Go-no Go Requirements

Draft 2009-09-04 CAMN, KORK,RONY

IKEA Supplier Quality Standard

Issued By:

Approved By:

Date

Edition

Quality Improvement Group

Product Quality Manager, Trading Operation

2010-09-02

2

Table of content: Introduction GO / NO GO requirements 1. Management 2. Start-up process 3. Secure Incoming Goods 4. Production Control 5. Final Inspection 6. Document and Sample Control 7. General Requirements

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INTRODUCTION IKEA Supplier Quality Standard This IKEA Supplier Quality standard together with Special processes appendixes describes IKEA Supplier Quality level for all IKEA IK EA Suppliers. As a minimum before first delivery to IKEA, GO/NO GO requirements must be fulfilled. IKEA Supplier Quality standard shall be assessed not later than 12 months from first delivery. The result of the assessments is defined in Improvement Potential Points.

Support documents are:   

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IKEA Supplier Quality Checklist IKEA Supplier Quality Guideline IKEA Working methods for Supplier Quality Development Special processes appendixes

IKEA Supplier Quality standard Page 1 of 10



GO / NO GO Requirements In order to deliver to IKEA all GO / NO GO requirements have to be fulfilled: 1. The product shall fulfill Customer Experienced Product Quality. Well-designed Customer Friendly Durable and Functional Safe to use    

6. The IKEA Supplier shall have a documented test status summary with all required valid test reports, self declarations and certificates of compliance. Test status summary shall include as a minimum: Connection to article number Connection to production datestamp Type of material Sub-supplier Reference specification number and edition Type of test / self declaration / certificate of compliance Renewal date Early warning date  

2. The IKEA Supplier shall ensure that all products pass Final Inspection in order to secure agreed quality before delivery to IKEA. Final Inspection procedure shall be agreed with IKEA based on performance (KPI).

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3. The Final Inspection shall be carried out by an inspector who has knowledge of the IKEA product requirements as well as Customer Experienced Product Quality and has the authority from the top management to block the inspected batch. The Final inspector shall be calibrated with IKEA representative. 4. Special processes according to appendixes shall be implemented before start up of running production. Process scheme shall be followed The measurements are within tolerances Actual measurements are recorded Verification test report is available  

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5. The IKEA Supplier shall identify and segregate all non-conforming products.


7. The IKEA Supplier shall secure that all products are produced according to valid IKEA product documentation. Changes shall be approved in the IKEA Product Documentation. 8. The IKEA Supplier shall secure that relevant requirements and conditions are communicated and agreed with the sub-suppliers, as a minimum: Special processes appendixes IKEA Product requirements  



1. MANAGEMENT 1.1 General Implementation of the standard shall be well founded and committed by the Supplier’s management. The IKEA Supplier shall have a Quality policy that reflects the commitment of the top management to work with continuous improvement. The Quality policy shall be the platform when the supplier sets quality objectives. The standard shall be integrated in the Supplier’s existing Quality system. 1.2 Objectives The IKEA Supplier together with IKEA shall agree on quality objectives and K ey Performance Indicators (KPI) to be measured and improved, as a minimum: Increased satisfaction for the IKEA Customer Reduction of cost of poor quality 

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The IKEA Supplier shall set internal quality objectives to be measured and improved. 1.3 Internal audits The IKEA Supplier shall perform internal audits at least once a year in order to evaluate the effectiveness of the Quality system. 1.4 Management review The IKEA Supplier’s management shall review the quality performance and the Quality system at least once a year. The input to management review shall include as a minimum: Customer feedback Quality objectives Action plans Result of audits (internal and external audits) Continuous Improvements    

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The quality objectives and KPI agreed with IKEA as well as Supplier’s internal quality objectives shall be achieved. 1.5 Secure resources and competence The IKEA Supplier shall determine and secure necessary resources in order to implement, maintain and improve the Quality system. The IKEA Supplier shall appoint responsible and authorized person(s) for implementation of the standard. The person(s) shall be qualified, trained and calibrated regarding IKEA requirements. 1.6 Continuous Improvement The IKEA Supplier shall measure and continuously improve the quality performance (KPI). In case of failure in the quality performance (KPI) or the Quality system, the IKEA Supplier shall perform a root-cause analysis and implement documented corrective actions in order to prevent a future reoccurrence. The IKEA Supplier shall actively work with Improvement projects based on quality objectives, Improvement Potential Points and Customer feedback. The IKEA supplier shall communicate the quality objectives and quality performance (KPI) to own co-workers. 1.7 Standardization The IKEA Supplier shall implement documented procedures for all chapters in the standard in order to establish, sustain and standardize working methods. See also chapter 6.1



2. START-UP PROCESS 2.1 General The IKEA Supplier shall secure start-up of production of new and modified product(s) in order to deliver right quantity, price and quality in agreed with IKEA time frame. The same procedure shall be followed when handling changes for running products, initiated by IKEA or Supplier.

2.2 Plan The IKEA Supplier shall create implementation plan for relevant activities in the start-up process, as stated in chapter 2.3, with appointed responsible person(s) and planned dates. 2.3 Activity steps 2.3.1 Quotation The IKEA Supplier shall review IKEA quotation request and provide capacity and capability assumptions. The quotation answer shall be in written form describing what the quotation is based upon. 2.3.2 Review of IKEA Requirements The IKEA Supplier shall ensure that the following are received, analysed and understood before signing agreements: IKEA Product documentation IKEA Contract review Special processes appendixes Quality objectives   

changes in the construction design of the product.

and/or

The result shall be communicated to IKEA. 2.3.4 Production Risk Assessment The IKEA Supplier shall document the process map. The process map shall cover the Critical to Quality (CTQ) parameters on product, processes and maintenance as well as identify value added/non-value added processes. The IKEA Supplier shall perform Failure Mode Effect Analysis (FMEA) on the CTQ parameters in order to identify potential product problems related to specific production, eliminate and reduce them by taking necessary actions on the identified risks. The results shall be communicated to IKEA. 2.3.5 Purchasing and Outsourcing The IKEA Supplier shall identify and evaluate all sub-suppliers delivering raw material / components / semi-finished products or contracted for Critical to Quality (CTQ) production processes. Evaluation of sub-suppliers shall be communicated to them. The IKEA Supplier shall secure that relevant requirements and conditions are communicated and agreed with the sub-suppliers, as a minimum: Special processes appendixes IKEA Product requirements  

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2.3.3 Customer Experienced Product Quality The IKEA Supplier shall review Customer expectations, not limited to IKEA requirements but necessary to fulfill Customer Experienced Product Quality, in order to give input regarding potential


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Capacity Supplier specific requirements

In case of outsourcing of ready-made products or CTQ production processes, the IKEA Supplier shall secure that relevant requirements from the standard are implemented at sub-suppliers.



2.3.6 Test status summary The IKEA Supplier shall have a documented test status summary with all required valid test reports, self declarations and certificates of compliance. Test status summary shall include as a minimum: Connection to article number Connection to production datestamp Type of material Sub-supplier Reference specification number and edition Type of test/self declaration / certificate of compliance Renewal date Early warning date  

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2.3.9 Implementation and Releasing of Running Production The IKEA Supplier shall secure that all activities in start-up process, including Special processes appendixes and signing of legal agreements are adopted and implemented before start-up of running production. The criteria of approval for releasing a new or modified product for running production shall be defined. First delivery shall be approved by IKEA before dispatch. 2.4 Continuous Improvement The IKEA Supplier shall continuously maintain and improve the following points from the Start-up process: Test status summary IKEA Product documentation Evaluation of sub-suppliers Capacity and Capability verification Communication of IKEA requirements to responsible persons Production Risk Assessment Customer Experienced Product Quality See also chapter 1.6 

Test status summary can be replaced by Connect system if all above requirements are fulfilled. 2.3.7 Capacity and Capability The IKEA Supplier shall plan and ensure that required capacity and capability will be available in order to fulfill the agreements. The IKEA Supplier shall perform a capability verification of CTQ production processes. 2.3.8 Communication The IKEA Supplier shall secure that relevant requirements and conditions are communicated and understood by responsible co-workers.


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2.5 Secure resources and competence See chapter 1.5 2.6 Document and Sample Control See chapter 6



3. SECURE INCOMING GOODS 3.1 General The IKEA Supplier shall secure the right quality, transport and storage of all incoming raw material / components / semi-finished products before taken into production. 3.2 Plan The IKEA Supplier shall prepare: Inspection method for each material Reference material to use Sampling plan for each material Acceptance criteria and Tolerances 

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3.3 Inspection As a minimum following shall inspected: Quantity Material batch number Transport conditions and damages CTQ parameters (when applicable)

be

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3.4 Continuous Improvement The method of securing incoming goods shall be continuously developed based on results from previous inspections, evaluation of sub-suppliers, nonconforming materials in production and Customer feedback. See also chapter 1.6 3.5 Secure resources and competence See chapter 1.5 3.6 Document and Sample Control See chapter 6 3.7 General Requirements See chapter 7




4. PRODUCTION CONTROL 4.1 General The IKEA Supplier shall secure production control by implementing product inspections, process control and maintenance in order to produce Everyday Product Quality products, reduce costs of poor quality and secure health and safety of Customers.

4.4 Maintenance The IKEA Supplier shall secure CTQ maintenance parameters. The Maintenance method shall as a minimum cover: Maintenance plan Spare parts supply Maintenance and cleaning records   

4.2 Product Inspection The IKEA Supplier shall secure the CTQ product parameters. The Product Inspection method shall as a minimum cover: Reference material to use Frequency of inspections /Sampling plan Acceptance criteria and Tolerances  

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4.3 Process Control The IKEA Supplier shall secure the CTQ process parameters. The Process Control method shall as a minimum cover: Process scheme Frequency of inspections /Sampling plan Acceptance criteria and Tolerances Data collection

4.5 Continuous Improvement The method of securing production control shall be continuously developed based on results from the measurement, non-conforming materials in production, Final inspection and Customer feedback. See also chapter 1.6 4.6 Secure resources and competence See chapter 1.5 4.7 Document and Sample Control See chapter 6

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Special processes according to appendixes shall be implemented before start up of running production. Process scheme shall be followed The measurements are within tolerances Actual measurements are recorded Verification test report is available  

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4.8 General Requirements See chapter 7



5. FINAL INSPECTION 5.1 General The IKEA Supplier shall ensure that all products pass Final Inspection in order to secure agreed quality before delivery to IKEA.

The product shall fulfill Customer Experienced Product Quality. Well-designed Customer Friendly Durable and Functional Safe to use    

Final Inspection procedure shall be agreed with IKEA based on performance (KPI). The ready made consumer pack, multi pack as well as the unit load shall be inspected. Products to be inspected shall be taken from a ready-made consumer pack (multi pack if applicable). 5.2 Plan The IKEA Supplier shall plan all activities in the Final Inspection including: Inspection method for each product Reference material to use Sampling plan for each product Acceptance criteria and Tolerances 

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5.4 Vehicle and Loading Inspection As minimum following shall be inspected: Right article and right quantity Correct loading Vehicle condition Enclosed freight documents    

5.5 Secure resources and competence The Final Inspection shall be carried out by an inspector who has knowledge of the IKEA product requirements as well as Customer Experienced Product Quality and has the authority from the top management to block the inspected batch. The Final inspector shall be calibrated with IKEA representative. See also chapter 1.5

5.3 Inspection The Final Inspection method shall as a minimum cover IKEA product requirements as well as Customer expectations, not limited to IKEA requirements but necessary to fulfill Customer Experienced Product Quality. IKEA product requirements: Right content of the package Barcode Labels, Marking and Customer information Packaging and Palletizing Product inspection - CTQ product parameters Assembly according to IKEA assembly instruction (when applicable) where fittings and tools from the inspected package shall be used  

5.6 Continuous Improvement Final Inspection shall be continuously developed based on results from previous inspections, non-conforming materials in production and Customer feedback. See also chapter 1.6 5.7 Document and Sample Control See chapter 6

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5.8 General Requirements See chapter 7



6. DOCUMENT AND SAMPLE CONTROL 6.1 Quality System Documentation The quality system shall describe What to do, How to do it, Who is doing it, When it is done and, if applicable, Where it is done.

The IKEA Supplier shall describe how IKEA original documents and samples are received, kept and maintained, how copies are distributed and how obsolete documents and samples are withdrawn.

The quality system documentation shall have an identity, edition status and be approved by authorized person at the supplier.

6.3 Secure resources and competence

The IKEA Supplier shall describe how the quality system documentation is established and maintained, how copies are distributed and how obsolete documents and samples are withdrawn.

6.4 Continuous Improvement

Documents and samples established by the IKEA Supplier shall have a reference to IKEA original and/or IKEA approved sample. Supplier’s reference samples shall be approved, labelled and dated by authorised person at the supplier. Results from inspections and trainings shall be documented, analyzed and acted upon. The IKEA Supplier shall archive verifying documents related to IKEA article in a proper way and for at least two years or according to requirement in IKEA product documentation. 6.2 IKEA Documents and Samples The IKEA Supplier shall secure that all products are produced according to valid IKEA product documentation. Changes shall be approved in the IKEA Product Documentation.


See chapter 1.5

See chapter 1.6 6.5 Traceability See chapter 7.7



7. GENERAL REQUIREMENTS 7.1 Facilities The IKEA Supplier shall have organized and designated areas for inspections, production and storage. Inspection and production areas shall have proper light and be equipped with needed tools and equipment. References and instructions shall be available in connection to the areas. Storage areas shall have proper conditions. 7.2 Non-conformances and Containment Actions The IKEA Supplier shall identify and segregate all non-conforming products. The IKEA Supplier shall document and report non-conformances to concerned departments. The IKEA Supplier shall apply immediate containment actions to all products with the same and similar non-conformity. If there is a risk that non-conforming products have been delivered to IKEA, then IKEA must be informed. 7.3 Corrective Actions The IKEA Supplier shall implement corrective actions based on nonconformances in order to prevent a future reoccurrence. The IKEA Supplier shall follow up corrective actions in order to verify and ensure that they have resulted in the intended effect. 7.4 Preventive Actions The IKEA Supplier shall implement preventive actions based on corrective actions and Production Risk Assessment in order to prevent a future occurrence.


7.5 Measurement System and Equipment 7.5.1 Measurement System The IKEA Supplier shall implement Measurement System Analysis (MSA) in order to secure repeatability and reproducibility. 7.5.2 Measurement Equipment The IKEA Supplier shall control and calibrate Inspection, Measuring and Test equipment (IMT equipment) used to verify conformance of the product and processes to the specified requirements. Control and calibration of IMT equipment shall cover: Identification of IMT equipment Calibration status List of IMT equipment Calibration schedule Calibration instructions Result of calibration      

7.6 Status of Goods The IKEA Supplier shall have an identification system to make it possible to easily determine the status of goods, meaning inspected/not inspected and approved/not approved. 7.7 Traceability The IKEA Supplier shall, when required by IKEA, have a documented procedure for traceability and unique identification of individual batches of raw material or products during all stages of production. Records shall enable traceability from production date stamp to material batch, process records and test reports, self declarations and certificates of compliance.

Go-no Go Requirements

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