Supplier Quality Manual
UNCONTROLLED DOCUMENT, see on-line master for current rev

Document Number: DCP 6050 Revision #: 2.8
Document Owner: Ed Roll, QA Manager Date Last Updated: 07/20/2015
Author: Ed Roll, QA Manager Status: Approved and Released

General Description Requirements Overview of Steps Detailed Steps
Revision History Authorization History Contributing Authors Annual Review Click to Verify  

General Description
Task / Scope: To provide Suppliers of Dayton Phoenix Group West Lafayette Facility (DPG West Lafayette) a guide line to the minimum quality system expectations. To provide instructional materials and forms for quality related documentation. The manual establishes the responsibilities of the supplier to DPG West Lafayette Facility
 
View this manual On-Line:
www.dayton-phoenix.com Click on ABOUT, then under SUPPLIER QUALITY MANUALS click on WEST LAFAYETTE
       or
Request the latest revision of this manual via E-mail.
Address the request to: sales@dynohm.com

Purpose: To support the requirements of DPG West Lafayette's Quality Policy manual, section 7.4.1.
It is DPG West Lafayette's Quality Policy that DPG West Lafayette will deliver the highest quality products, that have the best value and deliver them on time, every time. In order for DPG West Lafayette to achieve this goal it's suppliers must deliver goods and services that support this quality goal. The Supplier Quality Manual has been prepared to assist suppliers in understanding the basis of DPG West Lafayette's Quality expectations. It establishes minimum quality requirements for all suppliers of materials and services.

This supplier quality manual is a supplement to other terms and conditions covered by DPG West Lafayette's purchasing documents. It does not replace or alter any of the terms, conditions, and Engineering drawings or specifications stated in those documents.

Who Performs: Purchasing
Quality Assurance

The Quality Manager is responsible to provide copies and/or notify suppliers that the Supplier Quality Manual is available via the DPG Dayton web site, www.Dayton-phoenix.com



Department: Quality Assurance
Purchasing

When to Perform:
Specific Circumstances:
Supplier Quality Manuals are to be given to suppliers when:
New suppliers are approved;
Upon release and revision of this manual


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Requirements
Definitions: Certified Quality System
ISO 9001 or TS16949 based quality system that has been certified to a valid version of one or more of these standards by a third party registrar.

Compliant Quality System
ISO 9001 or TS16949 quality system that is fully documented and conforms to the standard.

Control Plan
A written description of the systems for controlling parts and processes.

First Article
A written record of dimensional and test results that show conformance or nonconformance to specifications.

Gage R & R
Gage Reproducibility and Repeatability study intended to determine the measurement system error which is the combination of gage bias, repeatability, reproducibility, stability and linearity.

Warrant
An industry standard document required for all newly-tooled or revised products in which the supplier confirms that inspections and test on production parts show conformance to customer requirements.

Equipment: MS Word, version 97 or higher
MS Excel, version 97 or higher
Acrobat PDF reader, version 4.0 or higher

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Overview of Steps
1. Quality System Requirement
2. Quality Planning
3. Nonconformance to specifications
4. Initial Sample requirements
5. Evaluations of suppliers
6. Forms and Instructions
7. Gage R & R study
8. Supplier Quality system survey
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Detailed Steps
1.
Quality System Requirement

How to Do:
The items outlined here are designed to clarify the basic elements required for an effective quality system. Suppliers should utilize procedures and systems that build from these basic elements. A Quality System based on a valid version of ISO 9001 or TS16949 quality system standards is preferred.

The preferred level of compliance is to have the Quality System certified by a third party registrar.
An acceptable alternative is assessment by a second party.

2.
Quality Planning

How to Do:



2.1
Quality Planning

How to Do:
Quality Planning:
The suppliers methods to control the quality of goods or services provided to DPG West Lafayette should be documented in a Quality Manual. The supplier should review and update their manual on a regular basis to assure the manual meets the suppliers current quality objectives and programs.

For specific parts, DPG West Lafayette may require Product Quality Planning documents. For parts that require product quality planning, the plans and related documents must be submitted to DPG West Lafayette Quality Dept. along with "First Article" submission. When required, DPG West Lafayette indicate what documents are required on the purchase order.

The supplier will perform design and/or process Failure Mode Affects Analysis (FEMA) when required by DPG West Lafayette
Quality Dept.

2.2
Drawing Control

How to Do:
The supplier must assure that the latest revision of all drawings are available to all concerned and that they understand their requirements.
Any clarifications or interpretations of drawings and/or specifications should be initially directed to DPG West Lafayette's Purchasing Dept.

2.3
Design and Process Change Control

How to Do:
As a supplier to DPG West Lafayette, your products play a key roll in helping assure we can keep our commitments to our customers. Our Quality Policy commits us to providing the highest quality products and best value with on time delivery every time. DPG West Lafayette can not achieve the goal of our Quality Policy without your support.

One area that must be given particular attention is the issue of change. It is essential that DPG West Lafayette be notified of all process changes, even those that do not obviously affect the measurable features of a part. DPG West Lafayette must approve changes in order to avoid any adverse impact on our customers.
The types of changes:

- Alternate materials
- New tooling/ Major refurbishment/ Modified tooling
- New sources for sub-contracted parts, materials or services
- Process changes for method of manufacture
- Production from tooling and equipment transferred to a different plant or location.

Notices of process changes are to be submitted in advance of implementation to the Quality Assurance Manager of DPG West Lafayette. Your support and compliance to this requirement is greatly appreciated.


2.4
Measurement and Test Equipment

How to Do:
The supplier should maintain adequate inspection and test equipment to assure product conformance to specifications. All measuring instruments, fixtures and test equipment used to measure conformance to specifications must be calibrated prior to use and at pre-established intervals to ensure continued accuracy. Calibration must be done in accordance with internationally or nationally recognized standards such as N.I.S.T. Records of calibration are to be maintained (by device) that show the date of calibration, the results of the last calibration and the next scheduled calibration date.

2.5
Manufacturing Process Control

How to Do:
The supplier should apply procedures and controls that maintain identification of materials, conformance to specifications and test requirements.
Some common elements used to maintain sufficient control include:
1) Instructions, written process, test and inspection procedures that are readily available and understood by the personnel performing the work.

2) Determination of Process Capability
The potential for a process to produce parts within specifications is determined through process capability study. A minimum goal should be a CPk of 1. ( a CPk of 1 equates to a process that produces 99.73% within specifications.)

3) Ongoing Process Control
The supplier should maintain in-process inspection or tests that are adequate to maintain continuous control of the production process. Characteristics identified by DPG West Lafayette as critical to quality should have statistical control measures applied. DPG West Lafayette may require statistical control for critical to quality characteristics. When specific controls are required by DPG West Lafayette, records of inspection or test results should be documented for review by DPG West Lafayette Quality Assurance.

2.6
Product Identification & Packaging

How to Do:
The supplier must maintain controls to identify and protect the product during the manufacturing and delivery cycle. These controls should be designed to protect the product from damage and contamination during manufacture, storage and delivery.

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3.
Nonconformance to specifications

3.1
Found at the Supplier

How to Do:
The supplier should have procedures in place to control non-conforming product and preclude it's inadvertent shipment to DPG West Lafayette. DPG West Lafayette Quality Assurance must be immediately notified of any shipments of non-conforming material. DPG West Lafayette can then contain the non-conforming material and initiate corrective action. The supplier will be responsible for any costs incurred by DPG West Lafayette to sort, rework or return non-conforming goods.

When material is known to be non-conforming Suppliers must obtain a signed deviation from DPG West Lafayette Quality Assurance before shipping.


3.2
Found at DPG West Lafayette

How to Do:
When a nonconformance is found at DPG West Lafayette the supplier will be notified by DPG West Lafayette Quality Assurance Dept. DPG West Lafayette will arrange for disposition of the nonconforming material. It is the Suppliers responsibility to bear the costs for returning goods or rework expenses if the rework is done by DPG West Lafayette employees. Any rework to be done at the suppliers expense will be agreed upon before the rework is started.
The supplier will be required to submit a written corrective action plan to DPG West Lafayette's Quality Assurance Department which outlines corrective action measures and effective dates. DPG West Lafayette's Quality Assurance Dept. will issue a Supplier Corrective Action Request (SCAR) when nonconformances occur.

3.3
Found from Warranty Claims

How to Do:
In cases where nonconformance is discovered through warranty claims, DPG West Lafayette may ask the supplier to share in the costs associated with the warranty expense. This is not meant to define legal rights and obligations of either DPG West Lafayette or the supplier.

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4.
Initial Sample requirements

4.1
When Initial Samples May be Required

How to Do:
DPG West Lafayette may request samples under the following conditions: when parts are being ordered for the first time; when an engineering revision is made to a part; when qualifying a new supplier; when the supplier changes tooling, process, alternate materials or manufacturing location.
Samples should be from production tooling when possible.

4.2
First Sample Inspection and Test

How to Do:
The supplier shall perform inspections and tests to assure the samples conform to specifications.
For new parts, the supplier shall submit a first article inspection report upon delivery of the parts. The first article must contain dimensional and test results. The number of parts to be 100% checked will be determined at the time the order is placed, and will come from DPG West Lafayette's Purchasing Dept.

When part revisions, due to Engineering changes or correction(s) to nonconformance from previous sample submissions, the first article inspection need only cover the characteristic(s) affected.



4.3
Sample Identification

How to Do:
Sample parts submitted shall have the package marked as samples, contain the Purchase Order number and noted that a sample inspection report is included.
If the supplier does not have a first article inspection form, see the Forms section of this document.

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5.
Evaluations of suppliers

5.1
Potential Suppliers

How to Do:
DPG West Lafayette's first preference for suppliers quality systems is ISO 9001, M1003 or TS16949
third party registered.
The next preference is certified to be compliant by a second party to the above quality system standards.


5.2
Current Suppliers

How to Do:
Quality system surveys may be sent to current suppliers that are not certified to ISO 9001, M1003 or TS16949 quality system standards. The surveys are used to assess the suppliers quality system compliance to DPG West Lafayette's minimum requirements.


5.3
Supplier Surveillance

How to Do:
Suppliers may be asked to participate in Quality System audits by DPG West Lafayette personnel. Quality System audits are designed to certify a suppliers Quality System so that incoming inspection is not required at DPG West Lafayette. Suppliers may also be asked to provide records of inspection and/or test results for part and materials supplied to DPG West Lafayette.

5.4
Supplier Rating System

How to Do:
Supplier ratings are performed by DPG West Lafayette's Purchasing Dept on selected suppliers via a supplier report card. Ratings are based on three categories: Delivery; Quality of products supplied; Commercial. Supplier report cards are completed once each quarter (four times per year).

A supplier may be placed on probation at the discretion of Purchasing or Quality Assurance based upon the nature and severity of the problem, regardless of suppliers rating.

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6.
Forms and Instructions

6.1
Control Plan

How to Do:
The purpose of a Control Plan is to aid in the manufacture of quality products according to customer requirements. Control Plans provide a written summary description of the systems used to minimize process and product variation. The Control Plan describes the actions that are required at each phase of the process including receiving, in-process, out-going, and periodic requirements to assure that all process outputs will be in a state of control. The Control Plan is to be maintained and used throughout the product life cycle.
Click for Control Plan form
Click for Control Plan Instructions

See attached instructions for completing a Control Plan .
The following item numbers must be completed: 1,2,3,4,5,10,11,16,17,19,20,21*,22,23,24,25,26
* denotes Critical to Quality dimension/feature.

Note: Control Plan form and instructions:
Reprinted with permission from the APQP Manual (DaimlerChryser, Ford, General Motors Supplier Quality Requirements Task Force).


6.2
First Article

How to Do:
Click to obtain form:   Sample Inspection form
How to fill out the form:
All lines in the header must be completed, with the exception of: Approved by.

Dimension Number:
Assign a corresponding number to a dimension or feature on the print and circle the number on the print.

Print Specified Dimension:
Record the dimension to be measured.

Measured Undersize:
Record actual reading if under (nominal dimension - tolerance)

Measured OK:
Record actual reading if with-in specifications

Measured Oversize:
Record actual reading if over the (nominal dimension + tolerance)

Measurement Method/Notes:
Record what instrument(s) were used to measure the feature and if the measurement method has passed gage R & R

6.3
PPAP Warrant

How to Do:
Suppliers may be asked to provide a completed Warrant (along with other Production Part Approval Process (PPAP) documents. When PPAP documentation is required the supplier will be notified by DPG West Lafayette Purchasing Dept of the requirement and the documents that must be submitted.
Click to obtain form:
PPAP Warrant form
Click to obtain Warrant instructions: Warrant Instructions

Note: Warrant form and instructions
Reprinted with permission from PPAP Manual(DaimlerChryser, Ford, General Motors Supplier Quality Requirements Task Force).

6.4
Gage R & R Study

How to Do:
Suppliers may be required to perform Gage R & R studies for validation of measurement systems used to check critical to quality feature(s) identified on parts supplied to DPG West Lafayette. Gage R & R studies may also be required as part of the Production Part Approval Process (PPAP). Requirements for Gage R & R will be coordinated through DPG West Lafayette's Quality Assurance Dept.
Suppliers are encouraged to perform Gage R & R studies on their own, so they may be assured that the measurement systems used to qualify parts or process are providing reliable data upon which to make decisions.


Note: Gage R & R forms and examples
Reprinted with permission from the MSA Manual (DaimlerChryser, Ford, General Motors Supplier Quality Requirements Task Force).


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7.
Gage R & R study

How to Do:
There are two types of gage studies, the most common is measurement, or variables data, the other is attribute, or go, no-go, pass/ fail. Examples of variables: using a caliper to measure a feature on a part, using a ruler to measure length. Examples of attribute : using a plug gage to check a hole diameter, using a thread gage to check a tapped hole.

Note: all instructions and forms
Reprinted with permission from the MSA Manual (DaimlerChryser, Ford, General Motors Supplier Quality Requirements Task Force).


7.1
Variables or measurement type Gage R & R

How to Do:
Variables Gage R & RClick to open file:  
Click open Instructions: Variables Gage R & R Instructions

See attached instruction example and forms.
Note: If the supplier does not have the capability to receive files via E-mail or does not have access to the Internet, contact DPG West Lafayette's Quality Department for copies of the manual calculation method for variables gage R & R.

7.2
Attribute or go, no-go type Gage R & R

How to Do:
See attached example and instruction.
Click for Attribute form:
Attribute form
Click for Attribute instructions:
ARRINSTR.DOC  

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8.
Supplier Quality system survey

How to Do:
The Supplier Quality System Survey is to be used as a self assessment tool. The survey provides the supplier a means to communicate the level of development of their quality system to DPG West Lafayette.
Click to obtain Supplier Self Survey form:
Supplier Quality System Survey

Suppliers that are not ISO 9001 or TS16949 certified are generally asked to complete a self assessment.

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Revision History
Revision #:
2.6
03/04/2009
Changed company name from Dynamic Corp to DPG Montmorenci Facility

Revision #:
2.7
06/24/2013
Step 6.2 updated link to sample inspection form, step 8 updated link to supplier quality system survey form

Revision #:
2.8
07/22/2015
added M1003 quality standard to steps 5.1 and 5.2. step 5.4 removed customer service as a rating factor.

Revision Notes: Ver 2.6: Annual review by Ed roll on 5/21/09, no changes needed.
Ver 2.6: Annual review by Ed roll on 5/10/10, no changes needed.
Ver 2.6: Annual review by Ed roll on 5/18/11, no changes needed.
Ver 2.6: Annual review by Ed roll on 5/31/12, no changes needed.
Ver 2.7: Made as result of annual review by Ed roll on 6/24/13.
Ver 2.7: Annual review by Ed roll on 6/20/14, no changes needed.
Ver 2.7: Annual review by Ed roll on 6/3/15, no changes needed.
Ver 2.8 : Made as result of internal audit by D. Fleming, 6/29/15



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Authorization History
Debbie Fleming
Dir Operations
debbie@dynohm.com
1.0
Date Approved:
02/11/2000

Ed Roll
QA Manager
edward@dynohm.com
1.0
Date Approved:
02/11/2000

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Contributing Authors
The following are subject matter experts who contributed to this document:
Debbie Fleming, Dir Operations
Diana Venable, Buyer

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