Aisin Europe SQAM 20170804 - Comments

Aisin Europe SQAM Page |1
Aisin Europe
Supplier Quality
Assurance
Manual
Revision: A Copyright © 2017 Aisin Europe 01/08/2017

All rights reserved.
I. I – INTRODUCTION AND GENERAL INFORMATION

This manual was developed to foster positive supplier relationships, continuous improvement, strengthen quality systems, and
at the same time eliminate redundant or vague requirements, thus reducing costs.
In the spirit of continuous improvement suppliers are encouraged to suggest how this manual and its implementation can be
improved.
Any suggestions should be directed to Aisin Europe OEM Quality dept.
.

II. Table of Contents

I. I – INTRODUCTION AND GENERAL INFORMATION..................................................................................................2
II. Table of Contents....................................................................................................................................................3
III. Revision Records.................................................................................................................................................7
IV. INTRODUCTION TO THE SUPPLIER QUALITY ASSURANCE MANUAL....................................................................8
Purpose.......................................................................................................................................................................8
Document Administration Responsibilities.................................................................................................................8
Contact information....................................................................................................................................................8
V. COMMUNICATION..................................................................................................................................................9
Purpose.......................................................................................................................................................................9
Supplier Responsibilities..............................................................................................................................................9
Mass production contact.........................................................................................................................................9
Pre-production contact...........................................................................................................................................9
VI. SAFETY, AND SECURITY REQUIREMENTS...........................................................................................................11
Purpose..................................................................................................................................................................... 11
Supplier Responsibilities............................................................................................................................................11
VII. ENVIRONMENTAL REQUIREMENTS...................................................................................................................12
Purpose..................................................................................................................................................................... 12
Supplier responsibilities............................................................................................................................................12
VIII. REQUEST FOR QUOTE (RFQ)..............................................................................................................................13
Purpose..................................................................................................................................................................... 13
Quote Process...........................................................................................................................................................13
IX. SUPPLIER DRAWING STUDY...............................................................................................................................14
Purpose..................................................................................................................................................................... 14
X. SUPPLIER SURVEY (GENERAL INFORMATION SHEET)............................................................................................15
Purpose..................................................................................................................................................................... 15
Responsibilities..........................................................................................................................................................15
XI. LETTER OF INTENT (LOI)....................................................................................................................................16
Purpose..................................................................................................................................................................... 16
Aisin Responsibilities.................................................................................................................................................16
XII. OVERVIEW OF MASS PRODUCTION PREPARATION ACTIVITIES (APQP).............................................................17
Purpose..................................................................................................................................................................... 17

Contact List............................................................................................................................................................17
Development Timing and ECI................................................................................................................................17
Tooling development............................................................................................................................................17
Development phases.............................................................................................................................................17
Supplier Part Tracking Team (SPTT).......................................................................................................................19
XIII. MASTER SCHEDULE...........................................................................................................................................22
Purpose..................................................................................................................................................................... 22
Quality Assurance Process (QAP)..........................................................................................................................22
General requirements...........................................................................................................................................23
XIV. SPECIAL CHARACTERISTICS / PROCESS CAPABILITY STUDIES (PPK/CPK)............................................................24
Purpose..................................................................................................................................................................... 24
Capability...............................................................................................................................................................24
Measurement System Analysis (MSA)...................................................................................................................25
Special Processes...................................................................................................................................................26
XV. PART INSPECTION STANDARD...........................................................................................................................27
Purpose..................................................................................................................................................................... 27
XVI. BOUNDARY SAMPLES........................................................................................................................................28
Purpose..................................................................................................................................................................... 28
XVII. CHECKING FIXTURES, GAGES AND TEST EQUIPMENT........................................................................................29
Purpose..................................................................................................................................................................... 29
XVIII. PROCESS FMEA..............................................................................................................................................30
Purpose..................................................................................................................................................................... 30
XIX. CONTROL PLAN/ MANUFACTURING QUALITY CHART (CP/MQC)......................................................................31
Purpose..................................................................................................................................................................... 31
XX. TRAINING AND QUALIFICATION OF TEAM MEMBERS.......................................................................................32
Purpose..................................................................................................................................................................... 32
XXI. SUBMISSION OF SAMPLE PARTS / EVALUATION OF RESULTS (TRIALS).............................................................33
Purpose..................................................................................................................................................................... 33

XXII. IDENTIFICATION AND TRACEABILITY.................................................................................................................34
Purpose..................................................................................................................................................................... 34
Identification.........................................................................................................................................................34
Traceability............................................................................................................................................................34
XXIII. MASS PRODUCTION TRIAL (MPT)..................................................................................................................35
Purpose..................................................................................................................................................................... 35
XXIV. PROVISIONAL APPROVAL FORM/ FINAL APPROVAL FORM (PAF/FAF)..........................................................36
Purpose..................................................................................................................................................................... 36
XXV. SOP, RAMP-UP, QCS & QRE...............................................................................................................................37
Purpose..................................................................................................................................................................... 37
XXVI. SUB-SUPPLIER QUALITY ASSURANCE.............................................................................................................38
Purpose..................................................................................................................................................................... 38
XXVII. CHANGE IMPLEMENTATION AND CONFIRMATION (ECI/PCR).......................................................................39
Purpose..................................................................................................................................................................... 39
Suppliers responsibilities...........................................................................................................................................39
XXVIII. DEVIATION REQUEST.....................................................................................................................................40
Purpose..................................................................................................................................................................... 40
XXIX. NONCONFORMING PARTS, COST OF QUALITY RESPONSIBILITY & CORRECTIVE ACTION (CAR)....................41
Purpose..................................................................................................................................................................... 41
Supplier Responsibilities:...........................................................................................................................................41
Initial response (containment actions)..................................................................................................................41
Problem resolution................................................................................................................................................41
Final response.......................................................................................................................................................41
Poor performances and recurrence......................................................................................................................42
Special focus Process (SPF)....................................................................................................................................42
Cost of poor quality...............................................................................................................................................43
Abnormal cost clarification....................................................................................................................................43
XXX. SUPPLIER QUALITY SYSTEMS AUDIT / PROCESS AUDIT.....................................................................................44
Purpose..................................................................................................................................................................... 44

Supplier Responsibility..............................................................................................................................................44
XXXI. PACKAGING, LABELING, PRESERVATION AND SHIPPING...............................................................................45
Purpose..................................................................................................................................................................... 45
Packaging..............................................................................................................................................................45
Labeling................................................................................................................................................................. 45
Preservation..........................................................................................................................................................45
Shipping.................................................................................................................................................................45
General conditions................................................................................................................................................45
Corrective actions (CAR)........................................................................................................................................46
XXXII. WARRANTY/FIELD QUALITY ASSURANCE & COST OF QUALITY RESPONSIBILITY...........................................47
Purpose..................................................................................................................................................................... 47
XXXIII. GLOSSARY......................................................................................................................................................48

III. Revision Records

(Table 1)
Revision Revision Date Comments
A 02/08/2017 First Issue (Draft)

IV. INTRODUCTION TO THE SUPPLIER QUALITY ASSURANCE MANUAL

Purpose
1. Communication of:
a. Expectations of Aisin Europe (AE) including: common goals and minimum requirements AD: message
is not clear
b. Required adherence to Quality Assurance (QA) procedures and documents to assure an effective
quality system that is based on continuous improvement, built-in quality, and quality problem
prevention
2. Develop and maintain overall plans to assure smooth, successful product start-ups and sustain those
successes into mass production leading to Aisin Europe and OEM customer satisfaction.
Document Administration Responsibilities

(Table 1)
AE Responsibilities Suppliers Responsibilities
 SQAM Revision  Maintain controlled copy of SQAM
 Revision Records  Identify uncontrolled copies
 Train appropriate personnel
 Understanding of SQAM requirements
 Understanding that SQAM updates are effective
immediately
 Determine record retention requirements in compliance
with Aisin Europe expectations
Contact information
Aisin Europe S.A.
OEM Division
Quality Assurance & Quality System Dept.
21, Avenue de l’industrie
1420 Braine l’Alleud
Belgium
Tel: 0032/ 2 387 01 10

V. COMMUNICATION
Purpose
To clarify Aisin expectations regarding communication and response with supplier.
To ensure effective communication between the supplier and Aisin Europe.
Supplier Responsibilities
Aisin wish to keep close relationship and communication with their suppliers. In all communication with Aisin, it is
recommended to:
 Identify to whom your e-mail is addressed
 Identify who should appear in copy of your e-mail
 Avoid to address your e-mail to inappropriate personnel (to avoid MUDA)
 Identify in few key words reason of your e-mail (Project code, specific document name, …)
 Keep same title in next e-mail exchange on same subjects
It is recommended to send all formal information by written form (preferably by e-mail).

Formal communication must never be exclusively verbal!
It is in supplier responsibility to highlight any kind of trouble as soon as possible to Aisin.
Pre-production contact
List of contact should cover all key persons in charge of project development, as by example:
- Executive Management responsible
- Project Leader
- Quality responsible
- Logistic responsible
- Engineering responsible
- Environmental responsible
- Manufacturing responsible
A single list to be provided per project, if more than one part is under development at the same supplier, and the
responsible of each part are different, this must be highlighted in the contact list.
Mass production contact

It is under supplier responsibility to send once per year quality supplier contact list and to reflect name and function
of all persons in charge of quality, for example:
- 24hours contact
- Quality engineer
- Quality Manager
- VP
- President
The usual communication between Aisin and supplier is by e-mail, in case of the urgent issue (as line claim issue),
Aisin can contact supplier quality responsible also by phone.

Aisin Europe SQAM P a g e | 10
Example of contact list:
Name Dept. Phone (0032) Cell (0032) e-mail
AE-B
Role & Responsibility Name Phone Cell-phone e-mail
Supplier
Contact List for project XXX

AISIN
Role & Responsibility Supplier
Japan side Europe side
Executive Management
Project Leader
Cost Sales
Purchase
Quality SPTT/PPAP
Administration
Logistics
Delivery Packaging
Plant PC for new parts

Delivery
Global PC
PC
Engineering Material
Product
Perfomance / Test
Manufacturing
PE
Environment
IMDS

VI. SAFETY, AND SECURITY REQUIREMENTS

Purpose
The purpose of these requirements is to assure the healthy and safe environment at Aisin facilities for:
- Aisin Europe members
- Aisin Europe Visitors
- EPCs members
- EPCs Visitors
- Suppliers and contractors
Suppliers and sub-contractors must conform to all safety requirements presented to them before entering into EPCs or
AE facilities:
1. Supplier personnel shall arrive at the Aisin Europe equipped with the appropriate safety equipment and
information and wear them appropriately.
2. Supplier and their sub-contractors must conform to all Aisin safety rules, procedures and guidelines, including
specific sign/pictograms in facilities.
3. To prevent accidents, injury or damages, suppliers are not allowed to tour Aisin facility unless accompanied
by Aisin personnel
4. In case of the emergency to Follow the evacuation route of team members in the area where the visitor is
working. After exit from the building, the visitor should check in with their host member, so that an accurate
head count can be taken to insure the safety of all Aisin employees and visitors.
5. It is prohibited to bring chemicals on-site, unless Suppliers have obtained prior written approval by the Aisin
Safety advisor and/or Product Environmental department.
a. A Material Safety Data Sheet (MSDS) must be provided to the Aisin safety advisor and/or Product
Environmental department prior to bringing the substance on-site.
6. Not smoke outside authorized areas.
7. Not come on Aisin under effects of drugs, alcohol, others legal/illegal psychotropic substances without
informing Aisin contact.
8. Suppliers and sub-contractors are not allowed to drive vehicle inside Aisin facilities without prior written
approval.
9. Suppliers are not allowed to touch part or equipment without approval from their host, moreover, jewelry
should be taped over or removed as this can cause damage to parts.
Any weakness, identified risks or suggestions related safety are welcome and could be addressed directly to your
accompanist.
Pictograms examples:

VII. ENVIRONMENTAL REQUIREMENTS

Purpose
The purpose is to clarify Aisin expectations related environmental aspects.
Supplier responsibilities
It is supplier responsibility to confirm its compliance to all legal requirements related product substances as REACH,
CLP, ELV, Conflict Minerals (CMRT) and others international, national, regional, legal regulations as well as customer
requirements (CR).
It is up to supplier to check regularly its compliance with current and incoming regulation and to take all necessary
actions to avoid loss to Aisin or to their final customers.
Aisin might launch specific survey for further or potential further incoming regulation in order to prevent non-
conformance or to evaluate risks.
Supplier must complete IMDS by their own or by a third party within 30 days after Aisin request, if this timing is not
possible, the supplier must inform Aisin immediately and explain why it is not possible to provide IMDS data on time.
It is under supplier responsibilities to update IMDS sheet as soon as necessary to reflect any ECI/PCR implemented in
their processes or sub-processes.

VIII. REQUEST FOR QUOTE (RFQ)

Purpose
The purpose of this section is to ensure the proper understanding of the request and submission of quotations for
new or modified business by Aisin suppliers.
Quote Process
Responsibilities
(Table 1)
Aisin Europe Supplier
Submit RFQ package including : Review the material provided and submit quote
1. Product drawing (cf Art. IX) response with the following:
2. 3D model if applicable 1. Fully completed quotation on form
requested by Aisin purchasing including
3. Aisin Europe or customer standards
quote decision
associated to the drawing
2. Tooling Quotation detail (or estimated)
4. SQAM 3. Identify and document ALL exceptions
5. Master schedule or milestones to the drawing or standards and
6. General Purchase Agreement (GPA) provide suggested solutions with the
7. Other pertinent information not listed quote
here 4. Clearly document any assumptions /
clarify any requirements prior to
submitting the quote including
requirements for:
a. Trial Part Shipment
b. Inspection
c. PPAP
d. Special characteristic control
e. Process Capability
f. Annual revalidation
g. contingent design changes
5. Ensure the quote provides relevant
lead-times, tooling, incoterms and cost
information.
Direct any/all questions to the Aisin Purchasing

agent requesting the quote
Return quote and all other requested
documents to the Aisin Purchasing agent.
Supplier must take all documentation requirements into account in their quotation, submission of a quotation
implies the agreement to all requirements listed in the documents listed in Art. VIII table 1.

IX. SUPPLIER DRAWING STUDY

Purpose
To find potential problems before tooling is started and processes are established.
Before quotation, supplier must review drawing and raise any concerns to Aisin.
The list of concern must be sent to Aisin before quotation or as soon as a trouble is found.
Key points to consider are:
- Dimensions
- Appearance
- Performance
- Weight
- Manufacture potential issue
- Workability issue during part assembly
- Safety concern
- Opportunities for cost reduction
- Items that could affect packaging
- Deviation from standards
- Trouble in timing (cf Master schedule/milestones)
o With production
o With tooling development
Discrepancy or potential troubles must be highlighted directly on drawing.
All considerations must be made using “worst case” tolerance or manufacturing conditions.
All standards provided by Aisin, in reference on drawing, or in reference in another standard must be taken into
account.

X. SUPPLIER SURVEY (GENERAL INFORMATION SHEET)

Purpose
The purpose of this section is to clarify the process to provide and update key information about current or potential
suppliers.
Responsibilities
Aisin Supplier
Provide supplier survey to the supplier with a Complete ALL tabs of the survey.
clear target date.

XI. LETTER OF INTENT (LOI)

Purpose
The purpose of this section is to ensure that the supplier understands the impact and responsibilities associated with
the reception and acceptance of a Letter of Intent (LOI).
Aisin Responsibilities
Aisin will provide General Purchase Agreement (GPA).
After receipt of the signed Purchase Agreement from supplier, Aisin will issue a controlled copy of the complete
Supplier Quality Assurance Manual (SQAM) and a Letter of Intent informing the supplier of the Aisin intent to source
the relative part from the supplier.
The General Purchase Agreement must be reviewed, signed, and returned to the Aisin purchasing dept. in order to
proceed in the sourcing process.
Unless otherwise instructed by purchasing or quality, the supplier shall submit the PPAP package in accordance with
the submission plan of this manual.
Aisin will stipulate the PPAP submission level and PPAP due date in the Project Master Schedule (PMS) or other
document detailing milestones (including emails). If no PPAP stipulation is made, the supplier shall assume a level III
PPAP (as described by the AIAG PPAP Manual) is required.
PPAP level might be changed during project development by decision of Aisin.
In certain circumstances, depending of final customer, PPAP could be replaced by customer equivalent system (as
Toyota SPPM, German VDA, etc.).

XII. OVERVIEW OF MASS PRODUCTION PREPARATION ACTIVITIES

(APQP)
Purpose
The purpose of this section is to provide an overview of the sequence of events during pre-production used to assure
the required quality of the parts and components for mass production.
Contact List
Before any activities, it is up to supplier to provide a list with clear description of person in charge of project
development and activities.
Development Timing and ECI

All suppliers are strongly encouraged to utilize a multidisciplinary team during mass production preparation
incorporating members of all affected functions such as engineering, production control, customer service, quality,
logistic and manufacturing.
Key milestones and event timing for the project will be communicated by Aisin and the supplier should use this
schedule for developing their activities and schedules from project inception to mass production start.
Pre-Production planning dept. will communicate detailed timing as well as any special or additional requirements
that may be required for part approval and launch.
The following process map outlines the phases and documentation requirements expected during mass production
preparation and/or a major engineering change.
The following diagram provides an overview of project timing. Specific timing will be provided by Aisin Pre-
Production planning team. This table (Art. XII Table 1) is an example and will be adapted to final customer
requirements.
Tooling development
The progress of tooling development should be properly documented and controlled throughout the project.
Sub-supplier activities should be controlled by each supplier in a similar manner to that detailed in the SQAM.
Development phases
Prototypes: 1st phase of project
Off-Tool (OT): Parts are produced on mass production tools
Off-Process (OP): Parts are produced in same conditions as Mass Production (with trained operators, on mass
production tools, with mass production machines at mass production location) at lower rate
Mass Production Trial (MPT): Same as Off-Process with minimum 1 hour of mass production at Run & Rate
Quality Resident Engineering (QRE): Aisin and supplier keep necessary resources ready for fast reaction and potential
intervention at final customer plant if necessary

Legend
Last update : 2015 2016 2017
Action/decision timing
p Plan not respected
PRE PRODUCTION PLANNING X Duration
(Table 1)
i
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
April
May
June
July
August
September
October
November
December
January
February
March
EPC/ Pass
Customer Program Project Line Off/ SOP
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W35
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
W50
W51
W52
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W35
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
W50
W51
W52
W1
W2
W3
W4
W5
W6
W7
W8
W9
W10
W11
W12
through W13
Company DPT PIC
OT
OP
L/O
+90
Customer EVENT schedule CV CF1 CV1.5 CF2 0A CF3 1A CF4 MPTA CF5
SPTT1 Period i i i i i i i i i
Revision: A
SPTT1 Document preparation i i
SPTT1 Hold the meeting p
SPTT1 Share final document with Toyota p p
SPTT2 Period i i i i i i i i i i i i i i i i i i i i i i i i i
SPTT2 Document preparation i i i i i i
SPTT SPTT2 Hold the meeting p p
SPTT2 Share final document with Toyota p
SPTT3 Period i i i i i i i i i i i i i
SPTT3 Document preparation i i i i i i
SPTT3 Hold the meeting p
SPTT3 Share final document with Toyota p
Gate 1 (RFQ - Requirements Review & Planning) - meeting AEB SALES/SA/PUR/QA Project leader p
Gate 1 - LOP review AEB SALES/SA/PUR/QA Project leader p
Gate 2 (Product and Process - Design Completion) - meeting AEB SALES/SA/PUR/QA Project leader p
Gate Gate 3 (Pre-Production/Production Prep) - meeting AEB SALES/SA/PUR/QA Project leader p
Review Gate 3 - LOP review AEB SALES/SA/PUR/QA Project leader p
Gate 4 (Mass Production Confirmation - OFF PROCESS) - meeting AEB SALES/SA/PUR/QA Project leader p
Gate 5 (LAUNCH Mass Production) - meeting AEB SALES/SA/PUR/QA Project leader p
Engineering level fixed
Customer to advise order requirements p
Place all orders to suppliers p
Part production Crush Bracket i i i i i
CV-W Crush Bracket shipment from supplier i
QA check p
Shipment preparation p
Delivery AI
Delivery TMC p
Engineering level fixed p
Part production Crush Bracket i i i i i
CV1.5-W Crush Bracket shipment from supplier i
QA check p
Delivery MSE
Delivery TMC p
Part production Crush Bracket i i i i
0W Crush Bracket shipment from supplier i
QA check p
Shipment preparation

p
Delivery TMMT p
Copyright © 2017 Aisin Europe

1W Crush Bracket shipment from supplier i
Aisin Europe
QA check p
Delivery TMMT p
MPTW Crush Bracket shipment from supplier i
QA check p
Delivery TMMT
SQAM
p
Customer to advise 12 weeks forecast p
SOP Crush Bracket shipment from supplier i
QA check p
Delivery TMMT p
01/08/2017
P a g e | 18
Supplier Part Tracking Team (SPTT)

The SPTT is a method for Aisin (or the customer) to audit project status during development.
The SPTT audits are conducted at predetermined intervals within the product launch process to provide information
as to the supplier’s readiness at any point in the launch process. This process is established to ensure mutual
communication and readiness.
During a normal project development, Aisin will conduct 3 SPTT activities.
In certain conditions, additional SPTT activities might be conducted, suppliers will be notified if they are selected for
additional SPTT. Suppliers that are new, have new processes, or special processes are generally more likely to be
selected for additional SPTT activities.
The supplier should be aware that Aisin and/or Aisin Seiki executive management may request SPTT reviews at any
point in the process.
The audit sheets are used to assess the level of completion at each stage within the process. All items must be
confirmed to ensure that the supplier has all necessary information to properly provide the product requested.

Items SPTT1 (OT) SPTT2 (OP) SPTT3 (MPT)

Achievements Documents Achievements Documents Achievements Documents
Timing 100% Process OT; Agenda 100% Process OP Agenda 100% OT/OP Agenda
OT PAD Master OP PAD Master Process MPT Master
Visit assigned schedule Witness OT production schedule MPT PAD Schedule
location and plant PPP PPP Witness 1hour production at PPP
TPR TPR Run & rate TPR
Capacity PCS available; PCS PCS available & PCS Achieve capacity + 10% in a PCS
Volume correct; TT updated TT sustainable way
Spare capacity 10% Calculation Volume correct Calculation
Spare capacity 10%
Cycle time show
achievable figure
Supplier 100% Documentation 100% Documentation All docs 100% Documentation available All docs
preparation available; available & printed & printed
100% attendance Printed version Printed version available
available 100% attendance
100% attendance
Risk Map Risk controlled Risk Map Risk controlled Risk Map Risk controlled
ECI Change point 100% ECI implementation on PSS Target ECI implemented
controlled; time with schedule
Consideration to
potential risks
PIS (Art XV) PIS draft available; PIS Draft PIS approved in final PIS Final Approved & reflect latest ECI Risk Map
SDS 100% critical items SDS blank version, reflect latest SDS Final level
controlled Draft ECI level 100% accuracy
95% part accuracy 100% part accuracy CP/CPK value available
MQC (Art XIX) MQC Draft level MQC Draft MQC approved MQC Final Fully approved PSS
available; No revision required
100% critical items Comparison to actual process
controlled
CF (Art XVII) 100% critical items CF concept CF in place CF final C/F approved and in compliance
controlled User trained approval with PIS requirements
WI & Calibration sheet form WI in place
ready CF WI Users trained
CF Calibration
sheets
PESS Timing clear PESS 100% confirmed with PESS 100% confirmed PESS
Prototypes results QA & Design
completed Evaluation on time with
scheduled targets
PFMEA (Art XVIII) Available at supplier PFMEA Available & updated PFMEA Available for new PFMEA
location with all identified product/processes reflects
Reflect all C/M concerns learning with C/M for new
related weakness Each items status clear processes
discovered
CPRF 100% Critical Process CPRF
identified
Drawing & Design No concern with Drawing No design concern No design concern
review (Art IX) drawing study Latest ECI level drawing Latest ECI level implemented
No concern with available
design review
No revision required
Tooling available
PPAP All specifications All specification All specification identified
identified identified Capability confirmed
Production Packaging proposal Packaging Generic Packaging GPS GPS applied at 1A GPS
Control proposal specification approved TPS Validation completed TPS
Temporarily Packaging TPS approved
specification approved Logistic way and communication
Parts order confirmed
communication clearly Exact quantity of returnable
identified packaging is determined and
available
Problem follow- Problem follow-up PFUS All actions listed in PFUS Evidences showing complete PFUS
ups blank, ready to use PFUS from SPTT1 cross check QPR
completed Suitable C/M implemented
100% QPR answered
Color/Grain (if N/A GDS Grained/colored part fully GDS

applicable) approved
Boundary Sample N/A Defect Final boundary sample available
(Art XVI) catalog in min 3 set
Safety (Art VI) General safety All operators & equipment
sufficient to prevent following safety requirements
risks
Standardized N/A Graining/color Work instructions available at Training
work (Art XX) approved workstation records
Graining/color All operators trained
schedule available Training plan/matrix available
Graining/color
requirements reflected
in PIS/SDS
Scrap/Rework 100% Boundary sample Procedure available WI
requirements identified No risk to mix with ok parts
Temporarily boundary
sample approved
Poka Yoke General safety All poka-Yoke in place and
sufficient to prevent detecting negative parts
risks
Environment (Art All materials are validated IMDS
VII) IMDS provided

XIII. MASTER SCHEDULE

Purpose
To provide the best possible opportunity for good quality during mass production it is essential to prepare properly
during the prototype and pre-production phases. The key tool used to monitor pilot production and pre-production
preparation is the Supplied Parts Master Schedule.
Supplier Parts Master Schedule (SPMS)
The Supplied Parts Master Schedule (SPMS) is a comprehensive project schedule that must be completed by the
supplier for all new components and major engineering changes. The supplier is responsible for completing the
timeline for all relevant items listed and communicating them back to Aisin.
The SPMS consists of three main components:

- Master schedule
- Production preparation plan (PPP)
The PPP contains all the different steps of project preparation (as facilities, sub-supplier preparation, preparation of
standards and gages, Part evaluation, Packaging a transportation, training, etc)
- Tooling Progress Report (TPR)
The Tooling Progress Report contains tooling implementation plan, including dies, jigs, checking fixtures, machines,
equipment and trials.
Once target started and completion dates have been identified, they must not be changed or modified. Any slip or
pull-ahead in the schedule is documented in the actual start and completion columns.
After completion of the SPMS, it should be returned to Aisin and reviewed on a regular basis to ensure proper
project completion.
The supplier should develop an acceptance plan that evaluates Safety, Environmental Impact, Quality, Cycle Time
(compared to Takt Time), and Production Rate. Quality acceptance methods must comply with all items identified in
this manual, as well as any additional criteria communicated by Aisin Purchase and/or Quality dept.
Quality Assurance Process (QAP)

The supplier shall ensure part quality and production process sustainability, [including Material, Dimension,
performance, appearance, and function] and plan necessary actions as (non-exhaustive list):
- Include timing for parts to be delivered; called Part Availability Date (PAD)
- Meet trial requirements related ECI
- Adapt their stock to minimize loss related
o Shutdown period
o ECI
o Build out/start-up
- Hiring and training of qualified personnel
- Provide part/component at appropriate timing
- Provide part measurement on time
- Maintain
o Equipment
o Jigs

o Checking fixtures
o Tooling (in general)
This development method (QAP) is requested for each part supplied separately. It is up to supplier to develop/use
his own format in line with above requirements.
QAP Format developed shall reflect “target vs actual” reviews of process, tooling, countermeasures activities, etc.
General requirements
QAP must be approved by all related dept. within the supplier. Supplier Top Management is responsible for
monitoring this plan to achieve milestones and provide necessary resources as scheduled.
The supplier must submit QAP & SPMS on a monthly base to Aisin Quality and/or Purchase and/or pre-production
planning dept.

XIV. SPECIAL CHARACTERISTICS / PROCESS CAPABILITY STUDIES

(PPK/CPK)
Purpose
Special characteristics are part characteristics that significantly affect performance, form, fit, function or
manufacturability.
Because of their significance in impacting the quality of the assemblies being manufactured by Aisin, those
characteristics designated as “Special Characteristics” require statistical control methods to be applied for quality
assurance. Suppliers should reference the AIAG publication entitled “Statistical Process Control” for correct SPC
techniques and methods.
Capability
Capability study is required for SPTT3 activities on measures agreed on PIS.
Capability studies may be required for any of the following activities:

1. New model or part release
2. Engineering change preparation and implementation
3. PPAP submissions
4. Annual Part Validations
5. Corrective Action Requests (CAR)
6. On-going SPC data collection.
Capability requirements may be added or removed over the course of a part life cycle as required by design criteria,
process capability results, or customer expectations.
Capability data must be recorded, unit used must be same as shown on the drawing.
A histogram representation of the data, although not required, is welcomed for easier review. Alternate forms are
accepted where statistical software packages are used that generate reports or datasheets. It is the supplier’s
responsibility to assure that the process has a normal distribution prior to calculation of capability.
The Aisin Quality group will inform suppliers which dimensions will require capability monitoring and control. As a
general note, all special characteristics, which are noted on Aisin drawings by diamond and inverted delta symbols,
will require capability monitoring and control.
At the discretion of Aisin and without having to provide any reason, SPC may be requested to any other measure on
drawing.

Characteristic Type Short Term (PPK) Long Term (CPK)

Number of Subgroups 30 Minimum 50 Minimum 1
Subgroup Size N/A 3-5
- Individuals per subgroup
Process Condition In Statistical Control In Statistical Control
Capability ≥ 2.00 ≥ 1.67
- Special Characteristics, Safety,
Regulatory
Capability ≥ 1.67 ≥ 1.33
- Other Characteristics
When the performance of a process is unknown, base information must be gathered. Short term capability studies
(PPK) measure the current performance of a process; not long-term capability. In order to acquire the necessary base
information, the following method should be applied:
1. Take a series of at least 30 samples from the process. As part of these samples, all cavities within a mold or
tool MUST be represented within the study and, where applicable, all significant cores (spare slides) must
also be included. Complete spare or additional tooling must be conducted independently.
2. Keep detailed records on process conditions, noting any changes in operators, machines, or materials.
3. Compute sample control limits from the data collected.
4. Plot the data on a control chart with the sample limits to determine if any samples fall outside of the control
limits.
If none of the points fall outside of the limits, the process is considered to be “In Statistical Control”. If points fall
outside of the limits, the process is considered to be “Not in Statistical Control”. This means assignable cause
variation is present that will require correction prior to calculating P PK. The use of control charts does not indicate
CPK; but, rather a determination of the state of the process performance.
For additional information and guidance on statistical methods, reference the AIAG publications “Statistical Process
Control – SPC” and “Measurement Systems Analysis – MSA”.
If process is not in statistical control: Contact Aisin QA dept. immediately to identify a countermeasure plan
If process is in statistical control: Take necessary actions to maintain continuous improvement activities
Measurement System Analysis (MSA)

Gage Repeatability and Reproducibility (GR&R) requirements are as follows:
 GR&R’s must be completed with each PPAP level, but provided with all Level 3, 4 and 5 PPAP submissions for
each special characteristic at a minimum, but, typically, all measurement systems called out in the control
plan. For PPAP levels 1 and 2, the GR&R’s must be retained for review as necessary.
 Each inspection instrument used to measure special characteristics must have an acceptable GR&R value.
(Note: Instruments that perform destructive analysis on parts do not require a GR&R study.)
 If one instrument, using the same measurement range (not tolerance), is used to measure multiple special
characteristics, then only one GR&R study is required.
 All calibration records and GR&R studies must conform to ISO9001, and IATF16949 requirements.
Annual revalidation of Gages (using GR&R methods described) must be available on demand for review by the Aisin
Quality department for all Special, Regulatory, and Safety characteristics.

Additional MSA techniques and methods (e.g., linearity) should be utilized as directed by Aisin Quality department
personnel.
Note: Gage resolution accuracy must be 10% (1/10) of the dimensional specification for which the gage will be used.
Special Processes
A special process is a process that produces product that cannot easily be sorted or inspected or must use a
destructive test method to confirm quality. The process parameters, therefore, become extremely important to
prevent defects from being made and shipped. Therefore, the supplier must ensure that the necessary controls are
implemented to maintain control of the process parameters. Aisin will conduct special process audits at supplier
facilities who provide product from special processes. Aisin may also request suppliers to be trained and qualified to
perform their own special process audits.
Examples of special processes include: spot welding, projection welding, arc welding, laser welding, resin welding,
heat treatment (all kinds), die quenching, and certain coating processes such as plating and e-coating.
There are special process audit check sheets developed for each type of special process. These check sheets could be
Aisin developed, customer developed or industry developed (AIAG). Suppliers of these special processes must meet
the requirements of the audits as shown on the check sheets.

XV. PART INSPECTION STANDARD

Purpose
A document consisting of part critical characteristics, their acceptance criteria, the method, tool and frequency by
which the part must be monitored and controlled by the supplier.
The supplier must develop a draft Inspection Standard to be submitted to the Aisin Quality Department for review
and/or approval. The supplier may be requested to modify the Inspection Standard draft.
Specific quality requirements and/or to fabrication of checking fixtures may be included. An Inspection Standard
must be supplied for each part number.
The Part Inspection Standard (PIS) cannot conflict with the drawing specification, but is intended to clarify and
enhance quality assurance related requirements.
The part inspection standard, at a minimum, must define the following items:
1. Datum Structure
2. Dimension and Tolerance
3. Performance
4. Weight
5. Material
6. Appearance
7. Function
8. Color
9. Special Inspection Items
10. Special characteristics
11. Identification Method
The supplier must meet the drawing tolerance. The tolerance must be considered in process design. All items listed
on the drawing with a tolerance MUST be included in the inspection standard.
If a specific standard is mentioned on drawing, it must appear on PIS.
The Inspection Standard must consider and include inspection related criteria as indicated on the Control Plan,
PFMEA, etc., and the identified frequency of inspection must be developed from process capability studies and
results. Typical inspection frequencies for dimensional items that are NOT special characteristics are at least first and
last piece of each run or each shift whichever is shorter in duration
The approved Inspection Standard criteria, subject to revision, must be consistently complied with for the life of the
part without exception.
Final PIS version, on latest ECI level, must be provided at SPTT2 Meeting.
The supplier must initiate revisions for all Engineering Change Instructions (ECI). The change details must be clearly
identified on the Inspection Standard Revision form
Where service parts are required, service parts inspection standards must be created in accordance with this section.


XVI. BOUNDARY SAMPLES

Purpose
Boundary samples are used as a supplement to the part inspection standard (e.g. visual or sensory) when the
characteristics are difficult to define or communicate by any other method.
Boundary samples must be prepared and submitted for approval for all items noted on the Inspection Standard.
Preliminary boundary samples should be discussed prior to tooling and process development to determine quality
expectations and process capability. Clear quality expectations and characteristics should be agreed upon with the
objective being no boundary samples required.
Boundary samples may also be created to define problems discovered in both production preparation and mass
production stages. When submitting boundary samples for this purpose, the supplier must be prepared to discuss
process capability and previously tried countermeasures.
Boundary sample approval is based on internal Aisin quality standards, OEM customer acceptance impact, part
design characteristics, and supplier process capability.
A minimum of three equivalent sets of boundary samples must be prepared and must be send to the Aisin Quality
Dept. for review.
After approval with customer, one set [called Master Boundary Sample] will be returned to supplier. (1 for customer
[best], 1 for Aisin [middle], 1 for supplier [worst]).
An additional set might be required if use of a working set is relevant.
The Supplier must provide sufficient lead time for the boundary samples to be evaluated, PPAP approval will not be
granted until all boundary samples have been approved by Aisin and final customer.
The supplier must maintain the master boundary samples in a location where it is not susceptible to damage, aging,
etc.
If boundary sample result in excessive process scrap, rework or sorting, final customer complaints due to process
capability, then the Master Boundary Sample may be renegotiated.
The supplier may request approval of a temporary boundary sample that deviates from the approved boundary
sample for a specific lot or time period. Temporary boundary sample requests are intended to be utilized for
extraordinary circumstances where all other considerations have been exhausted.
Temporary boundary sample requests must be submitted along with a Deviation Request Form.

XVII. CHECKING FIXTURES, GAGES AND TEST EQUIPMENT

Purpose
Devices used to evaluate production parts for compliance to drawings, inspection standard, process control
requirements or other quality standards.
As it is the supplier’s responsibility to demonstrate that their products meet all drawing requirements, the supplier
must provide a mean to verify quality characteristics specified on the drawing and part Inspection Standard.
The supplier must develop, utilize, and maintain the required inspection related tools such as checking fixtures,
gages, or other inspection/test equipment that Aisin may specify.
The supplier shall prepare the necessary checking fixture, gage and test equipment detail, and MUST obtain Aisin
Quality approval of the design concept before detailed design begins. The gage, checking fixture or test equipment
drawing must specify the build tolerance and clearly indicate part features that will be checked.
The completion date and price quote (if applicable) must be indicated on the Checking Fixture, Gage, and Test
Equipment Approval Request form. Ensured quality is a requirement of Aisin, but part specific gauges, fixtures or test
equipment may not be required to achieve this goal. Any cost expected to be reimbursed for part specific gauges,
fixtures, or test equipment must be detailed out in the original sourcing quote and approved prior to product
sourcing.
Equipment must conform to MSA requirements. Checking fixtures, gages and test equipment are to be completed,
qualified, and available to evaluate no later than first off-tool sample parts. Any deviations from the approved plans
and schedules must be communicated to Aisin.
In the event of supplier is allowed to develop equipment fabricator, supplier must ensure all SQAM requirements are
achieved.
Checking fixtures, gages, and inspection/test equipment must meet recognized automotive industry standards for
accuracy (reference MSA Manual available from AIAG). The word accurate in this context refers to the relative
degree of errors associated with bias, repeatability, reproducibility, stability, and linearity. The device should include
documentation to the appropriate national/international standard.
Any dedicated checking fixtures, gages, or test equipment must be permanently identified with a unique gage
number and owner should be easily identified.
Calibration and gage records should also indicate ECI level, part number, certification date, and re-certification due
date.
The supplier is responsible for maintenance and calibration of checking fixtures, gages non-destructive
inspection/test equipment, including recertification on a planned basis and GR&R studies for Special Characteristic
items. Certification must be traceable to a national or international certifying body.

XVIII. PROCESS FMEA

Purpose
A Process Failure Mode and Effects Analysis (PFMEA) must be developed for all parts. Proper development of a
PFMEA is essential to planning and producing quality parts and components. This quality document should be
developed prior to all other documentation and planning tools such as the Process Control Plan or Inspection
Standards.
The primary function of an FMEA is to understand the potential failures associated with a particular product or
process, and to develop means to reduce, if not completely eliminate, the failure from occurring. Should processes
be considered “proprietary”, the PFMEA may be retained at the supplier location if agreed upon by the Aisin Quality
Engineer or Project development Responsible.
NOTE: The entire production process must be reflected in PFMEA, including support activities such as Material
Handling, Receiving Inspection, Packaging, Rework/Repair, Final Inspection, Shipping, and Labeling.
FMEA may be requested and must be provided at least partially to highlight improvement following repetitive
system failures.
A multi-disciplinary team (Manufacturing, Quality, Engineering, Assembly, etc) must be developed to assure
maximum input into PFMEA.
Severity, Occurrence, and Detection values must conform to AIAG guidelines. This ensures that the most reasonable approach
was used in determining RPN values. RPN values are used to identify areas where improvement is necessary. The supplier must
determine a threshold value at which RPN values should be addressed, however, the highest RPN values should be addressed
with the proper recommended action, regardless of the RPN value. This is done to reassure that continuous improvement is
taking place by the supplier. If supplier didn’t develop his own threshold, AIAG FMEA Manual (latest edition) are applicable.
Corrective Action (CAR) or Quality Problem report (QPR) should include a reinvestigation of the FMEA, and an update to the
relevant potential failure modes.
FMEA’s for common components (i,e, part families) may be used if and only if the FMEA is traceable to the correct part number,
part name, and ECI level.
It may be necessary for additional quality analysis tools to be used to completely explain or understand the manufacturing
process. These tools should be used whenever necessary by the supplier and may also be requested by Aisin.

XIX. CONTROL PLAN/ MANUFACTURING QUALITY CHART (CP/MQC)

Purpose
The Control Plan or MQC are documents that defines all controls used for the prototype, pre-launch, and production
process.
Control plan is a living document and needs to be updated accordingly and resubmitted to Aisin.
Supplier is responsible for any processes that are outsourced to a sub-supplier and should be able to provide sub-
contractor MQC or control plan on demand.
The control plan must identify the correct Aisin part number, name, and ECI level, and must follow the process path
as described in the flow diagram. In certain circumstances, it is allowed to use final customer part number, name,
and ECI level.
The control plan must reflect the entire manufacturing process, including receiving inspection, packaging/shipping
and provide enough detail so that an individual not familiar with the process can understand the control methods in
place.
Aisin’s special characteristics, such as dimensions that affect form, fit, and function, and appearance items, must be
distinguished on the control plan. Also, supplier deemed special characteristics must be noted. In addition,
verification of any mistake proofing devices, especially POKA YOKE NG masters, should be addressed.

XX. TRAINING AND QUALIFICATION OF TEAM MEMBERS

Purpose
The purpose of this section is to specify the minimum supplier requirements in regards to training and qualification
of team members.
The supplier should effectively manage a comprehensive training program for all employees. Department training
needs shall be identified through a multi-disciplinary approach. Aisin requires all employees, including temporary or
contract workers, to be trained and that training be adequately documented.
Individual needs shall be identified through an evaluation process that includes references to retained employee
training records. An individual or a department should be designated to administer the training program.
The supplier is expected to continuously develop its employees’ capabilities, competences and knowledge through
various activities including on-the-job training (OJT), collective education, external trainings, etc.
The supplier should develop a method for documenting team members’ progress and capability.
All training necessary to meet Aisin objectives must be completed by Off Tool/Off Process part completion.
(SPTT2/SPTT3)

XXI. SUBMISSION OF SAMPLE PARTS / EVALUATION OF RESULTS

(TRIALS)
Purpose
To define the requirements for submission of sample parts and evaluation results.
The supplier must provide sample parts in accordance with the timing indicated on the Prototype Schedule, at a
minimum. Any change from the approved schedule and plan must be communicated to and approved by Aisin.
A Sample Data Sheet (SDS) must be made for each part number.
Judgment must be clearly reflected using the following format:

Symbol Color Status
(optional)
O Green Meets requirement (Measures are within tolerances)
 Yellow Meets requirement, but needs improvement
(all parts meet the tolerances, but are clustered near upper or lower specification limits)
X Red Does not meet requirement
(Even if 1 part is out of tolerance, all the line is a X)
An explanation and countermeasure plan must be provided for all " ", “X”. This can be accomplished through the
use of the Problem Follow-Up Sheet (PFUS).
The submitted samples, which were evaluated for dimensional characteristics on the drawing or inspection standard,
must be identified with sequential numbers (1, 2, 3, etc.) which correspond to the columns on the SDS.
Any changes or deviation from the stated part submission level part conditions must be communicated as early as is
known to Aisin.
Supplier must include an explanation of any significant change or deviation from the mass production level part
when submitting SDS.
A copy of SDS must be included in the sample parts container. A copy should be provided before shipment to Aisin
Quality dept.

XXII. IDENTIFICATION AND TRACEABILITY

Purpose
The purpose of this section is to define the requirements for part identification and traceability.
Identification
The supplier must develop an identification system that begins during production preparation prior to the 1st draft
of the part Inspection Standard.
The supplier must adhere to all identification requirements specified on the part drawing, inspection standard or
applicable regulation.
If no specification exists, the supplier should determine the appropriate level of identification based on past
experience and industry standards.
The supplier must clearly document the details of the identification method on the original draft of the approval Part
Inspection Standard before submitting to Aisin for approval. In the case of Aisin issued Part Inspection Standards,
when the identification mark is not specified on the drawing, then negotiation with Aisin Quality personnel prior to
Part Inspection Standard issuance is required.
Traceability
The supplier must develop a traceability system that begins from mass production through the life of the part.
If no specification exists, the supplier should determine the appropriate level of traceability based on past experience and
industry standards
Traceability must be considered based on the following two criteria:

 Process and machine control parameters This includes operation control parameters, maintenance, and
calibration, repair records, manpower changes and other data that documents machine or process control
criteria.
 Material and product flow, this includes material certification and date of receiving, date of manufacturing,
specific production equipment number, inspection date, and other data that records the flow through the
process.

XXIII. MASS PRODUCTION TRIAL (MPT)

Purpose
This is a sampling of the supplier’s overall readiness to meet the production expectations of Aisin Operations in
terms of quality, capacity, and delivery.
Aisin require to complete a mass production trial prior to launch of mass production on any new project.
Aisin will most probably want to witness this MPT during SPTT3 (~1hour at run&rate).
MPT may lead to document modification such as PFMEA, DFMEA, Control Plan, etc
Suppliers are expected to take all necessary steps to achieve all requirements of a successful MPT.
This should include internal run@rate trials, internal audits, and process reviews. The supplier MUST take all actions necessary
to ensure that they are prepared to perform a successful MPT during the Aisin team visit.
If a supplier does not successfully pass the MPT during Aisin visit, the supplier may be charged costs associated with
any follow-up visits to achieve successful MPT.

XXIV. PROVISIONAL APPROVAL FORM/ FINAL APPROVAL FORM

(PAF/FAF)
Purpose
In general, PPAP defines the core requirements of the automotive industry for new component / material approval. The purpose
of PPAP is to ensure that all engineering specifications are properly understood by the supplier, and that the process has the
capability to produce products to those standards at an agreed upon rate. PPAP applies to internal and external sites of bulk
materials, production materials, and to production and service parts.
PAF/FAF are the contractual agreement with suppliers. It is considered a direct reflection of the supplier in terms of
preparedness, attention to detail, and quality.
PAF/FAF confirms correct completion of PPAP. All information should be provided in English, unless otherwise
agreed upon. All AIAG approved forms will be accepted and are recommended for use.
A PAF is proposed after PPAP approval and before SOP, when all documents were provided and conform to
requirements.
After QRE period, if no troubles were highlighted during ramp-up and 3 first months of SOP, a Final Approval Form
will be submitted by supplier to conclude project development and confirm handover from project development
team to mass-production team.
If not reflected in other document, approval of the PAF leads us to the payment of 25% of tooling implemented and
owned by Aisin or by final customer and approval of FAF leads us to payment of remaining of tooling implemented
and owned by Aisin or by Final customer.
It is not mandatory to re-submit FAF after each ECI, however, ECI must be informed to Aisin as mentioned in Chapter
ECI.
For Aisin, supplier is responsible of part produced by them at any time and part submission warrant (PSW) is not
necessary unless specifically requested by final customer.

XXV. SOP, RAMP-UP, QCS & QRE

Purpose
This section outlines the responsibility of the supplier to guarantee quality during ramp-up to mass production and during the 3
first months after SOP. (This period might be increased in case of actual trouble found during mass production).
During the initial mass production ramp-up the supplier must take special precautions that the quality and process standards
developed during preparation are adhered to. If necessary, supplier will allocate additional resources in order to ensure correct
application of training, correct understanding of mass production processes and if applicable, additional sorting activities.
Swift reaction is expected from supplier within the 90 first days of production. During this period, supplier will be ready to send a
team, or the most appropriate employee, or to provide any other specific resources at final customer plant in order to support
quality activities. If applicable, more frequent quality review with all level of the supplier organization could be proposed by Aisin
or by final customer.
It is expected from supplier to establish a system for identifying and resolving issues in a quick and accurate manner.
If during the ramp-up period, the supplier cannot make the full scheduled shipment to the Aisin facility due to
quality problems, both the Aisin Production Control and Aisin Quality departments must be notified immediately.
Aisin Quality department reserves the right to visit the supplier or request detailed information about the activities being taken
during the ramp-up period.

XXVI. SUB-SUPPLIER QUALITY ASSURANCE

Purpose
To clarify the requirement that Suppliers must ensure the quality of product from Sub-Suppliers.
The Supplier must assure the quality of the parts and/or materials which are supplied by its Suppliers or external
sub-contractors. There shall be an established method of ensuring this quality.
The Supplier must establish with each Sub-Supplier, an understanding that Aisin Quality personnel may audit the
Sub-Supplier’s process and may be accompanied by OEM Quality representatives.
Sub-Supplier process changes must be communicated and approved by Aisin and by final customer prior application.
The required information is the same as that required of a Supplier Process Change or an Engineering change.
(PCR/ECI) [Art. XXVII]

XXVII. CHANGE IMPLEMENTATION AND CONFIRMATION (ECI/PCR)

Purpose
There are 2 primary methods of implementing change to products and/or processes: Engineering Change (ECI) and
Process Change (PCR).
The Supplier must complete Process/Engineering change requests to Purchase dept. prior any implementation.
ECI might be Minor or Major:
 Minor ECI : ECI not requiring a part Nr change
 Major ECI : ECI resulting in a part Nr change
Suppliers responsibilities
Each drawing is identified with its own ECI Nr. It is the supplier’s responsibility to make certain they are producing
parts to the current ECI.
The Supplier is expected to follow the agreed upon schedule and communicate any Quality, Production, Packaging,
or Delivery concerns to the Aisin Appropriate department. (In case of doubt, please address to Purchasing Dept.)
Once an ECI/PCR is approved, initial shipment must be identified using colored (Yellow for ECI/PCR) stickers and
pallet labels. Aisin may request additional part identification.
Prior the First shipment, Aisin delivery location will be informed by the supplier, information must include:
- First delivery etd
- Quantity of parts before ECI/PCR implementation
- Quantity of parts after ECI/PCR implementation
- One pictures of specific identification label
On first shipment, all boxes of parts produced after ECI/PCR implementation must be identified with yellow stickers.
Any boxes not identified will be considered as before ECI implementation.
Preferably, method of “running change” will be applied by supplier and Aisin.
It is formally prohibited to ship parts produced before ECI/PCR implementation after first shipment of ECI/PCR
implementation, it is supplier responsibility to ensure a good FIFO of their stock.
It is recommended to inform Aisin about any PCR/ECI request minimum 3 month before expected implementation.
ECI/PCR should reflect an improvement, in terms of quality, sustainability, cost reduction, etc.
ECI/PCR might be rejected by Aisin or by the final customer without justification.

XXVIII. DEVIATION REQUEST

Purpose
The purpose of a deviation request is to provide a method for the supplier to request deviation from part drawing,
inspection standard, or performance requirements.
A Deviation Request form must be completed by the supplier for each incident where the supplier wishes to ship
parts or material that do not conform to Aisin drawings, inspection standards, or performance requirements.
The deviation form must contain at minimum:

Sketch or digital image of the characteristic to be deviated,
 standards tolerances,
 actual measurements,
 Description of issue
 Limit date or deviated quantity expected
 part name,
 part Nr,
 ECI Nr,
 other relevant information.
Deviation request must be submitted immediately (maximum 7 calendar days) after issue findings.
It is not authorized to ship parts under deviation before to obtain the deviation form approval from Aisin.

XXIX. NONCONFORMING PARTS, COST OF QUALITY RESPONSIBILITY &

CORRECTIVE ACTION (CAR)
Purpose
Effective handling of quality problems and on-time, detailed quality problem reporting are essential in maintaining
quality performance. Aisin facilities will issue a Supplier Corrective Action Request (CAR) for issues identified at Aisin
locations.
Supplier Responsibilities:
If defective parts are found at an Aisin Production center or logistic center, Aisin quality dept. will inform supplier by
e-mail, supplier might also be contacted by phone for urgent issue.
Corrective action format might be adapted to final customer requirements as QPR or 8D. It is up to supplier to
complete form appropriately.
In certain circumstances, the Aisin Quality dept. may not feel the necessity to require corrective action responses for
minor defects, on the other hands, it might be requested to protect customer by implementation of urgent
containment actions.
Corrective Action (CAR) should include a reinvestigation of the FMEA, and an update to the relevant potential failure modes.
Initial response (containment actions)

Within 48 hours after information reception.
In certain circumstances, Aisin might launch immediate containment action (as sorting) at final customer location or
Aisin facilities before supplier approval, by themselves or by a third party personnel in order to secure current stock.
On a basic stage, as supplier is responsible to part quality, costs will be impacted directly to supplier.
A representative of supplier might be requested on site (Aisin or final customer facilities).
Suppliers responsible to ship to multiple Aisin locations must ensure all sites and all stock are protected.
Problem resolution
It is mandatory to make a root cause analysis on situation, any tool could be used to find the real root cause, as
Fishbone tool, Failure analysis, 5why, etc).
Root cause Analysis (RCA) must be focused on 2 different aspects:

 Why it happens?
 Why not discovered before shipment?
Actions proposed must be the direct consequences of RCA and must be implemented in a swiftly manner, in an
efficient and effective way.
Final response
CAR shall not be considered as closed until Aisin approval and final customer approval.

Corrective action plan must be provided within 30 calendars days after submission to supplier.
Permanent countermeasures must be clearly identified, and implementation date must appear. In case an ECI/PCR
(Art XVII.) is necessary to improve part quality, please refer to appropriate section in this SQAM.
Poor performances and recurrence

If supplier repeats defects, or if inadequate responses are provided, Aisin will enter in Special Focus Process (SPF).
The purpose of Special focus Process is to escalate problems or issues with the supplier and should serve as a
warning that serious consequences up to and including de-sourcing could occur if the situation is not corrected.
Special focus actions phase 1 will be notified via a formal letter from Aisin Purchasing dept. addressed to supplier
Quality Top Management.
Special focus activities will lead to regular visit from Aisin at supplier location to ensure correct application of
production process and to confirm application counter-measures in order to improve part quality.
Special focus Process (SPF)

Phase 1
Additional visit from Aisin Europe is a first step, closer supervising of production activities are requested, supplier
transparency is requested at any kind of potential trouble met.
Application of 100% sorting inspection. This sorting and all costs related will be impacted directly to supplier. The
objective is to certified “GOOD” material/parts to be delivered.
Simultaneous sorting could be requested:
 At final customer facilities
 At Aisin facilities
 At supplier facilities
First shipment of defect-free parts must be identified by Aisin and supplier. The 3 shipments following first defect-
free parts will be confirmed by inspection at Aisin, if no NG parts are discovered, Aisin will stop sorting at their own
facilities.
Supplier is responsible to find a permanent solution to identify and correct the sources of defects.
Evidences of implementation must be provided to Aisin. In addition, Aisin might visit supplier at any stage of Special
focus process, including unexpected by supplier.
If supplier can’t propose a sustainable permanent countermeasure plan, Aisin may decide to enter in Phase 2.
Special focus actions phase 2 will be notified via a formal letter from Aisin Purchasing dept. addressed to supplier
Top Management (President and Vice-President).
Phase 2
If supplier efforts to inspect their material are ineffective, 200% sorting inspection could be requested.

Quality department personnel or 3rd party will inspect all products prior to delivery to the assembly plant.
The cost of this activity is charged directly to the production part Supplier, and will include any accrued expenses including
rework, tooling, management hours, etc.
All defects, unless otherwise directed and data will be returned to the originating Supplier for use in the problem solving effort.
Phase 2 will end after 30 calendars days without defects and only after countermeasures implementation.
Supplier has to assume all costs related phase 1 and 2.
Cost of poor quality

Supplier has to make every reasonable effort to deliver 100% compliant components with no defects.
In the case of defects received by Aisin or their customers, the following costs responsibility conditions apply:
Item Cost Responsible
Supplier Aisin
Labor costs to sort product 100% 0%
Material scrap 100% 0%
Administrative costs 100% 0%
Freight costs 100% 0%
Customer costs as labor, freight cost for parts replacements, 100% 0%
administrative costs and Down time associated with defective
supplied parts.
Abnormal cost clarification

It is expected that supplier accepts responsibility for defects created by the supplier and detected at Aisin and/or
customer facilities. Supplier will be notified as soon as possible of the different costs to assume.
It is the responsibility of the supplier to provide all the necessary evidences of its disclaimer in case of amount or
responsibility dispute in an appropriate timing.
Even in the case of non-supplier responsibility, amount could be partially or completely assumed by supplier in case
of lack of reactivity.

XXX. SUPPLIER QUALITY SYSTEMS AUDIT / PROCESS AUDIT

Purpose
The purpose of this procedure is to outline the method and supplier responsibilities for Quality Systems Audits and
Process Audits.
This audit might be avoided for supplier certified ISO 9001 (cf IATF 16949).
Supplier Responsibility
Aisin quality dept. in relation with purchase dept. will issue a notification prior to the scheduled time of the audit.
The supplier must issue acknowledgement of this request within the specified time period.
Concerning existing suppliers, audit will be performed in the same way as Aisin Europe internal audit.
 Findings will be addressed to supplier and responses must be addressed to Aisin quality dept. within 30
calendars days.
Concerning new potential suppliers, audit will be performed in the same way as Aisin Europe second party audit. (cf
IATF 16949)
 Findings will be addressed to Aisin Purchasing dept. to support their decision to select or not audited
supplier.

XXXI. PACKAGING, LABELING, PRESERVATION AND SHIPPING

Purpose
The purpose is to explain the supplier packaging, labeling, preservation, and shipping requirements.
Shipping - 100% On Time Delivery is required.
Suppliers must comply with all Aisin Packaging and Labeling requirements as communicated by the Aisin Production
Control department, Purchasing dept. or Pre-production planning dept.
Packaging
It is supplier responsibilities to ensure procedure establishment in order to maintain correct packaging properties in
compliance with Generic Packaging specifications (GPS) agreed by both parties.
In certain circumstances, Temporary Packaging Specifications (TPS) might be determined.
When applicable, supplier and Aisin will privilege use of returnable packaging in compliance with Aisin Seiki
environmental requirements.
Stock of returnable boxes is under supplier responsibilities, in case of shortage, supplier must inform Aisin prior to
use temporary packaging specs.
ECI/PCR parts may not be mixed in same box or on same pallet without prior written approval by Aisin.
Labeling
Labeling must conform to the GPS/TPS.
In specific circumstances, specific color must be used:
Item Pre-notification Pallet Label Kanban
before shipment
PCR D-10 + D0 Blue Blue
ECI D-10+ D0 Yellow Yellow
New Part / SOP D0 Pink Pink
D: Delivery day
Preservation
Supplier is responsible to product preservation, before, during and after production. Supplier is responsible of
storage conditions in their own facilities or sub-contractor facilities.
It is the supplier responsibility to communicate specific conditions of storage and recommendations for goods
preservation to Aisin. (As example, humidity level, max/min temp level, dust protection requirements, etc)
Shipping
Shipping requirements are provided by Aisin to their suppliers. Shipping responsibilities are determined by Incoterms
agreed by contract. Shipping conditions must be confirmed by supplier to be in compliance with best preservation
conditions.
General conditions
Packaging and labeling may not be altered, modified or substituted without prior written approval from Aisin.

Barcode on labels and data matrix on parts must be legible.
Corrective actions (CAR)

Aisin expects all products will be shipped 100% on time, in the correct packaging with correct quantities, and with
appropriate identification.
If Aisin or final customer detects a defect with respect of logistical items, a CAR may be issued in the same way as
described Corrective action (section XXIX).
In a general way, after product development phase, in mass production phase, Aisin and final customer will request
to complete 8D/QPR form, those form are similar to CAR form and must be impacted in ECI/PCR/FMEA/DFMEA.

XXXII. WARRANTY/FIELD QUALITY ASSURANCE & COST OF QUALITY

RESPONSIBILITY
Purpose
Suppliers must be conscious of parts and material quality in field applications.
All suppliers must have warranty management systems in place for all warrantable commodities from mass
production release through the life of the part.
Supplier must establish a field quality management process, and it shall include at minimum:
 Defined targets on warranty performances
 Tracking and control of incoming field information and parts
 Analysis, identification and verification details
 Flow-out prevention
 No trouble found (NTF) procedure
 Reporting of results to Top Management
Suppliers are responsible to request warranty parts return for investigation within 7 days after have been warned.
Warranty responsibility will be determined by technical analysis. If responsibilities are unclear, all costs (including
administrative costs or others kind of costs impacted by final customers) will be assumed by supplier.
Supplier must ensure enough production and replacement of defective parts within 15 years after End of Production
(EOP). Even if this activity is launched before EOP, it will not protect supplier against environmental legal or extra-
legal requirements highlighted in environmental requirements listed in Art VII or in GPA.

XXXIII. GLOSSARY
0A/1A: Local Production Assembly Trials
0W/1W: Local Production Weld Trials
4S/5S: Method to organize & maintain workplaces
AE: Aisin Europe (including AE sales office and branches + EPCs)
AIAG: Automotive Industry Action Group
APQP: Advanced Product Quality Planning
ASSY: Assembly
CAR: Corrective Action
CF: Checking Fixtures
CLP: Classification Labeling, Packaging (cf REACH)
CMRT: Conflict Minerals Reporting Template (Frack Dodd Act, Art 1502)
CP: Control Plan
CR: Customer Requirements
CV: Confirmation Vehicle
DFMEA: Design Failure Mode and Effect Analysis
ECI: Engineering Change information
ECR: Engineering Change Request
ELV: End of Life of vehicle (2000/53/EC)
EPCs: European Production Centers
FMEA: Failure Mode and Effect Analysis
GPA: General Purchase agreement
GPS: Generic Packaging Specs
IMDS: International Material Data Sheet
LOI: Letter of Intent
MPT: Mass Production Trial
MQC: Manufacturing Quality Chart
MSA: Measurement System Analysis
MSDS: Material Safety Data Sheet
NTF: No Trouble Found
OJT: On Job Training
OP: Off-Process
OT: Off-Tool
PAD: Parts availability date
PFMEA: Process Failure mode and effect analysis
PIS: Part Inspection Standard
PFUS: Problems Follow-up Sheet
PPAP: Production Part Approval Process
PPP: Production Preparation Plan
PV: Part Validation
QA: Quality Assurance
QAP: Quality Assurance Process
QRE: Quality Resident Engineer
RCA: Root Cause analysis
REACH: Registration/Regulation, Evaluation, Authorization of Chemicals (EC 1907/2006)
RFQ: Request for quotation
QRE: Quality Resident Engineer
SA: Sales Administration
SDS: Sample Data Sheet
SPF: special focus Process
SOP: Start of Production

SPC: Statistical Production Control

SPMS: Supplier Part Master Schedule
SPPM:
SPTT: Supplier Part Tracking Team
SQAM: Supplier Quality Assurance Manual
TPR: Tooling Progress report
TPS: Temporary Packaging Specs
VDA: Verband Der Automobileindustries


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Aisin Europe SQAM Page |1

Revision: A Copyright © 2017 Aisin Europe 01/08/2017

I. I – INTRODUCTION AND GENERAL INFORMATION

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II. Table of Contents

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III. Revision Records

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IV. INTRODUCTION TO THE SUPPLIER QUALITY ASSURANCE MANUAL

Document Administration Responsibilities

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It is recommended to send all formal information by written form (preferably by e-mail).

Mass production contact

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Example of contact list:

Name Dept. Phone (0032) Cell (0032) e-mail

Role & Responsibility Name Phone Cell-phone e-mail

Contact List for project XXX

Plant PC for new parts

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VI. SAFETY, AND SECURITY REQUIREMENTS

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VII. ENVIRONMENTAL REQUIREMENTS

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VIII. REQUEST FOR QUOTE (RFQ)

Direct any/all questions to the Aisin Purchasing

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IX. SUPPLIER DRAWING STUDY

Discrepancy or potential troubles must be highlighted directly on drawing.

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X. SUPPLIER SURVEY (GENERAL INFORMATION SHEET)

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XI. LETTER OF INTENT (LOI)

PPAP level might be changed during project development by decision of Aisin.

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XII. OVERVIEW OF MASS PRODUCTION PREPARATION ACTIVITIES

Development Timing and ECI

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Company DPT PIC

All rights reserved.

Copyright © 2017 Aisin Europe

Supplier Part Tracking Team (SPTT)

During a normal project development, Aisin will conduct 3 SPTT activities.

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Items SPTT1 (OT) SPTT2 (OP) SPTT3 (MPT)

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XIII. MASTER SCHEDULE

The SPMS consists of three main components:

Quality Assurance Process (QAP)

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XIV. SPECIAL CHARACTERISTICS / PROCESS CAPABILITY STUDIES

Capability studies may be required for any of the following activities:

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Characteristic Type Short Term (PPK) Long Term (CPK)

Measurement System Analysis (MSA)

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XV. PART INSPECTION STANDARD