IMPORTANT NOTE: Customer-specific requirements are regularly updated. Check www.iatfglobaloversight.org and the Customer's websites for the latest requirements. Web Link
http://www.iatfglobaloversight.org/
Latest Revision TS16949 STD # 4.2.3 Control Of documents
4.2.4.1 Records Retention
4.2.4.1 Records Retention
4.2.2 Scope
Aug-09
Sep-08
Ford Reqmt
01/01/2009 (Ed. 06))
GM Reqmnt
Chrysler
Where the organisation uses Ford documents / Instructions or other documents of external origin, the organisation ensures that the appropriate revision level is used. Refer: http://portal.covisint.com or as specified by FMC 1.Production part approvals, tooling records, purchase orders and amendments shall be maintained for the length of time that the part (or family parts) is active for production and service requirements plus 1 calender year unless otherwise specified by FMC.This included all purchasing documents tooling included.
Formel Q - 01/01/2005 (Rev. 5)
SQAM 19/12/2006
VW
Toyota
Where the organisation uses VW documents / Instructions or other documents of external origin, the organisation ensures that the appropriate revision level is used. Refer:
Suppliers must maintain an ECI Implementation log to show engineering change history. May only use alternative document if it had been approved by TSAM See sec 18-2
Compliance Reference QOPM 4.2.3
http://www.vwgroupsupply.com Production part approvals, tooling records, purchase orders and amendments shall be maintained for the length of time that the part(or family parts) is active for productionand service requirements plus 1 calender year unless otherwise specified by GM
Production part approvals, tooling records, purchase orders and amendments shall be maintained for the length of time that the part(or family parts) is active for productionand service requirements plus 1 calender year unless otherwise specified by Chrysler
2. Records of inspection shall be maintained for each SAME AS FMC customer specification, unless waived in writing by STA.These records shall be retained for one calender year in which they were created. 3.Records of internal quality system audits and management review shall be retained for three years. 4. Retention periods longer than those specified above may be specified by an organisation in its procedures.
same as FMC
Entire facility/plant must be registered to TS16949: 2002
Entire facility/plant must be registered to TS16949: 2002
Entire facility/plant must be registered to TS16949: 2002
QOPM4.2.4.1
Production records must always be completed & available at the workstation or at the workplace ( pg 96) Audit records for D/TLDinimum 15 years archiving Documents must be pref backup on CD rom and stored in a flame-proof facility
QOPM4.2.4.1
QOPM 4.2.2
QMS certification according to VDA 6.1 and/or ISO/TS 16949 (pg 123) Requirements for Formel Q (QPN) implemented. (incl 2-day production acceptance) (pg 123)
4.2.4 Control of records
APQP, tooling, POs, PPAPs, and Amendments maintained for active production & service requirements plus one calendar, unless stated otherwise by Ford Mgmnt review and internal audits retained for 3 years
same as FMC
same
same FMC
QOPM 4.2.4
same
Quality performance records including inspection, control charts, test results, maintained for one Calendar year after they were created
Same
same
5.2, 8.2.4, 8.5.1 Customer Focus
Shall demonstrate enhanced customer satisfaction through continuous improvement requirements of Q1 as stated in QOS. QOS Assessments shall be used in development of QOS unless otherwise sated by the STA
Trends in Customer satisfaction must be compared to that of competitors and reviewed by top mgmt Ref: GM publications in 4.2.2 (15 in total)
no requirement
5.5.2.1 Customer Representative
Customer Rep change requires notification within 10 days or any changes in company ownership
No requirement
No requirement
5.5.3 Communication
No requirement
No requirement
No requirement
QOPM 5.1.1
5.6 Mngmt Review
The organization shall hold monthly QOS performance meetings as specified in in the Q1 manufacturing Site assessment. The results of these meetings and the Q1 assesment results shall be intergral to the senior management meetings
No requirement
QOPM 5.1.1
6.2.2.2 Resource Provision
Only trained & qualified personnel are to be involved in all No requirement aspects of manufacturing and design of Ford parts. Personell are to be trained to the current processes and requirements. Records to be maintained for 3 years from the date of training.
At least once per year
No Requirement
QOPM 5.2.1
Customer Rep change requires notification within 10
Only trained & qualified personnel are to be involved in all aspects of manufacturing and design of VW parts. Personnel are to be trained to the current processes and legal requirements. This includes any foreign nationals (pg 134 & 5)
QOPM 5.1.1
QOPM 6.1.1
Recources must be be accounted for at RFQ stage 6.3.1 Lean
Evidence of LEAN principles must be entrenched in the process as specified in the Q1 manufacturing site assessment
Recources including substitute opertors must be be accounted for at RFQ stage ( pg 97 & 136) No Requirement
No requirement
QOPM 6.3.1
http://web.lean.ford.com/ 6.3.2 Contingency
Notification of Buyer and STA engineer and assembly within 24 hours of any plant interuption and contingency plans activated to continue supply
No requirement
No requirement
6.4.2 Cleanliness
Part dunnage is included
No requirement
No requirement
7.1 Product Realization Planning
GPDS users must use must use APQP/PPAP Readiness Assessment schedule on Ford Portal - See page 11
See GM publications
QOPM 6.1.1
Use AQP requirements as defined in AQP/PSO DOC
Supplier shall develop Production Prep Plan (PPP) Updatedto TSAM by 4th each month
7.1.4 Change control
As per Ford SR's in table A & B on Pg 24 & 25
no requirement
No requirement
no requirement
No requirement
Report materials noted in PPAP instructions
no requirement
No Requirement
7.2.2.1 Review of requirement - Product
Authorization can be obtained from buyer or Ford Engineering where appropriate
no requirement
No Requirement
7.2.2.2 Feasibility
Include all supplier and Ford organizations as appropriate 20% volume increase requires full feasibility study
no requirement
no requirement
7.3.1.1, 7.3.3.2
Family parts may be covered by
No requirement
Need CP for all three build phases.
FMEAs, Control Plans
One FMEA or CONTROL PLAN This must be approved by FORD STA (Ford 4.2) emphasis on prevention
7.3.3.3, 7.3.3.2 Multidisciplinary approach
Assistance in CP3 or legacy data systems availabe through website http://webc3p.ford.com/index.html
FMEA & CP approval is required for parts supplied DFMEA & PFMEA required for all parts supplied to Ford
QOPM 7.1
Shall proactively communicate changes Shall notify SQ Manager and Purchasing agent of changes to material, process and manuf. location. Also supplier issues and capacity issues
7.2.1 Environmental requirement - materials
7.2.3.1 Customer Communication
QOPM 7.1
See TSAM production Trial requirements Sec 12 pg 1 - 7
The organization shall meet meet requirements of "Statement of Work" available on the Ford website Report APQP status as defined on website Use prototype data for production Use prototype data for production planning 7.1.2 Acceptance criteria
QOPM 6.2.3
Contingencies for ongoing supply of parts must be inplace
Supplier must submit Process change request when ECI affects any approved production process - see Sec 18-2
QOPM 7.1.4
QOPM 7.2.1 QOPM 7.4.1.1
Materials, substances & component must comply with EU regulations (pg102) Lists for declarable substances are to be considered and documented (pg 125) Information be be updated on IMDS
QOPM 7.2.2.1
Need CP for both build phases. ( pg 94) PFMEA must be updated for project changes with PFMEA & MQC shall be submitted to TSAM 8 implemented actions (pg 94) weeks prior to 1A trials Shall manage MQC of sub-suppliers and submit to TSAM on request
Electronic dat tranfer systems for GM's North operations and CX for SA
no requirement
Establish electronic communication with Chrysler on Covisint through Global Supplier Portal Forever Req. - The organization shall communicate any changes that may impact on quality on FRF on webCN Cross-functional teams must be used to to develop Manufacturing Quality Charts (MQC) & PFMEA
no requirement
As per GM key characteristic Designation (KCDS) Ref GM 1805 QN 7.3.2.3 Special Characteristics also 7.2.2.1
Critical and Special characteristics guidelines only Changes to monitoring of SC must be approved by STA
7.3.4, 7.3.6.1 Design & Development review
Must use GPDS for review of product, design and development stages - Pg15
No requirement
All design changes including those proposed by suppliers must have written Chrysler approval or waiver of such approval prior to implementation refer to OSO/TS cl 7.3.7 & PPAP manual
7.3.5 Design Verification
Design verification required to show conformance with Ford VDS & SDS
No requirement
must be performed before PSO can be completed Continuing conformance inspection/test shall be
Use GM KCDS
QOPM 7.2.3.1
"shall be knowledgeable of stds" PS-9336
PS-10125, AS-10119 Ref: The Diamond <> 4.2.1.5 for further detail refer to PS-7300
All D/TLD part special characteristics must be documented including those not identified by VW but by the supplier (pg 127 & 8 & 131)
Critical characteristics must be discussed & agreed to withTSAM QCE Sec 8 pg4 QOPM 7.2.1.1
All design/process changes including those proposed by suppliers must have written TSAM approval or waiver of such approval at least 3 months prior to the proposed change Sec 18 QOPM 7.3.1
performed during the model year. 7.3.7 Design Changes
No requirement
All changes shall have written approval or waiver
All changes shall have Chrysler approval or waiver of such approval prior to production implementation
QOPM 7.3.1
7.3.6.2 Prototypes
shall request confirmation of the need for prototypes
Ref: GP4
No ref
QOPM 7.3.1
7.3.6.3 PPAPs
1) Shall comply with AIAG PPAP process 2)Subcontractors must meet PPAP requirements 3) All design changes shall have approval per PPAP and made through WERS or SREA process 4) Run-at-rate is satisfied by demonstrating "Prod. Verification"
Same as Ford plus, PPAP's required from suppliers inaccordance with Chrysler's requirements - see pg 1 PPAP requirements for assembly centres shall from a specified prod run of saleable pilot vehicles
As specified in TRL requiremnts see Pgs 137 141)
Off Tool Sample evaluation must meet TSAM evaluation requirements -see sec 13 p1 - 3
QOPM 7.3.6.3
Trial & changed parts must be clearly labelled in accordance with TSAM requirements - See Sec 18-3
7.4.1.1 Regulations
no requirement All applicable including internations regulation shall apply as specified by Ford as specified on Ford portal on covisint
no requirement
Materials/substances must comply with REACH regulations Written confirmation of compliance to legal requirements are required
7.4.1.2, 7.4.1.3 Subcontractor QMS Development
Supplier Quality Management System Development to When sub suppliers are too small to certify to minimum ISO9000 level. When required, subcontactors to ISO/TS or ISO 9000 the organization shall have a be approved by Ford decision criteria for designating small suppliers. Such decision criteria shall be in writing, applied consistently in the application and verified by the third part auditor. Refer guidelines on pg 17
When sub suppliers are too small to certify to ISO/TS or ISO 9000 the organization shall have a decision criteria for designating small suppliers. Such decision criteia shall be in writing, applied consistently in the application and verified by the third part auditor. Refer guidelines on pg 5
Subcontractors for which influence the characteristics of mandatory documents must be audited to ensure that the requirements are verified (pg 130)
Sub supplier quality must be simular to Tier 1 supplier quality assurance activities. Tier 1 supplier is responsible for all production & quality issues. TSAM must be notified of any sub-supplier change at 3 months prior to change. Sec 9 pg 2
QOPM 7.4.1.2
7.4.3.1 Incoming
Need incoming quality measures, unless waived
No ref
Need incoming quality measures
QOPM 7.4.3.1
Product Quality
in writing by Ford STA Any inspection shall be commensurate with the risk and quality of the subcontractor
CGI fully responsible for Quality of incoming materials including that of VW assured suppliers (pg 99)
Only approved & qualified subcontractors to be used (pg 99)
Only approved suppliers as listed on the approved supplier's list can be used - See Sec 09 pg 1
Ref: GM 1746
QOPM 7.4.1.1
QOPM 7.4.3.2 7.4.3.2 Scheduling Subcontractors
100% on time delivery from subcontractors Monitor and minimise premium freight.
7.5.1.2 Job (work) Instructions
Operators shall use most current WI's unless authorised in No ref writing
See element 10 Operating instructions
QOPM 7.5.1.2
7.5.1.3 Verification of Job set ups
Set up records shall be maintained for 1 year.
No ref
No ref
QOPM 7.5.1.3
7.5.1.4. Preventive Maintenance
1) Documented system for preventive maintenance Includes timely review and documented action plan 2) Action plans to be included in management review 3) Records kept for 1 year
No ref
Refer requirements as per Element 19
QOPM 7.5.1.4
No requirement
No requirement
PSO shall be completed by product team to verify readiness prior to PPAP submittal. Parts that have been out of production for 12 months or more shall have production led PSO - Refer Element 21
QOPM 7.5.2
7.5.2 Process Validation
No ref
Identification, Traceability, preservation Storage & inventory
No ref
Shall conform to Chrysler Packing, shipping and labelling instructions
Key requirements are compliance to MMOG/LE specified by Fords MMOG/LE manual on covisint Ref 4.340 Cust Specifics
Ref: GM 1731
7.6.1. MSA
In accordance with AIAG manual Family gauge studies must be approved by STA
No ref
7.6.3, 7.6.3.2 Laboratory requirements
Independent laboratories shall be approved prior to use The acceptance criteria should be based on ISO/IEC 17025 or national equivalent, shall be documented other approval from Ford STA is required
Independent laboratories shall be approved prior to No Ref use The acceptance criteria should be based on ISO/IEC 17025 or national equivalent, shall be documented other approval from GM is required
7.5.3, 7.5.4, 7.5.5 7.5.5.1
All tooling shall be clearly identified & correctly stored
Packaging & ID of containers, data exchange must comply with requirements set out in B2BPlatform (pg 122)
Shall establish a system to assure Toyota packing specs are maintained - see sec 11 pg 1-3
QOPM 7.5.3,QOPM 7.5.5
Packaging, ID of containers & VW interphase communications (CX)shall comply with VW requirements as set out in B2B Platform
Refer requirements listed in Element 18 3rd Party cal lab certified to ISO/IEC 17025
The acceptance criteria should be based on ISO/IEC 17025 or national equivalent.
QOPM 7.6.3.2
8.1.1, 8.1.2 Statistical tools
Latest edition of AIAG manual for SPC, MSA VDA must be No ref applied. Capability Index must include Cpk & Ppk studies to determine possible sources of variation
8.2.1.1, 5.2 Customer
Shall notify 3rd party in 5 days
Notify within 5 days
Satisfaction
in writing if Q1 revoked. Shall monitor performance metrics as per Q1 and updates to FSP 2) Shall communicate customer satisfaction to all employees twice a year.
after being placed on "New business hold - Quality" For details ref 4.2.8 GM specifics
8.2.2 Internal Audits & Auditors
Internal audit reviews conducted at least anually Internal auditors qualified and competent in all core tools, and process approach. 5 internal audits in the company of a trained auditor covering all aspects relating to Ford Process and product audits can be performed by process specialists without full auditor training.
Internal auditors trained as per ISO 19011 1st edition
No ref
Short-term process capability Cmk/Ppk values >/= 1.67: Long-term process capability >/= 1.33 Capability regarding Mandatory documentation characteristics must be proven & fully documented (pg 132)
in 5 working days if placed in the "Needs Improvement" category.
Perform at least once per year
QOPM 8.1.1 Production & Mass production trila must be conducted to meet TSAM quality & delivery requirements See sec 12 pg 1 - 7
Customer satisfaction must be measured which should included packaging and delivery processes Supplier shall have documenred (pg 122) countermeasure sytem to analyze and improve quality concerns through waranty dat and customer returns
D/TLD-parts & additional legal requirements to be evaluated by regular internal audits
QOPM 8.2.1
QOPM 8.2.2.4
Auditors must be qualified & competent in process The organization shall complete the self-assessment audit 1/year approach, core tools & customer specifics commencing 7 Jan 2008 using Elements O Manufacturing Basics see pg 7 The organization shall conduct LPA & provide evidence of LPA being conducted on production parts
8.2.3.1. Monitoring & measurement of manufacturing 1) Need to reduce variability using process Six Sigma or other similar techniques
no requirement
No requirement
8.2.4 Monitoring and measurement of product
ES test failures shall be the cause to stop shipments. Ford shall be informed All suspect must be reworked. Test frequency requirements shall be noted in the control plan and FMEA Revisions to frequencies need STA approval
no requirement
No requirement
8.3.4 Customer Waiver
Approval is required before the use of non conforming or changed process
Approval is required before the use of non conforming or changed process
Approval is required before the use of non conforming or changed process
QOPM 8.3.4
8.2.4.1 Layout Inspection
Shall be be performed annually and the measurements shall be documented on the PPAP Dimensional Results sheet. Reference AIAG PPAP Manual
No requirement
Same as Ford
QOPM 8.2.4.1
8.2.4.2 Appearance Items
Where processes or environmental could affect the product the organization shall implement measures such as Ford Global Craftmanship. This should be covered in the CP and APQP reporting. Refer to FSP for further details
No requirement
No requirement
8.3,8.5.2,8.5.3 Control of NC product and correctve action
Shall have systems in place to prevent shipping of non conforming parts to any Ford company facility Respond to Ford with 8D within 5 business days Close out 8D within 10 days Internal notification system Communicate results and PPM's Implement corrective actions
PRR system must be actioned on the GM GQTS system on GMSupplypower
A written 8 step plan shall be submitted for corrective action e-CIMS - at least two people at each loc. must be trained in use and reg. access the system PSFD0270 to be incorporated to effectively respond to e-CIMS issues
Form No. Approved:
QOPM 8.2.3.1
QOPM 8.2.4 No parts can be shipped to TSAM unless Provisional or final approval has been granted by TSAM QCE - see Sec 17 Pg 1
Judgement for colour must be evaluated as per TSAM requirements - see sec 14 Pg 1 - 5
Respond to Quality Improvement Request Continuous & preventive methods to be applied to (QIR) or QPR by duae date or as specified in progress towards zero defect demand of customer the SQAM - see Sect 19 8D cause & effect taguchi type sytems must be considered
QOPM 8.2.4.2
QOPM 8.5.2
