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Quality Specifications For Purchased Parts
Quality Specifications For Purchased Parts
Quality Specifications For Purchased Parts
003-ENG
QUALITY SPECIFICATIONS FOR Rel. 01
PURCHASED PARTS Date 31/01/2018
Pag. 1 of 29
1 Introduction
2 Supply Management System
2.1 General requirements
2.1.1 Quality Management System
2.1.2 Environmental, Health & Safety Management System
2.1.3 Customer specific requirements
2.2 Supplier qualification
2.3 APQP – Product and process development
2.3.1 APQP – Product design
2.3.1.1 Project requirements
2.3.1.2 Feasibility analysis
2.3.1.3 DFMEA
2.3.2 APQP – Process design
2.3.2.1 Flow chart
2.3.2.2 PFMEA
2.3.2.3 Control plan
2.3.3 APQP – Process development
2.3.4 APQP – Product/process validation/processo
2.3.4.1 PPAP – Production Part Approval Process (was I07-151)
2.3.4.1.1 Sampling submission
2.3.4.1.2 Requested documentation
2.3.4.1.3 Saleri sampling levels
2.3.4.1.4 Dimensional, functional and visual findings
2.3.4.1.5 Critical and special caractheristics
2.3.4.1.6 Packaging
2.3.4.1.7 Warrant (PSW)
2.3.4.1.8 Deviations from the requirements
2.3.4.1.9 Samples identification
2.3.4.1.10 Outcomes of sampling process
2.3.4.2 Process Audit
2.3.4.3 Run&Rate
2.3.4.4 Requalification
2.4 Requirements for serial production
2.4.1 Process modifications management
2.4.2 Derogation request
2.4.3 Identification and traceability
2.4.4 Significant caractheristics management
2.4.5 Process capability
2.4.6 Sub-suppliers management
2.4.7 Non conformances management
2.4.8 Escalation management
2.4.9 Attrezzature di controllo di proprietà di Saleri
2.4.10 Markings
3 Specific requirements of Industrie Saleri Italo S.p.A.
3.1 Gravity die casting and HPDC parts
3.1.1 Packaging
3.1.2 Samples for die casting tool reconstruction
3.1.3 Identification and markings
3.1.4 Defects
IST.08.003-ENG
QUALITY SPECIFICATIONS FOR Rel. 01
PURCHASED PARTS Date 31/01/2018
Pag. 2 of 29
1 Introduction
Industrie Saleri Italo S.p.A. (hereinafter referred to as Saleri) operates in a very demanding
market that requires all the company to adopt policies to increase competitiveness.
In this context, only companies that will persue with determination the path of continuous
improvement of products and processes will excel.
Saleri Supply Management System here described, focuses on the goal to select, develop
and manage Suppliers able to maintain a high quality level of the supplies during all the
production process (from prototypes, SOP and EOP) thus satisfying Saleri requirements and
its final Customers.
Saleri requires to its Suppliers to achive the “0 ppm” level of scraps; this goal has to be achied
throughout:
- robust development of product and production process;
- compliance with Saleri approved processes;
- disclosure of this SPECIFICATION to all the sub-suppliers;
- delivery of material conforming to Saleri drawings, specifications and within the
agreed timing.
This document applies from the moment the Supplier his choosen for the development of a
new product until the end of the serial production.
The “Quality Specification for Purchased Parts” applies to all the supply relationships
between Saleri and its Suppliers.
To this end, Saleri Suppliers must adopt Quality, Environmental and Safety
Management Systems along with systems capable of developing product and
processes able to guarantee the quality and reliability of the supplied products.
Saleri does accept Suppliers certified ISO 9001 only if a plan to achieve the IATF
16949:2016 is available and strongly supported by Management (applies only
for OE Suppliers).
Saleri does also require that the Suppliers will use certified sub-suppliers in their
supply chain.
Moreover, they have to follow the local laws and to the practice defined by
Saleri when admitted to the Saleri plants.
To ensure the conformance to the laws, the Suppliers must introduce the
information of the materials used in theis manufacturing cycle inside the
International Material Data System (IMDS).
Possible areas for improvements will be listed in the Saleri document MOD.08.015
(Action Plan) stating for each item of the list due date for the solution of the non-
conformity found.
Depending on the result of the audit the Supplier will be rated as:
The Supplier must be qualified to enter the panel of the Saleri Suppliers to be able to
be nominated for new business.
Saleri PPAP
Applies to Requested documentation
Levels
Complete pumps Dimensional checks:
- position of pulley/flange from
mating plane
- flange guiding diameter (if
applicable)
- position of impeller from mating
Level 0
plane
PSW (Warrant)
Prototypes requested by pre- Balloned Saleri drawing
development Dimensional checks (§)
Material certificats and/or heat
treatments certificates
Prototypes (Saleri DPx.xxxxx.x) Declaration of product conformity
indipendently if referred to new Balloned Saleri drawing
parts or modified parts; Dimensional checks
Level 1 Tooling modifications or Material certificats and/or heat
refurbishment (fixed or moving treatments certificates
parts, machining fixtures, PSW (Warrant)
modification of injection
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PURCHASED PARTS Date 31/01/2018
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- (§§): in case the production is carried out with the use of mold and trimming tooling (for
example die-casting process), level 3 can be submitted with the use of mold serial tool
without the use of the trimming tool; when it comes to level 4 both tools have to be used
to produce the parts.
Notes:
(*): with regards to the MSA studies, the minimum requirement defined by Saleri is that Type 1 +
Type 2 or 3 studies be performed depending on the type of the instrument; if the
instrument/characteristic is defined by attributes, the requirement is to perform MSA study for
attributes.
(**): for Type 1 studies, the requirement is Cg ≥1.33
for Type 2/3 studies the requirement is that the percentage be ≤20%
Prototype part (DPx.xxxxx.x) Applies to all the parts no matter the technology:
all the parts delivered to Saleri must if the order is for smaller than 5 pieces, the requirement
be identified and the dimensional is to perform the control of 100% of the pieces for all
report must refer to the part the dimensions indicated in the Saleri drawing; if the
identification order is greater than 5 pieces then the same
requirement applies to 5 pieces;
moreover, if the order is greater than 5 pieces, it is
required that the critical charcteristics () be
measured for:
I. 100% of the pieces in case of orders smaller than
20 pieces;
II. 20 pieces taken from the production at regular
intervals for orders smaller than 100 pieces;
III. 1 part every 5 pieces taken at regular intervals for
orders greater than 100 pieces.
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QUALITY SPECIFICATIONS FOR Rel. 01
PURCHASED PARTS Date 31/01/2018
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Serial parts: (2.xxxxx.x) Die castings, castings, forgings and injection moulding:
(3.xxxxx.x) 3 pieces (for each cavity) controlled 100% for all the
(4.xxxxx.x) dimensions on the Saleri drawing.
(5.xxxxx.x) Machined parts:
5 pieces controlled 100% for all the dimensions on the
Saleri drawing (for each fixture if CNC machining or
jaw in case of transfer machine when the total number
of fixtures/jaws is smaller or equal to 4);
3 pieces controlled 100% for all the dimensions on the
Saleri drawing (for each fixture if CNC machining or
jaw in case of transfer machine when the total number
of fixtures/jaws is greater than 4).
Assembled and testes parts:
5 pieces controlled for 100% of the dimensions on the
Saleri drawing.
Note 1: in case of repeated orders on the same part number (prototype or preserial), if the
parts are coming from the same setup, the Supplier is oblieged to notify Saleri to be
able to receive a quick approval as an extension of the previous approved parts.
Note 2: the frequencies indicated in the above table can be modified only upon written
approval by Saleri Quality; this information has to be indicated into the PPAP
documentation.
2.3.4.1.6 Packaging
The packaging of the samples shall be such to guarantee
both the integrity of each single part and the cleanliness
requirements indicated in the drawing until the delivery to
Saleri.
Therefore, each single sample shall be placed in a
dedicated packaging to avoid possible damages during
the transportation.
For ferrous parts, it is also required to use a VCI sheet to
protect the parts from corrosion.
The Supplier might use its own PSW module or one used in
the Automotive field.
WARNING!
(**): the non-conforming parts will be stored in the bonded area for 10 days;
during this period, the parts are available for the Supplier.
Once the 10 days have expired, the materil will be scrapped automatically.
IST.08.003-ENG
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PURCHASED PARTS Date 31/01/2018
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(*): for the parts which are dimensionally conforming but under conditionally
approved CAP, the parts will be stored in Saleri and used after 10 days even
if the documentation will not be submitted; in this case a fee of 200€+VAT will
be charged to the Supplier.
Depending on the result ofn the audit, the global evaluation of the
Supplier will be rated as follows:
An action plan is issued with the list of activities that are necessary to
bring the Supplier to a level A.
The closure of this actions must be witnessed by Saleri SQE.
2.3.4.3 Run@Rate
Every year Saleri Purchasing sends to all the Suppliers the “Supply
Agreement” with the forecasted year quantity for each purchased
part number.
It is understood that the quantities indicated in the forecast could be
as high as a 20% more (flexibility).
Sareri requirement for the R&R is to produce sufficient to verify that the
process be able to guarantee:
- absence of bottle necks in all the process steps;
- efficiency and effectiveness of the process (OEE, production
stops, scrap management etc…);
- real installed capacity;
- possible criticalities not observed during the previous steps.
2.3.4.4 Requalification
The Supplier is oblieged to make a requilification of the product once
a year independently for the product/process change.
Upon Saleri request, the Supplier shall submit the documentation
according to the PPAP rules described in comma 2.3.4.1.2.
- to submit a sampling out of the new process and wait Saleri approval
before introducing the modification in series.
The supplier is prohibited from introducing process changes without the
approval of Saleri.
In case the Supplier will modify the process without Saleri approval, then Saleri
will act as follows:
- debit to the supplier all relevant costs coming from this action;
- inform the Supplier certification body.
2.4.2 Derogations
If during the controls a non-conformance shall be identified, the Supplier shall
ask Saleri for a derogation to deliver the parts.
Before delivering the parts, the Supplier shall wait for a written approval of the
derogation by Saleri.
In case the Supplier shall not follow this procedure, all the relevant costs will be
charged to the Supplier.
With referenc to the special characteristics (report and critic), the processes
have to guarantee the respect the required values of the indexes Cm/Cmk,
Pp/Ppk e Cp/Cpk.
Unless special customer specific requirements are defined, Saleri requires the
following:
If the Supplier cannot guarantee such values for the special characteristics, it
is mandatory to apply an alternative control method (100% control, poka-yoke
etc…) to guarantee the conformity of the products delivered to Saleri.
All the information related to the root cause analysis, corrective actions and
effectiveness verification must be collected in an 8D report (Supplier form or
Saleri form).
The Supplier must keep in an appropriate way the returned components for 3
months unless a different agreement is specified between the parts.
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In case the suspect parts are obtained from parts given by Saleri to the Supplier
for manufacturing purpose, it would be possible not to pay the work made by
the Supplier on the non-conforming parts even in case the parts might have
source defects.
In case the non-conformances shall arrive to the final customer, it will be Saleri
right to debit the Supplier for the costs incurred.
2.4.10 Markings
Saleri requires that the parts supplied be marked.
Markings shall be permanent and readable throughout the life of the
component.
Markings shall not compromise the functionality of the components.
The information contained into the markings and the position must be agreed
in advance with Saleri.
3.1.1 Packaging
Unless otherwise specified, the castings will need to be delivered inside orange
steel boxes property of Saleri.
The products should be arranged neatly by separating the different layers with
plastic separators to avoid damages during handling and transport.
It is the Supplier responsibility to cover the Saleri authorization time with the
appropriate stock to avoid any line stop at Saleri manaufacturing.
3.1.4 Defects
All the parts have to be free from burrs that might endanger the safety of the
operators during the handling procedures both in Saleri and at the final
customer.
The following defects are not accepted:
- metallization
- cracks
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PURCHASED PARTS Date 31/01/2018
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- missing material
- excess of material
- metal inclusions
as they might compromise the functionality of the product.
The parts shall also free from residuals coming from surface finishing processes
(sand, tumbling means); furthermore oxidations or stains are not allowed.
Any deviation needs to be communicated to Saleri Quality asking for an
official derogation to use the parts.
Saleri reserves the right to accept the derogation request depending on the
defect severity.
3.2.1 Packaging
The products, unless otherwise specified, must be delivered to Saleri in plastic
boxes (KLT for example) or in cardboard boxes; each layer must be separated
from the other by means of plastic separators; each component must be
separated from the other by means of plastic hives or similar to avoid any
damage during the transportation.
If Saleri assembly procedure will require an automatic handling, special
thermoformed layers could be required to handle the components.
3.2.3 Defects
The products should be free from burrs, burnings, streaking, bubbles, voids,
deformations, excessive retreats, junction joints, and breaks.
Any deviations must be promptly notified to Saleri Quality by asking for a
derogation to production or delivery.
Saleri reserves the right to accept or not the request depending on the severity
and criticality of the defect.
Burrs and mold splitting lines near the o-ring seats should be avoided by
defining the design of the mold and the movements of the moving parts
appropriately during the development phase.
If it is not possible to prevent closures in proximity to the o-ring seats, the size of
the burr should be monitored in the process by means of specific controls and
indicated in the control plan.
3.3.1 Packaging
Unless otherwise specified, machined parts shall be delivered to Saleri in blu
boxes property of Saleri.
To avoid any contact that can lead to damage, machined parts must be
placed into the boxes neatly and separated.
In any case the machine dand washed parts shall be placed into boxes with
a plastic bag necessary to block the contamination from outside.
If the parts are made in ferrous materials, a VCI sheets will be necessary to
guarantee the protection from corrosion.
If Saleri assembly procedure will require an automatic handling, special
thermoformed layers could be required to handle the components.
During prototype phases (CNC machining from blank or out of sand cast) the
parts must be packed one by one to guarantee the necessary protection
during transportation.
3.3.2 Defects
Machined surfaces must be free from burrs that can detach or that can be
dangerous for the safety during normal handling and manipulation through all
stages of production in Saleri as well as in use at the final customer.
If the Supplier shall machine parts given by Saleri in die cast condition, all the
parts showing defects due to die casting process detectable only after
machining, must be given back to Saleri identified.
If such defects shall have high impact on the functionality or delivery of good
parts to Saleri, the Supplier shall contact immediately Saleri to manage the
topic and take the necessary corrective actions.
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3.3.5 Impregnation
The impregnation of products intended for Saleri applications is not allowed
unless a specific agreement between Saleri and the Supplier rules this process.
3.4 Assembly
Here below are described the Saleri specific requirements for the supply of
components obtained by assembly either manual, semiautomatic or fully automatic.
3.4.1 Packaging
The products, unless otherwise specified, must be delivered to Saleri in plastic
boxes (KLT for example) or in cardboard boxes; each layer must be separated
from the other by means of plastic separators; each component must be
separated from the other by means of plastic hives or similar to avoid any
damage during the transportation.
If Saleri assembly procedure will require an automatic handling, special
thermoformed layers could be required to handle the components.
3.4.2 Marking
Unless otherwise specified, the parts must be marked with assembly date and
progressive number in the day.
The marking (either done by DMC or alse) must be linked to the process
parameters for complete traceability parts.
3.5.1 Packaging
The products, unless otherwise specified, must be delivered to Saleri in plastic
boxes (KLT for example) or in cardboard boxes; each layer must be separated
from the other by means of plastic separators; each component must be
separated from the other by means of plastic hives or similar to avoid any
damage during the transportation.
For ferrous components, it is also required to wrap the parts into VCI sheets.
If Saleri assembly procedure will require an automatic handling, special
thermoformed layers could be required to handle the components.
3.5.2 Defects
The products must be free of burrs that can be removed during the process
handling and in the final application.
Cracks, breakages, dings, dentsand inclusions that can compromise the
functionality of the part are not allowed under any circumstances.
If surface tratments are required, the parts will hav eto be free from residuals
or foreing particles that can come from the process itself (e.g. tumbling or
deburring residuals etc…).
Deviations must be reported promptly to Saleri Quality asking an official
waiver.
Saleri reserves the right to accept or reject the request for waiver according
to the severity and criticality of the defect.
6 Warranty
During all the project phases (prototypes, preserie, series and post series) Saleri receives from
its customers parts to be analyzed due to infant failure on the field (warranty).
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PURCHASED PARTS Date 31/01/2018
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If the first Saleri analysis should find that the failure is due to the purchased part, the Supplier
shall carry out all the necessary analyses to establish the root cause of the failure and the
necessary corrective actions to eliminate it (expecially in cases where the failure can arise
into a serial problem).
Moreover, the Supplier has to refund Saleri of the analyses costs and the debit received by
the final customer due to the infant failure (within warranty).
7 List of annex
IST.08.001-ENG Controlled Shipping Level
IST.08.002-ENG Vendor Rating
MOD.08.001-ENG Escalation procedure
MOD.08.003-ENG Declaration of product conformity
MOD.08.011 Production Part Approval (CAP)
MOD.08.013-ENG Check List ANFIA
MOD.08.014 Potential Analysis VDA 6.3
MOD.08.015 Action Plan
MOD.10.002 Non conformance report
8 Modifications history
Release Reason for release Date
00 First release 30/06/2017
01 Modified clauses 2.3.4.1.3, 2.3.4.1.4 and 2.3.4.4 31/01/2018