detected non-conformances and their causes. and initiate other appropriate action in response to opportunities for improvement identified by process participants or managers. Follow-ups are conducted to verify timely and effective implementation of the proposed action. skills. Quality/Environmental Systems processes are documented measured.5. ensures that production personnel monitor the quality of the work and that employees understand the procedures for reporting related problems and suspected nonconforming conditions. (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. controlled and evaluated (Section Page: 74 Work Instructions The need for work instructions is dependent upon the knowledge. Equipment The Plant Supervisor ensures the suitability and availability of all equipment. The ISO Management Representative maintains all internal audit records. results of internal audits and related follow-ups. Engineering. Qualified personnel who do not have direct responsibility for the activity being audited carry out audits. Audit checklists are prepared and used to aid in ensuring audit consistency and comprehensiveness. 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. through Production Shift Supervisors. 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.Auditor qualification Internal auditors are qualified to audit to ISO/TS 16949:2002 requirements (Section 6).1) The Quality Manager is responsible for planning and Page: 63 .

this includes any processes where deficiencies may become apparent only after the product is in use or the service has been delivered. 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).2. as identified in the contract. (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. (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 for reporting results and maintaining records. scope.2. (Section 8) SOP 8. frequency and methods used for internal audits and define the responsibilities and requirements for planning and conducting audits.2 defines the criteria. (Section 8) The Quality/Environmental Systems process. or quality system element under review is effective if it is achieving the desired results or established objectives. (Section 8) Release.5. As applicable. Delivery. and delivery. and improvement of Quality/Environmental Systems processes and systems. measurement. The Program Manager has overall responsibility for ensuring ¶Special Processesµ are validated in accordance with procedures detailed in SOP 7. Responsible managers may also request that the audit be used to gather ´value addedµ data serving as input to aid in monitoring. function. 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. and Post-Delivery Processes Release of product is dependent on its compliance with all specifications and its ability to meet customer requirements including packaging. and is reviewed at least once annually to determine effectiveness. shipping. with a special emphasis on our ¶core· customer oriented processes and our unique product realization processes.

Quality/Environmental Management System Audit The Company conducts system audits. Page: 65 Page: 72 . 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 Company identifies the product by suitable means throughout product realization. in identifying any opportunity for improvement. The Managing Director periodically reviews customer satisfaction survey data and other customer feedback (including complaints). 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. Identification and traceability ² Supplemental The identification and status of product is established and maintained during all product and service provision processes. (Section 5) Internal audit The Company·s internal audit results are critical inputs to aid in assessing the effectiveness of our QEMS.3. Identification and traceability The Program Manager has overall responsibility for establishing and maintaining product identification throughout all stages of design.5. as well as progress towards achievement of corporate level customer satisfaction improvement objectives (Section 5) and provides related recommendations for review by Top Management. Where product traceability is a customer-specified requirement. installation. 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. including inspection and testing activities.1. 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. ISO 14001. and delivery in accord with procedures defined in SOP 7. and in promoting awareness of customer requirements and effectiveness of the Quality/ Environmental Systems. production.Manufacturing process performance is monitored to demonstrate compliance with customer requirements for product quality and efficiency of the process. appropriate controls and records are established.

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

Measurement. as applicable. Analysis and Improvement General These sections describes how we define. SPC. and improvement activities needed to assure product and Quality/Environmental Systems conformity and achieve continual Quality/Environmental Systems improvement. (See SOP 7. 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.g.1 and the AIAG ´Statistical Process Controlµ (SPC) reference manual. and protection. 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.Laboratory Requirements ² Internal Laboratory The Company does not have an internal laboratory. Inventory turns and levels are goals defined within the business plan.) is controlled as nonconforming product. (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. These activities include assessment of customer satisfaction. Statistical techniques for on-going process control and improvement are established per SOP 8. packaging. the condition of stock is periodically assessed. Storage and inventory In order to detect deterioration. and preservation of product pending use or delivery. conduct of internal audits. or calibration services are either acceptable to the customer or accredited to ISO 17025. obsolete product (including expired age dated material. Further. analysis. A FIFO inventory system is used and regular tracking of inventory turns is reported at the management meeting. and implement the monitoring. External Laboratory The Quality Manager ensures external laboratories used for inspection.6 for calibration laboratories) 7. (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 . Designated storage areas are designed to prevent damage. Obsolete product is treated the same as nonconforming product and is appropriately identified and segregated to avoid using it for production. process monitoring and measurement. and product monitoring and measurement. storage. e. deterioration. measurement. handling. test. plan.

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. measuring. include: y Equipment identification. Verify and receive products into their system. In addition. frequency/method of checks. they are adjusted or re-adjusted as necessary and the validity of previous measuring results is documented. control. including employee and customer owned equipment. such as gage R & R studies. corrective actions to remedy the situation and preclude its recurrence. (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. location. (Section 8) Appropriate calibration records are maintained to document results of calibration activities and suitable indicators are used to show current calibration status. When monitoring and measuring devices are found to be out of calibration (or when calibration status is not known).y y y Determine and confirm goods in transit. Calibration/verification records Records of the calibration verification activity for all gauges. A number or other identifier is used to provide traceability to the device calibration record. Create an electronic invoice that will generate payment. actions taken are documented. including appropriate Page: 68 y y Page: 69 . uses/acceptance criteria and the action to be taken when results are unsatisfactory. 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. We identify and select monitoring and measuring devices and verify their capability of meeting such requirements prior to use. 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. and maintenance of monitoring and measuring devices including their identification. and test equipment needed to provide evidence of product conformity to determined requirements.

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