Upload
duongkien
View
237
Download
0
Embed Size (px)
Citation preview
Supplier Quality Improvement Manual
Tokai Eastern Rubber (Thailand), Ltd.
Issued by Checked by
Revision 11
Effective date : 01 April 2012
Approved by
Technical Section
Technical Supplier Manual
Supplier Quality Improvement Manual
ContentsItem Page
1. Quality assurance ideality 1
2. Purpose 1
3. Scope 1
4. Requests for supplier4.1 Initial Control Organization 2
4 2 Approval Initial Part of Supplier 34.2 Approval Initial Part of Supplier 3
4.2.1 Production Preparation Schedule 4
4.2.2 SPTT Audit 4
4.2.3 Inspection Standard 5
4.2.4 SBSC 7
4.3 Initial Delivery Control 8
4.4 PPAP Activity 8
4.4.1 Reason to submit PPAP 8
4.4.2 PPAP Retention / Submission Requirement for Supplier 9
4.4.3 TER PPAP Status 23
4.4.4 Record Retention 23
4 5 P Ch R i t 244.5 Process Change Requirement 24
4.5.1 Reason to information of process change 24
Submission requirement for supplier
4.5.2 Delivery requirement after PCN approved 25
4.5.3 Change Control Flow 26
4.5.4 Record Retention 27
4.6 Guideline for Environmental Hazardous Substance Management 27
4.7 Control of initial nonconforming products(NC) 32
5. Attachment List 33
Technical Supplier Manual Change Notification
Technical Supplier Manual
Supplier Quality Improvement Manual
1. Quality assurance ideality10
1.1 Supplier shall produce parts that meet to TER satisfaction as purchasing agreement.
TER would approve parts that shall be controlled quality continuously.
1.2 Supplier shall improve production process to achieve condition and requirement and
prepare quality assurance of part have not problem after delivery Especially for problems in TER
shall be corrected and prevented immediately.
1.3 TER shall audit QA system of supplier including monitoring and advising in order to
assure quality of supplier efficiently and continuously.
1.4 To conduct coordination between TER and supplier.
1.5 Supplier shall apply ISO9000 or ISO/TS16949 to implement in Quality Assurance
system.
1.6 Initial part of supplier shall approved by TER before start Mass production.
2. Purpose
This guide to Technical Supplier Manual is defined a standard of quality assurance for new or
changed product as supplied to "Tokai Eastern Rubber (Thailand),Ltd."
3. Scope
This manual applies to the quality assuarance activities of suppliers for new or change, which
related to TER in assembly product. If it difficult to carry out them please contact to Technical section,
QA&Technical department of TER
Page 1 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4. Requests for supplier
4 1 I iti l C t l O i ti4.1 Initial Control Organization
Establish and maintain the quality assurance system. The supplier shall assign a person
who responsible in quality and delivery for initial part. This assignment has aimed to ensure an establishment
of a consistent quality assurance and delivery system to cover all processes of each supplied product
for TER and response in our satisfaction of requirements. Supplier shall submit to Technical section within
11
7 days after received New Part Notice from Purchasing / TER. <for 1st SPTT activity>
** If Contact person change. Please Review /Revise this organization and submit to Technical
section within 7 days.
TER Engineering Div
Project Organization Chart
Project LeaderProject Name
RT-50Supplier Name
Factory ManagerName : Mr.N. YoshidaE-mail : [email protected]
Tel : (038) 893-557-61 ext.162Mobile Phone : 081-9496355
< Manager > < Staff >Project Leader (Department): Project Leader (Department):
TER Engineering Div.
Engineering Div. Engineering Div.
Core team4Marketing Div. Quality Div. Production Div. PE Div. PC Div. WH Div.
Core team6Core team1 Core team2 Core team3
RT 50
Core team5
j ( p ) j ( p )Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :
Core Team # 1 (Department): Core Team # 1 (Department):Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :081-629-4615
Mr.W.CherdpanMkt.Mgr.
02-685-3557-60 ext.110
Mr.T.Makino
Marketing Div. Marketing Div.
02-685-3557-60 ext.112084-084-6660
(038) 893-557-61 ext.210081-664-9426 085-436-4241
(038) 893-557-61 ext.112
Mr.T.SuppachaiMkt.Staff
QA & Technical GMMr.T.Chawalit
Technical Dept.Supv.
Mobile Phone : Mobile Phone :
Core Team # 2 (Department): Core Team # 2 (Department):Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :
Core Team # 3 (Department): Core Team # 3 (Department):Name : Name :Position : Position :E il E il
081 629 4615
Production Mgr.
Production Div. Production Div.
Quality Div. Quality Div.
(038) 893-557-61 ext.116
084 084 6660
Mr.C.AtthayaProduction Supv.
h @ h
Mr.K.Projob
j b@ h
089-939-5191
Mr.S.EkkaratQA Supv.
(038) 893-557-61 ext.117081-377-8504
Ms.S.SaranyaQA & Technical Dept.Mgr.
E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :
Core Team # 4 (Department): Core Team # 4 (Department):Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :
Core Team # 5 (Department): Core Team # 5 (Department):Production Control Production Control
Production EngineerProduction Engineer
081-663-6295
(038) 893-557-61 ext.175081-723-2936
081-663-6295
Mr.M.YoothasisthProduction Engineer Supv.
(038) 893-557-61 ext.175081-750-7738
Mr.K.ProjobProduction [email protected]
(038) 893-557-61 ext.175
(038) 893-557-61 ext.175
Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :
Core Team # 4 (Department): Core Team # 4 (Department):Name : Name :Position : Position :E-mail : E-mail :Tel : Tel :Mobile Phone : Mobile Phone :
(038) 893-557-61 ext.125 (038) 893-557-61 ext.125081-865-2072 081-330-4431
PC Asst.Mgr. [email protected] [email protected]
Production Engineer Production EngineerMr.W.Prapan Mr.K.Narest
Mr.W.Prapan Mr.P.Sakdinan
081-865-2072 081-7825986(038) 893-557-61 ext.125 (038) 893-557-61 ext.189
[email protected] [email protected]
PC Asst.Mgr. Supv.
Page 2 of 34 Technical Supplier Manual
Mobile Phone : Mobile Phone :
Rev.01
081 865 2072 081 330 4431
Supplier Quality Improvement Manual
4.2 Approval Initial Part of Supplier
T h i l ti t fl f l i iti l t t t f li i d PO tilTechnical section set flow for approval initial part start from supplier received PO until mass
production(MP). In each stage technical will check/audit document and process of supplier.
Page 3 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.2.1 Production Preparation Schedule(PPS)
S li i PPS hi h t i N P t N ti TER t l11
Supplier issue PPS which contains New Part Notice, TER master plan
(TD0, TM0, TM1, MP), SPTT stage and detail of part preparation. After received plan Supplier shall issue
Supplier plan submit to TER within 2 week and update supplier plan in PPS submit to Technical every
month. Technical will check progressive of part from PPS.
Supplier shall issue supplier's PPS to Technical / TER after received New Part Notice for
1st SPTT audit activity. Supplier shall update progressive of PPS by 25th of every month
Supplier : XXXXXXXXXXXXXXXX 3Part No. : XXXXXXXXXXXXXXXX 2 Approved Approved Checked Checked Approved Checked IssuedPart Name: XXXXXXXXXXXXXXXX 1Mfg.No.: XXXXXXXXXXXXXXXX PLAN 0 dd/mm/yy xxxx
ACTUAL Rev. Date PIC President Manager Advisor Engineer President Manager Engineer
7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1
sign sign sign
20112010
CUSTOMER Plan
Tokai Eastern Rubber(Thailand),Ltd.
History Recordnew issue sign sign sign sign
Production Preparation Schedule
ResponsibilityActivities
Supplier:________________
S-Lot ET PT1 PT2 SOP
Raw Material& CKD XXXComponent Local parts XXX
Process planning XXXXXXXXXxProd. Of Tooling/Equipment XXXXXXXXXxProd. Of Checking Fixture XXXXXXXXXxTry-out XXXXXXXXXxTurning & Modilication XXXXXXXXXxTooling & Equipment Transfer XXXXXXXXXxProd Of Tooling/Equipment XXXXXXXXXx
Supplier Plan
TER Plan
CUSTOMER Plan
Master Schedule
epar
ation
JAPAN
TM1TM0TD0 MP
TM1TM0TD0 MP1stSPTT 3rdSPTT2ndSPTT
Prod. Of Tooling/Equipment XXXXXXXXXxProd. Of Checking Fixlure XXXXXXXXXxInstallation XXXXXXXXXxTry-out XXXXXXXXXxTuning & Modification XXXXXXXXXxLow Volume Production Trial (LVPT) XXXXXXXXXxHigh Volume Production Trial (HVPT) XXXXXXXXXxStart of Vulume Production XXXXXXXXXxDimension & Appearance XXXXXXXXXxMaterial Evaluation XXXXXXXXXxPerformance Evaluation(Sample part) XXXXXXXXXxPerformance Evaluation XXXXXXXXXx(Re-comfirmation of Local Prod. Part) XXXXXXXXXxInspection Standard XXXXXXXXXx
THAI
Evalution
Proc
ess P
re
4.2.2 SPTT Audit
T h i l t SPTT ti it f
Inspection Standard XXXXXXXXXxQC Process Chart XXXXXXXXXxProcess Standard (WI,QCS,etc.) XXXXXXXXXxPPAP Submit (SPSW Submit) XXXXXXXXXxEducation & Training XXXXXXXXXx
Quality Document
Technical set SPTT activity for
1. 100% Quality meet to TER requirement
2. 100% On time delivery in each stage
3. Close communication between TER and Supplier
SPTT activity has 3 steps and criteria as list below.
Page 4 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
SPTT
1st Audit
ReferenceActivity
Check tooling plan/status
Stage Part Quality Quantity
TD0 Part Off Tool n=3 pcs/shots SPTT audit check sheet
11
1st Audit
2nd Audit
-Check tooling plan/status
-Co-check dimension of part
TD0 Part Off Tool n=3 pcs/shots SPTT audit check sheet
-Co-check dimension of part
(Trial Dimension) (CKD or Local) -Inspection std.approval
TM0 Part Off Tool Refer to Pilot PO
-Check production process
Can rework
SPTT audit check sheet
Off Process
TM1 Part Off Tool Refer to PO
(Trial mold at JP)
3rd Audit
Supplier shall control part follow Approval Initial Part of Supplier schedule.
MP Part Off Tool Refer to PO
(Trial mold at THA)
Can not rework
-Check capacityOff Process
Off Process -Confirm capacity PPAP Approved
-Confirm part before shipping
-Confirm production process
Can not rework -Supplier PPAP Approve
SPTT audit check sheet
(Mass Production)
4.2.3 Supplier shall issue Inspection standard and record which identify all measuring items
and specification for supplier product testing and submit to TER after received drawing within 2 weeks
Supplier shall maintain inspection item which TER approved. (TER form)
Doc. No. TES-IY- DCR No. Rev. 0 PAGE OF
(DATE)
MFG. NO PART NO PART NAME
MODEL ROUTE MATERIAL RANK
INSPECTION INSPECTION SAMPLING INSPECTIONCRITERION INSTRUMENT PLAN METHOD
①
②
Dimen-sion
THREAD ACCURACY
LENGTH
B
B
THREAD GAUGEM10 X 1.25
xxxxxx
ITEM
TSB1001G-11.9
NO INSPECTION ITEM RANK
xxxxxx
INSPECTION STANDARD
xxxxxxxxxxxxx
( 1 / 2 )
HEIGHT GAUGE / CMM
SAFETY PART
xxxxxxxx
FINISHEDUNFINISHEDMETAL
20-May-10
40 + 0.5
n = 5, c = 0 / METAL LOT
※ n = 5, c = 0 / LOT②
③
④
⑤ ※
⑥ ※
⑦
⑧
RADIUS B
CALIPERB 14 -0.25
B
OUTER DIAMETER
LENGTH B
DIMENSION B
DIAMETER B
B
DIMENSION
26 0 HEIGHT GAUGE / CMM
CALIPER / CMM9.5 ( MAX )
CMM40 0.5 ,SUPPLIER DATA
CHECK ONLY
1.35 ( MIN ) HEIGHT GAUGE / CMM
PROFILE
∅ 21.5 ( MAX )
R0.5 ( MIN )
CALIPER
+2.5
0
⑨
⑩ ※
⑪
⑫
⑬
⑭
DIMENSION
DIAMETER CALIPER
15.5 (MIN) CALIPER
A TSB1001G-11.9 EVIDENCE
B
B
ALL METAL LOT MATERIAL CERTIFICATE
MATERIAL CERTIFICATE
∅ 9.5 -0.15
n = 1, c = 0 / INITIAL OR PROCESS CHANGE
/ IF NECESSARY
BALANCER n = 5, c = 0 / METAL LOT
EVIDENCE
33 g
MATERIAL OF PART
NO USE OF 4ENVIRONMENTAL SOCs A CONFORM TO
TSZ0001G
VISUAL n=10%,c=0 / METAL LOTALL(SUPPLIER)
TSH7903GTSH6524G-B
Appea-rance
SURFACE TREATMENT B ZINC COATING
Charac-teristic
WEIGHT Ref
0
CUSTOMER QA DEPT
CHECK ISSUE
SUPPLIER QA DEPT (TER)
APPROVE CHECK CHECK CUSTOMER TOKAI EASTERN RUBBER (THAILAND) LTD APPROVE CHECK
ISSUE DATE REVISION RECORD
Page 5 of 34 Technical Supplier Manual
CHECK ISSUEAPPROVE CHECK CHECK CUSTOMER TOKAI EASTERN RUBBER (THAILAND),LTD. APPROVE CHECK
SUPPLIER XXXXXXXXXXXXXXXXXX
Supplier Quality Improvement Manual
INSPECTION RECORD ( METAL PART )
NO. 1 2 3 4 5 X JUDGE TESTEQUIPMENT NO. 1 2 3 4 5 X JUDGE
THREAD ACCURACYM10 X 1.25
Due
LENGTH40 ± 0.5
( 39.50 ~ 40.50 ) Due
LENGTH + 2.526 - 0
( 26.0 ~ 28.5 ) Due
DIMENSION
Due
RADIUS
Due
DIMETER
DueDIM
ENSI
ON
⑤ R 0.5 ( MIN )
⑥
③
④ 9.5 ( MAX )
1.35 ( MIN )
PROFILE
HEIGHT GAUGE / CMM
CALIPER/CMM
HEIGHT GAUGE / CMM
SPEC. INSTRUMENT SAMPLING PLAN
②HEIGHT
GAUGE / CMM
①THREAD GAUGE
n=5,c=0/METAL LOT
CUSTOMER NAME
PART NAME
SHIPPING QT'Y
SKETCHPART NO.
MFG NO.
MODEL
TER 's DATA
INSPECTION DATE
INSPECTION QTY
SUPPLIER 's DATA
SHIPPING DATE
QAINSPECTION RECORD ( METAL PART )
NG QTY
RECEIVING LOT
SUPPLIER NAME
SHIPPING LOT
QAINSPECTION RECORD ( METAL PART )
xx-xxxxxx-xxxxxxxxxxxxxxxTERxxxxx
xxxxx
OUTER DIMETER
Due
DIMENSION 014 - 0.25
( 13.8 ~ 14.0 ) Due
DIMENSION
Due
DIMETER 0∅ 9.50 - 0.15
( 9.35 ~ 9.50 ) Due
⑫
⑭
APPE
ARAN
CE
CALIPER
⑨ CALIPER 15.5 ( MIN )
PCS
∅ 21.5 ( MAX )
⑩
⑧
CALIPER
PCSGOODGOOD
CALIPER
PCS NG PCS
CHECKED BY
INSPECTED BY
NG
n=1 , c =0 / INITIAL OR PROCESS CHANGE &
IF NECESSARY
ALL SUPPLIERn=10%,c=0/LOT
TER⑪
SURFACE TREATMENT
VISUAL
n=5,c=0/METAL LOT
MATERIAL OF PART (TSB1001G-11.9)
NO USE OF 4 ENVIRONMENTAL SOCs (CONFORM TO TSZ0001G) EVIDENCE
⑦
EVIDENCE ※ SUPPLIER DATA CHECK ONLY
CHAR
ACTE
RIST
IC
⑬ WEIGHT: 33 g. (REF.)*VICKER
HARDNESSTESTER
ZINC COATING
(TSH7903G, TSH6524G-B)
RECEIVING LOT
INSPECTION QTY
QASKETCH
MFG NO. SUPPLIER 's DATA TER 's DATA
PART NO. INSPECTION DATESUPPLIER NAME
SHIPPING DATE
SHIPPING LOTPART NAME
MODEL
CUSTOMER NAME
SHIPPING QT'Y NG QTY
xx-xxxxxx-xxxxxxxxxxxxxxxTERxxxxx
xxxxx
Keep period : EFFECTIVE DATE :
CHECKED BY
(GM)
APPROVE
History Record
Rev. Date Revisior Record PIC
TER
CHECKED
(SUPV.)
SUPPLI
ISSUED CHECKED
APPROVE
(MGR.)
APPROVE APPROVE
Inspection Rank List Control
Keep period :
IER
(ENGINEER) (SUPV.) (MGR.) (MGR.)
RankControl Method
Dimension Appearance Characteristic RemarkDimension Appearance Characteristic Remark
Control method
-Visual 100% Inspection
-Test before shipping part to TER
- Test before start production evey lot - Use SPC control
-Test before shipping part to TER
A
B
- Test before shipping part to - Test before start
-Sampling check
and frequencyrefer to TER'srequirement
whichagree togetherC
R
For (Safety) (Regulation) (Emission)
S S TER evey lot- Use SPC control
-Visual 100% Inspection production evey lot - Use SPC control
S R ES
E
S S
Page 6 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.2.4 SBSC
SBSC i S li B d S b t Ch k Sh tSBSC is Supplier Banned Substance Check Sheet
Suppliers shall
check your material and reply to Technical by attach with TM0 Data. Concentration of banned substances
calculate from MSDS or Chemical ingredient. (Attach sheet No. 18)
SBSCTech Tech Mgr Tech SupplierSupplier Tech Tech Mgr. Tech Supplier
Supplier Name :
Address :
Responsible person :
Reason for submission
Supplier
Supplier Banned Substance Check Sheet (SBSC)
New model New Materials / Chemical Change ECN no. … … … Current material Correction for previous discrepancy with Mfg.No. ……...………….Change Process ……………..to……………….
Please fill form of your material or chemical name and concentation if it don't have these chemical Substanced, Pleases fill in that column.
No.Material Concentration of Banned Substances (ppm)
Ch i l N
7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1
2
3
4
5
6
7
Chemical Name
7
8
1 Cadmium and cadmium compounds 11 Polybrominated diphenylethers (PBDE) 21 Trinuvin 3202 L d d l d d 12 O h b i d i d 22 Di h lf ( DMF )
Remark7
72 Lead and lead compounds 12 Other brominated organic compounds 22 Dimethylfumarate ( DMF )3 Mercury and mercury compounds 13 Organic tin compounds 23 REACH (SVHC)4 Hexavalent chromium compounds 14 Asbestos 24 Other5 Polychlorinated biphenyls (PCB) 15 Azo compounds6 Polychlorinated naphthalenes (PCN) 16 Formaldehyde7 Polychlorinated terphenyl (PCT) 17 Polyvinyl chloride (PVC) and PVC blends8 Chlorinated paraffins (CP) 18 Perfluorooctane sulfonate anion (PFOS)9 Other chlorinated organic compounds 19 Recycled Meterial
10 Polybrominated bihenyls (PBB) 20 Polycyclic Aromatic Hydrocarbon(PAHs)
* For specification refer to Sony Technical Standards SS-00259 Yano standards and Green Procurement
7
7
7
For specification refer to Sony Technical Standards SS 00259, Yano standards and Green Procurement Standard of Matsushita group and GGP-001 of Pioneer Group *For REACH refer to the European Chemical Agency has announced the latest SVHC Candidate List - please see information from UK. The summary of the obligations is available on ECHA's website.
For Supplier
Approved by: ………………………… Checked by …………………………Checked by …………………… Approved by ………………………(Mgr) (Technical Engineer) (Technical SoC) (Tech Mgr.)
Date : ……../……../……… Date : ……../……../……… Date : ……../……../……… Date : ……../……../………
For TER
Page 7 of 34 Technical Supplier Manual
Page 1 of 1
Supplier Quality Improvement Manual
4.3 Initial Delivery Control
P t d li i h t h ll tt h d Shi i T f ll thi lPart delivery in each stage shall attached Shipping Tag follow this manual.
4.3.1 TD0 Stage (White color tag) 4.3.6 Last Lot (PCR Old Part)
4.3.2 TM0 Stage (Orange color tag) 4.3.7 First Lot (PCR New Part)
4.3.3 TM1 Stage (Sky blue color tag)
4.3.4 MP Stage (Green color tag)
4.3.5 Special Stage (Pink color tag)
TO: ARRIVAL DATE : dd/mm/yySUPPLIER : XXX MODEL: XXX
TOKAI EASTERN RUBBER (THAILAND), LTD.Technical
SUPPLIER : XXX MODEL: XXX
PART NO. : XX-XXXXX MFG. NO. : XX-XXXPART NAME.: XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
Q'TY (Pcs.) XXX P/O NO. XXX
PART FOR TD0 TM0 TM1 MP Other
Change PCN No.
DELIVERY BY MR.XXXXXXXX PHONE XXX-XXXXXX
Supplier shall attach delivery tag to every box and invoice.
Technical Contact Person IPP Name ESIE MR.XXXXXXXXXX
4.4 PPAP activity
PPAP: Production Part Approval Process is a activity for preparation of part and document to
control process and inspection to reach TER requirement before part approval process in TER. Refer to
Production Part Approval Process : PPAP 4th edition
4.4.1 Reason to submit PPAP
4.4.1.1 New part or product (e.g., a specific part, material, or color not previously
supplied to TER).
4.4.1.2 Correction of a discrepancy on a previously submitted part.
4.4.1.3 Product modified by an engineering change to design records, specifications,
or materials.
4.4.1.4 Any situation required by TER example 4M Change (Man, Machine, Method and
Material)
Page 8 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.2 PPAP Retention/Submission Requirement for Supplier
S li h ll b it d t f ll thi i t t t li i dSupplier shall submit document follow this requirement separate to supplier group or any required
by TER (supplier shall to use TER format some requirement at symbol is )
Metal part, Plastic part, Rubber part
Rubber CompoundPlastic Material
ChemicalOther
Requirement Fix TER format
Production Matetial
1 Design Record S - S
-For proprietary components/ details R - R
-For all other components/ details S - R
2 Engineering Change Documents S - S
(List of engineering standard and drawing) -
3 Customer Engineering Approval S - S
4 Process Flow Diagrams S S S -5 Process FMEA S - R -6 Control Plan S S S -7 Measurement System Analysis Studies S - - -8 Dimensional Results S - S
9 Material, Performance Test Results, Supply Chain S S S
10 Initial Process Studies S - - -11 Qualified Laboratory Documentation S - S -12 Master Sample S - S -13 Checking Aids R - - -14 Records of Compliance with Customer-
Specific Requirements S - S -15 Part Submission Warrant (PSW) S S S
16 SBSC, Certification of Non-Use of the S S S16 ,Controlled Substances S S S
17 Cover sheet and Test report S S S
18 Material Data Sheet S S S
19 Declaration of no use of PFOS S S S
20 SVHC survey S S S
S = Supplier shall submit to TER and retain a copy of records or documentation items at appropriate locations.
R = Supplier shall retain at appropriate location and make available to TER upon request.
Page 9 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.2.1 PPAP Retention/Submission Requirement for Supplier
TER i "S li PPAP R t Sh t" t li ft TM1 t S li h ll11
TER issue "Supplier PPAP Request Sheet" to supplier after TM1 stage. Supplier shall
submit document/PPAP folow the request sheet
Supplier PPAP Request Sheet Model : _______________
Supplier Name : Submit Criteria: Production Matetial
Part No. : ❒ Metal part, Plastic part, Rubber part
Part Name : ❒ Rubber Compound, Plastic Material, Chemical
Revision : E.C.I. No. : ❒ Other
Due Date of Submission : _______________________ Received Date from Supplier : _____________________
1
2
3
4
5
Customer Engineering Approval (Inspection std.)
Process Flow Diagrams
Process FMEA
Design Record
-For proprietary components/ details
-For all other components/ details
Engineering Change Documents(List of engineering standard and drawing)
Requirement
❒
TER Judge❒ Not Accept❒ Accept
Remark
❒ Accept ❒ Not Accept
TER's Request
❒ Accept ❒ Not Accept
❒ Accept ❒ Not Accept
❒❒
❒ A t ❒ N t A t
❒ Accept ❒ Not Accept
❒ Accept ❒ Not Accept
❒
❒❒❒5
6
Process FMEA
Control Plan
❒ Accept ❒ Not Accept
❒ Accept ❒ Not Accept
❒❒
19
20
Supplier PPAP Result
❒ Approved ❒ Interim ❒ RejectedResubmit within ________________ Resubmit within ________________
Detail of document (Not Accept item)
Declaration of no use of PFOS
SVHC survey
❒ Accept ❒ Not Accept
❒ Accept ❒ Not Accept
❒❒
Remark : TER will control Supplier PPAP by Supplier PPAP Request Sheet
Distribution Flow : TER(Technical) Supplier TER(Technical)
Request Submit Approve
SupplierTechnical
SupplierApprove Check Incharge Approve Check
TER
4.4.2.2 Design Record (List of Engineering Record)
Supplier shall have the design record for the saleable product/part, including design
records for components or details of the saleable product/parts which approved and distributed by TER.
Where the design record is in electronic format, e.g., CAD/CAM math data, the supplier shall produce
h d ( i t i l t i di i i & t l i [GD&T] h t d i ) t id tifa hard copy (e.g.pictorial, geometric dimensioning & tolerancing[GD&T] sheets, drawing) to identify
measurements taken.
Page 10 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.2.2(a) When supplier received "List of Engineering Drawing to Supplier" shall reply to
TER within 3 days for convenient date to receive new engineering drawing by supplier must to receive y g g g y pp
drawing within 7 days
4.4.2.2(b) In receive date supplier must return "Old Engineer Drawing" to TER
4.4.2.2(c) Supplier must review new engineering drawing by record date of "First Lot,
Last Lot" in List of Engineering Drawing to Supplier document and reply to TER within 7 days after supplier
have received drawing by result are reviewedhave received drawing by result are reviewed
Issued date : dd/mm/yyyyTo : From : Tokai Eastern Rubber (Thailand), Ltd.
Attn : Ms. Suthasri Suwannasri
Position : Position : Technical Staff
Dept. Dept. Technical
Tel. No.: CC : Ms. Maneerat / Technical Dept. Senior Staff
Model :
List of Engineering Drawing to Supplier
xxxxxxxxxxxxxMr. xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx(0xx)xx-xxxx
xxxxxxxxxxxxxxxxxxxx
① Supplier Confirm Sheet
วนัทเีขา้มารับ ………………………………………….……... เวลา 09.30 - 16.00 น. สถานท ี TER / ESIE
กรุณาเซ็นตร์บัทราบ และตอบกลบัเอกสารมายงั Fax: (038)-927594 หรอื E-mail: [email protected]
ภายในวนัท.ี.......................................... โดย Supplier จะตอ้งกรอกขอ้มูลในสว่นท ี2 ใหค้รบถว้น
รับทราบ ……………………………………………….
วนัท ี………………………………………………......
② List Engineering Drawing / Confirm Submittion Date
Inspection Standard** Supplier จะตอ้งกรอกขอ้มลูใหค้รบถว้น
** 1st Lot
dd/mm/yyyy
dd/mm/yyyySupplier Confirm
Receive date
S li C fi Fi1 XXXXX-XXXXX XXXXXXXXXXXXXXX XX-XXX A T-XXXX dd/mm/yyyy dd/mm/yyy
2 XXXXX-XXXXX XXXXXXXXXXXXXXX XX-XXX A T-XXXX dd/mm/yyyy dd/mm/yyy
No. Part No. Part Name MFG.No
dd/mm/yyyy
dd/mm/yyyy
Submittion Due DateDrawing Effective Date
Level ECI.No.** 1st Lot
(กรณุาระบวัุนทสํีาหรับ 1st Lot)
Supplier Confirm Firt Old ECI
หมายเหต:ุ Supplier จะตอ้งทําการยนืเอกสาร Inspection Standard ภายในวนัเวลาทกํีาหนด
หากมขีอ้สงสยัประการใด กรุณาตดิตอ่ : คณุนลิบุล เจยีมประสตูร / คณุมณีรัตน ์ แสงสงัข ์/ คณุสธุาส ี สวุรรณศร ีเบอร ์038-927-500 ตอ่ 601, 602, 630 E-mail: [email protected], [email protected], [email protected]
โดยสง่ถงึคณุนลิบุล เจยีมประสตูร แผนกเทคนคิคอล
TER Supplier
( ) ( )
Page 11 of 34 Technical Supplier Manual
ผูรั้บคนื/ผูส้ง่ ผูรั้บ
วนัที วนัที
Supplier Quality Improvement Manual
4.4.2.3 Engineering Change Documents (ECR, PCR and Deviation)
Supplier shall have any authorized engineering change documents for those changes
11
not yet recorded in the design record but incorporated in the product, part or tooling. * ECR (Engineering Change Reques)* PCR (Process Change Request)
4.4.2.4 Customer Engineering Approval (Inspection Standard and Record)
Where specified by TER, supplier shall have evidence of TER engineering approval. (TER's format )
<Engineering Standard> <Engineering Recorder>
TER's signature
4.4.2.5 Process Flow Diagrams
Supplier shall have a process flow diagram in a supplier-specified format that clearly
d ib th d ti t d i t d d ifi d TER d
TER's signature
describes the production process steps and sequence, as appropriate, and need specified TER needs,
(e.g., Advanced Product Quality Planning and Control Plan reference manual).
Page 12 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
Note: Process flow diagrams for "families" of similar parts are acceptable if the new parts have
b i d f lit b th li been reviewed for commonality by the supplier.
4.4.2.6 Process FMEA
Suplier shall develop a Process FMEA in accordance with, and compliant to, TER-p p p
specified requirements, (e.g., Potential Failure Mode and Effects Analysis referance manual).
Supplier must undertake efforts to reduce this calculated risk through corrective action
and preventive action
1. RPN more than 128
or 2. The highest RPN
After action will evaluate RPN again
Remark : Refer to Potential Failure Mode and Effects Analysis Manual 4th editionRemark : Refer to Potential Failure Mode and Effects Analysis Manual 4th edition
Page 13 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.2.7 Control Plan
S li h ll h C t l Pl th t d fi ll th d d f t l dSupplier shall have a Control Plan that defines all methods used for process control and
complies with TER-specified requirements, (e.g., Advanced Product Quality Planning and Control
Plan reference manual). Use TER format
Note: Control Plan for "families" of similar parts are acceptable if the new parts have been
reviewed for commonality by the supplier.
4.4.2.8 Measurement System Analysis Studies
Supplier shall have applicable Measurement System Analysis studies, e.g. gage R&R,
bi li it t bilit f ll idifi d t d t t i t (M t
11
bias, linearity, stability, for all new or midified gages, measurement, and test equipment.(Measurement
Systems Analysis reference manual)
G.R&R technique and/ or Hypothesis test use to analyze measurement system.
Guideline for acceptance of G.R&R
% R&R Value Judge
Under 10% Measurement system is acceptable
10% to 30% Acceptable based upon importance of application,
cast gage, cost of repairs.
Needs comment in result and approve by QA Mgr.
Over 30% Measurement system needs improvement.
Page 14 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
※ D4 = 3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limited individual R's.Circle those that arc beyond this limited.Identify thecause and correct.Repeat these reading using the same appraisers and unit as originally used for discard value and re-average and recomputeR and the limiting value from the remaining observation.% R&R Value Judge Recomment Action Supplier :
Under 10% Measurement system is acceptable Detail Due PIC
10% to 30% Acceptable based upon importance of application, 1
cast gage, cost of repairs. 2
Needs comment in result and approve by QA Mgr. 3
Over 30% Measurement system needs improvement. 4
CheckedApproved
4.4.2.9 Dimensional Results
Supplier shall provide evidence that dimensional verifications required by the design
record and the control plan have been completed and result indicate compliance with specified
requirements. The supplier shall have dimensional results for each unique manufacturing process, e.g.,
ll d ti li d ll iti ld tt di Th li h ll d ith thcells or production lines and all cavities, molds, patterns or dies. The supplier shall record, with the
actual results: all dimensions (except reference dimensions), characteristics, and specifications as noted
on the design record and control plan.
Supplier shall indicate the date of design record, change level, and any authorized
engineering change document not yet incorperated in the design record to which the part was made. The
supplier shall record the change level, drawing date, supplier name and part number on all auxiliary
documents (e.g., supplementary layout results sheets, sketches, tracings, cross sections, CMM
inspection point results, geometric dimensioning and tolerancing sheets, or other auxiliary drawings used
in conjunction with the part drawing).
Page 15 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
The supplier shall identify one of the parts measured as the master sample.
Dimension ResultsSupplier Name : Part No. : Revision :
Part Name : E.C.I. No. :
Stage : Test Date : Test Quantity :
1 2 3 4 5 X R 1 2 3 4 5 X R
①
Judge Judge
Supplier Measure TER Measure
ResultTestEquipment
ResultSpecificationTest Item
①
②
③
④
⑤
⑥
⑦
⑧
⑨
4.4.2.10 Material, Performance Test Results, Supplier Chain
The supplier shall have records of material and/or performance test results for tests
specified on the design record or control plan
Material test results shall indicate and include :
-the design record change level of the parts tested;
-any authorized engineering change documents that have not yet been incorporated in the
design record;
-the number, date, and change level of the specifications to which the part was tested;
-the date on which the testing took place; the date on which the testing took place;
-the quantity tested;
-the actual results (Attach with test result from laboratory) ;
-Mill sheet
-Supply chain check sheet
M t i l Li t & C t P t -Material List & Component Parts
Page 16 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
Mill Sheet
Supply Chain Check Sheet
Material List & Component Parts
Page 17 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
Performance test results shall indicate and include :
th d i d h l l f th t t t d -the design record change level of the parts tested;
-any authorized engineering change documents that have not yet been incorporated in the
design record;
-the number, date, and change level of the specifications to which the part was tested;
-the date on which the testing took place;
-the quantity tested;
-the actual results (Attach with test result from laboratory);
4.4.2.11 Initial Process Studies and Control
The level of initial process capability or performance shall be determined to be acceptable
prior to submission for all special characteristics designated by TER or supplier The supplier shall obtain
10
prior to submission for all special characteristics designated by TER or supplier. The supplier shall obtain
TER concurrence on the index for estimating initial process capability prior to submission.
The supplier shall perform measurement system analysis to understand how
measurement error affects the study measurements.
Note: For characteristics that can be study using X-bar and R charts, a short term study should
b b d i i f 25 b t i i t l t 100 di f ti be based on a minimum of 25 subgroups containing at least 100 readings from consecutive
parts of the significant product run.
Acceptance Criteria for Initial Study
Index > 1.67 The process currently meets the acceptance criteria.
1.33 < Index > 1.67 The process maybe acceptable. Contact the authorize TER
representative for a review of the study results.
Index < 1.33 The process does not currently meet the acceptance criteria.
Contact the authorize TER representative for a review of the study
results.
Page 18 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
After 2nd SPTT audit, supplier will launch to intial process control. Supplier shall record
k h t i ti d k d t h t i ti SPC d t Th d h ll t t TERkey process characteristic and key product characteristic as SPC data. The record shall report to TER
for 3 months or 30 production lots by 1 time per month or appropriate period which accept by TER.
4.4.2.12 Qualified Laboratory Documentation
The qualified laboratory (internal or external to the supplier) shall have a laboratory scope
and documentation showing that the laboratory is qualified for the type of measurements or tests
conducted.
When an external/commercial laboratory is used, the supplier shall submit the test
results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that
performed the tests, the date(s) of the tests, and the standards used to run the tests shall be identified.
4.4.2.13 Master Sample
Th li h ll b it l d t 3 3 h t d t i t lThe supplier shall submit sample product 3 pcs. or 3 shots and retain a master sample
for the same period as the production part approval records, or
-until a new master sample is produced for the same part number for TER approval
-where a master sample is required by the design record, control plan or inspection
criteria, as a reference and standard. The master sample shall be identified as such, and shall show TER
approval date on the sample. The supplier shall retain a master sample for each position of a multiple
cavity die,mold,tool or pattern,or production process.The master sample will attached with full lay out data.
Page 19 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
MASTER SAMPLE TAGSUPPLIER XXXXXXXXXXXXXXXXXXXXXXXXXXX
MFG.NO. XXXXXXXXXPART NAME XXXXXXXXXXXXX
PART NO. XXXXXXXXXX NEW
MODEL XXXXXXXX CHANGE
DATE XXXXXXXX RENEWAL
DESCRIPTION & SKETCH : LOT NO. :XXXXXX
MASTER SAMPLE TAG
MAKER : TOKAI EASTERN RUBBER (THAILAND) , LTD.APPROVED CHECKED
SUPPLIER : XXXXXXXXXXXXXXXXXXAPPROVED APPROVED CHECKED ISSUED
FRONT VIEW SIDE VIEW
4.4.2.14 Checking Aids
The supplier shall submit any part-specific assembly or component checking aids. The
supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The
supplier shall document all released engineering design changes that have been incorporated in the pp g g g g p
checking aid at the time of submission. The supplier shall provide for preventive maintenance of any
checking aids for the life of the part.
4.4.2.15 Records of Compliance with Customer-Specific Requirements
The supplier shall have records of compliance to all applicable TER-specific requirement.
4 4 2 16 Part Submission Warrant (PSW)4.4.2.16 Part Submission Warrant (PSW)
Upon completion of all PPAP requirements, the supplier shall complete the Part
Submission Warrant(PSW).
If production parts will be produced from more than one cavity, mold, tool,die, pattern,
or production process, the supplier shall complete a dimensional evaluation on one part from each.
Th ifi iti ld li t h ll th b id tifi d i th "M ld/C it / d ti P "The specific cavities, molds, line, etc., shall then be identified in the "Mold/Cavity/production Process"
line on a PSW, or in a PSW attachment
Note: One warrant per customer part number
Page 20 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.2.17 Certification of Non-Use of the controlled substances.
C tifi ti f N U f th t ll d b t i th d t f li tif10
Certification of Non-Use of the controlled substances is the document for supplier certify
the non-use of the controlled substances in process of supplier which produce production material to TER.
Certified with test report or ICP data.
Certification of Non-Use of the controlled substances
TOKAI EASTERN RUBBER (THAILAND), LTD.
Supplier name :
Supplier code :
Responsible person name :
Responsible Division/Dept. :
Certification of non-use of the controlled substances(for initial parts)
Part no./ Part name:
This is to certify that , these material/ products which were delivered to TER did not contains ;
1. Cadmium and cadmium compounds 13. Organic tin compounds
2. Lead and lead compounds 14. Asbestos
3. Mercury and mercury compounds 15. Azo compounds
4. Hexavalent chromium compounds 16. Formaldehyde
5 Polychlorinated biphenyls (PCB) 17 Polyvinyl chloride (PVC) and PVC blends5. Polychlorinated biphenyls (PCB) 17. Polyvinyl chloride (PVC) and PVC blends
6. Polychlorinated naphthalenes (PCN) 18. Perfluorooctane sulfonate anion (PFOS)
7. Polychlorinated terphenyl (PCT) 19. Recycled material
8. Chlorinated paraffins (CP) 20.Polycyclic Aromatic Hydrocarbon(PAHs)
9. Other chlorinated organic compounds 21.Trinuvin 320
10. Polybrominated biphenyls (PBB) 22.Dimethylfumarate ( DMF )
11. Polybrominated diphenylethers (PBDE) 23.REACH(SVHC)
12. Other brominated organic compounds 24. Other
* Remark:For REACH refer to the European Chemical Agenc has announced the latest SVHC Candidate List
334
334
334
* Remark:For REACH refer to the European Chemical Agency has announced the latest SVHC Candidate List -
please see information from UK. The summary of the obligations is available on ECHA's website.
Put a check in this box if applicable chemical substances are used are no used
If use that substances, what item do you use (1 to 24) ?
If use that substances, when change to no use ?
(date/ month/ year)
Approved by
(Manager or higher)
For Technical of TER
Received by Approved by
Date Date
Supplier Tech (TER) Tech Manager <Attached Sheet 19>Remark : Supplier shall submit this format together with PPAP
Date
Page 21 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.2.18 Cover sheet and Test report
Cover sheet Test report
4.4.2.19 Material Data Sheet
Material Data Sheet is the document which show and calculate ingredient or
use of substance. Supplier Name :
Contact Person : Tel :TOKAI EASTERN RUBBER (THAILAND), LTD.
Material Data Sheet
Measured Component Component Part Component Material Name Material No. / Symbol Material Norms/Standard Material Weight (g) Material Classification Basic Substance Percentage of SoC/ EHS SoC/ EHS Substance Weight Part/Item No. Measured Weight Part Or Or Inhouse Norm Surface Treatment (Select from sheet of Name Basic Substance Substance Name Purpose of Use
per Items (g) per Item (g) Quantity Surface Treat. Name Surface Treat. Code Surface Treat. Standard Weight (mg) Material Classification) %
Delivery Part Material SoC/ EHS
Part No. Part Name Component Part Name
Component Part
Position : Fax :
Dept. : Mobile :
Email:
TOKAI EASTERN RUBBER (THAILAND), LTD.
Issued byChecked byApproved by
Supplier
4.4.2.20 SVHC Survey
To survey substances of very high concern (SVHC) in product to comply with REACH
regulation. Accompanying Document Exhibit 2 : SVHC Questionnaire Supplier codeComponents that contain any of the proposed substances listed in Accompanying Document Supplier name in a concentration of 0.1% or more in a homogeneous material or not ? Authority's name
Company Stamp
11
( Please add your answer mark in the blank ) PositionPhone no.
If yes please fill in the following table regarding components that contain any of the proposed substances listed in Accompanying Document in a concentration of 0.1%
or more in a homogeneous material. ※If more lines are needed, please add lines as necessary.
a b c d e f
Material Name
Material Standard
Weight of basic material
(homogeneous material)
Concentration of SVHC in homegenious
material (%)Total weight of SVHC Weight of component
12
No.SVHC-containing part of component
Part name./Component name.
Part no./Component No.
Name of SVHC
Have
Not have
2345678910111213
Page 22 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.4.3 TER PPAP Status
4 4 3 1 A d4.4.3.1 Approved
Approved indicates that the part or material meet all TER requirements. The supplier is
therefore authorized to ship production quantities of the product, subject to releases from TER schedule.
4.4.3.2 Interim Approval
Interim Approval permits shipment of material for production requirements on a limited
time or piece quantity basis. The supplier shall re-submission to TER for status of "Approved" within
7 days after TER reply to supplier.
4.4.3.3 Rejected
Rejected means that the PPAP of supplier does not meet TER requirement. Supplier
shall be corrected to meet TER requirement then submit to TER within 15 days.
4.4.4 Record Retention
PPAP shall be maintained for the length of time that the part is active plus one calendar year.
Supplier shall ensure that the appropriate PPAP records from a superseded part PPAP file are included,
or referenced in the new pat PPAP file.
11
p
For (Safety) (Regulation) (Emission) Supplier shall keep the PPAP 11 years
after moldle run out.
Supplier shall keep approved PPAP in paper file and/or Electronic file (PDF file).
Electronic file shall submit to TER by 7 working days after received PPAP from TER.
S R E
Page 23 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.5 Process Change Requirement
4 5 1 R t i f ti f h d b i i i t f li4.5.1 Reason to information of process change and submission requirement for supplier
Type
PCN
PPA
P
Proc
ess
Flow
Cha
rt
and
cont
rol p
lan
MSA
Dim
ensi
on R
esul
t
Perf
orm
ance
Res
ult
Supp
ly C
hain
Initi
al P
roce
ss s
tudy
PSW
Sam
ple
Engineering Change from customer O O - - - - - - - -Shape Change O O
Item Cange
ct Shape Change O O - - - - - - - -Add/Change Tolerance O O - - - - - - - -Characteristic O O - - - - - - - -Material (Design Change) O O - - - - - - - -
MAN Subcontractor use O - - - - - - O - -Machine add to up capacity (same specification with current machine) O - - - O - - O O O
Machine change (change specification with current machine) O - - - O - - O O O
Process flow chart O O O O
Prod
uc(E
CN
)
MACHINE
Process flow chart O - O - - - - O - OControl item I control plan change O - O - - - - O - -Sub-supplier production (Tier3) O - O O O O O O OAdd material sourcing O O - - - - - - - -Change material sourcing O O - - - - - - - -Add mold/die/tooling to up capacity O O - - - - - O - -Change mold/die/tooling O - - - O O - O O OUse tooling which stop production over 12 months O - - - O O - O O O
Mold
MATERIAL
METHOD
Proc
ess
Cha
nge
4.5.1.1 Process Change Notice
Process Change Notice to define change previous process compare with new process for
months
Checking figure/inspection gauge add O - - O - - - - - OChacking figure/inspection gauge change (design change) O - - O - - - - - O
OTHERS Location change O - - - O - - O - O
MEASUREMENT
Process Change Notice to define change previous process compare with new process for
TER approve. The supplier shall submit Process Change Notice before
change 1 month. (N-1)
4.5.1.2 Sample production parts
The supplier shall provide sample product 3 pcs./shots or all cavity for TER evaluation.
d d t ld ith b f t P Ch N ti (B f 2 th )and compare data old with new before approve to Process Change Notice (Before 2 months)
4.5.1.3 Balance Stock Control
Supplier shall to confirm implement timing of change to TER below
N
N-2 -Submit Process Change Notice before 2 months
Confirm Item Remark
- Implement timing by forecast
N-1 - Co-Check the Sample production parts before 1 month
D-9 -Stock balance information to TER before 9 days
D-3 -Stock balance information to TER before 3 days
D-1 - Last & First Lot Confirm & Information before 1 day
D - First Lot arrive to TER Implement date
Page 24 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.5.2 Delivery requirement after PCN approved.
S li h ll i iti l t f t l hi i t h t TER f ll11
Supplier shall use initial tag for control shipping parts change to TER follow
Delivery requirement table
Deliver requirement
RemarkReason / identifyPurposeColor Tag
Last Lot Confirm Change is "Old Part in Last - Attach with Invoice and Part
(Old Parts) ECI" at " Others - Confirm by telephoen / e-mail
First Lot Confirm Change is "New Part Lot - Attach with Invoice and Part
(New Parts) ECI" at " Others - After PSW approved is 1 lot
- Confirm by telephone / e-mail
Red
Yellow
<Old Part in last ECI tag> < New Part Lot ECI tag>
TO: ARRIVAL DATE : dd/mm/yySUPPLIER : XXX MODEL: XXXX
PART NO. : XX-XXXX-XX MFG. NO. : XX-XXX
TOKAI EASTERN RUBBER (THAILAND), LTD.Technical TO: ARRIVAL DATE : dd/mm/yy
SUPPLIER : XXX MODEL: XXXX
PART NO. : XX-XXXX-XX MFG. NO. : XX-XXX
TOKAI EASTERN RUBBER (THAILAND), LTD.Technical
PART NAME.: XXXXXXXXXXXXXXXXXXXXXXXXXXXXX
Q'TY (Pcs.) XX P/O NO. XX
PART FOR TD0 TM0 TM1 MP Other
Change XXXXXXXXX PCN No. XXXX
DELIVERY BY MR.XXXXX PHONE XXX-XXX
Technical Contact Person IPP Name ESIE MR.XXXXXXXXXX
PART NAME.: XXXXXXXXXXXXXXXXXXXXXXXXXXXXX
Q'TY (Pcs.) XX P/O NO. XX
PART FOR TD0 TM0 TM1 MP Other
Change XXXXXXXXX PCN No. XXXX
DELIVERY BY MR.XXXXX PHONE XXX-XXX
Technical Contact Person IPP Name ESIE MR.XXXXXXXXXX
Page 25 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
4.5.3 Change Control Flow11
ItemQA &TC ‐ Issue ECR from supplier ‐ ECR
TC ‐ Issue ECR to TRI ‐ ECR
TC & TRI ‐ Review ECR from TER ‐ ECR
Customer ‐ Review & Approve ECI/ ECN from TER ‐ ECN / ECIPlanning I
P.I.C.CUSTOMER Concerned Doc.DetailTRI SUPPLIERTER
Review
ECR Issue
ECR Issue
Review
ECR Issue
Reject
Review
Reject
Reject
Accept
Accept
‐Received ECI from customer ECN/ECI/customer
part drawing
‐ Issue RFD ‐Doc.no.TES‐IZ‐6127
‐ Revise Internal drawing and send to TER ‐ Drawing
TC ‐ Revise and Register drawing ‐ Drawing
‐ Receive drawing ‐Drawning
( )
P
l
TRI Designer
Supplier
MKT
MKT
Review
ECI/ECN Issue
Drawing Release
Receive ECI
Issue RFD
Receive /Register Receive drawing
‐ Set up plan (Plan approved)
Core Team ‐ Review and set up trial plan ‐ TPCR
‐ Issue TPCR ‐ PCR
QA&TC ‐ Submit to customer approve(plan) ‐ PCR
Customer ‐ Review / Approve PCR plan ‐ PCR
‐Making sample part for evalaution
‐Trial Confirm Change point follow ‐Doc.no.TES‐PZ‐6513
Working step 6M ‐Scat Sheet issue
Planning II
Supplier
SupplierPE
Set up master plan&Issue PCR
(Target = 45 days)
APQP meeting & Issue PCR & TPCR
Trial
Sample
Approve
Reject
AcceptSubmission PCR
Supplier ‐ Prepare process (6M) support TER trial ‐S‐PPAP package
‐ Summary S‐PPAP submit to TER
QA &TC ‐Test confirm Chagne point ‐Scat sheet result
‐Compare Result with current condition ‐Compare data
‐Technical Supplier Manual
‐Submit OTS to customer for evaluation ‐ Part data (OTS)
QA&TC&PC ‐Audit supplier process ‐ SPTT Activity
Customer ‐Trial confirm part approve
‐ Tooling & Equipment preparation ‐ Working stepPE & QA
QA&TC
Scat sheet & Evaluation
Production preparation
Reject
Accept
Submit Off tool sample to customer
Part EvaluationAccept
Reject
Supplier Process audit
Production preparation
Accept
Reject
S-PPAP submission
‐ Process preparation ‐ Process control std.
‐ Work standard preparation ‐ I will check this
QA & TC ‐ Approve PCR and S‐PPAP ‐PCR
‐SPPAP approved
QA ‐ Process & Product confirmation ‐ TPCR
‐ Audit report
‐ First delivery to TER ‐ Firs lot data
MD ‐ Approved TPCR ‐ TPCR
Process capability monitoring RecordQA & PD
Verification
Supplier
Production preparation
Process audit
TPCR Approval
Reject
RejectAccept
Accept
Start mass productionat supplier
Supplier PCR & S‐PPAP approve
Accept
Reject
‐ Process capability monitoring ‐ Record
‐ % NG summary
QA ‐ Process capability monitoring ‐ Record
‐ % NG summary
‐ Submission concern document ‐PPAP pacakge
of PPAP to customer approve
‐ Approved process before start mass ‐PCR & PPAP
production
S d i i st l d l dApproval
QA & PD
QA & TC
Customer
Monitoring & Special control
Process capability evaluation
Submission PPAP
Approval
Accept
Reject
(Target = 15 days)
Reject
4.5.4 Record Retention
PCN or ECR shall be maintained for the length of time that the part is active plus one
calendar year. Supplier shall ensure that the appropriate PCN and ECI records are included,
11
‐ Start production continue ‐ 1st lot delivery record ‐ Balance stock & run out old part
‐ 1st lot delivery confirm to customer
A
PD, QAPC, TC
(Target = 7 days)Start mass production
Accept
or referenced in the past PPAP file.
Page 26 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
[Responsible to QA department]4.6 Guideline for Environmental Hazardous Substance Management
4.6.1. Introduction
4.6.1.1 Introduction
According to automotive parts and electronic equipment are commerced to EU market, it is
enforced by ELV, RoHS Directive and REACH regulation. The ELV concept is about "Do not use Lead
Mercury, Cadmium and Hexavalent Chromium for automotive parts (some material / parts are exempted
by Annex II). For RoHS (Restriction of the use of certain Hazardous Substances in electrical and
electronic equipment) is about "Do not use Lead, Mercury, Cadmium, Hexavalent Chromium, PBBs
(Polybrominated Biphenyl) and PBDEs (Polybrominated Diphenyl Ether) for electronic part.
REACH concept is to survey use of SVHC in product.Tokai Eastern Rubber (Thailand), Ltd. have many
supplier that manufacture and deliver raw material / part. It will be finished goods which send to OEM
customer who export the goods to EU market. Then we would like to coorperate with our
supplier in order to establish Environmental Hazardous Substance Management System and protect
contamination of these substances in raw material and product.
4.6.1.2 Purpose
*1 *2 *3
*4
11
This document is a guideline of quality management for our supplier to comply with it.
4.6.1.3 Scope
This document can apply for all suppliers to prevent Environmental Hazardous Substances
contamination in raw material, part and solution include in-direct material. Supplier will be considered
by supply chain.
4.6.2. Implement
4.6.2.1 Policy/ Objective & Target / Action Plan
(1) Policy/ Objective & Target/ Action Plan is issued by top management. The detail shall
concern activity to decrease Environmental Hazardous Substances. These document shall implement
and review cover organization.
(2) Shall set up training program about Environmental Hazardous Substances for employee.
4.6.2.2 Organization
Shall set up responsible person or team to support management of Environmental Hazardous
Substances in organization. The purpose is to achieve the target.
Note
1 ELV: Directive of End-of-Life vehicles (2000/53/EC)
2 RoHS: Directive of Retriction of the use of certain hazardous substances in electrical and electrinic equipment
(2002/95/EC)
3 REACH: Registration, Evaluation, Authorization and Restriction of Chemicals (Regulation 2006/1907/EC)
4 SVHC: Substance of Very High Concern
Page 27 of 34 Environmental Supplier Manual
Supplier Quality Improvement Manual
4.6.2.3 Communication
(1) Shall set up communication route and information method inside and outside company
about Environmental Hazardous Substances.
(2) Shall have procedure for report to top management and customer when Environmental
Hazardous Substances are found in raw material, part and product.
4.6.2.4 Internal audit
(1) Shall have internal audit and audit report that contain Environmental Hazardous Substances
item.
(2) Shall set up skill and/ or training of internal auditor.
(3) Shall set up procedure for corrective action from internal audit result.
(4) Shall present internal audit result to top management for review performance.
4.6.2.5 Supplier selection
(1) Shall set up supplier selection standard and activity of top management about Environmental
Hazardous Substances with supplier.
(2) Shall set up / inform analysis method of Environmental Hazardous Substancess to supplier.( ) p y pp
4.6.2.6 Supplier management
(1) Shall set up plan to monitor Environmental Hazardous Substances at supplier
manufacturing site.
(2) Shall inform supplier about Environmental hazardous Substances control and standard.
4.6.2.7 Receiving raw material
(1) Shall have standard for raw material and part receiving. The standard have to contain
Environmental Hazardous Substances item in check sheet and keep record of it.
(2) Shall have standard for material receiving / distribution from Warehouse and record it
such as lot number.
(3) Shall have analysis result of Environmental Hazardous Substances of raw material.
(4) Shall have method to prevent contamination of Environmental Hazardous Substances in
receiving area.
4.6.2.8 Production
(1) In case of using same equipment/ machine with other customer, production shall have
method to prevent Environmental Hazardous Substances contamination when change raw material.
(2) Shall have procedure for protection of wrong material using.
(3) Shall not use recycled material.
Page 28 of 34 Environmental Supplier Manual
Supplier Quality Improvement Manual
4.6.2.9 Shipping
(1) Shall have supplier history record about lot no.
(2) Shall have procedure for stop shipping raw material when Environmental Hazardous
Substances are found.
(3) Shall have procedure for protection of product mixing.
4.6.2.10 Prevention of re-occurrence
(1) Shall have preparation to protect Environmental Hazardous Substances contamination.
It shall find root cause to protect re-occurrence.
Reference TER's customer requirements
Requirement
The Environmental Hazardous Substances shall not be used for material/part, in-direct & sub-material
which are delivered to TER according to EU Directive 2000/53/EC.The amendment on a regular basis
shall be obeyed, regarding Annex II (2005/673/EC) for automotive part and RoHS Directive 2002/95/EC
for electronic part. All products must be free from Perfluorooctane Sulfonates in accordance
with laws and regulation Directive 2006/122/EC, and REACH Regulation (Regulation 2006/1907/EC)
for chemical.for chemical.
Supplier' s Responsibility
(1) Supplier shall fulfill all requirements that contained in this manual regardless if is mentioned
in the drawing or not.
(2) Supplier shall fulfill the latest version for amending of the related directives, laws regulations etc.
(3) In case of use of Environmental Hazardous Substance can not be avoided, supplier shall
report to Technical and Purchasing of TER.
Standard of environmental hazardous substances control
Environmental Hazardous Substance Control Flow
TER Supplier
Technical
Technical
Technical
Technical
QA
In case of change : When supplier have change, shall consider environmental hazardous substance which may be effect to
Flow In charge Document
Request new material/part
Trial new material/part
Approve PPAP
Start Mass Production
New Part Notice
SBSC (at TM0stage)
- Test report (ICP Data) + Cover sheet - Certificate of non-use of the controlled substances- Declaration of no use of PFOS- Material Data Sheet + Mill sheet/certificate- SVHC survey sheet- PPAP
PPAP
- Certificate of non-use of the controlled substances- Mill sheet- Test report (ICP Data) + Cover sheet (annual) (when request)
11
Submit PPAP
g pp g , y
material/part which are sent to TER. Supplier shall submit test report of environmental hazardous substance to Technical section of TER.
Page 29 of 34 Environmental Supplier Manual
Supplier Quality Improvement Manual
Standard for environmental hazardous substances control
In case of found environmental hazardous substances
intentional use unintentional use
inform top management and customercompare with criteria at Table 1, 2
And Annex II
acceptover than criteria
inform top management and customer
Corrective action such aschange raw material, change chemical
change process
re-submit PPAP to TER Corrective action such aschange raw material, change chemical
change process
submit PPAP to TER
In case of unintentional using
Table 1 Criteria of environmental hazardous substances for metal, rubber, chemical which use for
automotive parts
100 100 100 50 1000
ppm max ppm max ppm max ppm max ppm max
Table 2 Criteria of environmental hazardous substances for rubber, chemical which use for
electronic parts
100 None None 5 None
ppm max ppm max ppm max less than ppm max
Remark: Cr6+ Criteria for rust preventive plating part (for TM, JT, DR, DT part) and criteria for reference
is less than 300 ppm by use method prEN 15025 for testing.
: Preparation of PFOS must be less than 50 ppm .
Reference
Chiorinated Paraffin
None
ppm max
Cd PBBs, PBDEs
None
Pb Hg Cr6+
Criteria for reference
Criteria for reference
ppm max
CdCr6+HgPb
PFOS
PFOS
TER' s customer requirements
Page 30 of 34 Environmental Supplier Manual
Supplier Quality Improvement Manual
Analytical method of Environmental Hazardous Substances
There are 2 types of analysis methods, having different purposes.
(1) Qualitative analysis
The qualitative analysis is the method for determining with each whether a substance of
environmental concern is contained. Basically, the methods specified in Table 1 shall be used.
The main purpose of this analysis is to examine whether there is a content of a substance of
environmental concern in production materials, production trial materials and products. If no such
substances are detected, it means that there is no substances of environmental concern.
Table 1 Qualitative Method and Lower Limit if Detection Level
Cadmium - Fluorescent X-ray method - when measured with magnified
Lead/ Mercury (ED-XRF) detection ability, a signal
intensity level of the concerned
element shall be approximately
Controlled elements Analysis method Lower limit of detection level
3 times the fluctuation of
background intensity (S/B ration
shall be approximately 1/1)
Hexavalent chromium - Colorimetric testing paper(1) - The lower limit of the detection
(Colourometric analysis using level when using a colorimetric
diphenyl carbazide) testing paper shall be such that
the color corresponding to the
corresponding to the color that
indicates the minimum
concentration on the testing
paper can be visually identified.
Note (1); Pack test: KYORITSU CHEMICAL-CHECK Lab., Corp.
(2) Quantitative analysis
The quantitative analysis is the method for accurately determining the amount of a substance, in
order to quantitatively prove that the amount of the substance is equal to or less than the threshold value.
Table 2 shows the analysis method and the lower limit of determination amount for each substance.
However, other quantitative methods may be used instead as long as the method assures the
accuracy of measured value with use of a standard sample and a standard substance, and satisfies
a lower limit determination amount as specified in Table 2a lower-limit determination amount as specified in Table 2.
Page 31 of 34 Environmental Supplier Manual
Supplier Quality Improvement Manual
Table 2 Quantitative Method and Lower Limit of Determination Amount
amount (ppm)
Cadmium - Inductively coupled plasma atomic
Lead/ Mercury emission spectrometry (ICP-AES)
- Atomic absorption
spectrophotometry (AAS)
Hexavalent chromium - Colourometric analyses using
diphenyl carbazide
Outline of Analysis
The outline of the analyses shall be as shown.
50
Controlled elements Analysis method Lower limit of determination
10
Materials/ parts
Qualitative analysis
Reporting of nodetection
Quantitative analysis
Reporting measured value
Controldivision
Not detected
Detected
Analytical Instruments
(1) ICP - AES analytical instrument
An instrument comprising an excitation power supply unit, sample injection unit, atomic
emitting unit , spectrometer, device control system, and recorder. It is desirable to use an
instrument equipped with a device for producing atomic vapor by reduction (for Mercury) as an
auxiliary instrument.
(2) AAS analytical instrument
An instrument comprising a light source unit, sample atomization unit, wavelength selection
unit, measuring unit, and data display / recording unit. It is desirable to use an instrument equipped
with auxiliary instruments such as device for producing atomic vapor by reduction (for Mercury)
and electrothermal type furnace.
(3) Absorption photometer
An instrument comprising a light source unit, wavelength selection unit, sample chamber,
measuring unit, and data display/ recording unit.
(4) Fluorescent X-ray spectrometer
An analytical instrument comprising an X-ray generation unit , spectrometer / detector /
proportional counter, data processing unit. Basically, for qualitative analysis, an energy dispersive
type instrument with less restrictions on sample surface shapes shall be used. Further , the
instrument shall be capacle of exciting targeted elements by means of X-ray that prevents detection.
Page 32 of 34 Environmental Supplier Manual
Supplier Quality Improvement Manual
4.7 Control of Initial Nonconforming Products(NC)
To determine supplier responsibility for control and make corrective action in initial nonconforming
product. Nonconforming product is the production part from supplier which their specifications do not
reach engineering drawing and related standard.
Nonconforming Product divided to 2 cases
-Major NC : NC effect to part functional
-Minor NC : NC not effect to part functional
When Technical found NC which occur in supplier process, Technical and supplier shall action
follow this step.
Control of Initial Nonconforming Products(NC) Flow Chart
Technical/TER found NC part
Issue Quality Information(QI)
Judgement
Major NC Minor NC
TER Problem Follow Up Sheet
Note: When Technical found NC may effect to quality score in TER Initial Technical Control(TITC) refer
to TITC criteria.
For special control of initial part, supplier shall take activity QRE (Quality Resident Engineering)
3 months or 30 supplier's production lot. Supplier shall inspect part whice supplied to TER before use
in TER's production process, record for inspection result and identified on delivery tag is "QRE Passed"
Criteria for QRE Approve No major case in part function
Minor case in appearance less than 0.05 ppm
QA/TER issue CAR Technical/TER issue Problem follow up sheet
Supplier analyze and report CAR within 7 days
QA and Technical follow up CAR in
process of supplier
Technical follow up Problem follow up sheet
in process of supplier
Supplier analyze and report Problem follow up sheet within 7 days
CAR closing Problem follow up sheet closing
Accept Accept
Not accept Not accept
Page 33 of 34 Technical Supplier Manual
Supplier Quality Improvement Manual
5. Attachment list
Att h d Sh t N 1 P j t O i ti Ch tAttached Sheet No.1 : Project Organization Chart
Attached Sheet No.2 : Production Preparation Schedule : PPS
Attached Sheet No.3 : List of Engineering drawing of supplier
Attached Sheet No.4 : SPTT Audit Report
Attached Sheet No.5 : MSA format
Attached Sheet No.6 : Shipping Tag
Attached Sheet No.7 : List of Engineering Change
Attached Sheet No.8 : Process Flow Diagram
11
Attached Sheet No.9 : Control Plan
Attached Sheet No.10 : Dimension Results
Attached Sheet No.11 : Material Test Results
Attached Sheet No.12 : Supply Chain Database List
Attached Sheet No.13 : Material List & Component Parts
Attached Sheet No.14 : Performance Test Results
Attached Sheet No.15 : Initial Master Sample Tag Format
Attached Sheet No.16 : Supplier PPAP request sheet11
Attached Sheet No.17 : Part Submission Warrant(PSW)
Attached Sheet No.18 : Supplier Banned Substance Check Sheet (SBSC)
Attached Sheet No.19 : Certification of Non-Use of the Controlled Substances
Attached Sheet No.20 : Process Change Notice
Attached Sheet No.21 : Quality Problem follow up sheet
Attached Sheet No.22 : Environmental test report cover
Attached Sheet No.23 : Material Data Sheet
Attached Sheet No 24 : Declaration of no use of PFOS11 Attached Sheet No.24 : Declaration of no use of PFOS
Attached Sheet No.25 : SVHC Survey:
Attached Sheet No.26 : Inspection Standard and Inspection Record:
Attached Sheet No.27 : Allowed maker <Making paint list free SoC>:
Attached Sheet No 28 : Engineering Change Request (ECR)
11
Attached Sheet No.28 : Engineering Change Request (ECR)
Page 34 of 34 Technical Supplier Manual
11
Technical Supplier Manual Change Notification
1 Quality assurance ideality 1 Quality assurance ideality
2 Purpose 2 Purpose
3 Scope 3 Scope
4 Requests to supplier 4 Requests to supplier
4.1 Initial Control Organization 4.1 Initial Control Organization
Purchasing / TER. <for 1st SPTT activity>4.2 Approval Initial Part for Supplier 4.2 Approval Initial Part for Supplier
4.2.1 Production Preparation Schedule (PPS) 4.2.1 Production Preparation Schedule (PPS)
For 1st SPTT audit activity
4.2.2 SPTT activity 4.2.2 SPTT activity
Activity of each stage
4.2.3 Supplier Inspection standard 4.2.3 Supplier Inspection standard
4.2.4 SBSC 4.2.4 SBSC
4.3 Initial Delivery Control 4.3 Initial Delivery Control
4.4 PPAP Activity 4.4 PPAP Activity
4.4.1 Reason to submit PPAP 4.4.1 Reason to submit PPAP
4 4 2 PPAP Retention/S bmission Req irement for 4 4 2 PPAP Retention/S bmission Req irement for
New Technical Supplier Manual (Rev.10) New Technical Supplier Manual (Rev.11)
4.4.2 PPAP Retention/Submission Requirement forSupplier
4.4.2 PPAP Retention/Submission Requirement forSupplier
Production material type Inspection standard
4.4.2.1 Supplier PPAP request sheet 4.4.2.1 Supplier PPAP request sheet
Submit Criterial : Production Material
4.4.2.2 Design Record 4.4.2.2 Design Record
extend the detail and format
4.4.2.3 Engineering Change Documents 4.4.2.3 Engineering Change Documents
extend the detail and example Engineering Change Request Form
4.4.2.4 Customer Engineering Approval 4.4.2.4 Customer Engineering Approval
extend the detail and format
4.4.2.5 Process Flow Diagrams 4.4.2.5 Process Flow Diagrams
4.4.2.6 Process FMEA 4.4.2.6 Process FMEA
Established standard for preventive/corrective action
4.4.2.7 Control Plan 4.4.2.7 Control Plan
4.4.2.8 Measurement System Analysis Studies 4.4.2.8 Measurement System Analysis Studies
Signature of TER change to Supplier
4.4.2.9 Dimensional Results 4.4.2.9 Dimensional Results
4.4.2.10 Material, Performance Test Results,Supply Chain 4.4.2.10 Material, Performance Test Results,Supply Chain
4.4.2.11 Initial Process Studies 4.4.2.11 Initial Process Studies
4.4.2.12 Qualified Laboratory Documentation 4.4.2.12 Qualified Laboratory Documentation
4.4.2.13 Master Sample 4.4.2.13 Master Sample
4.4.2.14 Checking Aids 4.4.2.14 Checking Aids
4.4.2.15 Records of Compliance with Customer-SpecificRequirements
4.4.2.15 Records of Compliance with Customer-SpecificRequirements
4.4.2.16 Part Submission Warrant (PSW) 4.4.2.16 Part Submission Warrant (PSW)
Technical Supplier Manual Change NotificationNew Technical Supplier Manual (Rev.10) New Technical Supplier Manual (Rev.11)
4.4.2.17 SBSC, Certification of Non-Use of the ControlledSubstances
4.4.2.17 SBSC, Certification of Non-Use of the ControlledSubstances
format change by not separate initial /mass production4.4.2.18 Cover sheet and test report 4.4.2.18 Cover sheet and test report4.4.2.19 Material data sheet 4.4.2.19 Material data sheet
4.4.2.20 Declaration of no use of PFOS 4.4.2.20 SVHC survey4.4.2.21 SVHC survey 4.4.2.21 -
4.4.3 PPAP Status 4.4.3 PPAP Status
4.4.3.1 Approved 4.4.3.1 Approved
4.4.3.2 Interim Approval 4.4.3.2 Interim Approval
4.4.3.3 Rejected 4.4.3.3 Rejected
4.4.4 Record Retention 4.4.4 Record Retention
keed the PPAP by PDF file and/or
4.5 Process Change Requirement 4.5 Process Change Requirement
4.5.1 Reason to information of process change and 4.5.1 Reason to information of process change and
submission requirement for supplier submission requirement for supplier
4.5.1.1 Process Change Notice 4.5.1.1 Process Change Notice
4.5.1.2 Sample Product parts 4.5.1.2 Sample Product parts
4.5.1.3 Balance Stock Control 4.5.1.3 Balance Stock Control
remark remark
4.5.2 Delivery requirement after PCN approved 4.5.2 Delivery requirement after PCN approved
technical control person in tag Mistake "Invoise" to "Invoice"
SRE
4.5.3 Change Control Flow 4.5.3 Change Control Flow
Balance Stock Control flow change
4.5.4 Record Retention 4.5.4 Record Retention
4.5.5 - 4.5.5 -
4.6 Guideline for Environmental Hazardous Substance Management 4.6 Guideline for Environmental Hazardous Substance Management
[Responsible to QA department]
cancel certificate of non-use the controlled substancestest report (when request)
4.7 Control of Initial Nonconforming Products (NC) 4.7 Control of Initial Nonconforming Products (NC)
5 Attachment list 5 Attachment list
format change format change
5 Technical Supplier Manual Change Notification 5 Technical Supplier Manual Change Notification