quality control standards for suppliers.doc

此文檔收集于網(wǎng)絡(luò)，如有侵權(quán)，請(qǐng)聯(lián)系網(wǎng)站刪除天馬行空官方博客：/tmxk_docin ；QQ:1318241189；QQ群：175569632 QUALITY CONTROL STANDARDS FOR SUPPLIERS 1996 Edition Mazda Motor Corporation QUALITY CONTROL STANDARDS FOR SUPPLIERS This document is issued by the Mazda Supplier Quality Assurance Department (Mazda SQA). All additions and revisions must be approved by the Mazda Inspection Division. The material in this document is the property of Mazda. Mazda reserves the right to modify or change the content of this document. Edition 1996 PREFACE Mazdas success is based on the quality, performance, and affordability of our products and is impacted heavily by the quality of the products we purchase from our Suppliers. Because of this, Mazda views its Suppliers as key members of the Production Team. PURPOSE Mazda believes quality must be inherent in every step of the design and manufacturing processes and is the result of careful planning. Each Supplier must document the procedures and operations utilized during the performance of work required by a Mazda purchase order. Those procedures and operations may be reviewed by Mazda. This document outlines the quality requirements to which all Mazda Suppliers must adhere. It also serves as a guide to help Suppliers establish quality assurance programs to meet these requirements. SCOPE All material supplied to Mazda for production must be produced, controlled, inspected, and tested in accordance with the requirements set forth in this document and other applicable documents. Relations with the Sales and Purchase Agreement This Standards is defined as supplementary rules to Article: Quality Control” of the Sales and Purchase Agreement.此文檔僅供學(xué)習(xí)與交流 TABLE OF CONTENTS 1.0 GENERAL PROVISIONS 1.1 Purpose 6 1.2 Scope of Application 6 1.3 Glossary 6 2.0 QUALITY SYSTEM REQUIREMENTS FOR SUPPLIERS 2.1 Basic Requirements 11 2.2 Quality Planning 12 2.3 Quality Maintenance and Improvement 16 2.4 Special Requirements for A- and AR- Ranked Parts 20 3 .0 QUALITY PROCEDURE 3.1 Submitting the Notice of Persons Responsible for Quality Assurance 25 3.2 Preparing and Submitting the Part Development Schedule (PDS) 26 3.3 Submitting Part/Product Drawing for Mazdas Agreement 28 3.4 Preparing and Submitting the Quality Control (QC) Process Chart 29 3.5 Preparing and Submitting the Inspection Standard 31 3.6 Labeling Procedure for Quality Control Items 34 3.7 Preparing and Submitting an Acceptance Sample Application for Approval 35 3.8 Preparing and Submitting Pilot Production Part Product ISR 37 3.9 Preparing and Submitting the MP Inspection Sample Reports and Obtaining First Delivery Approval for Controlled New Part/Product 39 3.10 Preparing and Submitting Delivery Notice for Change Control 42 3.11 Preparing and Submitting the Part Quality Improvement Sheet 45 3.12 Analyzed Report for Recurrence Prevention 46 1 Table of Contents Continued3.13Application Procedure for Deviation 473.14Procedure for Lot Traceability 483.15Procedure for Process Audit 523.16List of Documents to be Submitted 544.0 EXAMPLE FORMS (form numbers located in the upper right corner) 3.1Notice of the Persons Responsible for Quality Assurance 573.2(PDS) Part Development Schedule 582.2.6Supply Request 593.4.3.AQC Process Chart (control plan) 60Inspection Standard 6Inspection Standard Attachment Sheet 623.6.APrototype Label 633.6.BPilot Part Label 643.6.CInspection Sample Label 653.6.6First MP Shipment Label 663.7Acceptance Sample Application 673.8Mazda Inspection Sample Report ISR Cover Sheet 683.8.AInspection Sample Report 693.8.BInspection/Sample Report (Data Attachment Sheet) 703.9.4Request for Production of MP ISR Sample 713.9.8Request for Delay of Submission of Test Results 723.9.11First Production Delivery Approval 732 3.10 Delivery Notice 74 3.11.A Part Quality Improvement Sheet 75 3.11.B Part Quality Improvement Sheet (Attachment Sheet) 76 3.12.A Analyzed Report for Recurrence Prevention 77 3.13 Request for Deviation 78 5.0 BLANK FORMS 3.1Notice of the Persons Responsible for Quality Assurance3.2(PDS) Part Development Schedule2.2.6Supply Request3.4.3.AQC Process Chart (control plan)3.4.3.BQC Process Chart (control plan) attachment sheetInspection StandardInspection Standard Attachment Sheet3.6.APrototype Parts Label3.6.BPilot Production Label3.6.CInspection Sample Label3.6.6First MP Shipment Label3.7Acceptance Sample Application3.8Mazda Inspection Sample Report ISR Cover Sheet3.8.AInspection Sample Report3.8.BInspection Sample Report (Data Attachment Sheet)3.8.CInspection Sample Report (Data Attachment Sheet)3.9.4Request for Production of MP ISR Sample33.9.8 Request for Delay of Submission of Test Results 3.9.11 First Production Delivery Approval 3.10 .Delivery Notice 3.11.A Part Quality Improvement Sheet 3.11.B Part Quality Improvement Sheet (Attachment Sheet) 3.12.A Analyzed Report for Recurrence Prevention 3.12.B Analyzed Report for Recurrence Prevention (Attachment Sheet) 3.13 Request for Deviation4 1.0 GENERAL PROVISIONS 1.1 Purpose 6 1.2 Scope of Application 6 1.3 Glossary 651.0 GENERAL PROVISIONS 1.1 Purpose This Standard describes the Minimum Quality Assurance Requirements. The Supplier must meet or exceed to assure quality. 1.2 Scope of Application This standard applies to all Suppliers of export part/product to Mazda. 1.3 Glossary A glossary of terms used in the Quality Control Standard for Suppliers is provided below: Acceptance Sample An acceptance sample is a physical sample provided by the Supplier. This sample is used for quality criteria of specific items. Controlled Changed Parts Controlled changed parts have had their design changed or process changed and their process capability has not yet been verified. Controlled New Parts Controlled new parts are being developed for mass production, but their process capability has not yet been verified. Critical Parts Critical parts are automobile parts with a quality rank of A, AR. Critical Characteristics Critical characteristics are product characteristics, including material or dimension specifications, that can affect compliance with government regulation and/or safety -AND-which required specific actions during manufacturing. 6 Significant Characteristics Significant characteristics are product characteristics or process parameters that are important for customer satisfaction, function, fit, durability, and/or appearance. Characteristic Rank See Quality Rank. Design Change Design changes are indicated by Mazda via an Engineering Change Notice. Deviation A product deviation is a temporary authorization from Mazda for a Supplier to deliver/use a specified quantity of material or parts that do not comply with the final drawing or specifications. Deviations are approved only when the noncompliance has no affect on product function, durability, safety or performance. FMEA (Failure Mode and Effect Analysis) FMEA is a “bottom up” technique used for examining all potential failure modes that may occur in product and component parts. It is also used to predict the resulting effect of potential failure modes on the system. This technique allows Mazda and its Suppliers to prioritize corrective actions. Initial Parts Initial parts have the following classifications: 1. Controlled New Parts 2. Controlled Changed Parts Inspection Standards This document identifies product characteristics that are tested or inspected (including characteristics that have been fully covered in Mazda Engineering Standards documents). This document also states the frequency at which inspections should occur, the acceptable size for samples and provides inspection criteria. In process- 1 (IP- 1) The stage in which process capability has not yet been verified.7 In process-2 (IP-2) The stage in which process capability has been verified, and requirements have been met. Mazda Engineering Standards (MES) Mazda Engineering Standards (MES), in conjunction with the design drawing(s), define the quality standards using quality evaluation items and criteria for applicable characteristics. In addition, MES define the evaluation method which includes a description of the test method, frequency and sample size. Part Rank Part rank is the highest quality rank assigned to a characteristic of the part. PPM Parts per million. Process A combination of people, machines, environments, methods, and materials that produce a given product or service. Process Capability The total variation of a products controlled characteristics when the process is in a state of statistical control. PV (Production Validation) for ISR PV is a confirmation of the function and performance of a part that is produced using mass production tooling processes. Quality Control (QC) Process Chart This is the document that describes the machine and product characteristics that must be monitored during production to produce a product that meets Mazda requirements. This chart clearly specifies who will control what, when, and how during each stage in the process flow.8 Quality Rank Quality Rank is a ranking assigned to a characteristic of the product by the design engineer. The quality rank reflects the effect of the characteristic on the part. A Rank-Critical Quality characteristics related to the safety of the vehiclepassenger, occupants of other vehicles, or pedestriansAR Rank-Critical Quality characteristics related to government regulationsB Rank-Quality characteristics that have a significant effect on marketability, manufacturing, assembly or overall image of MazdaC Rank-All other characteristics not covered by A , AR and B Rank Regulated Parts (AR Rank Parts) Regulated parts are automobile parts that are subject to the relevant laws and regulations regarding safety, the environment, etc.9 2.0 QUALITY SYSTEM REQUIREMENTS FOR ALL SUPPLIERS2.1Basic Requirements 112.2Quality Planning 122.2.1Registration of Persons Responsible for Quality Assurance 122.2.2Part Development Schedule 122.2.3Agreed Specification Drawing 122.2.4Inspection Standard 122.2.5Quality Control (QC) Process Chart 132.2.6Mazda Supplied Material 132.2.7Packaging Planning 142.2.8Labeling for Identification 142.2.9Control of Pilot Production 142.2.10Acceptance Sample 142.2.11Obtaining First Production Delivery Approval 142.2.12Controlled Shipping Status of IP-1,1P-2 152.3Quality Maintenance and Improvement 162.3.1Process Control Verification 162.3.2Change Control 172.3.3Nonconforming Product Rejection Processing (Fault Control) 172.3.4Mazdas Audits 192.3.5Lot Traceability 192.3.6Record Retention 192.4Special Requirements for A- and AR- Ranked Parts 202.4.1Certification of Regulated Parts 202.4.2Agreed Specification Drawing 202.4.3Secondary Drawing/Specification Documents 202.4.4Process Failure Mode and Effect Analysis (FMEA) 202.4.5QC Process Charts and Inspection Standard Forms 202.4.6Process Capability 212.4.7Traceability 212.4.8Record Retention 21102.0 Quality System Requirements for All Suppliers 2.1 Basic Requirements The Supplier shall bear responsibility for quality assurance of all parts delivered to Mazda. That is, the Supplier must guarantee that delivered parts conform to the quality specifications stipulated by Mazda. The Supplier is also expected to provide evidence of such conformance. Accordingly, the Supplier has the responsibility to establish and maintain its own quality assurance system through implementation of the following measures, or in accordance with ISO 9000, etc. 1.Establish and promote a Quality Assurance system based on consistent policiesand quality goals2.Incorporate the use of Design FMEA, Quality Function Deployment activities andadequate Design Validation Testing to ensure Mazdas design requirement aremet during development3.Establish a manufacturing process control system that enables Parts Per Million(PPM) control and ensures 100% quality compliance4.Ensure that the