Automotive OEM Glass Supplier Quality Manual

Automotive OEM Glass Supplier Quality Manual

Introduction Purchasing Requirements Supplier Performance Quality Requirements Acronyms and their Meanings Supplier Quality Forms Revision Record

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Table of Contents Section I - Purchasing

1. Introduction 1.1. Purpose 1.2. Supporting Documents 1.3. Certification 2. Purchasing Requirements 2.1. Supplier Qualification Background Information 2.2. Quality System Audit 2.3. Contact Lists 2.4. Launch Support OEM Program 2.5. Competitive Pricing/Payment 2.6. On-Time Delivery 2.7. Incoming Quality Methods 2.7.1. Manufactured Parts 2.7.2. Chemicals & Compounds 2.8. Suppliers Premises Inspection 2.9. Tooling 2.10. Packaging 2.11. Environmental, Health and Safety Requirements 2.12. End of Life (ELV) Regulations 2.13. Supplier Quotations 2.14. Contingency Plan 3. Supplier Performance 3.1. Supplier Measurement 3.2. Supplier Non-Conformance Notice (SNN) 3.3. Supplier Alert (SA) 3.4. Supplier Praise Notice (SPN) 3.5. Defective Parts Certification Process 3.6. Continuous Improvement - $AVE 3.7. Supplier Recognition

Section II Quality
4. Quality Requirements 4.1 Program Management 4.2 Product Development Plan (Timing Chart) 4.3 The Design Failure Modes Effects Analysis (DFMEA) 4.4 The Production Inspection Standard

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4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

The Process FMEA Product Validation Process Flow Chart and Control Plan Process Capability Studies Engineering Change and / or Manufacturing Change Prototype / Pre-production Parts Launch Support and the Supplier Conference Production Process Audit Production Part Approval Process (PPAP)

Section III - Acronyms and Their Meanings Section IV Supplier Quality Forms Section V Revision Record

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Section I - Purchasing
1. INTRODUCTION
1.1. Purpose

The purpose of this document is to communicate PPGs Automotive OEM Glass Business Unit, quality management systems requirements to those companies that supply parts and services to PPG. The basis for PPGs Supplier Quality Manual is the Quality System Requirement ISO/TS16949 developed in coordination with the Automotive Industry Action Group (AIAG). This standard is based on ISO 9000 Series Standard. PPG has adopted ISO/TS16949 as the framework for the basic quality systems required for all suppliers of parts and services. The goal of ISO/TS16949 is to develop quality processes that provide for continuous improvement, emphasizing defect prevention, the reduction of variation and waste in the supply chain. It applies to all critical internal and external suppliers of parts and services. Design responsible suppliers must meet all requirements of this document. These requirements support the ISO/TS16949 and ISO 9000 clauses as stated in PPGs purchase order. PPG requires that the supplier: Manage facilities, processes, quality systems and personnel to consistently and cost effectively produce product and furnish services that meet the needs of PPG and its customers. Develop, implement, document and maintain an Advanced Product Quality Planning process to assure that product and service requirements are met. Provide objective evidence that initial sample requirements have been met and that acceptable process capabilities for all key characteristics have been established. Be committed to continuous process improvement by emphasizing reduction of part-topart variation and waste through defect prevention.

1.2.

Supporting Documents

The following publications are available from the Automotive Industry Action Group (AIAG). These documents contain additional reference information for suppliers to PPG Automotive OEM Glass: Quality System Requirements QS9000 or ISO 9001:2000 ISO/TS 16949 Technical Specification Quality System Assessment (QSA) Production Part Approval Process (PPAP)

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Advanced Product Quality Planning and Control Plan Reference Manual (APQP) Potential Failure Modes and Effects Analysis Reference Manual (FMEA) Measurement Systems Analysis Reference Manual (MSA) Fundamental Statistical Process Control Reference Manual (SPC) Customer Specified Requirements The latest versions of these documents can be purchased from: Automotive Industry Action Group 26200 Lahser Road, Suite 200 Southfield, Michigan 48034 USA Phone (248) 358-3570 Fax (248) 358-3253 Or www.aiag.org

1.3.

Certification

PPG Industries, Inc., a global and diversified producer of Glass, Coatings and Chemicals, is committed to providing products and services to our customers that fully meet their present and future requirements. PPGs suppliers are a critical strategic resource in meeting this customer commitment. PPG requires suppliers to have an effective Quality System. The basis for PPGs quality system requirements is the Quality System Requirements ISO/TS16949 developed in coordination with the Automotive Industry Action Group (AIAG). This standard is based upon the ISO 9000 series standard. PPG has adopted ISO/TS16949 as the framework for the basic quality systems required for all suppliers of products and services. These requirements are an integral aspect of PPGs purchase order. PPG requires the following: Suppliers to PPGs ISO/TS 16949 registered facilities are encouraged to achieve ISO/TS 16949, but must achieve third party registration to ISO 9001:2000. Suppliers to QS-9000 registered PPG facilities are encouraged to achieve third party registration to QS-9000 but a minimum compliance requirement will be certification to a current version of the ISO 9000 Quality Management series Standard, (by the end of 2002) excluding ISO 9003; plus any requirements specified by the customer. Supplier assessments to QS-9000 and/or ISO/TS 16949 by the OEM Customer, an OEM Customer-approved second party or an accredited third party registrar will be recognized by PPG as supplier quality audits.

   
  
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2. PURCHASING REQUIREMENTS
2.1. Supplier Qualification Background Information

PPG requires suppliers to complete the Supplier Qualification Background Information form (QA4.SQM.01.01). In addition to this form, we also require a copy of the Suppliers Quality Policy, Mission Statement, Organization Chart, a typical Control Plan, DFMEA, PFMEA, a quality system procedure and a process work instruction. The information provided by you will be held strictly confidential within PPG.

2.2.

Quality System Audit

The Quality System Audit consists of a visit to a specific suppliers production site. This is normally completed in one to two days. PPG Supplier Quality System Audit Form (QA4.SQM.01.02) is included in the manual for your review. At the discretion of PPG, all potential suppliers will be subject to an on-site audit by Purchasing and Supplier Development. The supplier audit is intended to help further the suppliers awareness of PPGs quality requirements. It is also intended to verify that the supplier has an adequate quality process and to confirm that it is functioning properly. A formal response and follow-up action for all significant elements identified as needing improvement during the audit is required on a timely basis. In some cases, adherence to a recognized standard such as ISO 9000 or QS 9000 may eliminate the need for all or part of a formal on-site audit by PPG. At PPGs discretion, a full QSA audit may be required. Purchasing will coordinate and lead all initial quality system audits of the supplier.

2.3.

Contact Lists

After the program has been sourced, the PPG Program Manager will complete the PPG Contact List (QA4.SQM.01.20). The Program Manger will also provide the list to the suppliers representative on PPGs Program Management Team. The supplier is required to complete the Supplier Contact List (QA4.SQM.01.21) and to forward the list to PPGs Supplier Development Engineer with a copy to the PPG Purchasing Manager.

2.4.

Launch Support OEM Program

Launch support is an integral part of any new product introduction. PPG highly recommends that the supplier reviews the risks associated with the new product introduction and plans for support of the product launch. PPG actively supports launch activities at their customer facilities. The supplier is expected to provide launch support at either the PPG facility or the PPG customer facility.

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2.5.

Competitive Pricing / Payment

Suppliers are expected to be globally competitive and will be benchmarked by PPG Purchasing Managers. PPG expects its suppliers to continually strive for increased efficiency, and cost reductions in their processes in order to meet PPGs customers annual cost reduction initiatives. Refer to Section 3.6 Continuous Improvement - $AVE for more details on submitting your improvement opportunities. Minimum Payment terms are Net 60 days. All invoices, packing slips and correspondence must reference PPGs individual purchase order number, line item number, storeroom part number, and releasers name, (if applicable). Excessive or premium freight charges related to a PPG expediting requirement are to be detailed in a separate line item on the supplier' s invoice and previously approved by PPG personnel. Excessive or premium freight costs related to the suppliers issue and necessary to meet the PPG delivery date will be at the suppliers expense. The supplier will be required to submit a premium freight report covering all excessive or premium costs as requested by PPG. PPG reserves the right to audit supplier' s invoicing against agreed to pricing.

2.6.

On-Time Delivery

All deliveries of requested materials will be made to the facility receiving dock and the packing list will refer to the purchase order number, release number, line item number and storeroom part number (if applicable) and releaser' s name (if applicable). 100% on time full shipment deliveries are required. Supplier is expected to maintain, at his own volition, sufficient stock to achieve and maintain specified delivery. Delivery lead times quoted by the supplier are as important as price to PPG. Deliveries made against releases are to be unloaded only at the PPG' s facility. Requests for deliveries elsewhere are to be approved in writing by purchasing Backorders are not acceptable. Shipping costs on backorders necessary to meet the PPG delivery date will be at the suppliers expense.

2.7.

Incoming Quality Methods

2.7.1. Manufactured Parts - SPC data showing process capability of Key Product Characteristics (KPC) shall be sent per lot, prior to shipment and on request via fax or mail to the attention of the PPG Facility Quality Representative. The minimum acceptable long term CPK value is 1.33. 2.7.1. Chemicals & Compounds - A certificate of analysis or compliance must be sent with each shipment, each lot or upon request to the PPG Facility Quality Representative.

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2.8.

Supplier Premises Inspection

PPG or PPG' s customer shall be afforded the right to perform inspection and/or expediting of the materials and the fabrication at the suppliers facility at any reasonable time. All materials or services are subject to final inspection and acceptance by PPG at destination, notwithstanding any prior payment or inspection at seller' s source and inspection shall be made within a reasonable time after delivery or completion of work.

2.9

Tooling

All tooling must be identified with the owners name and other information as required by PPG or its customer. Maintenance and refurbishing of the tooling required to meet requirements defined, shall be the sole financial responsibility of the supplier, without liens being attached for any reason. The supplier is prohibited from using this tooling to make any product for any company except for the owner or its representative without written authorization from its owner or its representative.

2.10.

Packaging

PPG and supplier shall agree upon the packaging plan. All packaging units shall be labeled with PPGs purchase order number, storeroom part number, quantity, and supplier name (minimum requirements). All unique parts must be shipped in separate packaging units and shall not be mixed with other unique parts.

2.11.

Environmental, Health, and Safety Requirements

Supplier must be in compliance with all federal and state policies as outlined in PPGs Purchase Order General Terms and Conditions as well government regulations in the country of manufacture or sale. PPG encourages registration to ISO 14001.

2.12.

End of Life (ELV) Regulations

The European Union (EU) introduced regulations, effective in 2003, to control the design and recyclability of automobiles. This Directive, called End of Life Vehicle (ELV) prohibits the use of lead, mercury, cadmium and hexavalent chromium in any component of automobiles placed on the market after 1 July 2003. It applies only to cars and light commercial vehicles (<3.5 tonne gross weight). These regulations apply to any affected product sold in Europe. Further down the supply chain, your product sold to a customer in the USA may become part of an automobile sold in Europe. Then a request could come back up the supply chain for you to confirm that your product does not contain any of the restricted substances. Additionally, similar regulations are proposed in Japan and other parts of the world so you may get various requests related to end-of-life 2.13.

Supplier Quotations

All quotations for new business and proposed changes must be submitted to the PPG Purchasing Manager and include part cost, tooling cost and delivery lead-times (minimum requirements). All supplier quotations must be submitted on PPG forms or through PPGs e-sourcing tool.

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2.14.

Contingency Plan

Suppliers shall develop a Disaster Recovery Plan for potential catastrophes/work interruption that would interrupt the supply of their product to PPG. This Disaster Recovery Plan shall include at a minimum: material contingency plan, transportation contingency plan, computer contingency plan and sub-supplier contingency plan. Supplier must immediately notify PPG of the course of action during this period as well as the chain of command contacts.

3. SUPPLIER PERFORMANCE
3.1. Supplier Measurement
Supplier performance measurement is an important function in PPGs quality process. We have implemented a formal method to evaluate suppliers through PPGs Supplier Performance Measurement System. There are four (4) key elements to the Supplier Performance Measurement System, Quality, Delivery, Documentation, and Value. Supplier Non-Conformance Notices (SNN), Supplier Alerts (SA), and Supplier Praise Notices (SPN) are the important factors in the performance monitoring process and become part of the suppliers performance rating. Suppliers will receive a Supplier Performance Evaluation report on a periodic basis or at least once per year. The measurement elements will be used to provide feedback to key suppliers and identify areas of opportunity for PPG and suppliers to continuously improve. These evaluations will also be used in Supplier Selection and Supplier Recognition. Input to this measurement process may include associates from Purchasing, Manufacturing Operations, Quality Assurance, Research, Sales, Receiving, Stores, Accounting, Engineering and Maintenance. Poor performing suppliers will be notified and required to develop a formal corrective action plan with Purchasing. Consistent poor performance can lead to disqualification of the supplier. The elements of PPGs Supplier Measurement System are: Quality - Conformance of products and services to specifications and standards with minimum variability and with all required documentation supporting the conformance. Delivery - PPG requires 100% on time delivery of error free products and services. Documentation - Proper and accurate labeling and shipping documentation. This includes all Safety, Health and Environmental information requested by PPG. Value - $AVE contributions, competitive price, technical support, e-commerce initiatives, inventory programs (CDI, JIT, consignment), and responsiveness to PPGs needs.

3.2. Supplier Non-Conformance Notice (SNN)

If PPG receives a product or service from a supplier that does not meet requirements and it is deemed to be a significant non-conformance by the PPG receiving location, a Supplier NonConformance Notice (SNN) will be issued to you by that location. A SNN requires the supplier to

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complete a five (5) step corrective action process within fifteen (15) days. If you have a corrective action process, you may submit your form (attached to PPGs) as long as it addresses all of the elements contained on the PPG form provided. On occasion, PPGs end customer requires immediate responses to the problem. When this situation exists, PPG will require an immediate initial response with the understanding that a formal corrective action review will be completed in an appropriate time period. The Root Cause section is to include results of the investigation into what specifically caused the non-conforming condition as well as the reasons why the quality system did not prevent the condition from occurring and being detected. Why did it happen and why did it ship? Interim action may include the immediate action steps that have been taken as well as the shortterm fixes that will be used until a permanent solution can be implemented. Preventive action plans that require a delay beyond the specified time limit are to be coordinated between the supplier and the originating PPG location. Permanent corrective action is to be described in sufficient detail to cover the activities taken to prevent recurrence of the problem identified. There should also be an audit performed by the supplier that the preventive action is fully implemented and effective.

3.3.

Supplier Alert (SA)

If the non-conformance does not reach the severity to warrant an SNN, a Supplier Alert (SA) (for information only) may be issued to the supplier. A Supplier Alert (SA) will be issued to suppliers when the non-conformance does not affect the manufacturing process in such a way to warrant a formal corrective action review by the supplier. SAs are to improve communications between PPG manufacturing facilities and suppliers in order to facilitate continuous improvement. If a SA is issued repeatedly to a Supplier for the same reason, the PPG location will issue a SNN, which will require a five (5) step corrective action process.

3.4.

Supplier Praise Notice (SPN)

A Supplier Praise Notice (SPN) will be issued by a PPG location to acknowledge the superior performance of a supplier for an individual contribution to that location. The ultimate recognition for a supplier is through the PPG Excellent Supplier Award program, which consists of both Group and Corporate awards.

3.5.

Defective Parts Certification Process

The importance of PPG receiving purchased products which comply with the agreed upon product specifications cannot be stressed strongly enough. Receipt of defective products, incorrect quantities, incorrectly labeled products, etc., can have a significant impact on PPG' s overall performance, and can negatively impact our ability to retain the business of our end customer.

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PPG have determined that receipt of defective materials cannot be tolerated. Therefore, and at our discretion, PPG has chosen to initiate a "Parts Certification Process" (PCP). The PCP, can and will be at the discretion of the manufacturing facility impacted by receipt of non-conforming products. The PCP, can and will be an extension of the Supplier NonConformance Notice (SNN) communications tool. At the discretion of the facility impacted, and at the time a SNN is issued, so, too, may the Defective Part Certification Control (DPCC) letter. The DPCC is self-explanatory, but we will highlight the key points here. (It is understood that all costs associated with the defective parts supplied will be captured and presented to the supplier for reimbursement to PPG.) 1. Supplier will immediately dispatch resources to PPG for the purpose of 100% part inspection/certification. 2. Supplier will immediately hold and certify all products in suppliers facility. 3. All further shipments will be certified for a period of 20 working days, or until corrective actions are initiated and confirmed effective. 4. Re-occurrence of the same defect within 6 months will require supplier to secure a Third Party company to sort and certify all further shipments to PPG, until such time as PPG Supplier Quality Group confirms effectiveness of the counter measures implemented. 5. Label errors immediately require Third Party certification.

3.6. Continuous Improvement - $AVE

PPG works to reduce costs through the effective use of the Quality process, of which $AVE is an integral part. Through the $AVE process, suppliers are challenged to implement annual valueadded cost saving proposals equaling at least five percent, or higher, as dictated by PPGs business needs. The goal is based on the suppliers total company global annual sales to PPG. PPG expects all suppliers to submit proposals that will result in significant, measurable cost reductions, including those that challenge traditional thinking. $AVE Opportunities are designed to achieve added value and to reduce costs for both PPG and the supplier. Although $AVE Opportunities include direct (bottom line effect) and indirect value propositions, emphasis should be placed on those opportunities where direct savings can be realized. Suppliers can register to $AVE by accessing the PPG $AVE website:

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3.7. Supplier Recognition

At PPG, we are committed to recognize our suppliers superior achievements at various levels of our operations. PPGs Excellent Supplier Award honorees must demonstrate their commitment to total customer satisfaction. These suppliers are characterized by their consistent provision of value-added services and products that differentiate them from others and demonstrate their commitment to PPG through actions that clearly elevate them above their competition. Appropriate recognition may occur at Group or Corporate level.

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Section II Quality
4. Quality Requirements
4.1. Program Management Team
PPG utilizes a team approach for the management of Advanced Product Quality Planning (APQP). The Program Management Team (PMT) is a cross-functional team responsible for assuring that the new product being launched satisfies the customer. The PMT follows a structured method of defining the customer requirements and establishing the steps necessary to provide a quality product on time and at the lowest cost to the customer. The typical crossfunctional PMT includes representatives from sales, engineering, manufacturing, quality, purchasing, packaging and suppliers as appropriate. Depending on the complexity of the new product launch, the supplier may be asked to participate on the PPG PMT. Irrespective of this participation, the supplier also has an obligation to establish a cross-functional team that coordinates their APQP activity. The outputs of the PMT activity are: Select the disciplines and individuals required to address the scope of the APQP activity Define the roles and responsibilities for each area represented Identify the customers, both internal and external Define the customer requirements Understand the customer expectations Assess the feasibility of the proposed product design Identify the costs, timing and constraints of the processes that will be used Determine what customer assistance will be required Complete all the APQP requirements required by PPG (see QS-9000 Advanced Product Quality Planning and Control Plan manual)

Documentation of the PMT process is essential to assure that all parties are aware of the program requirements and that all deliverables are completed. The PMT activity may be documented using the following: PMT Charter defines team membership, program scope, key timing milestones and key deliverables Product Development Plan defines all program milestones (typically in Gantt format) Statement of Work defines program scope and provides a of review product specifications Open Issues list A document to track open issues from inception to completion/resolution. This is a living document that the team reviews usually weekly to keep a pulse on the progress of the team.

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4.2. Product Development Plan (Timing Chart)

The supplier is responsible to provide a Product Development Plan (PDP) showing the tooling, manufacturing, and quality planning activities necessary to assure quality parts on a timely basis for production. The format is optional (Microsoft Project or Excel preferred) but must contain key activities. PPG Industries will provide key dates as received from our customers for various build dates, PPAP and start of production. The supplier must create and submit the PDP to the Program Management Team, Supplier Development Engineer and should include, at a minimum, the following information: Master Schedule Contains milestone dates supplied by PPG for key customer and PPG build dates. Tooling Summary Schedule including tool builds, check fixtures, assembly jigs and any new equipment required. Details of the tooling are captured on the Tool Progress Report (QA4.SQM.01.03) and are not required here. Supplier Trial and Sample Schedule Indicates the timing of the supplier production development trials and sample production. These trials should support PPG in meeting our customers build dates. Quality Planning Requirements - Shown with completion dates for planning purposes. The following items are the minimum to be included: Process Flow Diagram Design FMEA * Process FMEA Control Plan Tool Progress Report * Product Validation Plan * Inspection Standard * Engineering Change Log * Launch Support Plan *

List all major steps from the design through trial parts fabrication to PPAP. List planned and actual completion dates for each step of the process. The PDP and Tool Progress Report must be kept up-to-date and submitted monthly per the request of the Purchasing Agent or Supplier Quality Development Engineer. * At the discretion of the Supplier Development Engineer.

4.3. The Design Failure Modes Effects Analysis (DFMEA)

The Design Failure Modes Effects Analysis (DFMEA) is an analytical technique utilized by a Design Responsible Engineer to assure that potential design failure modes and their associated causes have been considered and addressed to the extent possible. During the initial DFMEA process, the responsible engineer is expected to directly and actively involve representatives

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from all the affected areas. These areas should include, but are not limited to: assembly, manufacturing, materials, quality, service and suppliers, as well as the design area responsible for the next assembly. The DFMEA should be a catalyst to stimulate the interchange of ideas between the functions affected and thus promotes a team approach. The DFMEA is a living document and should be initiated before or at the design concept finalization, be continually updated as changes occur or additional information is obtained throughout the phases of product development, and be fundamentally completed before the production drawings are released for tooling. The DFMEA addresses the design intent and assumes the design will be manufactured/assembled to this intent. Potential failure modes and/or causes that can occur during the manufacturing process need not, but may be included in a DFMEA, when the Process FMEA covers their identification, effect and control. The DFMEA does not rely on process controls to overcome potential weaknesses in the design, but it does take the technical limits of a manufacturing process into consideration, e.g.: Necessary mold drafts Limited surface finish Assembly space/access for tooling Limited hardenability of steels Process capability/performance

The process begins by developing a listing of what the design is expected to do, and what it expected not to do, i.e., the design intent. Customer wants and needs should be incorporated. The better the definition of the desired characteristics, the easier it is to identify potential failure modes for corrective action. For information about Design FMEAs, see the AIAG Advanced Product Quality Planning and Control Plan (APQP) Reference Manual and the AIAG Potential Failure Mode and Effects Analysis (FMEA) Reference Manual, latest editions.

4.4. The Production Inspection Standard

The Product Inspection Standard defines all characteristics and acceptance criteria for each part along with the method and frequency by which the part should be monitored and controlled at the supplier. The Product Inspection Standard must define elements such as the datums, dimensional tolerances, performance, weight, material appearance and any special inspection requirements. The Product Inspection Standard may be developed by PPG or PPG may request the supplier to prepare the initial draft of the Product Inspection Standard and submit to PPG. These drafts will be reviewed by the respective companies for completeness. Once approved, the signed original will be returned to the supplier and PPG will keep a copy. Other means of defining part requirements can be used at the discretion of the Supplier Development Engineer.

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Updates or changes to the Product Inspection Standard can be requested for the following reasons: Change or update due to Engineering Change A correction to the Product Inspection Standard (must be approved by both Supplier and PPG) An addition or correction based on process capability studies in production A change to improve the PPG part or PPG Customer build condition (must be approved by all parties)

The Product Inspection Standard form (QA4.SQM.01.06) shows a suggested format for the Product Inspection Standard.

4.5. The Process FMEA

A Process FMEA is a required document needed for PPAP submission. The Process Failure Modes Effects Analysis PFMEA (QA4.SQM.01.07) is an analytical technique utilized by a Manufacturing Responsible Engineer or Manufacturing Team to assure that potential process failure modes and their associated causes have been considered and addressed to the extent possible. In its most rigorous form, a PFMEA is a summary of the engineers or teams concerns as a process is developed. The Process FMEA: Identifies potential product related process failure modes, including an analysis of items that could go wrong based on experience and past concerns. Assesses the potential customer effects of the failures. Identifies the potential manufacturing or assembly process causes. Identifies process variables on which to focus controls for occurrence reduction or detection of the failure considerations. Develops a ranked list of potential failure modes, thus establishing a priority system for corrective actions. Documents the results of the manufacturing or assembly process.

During the initial PFMEA process, the responsible engineer is expected to directly and actively involve representatives from all affected areas. The PFMEA should be a catalyst to stimulate the interchange of ideas between the functions affected and thus promote a team approach. The PFMEA is a living document and should be initiated before or at the feasibility stage, prior to tooling for production, and take into account all manufacturing operations. Early review and analysis of new or revised process is promoted to anticipate, resolve or monitor potential process concerns during the manufacturing planning stages of a new model or component program. The PFMEA assumes the product as designed will meet the design intent. Potential failures which can occur because of a design failure, which can occur because of a design weakness, need not, but may be included in a PFMEA. Their effect and avoidance is covered by the Design FMEA.

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For information about Process FMEAs, see the AIAG Advanced Product Quality Planning and Control Plan (APQP) Reference Manual and the AIAG Potential Failure Mode and Effects Analysis (FMEA) Reference Manual, latest editions.

4.6. Product Validation

Product Validation refers to the development and successful completion of engineering tests that validate that those products made from production tools and processes meet all functional and reliability criteria. The Product Validation Test Plan itemizes the test description, acceptance criteria, test responsibility, sample size and timing requirements. An effective Product Validation Test Plan provides a concise working document that aids technical personnel in the following areas: Development of reliability testing requirements Assurance that product reliability meets customer objectives Summary of functional, durability and reliability testing requirements and results in one document Provides communication format with the customer

Reliability of the product is paramount to the success of the overall program. PPG will review and approve the Product Validation Test Plan for appropriateness of the planned reliability tests and the successful completion of the tests during the Production Process Audit. The suggested format is shown on the Product Validation Test Plan form (QA4.SQM.01.09). .Other forms can be used to document product validation.

4.7. Process Flow Chart and Control Plan

A Process Flow and a Control Plan are required documents needed for PPAP submission. The process flow chart is a schematic representation of the current or proposed process flow. It can be used to analyze sources of variations of machines, materials, methods, and manpower from the beginning to end of a manufacturing or assembly process. The flow chart helps to analyze the total process rather than individual steps in the process. The flow chart also helps in the development of the PFMEA and Control Plan. The Control Plan provides a written description of the systems used to minimize process and product variation. The Control Plan also provides a structured approach that aids in the manufacture of quality products according to customer requirements. The Control Plan is an integral part of an overall quality process and is to be utilized as a living document. The Control Plan describes the actions that are required at each phase of the process. During regular production runs, the Control Plan provides the process monitoring and control methods that would be used to control characteristics. Since processes are expected to be continually updated and improved, the Control Plan reflects a strategy that is responsive to these changing conditions. The Control Plan is maintained and used throughout the product life cycle. Early in the product life its primary goal is to document and communicate the initial plan for process control. Revision Date: 03/01/2006 Page 16 of 24

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Subsequently, it guides manufacturing in how to control the process and ensure product quality. Ultimately, the Control Plan remains a living document, reflecting the current methods of control and measurement systems used. The Control Plan is updated as measurement systems and control methods re evaluated and improved. For process control and improvement to be effective, a basic understanding of the process must be obtained. A cross functional team should be established to develop the Control Plan by utilizing all the available information to gain a better understanding of the process, such as: Process Flow Diagram Design Failure Mode and Effects Analysis Process Failure Mode and Effects Analysis Special Characteristics Lessons Learned from Similar Parts Teams knowledge of the process Design Reviews Optimization Methods

For information about Control Plans, see the AIAG Advanced Product Quality Planning and Control Plan (APQP) Reference Manual, latest edition.

4.8. Process Capability Studies

Process capability refers to a comparison between the inherent variability of a process and the specified tolerance. It is important to note that acceptable process capability is achieved through the study and control of key process parameters (e.g. temperature, pressure, shot weight, etc.). It is recommended that the supplier use the AIAG Reference Manuals, Statistical Process Control (SPC) and the Advanced Product Quality Planning and Control Plan (APQP) Reference Manual, latest edition as the reference for conducting process capability studies. Process Capability Requirements are as follows*: Short Term ExpectationProcess Capability If Expectation is not met, but parts are within spec. If Expectation is not met and one or more parts are beyond specification. Stable Ppk > 1.67 Provide Correction Action 100% inspection contact SDE Provide Corrective Action Long Term Stable Cpk > 1.33

Provide Correction Action 100% inspection contact SDE Provide Corrective Action

* Or as negotiated with SDE

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4.8. Engineering Change and / or Manufacturing Change

The supplier must have a system in place for the control and tracking of engineering and manufacturing changes. Engineering Changes: PPG Purchasing will notify the supplier in writing when an engineering change to the product being supplied is required. Prior to implementation of the engineering change, the supplier is responsible for updating all quality planning documents, inspection standards and checking fixtures to reflect the new engineering change. Typically, PPG will require sample parts before the conversion to the new engineering change. Also, a new PPAP submission will be required for each engineering change. Any additional requirements will be communicated by the PPG Supplier Quality Engineer. The PPG Supplier Development Engineer will communicate any additional requirements. Engineering changes must be incorporated in a timely manner, in accordance with the instructions from PPG. All product shipped to PPG must be clearly marked with the engineering change level. In addition, an Engineering Change Log (QA4.SQM.01.11) or similar document showing the history of engineering changes must be maintained by the supplier. The Log must be made available upon request by the PPG Supplier Quality Development Engineer. Manufacturing Changes: The supplier is expected to notify the PPG Supplier Development Engineer and Purchasing in advance of any planned manufacturing process or product changes. The notification must be made using the Manufacturing Change Notification Form (QA4.SQM.01.12). These changes include, but are not limited to: Product material changes or changes in product material suppliers New or revised production tooling New or upgraded production processes Movement of product to a different production operation Product design changes

PPG will review the proposed change and request samples for evaluation. Depending on the extent of the manufacturing change, PPG may also request: DFMEA and/or PFMEA Product Validation Test Plan Capability analysis PPAP submission

In all cases, the supplier is not to ship production quantities of the product produced under the manufacturing change conditions until PPG has validated that the product does not adversely affect overall product performance.

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4.9. Sample Submissions

Sample submissions to PPG, other than PPAP samples will be guided by the PPG Program Manager or PPG Plant Development Team leader. PPAP sample submissions will be dictated by the Supplier Development Engineer or his/her designate.

4.10. Process Checklists

The following checklists can be used by the supplier to develop their APQP process. Other means to track the APQP process can be used. Design Information Checklist (QA4.SQM.01.15) Product Validation Plan Checklist (QA4.SQM.01.16) Design FMEA Checklist (QA4.SQM.01.05) Process FMEA Checklist (QA4.SQM.01.08) Control Plan Checklist (QA4.SQM.01.17) Product / Process Quality Checklist (QA4.SQM.01.18)

Reviewing the checklist items will help assure that the APQP requirements have been completed to the satisfaction of both the supplier and PPG. PPG recommends that the format of the quality planning documents follow the AIAG standards shown in the QS-9000 manuals. However, a welldocumented system created by the supplier can be used if found acceptable by the PPG team.

4.11. Prototype / Pre-production Parts

The PPG Prototype and Pre-Production Process has been established to assure purchased components meet dimensional and functional requirements at the earliest stages of the process, i.e. Prototype and/or Pre-Production. It is the responsibility of all component suppliers to provide PPG with products, which meet or exceed dimensional, functional and material requirements agreed upon during the bid process. PPG Prototype/Pre-Production Part Certification Form (PPPCF) is to be fully completed and be included with all prototype or pre-production submissions. Any component deviations, which do not meet design intent, must be clearly denoted. Corrective actions and timing to bring components to full design intent must be provided with component part submission and must be reviewed prior to submission with the PPG Program Manager and PPG Satellite Development Engineer. Even if the supplier provides multiple submissions from a single fabrication run, PPG expects each separate shipment will be documented in compliance with this procedure. Any submission that deviates from design must have signed approval by PPG Program Manager. This document must be included with submission. For each Prototype or Pre-Production Part Submission, PPG requires that 3 (three) parts be fully certified by documenting measurements to all dimensional or material characteristics on the part drawing or requirements sheet. In addition, all Key Product Characteristics agreed upon between Revision Date: 03/01/2006 Page 19 of 24

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PPG and Supplier will be evaluated and documented on the three certification parts. PPG prefers that the three certified parts be taken from throughout the production run, i.e. beginning, middle and end. Even if the supplier provides multiple submissions from a single fabrication run, PPG expects each separate shipment will be documented in compliance with this procedure. The three (3) certified parts will be packaged separately from the remaining parts provided. Included within the certified part package will be a copy of the PPPCF form. The three parts will be clearly marked with either an alphabetic or numeric designation (at the suppliers discretion) and these designations will carry over to the certification form. These parts will not be utilized for PPG part submission, but will be maintained for future review should questions arise regarding their compliance to design. This will aid in any discussion or review that may be necessary with the supplier. Note: If parts are produced in a multi-cavity operation, three (3) samples from each cavity must be measured, documented and submitted to PPG. Example: Part XYZ produced in a four (4)cavity mold. Therefore, 12 parts (3/cavity) are to be measured.

Ticketing Requirement: All Prototype and Pre-Production packages must utilize BLUE color-coded tickets, as these will be clearly definable when compared to mass production parts. PPG will not define a specific blue color standard. Each supplier may choose from materials available to them.
4.12. Launch Support and the Supplier Conference
Launch support is an integral part of any new product introduction. PPG highly recommends that the supplier reviews the risks associated with the new product introduction and plans for support of the product launch. PPG actively supports launch activities at their customer facilities. The supplier is expected to provide launch support at either the PPG facility utilizing their product and at the PPG customer facility utilizing the PPG product. To assure a full understanding of how PPG will utilize purchased components, the PPG Supplier Development Engineer (SDE) will schedule and facilitate a Supplier Conference (SC). The Supplier Conference will be at the discretion of PPG SDE and PPG Purchasing, and will be based upon the complexity of the program or unique product being purchased. The SC will be held at the PPG assembly site utilizing the purchased component(s). The goal is to complete this SC 90 days prior to the program SOP (start of production). Engineering and Production representatives from the component supplier are required to attend. The Supplier Conference will be inclusive of all tier 2 suppliers for the given program. During the SC, PPG will provide information on assembly methods, incoming material requirements, quality expectations, launch support expectations, and a review of any open issues.

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4.13. Production Process Audit

The Production Process Audit is a systematic review of the suppliers manufacturing process prior to launch to verify the suppliers production readiness. The Production Process Audit will be conducted in advance of the Production Part Approval Process (PPAP) submission at the discretion of the PPG Supplier Development Engineer. If necessary, the PPG Supplier Development Engineer will visit the suppliers facility to insure that PPG requirements are clearly understood and activities will be put in place to comply with all elements on the Production Process Audit Checklist, QA4.SQM.01.19.

4.14. Production Part Approval Process (PPAP)

The default PPAP submission will be a level 5 submission comprised of those elements listed in rd the latest edition of the AIAG PPAP document (for the 3 edition, page 16).:

Part Submission Warrant (AIAG CFG 1001) Design Records, e.g. part print. Engineering Change documents, if any Customer Engineering Approval, if required DFMEA, if applicable Process Flow Diagram PFMEA Control Plan Dimensional Results Material Test Results, if applicable Performance Test Results, if applicable Initial Process Study Measurement System Analysis Studies Qualified Laboratory Documentation Appearance Approval Report, if applicable Sample product Master Sample Checking Aids Component part warrant documents

PPAP submission requirements are dictated by the PPG SDE and can be changed to meet particular requirements of a program. A run at rate trial may be required to be completed at the suppliers part process. This run at rate trial is a check to see if the production process can make enough good parts to satisfy both PPGs required peak demand and also a demand equal to 20% greater than peak demand. The Run at Rate Blank Form can be used to document the trial.

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Section III - Acronyms and Their Meanings

Acronym AIAG APQP DFMEA DPCC ISO KCC KPC PCP PFMEA PM PMT PPAP PPM PSO QSA RPN SA SNN SPC SPN SDE Meaning Automotive Industry Action Group Advanced Product Quality Planning Design Failure Mode and Effects Analysis Defective Part Certification Control Internal Organization for Standardization Key Control Characteristics Key Product Characteristics Part Certification Process Process Failure Mode and Effects Analysis Program Manager Program Management Team Production Part Approval Process Parts per Million (defective) Process Sign Off Quality System Assessment Risk Priority Number Supplier Alert Supplier Non-conformance Notice Statistical Process Control Supplier Praise Notice Supplier Development Engineer

Section IV Supplier Quality Forms

SUPPLIER QUALITY FORMS

Document No. QA4.SQM.01.17 QA4.SQM.01.22 QA4.SQM.01.05 QA4.SQM.01.04 QA4.SQM.01.15 QA4.SQM.01.11

Document Name Control Plan Checklist Control Plan Form Design FMEA Checklist Design FMEA Form Design Information Checklist Engineering Change Log Form

Revision Level Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999

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SUPPLIER QUALITY FORMS

Document No. QA4.SQM.01.12 QA4.SQM.01.14 QA4.SQM.01.06 CFG-1001 QA4.SQM.01.20 QA4.SQM.01.23 QA4.SQM.01.08 QA4.SQM.01.07 QA4.SQM.01.18 QA4.SQM.01.16 QA4.SQM.01.09 QA4.SQM.01.19 QA4.SQM.01.24 QA4.SQM.01.13 SA 0100 QA4.SQM.01.21

Document Name Manufacturing Change Notification Form Measurement Result Sheet Form Product Inspection Standard Form PPAP Warrant PPG Contact List PPG Prototype/Pre-Production Part Certification Form (PPPCF) Process FMEA Checklist Process FMEA Form Product/Process Quality Checklist Product Validation Plan Checklist Product Validation Test Plan for Suppliers Form Production Process Audit Checklist Run at Rate Blank Form Sample Submission Checklist Supplier Alert (Issued by PPG) Supplier Contact List

Revision Level Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 July 1999 Dec. 21, 1999

Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 Dec. 21, 1999 Sept. 23, 2002

Dec. 21, 1999 Jul. 1, 2003 Dec. 21, 1999

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SUPPLIER QUALITY FORMS

Document No. QA4.SQM.01.21 SNN1096-3 QA4.SQM.01.01 QA4.SQM.01.02 QA4.SQM.01.03

Document Name Supplier Contact List Supplier Nonconformance Notice (SNN) (Issued by PPG) Supplier Qualification Background Information Form Supplier Quality System Audit Worksheet Tool Progress Report

Revision Level Dec. 21, 1999 Dec. 1, 2005 May 1, 2004 July 19, 2005 Dec. 21, 1999

Section V Revision Record

REVISION RECORD
Date 22-Sep-04 Revision Comments Prepared By Added Defective Parts Certification B. Loftus Process and accompanying Defective Part Certification Control (DPCC) letter. Mar 7, 2001 Added "including a Part Submission B. Loftus Warrant form" to Engineering Change section; removed Approval Request Form and Sample Submission Summary Form. Mar 3, 2006 Major Revision C. Adsit Approved By A. Eckstein

C. LaRocque

A. Eckstein C.Siess

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