Status reports on actions from previous Management Reviews Identification of any strategic or operations changes that 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 efficiency including an evaluation of the cost of poor quality y Manufacturing process effectiveness and efficiency including performance against customer specified (or other targets for productivity, process capability and cost y Overall product performance including an analysis of actual and potential field failures and their impact on quality, safety, or the environment y Overall product quality including performance against customer specified (or other) targets related to product quality y Overall effectiveness of training completed including skills training, on-the-job training, and employee awareness and effectiveness of employee motivation y Recommendations for improvement and plans By Wes Westberg

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MANAGEMENT REVIEW FC-MR-5.6
Assess Overall System Effectiveness Monitor Objectives and Operations

CONTENTS
Quality/Environmental Manual ................................................... 5
SOP 4.2.2 ......................................................................................... 5 Scope ............................................................................................ 5 Procedures ......................................................................................... 78 Documentation Requirements ....................................................... 79 SOP 4.2 .......................................................................................... 79 Control of Documents .................................................................... 82 SOP 4.2.3 ....................................................................................... 82 Control of Records .......................................................................... 85 SOP 4.2.4 ....................................................................................... 85

Plan & Schedule Management Review Meeting

Significant Impact on System

Analyze Results & Trends

Management Review ........................................................................ 88 SOP 5.6 .......................................................................................... 88 Competence Awareness & Training .............................................. 94 SOP 6.2.2 ....................................................................................... 94 Control of Nonconforming Product............................................. 98 SOP 8.3 .......................................................................................... 98

Issue Management Review Agenda

Prepare Management Review Inputs

Issue Management Review Minutes

Review Inputs & Develop Outputs Action to improve Effectiveness of the System & its processes Actions to improve products Actions to provide needed resources New or revised improvements of objectives

Corrective and Preventive Action................................................ 101 SOP 8.5.2/8.5.3 .......................................................................... 101 Work Instructions .......................................................................... 105 WI-SB-5.2.2 ................................................................................. 105 Work Instructions .......................................................................... 107 WI-DL-6.2.2 ................................................................................ 107 Management Review FC-MR-5.6................................................. 110

Monitor Implementation of Actions Resulting from Management Review

Assess Process for Effectiveness

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13. The quality inspector performs part inspection and looks for (see boundary sample): Correct Color No Forming Flaws (I.E., Excess Carpet, Carpet Wrinkles) y Clean Trim Edge ² No Fuzz Or Debris y Hole Clean ² No Slugs y Cut or punched clean Slots and any additional cutouts. y Overall Appearance Good 14. The quality inspector records the findings (If needed follow SOP 8.3 ² Nonconforming product) 15. The quality inspector also checks for container quantity and correct label y y 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. 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. Revision History

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y Process:

Provides shipping containers as required during the shift

QUALITY /ENVIRONMENTAL

MANUAL
SOP 4.2.2 SCOPE GENERAL The Company is a design-responsible supplier of (name your product here). 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, and The Company·s quality and environmental policies. 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, and to operate with increased effectiveness and efficiency with the overall aim of enhancing customer satisfaction consistently. We developed Quality/Environmental Systems in accordance with the following four additional types of documents containing recommended automotive industry practices, examples, illustrations, and explanations, to smooth the progress of continual improvement by emphasizing defect prevention and the reduction of variation and waste: y International Automotive Task Force (IATF) Guidance to ISO 9001 and all related documents Quality System Assessment Checklist to ISO 9001 and all related documents

1. The operator uses pre-cut carpet and the operator attaches the tenor frame to the carpet 2. 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. The operator cycles the press by pressing the two black palm buttons simultaneously 5. When the press finishes its· cycle, the operator removes the parts and the left over material 6. The operator then places the waste material into the compactor 7. The operator inspects the part to verify 15 holes, one slot, and 3 additional cutouts are clean with no slugs or fabric strings or debris. If holes, slots, or cutouts are not punched clean, follow Rework Instruction. 8. The operator burnishes the part edges of extra fuzz (if necessary). 9. The quality inspector performs 1st piece inspection at beginning of shift (If needed follow SOP 8.3 ² Nonconforming product), and records the information 10. The operator then places the finished parts into a shipping container to packaging specifications 11. When the container is full, the operator has the material handler to remove the container and bring an empty one as needed 12. The material handler puts a shipping label on container and moves the container to the inspection holding area Page: 108

y

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State. The Company·s· Quality and Environmental Policy are available upon request. established in XXXX. and encompasses all operations at both of our facilities. zip. APPLICATION Our Quality/Environmental Systems comply with all applicable requirements contained in ISO/TS 16949:2002. XXXX General Notes Setup includes: y y y y Press (See Setup Sheet) Check Fixture Burnishing Table Final Pack Container Carpet ² Milliken -62 µ roll Where possible we integrated the quality system and the environmental management system to ensure that operations are cost effective and environmentally responsible. covers the design and provision of all company products. The Company currently supplies to the following manufacturers: y y XXXX.2. 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: Page: 6 Material Needed: y 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 General Safety Notes PPE: y y y y Safety Glasses Kevlar Gloves Kevlar Sleeves Knife Company Background The Company.y ISO/TS 16949 Automotive Certification Scheme-Rules 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 WORK INSTRUCTIONS WI-DL-6. and the headquarters is located at XXX Some Street. The material handler: y Brings carpet to the press and helps the operator to load the carpet onto carpet feeder Page: 107 . City.

which. General Motors Customer Specific Requirements . When the container is full. Quality management systems ² Requirements ISO 9004:2000. The operator then places the finished parts into a shipping container 11. When the press finishes its· cycle. Reference Documents The following external documents contain provisions. Production Part Approval Process (PPAP Fourth Edition) Page: 7 . the operator removes the parts and the left over material 8. The operator cycles the press by pressing the two black palm buttons simultaneously 7. Potential Failure Mode and Effects Analysis (FMEA Third Edition) PPAP-4. Part inspection 14.3. the operator calls the material handler to remove the container and bring an empty one 12.ISO/TS 16949:2002 CSR-DC. Advanced Product Quality Planning & Control Plan (APQP) FMEA-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 part on over bend fixture and the waste material into the compactor and presses the green palm buttons simultaneously 9. through reference in this manual. at beginning of shift. Quality management systems ² particular requirements for the application of ISO 9001:2000 for automotive production and relevant service part organizations CSR-Ford. The quality inspector performs 1st piece inspection. Quality management systems ² Guidelines for performance improvements  Customer Specific Requirements: y ISO/TS 16949:2002. constitute provisions of our Quality/Environmental Systems: y y y ISO 9000:2005. Pack and label Revision History 1. Ford Motor Company Customer-Specific Requirements for Use with ISO/TS 16949:2002 CSR-GM. DaimlerChrysler (Chrysler Group) Customer-Specific Requirements for Use with ISO/TS 16949:2002 y y y  Customer Reference Manuals: y y y Page: 106 APQP-2. Raise carpet to the cutter and cut the carpet just above the tenor frames 5. Attach both tenor frames to the carpet and cut the carpet between them 4. Place the both tenor frames central over the cavities (one tenor frame per two cavities) 6. and after the removal of the part from the over bend fixture 10. Quality management systems ² Fundamentals and vocabulary ISO 9001:2000.

Provide shipping container 4. Reinforces the need for a systemic approach to analysis of variation in data 3. The SPC Reference Manual. Terms and Definitions Our Quality/Environmental Systems uses the same internationally recognized terms. Material handler brings carpet to the press to be loaded onto carpet cutter 3. Page: 8 y y y y Stage Material for production: 1. Quality Management System GENERAL REQUIREMENTS The responsibility belongs to Top Management for defining the organization·s quality and environmental policy and to ensure the documented. Statistical Process Control (SPC) Note: 1. Checklist to ISO/TS 16949:2002 TS-GS. customers. Section 3. Acronyms. Terms and Definitions. Quality System Assessment Checklist. vocabulary. Material handler brings material to conveyor and setup in proper position for conveyor load 2.2 Important General Safety Notes PPE: y y Safety glasses Gloves Important General Notes Setup includes: y Press Carpet Cutter Over Bend fixture Check Fixture Final Pack Container 2. and understood throughout the organization. Two frames are required Process: 1. Second Edition. and region and referenced throughout our Quality/Environmental Systems are contained in Appendix A.2. IATF Guidance to ISO/TS 16949:2002 WORK INSTRUCTIONS WI-SB-5. terms. Management review meetings. Addresses additional control chart methods and tools MSA-3. The operator uses the controls to roll out the carpet long enough to place the tenor frames on the carpet Page: 105 .y y y SPC-3. and definitions unique to our organization. communicated. 3. The material is automatically loaded onto conveyor and into oven while the operator prepares the carpet for insertion into the press 2. industry. and definitions given in ISO 9000 as supplemented by terms defined in ISO/TS 16949:2002. has an improved flow and 2. Measurement Systems Analysis (MSA) TS-QSA2. vocabulary. include the Quality and Environmental policies and objectives for continuing suitability.

We have adopted the process approach advocated by ISO 9000. which meet or exceed customer requirements. and satisfies Quality/ Environmental Systems requirements of ISO900/14001. Appendix A contains a List of Key Quality/ Environmental Systems Documents. Page: 104 Page: 9 . controls. Our flowcharts depict outsourced processes and procedures describe the governing of their management in documents referenced in applicable SOPs. and related processes for providing products and services. and outputs to ensure desired results are achieved. many of which contain or reference deployment flow charts depicting the process or procedure described in the narrative SOP. and y Interfaces between interrelated processes to ensure system effectiveness. which establishes documents and implements our quality policy. Our Quality/Environmental Systems is part of our overall management system. They are very generic in nature. including all SOPs and other key Quality/Environmental Systems documents. by defining and managing: y Process inputs. 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 outsourced Quality/ Environmental Systems processes (Section 7). Specific responsibilities for and the sequence and interaction of our key Quality/Environmental Systems processes are detailed in the Standard Operating Procedures (SOPs).Work Instructions This booklet contains sample Work Instructions.

Analysis of customer returned rejects begins upon receipt of the defective material.DOCUMENTATION REQUIREMENTS GENERAL The Management. lessons learned follow up. Quality/Environmental Systems documents and data may be in hard copy or electronic media. If a corrective action is initiated because of the analysis will be tracked through the corrective action format. Revision History Page: 103 . The Company recognizes that control of any outsourced processes is necessary in order to ensure the product conforms to customer requirements. We will make records of the analysis available upon request. We track preventive actions on the Preventive Action Log. SOPs. is responsible to implement and maintain a quality and environmental management system. we identify and document in this Quality/ Environmental Manual. The Management ensures that adequate resources and information necessary to support the operation. TPM activities. monitoring. Quality/Environmental Management System processes. Management gives individuals total support and the necessary authority to perform the assigned tasks. We initiate Preventive Actions because of. Lean activities. or technology changes. and analysis of these processes is made available and actions necessary to achieve planned results and support continuous improvement. This quality manual. including the implementation and control of the Environmental Management System. Management reviews the identified and documented indicators for measurement and analysis to assure effectiveness and efficiency. We review preventive actions during regular management review meetings. and other internal and external documents and data Page: 10 We retain all forms used in the corrective and preventive action procedure for active life of the product for reference to prevent reoccurrence. and managed in accordance with ISO and customer requirements. including their sequence and interaction with other processes. through the Management Team. and continually improve its effectiveness. Each Department Manager is responsible for evaluating and adjusting resource requirements to efficiently execute assignments and accomplish goals defined in the business plan. measuring. the APQP process.

0 Procedure An immediate (possibly temporary) fix is developed and implemented with documentation. procedures. job descriptions. within twenty-four hours of the receipt of the notice of concern. perform. diagrams. Each Process Owner is responsible for identifying which records they consider quality and environmental records and for collection.e. and the retention and disposition of these records Page: 102 Page: 11 . If the action is successful. We monitor the corrective action for thirty days to assure that the action taken has been successful. We use Statistical methods (i. and the customer (if applicable) must establish a method and duration. and disposition of stock are determined and recorded. We review all corrective actions during management review meeting. The corrective action team determines the period to verify the effectiveness of the corrective action is to be by. retrieval. Pertinent records from our subcontractors are an element of this. etc. QUALITY MANUAL This manual is that part of our Quality/Environmental Systems defines the scope of our Quality/Environmental Systems and documents the policy. 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. needed to manage. The team will utilize mistake-proofing methodology to the degree appropriate to the magnitude of the problems and commensurate with the risks encountered. appropriate documents (procedures. Corrective/Preventative action reports must be complete through interim corrective action within three days of issuance.6. We also issue and control work instructions.If future shipments are to be certified. x-bar and r charts. The quantity checked. and processes needed to implement our quality policy and achieve our quality objectives. 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. the quantity defective. and other internal and external documents and data as appropriate and needed to manage our systems (Section 4). The root cause of the problem is established and documented after the initial write up. A team will determine permanent corrective action within 7 days of issuance. protection. Manufacturing.) when applicable.) are updated to permanently implement the changes required by the corrective or preventive action. We inspect and inventory all suspect parts. storage. Quality. work instructions. We use SOPs and flow charts to document and define the key Quality/Environmental Systems processes. or verify work affecting product quality. etc.

0 Purpose This procedure provides a systematic means in which quality problems will be eliminated.3). below includes forms used to create controlled quality records as detailed in procedure SOP 4. 2. e) Ensure that documents remain legible.2. The Top Management Team is responsible for analysis of customer-rejected material.2. When we reach retention time.3 FOPARLOG Concern Report (MCR) Material Concern Report Tracking Log Control of Nonconforming Product Procedure Preventative Action Log Page: 101 . problems from subcontractors and customer complaints. 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.3: a) Approve documents for adequacy prior to issue.2/8. d) Ensure that relevant versions of applicable documents are available at points of use. 3. c) Identify the current revision status of documents.5. and to apply suitable identification to them if they are retained for any purpose. readily available and retained for a specified period in Quality Record Matrix.5.Quality and Environmental records are legible.0 Associated Materials FOCAR 8. and re-approve documents.5. records should be disposed of accordingly. including internal rejections.0 Responsibility It is the responsibility of the Quality Manager to manage the corrective/preventative action. 5. unless otherwise directed by the customer.0 Definitions Not applicable 4. as well as ISO or TS requirements. readily identifiable. update as necessary.0 Application This procedure applies to all quality problems. The Company uses a Product Data Management system to manage and control engineering records and data (see SOP 4. The information Quality Manager has overall responsibility for ensuring that all Quality/Environmental Systems documents. b) Review. distribution. The format utilized will be an 8D.2 FOMCRLOG SOP 8. Page: 12 CORRECTIVE AND PREVENTIVE ACTION SOP 8. and implementation of all customer-engineering standards/ specifications and changes based on customer-required schedule. Record retention must satisfy both regulatory and customer requirements. ENGINEERING SPECIFICATIONS The Program Manager oversees our process for assuring the timely review.3 1.

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. No rework shall be visible on the exterior of the product. Unacceptable Product (placed in red ´SCRAPµ container / on rack) Questionable Product (QA disposition required) The Company considers reviews timely if performed within two working weeks of receipt.some rework necessary with written instructions & records. parts. The designated Quality Representative re-inspects the material. Scrap Nonconforming materials or reworked accordingly. Remove Conforming materials from the container and returned to production flow. Revision History Page: 100 . employee responsible for reprocessing. d) Identification of material. Production personnel complete sort or rework. or they affect PPAP documents. etc. Pertinent Records from our sub-contractors are an element of this. SOP 4. or instructions used to perform an activity.The Production Supervision and Quality Manager determine the disposition of the non-conforming material and record it on the Quarantine Area Record. all material shipped under a customer concession or deviation will be. number of acceptable/ unacceptable parts. Records may be in the form of hard copy or electronic media. Quality or a member of management will provide written instructions to the employee conducting these activities. Identify. Record Scrapped material in the Scrap Log and the Material Concern Report. as a minimum. There are four possible determinations of inspected product: y y y y Acceptable Product ² green check mark Acceptable Product . A Quality representative records the results of the inspection and rework on the Material Concern Report listing the method of rework. or equipment used in the making of the product e) Personnel. including identification of the individual performing the activity. including revision or date of document. b) Product/process evaluation/acceptance criteria c) Procedures.4 details procedures necessary to control Quality/Environmental Systems records that. date. material or equipment qualifications f) Pertinent technical records from sub-contractors Page: 13 Quality disposes of questionable product and records the final counts and outcomes. drawings. as required by the customer. (Section 7) MASTER LISTS We define requirements for the establishment and maintenance of Master Lists of internal and external Quality and Environmental Systems documents in SOP 4. Maintain Records of the quantity and expiration date. we submit an updated PPAP.2. are prepared to document: a) Results of processes performed.2.3. When a change involves standards or specs that are reference on design records.

4 contains related procedures and responsibilities to ensure: y y y y y Record controls established satisfy all regulatory and customer requirements. We ensure understanding. The Program Manager/Production is responsible for managing the customer authorization of products or processes and the procurement of a deviation or concession. the Quality representative or production supervisor identifies the container(s) with an initial Material Concern Report.0 Associated Materials FO 8. 5.3 NCMR Material Concern Report SOP 8. along with the management team. completes the Quarantine Area Record. that differ from those currently approved according to the Production Part Approval Process Manual.5. Page: 99 The Managing Director. and maintenance of our quality policy at all levels of the organization through widespread printed distribution of our quality policy statement. and services. regulatory and legal requirements) through continual improvement of our processes. Management Responsibility Management commitment The Quality Department is responsible for maintaining and analyzing data from NC material activities. products. We provide evidence of commitment to the development. and improvement of our Quality/ Environmental Systems in very tangible ways: Our quality policy statement (Section 5) documents and communicates the importance of meeting or exceeding all applicable requirements (including customer. This managing includes the procurement of a deviation or concession from the customer if changes to the product differ.0 Procedure When finding nonconforming material.2. and corporate level improvement objectives. implementation. issue a Material Concern Report at the time of occurrence) We move non-conforming material to the Quarantine Area and a member of the quality department or Production Supervision. is responsible to communicate the importance of meeting customer as well as statutory and regulatory requirements. Page: 14 . up to the disposition section. The Quality Manager will take Actions such as stock returns and replacement.RECORDS RETENTION SOP 4. Disposition of records also includes their disposal. The Quality Manager is responsible for notifying the customer of non-conforming material found after shipment or use has started. 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). Records controlled include customer-specified records. including materials and services provided by vendors. through periodic management review of the quality policy statement. implementation.3 Quarantine Area Record 6.2 Corrective/Preventive Action Procedure FO 8. sorting or even sending a company representative to their site to protect their interests. (If material is part of an accumulation.

CONTROL OF NONCONFORMING PRODUCT SOP 8.0 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.0 Responsibility The Production Supervision and Quality Department are responsible for following documented procedures and work instructions for product that does not conform to specified requirements. work-in-progress. Our quality policy statement indicates our commitment and focuses on what is important to us as an organization: achieving customer satisfaction. customer rejection / returns or material received from a supplier. explicit customer requirements and expectations in the form of a contractual agreement or customer order. through their involvement in the internal audit process.) that does not meet established parameters (e. These customer focused communications and interactions ultimately yield clear. in-house rejections. etc. 4. but is not limited to.0 Application This procedure applies to. Page: 98 All managers demonstrate their commitment to the development and improvement of the Quality/ Environmental Systems through the provision of necessary resources (Section 6). CUSTOMER FOCUS Customer requirements are determined during Quoting and Contract review processes. Material is reviewed and disposition is determined by management and quality. resin. 2. unidentified or suspect material. We place emphasis on improving both effectiveness and efficiency of our key Quality/Environmental Systems processes. and it prescribes the Page: 15 y y . PROCESS EFFICIENCY Top management reviews product realization and support processes to assure both effectiveness and efficiency during management reviews (Section 5). etc. 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). understood. the Managing Director has overall responsibility for ensuring that specified and unspecified requirements are determined.. and converted into requirements (Section 7). purchased components. dimensions. 3.. It is clearly (visually) identified and quarantined or segregated to prevent inadvertent use or installation.0 Definitions Nonconforming Product: Material (e. visual.3 1. and through their proactive involvement in our continual improvement activities (Section 8).) Suspect Product: All material having the same lot number as known nonconforming product.g. Top Management ensures that we meet these requirements with the aim of enhancing Customer Satisfaction.g. melt flow.

method by which we accomplish this: by continually improving processes. y On-The-Job training is provided for all personnel. Moreover. when applicable Employee on the job performance y Revision History QUALITY/ENVIRONMENTAL POLICY Management review meetings checks the Quality and Environmental policies and objectives for continuing suitability. and services to ensure they consistently meet or exceed requirements. QUALITY OBJECTIVE Our objective is to satisfy all of our customers with quality products and services. Make statement 2. our quality policy statement acts as a compass in providing the direction and a framework for establishing key corporate level performance measures and related improvement objectives. and reinforcement during annual employee performance reviews (Section 6). in any new or modified job. including contract or service personnel. QUALITY POLICY We will Accomplish Our Objective through Customer Satisfaction by Providing: 1. regular communication. is reviewed for continuing suitability during management review meetings (Section 5). and along with all policies contained in this manual. (Section 5) y We ensure that our quality policy is communicated and understood at all levels of the organization through documented training. 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. products. Make another statement Page: 16 Page: 97 . We control our quality policy statement by including it in this manual.

This review occurs concurrently with the employee·s performance evaluation or upon need. to encourage customer satisfaction and overall growth of the organization.0 Procedure Identify training needs. customer feedback. We accomplished Benchmarking formally and informally via trade shows. and charting of performance measures (Section 6). as information is available. 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. 5.evaluation form. The business plan includes short and long-term goals relating to quality and environmental policy objectives. and defines timeframes to achieve each goal. 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. and give an assessment test (if applicable) upon completion of the course. productivity. The Company benchmarks trends in quality.0 Associated Materials Orientation Manual Job Descriptions 6. The Company·s Management Team annually reviews business plan and revises. The Company employees and their manager/supervisor shall review the employees training status to determine training needs. and effectiveness are. as appropriate. efficiency. Provide Training One or more of the following provides formal training: y y y y Identified The Company Trainers Professional / Industry Organizations or Societies Local Community and Trade Schools College and University Sponsored Classes Page: 96 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. We also have methods to track update and revise fall under the Continuous Improvement Process. including those needed to meet product requirements. The quality manual documents the necessary processes that define the planning process for quality/environmental management system and objectives. Objectives may include the following possible measures (Section 5): y y y y Customer Satisfaction: Managing Director (Section 8) Supplier Performance: Materials Manage (Section 7) Quality/Environmental Systems Effectiveness: ISO Management Representative (Section 8) Overall Operational Efficiency and Manufacturing Process Efficiency (Section 5 and 6) Page: 17 . reading material.

They evaluate content of the courses through a training feedback and Page: 95 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. 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. processes. Evaluating Training Needs All employees (salaried and hourly) must complete the specific orientation program administered by the Human Resource Department. (Section 7 and 8) b) Manage and control facilities. quality systems and personnel to consistently and cost effectively produce products and furnish services that meet customer needs (Section 7). Salary Employees: Human Resource Department shall maintained records of salary training needs and training received by active employees performing activities affecting quality. relevance. We inform personnel whose work affects quality about the consequences to the customer of nonconformity to quality requirements. All employees have training in awareness. and importance of their activities and how they contribute to the achievement of our overall quality objectives. but are not limited to. Page: 18 . PPAP-4¸ (Section 7) as required including acceptable process capabilities for all Special/Control Characteristics that have been established. which the Human Resource Department maintains. Evaluating Training The Human Resource Department continually assesses the training courses offered internally. c) Develop and implement Advanced Product Quality Planning (APQP) practices and procedures in accordance with ISO/TS 16949:2002. including the AIAG ´Advanced Product Quality Planning and Control Planµ reference manual. and associated customer specific requirements documents.y y y y Training Effectiveness and Employee Awareness: Human Resource Director (HRD) with input from the Training Manager (Section 6) Product Performance: Program Manager (Section 7) Effectiveness of Manufacturing Processes: Production Manager (Section 7) Product Quality: Quality Manager (Section 8) limited to. The employee·s manager/supervisor in the performance review process determines individual training needs. training matrices and copies of training certificates. APQP-2. We base specific measurable objectives on achievable performance within a specified period. training matrices and copies of training certificates. Each salary employee has an individual training record. These records include. 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. (Section 7) d) Provide objective evidence that all supplied products and services satisfy all AIAG Production Part Approval Process (PPAP) requirements.

2 1. 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). Page: 19 . Meet customer requirements by controlling and using returnable packaging. This manual constitutes our overall plan for establishing. 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. (Section 8) Conduct operations in conformance with. and associated customer specific requirements documents. and improving systems. (Section 7). projects. SPC-3. 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.0 Application The scope of this procedure incorporates the training of all employees performing quality related activities. we will default to a level 3 PPAP submission. 3. of. and through the provision of resources needed for its effective implementation. (Section 7) Utilize appropriate statistical techniques for on-going process control and improvement as established in the AIAG ´Statistical Process Control (SPC)µ reference manual. which the Human Resource Department maintains. 6. all applicable environmental laws and regulations of the jurisdictions in which we do business (Section 6). skills appropriate required for the position. (Sections 5. (Section 8) Be committed to continuous process improvement by emphasising reduction of part-to-part variation and the elimination of all waste.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. 2. Each job description identifies the competence level/ education. but are not Page: 94 e) f) g) h) Note: In the absence of any specific instructions. and 8) The Quality Manager develops appropriate quality planning documents for specific products. These records include. Each hourly employee has an individual training record. or to exceed. as appropriate.0 Definitions Not applicable 4. We maintain our management review process and internal audit process ensure the integrity of our System when we plan significant changes and implemented that affect our key Systems. maintaining. the training provided.COMPETENCE AWARENESS & TRAINING SOP 6.0 Responsibility Job Description Each position has a written job description maintained by the Human Resources Department.2.

Operational Procedure SOP 4. and concluded the review with appropriate decisions and actions. processes. absent participants. to include presented and discussed topics and issues. and any actions initiated to implement the conclusions and policies. with the help of department managers. sets direction and ensures the success of our business through the clear definition and communication of Quality/Environmental Systems responsibilities and authorities. if any.2 Operational Procedure. Corrective and Preventive Action Associated Records Management Review Report: Record of the management review meeting. Management Review Report Documented using form FO-MRR-5.4.0 8. Other members of Top Management include: y y The Operations Managing and The Human Resource Director 7. Control of Records SOP 8.6) Revision History Page: 93 . MANAGEMENT All managers are responsible for execution of the Business Plan and implementation of the policy. They will be the sole evidence that the agenda of the review was completely covered. Top Management is responsible for Business Planning. Control of Records The location. the provision of resources needed to implement and improve Quality/Environmental Systems and management reviews (Sections 5 and 6). We document the Management Review output in the Management Review Report based on form MRR 5. Quality/Environmental Systems Planning including the establishment and deployment of objectives (Section 5).4 Operational Procedure. and retention period for management review records.0 Referenced Documents 5. Quality Objectives Matrix: We document Record of established quality objectiveson the title page of the Management Review Report (MRR 5.0 Records Management review records must be as comprehensive as possible.6. policies and changes.1.6.2. The interrelationship of Top Management and other key personnel is depicted our Organization Chart.1. conclusions.2. and systems Page: 20 9. development and communication of our quality policy. AUTHORITY.6. RESPONSIBILITY FOR QUALITY Overall Quality/Environmental Systems responsibility and authority is as follows: 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.1 Management Review Report Form SOP 4. AND COMMUNICATION The Managing Director (MD). The report is prepared by the Quality Manager and is distributed to the attending and.5.RESPONSIBILITY.

Quality objectives Documented on the title page of the Management Review Report (refer to Section 6 of this procedure). and other necessary resources.5. equipment. We normally use CARs for improvements related to specific actual or potential product or process nonconformities.2.2.6. Management ensures the staffing of all production shifts with personnel in charge of.6. and do not directly related to product or process conformity. The management representatives have the responsibility and authority to: y Ensuring that the ISO system processes needed for quality and environmental management systems are established. Assigned to. and Preventive Actions. flow charts. Page: 21 . Corrective or preventive actions Documented in the Corrective Action Request (CAR) form (FO-NCCAR-8.1) in the Actions. and Due Date columns. work instructions. MANAGEMENT REPRESENTATIVE The Company has appointed Quality and Environmental Management representatives for each system. This method is most suitable for implementing long-term improvement goals. Management with responsibility and authority for corrective action promptly notifies employees of non-conformities (Section 8). Page: 92 described in this manual. Improvement of quality performance. Personnel responsible for product quality have the authority to stop production to correct quality problems (Section 8). All managers are responsible for planning and controlling Quality/ Environmental Systems processes within their area(s) of responsibility. This type of action is most suitable for minor improvements that we can implement quickly. and the provision of resources needed to implement and improve these processes. We identify resource needed for implementing improvement actions These include assignment of responsibility. time frame. including the establishment and deployment of operational level objectives (Section 5). 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. and Improvement of products and/or services to better meet customer requirements and increase customer satisfaction We define these improvement actions implemented as: Management review actions Documented in the Management Review Report (FOMRR-5. or delegated responsibility for product quality (Section 7). and allocation of human.0 y y y Management review output Improvement of the quality management system. job descriptions. Managers also conduct employee performance reviews (Section 6). EMPLOYEES All employees are responsible for the quality of their work and implementation of the policy and procedures applicable to processes they perform. technical knowledge. Corrective.3) and processed in accordance with procedure SOP 8. etc.

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). and its policies. reduce its target value. continual improvement. and records their status in the Status Next Management Review column. and corrective/ preventive action processes (Section 8). memos. We review the principal quality policy to ensure its continuing suitability. objectives and significant environmental aspects. Page: 22 . and any other such issues related to the quality management system. Following each presentation. compare their status and performance with preceding periods. and the status and importance of quality activities. the participants decide whether to drop the objective. 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. The policy is changed when the goals expressed in the policy have been achieved. market and customer response to the quality effort. new employee orientation. or extend the target due date. y Ensuring the promotion of awareness of customer and environmental requirements throughout the organization (Section 5) The Environmental Management Representative is responsible for documenting and responding to relevant communication from external parties. from contract review through production INTERNAL COMMUNICATION The Company uses a variety of tools. or when changes within or outside the company render the policy inadequate or inappropriate. the internal audit process (Section 8). the participants discuss the issues. 5. and specific training sessions to communicate internal information about the effectiveness of our quality and environmental management system.implemented. Page: 91 y CUSTOMER REPRESENTATIVE The Program Manager will ensure and address customer requirements and will represent the needs of the customer internal functions.0 other operations and activities. 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. including but not limited to workplace meetings. When an objective is not achieved. We communicate information regarding Quality/ Environmental Systems processes and their effectiveness through documented training (Section 6). bulletins. At the end of the meeting. Quality objectives are established to improve performance and/or the quality system and thus fulfill the quality policy and other organizational goals and aspirations. and identify areas where improvement is required. and maintained in accordance with their respective standards (Section 5). We carry any quality objectives into the next period and any new objectives established by the review meeting and document in the Quality Objectives Matrix on the title page of the Management Review Report.

the frequency of audit findings against particular elements of the quality system and discussion of significant findings. Customer feedback and complaints Customer Service presents summaries of customer feedback and customer complaints. and the status of pending actions. are responsible for establishing internal communications as needed to convey to their employees the relevance and importance of their activities. including analysis of trends. and related statutory/regulatory requirements. programs. involvement opportunities. adequacy. process. Changes and quality system planning Quality highlights any product.4. This includes summaries of results for the cycle. All managers and supervisors.delivery performance. 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. evidence of achievement of quality/environmental objectives and customer satisfaction. (Section 8) The Company record review results provide at a minimum. In addition to the topics listed above. capacity.6. The Managing Director or designee chairs the corporate reviews and top management from all relevant functions attends. We retain meeting records. typically this information is conveyed through production team meetings and cross-functional improvement projects (Section 8). which we convey and reinforce during employee performance. the management review may also consider such issues as cost of quality and non-quality. and coordinate with ISO/TS 16949 Element 8. and applicable statutory/regulatory requirements. MANAGEMENT REVIEW Top Management conducts formal review meetings at least quarterly to ensure the continuing suitability. 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. The Human Resources Department posts information on employee bulletin boards throughout the facility to convey information regarding employee benefits. and productivity data. Communications regarding how employees contribute to the achievement of objectives. Edit the scope of the quality performance data as appropriate. (Section 5) Page: 23 . Recommendations for improvement Quality concludes the input phase of the review with recommendations for improvement. Internal quality audits Quality presents results of internal quality system audits. supplier quality performance. and effectiveness of our Quality/Environmental Systems in accordance with procedures detailed in SOP 5. Corrective and preventive actions: Quality presents the most important corrective and preventive actions implemented through the period.Analysis of Data. integration of the quality system with Page: 90 y The Company uses internal audits (Section 8) to reinforce or communicate appropriate information to employees. reviews (Section 6).

identifying opportunities for improvement and corrective and preventative actions. after reviewing the minutes. we use these results to demonstrate achievement of the quality objectives in our Business Plan and customer satisfaction with supplied product. and Purchasing. results of self-assessments (Section 8). and environment. related performance trends. facility and equipment. all applicable requirements of the QEMS.The Quality Manager ensures that review includes analysis of actual and potential field failure and their impact on quality. safety. We document the agenda on the cover page of the Management Review Report. Process performance and product conformity Quality presents quality performance data. corporate level. This includes rates of process and product nonconformities.e. No more than one manager may be absent from the meeting. plant. and opportunities for improvement. At a minimum. changed. Actions which are not completed may be extended with a new due date. and an assessment of the suitability and effective of support processes (i. Those managers who are unable to attend shall receive minutes of the review meeting and. or abandoned. regular evaluation of the cost of poor quality (Section 8) . may submit their input and comments to the Quality Manager. we present the following information and data for review: Follow-up actions from previous reviews Quality reports on the status of action items from the previous meetings. Section 6) as an essential part of our continual improvement process (Section 8). QUALITY SYSTEM PERFORMANCE Each management review includes all requirements of the Quality/Environmental Systems including monitoring of quality objectives (Section 5). Management review input At a minimum. effectiveness and/or efficiency improvement objectives (Section 5) documented in prior Page: 24 Attendance The Quality Manager chairs the Management Reviews attended by Management. The Operations Manager and Quality Manager must always attend. Production. Agenda The agenda for management review meetings covers at least all items listed in Section 4 of this procedure. follow-up actions from earlier management reviews. The Company holds review meetings at least monthly to review plant specific data and process effectiveness indicators. reassigned to another person/function. on-time Page: 89 . 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. We record reasons for the failure to implement the action and any decisions regarding continuation of the action in the Management Review Report. REVIEW INPUT The management review meeting includes a review of our quality policy (Section 5). At a minimum. Engineering. and strategic or operational changes that could affect the QEMS.

In response to changing or special conditions and events. and to enhance customer satisfaction by meeting customer requirements. of this procedure.0 Definitions None 4. management reviews (and/or specified in our Business Plan) and reviewed for status and continuing suitability. We accomplish verification of work through budget comparisons. improvement of product related to customer requirements. In addition. capital expenditure review. Quoting process.0 Purpose The purpose of this procedure is to provide for a system and instructions. 3. 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. through the Management team. For the first two years (i. and in particular. 2. Review Input.0 Procedure Frequency and Scheduling Quality performance and the quality management system and reviewed at least once a year.e. REVIEW OUTPUT At a minimum. Resource requirements identified during the Business Plan Process. and advanced Quality/ Environmental Planning. RESOURCE MANAGEMENT PROVISION OF RESOURCES The Company.MANAGEMENT REVIEW SOP 5. We conduct the additional review in September. safety or the environment as an input to the management review process. Per SOP 5. determines its resource needs and provides the resources to implement and maintain the quality management system and continually improve its effectiveness.. through the maturation phase of the quality system). and provision of resource needs. we record the results of management review meetings and the ISO Management Representative maintains the records. those named in Section 4. The Program Manager provides an analysis of actual and potential field-failures and their impact on quality.0 Application This procedure applies to all activities comprising the quality system. management reviews are conducted twice a year.6. performance measurements. the Operations Manager may call for unscheduled extraordinary reviews. REVIEW INPUT ² SUPPLEMENTAL.6 1. and recording management reviews of the quality management system. conducting. and to assign responsibilities for scheduling. as well as through the results of internal audits of the quality and environmental Page: 25 Page: 88 . We conduct the annual review in March.

we shall maintain them for the length of time established by the corresponding Department Manager and in accordance with minimum customer requirements. Analysis. and Service Provision Planning Measurement Systems Planning (including the conduct of MSA) Measurement. (Section 5) Page: 26 Page: 87 . Services and Vendors) Production. other than production part approvals.provided through our budgeting and other business management processes including: 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. Equipment and other Infrastructure Planning Contingency Planning Work Environment. tooling records. Revision History The MD. and Improvement Planning (including the use of SPC) Organizational Continual Improvement Planning Manufacturing Process Continual Improvement Planning Obsolete documents. Facility. 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. with input from other responsible managers. purchase orders and amendments. 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.

It is a four-quadrant system. In the second phase.6 SOP 7.2. 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. The Quality Department retains superseded part documents used for new part qualification. This Competency Matrix is available to persons assigning work.0 Associated Materials AIAG APQP AIAG FMEA AIAG MSA AIAG SPC AIAG PPAP SOP 5. (SOP 6) Page: 27 . We might retain the records longer for reference at the discretion of the responsible party. The status of archived records is determined and appropriate records are disposed of annually. The retention duration listed is a minimum retention. In the third phase. and determine the filing and storage method (for retrieving and preventing damage) and the retention duration (conforming to TS16949 requirements) for quality records.4 QR 6. skills.0 Procedure The responsible personnel and/or departments ensure the validity and completeness.The Materials Manager and Accounting department are responsible for ensuring the proper retention of customer related purchase orders and amendments. COMPETENCE. All personnel understand the importance of their activities and their contribution to the achievement of the quality and environmental objectives. 5. AWARENESS. we deem the new person ´competentµ to work on his or her own.2. It is which visually displays the capabilities of the person according to which of the quadrants have been achieved.2 FO 4. Page: 86 Advanced Product Quality Planning Manual Failure Mode Effect Analysis Manual Measurement Systems Analysis Manual Statistical Process Control Manual Production Part Approval Process Management Review Procedures Contract Review Procedures Internal Audit Procedure Quality Records List HUMAN RESOURCES GENERAL The Company ensures that all employees who perform activities that may affect product quality or have significant impact on the environment have the appropriate training. experience and competence. The Quality Department ensures quality records are available for evaluation by the customer for the stated period. the experienced person or member of management continues to observe the new person. Some persons may move on to the fourth stage and we deem them an ´expertµ allowing them to train others or assume other responsibilities. AND TRAINING The Company maintains a Training/Competence Matrix for personnel by job description.2 SOP 8.

Personnel performing specific assigned tasks are qualified. we help existing employees qualify for new/changed jobs through the provision of appropriate education and training. quality performance records. Our Training Coordinator is responsible to analyze effectiveness of training and competence. 3. and management review.0 Definitions None 4. ON-THE-JOB-TRAINING Responsible managers ensure on the job training (OJT) is provided for personnel in any new or modified job affecting Page: 28 CONTROL OF RECORDS SOP 4. 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. with particular attention to the satisfaction of customer requirements (application of digitized mathematically based data. 2. collection.2. availability. Where possible. as required. and disposal. protection. indexing. storage. TRAINING Responsible managers identify training needs for their employees and achieve competence of all personnel performing activities affecting product quality.g. internal quality system audits. Page: 85 . and update of hourly employee Training/Competence Matrix records.). This is inclusive of all prints. filing. The Program Manager and/or designee are responsible for ensuring the proper retention of appropriate tooling records. including on-the-job-training (OJT). with input from responsible managers. and disposal. evaluates and qualifies applicants for specific job openings based on documented or demonstrated competencies. The Human Resource Department. The Quality Manager is responsible for ensuring the proper retention of production part approvals.0 Application This procedure applies to all departments responsible for the maintenance of quality records.0 Purpose This procedure provides a method of maintaining quality records consisting of identification. e. Accounting department and the Materials Manager are responsible for ensuring the proper retention of subcontractor purchase orders and amendments.0 Responsibility Each Department Manager is responsible for records their department creates and for their maintenance.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.4 1.

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.4 Control of Quality Records Procedure SOP 7. EMPLOYEE MOTIVATION AND EMPOWERMENT The management team is responsible to motivate employees to achieve quality objectives.3 Revision History Advanced Quality-Planning Procedure Documentation ² Writing Procedures and Work Instructions product quality. and supervisors re-evaluate employee competencies and evaluate employee performance against established objectives through our employee performance review process. to make continual improvements and to create an environment to promote innovation. The Plant Supervisor is responsible for ensuring the maintenance of records for Total Preventive Maintenance activities. Responsible managers ensure that employees are aware of the relevance and importance of their activities and contributions to the achievement of our objectives. Responsible managers. Department Managers are responsible for reviewing all of their applicable documents within their departments at a minimum of annually to insure relevance and conformance.2.2.3 WI 4.0 Associated Materials SOP 4. first piece. including agency or contract employees. PROVISION 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). We conduct Annual employee reviews to give one on one interaction of communication employee with The Company Management. officers. and in-process and operator instructions) and that they agree with each other.ensuring the identification and/or disposition of obsolete copies. The Program Manager is responsible for ensuring all levels of documents and subordinate documents (such as control plan. Page: 84 Page: 29 . 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. 5.

The Program Manager is responsible for receiving. or supervisor who identified the training requirement. The Plant Supervisor is responsible for ensuring current instructions are available at all work instructions. The Training Manager maintains records of all training completed. We accomplished this through awareness training. the relevance. we ensure that our employees are aware of customer requirements (Section 5 and Section 5).EFFECTIVENESS The Company evaluates the effectiveness of all actions taken to meet competency needs. We evaluate provided training through immediate feedback from the employee and the manager. The responsible manager collects the documents for each training event. skills. Both the person receiving a copy of a new or revised document and the person distributing the document are responsible for Page: 83 . The Human Resources Department maintains employee qualification and competency review records and annual performance review results. reviewing and retaining CAD/ Math data. including buildings. All Department Managers listed above are also responsible for making sure distributed and or retrieving and replacing obsolete copies with the latest revision. System. and maintaining their individual department work instructions. ISO 14001 The Program Manager is responsible for a timely review of customer drawings and specifications. and importance achieving our quality policy (Section 5) and objectives (Section 5). employee performance reviews (Section 6). Instructions and Test Procedures are available. 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). Department Managers are responsible for creating. INFRASTRUCTURE The Company provides and maintains the infrastructure needed to achieve conformity to product requirements. and employee participation in our internal audit (Section 8) and improvement (Section 8) processes. training. RECORDS We maintain appropriate records of education. process Page: 30 The Quality Manager and/or designee is responsible for retaining master copies and assuring current revision level of the AIAG reference manuals: y y y y y y 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 ISO 9000 or TS 16949 Environmental Mgmt. The PM has 10 business days of receipt to document the receipt of drawings and maintain the engineering standards according to the Drawing Control Procedure and Engineering Change Process. approving. EMPLOYEE AWARENESS Through their activities and contributions. workspace and associated utilities. and experience in accordance with provision of Section 4.

including documents of external origin. and distribution of drawings and documents.2) The Plant Supervisor has overall responsibility for managing our Facilities and Equipment Maintenance programs in accordance with SOP 6.6. labor shortages. 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 equipment (hardware and software as necessary). We use a multi-disciplinary approach to develop plant. maintenance. and repair PLANT. 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. Application This procedure applies to statutory & regulatory requirements the drawings specifications and documents that explain the engineering requirements.1. maintenance and repair Production tooling management. 2. Purpose This procedure describes the responsibilities for receipt. The Company prepared contingency plans to satisfy customer requirements in event of an emergency such as utility interruptions. work instructions and inspection instructions related to deliverable goods and our processes. and key equipment failure and quality issues. FACILITY. assembly methods. manufacturing processes. and any supporting services that are needed. test procedures. facility. and equipment. and equipment plans.3. such as transportation or communication. Page: 82 Page: 31 . and Transportation and material handling equipment management.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.3 1. (SOP 6. processes. handling and valueadded use of floor space and facilitate synchronous material flow. maintenance and repair Housekeeping/custodial services management Process equipment management. these programs include: y y y y y Facilities management.2.5. In addition. y 4. we detail methods to evaluate and monitor the effectiveness of existing operations in SOP 7.4 and SOP 5. facility.CONTROL OF DOCUMENTS SOP 4.3. review. 3. AND EQUIPMENT PLANNING The MD uses a multidisciplinary approach for developing plant.

health. All documents used during. and ergonomics by following proper manufacturing practices. implementing. The Information Systems Manager has overall responsibility for managing our automated data processing and communications systems. labor shortages. procedure. Revision History Page: 81 . interesting work. and through safety team meetings and training (Section 6). or instruction. and involvement of our employees in an empowered environment of continual improvement (Section 6). The Human Resources Department has overall responsibility for identifying. acceptable to use ¶as is· due to unavailability of revised forms or unacceptable costs which would be incurred by disposing of unused forms. and maintaining effective employee benefit and workforce involvement programs. Page: 32 revised policy. Management reviews the effectiveness of these efforts during management review meetings (Section 5). implementing. The Operations Manager has overall responsibility for identifying. or forms generated before the revision process shall be considered ¶grandfathered·. We monitor and improve workplace safety. statutory or regulatory requirements. in conjunction with the Information Systems Manager and other appropriate managers. processes and controls needed to ensure product conformance and meet customer. and key equipment failure and field returns. and maintaining safety and environmental management systems. We engender total participation by involving employees in internal audit (Section 8) and improvement (Section 8) activities. The Quality Manager. 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. WORK ENVIRONMENT We provide employee benefits. Contingency plans. job and schedule flexibility. the recipient updates the manual.The Plant Supervisor develops and implements an effective preventive maintenance program utilizing predictive maintenance methods (Section 7) as appropriate.

the following: a. The Administrator will maintain a master list of qualityrelated documents. 2. initial issue. Error proofing for processes. The quality department distributes a copy of the new or revised policy. Upon receipt of the new or Page: 80 Document Control Control of Quality/Environmental Records Quality Manual Change Request Department Specific Manuals 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). and repair consistent with the product and manufacturing process needs (Section 6) PRODUCT REALIZATION PLANNING OF PRODUCT REALIZATION 1. cleanliness. and amendments of all documents and data relating to the requirements of the quality system. The responsible Department ensures that designated personnel receive approval. The Quality Department files original form.3 6. and tooling Page: 33 . The responsible Department ensures availability of appropriate documents at all locations where the performance of operations affect the quality system.2.manuals and data within their area of responsibility as required. but not limited to. send a Quality Manual Change Request Form to the Quality Manager describing the proposed change. If not approved. Environmental aspects/impacts c. or instruction according to the Quality Policy Manual. CLEANLINESS OF PREMISES We provide and maintain a work environment in a state of order. facilities. Product special characteristics. Procedure Manual.3 SOP4. 5.2.0. procedure. The quality/environmental objectives and requirements for the product b. equipment. The Company has implemented a Quality and Environmental-planning process to define and document how the respective requirements will be met (See SOP 7.4 FO 4. and Operator Instructions Distribution List. the request form gives an explanation and a copy returned to the originator. through their department manager. Reference 6. The changes become part of the revision history. including safety characteristics d. the revision history identifies the changes. may request document changes. For new projects. and for the recall of obsolete documents. a cross functional team plans the processes with consideration given to.0 Associated Materials SOP 4.0 Procedure Any member of staff. Where practical. This planning process is consistent with the requirements of the ISO standards and sets the framework for all Company processes of the quality/environmental management systems.2. If a Quality System procedure needs to be changed.2).1 & SOP 7.

drawings. training and skills needed to achieve the required quality and environmental objectives and targets. SPC PFMEA. We confirm defined activities to ensure compliance with customer requirements. When we receive the approval for any changes affecting customer requirements. The quality plan and relevant work instructions clearly define acceptance criteria and approved by the customer. The Program Manager and/or designee are responsible for controlling issuance and maintenance of drawings.0 Responsibility The Process Owners/Area Managers are responsible for controlling issuance and maintenance of quality/and environmental-related policies. e. and operator instructions.0 Definitions Not applicable 4. 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. and related product information. We maintain customer confidentiality for all products and projects under development. including the prevention of pollution f.2 1. and instruction elements. and specifications. Quality receives. documentation. and operator instructions for original release and the release of changes. procedures. 3. procedures. The Company assesses product and manufacturing process changes that affect product realization. Identification of required verification. and Control Plan manuals as required. Department/Plant Supervisor are responsible for controlling issuance and maintenance of associated Page: 34 Page: 79 . revises.3. equipment (including inspection and test equipment). reviews. MSA. inspection and test activities g. prepares. The identification of any controls. 5. Customer requirements and references to technical specifications are to be included in the quality plan The Company uses the methods in the APQP. measuring. we notify the customer and validate changes before implementation. 6. 4.0 Purpose This procedure addresses the maintenance of quality documents pertaining to customer requirements.0 Application To maintain designated secured locations for original policy. monitoring. DOCUMENTATION REQUIREMENTS SOP 4. procedure. One level above the author will be an approver for reviewing and approving companywide policies. fixtures. and PPAP. processes. including electronic data. 2. and systematically issues documents in a controlled manner. approves.

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. see SOP 7.1) in the absence of any specific instructions. impact use with the customer.e. we will default to a level 3 PPAP submission.) Special Characteristics for inclusion in the control plan comply with customer specifications (including drawings. PPAP-4. etc.) that affect product characteristics and process parameters. PPAP. Production Part Approval Process (PPAP) (Section 7). (Section 7) Our APQP/PPAP process. PFMEA. FMEAs. Control Plans. The APQP Team Leader ensures: y Submissions for part approval prior to the implementation of changes. to determine the type of quality re-certification required (PPAP documentation. Fixtures. Tooling.PROCEDURES This booklet contains sample procedures.1 provides a consistent advanced product quality planning process acceptable to all of our customers. We obtain PPAP approval prior to the first production shipment of product (unless specifically waived by the customer). They are very generic in nature. PLANNING OF PRODUCT REALIZATION ² SUPPLEMENTAL We review proprietary designs. etc. The APQP Team Leader implements the PPAP recognized by our customers. operator instructions.) Production following any change in process or method of manufacture Page: 35 y Page: 78 . as detailed in SOP 7. Run @ Rate.

CONFIDENTIALITY We ensure the confidentiality of customer-contracted products and projects under development and related product information (Section 7). understand. and all related changes that may affect product realization.g.1.y y Change of source for subcontracted parts. For attribute data sampling. CHANGE CONTROL The Quality Manager obtains necessary customer approval of quality plans. acceptance criteria. we perform additional verification and identification requirements. and function (including performance and durability) and reviewed with the customer. heat treating or plating) Product re-released after the tooling has been inactive from volume production for twelve months or more. ACCEPTANCE CRITERIA Acceptance criteria is approved by the customer. so all effects can be properly. For propriety designs. fit. (Section 7) CUSTOMER-RELATED PROCESSES Achieving our quality policy ´to meet or exceed customer requirementsµ requires that we determine. and/or manufacturing process. validation. and that we establish effective communication systems with our customers with regards to product Page: 36 Page: 77 . the acceptance level is zero defects (Section 8). When required by the customer. where required. and consistently meet or exceed our customers· requirements and expectations. materials. such as required for new product introduction. impact of form. product. or services (e. and SOP 7.

contract or order requirements differing from those Page: 76 Page: 37 . MONITORING AND MEASUREMENT The Company shall establish and maintain documented procedures to monitor and measure. and control of indentified special characteristics that occur during the planning phase. and customer feedback. information. safety. applicable statutory. annually. we review requirements related to the product to ensure that product requirements are defined. (Section 8) DETERMINATION OF REQUIREMENTS RELATED TO THE PRODUCT The Company maintains documented procedures for quoting and contract review and the coordination of these activities.EMERGENCY RESPONSE When appropriate. handling. and conformance with objectives and targets. documentation. Requirements include those specified by the customer (including delivery and post delivery requirements). When a request for quote is received. safety and environmental regulations and requirements. and any additional requirements determined by the Company. government. REVIEW OF REQUIREMENTS RELATED TO THE PRODUCT During Quoting and Contract Review. The Company conforms to customer requirements for designation. requirements not stated by customer but are necessary for specified or intended use. including complaints. All applicable government. environmental impact. We review and revise procedures and instructions after drills and after the occurrence of accidents or emergencies. This will include the recording of information to track performance. and identified characteristics (Section 7). it is processed according to the Quoting Process to ensure that quality and environmental requirements adequately define and document considerations for recycling. or disposal of materials. recycling. elimination. Procedures provide general guidelines to follow in the event of an environmental accident or incident and references appropriate emergency response instructions. where they exist. inquiries. contract or order handling and related changes. as a minimum. and environmental regulations applied to the acquisition. storage. relevant operations controls. on a regular basis. specific emergency response instructions are prepared to allow rapid and effective response to environmental incidents. the key characteristics of the operations and activities that can have significant impact on the environment. We conduct emergency response drills.

The Company has also established procedures related to the identifiable significant environmental aspects of the goods and services used by the company. including its commitment to the prevention of pollution. The Company considers its· legal and other voluntary requirements. including risk analysis. To prepare for product realization. See Procedure the Company Supplier Manual located on The Company website. (Section 7) Where product requirements are changed. and establishes action plans and programs for achieving these objectives. The Company shall document procedures to cover situations where the absence of such procedures could adversely affect quality or have a significant environmental impact. 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. as described in the objectives. and validation that are appropriate to each design and development stage and the responsibilities and authorities for design and development. and targets. its significant environmental aspects.1 in accordance with APQP. its technological options and its financial. unless customer waives review requirement. we carry out activities using a multidisciplinary approach including identification and Page: 38 OBJECTIVES/TARGETS AND ENVIRONMENTAL MANAGEMENT PROGRAMS The Company identifies environmental objectives and targets. and The Company can meet the defined requirements. targets and action plans establish them at each relevant function and level within the organization. During Quoting. review. Page: 75 . feasibility reviews and risk analysis we carry out and document to determine the manufacturing feasibility of the product. when establishing its environmental objectives and targets. Environmental objectives and targets are consistent with The Company environmental policy. This review is conducted before the purchase contract is accepted.previously expressed are resolved. and business requirements. as well as the views of interested parties. objectives. and communicates relevant procedures and requirements to suppliers and contractors.2) CUSTOMER COMMUNICATION During the design and development planning the following are determined and controlled: the design and development stages. we make amendments to ensure relevant documents and make relevant personnel aware of the changed requirements (SOP 7. verification. We maintain records of feasibility reviews as noted in the Quality and Environmental Records. operational.2. ORGANIZATION MANUFACTURING FEASIBILITY The Program Manager confirms and documents the manufacturing feasibility of proposed automotive products. and product design input and manufacturing process design input in accordance with customer-specific requirements governing the APQP/PPAP process detailed in SOP 7.

including data. i. monitoring of special characteristics. 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. policies. We identified these significant environmental aspects and their associated impacts during the Initial Environmental Aspects Review. and Action Plans. Page: 74 Page: 39 . or could have. CUSTOMER COMMUNICATION ² SUPPLEMENTAL The Information Systems Manager establishes/maintains an ability to communicate necessary information. and federal agencies and review of environmental publications. in a customer specified language and format. We maintain the Environmental Laws and Regulations by the Corporate EMS Coordinator thru periodic contact with local. processes. Customer environmental requirements and identify them during the Quoting Process and are documented in specific contracts. including but not limited to computer-aided design (CAD) data and electronic data interchange (EDI). state. The Program Manager has overall responsibility for managing tooling design and development activities in accordance with SOP 7. or change an existing. development. We have developed a list of applicable Environmental Requirements and maintained by the EMS Department. We conduct ongoing determination of environmental aspects and impacts during Advanced Quality/ Environmental Planning The Company considers these significant environmental impacts and aspects when establishing environmental objectives as described in Environmental Objectives. The Program Manager maintains a list of products for which The Company has design responsibility.3. or systems. and production documents. The Company and our customers require we employ EDI methods by all partner suppliers throughout the supply chain. products.ENVIRONMENTAL MANAGEMENT SYSTEM ENVIRONMENTAL ASPECTS The Company has identified the environmental aspects of its activities. and transaction sets comply with the guidelines set forth by the AIAG and our key suppliers mandate we have the capability to interface with us electronically. a significant environmental impact. and review of FMEAs and control plans. associated work instructions.e. legal and other voluntary requirements that are applicable to its activities. and has access to. LEGAL AND OTHER REQUIREMENTS The Company has identified. All of our EDI initiatives. and services. the authority to establish a new. products and services that it can control and influence and has determined those that have. DESIGN AND DEVELOPMENT Design and development processes for tooling is employed by The Company to transform customer requirements into specifications. Targets. tooling specification. this responsibility includes testing and verification of design performance within customer specified applications. products.

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. fixed design reviews. policies. When external non-conformances occur. and requirements Development and review of control plans Page: 40 Page: 73 . (Section 5) y 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. The Design (or APQP) Team Leader uses project management planning tools (available software etc.1 in accordance with customer specific requirements (see APQP and serves as the overall APQP Team Leader (as referenced throughout this section). (Section 7) DESIGN PLANNING The Program Manager serves as Design Team Leader for tooling design projects for new/changed non-automotive products.) to establish a Design Plan that identifies design stages. quality. through: y y We consider the size and effects of the nonconformities when corrective/preventative actions are taken. Results of this analysis and related recommendations and present them to Top Management for review and action during management reviews. scheduled verification and validation activities. procedures. We conduct follow-ups (through the internal audit process (Section 8) to ensure that we take effective corrective action appropriate to the impact of the problem encountered. Results of this analysis and related recommendations presented to Top Management for review and action during management reviews. we change work instructions as appropriate. We consider our preventive action system effective if we avoid potential losses. The Company responds in the problem-solving format prescribed by the customer. We apply corrective actions and controls to similar processes and products. There is a defined problem-solving process used in all plants. employee suggestions. engineering. 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. manufacturing. When we implement a process change. 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. when appropriate. customer feedback. MULTIDISCIPLINARY APPROACH The Design (or APQP) Team Leader forms a Design (or APQP) Team composed of design. FMEA. Investigating and eliminating the root cause of potential failures is a critical part of our continual improvement process. production and other appropriate qualified personnel to prepare for product realization. (Section 5) PREVENTIVE ACTION Data from internal audits.

where applicable. returned products. including error proofing Documenting results of action taken and reviewing action taken SOP 8. As designs and processes are developed. and reviewed including: a. timing and cost We identify process design inputs. We identify product design inputs. These records are available to the customer upon request and we follow corrective action procedures to prevent recurrence. The Company maintains a corrective action system that provides for the identification. internally recognized product or process non-conformities or potential non-conformities. Product design output data (i. analysis. The procedures also define requirements for determining: y y y y The causes of non-conformities and potential nonconformities Evaluating the need for action to prevent occurrence or recurrence Determining and implementing action needed. or conflicting requirements are resolved prior to the release of the final design. process capability and cost c. life reliability. documentation and reviewing all applicable design inputs are for adequacy..5. These inputs include functional and performance requirements. Customer requirements Page: 41 We analyze Non-conformities relating to customer returns from assembly plants. DESIGN INPUTS The Product Engineer or Program Manager is responsible for identification. non-conforming material from suppliers.e. and reviewed. durability. including external party communications. maintainability. If a customer requires another format. These inputs include functional performance requirements. DFMEA) b. and elimination of the cause of quality and environmental problems in order to prevent recurrence. engineering facilities. See SOP 8. internal. Incomplete. customer or third Party Audit nonconformities. identification. Customer requirements such as special characteristics. which define requirements for the review and handling of customer complaints. documented. Information from similar product experience including field data and internal input and Competitor Analysis c. and environmental non-conformities. including: a. document and review all valid design inputs. a document for lessons learned is maintained which documents information derived from previous similar designs. Page: 72 . applicable legal and regulatory requirements and other requirements essential for design and development. traceability and packaging b.2 which describes the 8D methodology we use internally. (See APQP Workbook Master) (Section 7) The Product Engineer or Program Manager is responsible for ensuring that we identify.5. unclear. applicable statutory and regulatory requirements and other requirements essential for design and development.CORRECTIVE ACTION It is the policy of The Company to strive to prevent problems before they occur. Targets for productivity. and dealerships in a timely manner and the results are. documented.2. This information is also reviewed as an input to new designs. The corrective/preventive action system utilizes documented procedures. Targets for product quality. we do as they wish.

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). Process design includes the use of error proofing We use Advanced Product Quality Planning 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. or where product characteristics are predictable and meet customer requirements. (Section 5) MANUFACTURING PROCESS IMPROVEMENT The Program Manager plans and implements continual improvement of manufacturing processes that are capable and stable. and other process documents as appropriate. including: Page: 42 Page: 71 . Control Plans. and diagnostic guidelines Essentially. As warranted. Product error-proofing Product definition including drawings or mathematically based data Product design review results. We identify such opportunities through analysis of manufacturing process monitoring. such actions are effective if the problems corrected do not reoccur.5) which includes improvement actions and corrective and preventive actions as outlined in Section 8. and are approved before issuance: PRODUCT DESIGN OUTPUTS ² SUPPLEMENTAL We verify and validate product design requirements outputs against product design input using: y y y y y Design FMEAs and reliability results Product special characteristics and specifications. product monitoring and measurement activities (Section 8).d. include information needed for production and service provision. and processoriented audits (Section 8) of key manufacturing processes at least once annually. The overall objective of manufacturing process improvement is to reduce part-to-part variation and eliminate all waste. 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). include or reference acceptance criteria. potential problems identified do not occur. and other improvement actions accomplish the desired results or objectives. The Program Manager summarizes and reports results of manufacturing process improvement activities to Management for review. DESIGN OUTPUTS The Design (or APQP) Team Leader ensures that design outputs comply with the design input requirements. (Section 5) The Quality Manager has overall responsibility for establishing and implementing an effective continual improvement system (SOP 8. We use inputs to the management review process to establish new or changed improvement objectives and to initiate/prioritize additional improvement actions.

we may initiate corrective/preventative action. costs. Measurements may include quality risks. corrective and preventive actions. and compare with competitors and/or appropriate benchmarks. When we notice negative trends during data analysis. analysis of data. We implement computerized information systems for timely reporting of data related to product usage. the Design (or APQP) Team Leader conducts design reviews as planned and records results and any necessary actions. and critical paths. and longer term planning. Page: 43 Page: 70 . (Section 5) y y y y y y y y 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. Our Management Review Process assesses the overall effectiveness of continual improvement program. MONITORING The Design (or APQP) Team Leader monitors the design project by defining. analyzing and recording measurements at specified stages of design and reports summary results as an input to management review (Section 5). support status review. corrective and preventive actions and management review.5-1. (Section 5) CONTINUAL IMPROVEMENT We implement Continual Improvement with the goal of continually improving the quality/environmental management system using the quality policy. customer feedback. We prioritize and implement all management an action based on data analysis (Section 8) and performs cost/benefit analyses to identify and prioritize improvement actions. We use this information to develop priorities for prompt solutions to customer-related problems. quality and environmental objectives. audit results.We report and compare with progress towards the overall business objectives During Business Planning and Management Review processes. trends in data and information. DESIGN VERIFICATION We conduct design verification to ensure that the design and development outputs have met the specified input requirements. work instructions Manufacturing process FMEAs Specifications and drawings Tool designs DESIGN REVIEW During the evolution of each design project. Records of verification results and any necessary actions which we record on the DVP & R and Program Open Issues. is used to document improvement. lead-times. Management Action Requests (MARs). (Section 5) We use comparative Analysis and Use of Data Trends in quality and operational performance with progress toward objectives and we develop recommendations for improvement and present them to Top Management for review and action during management reviews. Form 8. decisionmaking. The Design (or APQP) Team Leader uses input from those involved in the review to propose a remedy for each identified problem.

after process verification we submit the Product approval. and guidelines contained in SOP 8. It is the responsibility of the Program Manager in cooperation with the Quality Manager to ensure The Company submissions meet functional. if applicable. including program timing. This helps us to find opportunities for continual improvement of the effectiveness of the quality/environmental management system. As applicable. 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. We maintain Engineering Approved Product Authorization (EAPA) records. We perform design validation on products that we produced from production equipment and tooling wherever and to the extent possible. and appearance specifications as required by the customer. these we document these changes and keep them in the ECN documentation. Production Part Approval Process (PPAP) for customers requiring this program or other sample submission programs as required. Page: 44 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. we complete validation prior to the delivery or implementation of the product. The Program Manager keeps records of required tests in the APQP documentation. including expiration date or quantity authorized. we obtain prior written customer approval whenever the product or process is different from currently approved. Page: 69 . Wherever practicable.3. We perform Validation in accordance with customer requirements. CUSTOMER WAIVER According to the production Part Approval Process (PPAP) manual. characteristics and trends of processes and products. including program timing. Analysis of this data provides information relating to customer satisfaction. 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 OF DATA We collect and analyze data from quality and environmental system processes evaluate the effectiveness of the quality/environmental management system. If there needs to be corrective actions. Suppliers are required to follow The Company product and manufacturing process approval procedures and requirements. design. and process.Design Validation includes a review of field reports for similar products. We perform design validation to ensure the product or service resulting from design efforts performs as intended for all specified or known uses and applications. 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. If placed on ´containment statusµ (due to continued poor performance and/or failure to achieve goals and objectives). The original or superseding specs and requirements are complied with when the authorization expires. and suppliers. The Company will take all actions required by the customer. product conformity. material. and label the carton of parts.3. We conduct final validation testing to validate the final product.

and approve. sequencing. The Quality Control Manager has the responsibility to ensure disposition of all suspect or nonconforming material within an appropriate timeframe. We also rework or segregate any material or product that is suspect or does not conform to the appropriate specifications and will be disposed of as detailed in the Nonconforming Product Procedure. validate. (Section 4) CONTROL OF NONCONFORMING PRODUCT ² SUPPLEMENTAL We classify and process product with unidentified (Section 7) or suspect status as nonconforming. PRODUCT APPROVAL PROCESS To ensure proper employee understanding. The Company will validate all productionengineering changes to PPAP requirements. PRODUCT RECALL In the event we detect nonconforming product after delivery or use has started. We distribute an internal work order for changes as is detailed in the Design Release and Change Procedure. Note: In the absence of any specific instructions. we use the original process instructions and rework material and we verify activities specified on the control plan.1 Details in. Page: 45 Page: 68 . depending on the nonconformity. All customer engineering design records and specification requirements and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. the Quality Manager notifies the customer and initiates action appropriate to the effects. sorting. Because we perform rework/repair for minor defect problems. verify. PURCHASING We work in partnership with our suppliers to ensure that purchased products and services meet all applicable requirements. Therefore. including concessions obtained. and Manufacturing before their implementation. acquisition and verification of all products and services that affect customer requirements (such as sub-assembly.Suspect or rejected material is either clearly identified with yellow Quality Hold tape or is stored in clearly marked designated areas. The review of a change includes an evaluation of the effect of the changes on component parts and product already delivered. of the nonconformity. 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. and rework and calibration services) are defined in accordance with the policies outlined in this section. Sales. the operations are a repetition of one or more original production processes. and the APQP processes. we use our Standard Operating Procedure 7. we will default to a level 3 PPAP submission (Section 7). along with the PPAP process. and maintain them according to SOP applicable inspection and test procedures. Where appropriate. or potential effects. The processes applicable to the planning. design changes with Engineering. We maintain records of the review and any necessary actions. CONTROL OF DESIGN CHANGES We review. as appropriate. The customer will authorize design changes before implementation.

We have documented Purchasing procedures. (Section 8) SEGREGATION Nonconforming product is segregated pending evaluation and disposition. the potential impact of the product on our processes. obtain (from relevant authority) a waiver of or deviation from requirements. products. including those from the customer. use as is (under customer concession or other required approval authority). the results of supplier evaluations. Dispositions resulting from the evaluation of nonconforming product may include rework to meet specified requirements. and location where the nonconforming product is being held pending further review or disposition. EVALUATION The Quality Manager through authorized Quality Control personnel. Purchasing. the same requirements imposed on The Company are cascaded down to our supply base.4.1. and engineering work together to ensure purchased products and /or services conform to all specified requirements. REGULATORY CONFORMITY We also verified purchased products or materials to ensure conformity to applicable regulatory requirements. In order to ensure the quality of the parts shipped by The Company. perform the initial evaluation of nonconforming product in accordance with approved test and inspection procedures. Page: 46 Page: 67 . as well as consideration of other characteristics including the type of product. 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. or services. return to supplier. 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. scrap or other disposal. DISPOSITION The results of the evaluation and resultant disposition determinations are documented. description of nonconformance. Where needed.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. re-grade for an alternative application. and past performance. Purchased products are verified (Section 7 and 8) to ensure conformity to specified purchase requirements. SUPPLIER QUALITY MANAGEMENT SYSTEM DEVELOPMENT Essentially. Engineering. Quality Control. Production and other technical personnel may become involved in the evaluation and recommendation for disposition.

We then recorded the results of evaluations and follow/up actions. or services from customer-approved sources. processes/systems. nonconforming product until status can be confirmed. 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.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. which is product with unidentified status. Documented procedures are available for the control of non-conforming materials and product. including performance of color eyesight testing. internal testing. materials. equipment. appropriate resources. and quality management system requirements. and special status customer notifications related to quality or delivery issues. customer engineering drawing. for evaluation areas for appearance items. qualification of personnel. APPEARANCE ITEMS For parts designated by the customer as ´appearance itemsµ The Company provides. delivery schedule performance (including incidents of premium freight).e. (Section 6) CONTROL OF NONCONFORMING PRODUCT The Company procures raw materials and manufacture products that are defect free.4. Personnel responsible for making appearance evaluations are qualified and competent to do so.3). grain. procedures. (SOP 8. Page: 47 . The Materials Manager monitors Supplier performance per SOP 7. IDENTIFICATION Identification of nonconforming product originates from inspection. gloss. VERIFICATION OF PURCHASED PRODUCT The Quality Manager ensures and verifies that purchased product prior to use or release in accordance with provision of this section. or specification) we purchase products. including. where appropriate.4) Results are retained and available for customer review. customer disruptions including field returns. We maintain a master list of approved suppliers to ensure we only purchase product from The Company qualified sources or customer-approved sources. Page: 66 CUSTOMER-APPROVED SOURCES Where specified (by contract. including lighting. requirements for approval/qualification of product. & texture and evaluation equipment in the QC laboratory.2 and the following policies. Employees clearly mark or otherwise identify nonconforming product or suspect material.2.4. We maintain Masters for color. drawings). the applicable control plan and design records (i. Purchasing information communicated to our suppliers contains the appropriate data needed to clearly and fully describe requirements for purchased materials and services.1 through one or more of the following indicators: delivered product quality. including suspect products. to prevent their use or delivery to the customer (SOP 8. We consider suspect product. product audits or customer complaints.

Employees must be equipped to perform the process properly through appropriate education. stored. and certification.2. accurate. Our initial focus is to assure the quality of process inputs . As applicable. Equipment and facilities must be adequate. These records include final inspection authority. We have Inspection procedures in the Receiving Inspection Process and on Incoming Inspection Form. facilities and equipment.4. and methods. identify. PRODUCT RELEASE AND DELIVERY: We do not release product or deliver until we complete all planned inspections and.4. and properly utilized the suitability of the fundamental process inputs must be assured.INCOMING PRODUCT QUALITY Quality Control is responsible for conducting verification inspections to ensure incoming materials meet customer specifications. RELEASE We do not release products for further processing or delivery until we have objective evidence that meet all requirements. FINAL INSPECTION AND TEST: We verify all finished products and completed services by final inspections/tests specified in the control plan and SOP 8. and processes must be measured. 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. (Section 8) Page: 48 Page: 65 . The Quality Manager plans and implements appropriate sampling plans and other statistical techniques to verify purchased product per Section 8. material.that is. and controlled to assure effectiveness and/or to identify opportunities for improvement.2. Production personnel in accordance with the applicable control plan perform manufacturing process monitoring (Section 7 and 8). Additionally. and issued. monitored. EVIDENCE OF CONFORMITY We maintain test and inspection records for a minimum of three years. employees. IN-PROCESS INSPECTION Quality Control personnel perform formal in-process inspections in accordance with the control plan and SOP 8. training. product samples are stored for a minimum of 3 years. and confirm that all critical parameters are in accordance with established requirements and specifications. the Quality Manager documents and communicates the intended verification arrangements and method of product release related to verification activities performed at our suppliers· premises. and records have been maintained providing evidence of conformity with acceptance criteria and identifying the person(s) authorizing release. We try to identify and control Nonconforming (or suspect) product to prevent its inadvertent use. Material must meet specified requirements and be properly identified. available.

including processes producing bulk materials. When selecting product parameters to monitor compliance to internal and external requirements. measurement logistics. or delegated responsibility for product quality Tooling Management: The Company personnel maintain control over any work that is outsourced. (Section 7) JOB SET UP VERIFICATION Job set ups are verified per SOP 8.2. in-process inspection. and material level for the product supplied. evaluation by accredited laboratories. component. final inspection and test. (Section 7) The scope of our product monitoring and measurement system (SOP 8.2. This is responsibility if Program Manager.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. Methods used to verify incoming product from the supplier. subsystem. as well as parts. 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. job set up verification. and special consideration regarding monitoring and measurement of appearance items. CONTROL PLAN The Quality Manager develops control plans at the system.4) includes receiving inspection. and the required capability and inspection/test skills needed. layout inspection and functional test. List the controls used for manufacturing process control Include methods for monitoring of control exercised over special characteristics defined by both The Company and the customer Include customer-required information. 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. manufacturing process.2. product characteristics are determined leading to the types of measurement. supply sources or FMEA y The Quality Manager further ensures that control plans: y y y y y WORK INSTRUCTIONS The Production Manager prepares appropriate work instructions for all employees having responsibility for processes that impact product quality and employee safety (Section 6). suitable measurement means.4 prior to commencing each new production run and/or when process changes are made. (Section 7): y y For pre-launch and production that takes into account the design FMEA and manufacturing process FMEA outputs Ensures that productions across all shifts are staffed with personnel in charge of. such as receiving inspection or (SOP 8. Page: 49 Page: 64 . or source inspections.4). if any Initiate the specified reaction plan when the process becomes unstable or not statistically capable Are reviewed and updated when any change occurs affecting product.

acceptance criteria. including: y y Setup Storage and recovery Page: 50 Page: 63 . where applicable. (Section 7 and 8) Production personnel follow documented reaction plans when processes become unstable or no longer capable. The Quality Manager then initiates a corrective action plan indicating the timing and assigned responsibilities to assure the process becomes stable and capable. (Section 7) PROCESS MONITORING Process operators per applicable instructions monitor processes. For attribute data sampling. the acceptance level shall be Zero Defects. evaluating. and develops an effective total preventive maintenance system that at a minimum includes: y y y y Planned maintenance activities Packaging and preservation of equipment. PREVENTIVE AND PREDICTIVE MAINTENANCE Per Section 6. and verification activities. through our APQP/PPAP process. (Section 7). MONITORING AND MEASUREMENT OF MANUFACTURING PROCESSES As part of manufacturing process design. the Program Manager.VERIFICATION OF JOB SET-UPS Job set ups are verified prior to commencing each new production runs and when process changes are made. and use statistical methods of verification where applicable. The Production Manager establishes and implements a system for production tooling management (or monitors these activities if any work is outsourced). and maintenance instructions) are documented. Control plans and process flow diagrams are implemented to ensure adherence to the specified measurement techniques. measurement and test. and gauging. maintainability and availability) and appropriate reaction plans are included in control plans and/or job packs. Acceptance criteria (as well as objectives for process capability. provides resources for their maintenance. reliability. (Section 8). the Plant Supervisor identifies key process equipment. Process capability study results. The corrective action plan is reviewed with and approved by the customer. and improving maintenance objectives. Work instructions governing set ups and related verifications are developed and available. sampling plans. the Program Manager provides resources and oversees efforts related to tool and gauge design. and requires application of a customer recognized or approved problemsolving approach (Section 8). tooling. Availability of replacement parts for key manufacturing equipment Documenting. MANAGEMENT OF PRODUCTION TOOLING As part of manufacturing process design. and reaction plans when acceptance criteria is not met. fabrication. ensures we perform process studies on all new product realization processes to verify process capability and provide additional input for process control. and specifications (including methods of production.

y y y y Maintenance and repair facilities and personnel Tool changing programs for perishable tools Tool design modification documentation. where applicable. measure the quality and environmental management system process. preventive or other improvement action. We carry out process audits (Section 8) to monitor and. At a minimum. such as production. defining the status. results of internal audits and related follow-ups. including internal auditor training records. corrective or preventive action (Section 8).e. repair. Manufacturing and other appropriate personnel for the purpose of initiating appropriate corrective. and carry out that production and service jobs in accordance with procedures detailed in SOP 7. FEEDBACK ON INFORMATION FROM SERVICES The Managing Director collects and communicates servicing concerns to Engineering. analyzes process performance (Section 8) and takes appropriate improvement.(Section 8) SERVICE AGREEMENTS WITH CUSTOMER If there is a service agreement with the customer. including engineering change level Tool identification. the Quality Manager will establish and implement a plan to verify the effectiveness The Production Manager ensures we plan. INFORMATION Information inputs to the process include both product characteristics and appropriate work instructions containing specific work methods and other pertinent information. schedule. when we do not achieve planned results.The ISO Management Representative maintains all internal audit records. as appropriate. In addition. Page: 62 Page: 51 . or disposal PRODUCTION SCHEDULING The Production Manager schedules production to meet customer requirements and our goal to achieve 100% on-time delivery performance through a just in-time production control. we monitor and measure-manufacturing processes to ensure to ensure continuing process capability and suitable performance as specified by the customer part approval process (PPAP) requirements (Section 7). achieve desired results) and to identify opportunities for improvement. managers with overall responsibility for carrying out a Quality/Environmental Systems process. 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. (Section 5) MONITORING AND MEASUREMENT OF PROCESSES We apply suitable methods for monitoring and measuring all Quality/Environmental Systems processes. We also take Corrective action. controlled and evaluated (Section 8) to ensure they are effective and efficient (i. Quality/Environmental Systems processes are documented measured.

We use qualified personnel to audit areas for which they have no direct responsibility for the activity. skills. is provided to production personnel throughout the product and service provision process. AUDITOR QUALIFICATION Internal auditors are qualified to audit to ISO/TS 16949:2002 requirements (Section 6). and reviewed at least once annually to determine effectiveness. Page: 52 Page: 61 . Engineering.2 defines the criteria. WORK INSTRUCTIONS The need for work instructions is dependent upon the knowledge. (Section 8) The Quality/Environmental Systems process. frequency and methods used for internal audits and define the responsibilities and requirements for planning and conducting audits. EQUIPMENT The Plant Supervisor ensures the suitability and availability of all equipment. and abilities of our employees and the complexity of their assigned work process. The Production Manager ensures that all appropriate information including final product specifications. Responsible managers may also request that the audit be used to gather ´value addedµ data serving as input to aid in monitoring. measurement. We conduct follow-up audits to verify timely and effective implementation of the proposed action. or quality system element under review is effective if it is achieving the desired results or established objectives. (Section 8) SOP 8. scope. plans. raw material characteristics and the required product parameters. with a special emphasis on our ¶core· customer oriented processes and our unique product realization processes. and through job specific information included in individual job packs. and for reporting results and maintaining records.including process monitoring and verification instructions and criteria developed during product quality planning and manufacturing process development (Section 7). 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) INTERNAL AUDIT PLANS Each of our key Quality/Environmental Systems processes. Management is responsible for the area-audited implement and timely corrective action to eliminate detected non-conformances and their causes. facilities. work instructions posted in areas as needed. function. Audit checklists are prepared and used to aid in ensuring audit consistency and comprehensiveness.2. 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 needed. We provided such information through job schedules. and improvement of Quality/Environmental Systems processes and systems. team meetings. and initiate other appropriate action in response to opportunities for improvement identified by process participants or managers.

5. and delivery. 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 8) RELEASE. As applicable. in identifying any opportunity for improvement. this includes any processes where deficiencies may become apparent only after the product is in use or the delivery of services. as well as progress towards achievement of corporate level customer satisfaction improvement objectives (Section 5) and provides related recommendations for review by Top Management. ISO 14001. through Production Shift Supervisors. arrangements are established: y y Defining criteria for review and approval of the processes Approval of equipment and qualification of personnel Page: 53 Page: 60 .2. shipping. (Section 5) VALIDATION OF PROCESSES FOR PRODUCTION AND SERVICE PROVISION The Company defines processes in which we cannot verify results by subsequent monitoring or measurement as ´Special Processesµ.Director periodically reviews customer satisfaction survey data and other customer feedback (including complaints). QUALITY/ENVIRONMENTAL MANAGEMENT SYSTEM AUDIT The Company conducts system audits. as identified in the contract. and in promoting awareness of customer requirements and effectiveness of the Quality/ Environmental Systems. The Program Manager has overall responsibility for ensuring ¶Special Processesµ are validated in accordance with procedures detailed in SOP 7. MANUFACTURING PROCESS AUDIT We conducted Audits of our key product realization processes annually to determine their effectiveness and performance and to identify opportunities for improvement (Section 8) PRODUCT AUDIT We conducted Product audits at appropriate stages of production and delivery to verify conformance to all specified requirements contained in the control plan (Section 8). AND POST-DELIVERY PROCESSES Release of product is dependent on its compliance with all specifications and its ability to meet customer requirements including packaging. MONITORING ACTIVITIES The Production Manager. (Section 5) INTERNAL AUDIT The Company·s internal audit results are critical inputs to aid in assessing the effectiveness of our QEMS.5.1) The Quality Manager is responsible for planning and implementing in-process inspections needed to ensure process control and product quality. (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.( SOP 7. The purpose of these audits is to verify that the quality/environmental system conforms to product realization arrangements and to the requirements of ISO/TS16949. DELIVERY.

installation. Measurements of customer satisfaction include evaluation of Customer feedback such as complaints.3. We assign Incoming material part numbers. We tag or label. IDENTIFICATION AND TRACEABILITY The Program Manager has overall responsibility for establishing and maintaining product identification throughout all stages of design. customer performance ratings and delivered part quality. QC Receiving personnel are Page: 54 .1: CUSTOMER SATISFACTION ² SUPPLEMENTAL Customer Satisfaction is a critical measurement of the performance of the quality management system. incoming product received without part numbers in Receiving.2. SPC. production. See Management Review Process. (Section 6) MONITORING AND MEASUREMENT CUSTOMER SATISFACTION Customer satisfaction is the reason we exist. and revalidation Use of specific methods and procedures improvement when established per SOP 8.y y Requirements for records. The Company identifies the product by suitable means throughout product realization. control (stability) process capability.1 and the AIAG ´Statistical Process Controlµ (SPC) reference manual. and delivery in accord with procedures defined in SOP 7.5. or perform work will attend a Basic Statistics course containing an overview on basic concepts such as variation. 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. 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. We monitor the manufacturing process performance to demonstrate compliance with customer requirements for product quality and efficiency of the process. Where product traceability is a customer-specified requirement. including inspection and testing activities. warranty reviews.1. We must receive incoming material with labels indicating the assigned part numbers. returned goods. The Managing Page: 59 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. We analyze Customer satisfaction data and report it in management review meetings. This drives our quality policy ´to meet or exceed customer requirementsµ. (Section 7) KNOWLEDGE OF BASIC STATISTICAL CONCEPTS Employees using statistical tools to manage. verify. appropriate controls and records are established.

and maintains appropriate traceability records in accordance with customer requirements. process monitoring and measurement. storage. analysis. verifies. Where contractually required. and protection. handling. Statistical techniques for on-going process control and Page: 58 . packaging. The Quality Manager ensures that we record lost. and product monitoring and measurement. (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. A FIFO inventory system is used and regular tracking of inventory turns. by applying the same process controls as we do to purchase product. we report at the management meeting. (Section 7) CUSTOMER PROPERTY Customer property includes customer-owned material. as applicable. The Company identifies. test. We design designated storage areas to prevent damage. These activities include assessment of customer satisfaction.6 for calibration laboratories) MEASUREMENT. and improvement activities needed to assure product and Quality/Environmental Systems conformity and achieve continual Quality/Environmental Systems improvement. protects. tools (including returnable packaging). Page: 55 LABORATORY REQUIREMENTS ² INTERNAL LABORATORY The Company does not have an internal laboratory. and preservation of product pending use or delivery. measurement. plan. or unsuitable customer property and immediately reported to the customer.y y Revisions following engineering changes Statements of conformance to specification after calibration/verification responsible for verifying incoming material part numbers and date coding as detailed in the Receiving and Inspection Process. or calibration services are either acceptable to the customer or accredited to ISO 17025. (See SOP 7. ANALYSIS AND IMPROVEMENT GENERAL These sections describes how we define. EXTERNAL LABORATORY The Quality Manager ensures external laboratories used for inspection. conduct of internal audits. the Quality Manager plans for. and implement the monitoring. deterioration. and intellectual property. (Section 8) 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. tooling (including test/inspection tooling and equipment). IDENTIFICATION OF STATISTICAL TOOLS The Quality Manager ensures that statistical tools used to monitor Quality/Environmental Systems processes identified during quality planning and included control plans. establishes. and maintains customer property provided for use or incorporation into the product. damaged.

(Section 8) ADVANCED SHIPPING NOTIFICATION (ASN) The Company utilizes an ASN to facilitate the electronic transfer of data utilized by our customers to: y y y Determine and confirm goods in transit. frequency/method of checks. include: y Equipment identification. In addition. We identify and select monitoring and measuring devices and verify their capability of meeting such requirements prior to use. we periodically assess the condition of stock. e. All monitoring and measuring devices that can affect product quality we identify and calibrate at prescribed intervals against certified equipment having a known valid relationship to internationally or nationally known standards. including the measurement standard against which the equipment is calibrated Page: 57 CONTROL OF MONITORING AND MEASURING DEVICES We determine what measurements we need and the accuracy required assuring conformity of our product to specified requirements. measuring. Obsolete product is treated the same as nonconforming product and is appropriately identified and segregated to avoid using it for production. (Section 8) We maintain appropriate calibration records to document results of calibration activities and suitable indicators are used to show current calibration status. and maintenance of monitoring and measuring devices Page: 56 . including employee and customer owned equipment. STORAGE AND INVENTORY In order to detect deterioration. location. such as gage R & R studies. When we find monitoring and measuring devices out of calibration (or when we do not know the calibration status). which conform to the Measurement Systems Analysis manual.) is controlled as nonconforming product. actions taken are documented. control. Create an electronic invoice that will generate payment. (Section 4 & 7) MEASUREMENT SYSTEMS ANALYSIS The Quality Manager is responsible for selecting appropriate analytical methods and acceptance criteria. including their identification. and test equipment needed to provide evidence of product conformity to determined requirements. we adjust or re-adjust as necessary and the validity of previous measuring results and document. obsolete product (including expired age dated material. We used a number or other identifier to provide traceability to the device calibration record.g. CALIBRATION/VERIFICATION RECORDS Records of the calibration verification activity for all gauges. including appropriate corrective actions to remedy the situation and preclude its recurrence. uses/acceptance criteria and what actions to take when results are unsatisfactory. Further. 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. Verify and receive products into their system.Inventory turns and levels are goals defined within the business plan. The Company uses an automated inventory management system to optimize inventory turns over time and assure stock rotation on a ¶first-in-first-out· (FIFO) basis.

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