Supplier Parts Quality Manual

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL Supplier Systems Requirements Table of Contents
1 1.1 1.2 1.3 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 4 4.1 4.2 4.3 4.4 4.5 5 6.0 6.1 6.2 Introduction Scope Purpose Definition General Requirements Supplier Contact Information Supplier Registration (Keihin Website) Continuous Improvements Government Statues, Regulations and Standards Record Retention Cost Recovery Warranty Sub-Supplier Control Quality Systems Requirements Advanced Quality Planning Process Quality Control Table Minimum Process Requirements (MPR) Failure Mode & Effect Analysis Packaging and Lot Control - Barcode Labeling Requirements Process Capability Certificates of Conformity Measuring and Test Equipment Quality Assurance Visit Advance Supplier Assessment QAV1 QAV2 C/M QAV Nonconforming Parts 0, 1, 3 Response Nonconforming Parts Control Advance Notice of Nonconforming Parts Nonconforming Parts at the Customer Nonconforming Part Disposition Quality Waiver Supplier Quality Rating System Annual Review Supplier Escalation Process (SEP) Levels Change Point Control Initial Production Parts Control System Items of Initial Production Parts Control Advanced Initial Production Parts Procedure Rank of Initial Production Parts Control Rank and Items of Initial Production Parts Control Minimum Process Requirements Quality Assurance Systems Timeline Quality Regulation Revisions History of Revisions
KEIHIN CAROLINA SYSTEMS TECHNOLOGY
SPQM 001 Issue Date: Effective Date:
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2 2 2 2 3 3 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5, 6 6 7 7 7 7 7, 8 8 8, 9 9 9 10 9 10 10, 11, 12 12, 13 13 13 13, 14 14, 15 15 15 16 17-39 39 40 41
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SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL
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1 1.1
Introduction SCOPE The details stipulated within this manual are in addition and supplemental to any other quality and purchasing agreements or specifications. No action taken by Keihin Carolina System Technology or the Supplier shall relieve the Supplier of the responsibility to supply useable product that conforms to all purchase orders, agreements, quality agreements, prints, and requirements. All contractual obligations are set forth in the Master Supply Agreement executed between Supplier and KCST. The Supplier acknowledges and agrees to meet the items of quality assurance required hereunder; the Supplier shall achieve or implement a system to achieve: (1) 100% on time delivery; (2) zero defects in all products sold to KCST; (3) immediate and complete failure analysis and countermeasures; (4) shall provide product/services that are environmentally conscious in accordance with KCST policy. The Keihin Carolina System Technology and Environmental Systems Requirements are based upon the latest edition of ISO/TS 16949 Quality System Requirements and ISO 14001 Environmental System Requirements.
1.2
PURPOSE The purpose of this manual is to communicate Keihin Carolina System Technologies basic quality requirements / standards necessary to ensure a successful partnership between Keihin Carolina System Technology and our suppliers. This shall apply to all parts, components, and raw materials that are intended for use in Keihin Carolina System Technology manufacturing processes. This Manual and any updates will be on Keihin (KCST) website (www.cstech-inc.com). It is the Suppliers responsibility to maintain and comply with the latest version of this manual as of its effective date. This Manual is subject to change by Keihin Carolina System Technology (KCST). The Revision Level of the Manual will be clearly indicated.
1.3
DEFINITION Through the remainder of the Manual, Keihin Carolina System Technology shall be referred to as "Customer, or by their respective abbreviations, "KCST". Through the remainder of the Manual, the Supplier shall be referred to as "Supplier" and shall be defined as any Company that supplies parts, components, etc., that are intended for use in mass production, and to be sold by KCST, or to KCST's customers. QSDMPRASA QAVQASTSAPTMRFMEAPQCTQLVSIPPAARIPP (Tag)PLCSQuality Systems Database (KCST Website) (www.cstech-inc.com) Minimum Process Requirements Advance Supplier Assessment Quality Audit Verification Quality Assurance Standard Table Specified Action Plan Trial Maturation Results Failure Mode & Effect Analysis Part Quality Control Table Quality Level Verification Sheet Initial Production Part Advanced Approval Request Initial Production Parts Packaging and Lot Control Sheet
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2 2.1 GENERAL REQUIREMENTS Supplier Contact Information
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All Suppliers must submit Supplier Contact Information in its entirety and return it to your KCST Supplier Part Quality Representative. (See Strategic Sourcing for Contact form document) The Supplier Primary Quality Contact information shall be the contact who will respond to any quality inquiries. Additionally, the Supplier will provide an organizational chart with phone numbers to include Senior Management. 2.2 Supplier Registration To register the Supplier must submit the Supplier contact Information to your KCST Supplier Quality Engineering representative. This completed form will allow registration of the Supplier to have access to review your Supplier Quality Rating and Non-conformances. For further information and assistance in the registration process please refer to your KCST Supplier Quality Engineering representative. 2.3 Continuous Improvements The Supplier shall continually improve quality, cost, delivery and other services provided. Continuous improvement efforts shall include mistake-proofing methods in an effort to further reduce defects, part variability, and processing cost. 2.4 Government Statues, Regulations and Standards KCST is committed to ensuring that all its operations are conducted in a manner that preserves and protects our natural resources, the environment, and safeguards the health and safety of its employees and the public. The Supplier shall comply with all applicable Government Regulation and Standards. Suppliers must ensure their products comply with all current applicable government statues, regulations and standards (e.g. US FMVSS safety standards). 2.5 Record Retention KCSTs record retention policy is set forth in the Master Supply Agreement. 2.6 Cost Recovery Supplier Cost Recovery (CR) will be initiated by KCST when it has been determined that the supplier is responsible for nonconforming / defective product quality. Cost Recovery process will include, but is not limited to: contaminated stock received to KCST, product in transit, non-conforming received goods, assembly line downtime due to delivery or quality related issues and or warranty claims. If there is an occasion due to production schedules and material availability, that do not allow the supplier the opportunity to replace suspect material or sort in a timely manner then KCST reserves the right to: a) Have KCST personnel inspect and sort all suspect materials at the cost to the supplier. b) Initiate third party sort for all suspect materials. This cost will be billed to the supplier by the third party sorting company unless supplier has requested assistance to KCST to arrange third party sorting company. If agreed KCST will recover this cost from the supplier. Supplier shall reference Cost Recovery (SPQD # 0001).
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2.7
Warranty Terms of warranty are set forth in the Master Supply Agreement.
2.8
Sub-Supplier Control The Supplier shall be responsible for Sub-Supplier Control and the quality of components supplied by sub-suppliers. KCST reserves the right to request and perform on site visits at sub-supplier to confirm manufacturing conditions, manufacturing changes, or as a result of nonconforming product reaching KCST.
3 3.1
Quality Systems Requirements Advance Quality Planning Supplier shall be responsible for planning, generating, implementing, and maintaining a Quality Assurance System, (the "Quality System"). Supplier shall establish a Specified Action Plan (SAP), which shall be a system of tracking the development of Supplier's Quality System status. The SAP shall be developed and maintained by Supplier for each new part or model development. The SAP should show development / testing schedules for the following items: 1 2 3 4 Trial and / or production schedules Machine / equipment, purchasing / development schedules Part testing / qualification plans Quality document / systems implementation schedules
The Quality System shall assure the production of parts that conform to all specified requirements. These requirements shall include the following: 1 2 3 4 Systems to prevent the production of nonconforming parts Verification of compliance to all standards, procedures, and quality requirements Defining and recording of quality problems Implementation of timely and effective corrective actions
Supplier shall establish a Trial Maturation Results sheet, ("TMR"), which shall be a system of tracking the development and results of Supplier's trials. The TMR shall be developed and maintained by Supplier for each new part or model development. Supplier shall reference the SAP (SPQD # 0002) for actual SAP documents and instruction sheets. Supplier shall reference the TMR (SPQD # 0003) for actual TMR documents and instruction sheets. 3.2 Process Quality Control Table Supplier shall generate and maintain an accurate Process Quality Control Table, ("PQCT") which shall coincide with the actual manufacturing process. The PQCT shall provide the Customer with auditable documentation of all in-process controls and is therefore subject to on-site audits. The PQCT shall be submitted to the Customer for verification prior to mass production of the relative part. The PQCT shall include all controls that are in place for production of parts. These control points shall include actual part controls such as material, dimensional, functional confirmations. Also these points shall reflect machine, or manufacturing controls that have a direct influence on product quality. These include, calibrated items, key quality points, but are not limited to, temperatures, feed rates, air/oil pressures, etc. Supplier shall reference the PQCT (SPQD # 0004) for actual PQCT documents and instruction sheets.
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3.3 Minimum Process Requirements (MPR)
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KCSTs requires Supplier and its sub-suppliers to meet minimum process requirements (MPR). These requirements represent the controls and methods that are required for manufacturing parts to prevent future process related defects. The MPRs should be reflected in the PQCT and the PFMEA. The MPRs will be evaluated during ASA, QAV 1, and QAV 2. Any changes made to a MPR designated process after mass production start will require IPPAAR approval. If a supplier cannot meet the requirements they should submit a concern in writing to SPQ and Purchasing. The concern will be reviewed by SPQ and an agreement will be reached. If an agreement cannot be reached; the issue will be escalated to KCST upper management. This may result in a change of supplier. MPR is reflected further within this SPQ Manual. (See Table of contents) 3.4 Failure Mode Effect Analysis Supplier shall generate and maintain an accurate Failure Mode & Effect Analysis, ("FMEA"), which shall coincide with the actual manufacturing process. The FMEA shall provide the Customer with auditable documentation of all in process controls and is therefore subject to on-site audits. The FMEA shall be submitted to the Customer for verification prior to mass production of the relative part. The FMEA shall identify potential causes of defects and provide adequate means of ranking the severity of defects as well as their occurrence probability. The results of the FMEA shall be reflected in the supplier's quality planning, such as, but not limited to, the PQCT and the QMP. Supplier shall reference the FMEA (SPQD # 0005) for actual FMEA documents and instruction sheets. 3.5 Packaging and Lot Control Supplier shall guarantee the lot traceability of all manufacturing processes. Supplier shall establish a comprehensive system that ensures traceability from end product supplied to the Customer continuing back through supplied product to the Supplier. All product supplied to the Customer must be clearly identified with the following information: 1 2 3 4 5 Part name Part number Quantity Lot control number Name of supplier
Supplier shall generate and maintain an accurate Packaging and Lot Control Sheet, ("PLCS"), which shall coincide with the actual manufacturing process. The PLCS shall be submitted to the Customer for verification prior to mass production. Supplier shall reference the PLCS (SPQD # 0006) for actual Packaging and Lot Control Sheet. 3.6 Process Capability Supplier shall verify the repeatability of each manufacturing process. The items that are to be analyzed shall include critical features specified by the Customer on the Quality Level Verification Sheet, ("QLVS"), or the Quality Assurance Standard Table, ("QAST"). Additional items to be analyzed may be specified by the Customer based on previous defect history. Also, Supplier may specify additional items based on their expertise of the manufacturing process. All critical features shall have at least 1.33 for CPK to be considered acceptable. Any critical features with a CPK below 1.33 must be 100% inspected by the Supplier. Supplier shall supply a complete QLVS or equivalent with each trial shipment. Failure to supply the necessary data, as determined by the Customer, may result in the rejection of the affected shipment. In addition to QLVS data, the supplier should provide 100% dimensional layout of at least one part per cavity, tool, machine, etc. This data must be accompanied by a ballooned (numbered) print.
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Supplier shall reference the QLVS (SPQD # 0007) for the QLVS documents. Die Go Trials: T1 (Try1, Trial1) 1pc per cavity requires a full piece layout of all dimensions on the drawing. Supplier must submit data to customer. T2 (Try2, Trial2) T1 parts meet all dimensions on the drawing then no requirement for dimensional check for T2 parts. T1 parts that do not meet the drawing specification die must be fixed /corrected and dimensions re-verified. Data must be submitted to customer before shipment of trials. T3 (Try3, Trial3) Requires 30pc process capability per customer QAST requirements. Supplier may choose a third party for measuring capability. Supplier must retain all 30pc capability sample parts until released by KCST SPQ. Customer may request the 30pc process capability parts for correlation study. Customer Attach Points 100% Guarantee: The purpose of this document is to 100% Guarantee that all Critical Customer attach points are verified 100% by the supplier. If a problem occurs with one of these items, it could impact the performance and function of the entire product. Therefore KCST has specified these items as a critical area for 100% hard verification by the supplier. Please 100% guarantee these items with some type of inspection equipment or fixture and provide details. Supplier shall reference the (F-8500-034) for the Customer Attach Point 100% Guarantee document. After the Customer and all subsequent customers approve each part and supplier, the submission of data by the Supplier shall comply with the QAST. This mass production data shall be delivered to the Customer's SPQ department prior to the shipment of affected lots. This data may consist of either inprocess data, or final inspection data. However, the data must reflect the parts in the affected shipment. The data must be identified with the lot number and correlate to the actual shipment lots. The quantities, frequency, method, etc., of the data to be detailed shall include, but are not limited to, the items specified on the QAST. Supplier shall reference the QAST (SPQD # 0008) for the QAST documents. 3.7 Certificates of Conformance KCST defines Certificate of Conformances that all parts supplied by supplier meet KCST requirements. The supplier must certify each shipment stating material shipped has been tested in accordance with and meets the requirements of the applicable Customer drawing and/or specification. The data to support the certification will be maintained on file at the supplier facility and subject to examination upon request. The certificate will reflect the Customer part number, manufacturers part number, purchase order number, lot number, quantity and signature of the suppliers representative. 3.8 Measuring and Test Equipment Supplier shall provide adequate means of performing all measuring and inspections required for each part. Each tool should have the required accuracy, repeatability, and resolution per the specified tolerances. Supplier shall implement and maintain a calibration procedure which shall be adequate to recall measuring and test equipment in a timely manner; track all measuring and test equipment; and provide clear historical records of each piece of equipment. All tools used by the Supplier shall be clearly identified as to their current calibration status. If Supplier cannot perform the measurements required; then Supplier shall be responsible for the obtaining an accredited outside source to perform the measurements.
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3.9
Quality Assurance Visit The Customer may require one or more on-site audits of the Supplier's manufacturing process. The purpose of each audit shall be to judge the ability of the Supplier to provide the Customer with acceptable product. The audits shall be defined in the following manner. 1 2 3 4 ASA QAVI QAVII C/M QAV Advance Supplier Assessment Quality Assurance Visit 1 Quality Assurance Visit 2 Countermeasure Quality Assurance Visit
3.10
Advance Supplier Assessment The Customer's purchasing department shall be responsible for selecting one or more potential suppliers. The Quality department shall be responsible for determining the acceptability of each potential supplier's Quality System. Final supplier selection shall be made by a joint decision between the Customer's Development and Planning, Quality, and Purchasing departments. This ASA shall be focused as a systems audit.
3.11
QAV I After initial product development, members of the Customer's SPQ department shall meet with Supplier at Supplier's premises to conduct QAV I. The following are pre-requisites for QAV I: 1 2 3 4 Supplier shall provide initial drafts of the PQCT. Supplier shall provide initial drafts of the FMEA. Customer shall provide QAST. Supplier shall provide Op Standards including critical PQCT points.
All of the above four items shall be as close to the mass production levels as possible. When one of the above listed are not at mass production level, the supplier shall provide a detailed schedule, for the completion date of mass production readiness. Supplier shall reference the QAV (SPQD # 0009) for the QAV audit form and (SPQD # 0010) for agenda form. 3.12 QAV II Members of the Customer's SPQ department shall again meet with Supplier at Supplier's premises to conduct the QAV II, after the Supplier is ready for mass production, and before the production of significant inventories. The following items must be at final mass production level as planned by the Customer and Supplier. 1 2 3 4 5 6 Customer shall witness actual production of relative parts or parts. All quality documentation. All manufacturing equipment. All measuring and testing equipment. All handling and packaging procedures and materials. Confirm MPR (Minimum Process Requirements)
The Customer shall judge Supplier readiness based on, but not limited to the above items. If Supplier is judged not acceptable, then Supplier shall develop and implement a corrective action plan as to their readiness. This plan must be consistent with the Customer's schedules and acceptable to the Customer.
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If Supplier is judged as acceptable for mass production, then KCST will commence the approval procedure with our customer. KCST may submit the following information to our customer for approval. 1 2 3 4 5 Suppliers PQCT Suppliers FMEA ASA, QAV I, or QAV II results Process capability data Any additional information required by our customer.
Upon the acceptance and approval from our customer, KCST will notify Supplier as to their approval by issuing an Initial Production Part Advance Approval Request ( SPQD # 0011) IPPAAR. 3.13 C/M QAV In the incidence of Supplier delivering one or more unacceptable parts to the Customer, the Customer may visit Supplier's facility to verify the following: 1 2 3 4 Accurate identification of root cause, possibly including a re-creation of suspected cause. Verification of implemented countermeasures. Judgment of the effectiveness of implemented countermeasures. Parallel analysis of cause and countermeasures to similar product or processes.
In the event that the Supplier's identification of the cause of the nonconformity and/or countermeasure is not acceptable to the Customer, Supplier shall analyze the nonconformity cause and countermeasure and shall repeat this process as often as required by the Customer, to the satisfaction of the Customer, (see section 3.18) Nonconforming parts at the Customer. 3.14 Nonconforming Parts Non Conforming parts shall be handled according to the Master Supply Agreement. The Supplier shall use the KCST web-site in corresponding with KCST concerning a non-conformance claim. 3.15 0, 1, 3 Response Supplier shall respond immediately to the Customer in case of nonconforming or suspect parts being identified either at the Customer, or at any subsequent customer. After Supplier has been notified (see section 3.18 Nonconforming Parts at the Customer) of nonconformance, Supplier shall initiate prompt reaction, based on the 0, 1, 3 Response Policy. This action shall be designed to give rapid feedback to the Customer, quickly isolate suspect product, and progress towards root cause identification and implementation of effective, permanent countermeasures. Supplier shall reference the 0, 1, 3 Response Guide (below) for the 0, 1, 3 Response guidelines.
0, 1, 3 Response Guide Customer and in-house Trouble Response Guidelines 0 Timing Same Day Key Items Problem Found White Board Department Action Policy Mark / tag part, segregate from normal parts Report, document the trouble Define the complaint; 5W, 2H (Who, What, When Where, Why, How, How Many)
Who Associate, QC Staff, Team Leader Department Coordinator, Team Leader
Responsible Production Manager Production Manager
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Meeting 0 Response to Customer Information and update to Senior Management 1 Next Day Implement Permanent Countermeasure In-House Report Report to Customer
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Inspection Temporary Countermeasure Testing Inspection Results Judgment: Escape Quantity, Assessment, Function and Effect Correct the Root Cause (Machine, Materials, Method, Man, Maintenance, Management) Cause and Countermeasure presentation (5P) Forward 5P to Customer A-Rank Presentation at Customer Facility Actual parts, Actual place, Actual people review Is C/M implemented and correct? Has desired outcome been achieved? Have problems been eliminated?
QC Engineer, Production Manager
QC Manager
Third Day
Department Coordinator, Team Leader, QC Engineer Department Coordinator, Team Leader, QC Engineer Department Manager
Production Manager Production Manager
Day Five
Ongoing, Continuous
Follow-up Assure C/M Effectiveness
Department Coordinator, Team Leader
Production Manager, QC Engineer follow-up
3.16
Nonconforming Parts Control Supplier shall maintain a system that clearly identifies the status of any nonconforming materials. In addition, these materials or parts shall be clearly segregated from other production parts. In the event that suspect product escapes to the customer the supplier shall contact the customer of possible containment issue. Advance Notice of Nonconforming Parts The Supplier shall give notice as soon as possible to KCST of any nonconforming material shipped to KCST. Due to the nature of our product, these parts could result in bodily harm or injury to our final customers. This communication should be in written form.
3.17
3.18
Nonconforming Parts at the Customer In the event that the Customer detects nonconforming material, Supplier shall be immediately notified as to the details of the Customer's observations. Supplier may be notified initially by phone, however the Supplier shall also be given written notification of the problem by use of a ''Corrective Action Request" form, (a "CAR"), to be provided to Supplier by the Customer in the event of Supplier's delivery of nonconforming parts. Supplier may be required to respond using the "5 Principles for Problem Solving" form. When determined by the Customer, an on-site audit may be required, (see section 3.14 C/M QAV). The Customer using the "Countermeasure Response & Effectiveness" form, (the CMREF), shall evaluate each corrective action response. Supplier shall also evaluate each CAR on the CMREF form, and return it with the CAR to the Customer. This form evaluates c/m content and judges the amount of time taken before appropriate action was initiated. Upon request, if such actions are deemed inadequate, Supplier shall evaluate and submit countermeasures until judged acceptable by the Customer. Supplier shall reference the CAR (SPQD # 0012) for the Corrective Action Request. Supplier shall reference the 5 P (SPQD # 0013) for the 5 Principles for Problem Solving.
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Supplier shall reference the CMREF (SPQD # 0014) for the Countermeasure Response & Effectiveness. Supplier shall reference the Supplier Failure Analysis Minimum Requirement Check Sheet (SPQD 0019) All Supplier corrective actions should include such items listed in form (SPQD 0019) 3.19 Nonconforming Part Disposition The Customer may make one of the following judgments on suspected nonconforming parts: 1 2 3 4 Scrap/return to the Supplier Use after waiver Use after repair or rework Use after 100% inspection
It is the sole responsibility of Supplier to guarantee the product to the Customer's line. In the event that the Supplier's Quality System has failed to prevent delivery of nonconforming parts to the Customer, the Customer, at its sole discretion, may require Supplier to do one of the following: 1 2 3 Supplier Personnel arrive at the Customer in order to inspect or repair suspect parts. Supplier Representative and temporary personnel arrive at the Customer in order to inspect or repair suspect parts. (Contact Quality for approved source.) Replacement parts are immediately shipped to the Customer. These parts must be guaranteed to be free from the defect. To guarantee these parts, the supplier must 100% inspects these parts prior to shipment, or have already isolated root cause and proved to the Customer why the replacement parts are not affected.
3.20
Quality Waiver Supplier may request for nonconforming parts to be used. It is the Customer's policy to not use any part that does not meet the Specifications. However, due to extenuating circumstances, the Customer may agree to use waiver parts assuming the below criteria has been met: Does not violate end users requirements Supplier has isolated and documented the scope of the problem (i.e. suspect lot #'s). Supplier has documented the severity of the problem (i.e. measured actual parts) . Supplier has found root cause and has already determined C/M. Note: the problem must have a C/M before the Customer can give waiver approval. 5 The Customer has had sufficient time to do testing that guarantees functional and durability performance. Supplier shall reference the Waiver (SPQD # 0015) for the Quality Waiver Request sheet. 1 2 3 4
3.21
Supplier Quality Rating System In the industrial competition, perfect quality and continual improvement are the basic assumptions for success of our company. Our suppliers are business partners an expected to provide World Class performance in the areas of quality. Our common target is continual improvement of the quality of our products and services. We need to record and assess our performance in order to set targets for the future. The Supplier Parts Quality Rating Index is the Customers method for evaluating a Suppliers quality performance. It enables us to assess and to compare the performance of our suppliers objectively. The index is a weighted scale based on defect importance level, nuisance level, response level, part-permillion, and quantity of nonconforming parts received. This evaluation is done on a monthly basis and provides feedback to each supplier. INDEX The index is based upon a 100 point system (100 being the best possible score). Table 1 will explain the Calculation Formula. The Rating Scale (Table 2) shows the breakdown of classification for a supplier
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quality performance related to index score (defined as Good, Average, and Unacceptable). Table 3 offers complete breakdown of the four factors related to the Supplier Quality Index. RANKING After the Index is calculated for all suppliers, the Index scores are placed in ascending order and ranked. The lower the rank number, (the higher Index number), the better the Supplier performance for that evaluation period. For example, Supplier D below had an Index of 95, which was better than Supplier E's Index score of 92. Below is an example of ranking done for 10 suppliers, the suppliers are ranked from 1 best performance, to 10 worst performance. Company A B C D E F G H I J Monthly Review It is the responsibility of the individual suppliers to monitor their Quality Performance and identify continuous improvement opportunities. The monthly evaluation of a Supplier's index level is provided to each Supplier on the Supplier Quality Rating via KCST QSD Website. An example is provided for review. It summarizes Supplier ranking for the current month, SQR Index, and Supplier Classification. The report also provides graphs showing Customer's Supplier Occurrences YTD and the specific Supplier's occurrences YTD. The Occurrence Log breaks down each quality problem by; occur date, part number, part name, defect, defect rank, Corrective Action Report number, QSD issue date, QSD due date, and C/M results. Also provided is the Customer requirements section, where the Customer will list any information related to quality issues. Supplier Action section is provided for the Supplier to list any action taken for the quality issues listed in the Occurrence Log. Future Supplier Action section is provided for the Supplier to list any long term projects to improve overall quality performance. Supplier Verification section is designed to show that the appropriate personnel have reviewed the Supplier Quality Rating. Resubmission of Supplier Quality Rating to Customer: The Supplier is responsible for returning a complete and signed copy to Customer by the due date listed at the bottom of the report. Supplier shall reference SQR (SPQD # 0016) for the SQR sample and flow chart. Index points 100 99 98 95 92 91 85 79 55 21 Rank 1 2 3 4 5 6 7 8 9 10
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SQR Index System TABLE 1 CALCULATION FORMULA SUPPLIER =Total (Claim Points) PPM Index Points Total (NTF Response Time Points) INDEX = Sum(100 - ("A" + "B" + "C" + "D")) E Sum(NTF B) TABLE 2 RATING SCALE
GOOD AVERAGE BELOW AVERAGE UNACCEPTABLE
100 - 90 TABLE 3 EVALUATION CATEGORY

IMPORTANCE LEVEL INDEX SERIOUSNESS OF A PROBLEM
89 - 80
RANK INDEX VALUE
79 -60
59 - 0
STANDARD
50
B C
10 3 20 10 5 0 100 50 5 1
RESPONSE LEVEL INDEX
B
NUISANCE LEVEL INDEX
HOW LONG UNTIL FINAL REPORT RECEIVED WHAT LEVEL OF EFFORT WAS REQUIRED.
*DEFECT THAT MAY LEAD TO FIRE HAZARD *LOSS OF FUNCTION OF SAFETY RELATEDSYSTEMS AND/OR PART. *POTENTIAL VIOLATION OF GOVERNMENT REGULATION OR LAWS. *DEFECT OTHER THAN "A" THAT MAY IMPAIR THE FUNCTION OF THE PRODUCT AND HAS A HIGH POTENTIAL FOR AFFECTING THE CUSTOMER. *DEFECT OTHER THAN "A" OR "B", NOT A FUNCTIONAL PROBLEM. 31+ DAYS 21 -> 30 DAYS 11 -> 20 DAYS 0 -> 10 DAYS * DEFECT RESULTING IN MARKET ACTIVITY * DEFECT RESULTING IN HAM CLAIM. * DEFECT RESULTING IN SORTING OF FINISHED PRODUCT AT CUSTOMER. *DEFECT RESULTING IN SORTING OF PRODUCT PRIOR TO ASSEMBLY. *DEFECT NOT RESULTING IN HAM CLAIM, AND DID NOT REQUIRE ANY SORTING.
QTY OF DEFECTS
D
PPM LEVEL INDEX
QTY OF NG PARTS FOUND AT CUSTOMER
QTY 1000+ 100 - 999 1 -99 PPM 10,000 OR MORE 1,000 - 9,999 100 - 999 10 - 99 1-9
INDEX POINTS 5 3 1 INDEX POINTS 10 8 6 4 2
INCURRED PARTS PER MILLION
3.22
Annual Review (QIP) Those suppliers that did not meet the index point target may be placed on the KCST Supplier Quality Improvement Program. This Program is comprised of:
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The supplier is required to develop an internal Quality Improvement Plan based off last Ki (April 1 st thru March 31st) performance. The supplier will present quarterly to review the plan, as well KCST may visit the supplier for verification of countermeasures and planned improvements Supplier Rating Scale Evaluation Status: Score 90 100 80 89 60 79 0 59 3.23 Evaluation Status Certificate of Conformance data on file Certificate of Conformance and/or data with each shipment 3rd party certification or additional inspection or testing Immediate Plan for Improvement or Desourcing (SEP)
Supplier Escalation Process (SEP) Levels Below flow is typical representation of Suppliers, whose overall score falls below 60 will be required to submit and present their Supplier Quality Improvement Plan. The SEP is an important tool to identify the need as a valued member / partner for continuous improvement and development.
Upward flow = Increased expectations Management Review Purchasing Business Review Meeting
Business on HOLD
Process Review Submit QIP Individual Quality Meeting
Executive Level Meeting
Quarterly Presentation
6 months
2 years * (at discretion of Executive management)
Change Point Control It is critical to track and control ALL change points for Effective Quality Control and speedy investigation of failures. All change documents referenced in this manual must be submitted directly to KCST and approval obtained from KCST.
All changes must be approved by KCST BEFORE the changes are made.
4.1 Initial Production Parts Control System The Initial Production Parts (IPP) system is critical in identifying and recording manufacturing change points. It supports precise change point control. This specific control allows for speedy segregation of suspect part ranges during production. It also reduces quantities of vehicles involved in market actions. This type of control is mandated by government regulations for a variety of reasons. Finally, and most importantly, the IPP system informs the subsequent company / department associates of the change and enables those associates to evaluate the change and the effect on their process. The two main aspects of the IPP system are: 1 Initial Production Parts Advanced Approval Request (IPPAAR) The need for advanced notification is determined by change content as mentioned in the Approval Procedure and IPP Procedure.
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The IPPAAR must to be routed through your SPQ representative. Keypoints: * Proposed delivery date * Detail description * Supporting data * Part Number Change * Approval must be received prior to shipment of change parts Supplier shall reference the IPPAAR (SPQD # 0011) for IPPAAR forms and instructions. 2 Initial Production Parts (IPP) 1 An IPP tag is needed for all changes noted in the IPP procedure. It is placed with the actual change parts to identify or "flag" the change point. 2 The IPP tag must be included in the first container of IPP parts, and a yellow IPP TAG ENCLOSED sticker placed on the shipping container. 3 Customer SPQ Engineer should be notified when the shipment is made.
Supplier shall reference the IPP (SPQD # 0017) for IPP tag instructions. Supplier shall reference IPP Order Information (SPQD # 00018) to order tags and stickers. 4.2 Items of Initial Production Parts Control This IPP procedure covers the requirements of the Customer to the Supplier and it's "In-house" Departments. The purpose of this procedure is to describe how the Initial Production Parts (IPP) system works and to identify the importance of the system. This procedure will cover the steps required to document a change to a part, starting from receipt of design change information through, and including, mass production. This control is necessary to safeguard the quality of the finished product. The Initial Production Parts Process should generally be used whenever there is a change that affects the part in any way, including, but not limited to, instances when any of the following changes are made: A. Design Change When the part drawing changes, altering the physical structure of the part. A design change is only done by the Supplier when a new part drawing or a manufacturing instruction has been issued. New Supplier When a Supplier (first supplier) or sub-contractor (second, third, or fourth), who has never produced this particular part, begins manufacturing this part for the Customer. Material Change When any of the material(s) used to manufacture the part is changed or modified. This can occur at any of the first through fourth sub-contractors. Manufacturing Method Change When any process used in manufacturing the part is changed or modified. This method change includes any change that affects the way the parts are produced as reflected in the PQCC. This can occur at any of the first through fourth sub-contractors. Manufacturing Process Order Change Any time the order of the manufacturing process is changed or deviates from the PQCC. This can occur at any of the first through fourth sub-contractors. Machine Change When the machine that was used to produce the parts during the part approval process is not used but another machine is. This can occur at any of the first through fourth sub-contractors. Jig/Tool Change When any of the primary or secondary tooling or jigs are changed or modified, thus affecting the quality, function appearance, or reliability of the part. This can occur at any of the first through fourth sub-contractors. Die/Mold Change When any die or mold which is utilized in the manufacturing process is new, changed or modified. This can occur at any of the first through fourth sub-contractors. Inspection Method Change
B. C. D.
E. F. G.
H. I.
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J.
When the inspection of the part is changed or deviates from the PQCC, thus resulting in either an improvement or change in the parts quality or performance. This can occur at any of the first through fourth sub-contractors. Transportation When the method of transporting the part to the Customer or the packaging of the part deviates from the approved method, which could adversely affects the quality of the part. This can occur at any of the first through fourth sub-contractors.
4.3
Advanced Initial Production Parts Procedure Supplier shall contact the Customer to determine the lead-time that is needed to qualify the change requested. This lead-time will vary depending on the severity of the change, the criticality of the part function, and the level of testing needed to qualify the part change. After the notification to the Customer, Supplier shall provide the following: 1 2 3 4 5 6 Copy of the IPPAAR form Capability study, if required Sample parts, quantity determined by Customer Material testing results, if required Characteristics testing, if required Updated quality documents, PQCC, FMEA, etc.
The Customer will review the above and perform evaluations as necessary. Upon successful completion of the above items and the Customer's testing, a signed copy of the AIPP will be sent to the supplier. This is the official approval to proceed with the proposed change point. No Changed Product should be shipped prior to approval. The first lot shipped must then be labeled with IPP tags.
4.4
Rank of Initial Production Parts Control There are three levels of control in the IPP Process. These are defined in the chart below. (If unsure consult your Quality Representative.)
Rank IPPAAR
B C
IPP Supplier
Procedure 1. The supplier initiating the IPP must report to quality department prior to mass production using the advanced report form (IPPAAR). 2. IPP tag must accompany the first IPP parts, and the parts must be properly labeled IPP tags must be attached to first IPP parts shipped Internal
Control Method IPP delivery must be done with FIFO, and not mixed with other lots. The following quality records must be kept, a. Content of IPP b. Date of IPP c. Date of delivery d. Quality confirmation data such as inspection or test data
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4.5 No. 1
5 6
7 8 9 10
Rank and Items of Initial Production Parts Control Item Contents Design Newly Designed Part Change Design Change that Affects the Parts Itself Design Change that does not Affect the Part (Name and Number Stay the Same) New Supplier Adding a New Supplier or SUB-Contractor Includes Plant Additions at Supplier or Sub-Contractor Changing the Supplier or Sub-Contractor Change in the Delivery Location Change from In-House Production to Outsourced Supplier Material Change in Material Supplier Change Change from Material Supplied to In-House Supply Change in Material Itself (Including Anti-Rust Agents) Manufacturing Change in Manufacturing Method Method Change in Manufacturing Conditions Change (Time, Temps, Speeds, Pressures, etc.) Change in Sub-Contractor/Sub-Supplier Manufacturing Method Change in Sub-Contractor/Sub-Supplier Manufacturing Conditions (Time, Temps, Speeds, Pressures, etc.) Change the Associate Process Order Change in the Sequence of the Process Change Change from Temporary Process to Permanent Process from Permanent Process to Temporary Process Machine Modification or Major Repair to Machine Change Initial use of Machine Move Existing Equipment to New Location Within the same plant Jig/Tool Change in Tooling or Jigs for Master Parts Change Die/Mold Modification or Touch up of the Change Die Renewal or New Die Inspection New or Modified Inspection Jigs or Equipment Method New or Modified Inspection Frequencies Change New or Modified Inspection Method Transportation Change in delivery Method /Packaging Change
A B C
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Minimum Process Requirements The purpose of this document is to clarify and communicate minimum process requirements to reduce process related defects. This procedure applies to all OEM purchased parts and material products shipped to Keihin Carolina System Technology Inc., plant. This also includes any component parts shipped to a Tier 1 supplier. This procedure applies to the following processes Casting Electronics (Printed Circuit Boards) General requirements Heat Treatment Injection Molding Machining Stamping Welding (Projection, Mig, Resistance) Wire Harness
Purpose
Scope
Minimum Process Requirements Definition Initial Quote
The Minimum Process Requirements define the controls and methods KCST requires in applicable manufacturing processes. These requirements were established to prevent future process related quality defects. These requirements are minimum process requirements. SPQ may require additional process requirements where applicable. The supplier must assure the Minimum Process Requirements are built into the applicable processes. Requirements must be included when developing each manufacturing process and reflected in the PQCT. The supplier must complete the Minimum Process Checksheet. The quote must include meeting the minimum process requirements as stated in this procedure. KCST purchasing is responsible for requesting quotes per drawing specifications. At that time, KCST purchasing communicates through the RFQ that the supplier must quote based on meeting the Minimum Process Requirements. If a supplier cannot or will not meet the minimum process requirements, the supplier is required to respond in writing explaining the requirement that they are unable to meet and the reason. This correspondence must be sent to purchasing with the part quote. Purchasing forwards the suppliers response to SPQ. Purchasing, SPQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management. The quote may be considered a supplier no quote. Note If a supplier cannot or will not meet the minimum process requirements, the supplier is required to present how it will guarantee quality.
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Minimum Process Requirements QAV-1 Evaluation Suppliers are responsible to confirm the Minimum Process Requirements are included in the PQCT before submission to SPQ for review. If a supplier cannot or will not meet the minimum process requirement, the supplier communicates concerns to SPQ. SPQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management. The supplier is responsible to develop their manufacturing process, incorporating the minimum process controls. Note the applicable Minimum Process Requirements are included in the PQCT development. QAV-2 Evaluation At SPQ managements discretion, SPQ project members will audit the suppliers processes to confirm conformance to the PQCT. Any deviations must be addressed immediately. SPQ will document concerns on a QAV report when applicable. Suppliers are responsible to maintain adherence to all applicable minimum process requirements during process development and revisions to the PQCT. The MPR Check sheet is used as a tool for confirmation that the minimum process requirements were verified when developing the suppliers manufacturing process. The check sheets can be found on the KCST website in the Supplier Quality Manual. The website is www.cstech-inc.com If a supplier does not adhere to the minimum process requirements, SPQ communicates concerns to the supplier. SPQ and the supplier attempt to resolve the issue. If no agreement can be made, the issue is escalated to upper management. SPQ notifies Management of the suppliers failure to conform to the minimum process requirements. Failure to comply, results in a supplier class change. Mass Production At SPQ Managements discretion, SPQ audits the suppliers processes to confirm conformance to the minimum process requirements. Any deviations found must be addressed immediately. SPQ will document concerns on a QAV report when applicable. In the event of a design change to the part, that would impact a MPR requirement, the IPPAAR process must be followed to ensure MPRs are incorporated. It is the suppliers responsibility to maintain the minimum process requirements.
Technical The flow below shows the technical question flow for Minimum Process Requirements. Question Flow for MPRs
Minimum Process Requirements (MPR) Technical Question Flow

Supplier Email MPR Question to your KCST SPQ Engineering Representative MRP Answer KCST SPQ
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Minimum Process Requirements
General The table below shows the general minimum process requirements. Minimum Process Requirements
No. 1 Requirement Equipment must have start up checks using a detailed check sheet a minimum of once per shift and after maintenance. Shift start up checks must include verification (good and no good condition) of process controls (e.g. preset wrenches, alarms, poka yoke, etc...). Equipment must have documented Preventative Maintenance Schedule and tracking method to alert scheduled maintenance. PM schedule must be based on manufacturer recommendations and past problem history. Must have process operation standards at each process. Operations standards to include the detail of part(s) to be manufactured including materials, components, and process order, as well as machine, tooling, and equipment settings. Operation standards must have sign off by line associates and management. Must have a detailed training procedure for each process. Training must be documented showing evidence of operators trained on each process including updated (refresher) training as required. Training must include the repair/rework and maintenance processes. Must have documented procedure for containment of non-conforming parts. Nonconforming parts must be identified and stored in designated containers until disposition is made. Inventory prior to concern and after concern must be guaranteed to be free of nonconforming parts. Must have procedure for off line repair, which is approved by the Quality Group. Repair/rework parts must go through final inspection area after repair complete. All off line repairs must be documented. Documentation to include part number, date, shift, and name of repair associate. Only trained or authorized associates should have access to change equipment parameters and controls. Must have documented and certified gage program to guarantee the collection of variable and attribute data. Must practice FIFO throughout. All parts, materials, and containers must be clearly identified throughout the supplier's manufacturing process.
2 3
6 7 8 9 10
Minimum Process Requirements ElectronicsPCB Minimum Process Requirements The tables below show the minimum process requirements for Printed Circuit Boards.
Note: Final product must conform to IPC-A-610. (Association Connecting Electronics Industries) Final class to be agreed to by KCST and supplier. 1. Solder Stencil Item Solder paste volume Method Measure solder height or volume on sample of smallest pads across PCB. Comparison measurements to be done across PCB to guarantee even distribution.
Frequency Once per 2 hour minimum
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Stencil cleaning method Stencil manufacturing method Stencil underside wiping method Stencil print registrationStencil to PCB 2. Component Placement Item Placement capability (each machine) Ensure correct component when changing reel/tray 3. Manual Insertion Item Confirmation of correct component Reflow Item Thermal Profile 5. Glue Dispense and Cure Item Glue Dot size (diameter) Glue dot placement 4. Automatic Stencil Cleaner Laser cut or Electroformed (E-FAB) Automatic underside wipe Vision alignment with fiducial
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Once per shift or per work order, whichever is less Per supplier specifications Per supplier specification 100%
Method CpK analysis on actual product for smallest component, finest pitch IC, any other component of concern Documented changeover with 2 person control or scan system
Frequency New Model (MN) timing, during trial build at T-3 level PCBs Each component change over
Method Visual confirmation of component for presence and polarity Method Per suppliers specification and solder paste
Frequency 100 %
Frequency Minimum 1 time per week
Method CpK analysis on actual product CpK analysis on actual product, for smallest Bside component
Frequency NM timing, during trial build at T-3 level PCBs NM timing, during trial build at T-3 level PCBs
Minimum Process Requirements Electronics- PCB Minimum Process Requirements (continued) 6. Solderwave/Selective Solder Item Method Thermal Profile Per suppliers specification Flux Control Per Technical Data Sheet (TDS) 7. Soldering Item Hand Soldering not permissible for mass production 8. Conformal Coating Item Conformal coat application method
Frequency Minimum 1 time per week Per suppliers Specification Frequency Not permissible
Method Not Permissible
Method Automatic spray, dispense or automatic dip. Brushing by hand not allowed.
Frequency 100%
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9. In-Process Handling Item PCB contamination- No skin contact to PCB allowed PCB storage for work in progress (WIP) when not on conveyer PCB flexure, at any process in which the PCB is engaged or could be flexed ESD control Material storage control(including storage, in process, and finished goods) 10. Panel Separation Item PCB flexure 11. Screw Insertion Item Screw torque Screw presence- No missing screw (all parts with more than two screws) Manual screw insertion
Method Glove or finger cots Racks which hold PCB by an unpopulated tab, and do not allow any contact with other PCBs Strain gauge analysis Conform to ANSI/ESD S20.20 As per technical data sheet 100% 100%
Frequency
NM timing 100% 100%
Method Strain gauge analysis Method Torque CpK on actual product Automatic screw counting. Presence is counted when torque/angle is achieved. Part should not proceed to next process step until proper count is achieved. PCB must be protected by product design or fixture from potential damaged by insertion device
Frequency NM timing Frequency NM timing, during trial build at T-3 level PCBs 100%
100%
Minimum Process Requirements Electronics- PCB Minimum Process Requirements (continued) 12. Test Item Test coverage by component Method Matrix showing capability of detection presence, proper polarity, and value for each component by test process (ICT, Functional Test, Final, etc.) Matrix showing confirmation of function per specification by test process (ICT, Functional Test, Final, etc.) Per suppliers specification Frequency NM timing
Test coverage by function Case grounded (if conductive) at final test 13. Repair/Rework Item Rework control Repair control For other flux types which requires washing: Level of ionic contamination after manual
NM timing 100 %
Method Conform to IPC-7711 Conform to IPC-7712 Ionic chromatograph or surface insulation resistance (SIR)
Frequency As required As required NM timing and a minimum of 1 time per shift 21
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solder/touch-up process Minimum Process Requirements
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Weld Minimum The tables below show the minimum process requirements for Welding Process Requirements 1. Equipment Resistance Projection Welding Welding
Mig Welding
Inspection Item Tip dress and Tip change frequency
Method Capability study must be performed to determine trip dress and tip change frequency
Frequency New equipment installed Tip style change, Tip manufacturer change, Tip composition change, Material grade/thickness change, and/or New model timing 100%
Auto/Must Manual/Want
Equipment Control

Auto/Must Manual/Want Weld Failure/ Interruptions/ Adjustments
Equipment must have lockout to prevent unauthorized weld adjustment. Equipment must have visual and audible alarm and line must stop in the event of a weld failure Equipment must not release or advance parts to the next process in the event the cycle is interrupted or fails. Adjustments made to the process must be documented and the quality characteristics of all weld must be guaranteed.(jig change ,robot teaching,etc) Equipment must have part presence sensor/poke yoke
100%
100%
100%
Auto/Must Manual/Want Part Presence
Nut Presence na
n/a
na na Automatic tip dresser
Equipment must have nut presence sensor/poke yoke for presence and proper orientation. Must have automatic tip dresser
100% And sensor to be verified at the start of each shift 100%
100%
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Minimum Process Requirements Weld Minimum Process Requirements (continued) 2. Process Control
Resistance Welding Projection Welding Mig Welding Inspection Item Method Frequency
n/a
Inspection of part
Production associates must confirm quantity and location of welds to a master part Must have final inspection on each part at the end of the process (burrs, cracks, missing pin holes, excess splatter, off location, etc) Supplier must have a master part that matches the drawing. Master part to be updated when there is a design change. All markers must be approved by KCST, for compatibility to customers paint system, before use on metal parts, prior to e-coat
1 time per shift
Final Inspection
100%
Master Part
100%
Marker Check Inspections
100%
3. Quality Confirmation Resistance Projection Welding Welding
Mig Welding
Inspection Item Datum Targets
Method Must have datum targets on all welding jigs bases, inspection fixtures, and included in jig and fixture standards. Quality checks must be done and results must be recorded. All parts utilizing 780Mpa materials and above: actual parts that are driver checked must be controlled and quarantined at supplier and shall not be shipped to KCST plants for usage.
Frequency 100%, confirmed NM start-up and used during all jig modifications and/or adjustments. Beginning/middl e/end of shift Abnormal conditions Unless otherwise negotiated during New Model timing
Quality checks (i.e. driver checks)

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Weld Minimum Process Requirements (continued) 3. Quality Confirmation (continued) Resistance Welding Projection Welding Mig Welding Inspection Item Method Frequency 1 complete test every 3 months(supplier must set-up a weekly rotation covering all welds in a 3 month period, including all jig/line combinations Abnormal conditions At New Model and weekly there after
HES E 00199 HES A 1018-04
HES B 03199
Customer Specification 5135Z-SX8T000
Quality Testing(i.e. macro testing)
Quality group must confirm product by listed test method. Result must be recorded.
n/a
Quality Testing
Quality group must confirm length, quantity, and location of welds to KCST drawing. The following requirements apply if NDT is to be used as an alternative to driver checking: * Supplier must achieve and maintain inspector certification per equipment maker guidelines.
HES E 00199 HES A 101804
HES B 03199
Customer Specification 5135Z-SX8T000
Non Destructive Testing (NDT)
* Supplier shall have certified inspectors on site during all supplier production hours and shifts. * Supplier shall conduct NDT data correlation to destruct testing and driver check testing and review with customer prior to implementing as a substitute to driver checks. * In the event of equipment downtime or certification lapse, supplier is required to follow the above driver check guidelines
Negotiated between Plant and Supplier. NDT does not replace the minimum destruct requirements

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4. Abnormal Process Conditions Resistance Projection Mig Weld Welding Welding
Inspection Item Driver/ Destruct Confirmations
Method Must have documented containment and process feedback procedures for use when finding no good weds during driver/destruct confirmation. All parts utilizing 780 Mpa material and above: actual part that are driver checked must be controlled and quarantined at supplier and shall not be shipped to Customer plants for vehicle usage.
Frequency
100%
Casting Minimum Process Requirements
Note: The supplier must quote a part based on porosity allowed per specification
1. Receiving Inspection (All Casting Types) Inspection Item Method Raw Material being Received and confirm properties of incoming raw received material. Information must be documented. Raw Material being loaded Must record all raw material loaded into each into furnace, by furnace identification- Must record: Furnace Lot number, Date, Time, bundle or Heat number, Supplier name 2. Melting Furnace (All Casting Types) Item Method Must control molten Pyrometer/Thermocouple/control Panel material Temperature Must control re-melt % of scrap added per SOP (Standard operation percentage Procedure) Must verify correct Per specification material properties (if no holding furnace) 3. Holding/Casting Furnace(All Casting Types) Item Method Pyrometer/Thermocouple/Control Panel Document temperature of material Most control molten material Temperature Most control casting Chart recorder/PLC interlock and /or manually material temperature recorded. When temperature is out of before entering mold specification prior to pouring, must have immediate alert. Must verify correct material properties Per specification
Frequency Each heat or lot Each bundle or change
Frequency Continuous monitoring Continuous or each heat Each heat lot
Frequency Continuous monitoring
Continuous
Each heat lot

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Casting Minimum Process Requirements (continued) 4. Degassing (Per part specification) Item Method Must control settings Check sheet Must confirm correct gas Certification sheet from supplier being Used Must confirm gas content Vacuum Fusion analysis or equivalent after degassing 5. Sand Core/Pattern (Tilt, LPDC, Ferrous Item Method Must confirm sand Certification sheets from supplier properties
Frequency Once per day Per lot of gas received Per heat
Frequency Per lot of sand received
6. Molding (Tilt, LPDC, Ferrous)

Item Must confirm mold machine and Die alignment Must control parameters of Mold machine Method Height gauge, dial indicators, alignment fixtures Gauges on machine/check sheet Frequency Per PM schedule New Model Launch/Setup/Once per Shift
7. Pouring (All Casting Types) Item

Must control mold filling speed, pressure curve, curing time, die clamp pressure Must control inoculation Amount/nodularity Must control die temperature/die flame and cooling rate
Method
PLC
Frequency
Continuous or check sheet
Per specification PLC/flow gauge/ Temperature controller
Per batch Continuous or check sheet
8. Die (All Casting Types) Item

Must confirm die dimensions Must have documented die maintenance and repair Must have model type and cavity number on die Must confirm die lube Must confirm die coating
Method
Frequency
New Model launch and when a new die is issued Per supplier PM schedule/As needed At model change Per certification sheet/At mix timing/At setup Per supplier PM schedule/As needed
Die marker data, Measure parts off die PM schedule/Signed off completed work order Setup check sheet/ part confirmation Lube ratio and application pattern Thickness check gauge/SOP
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Casting Minimum Process Requirements (continued) 9. Shot Blast/Flash Removal/Trim Die (All Casting Types) Item Method
Must confirm shot size and type Must control load size, time, and shot speed/pressure for flash removal equipment Incoming receiving inspection PLC, pressure gage
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Frequency
New Model launch/Once per Lot Shift startup
10. Quality (All Casting Types) Item Method Must have material checked to verify Brinnell Test, SEM, Test lab hardness and chemistry Spectrometer, Rockwell (Ferrous and Aluminum Casting) Must complete visual Visual/Magnaflux casting defect checks Must perform a casting CMM, QC gages dimension check Must perform a core CMM , QC gages dimension check Must perform mechanical properties Tensile tester testing Must have capability and perform destruct Per specification testing (porosity, color etc) Must have capability and perform nonX-ray, Eddy current, Magnaflux, etc destruct testing
Frequency Per batch Continuous At die set and once per shift At die set and once per shift New model launch
As required
As required
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Machining These requirements apply to both machining and grinding processes. Machining Process Requirements No. 1. Requirement 30 pieces Cp/Cpk must be done per machine on each fixture for machined dimensions including surface roughness as negotiated by Honda Parts Quality. 30 piece random sample including all fixtures also acceptable. 1.33 Cp/Cpk must be continually maintained. Must be completed at each New Model and per IPPAAR procedure matrix. Machining/ layout datum and critical dimensions must be determined/ documented between the supplier and Honda at New Model timing or IPPAAR change. Must develop a plan at New Model timing to complete a tool life and grinding wheel dress frequency study. Results must be available upon request. Equipment must have system to prevent unauthorized machine adjustment (e.g. lockout, password, etc.). Process must have system to detect a broken drill/tap/tool or an automated check to verify the machined feature. Equipment must have fixturing to guarantee part presence and proper position during process (no mislead). Machine/ fixture ID must be indicated on each part for duplicate processes (e.g. two machines making same part. Fixture must have model type detection/ poka yoke where applicable (e.g. multi-application exists). In the event of tool interruption during production, must have documented operation standard to recover equipment. In addition, the last piece produced before tool interruption and first piece before continued production, must be confirmed (e.g. power outage, tool breakage, etc.). Quality checks must be done at the beginning/middle/end of each shift or as negotiated during New Model. Variable data must be documented and analyzed for trends. Additional confirmation required during abnormal situations. Threaded holes must be verified with a thread gage. Minor thread diameter must also be confirmed with a plug gage to assure proper thread engagement. Frequency to be documented on PQCT Parts must be free from contamination that could impact the functionality of the part or the mating parts.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Minimum Process Requirements Heat Treatment The tables below show the minimum process requirements for Heat Treatment.
28

Minimum Process Requirements 1. Receiving Inspection (All Heat Treatment Types) Inspection Item Method Raw Material being No rust, dents, abnormal damage, per received standard. Parts being received No rust, dents, abnormal damage, per standards. Confirm lot identification. 2. Lot Control of Product (All Heat Treatment Types) Inspection Item Method Must have Lot Control Identification on the parts, racks, bundles, on incoming and etc Heat treated parts must be traceable outgoing material back to all processes. (e.g... Heat treatment, traceable back to heat casting number.
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Inspection Frequency Each heat or lot Each lot number
Inspection Frequency Continuous monitoring
3. Stacking/ Loading Method (Based on New Model development results) (All Heat Treatment Types except Induction Hardening) Inspection Item Method Inspection Frequency Must have uniform Must have standard to stack parts or stacking for parts going method to perform uniform loading into furnace to confirm 100% through heat treatment of all parts. Parts cannot touch (will be easy case) 4. Rack/ Belt Requirements (Carburizing, Nitriding, Liquid Carbon Nitriding, etc...) Inspection Item Method Inspection Frequency New furnace racks or Must run racks or belts through one heat belts must be seasoned treatment cycle prior to using for mass before using for mass production 100% production (Ferrous material only)
Minimum Process Requirements Heat Treatment Minimum Process Requirements (continued)
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5. Start-up and In- Process Equipment Checks Inspection Item Method Must have start-up and Temperature Gages/ Controls in-process checks with detailed worksheet. Must be documented.
Inspection Frequency Checks to be verified at the start and end of each lot
Minimum Start-up Checks Anneal, Induction Normalizing, Hardening Neutral- Hardening, Through-Hardening, Quench, Temper, and Sintering X X X X X X X X X X X X X X X X X X X X X X X
Flame Hardening
X X X X X X X X X X
Surface Hardening/ Carburizing, Carbonitriding, Nitriding, Ferritic Nitro carburizing X X X X X X X X X X X
Check Item (Verified at start and end of each lot)
X X X
X X X
Carbon potential verification Temperature Set Point Atmosphere controls where applicable Time in furnace Belt Speed if continuous conveyer Circulating fans - verify running Flow meters, temperature, digital and pressure gages must have limit marks Quench temperatures Quench concentration Quench oil type/Media Quench flow/agitation Coil condition Flame burner condition Energy monitor- amperage Coil or torch gap position Heat time- actual time is on part or time at temperature Quench time Quench delay
6. Process Control Alarms (All types of Heat Treatment) Inspection Item Must have alarms for Temperature, Conveyers, Atmosphere flow, Circulating fans, and Quench parameters.
Method
Inspection Frequency Continuous
Alarms to detect abnormal conditions for automated processes.
Minimum Process Requirements Heat Treatment Minimum Process Requirements (continued) 30
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7. Quality Confirmation (All types of Heat Treatment) Inspection Item Must have quality confirmation. Minimum Quality Checks Anneal, Normalizing, NeutralHardening, Induction Flame ThroughHardening Hardening Hardening, Quench, Temper, and Sintering X X X Per Per Per Drawing Drawing Drawing Per Per Per Drawing Drawing Drawing Per Per Per Drawing Drawing Drawing X X Per Drawing Per Drawing Per Drawing 8. Abnormal Process Conditions (All Heat Treatment Types) Per Drawing Per Drawing
Rev B 10/28/10 11/08/10 Inspection Frequency Continuous
Method
Hardness tester, Microscope, per Honda requirements
Surface Hardening/ Carburizing, Carbonitriding, Nitriding, Ferritic Nitro carburizing X Per Drawing Per Drawing Per Drawing X X Per Drawing
Check Item (New Model Timing and as specified)
Surface hardness per specification Core hardness per specification Micro Structure verification De-carb verify layer thickness Case Depth Position of Heat Treatment (macro-etch) White layer thickness / diffusion depth Mechanical properties (case by case) Density (powder metal parts)
Inspection Item
Must have downtime/abnormal condition procedure
Method
Procedure to include containment of suspect lot, reconfirmation of part quality and furnace condition at re-start Must have procedure to explain, types of processes to be reworked, number of times to rework, quality checks to be conducted, and notification of supervisor. Supplier quality must approve procedure and parts. All reworks must be documented.
Inspection Frequency
Continuous
Rework of non-conforming parts
Continuous
Minimum Process Requirements 9. Preventative Maintenance (All Heat Treatment Types)
Inspection Item
Method
Inspection
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Frequency
Must have PM schedule on Thermal couples, Atmosphere controls, Alarms, Fan bearings, Water jackets, Coils, and other recommendations specified by equipment manufacturer. Per PM schedule Per Equipment manufacturer's recommendations or normal heat treating process.
Minimum Process Requirements Injection Molding Minimum Process Requirements The following Minimum Process Requirements are required for the Injection Molding processes listed below: Insert, Low Pressure, Dual, RIM, Gas Assist, Co-Injection. 1. Receiving Inspection
Inspection Item
Material confirmation Traceability 2. Material Preparation
Method
Receive and confirm critical properties of incoming raw material. Information must be documented. A method to track all material from receiving through final product. (i.e. .date stamp, date wheel, or date matrix.
Each material lot Each material lot
Inspection Item
Correct Material Re-Grind Control Material Drying Material Contamination Color Concentrate Reactants Confirmation/Correct Formula
Method
Must have procedure to identify correct material is used to mold part Must have procedure to verify percentage of re-grind allowed. Must have procedure to verify material moisture content per material data sheet Must have method to protect material from contamination throughout process. (i.e. gaylord with covers, etc.) Must have procedure to control color concentrate percentage and confirm the color of the final product. Must have procedure to control color concentrate percentage and confirm the color of the final product.
100% 100% 100% 100% 100% Each material lot
Minimum Process Requirements Injection Molding Minimum Process Requirements (continued) 32
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3. Machine Set-up (Based on New Model development results)
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Inspection Item
Method
Must have equipment set-up sheet approved during New Model. Must have procedure in place to document any deviation from set-up.
All checks listed below to be verified at start up and at mold change.
Insert
Low Pressure
Dual
Gas Assist
Injection Molding
Reaction Injection Molding
CoInjection
Minimum start up checks:

Injection Velocity Hold and pack Injection time Peak pressure Minimum cushion Screw recovery Cooling time Nozzle and heater band (zone) temperature control Hot runner (zone) temperature control, if applicable Theromolator control Water hook-up control (ie. color code in and out connections) Cavity temperature Core temperature Reactant tank temperature (poly and iso) Pouring time Opening control Closing control Clamp tonnage Mold position Mold safety control Speed control Position control Air pressure Fluid/reactant pressure Speed control Position control Gas injection pressure Speed/ramp control Time Cylinder position if applicable
X X X X X X X X X X X
X X X X X X X X X X X X X X X
Barrel
Mold
X X X X X X X X X X
X X X X X X X X X X
X X X X X X X X X X
X X X X X X X X X X X X X X
X X X X X X X X X X X X X
X X X X X X X X X X
Clamp
Ejection/ Mold
Hydraulic or Air Cycle Time Gas Assist
Minimum Process Requirements Injection Molding Minimum Process Requirements (continued) 4. Molding 33
9/21/2013

Inspection Item
Location of Film/Top coat (Insert / Low pressure / RIM) Paint removal Gate Trim Appearance confirmation for cosmetic parts 5. Quality Confirmation
Rev B 10/28/10 11/08/10
Method
Must have method of location film / topcoat inside of mold. Automatic method of removing part. Method must not damage part. If manual unload must have an operations standard. Gate trim must not exceed limit sample. Removal of gate must not damage part. Must match drawing or limit sample.
100% 100% 100% 100%
Inspection Item
Quality confirmation check sheet
Method
Must have check sheet which lists items to be verified (check sheet must include harness check for RIM product, durometer) Check fixture, measurement tools, or CMM per data sheet Per master sample Per drawing. Results must be documented and verified for trends Visual confirmation per production sample
At set-up(all items listed below) and one piece per shift At start up and one piece per shift At start up and each color change. At start up and each color change. At start up and each color change.
Dimensional confirmation Color confirmation Gloss confirmation Visual defects 6. Abnormal Process Conditions
Inspection Item
Must have downtime/abnormal condition procedure
Method
Procedure to include: containment of suspect lot, reconfirmation of part quality, machine condition, and purging of material at re-start.
Continuous
Minimum Process Requirements Wire Harness Minimum Process Requirements Note: Must conform to HES and other applicable standards (IPC/WHMA-A620, JIS, etc.) 1. Receiving Inspection
Inspection Item
All components (clips, grommets, terminals, wire, waterproof seals, couplets, JC caps, etc.) Wire Testing
Method
Must have documented procedure for receiving inspection. Results must be documented and filed. Spark test to be conducted per related standard. Results must be documented and filed. (inhouse or at subsupplier) Voltage test to be conducted per related
Per lot 1 time per month on each wire size 1 time per month
9/21/2013
34
Rev B 10/28/10 11/08/10 on each wire size
standard. Results must be documented and filed. . (inhouse or at subsupplier) 2. Cut, Crimp, and Terminating
Inspection Item
SRS harness circuits denoted by Q point on drawing A and G Rank circuits (see the Supplier Quality Manual for explanations on rank) All other automatic cut and crimp circuits All other manual cut and crimp circuits
Method
Must have designated/automated cut and crimp equipment. Must have crimp force monitors and be identified throughout the process. Must have crimp force monitors and be identified throughout processes. Mis-strip sensors Visual inspection Bell mouth, crimp heights, vinyl height, pull test, strip length, wire size, wire type, wire color, etc. Must be verified and documented. Set-up wire samples must be different length than mass production lengths to be easily distinguishable Visual inspection for damaged terminals, no strands out, no cut strands, no high/low insulation, etc. All bundles must have protective covering over terminals for transportation and handling. Machine set up for pitch control When stripping no nicks or cuts to core wire Taping must completely cover splice area. Must have visual inspection to confirm. Must conform to HES, IPC, JIS (when applicable) Visual inspection
100%
100% 100% 200% ( two separate 100% checks) One per lot 100% 100% 100% 100% 100% 100% 100% 100%
Set-up procedures
Crimping Condition Terminal Protection Twisting Wire Shielding Splice Taping Shielding, splicing and welding Shielding, splicing, welding, and taping Minimum Process Requirements
Wire Harness Minimum Process Requirements (continued) 3. Sub-Assembly / Assembly
Inspection Item
Wire Condition at sub-assembly storage Terminal Insertion Terminal Condition Terminal Location Wire Layout Wire Layout
Method
Racks to be clear of sharp edges to ensure no damage to wires Push, click, pull must be performed on each terminal insertion Visual inspection for damaged terminals. Damaged terminals to be place in scrap bin. Visual aid and operations standard at processes. Same colored wires that have similar lengths must be assembled at different assembly stations Tape wires by pulling back from couplers to ensure wires are even lengths.
100% 100% 100% 100% 100% 100%
9/21/2013
35

Component Containers and Aprons Correct Components Directional component, protector, and grommet orientation/presence Branch orientation and length Part change over Terminal contact with floor Taping Techniques Board Maintenance Corrugated Tube Applicator
Rev B 10/28/10 11/08/10 100% 100% 100% 100% 100% 100% 100% Start of shift 100%
Containers and aprons must be free of dirt and foreign objects. Operation standards/visual aid/Kanban Poke yoke to assure correct orientation/presence as per section views Board layout and fixtures Boards to be identified with part number and design level. Supplier must have method to prevent terminals from contacting plant floor. (aprons, troughs, etc.) Must have effective taping method which does not change branch length or orientation Inspection of board fixtures to ensure fixtures are tight, no broken, etc. Use applicator to install tubing to ensure no Insulation damage.
4. Inspection
Inspection Item
Method
100% 100% 100% At New Model timing, design change or Manufacturing Instruction 100%
Component presence (clips, grommets, Detection system to assure presence protectors, clamps, retainers, (micro-switch, fixture, holder, etc.) secondary locks, boots, etc.) Circuit check to verify continuity, missing Multi-circuit harnesses have Circuit circuits, missing components, terminal Program. back out, shorts, extra circuits, etc. Confirm JC connectors have continuity/no shorts after JC caps are installed. Circuit Program Circuit programs to be confirmed and Approved by supplier. Must have backup circuit program available in the event of loss of data. Minimum Process Requirements Wire Harness Minimum Process Requirements (continued) 4. Inspection (continued)
Inspection Item
Circuit check master harness Dimensional Inspection Board Dimensional Master Harness
Method
Confirm correct program of circuit board and detection system. Must be confirmed and approved by supplier. Must have to verify harness. Inspection board to be made at nominal. Master harnesses to be made 50% or less of tolerance. Must be confirmed and approved by supplier.
At set-up and change over 100% At New Model timing, design change 36
9/21/2013
Rev B 10/28/10 11/08/10 or Manufacturing Instruction.
Inspection Identification Confirmation Boards
Parts must be identified that they passed inspection unless specified by Honda. Board to be identified with part number and design level. Inspection data received from supplier must use Honda drawing when judging quality of part.
100% 100% At New Model timing, design change or Manufacturing Instruction and as specified by Honda.
Inspection Data
5. Part Identification
Inspection Item
Method
Part identification as specified by customer. Labeling must have traceability back to production and component lot/date range. Must have method to verify correct labeling. (bar code scanning procedure, etc) Part markings must be confirmed to part marking drawing.
100% 100% at New Model timing, design change or Manufacturing Instruction.
Labeling
Part Marking as specified by Honda.
6. Abnormal flows
Inspection Item
Change Point Control SRS Harness
Method
Must have procedure to confirm assembly and inspection boards and fixtures are at proper design level. No repairs allowed
Per procedure 100%
Minimum Process Requirements Stamping Minimum Process Requirements 1. Material Ordering Confirmation Inspection Item Material ordering confirmation (typically 3 months prior to receiving) 2. Material Inspection Inspection Item Receiving Inspection Method Comparison of MSA/Purchasing order to most current drawing specification Method Material certification sheet must be confirmed to the coil specification and the material order at receiving. The supplier must keep a copy of the Material Confirmation Sheet on file. Inspection Frequency Each material order Inspection Frequency Per coil
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37

Confirmation of material type, mechanical properties, grade, thickness, width, and coating weight. (Coating weight if applicable.)
Rev B 10/28/10 11/08/10 Per coil
Confirmation to be done prior to each stamping production run and the results must be documented. Hardness testing may be used as a method of inspection for material type confirmation. Method
3. Stamping and Blanking Process Set up Inspection Item
Process Control 4. Process Control Inspection Item Poke Yoke Approved Lubrication
Supplier must have a documented press and tool (die) set up procedure. Set-up results and die condition results must be documented. (e.g. Shut height, lead check results, cushion pressure, poke yoke, etc). Method Press and tools (die) must have Poke Yoke systems to detect press and tool malfunctions. All lubricants must be approved by customer to prevent contamination to customers paint system.
Inspection Frequency At each production run start-up
Inspection Frequency At each production run start-up As negotiated during New Model timing or when a lubricate changes is made per SQM procedures. 100% 100% Per Supplier Quality Manual
Excessive Lubrication
Rust Preventative Traceability
Finished product shall not be stored or shipped with excess lubricant that ma lead to a safety or quality concern. Finished product must be shipped and received at customer free of rust and contamination. If a used preventative is used, Honda must approve. Supplier must have the ability to provide lot traceability from the finished product back to the material heat number.
Minimum Process Requirement
Stamping Minimum Process Requirements (continued)

38
Rev B 10/28/10 11/08/10
5. Quality Confirmation Inspection Item Dimensional Check
Method (i.e. CMM, Inspection fixtures, and/or other inspection tools) Part inspection data must be documented and kept on file. Additional confirmation required during abnormal situations.
Inspection Frequency Quality checks must be done at the beginning and end of each production run or as negotiated during New Model. 100% unless otherwise negotiated with customer. 100% unless otherwise negotiated with customer. 100% unless otherwise negotiated with customer. 100% unless otherwise negotiated with customer. 100%
Wrinkles, folds, cracks and an other detrimental defects called out on the Honda drawing. Burrs must meet the specifications identified by the drawing unless otherwise specified by Honda. Material thinning not to exceed 25% from nominal material thickness unless otherwise specified by Honda. Controlled Master Part
Visual verification for folds, cracks, necking. Wrinkles in non-mating and non-critical areas may be allowed on after prior approval by Honda (Limit sample) Visual verification for burrs.
Dimensional data. (identified in HES)
Marker Check Inspections
Supplier must maintain a master part that meets the drawing specifications. A new master part is required if a design e occurs that alters the part characteristics. Master part shall reflect part name, part number, design change level, and date of approval. All markers must be approved by customer for compatibility to customers paint system, before use on metal parts, prior to e-coat.
6.0
Quality Assurance Systems Timeline Supplier agrees to perform or participate in, whichever is indicated, each element of the Quality Assurance System provided for in this agreement in strict accordance with the timeline set forth in the QA System schedule, attached hereto and made part hereof. Supplier shall reference (SPQD # 0018) for the Quality Assurance System schedule.
6.1
Quality Regulation Revisions Any changes or modifications to this agreement will be posted on the website. It is the responsibility of supplier to periodically review and ensure compliance. This agreement is subject to the Agreement and General Terms and Conditions separately executed by Customer and Supplier (the "General Contract"). 39
9/21/2013
Rev B 10/28/10 11/08/10
In the event of any conflict between this Agreement and the General Contract, the terms of the General Contract shall control.
Reference Documents
SPQD # 0001 SPQD # 0002 SPQD # 0003 SPQD # 0004 SPQD # 0005 SPQD # 0006 SPQD # 0007 SPQD # 0008 SPQD # 0009 SPQD # 0010 SPQD # 0011 SPQD # 0012 SPQD # 0013 SPQD # 0014 SPQD # 0015 SPQD # 0016 SPQD # 0017 SPQD # 0018 F-8500-034 SPQD # 0019
Cost Recovery SAP TMR PQCT FMEA PLCS QLVS QAST QAV QAVA IPPAAR CAR 5P CMREF Waiver SQR IPP Quality Assurance System Customer Attach Point Guarantee Supplier Failure Analysis Minimum Requirement Check Sheet
9/21/2013
40

6.2 HISTORY OF REVISIONS
SECTION REVISED
Rev B 10/28/10 11/08/10
# 6001
DATE Mar-99
6002
Apr-01
Rev A
May-08
Rev B
Nov-10
REVISION CONTENTS DOCUMENT RETENTION 0,1,3, RESPONSE SUPPLIER QUALITY RATING CHANGE C.A.R. FORMAT PUT SPQM INTO M.S. WORD Change CMREF requirements Added approved source reference Add yellow "IPP TAG" sticker Change AIPP to IPPAAR Transportation rank - B to A IPP tag & sticker order reference New corrective action request Changed manual for easy flow and understanding / with supplier document forms updated to reflect manual. Add ( MPR) Minimum Process Requirements) Removed Supplier Acknowledgment form Add T1, T2, T3 requirements Add Customer Attach Point 100% Guarantee requirement Add Supplier Failure Analysis Minimum Requirement Updated Reference Document section
ALL 3.2 3.3 4.0 4.0 4.4 4.0 Page 38
All Pages 1 - 16 Pages 17 - 42
Page 6 Page 6 Page 9 Page 41
9/21/2013
41

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SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL Supplier Systems Requirements Table of Contents

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

Who Associate, QC Staff, Team Leader Department Coordinator, Team Leader

Responsible Production Manager Production Manager

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

QC Engineer, Production Manager

Production Manager Production Manager

Follow-up Assure C/M Effectiveness

Department Coordinator, Team Leader

Production Manager, QC Engineer follow-up

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

100 - 90 TABLE 3 EVALUATION CATEGORY

RESPONSE LEVEL INDEX

QTY OF NG PARTS FOUND AT CUSTOMER

INDEX POINTS 5 3 1 INDEX POINTS 10 8 6 4 2

INCURRED PARTS PER MILLION

KEIHIN CAROLINA SYSTEMS TECHNOLOGY

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL

SPQM 001 Issue Date: Effective Date:

Rev B 10/28/10 11/08/10

Process Review Submit QIP Individual Quality Meeting

Executive Level Meeting

2 years * (at discretion of Executive management)

SUPPLIER PARTS QUALITY REQUIREMENTS MANUAL