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CAP0600698-09
Creator
Mariana Solomon
SQM - Quality
Date: 27.03.2015
E-sign ID: 3770142
Process Owner
Hans-Guenther Kein
Quality Manager
Date: 27.03.2015
E-sign ID: 3770142
Change Reason
Add information about the
storage of the scraped parts
in quarantine area.
Objective
Subject: To define the process in case a quality alert is initiated from production line, from the raw material
supplier, or from other Continental locations (in a form of Early Warning or Read Alert) related to the raw materials
waiting to be assembled in CA Plant BSV's production line.
Goal: This procedure is applicable for Continental Powertrain Romania, production site 1 (Cristian) production site
2 (Ghimbav). Note: For situations when the quality alert also affects materials in unrestricted stock, the reaction
process to be applied is described in CAP0600703 Faulty Materials in Unrestricted Stock.
Scope
This regulation is mandatory for:
Continental Automotive and its majority
interests as well as minority interests with
management control by Continental Automotive.
Division
Business Unit
Automotive Function
Region
Country
Site
Plant
Brasov
Other
Table of Content
Procedure: Faulty Material in Production Area ............................................................................................................. 1
1 Process Flow ......................................................................................................................................................... 2
1.1
Faulty Material in Production Area ............................................................................................................... 2
1.1.1 Rasi Chart ................................................................................................................................................. 4
2
3
4
5
6
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Automotive
CAP0600698-09
1
1.1
Process Flow
Faulty Material in Production Area
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Automotive
CAP0600698-09
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Automotive
CAP0600698-09
Input
Identify the
suspect materials
in production line
Good materials in
unrestricted stock
Suspected materials to
be quarantined
10
11
12
NCR updated
Suspected
materials to be
quarantined
All affected
departments must
take actions if
production could
be affected
Sort necessary?
Logistics, SQM
and supplier
decide if sorting is
necessary
Sort needed
Sort needed
Sort needed
Identify good/bad
materials
Quality information to
the supplier and
request sorting
Verification of the
next 3 deliveries
I
Suspected materials
blocked
Output
Quality issue in
production area
2
Activities
Applic
able
Docu
ments
LO Whs.
LO
Analyze Technician
Financial
Quality Inspector
IQC Technician
Shift Supervisor
PQE
ME
Supplier
SQM
N
o.
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CAP0
6
00694F01
Automotive
CAP0600698-09
14
15
16
17
18
19
Input
Activities
Output
Sorting activity
necessary
Parts in
Quarantine area
Segregate between
good and bad materials
Good Materials?
Good materials
needed for
production
Good materials
Good materials
needed for
production
Good materials
Good materials
needed for
production
LO Whs.
LO
Analyze Technician
Financial
Quality Inspector
IQC Technician
PQE
ME
SQM
13
Shift Supervisor
Supplier
N
o.
S
Bad materials
20
R
Bad materials identified
21
22
23
Bad materials in
quarantine
Quality claim to
the supplier
All affected
departments must take
actions if production
could be affected
Additional costs
generated by the
quality complaint
Invoice the
additional costs to
the supplier
SQM request
confirmation for
returning the affected
batches to supplier
Invoice of raw
material costs
Incoming Inspection
needed
Due to
disturbance
materials must be
inspected
Segregate between
good and bad parts
24
I
25
26
27
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Applic
able
Docu
ments
Automotive
CAP0600698-09
28
2
2.1
Input
Activities
Output
Additional costs
generated by complaint
Invoice the
additional costs to
the supplier
Applic
able
Docu
ments
LO Whs.
LO
Analyze Technician
Financial
Quality Inspector
IQC Technician
Shift Supervisor
PQE
ME
Supplier
SQM
N
o.
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CAP0600698-09
16. All good materials are transferred in SAP by IQC tech from IQC area to WHS (unrestricted stock) using
transaction LT10 (Movement type: 945).
17. Good materials are transported from IQC area to WHS unrestricted stock.
18. All released materials are transferred from IQC to Raw material WH by WH operator.
19. Transfer the bad raw material phisycal and in SAP to Quarantine by IQC.
20. IQC technician must create the Quality Notification into SAP and link it with the NR from production
21. SQM create non-conformance report (QM01 - Create Quality Notification) and SQM sends official
complaint to the supplier which caused the disturbance.
22. SQM must ensure collection of all additional cost using the ADCOM tool. Before an ADCOM to be opened,
SQM must get the confirmation from supplier that he will assume the scrap cost. In case the supplier wants
to see the physical parts, a temporary zone will be defined and marked inside the quarantine area.The
parts will be labeled accordingly and they will exist only physical (once the parts are charged in ADCOM,
they are automatically scraped in SAP).In SAP the temporary zone occupied with parts charged in ADCOM
will not be available for SAP transactions (the zone will be bloked - LS06). Possible situations after costs
are issued in SAP: CLD closed debited ( all costs are invoiced to supplier and will be reimbursed) or CLN
closed not debited ( costs are invoiced, but will not be reimbursed ).
23. SQM must receive the approval from the supplier to send back the bad parts.
24. Finance must issue a Debit Note to the supplier for the cost of the materials ready to be shipped.
25. SQM must update the Incoming Inspection Test Plan for the new deliveries.
26. LO WHS will pack the goods for shipping.
27. SQM must ensure receipt of 8D report.
28. Finance must charge the additional costs to the supplier as directed by the SQM / Purchasing Dept.
Close official complaint.
2.2
Abbreviations
ME
PQE
STS
IQC
IQC tech
SQM
LO
LO WHS
STS flag
SAP
TO
S
NCR
Rcvg SLoc
SLoc
AT
QI
2.3
- Manufacturing Engineer
- Production Quality Engineer
- Ship to Stock
- Incoming Quality Control
- IQC Technician
- Supplier Quality Management
- Logistic Order
- Logistic Warehouse
- Ship to stock, no incoming inspection required
- ERP system
- Transfer Order (initiated via SAP_WM)
- Special stock
- Non conformity report
- Receiving storage location
- Storage location
-Analyze Technician
-Quality Inspector
Definitions
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Automotive
CAP0600698-09
Implementation
References
4.1
Mandatory
4.2
Other
Document History
Rev.
#
Change Description
Process
Owner
Date
01
Irina Gaceu
05.11.2010
02
Irina Gaceu
01.04.2011
03
Irina Gaceu
28.04.2011
04
Modify RASI chart with only one responsible per action, adding SAP
transactions at step 6 from point 1.3 (E-sign: 1463990).
Irina Gaceu
07.11.2011
05
Irina Gaceu
18.03.2013
06
Irina Gaceu
08.08.2013
07
New transaction numbers added; new process owner (E-sign ID: 2967029)
Rainer
Kehnscherper
26.03.2014
08
IQT makes the Quality Notification and links the Nonconformity Report
from production with the claim. Quality Inspectors and Analyze
Technicians are introduced and their responsibilities are defined. New
forms added, CAP0600698-F01 - Test Report Nonconformity and
CAP0600698-F02 - Nonconformity Order Registry (E-sign ID :3750296)
Add information about the storage of the scraped parts in quarantine area
(E-sign ID: 3770142).
Hans-Guenther
Kein
20.03.2015
Hans-Guenther
Kein
27.03.2015
09
Responsible persons
6.1
Process Team
(dd.mm.yyyy)
The members of the Process Team have reviewed the procedure and their feedback has been considered. The
Process Owner keeps records about the Review.
Name
Department
Site
Cristian Lupsiasca
SQM
Brasov
Hilmar Burg
Logistics
Brasov
Manuela Aghiana
Finance
Brasov
Rainer Kehnscherper
Plant Manager
Brasov
Adrian Cotarlea
Production
Brasov
Bogdan Pruteanu
Manufacturing Engineering
Brasov
Joerg Beisheim
Production
Brasov
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