Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 14 of 59 8. QMS objectives Our quality objectives (extract related to supply chain for the period) are defined below: Objective 1 Supplier delivery performance: Increase OTIF from 98.5% > 99.5% Objective 2 Supplier quality performance: Increase PPM from 3000 < 500 Objective 3 Reduce no of supplier CARs raised from 5/month to < 3/month Objective 4 Improve PPAP RFT from 97% to 98.5% Objective 5 Reduce number of PO errors from 5/quarter to < 3/quarter Objective 6 No of certificates out of date to reduce from 5/quarter < 3/quarter 9. Competencies The competency of staff at OML is important to the continued success of the business. All jobs have had their competencies assessed and staff doing those tasks will have been assessed to ensure they have the necessary competencies. There is a competency matrix showing jobs and staff. Competencies are assessed on a six monthly basis. 10. Documented information All documentation within OML falls within the ‘Master Document Control Form - QMS01’. As such all documents are controlled and show approval and version status. Documentation is only issued on a need to know basis. As all documentation can be found on the intranet all hard copy documentation is deemed as being uncontrolled. Doc No QMS 06 Authorised by: QM Version No 3 Date: 25/04/20xx
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 15 of 59 11. Customer satisfaction The satisfaction of our customers is key to OML. We use the following performance indicators to evaluate customer satisfaction: Customer scorecard(s) Delivered part quality performance (PPM) Customer disruptions Delivery schedule performance (including incidents of premium freight) Customer notifications related to quality or delivery issues, including special Corrective action requests These are subject to monthly review. This is supported by perception based on surveys which include: Communication Responsiveness Accuracy On time delivery Quality Surveys are sent out annually and responses are scored 0-10 categorised as below: Excellent: 8-10 Good: 6-7 Average: 4-5 Poor: 0- 3 12. Complaints, nonconformity and improvement Customer complaints are logged onto the CAR Log which will identify the nature of the complaint, internal or external (customer/supplier). Customer-specified documentation and processes will be used where required. Nonconformity is logged through the MRB cages and all nonconforming product will be segregated and quarantined until disposition. Known scrap product will be rendered unusable prior to being disposed of. Improvement teams operate within the organization, these are given management support and improvement activity is reported at the monthly operations meeting.
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 16 of 59 [Thanks for reading the background. The below is for your general reference throughout your audit] Doc No QMS 01 Authorised by: QM Version No 12 Date: 03/06/20xx Master document control form (extracts) This form (extract) applies to all policies, processes, and documented information, produced by OML, that need to be controlled within the automotive quality management system (AuQMS). Document Information Version status Document description QMS 01 12 Master document control form QMS 02 3 QMS scope QMS 03 5 Context QMS 04 2 Policy, roles and responsibilities and customer focus QMS 05 5 Organizations processes and QMS overall objectives QMS 06 4 Competencies, documented information, customer satisfaction, nonconformity and improvement OML-P06 4 Supply chain management process PF-06-01 2 Supplier questionnaire PF06-02 3 Approved supplier list PF06-03 3 Purchase order HRF-01 3 Job specification HRF-02 2 Competency matrix HRF-03 3 Training plan HRF-04 2 Appraisal plan SRM-01 5 OML Supplier requirements manual [To prepare for your audit, please now review the information presented overleaf, which is the documented information directly associated with your Audit Criteria]
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 17 of 59 Supply chain management process Process step Resp. Process step description Activity (inputs/outputs) 1 Buyer/QA Supplier selection and approval Production materials The Buyer will choose prospective new production suppliers at the start of each project. All prospective new suppliers will be sent an electronic version PF06-01 Supplier Questionnaire. All questionnaires will be reviewed and the supplier will be: Accepted Require site audit and/or Accepted subject to CA If the supplier meets the initial criteria they will be signed off by the Buyer and Operations Manager then will be contacted, and added to the Approved Supplier List PF06-02. Note: Customer nominated suppliers will be placed onto the system and will be sent an electronic version of PF06-01 Supplier Questionnaire. The systems will be set to ensure that they can’t be changed without reference to customer. The approved supplier list will include: Supplier name Supplier grade Commodity/scope Customer nominated (Y/N) Special processes Where suppliers are delegated responsibilities for special processes delegations will be included in ERP System and identified on the purchase order as required and may include: Testing/inspection as defined on the drawing/specification Documentation to be supplied with each delivery Documented information is maintained by the supplier Monitoring and measurement: Review of all returned supplier questionnaires and certificates. Competencies: Supplier selection processes knowledge and application. Intended results: Selecting capable suppliers and maintaining certification. Performance indicator: Currency of supplier certificates. Doc No OML-P06 Authorised by: Ops Manager Version No 4 Date: 30/09/20xx
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 18 of 59 Process step Resp. Process step description Activity (inputs/outputs) Resources needed: IT equipment, suitable software, competent buying and QA staff. Objective: All current suppliers are listed on approved supplier list have a current certificate. No of certificates out of date to reduce from 5/quarter < 3/quarter. 2 Buyer Production Material Procurement Purchase enquiries The Buyer will send a quotation request to the appropriate supplier(s), three will be required. This quotation request will require suppliers to give detailed cost breakdowns. The supplier will be sent drawings, specification, and samples etc. where applicable. QA Supplier PPAP process The supplier will be requested to submit PPAP prior to delivering production parts. OML-P05 New Product Introduction Process (APQP) will detail all the need dates; this may be supported by a project plan. When PPAP approval has been given by QA, production deliveries can commence. Buyer/ MD/Ops Manager Purchase orders The Buyer will raise a PF06-03 Purchase Order using the ERP System to cover production requirements. The order will define: Quality required Part number/description/rev. level Unit price (£'s) All purchase orders shall be countersigned by the Managing Director or the Operations Manager and the Buyer. Approved PO’s will be sent to the supplier via fax or email. Buyer / Ops Mgr Expediting The buyer will report all stock outs/shortages to the Operations Manager. When over deliveries/under deliveries are identified the Buyer will contact the supplier and resolve the issue. Monitoring and measurement: All enquiries reviewed prior to acceptance. All purchase orders reviewed prior to issue. PPAP Reports reviewed prior to acceptance. Competencies: Purchase order process knowledge and application. PPAP process knowledge and application. Intended results: Accurate purchase orders, first time approval of PPAP. Performance indicator: Accuracy of PO’s, PPAP submission RFT.
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 19 of 59 Process step Resp. Process step description Activity (inputs/outputs) Resources needed: IT equipment, suitable software, competent buying staff. Objective: Reduce number of PO errors from 5/quarter to < 3/quarter. Improve PPAP RFT from 97% to 98.5%. 3 Storeman /Accounts Receipt of Materials, Product or Processed Parts from Suppliers Raw material The material will be located in the holding area and will book the material into ERP System. A Blue Identification Ticket is then created and endorsed with the unique number, the material will be located in the stores in readiness for manufacture. The delivery note will be passed to accounts. QA/Buyer If the material is found to be defective they will be processed as detailed in OML-P10 Control of Nonconforming Product and Corrective Action Process. Storeman / QA Sub contract machining and processed parts The product will be located in the holding area and will book the product into ERP System. The Storeman will then identify the product or processed parts with a Yellow identification label detailing the Works order number/quantity Part number/status The Storeman to notify inspection that verification is required and the delivery documentation passed to QA. Inspection will then verify the product or processed parts in accordance with the purchase order requirements and specification and generate a Green label and the parts are located in the stores awaiting production. If the delivery is rejected the Quality Manager is informed and the batch will be processed as detailed in OML-P10 Control of Nonconforming Product and Corrective Action Process. Buyer Supplier terms and condition Supplier PO’s will ensure that OML T&C’s includes the requirement for PPAP approval prior to production shipments taking place. Monitoring and measurement: Monthly review of nonconformities and delivery performance at GII. Competencies: Receiving inspection processes knowledge and application, nonconforming product and corrective action process knowledge and application. Intended results: First time pass rate and on time delivery at GI.
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 20 of 59 Process step Resp. Process step description Activity (inputs/outputs) Performance indicator: Supplier delivery performance (DSA) Incidents of premium freight Supplier quality performance PPM Supplier CAR’s raised PPAP RFT PO errors No of certificates out of date Resources needed: IT equipment, suitable software, competent buying and QA staff. Objective: Increase DSA from 98.5% > 99.5%; Supplier quality performance: Increase PPM from 3000 < 500; Reduce no of Supplier CARs raised from 5/month to < 3/month Improve PPAP RFT from 97% to 98.5% Reduce number of PO errors from 5/quarter to < 3/quarter No of certificates out of date to reduce from 5/quarter < 3/quarter Human resources required for the operation of process; Buyer – (Process Owner), Ops Manager, QA Inspector, Storeman, Finance.
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 21 of 59 Doc No SRM 01 Authorised by: QM Version No 5 Date: 03/06/20xx Extract of customer specific requirements (OML-Supplier Requirements Manual) PPAP Procedure Suppliers submitting initial samples will ensure that all submissions are supported by the PPAP documentation at the level agreed with Orbit Manufacturing Ltd. (Using PPAP 4th Edition). Procedure There are 5 submission levels, these are: Submission Level Supporting Documentation Level - 1 Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the Orbit Manufacturing Ltd. Level - 2 Warrant with product samples and limited supporting data submitted to Orbit Manufacturing Ltd. Level - 3 Warrant with product samples with complete supporting data submitted to Orbit Manufacturing Ltd. Level - 4 Warrant (no product samples) with complete supporting data submitted to Orbit Manufacturing Ltd. Level - 5 Warrant with product samples and complete supporting data reviewed at the supplier’s manufacturing location. Level 3 will be the default level to be utilised for all submissions unless otherwise advised by Orbit Manufacturing Ltd. Special characteristics During the APQP process and particularly during the preparation of FMEA's and control plans the Suppliers planning team shall finalise special characteristics and establish appropriate process controls for such characteristics. The supplier shall make these available for review, when so requested. Potential Failure Mode and Effects Analysis (FMEA) Process FMEA's shall consider all special characteristics and efforts shall be taken by suppliers to improve the process to achieve defect prevention rather than defect detection. Suppliers may be required to seek Orbit Manufacturing Ltd., PFMEA review and approval prior to production. This requirement will be communicated on the purchase order documents, or during the SQA visits. An FMEA is a tool, which assists in the elimination of risk by a disciplined analysis of possible failure modes based on the severity, the probability of an occurrence and the likelihood of detection. (Using FMEA 4th Edition).
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 22 of 59 Control plans Suppliers shall develop control plans at the system, subsystem, component and / or material level, as appropriate for the product supplied. The control plan requirement encompasses processes producing bulk materials (e.g. steel, plastic resin, paint) as well as those producing piece parts. The output of the advanced quality planning process, beyond the development of robust processes, is the control plan. Control plans may be based on existing plans (for mature products and capable processes); as per APQP 2nd Edition Measurement systems analysis Measurement system analysis will be conducted on all measurement systems identified on the control plan and all measurement systems used for statistical studies. Studies will be conducted as per MSA 4th Edition (GRR ≤ 10%, unless otherwise agreed with OML representative). Statistical studies Initial process studies to support PPAP submissions will be conducted as per SPC 2nd Edition. The initial process capability is conducted to obtain early information on the performance on a new or revised process. At least 20 subgroups of 5 parts per subgroup should be used in plotting the chart, which form the basis of the study. A preliminary process capability study is unlikely to reflect the full extent of process variation due to, e.g. shift changes, different material batches, environmental changes etc. Initial process capability is measured by the preliminary process capability index (Ppk/Cpk depending in the stability of the data). The minimum requirement unless otherwise stated will be 1.67. [The extracts of documented information presented overleaf will be the documented audit evidence associated with your audit criteria, that have been provided to you during your audit. This documented information would normally have been selected, by yourself, through a sampling approach.]
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 23 of 59 Supplier questionnaire Supplier Questionnaire Company Orbit Manufacturing Limited Address Orbit Manufacturing Limited Units A to C Industrial Estate Telephone: 0111 2345 1111 Fax: 0111 2345 1123 Email: [email protected] To Supplier contact Bill Baker Company Auto Precision Pressings Ltd Address Telephone: 12929 – 10101 11 Fax: 12929 – 10101 222 Email: [email protected] Willbourne Street Wellington Completed by: Bill Baker Position: Sales Manager Date: Jan 20xx Signature: Bill Baker Description of product/service supplied Pressings and assemblies Complex assemblies Management information Managing Director Turnover Barry Sumner £1,000,000 Number of employees (company) Number of employees (this plant) 350 125 Number of engineers (Quality/Process/Design) 12 in total, 5 quality engineers, 4 process engineers and 3 design engineers Customer information Major customer(s) Main product(s) Customer A Customer B Pressings Pressings and assemblies Process control Prototype capability Tool manufacture No In House / Subcontract List of processes List of testing/inspection capability Machining, assembly, packaging Hardness testing
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 24 of 59 Commercial information Item Comments Acceptable Quotation(s) (any revisions) Quotation was accepted Yes/No Settlement terms 30 Days Yes/No Carriage paid Ex works Yes/No Any minimum charges < 10, 10% Additional charge Yes/No Estimated volumes per annum 18,000 Yes/No Tooling estimated life N/A N/A Tooling amortise N/A N/A Lead times 6 weeks Yes/No Confidentiality (any requirements) No – standard parts Banker’s details: (sort code, branch, account number) 0999190001 - 011 Quality Information QMS Comments Acceptable 9001 Approved with BSI Yes/No Certificate number 1234567 Yes/No Expiry date May 20xx, and June 20xx Yes/No Summary Quality audit required ISO 9001 therefore no audit required at this stage Comments Working towards 16949 Buyers signature: John Philips Date: Jan 20xx Operations Manager signature: Date: Jan 20xx
Case Study (Delegate) Approved supplier list Orbit Manufacturing Ltd Material - Approved Supplier List - Extract Description Scope Company Supplier Audited Supplier Questionnaire Returned Third Party Cert Third Party Cert Expiry Date Sub-contract supplier Metal Metal Finishing Co. Ltd Yes Yes Yes 10/2/20XX Sub-contract supplier Customer nominated Surface Technology Ltd No No Yes 18/05/20XX Sub-contract supplier Customer nominated Wibble Tubes Ltd No No Yes 20/09/20XX Material stockist Widgets Materials UK.Com Ltd No Yes Yes 30/09/20XX Material stockist Flat steel Any Metal Services Ltd No Yes Yes 08/01/20XX Sub-contract supplier Coating Aluminium Surface protection No Yes No N/A Material stockist Torque Bars and Roll Shafts Auto Precision Pressings Ltd No Yes Yes 24/12/20XX Mtiltkit Hihiihidt FitLtdY Y Y 27/02/20XX
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 25 of 59 PF06-02 Rev 3 Jan 20XX Material stockist High precision machined parts Farpoint Ltd Yes Yes Yes 27/02/20XX Sub-contract supplier Customer nominated Heat Treatments Ltd Yes No Yes 03/03/20XX Material stockist Metal Metals & Plastics Ltd Yes Yes No 19/11/20XX Material stockist Metal Merthyr Metals Ltd Yes Yes Yes N/A Sub-contract supplier Drilling fixtures Drilling services Ltd Yes Yes No N/A Sub-contract supplier Inserts for welding application E. Williams & Sons Ltd Yes Yes Yes 11/08/20XX Sub-contract supplier High precision machined parts High Precision Co. Ltd Yes Yes Yes 20/09/20XX Material stockist Metal Sintered Metals Ltd Yes No Yes 19/11/20XX Material stockist Metal Davies Alloys Ltd Yes Yes No N/A Sub-contract supplier Customer nominated Harrison Ford Ltd No No Yes 08/01/20XX Material stockist Metal Wilson Metals Ltd Yes Yes Yes 03/05/20XX
Case Study (Delegate) Purchase order Orbit Manufacturing Limited Date: September 28, 20xx Best in class supplier P.O. #: 12345 Vendor Bill Baker Ship to John Philips Auto Precision Pressings Ltd Orbit Manufacturing Limited Willbourne Street Units A to C Wellington Industrial Estate 0111 2345 1111 Delivery Date 17 November 20xx Qty Part No Description Rev Level Unit Price (£'s) Line Total HingeLH(PPAPsubmission Purchase Order
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 26 of 59 5.00 12345 Hinge LH (PPAP submission approval prior to first production shipment) TBA £0.43 £5.16 1500/month 12345 Hinge LH – schedule will be issued and deliveries can commence when PPAP is approved TBA £1.23 £18.45 Subtotal £28.61 VAT 20% Total £34.33 John Philips 15 Sept 20xx Authorized by Date Bob Irvine 15 Sept 20xx PF06-03 Rev 03 Jan 20xx Authorized by Date Additional terms PPAP submission and approval required prior to production shipments being delivered
Case Study (Delegate) Delivery note Auto Precision Pressings Ltd Willbourne Street Wellington Telephone: 12929 – 10101 11 Fax: 12929 – 10101 222 Email: [email protected] Bill to Finance Department Ship to: John Philips Delivery note
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 27 of 59 Orbit Manufacturing Limited Orbit Manufacturing Limited Units A to C Units A to C Industrial Estate Industrial Estate 0111 2345 1111 0111 2345 1111 Req date: 17 November 20xx Order date September 28, 20xx Sales Person Bill Baker Shipping date 29 November 20xx P/O No. 12345 Shipping method Truck Qty Part No Description Rev Level Unit Price (£'s) Line Total 5 123455234 Hinge LH (PPAP samples) 2 £0.57 £2.85 Received By: Date received: Bob Smith 17th Nov 20xx
Case Study (Delegate) Job description Orbit Manufacturing Limited Job description Job title: Buyer Responsible: Operations Manager Prime functions: Responsible for purchasing of goods and services in accordance with the companies procedures and requirements Main duties and responsibilities: Compiles relevant information and records to prepare purchase orders, for procurement of material, tooling or equipment to meet requirements of the production plan Verifiescorrectdrawingsissuesandspecificationsofpurchaserequests
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 28 of 59 Verifies correct drawings, issues and specifications of purchase requests Checks and investigates inventory records or stores locations to ensure accurate levels of material on hand are in sufficient quantity to cover requested demand Monitors and improve stock turns Achievement of purchase price variance targets Reports total cost of items purchased on a weekly/monthly basis Expedite deliveries with suppliers Resolves all invoices queries with supplier Responsible for identifying new suppliers and ensuring they are approved based on the companies quality requirements Responsible for purchasing spend of £1300K/annum Negotiate of all price increases Responsible for inventory management – value £300K Review and maintain the department quality objectives and develop action plans to address poor performance Actively participate in monthly management meetings and ensure that actions and monthly reports are done and regularly updated
Case Study (Delegate) Personnel procedures a) Ensure adherence to company codes of conduct, timekeeping and disciplines These guidelines are provided to assist you in the performance of your contract. Orbit Manufacturing Limited is a dynamic organization; therefore changes may be required from time to time. The summary of duties and responsibilities is not intended to be an exhaustive list of tasks performed. Other associated technical tasks are likely to be performed as directed by the line manager. Personnel specification Ability to interpret engineering drawings and technical specifications Understand and analyse supplier quotations Capable of identifying new sources of supply Experience of implementing ‘pull’ supply systems with suppliers Abilitytoidentifynonvalueaddedactivitywithinthesupplychainandimplementactionstoremove
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 29 of 59 Ability to identify non value added activity within the supply chain and implement actions to remove Experience/familiarity with ISO 9001:2015/IATF 16949:2016 Understanding of ERP system Buyer: Name: John Philips Signature: John Philips Date: 17th March 20XX. Approved By: Name: Bob Irvine Signature: Bob Irvine Date: 17th March 20XX. HRF-01 Rev 3 Jun 20XX
Case Study (Delegate) Competency Additional Skills Team member Clock number A B C D E F G H I J K L M N O P Q R S T U V W X Y Z John Philips 41 6 6 6 6 6 6 2 4 6 4 6 6 6 6 Sharon Willis 42 3 4 4 4 3 6 2 4 6 4 6 6 6 6 2 3 3 KEY 1 No requirement 2 Needs training 3 Training 4 Works to required competency 5 Can work unassisted 6 Can train others Reviewed: 01-Aug-20xx Department/Area Procurement Department Manager Bob Irvine To be reviewed on: 28-Jan-20xx Competency matrix
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 30 of 59 Nicola Beebe 43 4 1 1 2 4 1 2 1 4 3 3 4 4 4 Roger Mills 44 4 2 3 2 4 4 2 3 4 4 4 4 4 4 Betty Clarke 45 3 3 3 0 0 0 0 0 3 2 2 2 2 1 Sharon Willis 46 4 4 4 4 4 4 2 4 4 4 3 4 4 4 KEY A Supplier selection and approval F Company ERP system K Microsoft office suite P U B Raising purchase orders G IATF 16949:2016 basic understanding L Negotiating skills Q V C Expediting H PPAP Understanding M Progress chasing (sub- contracted work) R W D Planning and scheduling suppliers I Basic risk assessments N Problem solving S E Updating and maintaining approved supplier list J Customer documentation O T HRF-02 Rev 02 Jul 20xx x
Case Study (Delegate) Training plan Extract of Training Plan Jan 20XX – Dec 20XX Training Need Who Owner No of People External Internal £ Training Provider J F M A M J J A S O N D Accounts program Sharon Willis Julie Evans 1 x £2,500 TBA CMM training - operating Bob Smith Roy Thomas 1 x £1,500 LK Expediting Roger Millls Roy Thomas 1 x £2,000 LK PPAP Understanding Bob Smith John Philips 1 x N/A John Philips Updating and maintaining Nicola Beebe John 2xN/AJohn
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 31 of 59 Approved Supplier List Beebe, Bob Smith Philips 2 x N/A Philips CNC programming - milling Andrew Badland Karl Hevizi 1 x TBD Mark Woods Programme (Microsprint) John Edwards Karl Hevizi 2 x TBD Dean Aston Programme (Microsprint) Bob Smith Karl Hevizi 3 x TBD Dean Aston Programme (Microsprint) Piers Olner Karl Hevizi 4 x TBD Dean Aston Completed Planned HRF-03 Rev 03 Jan 20XX
Case Study (Delegate) Appraisal plan Extract of Appraisal Plan 20xx Name Department Appraisal Type Appraiser Planned Date (Month) Completed Date Completed Pete Russell Quality Indirect Roy Thomas Apr No Bob Smith Production Direct Karl Hevizi Apr 02/04/20XX Yes Dean Taylor Production Direct Karl Hevizi Apr 02/04/20XX Yes Dean Aston Production Direct Karl Hevizi May 12/04/20XX Yes John Whitmore Production Direct Karl Hevizi May 12/04/20XX Yes Mark Storer Production Direct Karl Hevizi May 12/04/20XX Yes Chris Harrison Production Direct Karl Hevizi Jun No
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 32 of 59 Martin Garner Production Direct Karl Hevizi Jun No John Philips Procurement Indirect Bob Irvine Apr No Sharon Willis Procurement Indirect Bob Irvine Apr 02/04/20XX Yes Nicola Beebe Procurement Indirect Bob Irvine Apr 02/04/20XX Yes Roger Mills Procurement Indirect Bob Irvine Apr 02/04/20XX Yes Betty Clarke Procurement Indirect Bob Irvine Apr 12/04/20XX Yes Sharon Willis Procurement Indirect Bob Irvine Apr 12/04/20XX No John Edwards Production Direct Karl Hevizi Aug 21/08/20XX Yes Dean Paul Production Direct Karl Hevizi Aug 21/08/20XX Yes HRF-04 Rev 02 Apr 20xx
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 33 of 59 Extract of PPAP Core Tools Forms Disc V5c Part name Hinge LH Part number 12345 Engineering change level 2 Engineering change level date 20/11/XX Organization name Auto Precision Pressings Ltd Organization code 12345 Street address Willbourne Street City Wellington State West Zip 12N12M Phone number 123456-12345 Customer name Orbit Manufacturing Limited Division N/A Application Automotive File Name FILE.XLS
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 34 of 59 PPAP Checklist Part name: Part number: Hinge LH 12345 Revision level: Customer name: 2 Orbit Manufacturing Limited Submission Level 1 2 3 4 5 Requirement Submitted Comments Yes No Design records of saleable products x - For propriety components/details x - For all components/details x Engineering change documents (If any) x N/A Design engineering approval x N/A Design FMEA x Not required Process Flow Diagram(s) x To be agreed by customer Process FMEA x Generic only Dimensional results x with samples Material and performance test results x COC provided Initial process study x For special characteristic Measurement systems analysis studies x Calibrated Three axis equipment Qualified laboratory documentation x Lab scope available on request Control plan x Appended Part submission warrant x Appearance approval report (if applicable) x N/A Sample product x 5 Samples appended Master sample x Retained on site Checking aids x N/A Records of compliance with customer specific requirements x See X-bar and R chart Comments: PPAP file reviewed by: Brian Baker Date: 27/11/xx
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 35 of 59 Process/Inspection Flowchart Product Program Auto Programme Issue Date 27/11/XX ECL 2 Supplier Name Auto Precision Pressings Ltd Part Name Hinge LH Supplier Location Wellington, West Part No. 12345 Legend: Operation Transportation Inspection Delay Storage STEP Operation or event Description of operation or event Evaluation and analysis methods 10 Material reception Verification versus delivery note Inspection See control plan Store in rack Transport to line 20 Progression tool Pierce Form Inspection See control plan (first off/in process inspection) 30 Pack Transport to stores Store 40 Dispatch to customer
Case Study (Delegate) POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA) FMEA Number: FILE.XLS Prepared by: AS/TS/IA Item: 12345 Process Responsibility: Auto Precision Pressings Ltd FMEA Date (Orig.): 27/11/20xx Model Year(s)/Program(s): Automotive Key Date: 17/11/20xx FMEA Date (Rev.): Initial issue Core Team: ________________________________________ Process step / Potential Failure Mode Potential Effect(s) of Failure Severity Classification Potential causes(s) of failure Occurrence Current process controls preven- tion Current process controls detection Detection RPN Recommended action Responsibility & target completion date Action results Function Actions taken & effective date Severity Occurrence Detection RPN Requirements
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 36 of 59 Requirements Operation 10 Material Reception (Coil) Unable to book in Disruption to Stores and production departments 1 No purchase order 2 none EFACS System 1 2 Purchase Order Number to be added to Delivery Schedule EK, 09/11/20xx Action complete 1 1 1 1 1 Purchase order coverage insufficient 2 none EFACS System 1 2 Delivery quantity to be added to Delivery Schedule and checked prior to issue to Goods Inwards department EK, 09/11/20xx Action complete 1 1 1 1 1 Label Missing 1 none - Supplier - Visual 7 7 none 1 Missing delivery note 1 none No delivery note 1 1 none
Case Study (Delegate) Wrong Packaging Unable to move/unload due to health and safety concern 9 CC Banding missing 3 none Supplier requirements manual 2 54 None 9 CC Banding/clip broken 3 none Supplier requirements manual 2 54 None Too Heavy (Coil Vertical) Unable to transport to storage area 9 CC Excess material supplied 2 none Supplier requirements manual 2 36 None Too Heavy (Coil Horizontal) Unable to transport to storage area 9 CC Excess material supplied 2 none Supplier requirements manual 2 36 Noe Operation 20 Pierce, Form & Blank from Coil No Hole Reject at customer, or next process 5 Broken punch 2 none First off, last off, inprocess checks 7 70 None Rejectat 5Missing 2noneFirstofflast 770None
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 37 of 59 Reject at customer, or next process 5 Missing punch 2 none First off, last off, inprocess checks 7 70 None Burr - Reject at customer - Health and safety risk 9 CC Worn punch 4 none First off, last off, inprocess checks 7 252 Tool(s) to be added to Tooling Maintenance plans AR Action complete 9 2 6 108 - Reject at customer - Health and safety risk 9 CC Worn die 2 none First off, last off, inprocess checks 7 126 Tool(s) to be added to Tooling Maintenance plans AR Action complete 9 1 6 54 - Reject at customer - Health and safety risk 9 CC Chipped punch 2 none First off, last off, inprocess checks 7 126 Tool(s) to be added to Tooling Maintenance plans AR Action complete 9 2 6 108
Case Study (Delegate) - Reject at customer - Health and safety risk 9 CC Chipped die 1 none First off, last off, inprocess checks 7 63 Tool(s) to be added to Tooling Maintenance plans AR Action complete 9 1 6 54 - Reject at customer - Health and safety risk 9 CC Excessive clearance 1 none First off, last off, inprocess checks 7 63 Tool(s) to be added to Tooling Maintenance plans AR Action complete 9 1 6 54 - Reject at customer - Health and safety risk 9 CC Insufficient clearance 1 none First off, last off, inprocess checks 7 63 Tool(s) to be added to Tooling Maintenance plans AR Action complete 9 1 6 54 Wrong Hole Reject at customer, or 7 Mis-feed due to 2 none First off, last off, 7 98 None
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 38 of 59 Position next process incorrect pitch setting inprocess checks Reject at customer, or next process 7 Mis-feed due to edge chamber 1 none - First off, last off, inprocess checks - Setter check list 9 63 None Reject at customer, or next process 7 Mis-feed due to coil width variation 1 none - First off, last off, inprocess checks - Setter check list 9 63 None Short Blank / Part - Reject at customer - Follow on tool damage 8 Short pitch on roll feed 2 none - Setter check list - First off check 7 112 None
Case Study (Delegate) - Reject at customer - Follow on tool damage 8 crowning on input coil 1 none - Setter check list - First off check 7 56 None Oversized Blank / Part - Inefficient material useage - Cannot locate 8 Overpitched on roil feed 1 none - Setter check list - First off check 7 56 Note-review if used for a finished part Distortion - Cannot locate - Customer reject 7 Worn or Broken springs 1 none First off, last off, inprocess checks 7 49 None 7 Worn / Deformed Stripper 1 none First off, last off, inprocess hk 7 49 None
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 39 of 59 checks Shallow Form - Reject at customer - Cannot locate 8 Die Height not set deep enough 1 none - Setter check list - First off check 7 56 None Splitting/T hinning Reject at customer 7 Die height set too deep 1 none - First off, last off, inprocess inspection - Visual 7 49 None Reject at customer 7 Lack of Lubrication 2 none - First off, last off, inprocess inspection - Visual 7 98 None Reject at customer 7 Wrong oil used 2 none Works order instructions. Visual 7 98 None
Case Study (Delegate) Reject at customer 7 Material gauge too thin 1 none - First off, last off, inprocess inspection 7 49 None Scoring Reject at customer 7 Lack of lubrication 2 none - First off, last off, inprocess inspection - Visual 7 98 None Reject at customer 7 Debris 1 none - First off, last off, inprocess inspection - Visual 7 49 None Reject at customer 7 Tool wear 1 none - First off, last off, i 7 49 None
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 40 of 59 inprocess inspection - Visual Reject at customer 7 Input material 2 none - First off, last off, inprocess inspection - Visual 7 98 None Operation 30 Packaging Cannot Receive stock Cannot dispatch product 3 Works order completed 1 none Message on EFACS system 1 3 None Incorrect Label Parts rejected by customer 3 Wrong customer part number 1 none - Dispatch audits - Visual 7 21 None 3 Wrong quantity 3 none - Dispatch audits - Visual 7 63 None
Case Study (Delegate) 3 Parts booked in against wrong works order no. 1 none - Dispatch audits - Visual 7 21 None Incorrect Packaging Damaged parts 7 Stores department issue mixed items 2 none - Dispatch audits - Process audits 7 98 None 7 Part packaging specification incorrect 1 none - Dispatch audits - Process audits 7 49 None Operation 40 Dispatch Unable to assemble delivery Unable to dispatch product 2 No requirement on EFACS main frame t 1 none - No parts found during assembly delivery d 1 2 none
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 41 of 59 system procedure Wrong product Dispatched Customer rejection 8 Incorrectly selected parts by warehouse department 2 none - Dispatch Audits - Picking list - Delivery note 9 144 Dock audits to commence CP/RP, 05/11/20xx Dock audits introduced – initially for automotive components only 8 2 4 64
Case Study (Delegate) CONTROL PLAN Prototype Pre-launch Production Control plan number: FILE.XLS Key contact/phone: 123456-12345 Date (Orig.) 27/11/20xx Date (Rev.) Initial Issue Part number: Latest change level: 12345 2 Core team AS/TS/IA Customer engineering approval date (if required) Part name/description: Hinge LH Organization/plant approval date Customer quality approval date (if required) Organization/plant: Auto Precision Pressings Ltd Organization code: 12345 Other approval date (if required) Other approval date (if required)
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 42 of 59 Part/ process No. Process name/ operation description Machine, device jig, tools for mfg. Characteristics Special char. class Methods Reaction plan No. Product Process Product/process Specification/ tolerance Evaluation/ Measurement technique Sample Control Size Frequency method 10 Material reception Material Grade DX52D + ZF Visual/purchase order 1 Each batch - - Quarantine stock - Inform supplier - Raise 8D report Condition: - Rust - Damage - Weight As per Supplier Manual Visual 1 Each batch - - Quarantine stock - Inform supplier - Raise 8D report
Case Study (Delegate) Part/ process No. Process name/ operation description Machine, device jig, tools for mfg. Characteristics Special char. class Methods Reaction plan No. Product Process Product/process Specification/ tolerance Evaluation/ Measurement technique Sample Control Size Frequency method 20 Progression tool, pierce, form SWIN0929 Op 1 1 12mm hole to edge 5.90mm ± 0.5mm Vernier caliper 0 – 150mm 1 - First off - Hourly Coil change Last off (QCT) - Process audit - Record sheet - Bond stock - Address cause 2 12mm hole to cut edge 40.00mm ± 0.5mm Vernier caliper 0 – 150mm 1 - First off - Hourly Coil change Last off - Process audit - Record sheet - Bond stock - Address cause
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 43 of 59 (QCT) 3 10mm hole to edge 24.40mm ± 0.5mm Vernier caliper 0 – 150mm 1 - First off - Hourly Coil change Last off (QCT) - Process audit - Record sheet - Bond stock - Address cause 4 Overall width 74.40mm ± 0.5mm Vernier height. Gauge 0-600mm or 0-1000mm 1 - First off - Hourly Coil change Last off (QCT) - Process audit - Record sheet - Bond stock - Address cause 5 Flange height SC 30.75mm ± 1.25mm Vernier height. Gauge 0-600mm or 0-1000mm 1 - First off - Hourly Coil change Last off (QCT) - Process audit - Record sheet - Bond stock - Address cause
Case Study (Delegate) Part/ process No. Process name/ operation description Machine, device jig, tools for mfg. Characteristics Special char. class Methods Reaction plan No. Product Process Product/process Specification/ tolerance Evaluation/ Measurement technique Sample Control Size Frequency method 6 Bend angle 94° ± 2.25° Protractor 1 - First off - Hourly Coil change Last off (QCT) - Process audit - Record sheet - Bond stock - Address cause 7 Material thickness 1.2mm ± 0.12mm Micrometer 0-25mm 1 - First off - Hourly Coil change Last off - Process audit - Record sheet - Bond stock - Address cause
AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 44 of 59 (QCT) 8 Is burr level ok? Burr < 0.12mm Visual as per cosmetic aid, and digital micrometer 1 - First off - Hourly Coil change Last off (QCT) - Process audit - Record sheet - Bond stock - Address cause 30 Pack and label Labelling machine Label details correct W/O Instruction Visual 1 Every batch - Packaging details Packaging SOP Visual 1 Every batch - 40 Dispatch Dock Audit As per dock audit record sheet and packaging SOP As per dock audit record sheet As per dock audit record sheet - - Dock audit – Record sheet
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 45 of 59 Production Part Approval: Dimensional Test Results Organization: Auto Precision Pressings Ltd Part number: 12345 Supplier / vendor code: 12345 Part name: Hinge LH Inspection facility: On site standards room Design record change level: 2 Engineering change documents: NA Item Dimension/ specification Specification/ limits Test date Qty. tested Organization measurement results (data) Ok Not Ok 1 12mm Hole to Edge 5.9mm ± 0.50 12/3/XX 5 5.96, 6.13, 5.85, 5.85, 5.91 2 12mm Hole to Cut Edge 40mm ± 0.50 12/3/XX 5 40.06, 40.02, 40.05, 40.04, 40.02 3 10mm Hole to Edge 24.4mm ± 0.50 12/3/XX 5 24.40, 24.41, 24.37, 24.46, 24.41 4 Overall Width 74.4mm ± 0.50 12/3/XX 5 74.79, 74.76, 74.72, 74.65, 74.79 5 Flange Height 31.7mm ± 0.50 12/3/XX 5 31.80, 31.44, 31.53, 31.51, 31.49 6 Bend Angle 94° ± 2.25° 12/3/XX 5 93.95°, 94°, 94°, 94°, 94° 7 Material Thickness 1.2mm ± 0.12mm 12/3/XX 5 1.2, 1.2, 1.2, 1.2, 1.2 8 burr < 0.12mm 12/3/XX 5 0.1, 0.05, 0.1, 0.1, 0.1 Blanket statements of conformance are unacceptable for any test results. SIGNATURE TITLE DATE
Case Study (Delegate) AUT03001ENGX v1.0 Jan 2017 ©The British Standards Institution 2017 46 of 59 Production Part Approval: Material Test Results Organization: Auto Precision Pressings Ltd Part number: 12345 Supplier/vendor code: 12345 Part name: Hinge LH Material supplier: *customer specified supplier/vendor code: Design record change level: 2 Engineering change documents: *If source approval is required, include the supplier (source) and customer assigned code. Name of laboratory: Material: Spec./ no./ rev./date Specification/ limits Test date Qty. tested Supplier test results (data) Ok Not Ok Blanket statements of conformance are unacceptable for any test results. SIGNATURE TITLE DATE Supplied previously