VDA Quality Management in the Automotive Industry Product Audit
Table of contents
st
1 Edition 1998
6
Part 5
Product Audit
st
1 Edition 1998
Verband der Automobilindustrie e.V. (VDA)
ISSN 0943-9412 Copyright 1998 by Verband der Automobilindustrie e.V. (VDA) (Association of the German Automotive Industry) Quality Management Center (QMC) D-60325 Frankfurt am Main, Lindenstraße 5 Online production: VDA-QMC D-60325 Frankfurt am Main, Lindenstraße 5
2
Liability exclusion
The VDA volumes are guidelines available for anyone to use. It is the responsibility of the person using the guidelines to ensure it‘s correct use in each specific case. The VDA volumes take into account state of the art technology, current at the time of issue. By using the VDA guideline, nobody is relieved of the responsibility for their own actions. Each person acts, in this respect, at their own risk. Liability by VDA, and those persons involved in issuing VDA guidelines, is hereby excluded. If during the use of VDA guidelines, errors or the possibility of misinterpretation are found, it is requested that these be notified to the VDA immediately, so that any possible faults can be corrected.
Referenced standards
The extracts from standards identified with their DIN number and issue date are reproduced with the permission of the DIN Deutsches Institut für Normung e.V. (German Institute for Standardization). The version with the latest issue date is definitive for the use of the standard, which can be attained from the publishers Beuth Verlag GmbH, 10772 Berlin.
Copyright
The publication, including all it‘s parts, is protected by copyright. Any use outside of the narrow boundaries of copyright law, without the written permission of the VDA, is unauthorized and illegal. This applies in particular to copying, translation, microfilming and the saving and processing in electronic systems.
3
Foreword
With respect to technical and economic progress, quality assurance determines the future of the automotive and supplier industry. The production process consisting of many individual processes has to take into account rational and economic aspects in order to achieve an optimum in quality, time and costs. To ensure this, the VDA has issued the following guidelines for the quality standard of the automotive industry: QUALITY STANDARD OF THE GERMAN AUTOMOTIVE INDUSTRY (VDA 6)
VDA 6
VDA 6 Part 1
Quality Audits
VDA 6 Part 3
Basics
VDA 6 Part 5
Quality System Audit
VDA 6 Part 2
Quality System Audit Services
Process Audit
Product Audit
VDA 6 Part 6
Product Audit Services
The product audit shall demonstrate the quality niveau of internally/externally manufactured products in a process chain. With knowledge of the quality niveau, short and long term conclusions regarding the production process and if necessary, the quality system are possible. The information gained from product audits promote the continuos process of quality improvement, to the benefit of customers and suppliers. A practical representation of the product audit was chosen, to make the content of the publication easily understandable. Guidelines are provided for the planner of product audits and product auditors. The subject „Product Audit„ is then rounded off with actual examples from practice.
4
We thank the following involved companies and their employees for their input in the preparation of this publication: Aktiengesellschaft Kühnle, Kopp & Kausch, Kirchheimbolanden Continental AG, Hannover Fichtel & Sachs AG, Schweinfurt Ford-Werke AG, Cologne GLYCO-METALL-WERKE Glyco B.V & Co. KG, Wiesbaden Daimler-Benz AG, Hamburg Works TRW Deutschland GmbH, Motor Components, Barsinghausen THYSSEN KRUPP STAHL AG, Duisburg Volkswagen AG, Wolfsburg ZDH-ZERT e.V., Bonn. and hope, that this publication finds successful application.
Frankfurt/Main, April 1998
VERBAND DER AUTOMOBILINDUSTRIE E. V. (VDA)
5
Table of contents
Page
Foreword
4
1
Introduction
9
2 2.1 2.1.1 2.1.2 2.1.3 2.2
Definitions and Purpose of a Product Audit Definitions Quality Audit (according. to ISO 8402 : 1994) Product (according to ISO 8402 : 1994) Product Audit Purpose
11 11 11 11 12 13
3 3.1 3.2
Product Audit at Car Manufacturers and Suppliers Distinguishing a Product Audit from other Audit Types Process of a Product Audit
14 14 16
4 4.1 4.3 4.4 4.5
Preparation and Planning of Product Audits Preconditions and Responsibilities Reference Documentation Inspection, Measuring and Test Methods and Equipment Auditor Qualification
17 17 18 19 19
5 5.1 5.2 5.2.1 5.2.2
Product Audit Questionnaire General Questions to the Physical Examination of a Product Review of all Documents Random Sampling
20 20 20 20 20
6 6.1 6.2 6.3
Performing a Product Audit Responsibility Process Reporting (Documenting)
21 21 21 22
7
Analysis of the Data and Investigation of Causes of Nonconformities
23
8 Evaluation of the Product Audit Results
24
9 Product Audit Report
25
6
10 10.1 10.1.1 10.1.2 10.2
Corrective Actions Resulting from the Production Audit General Corrective Actions for Major Nonconformities Corrective Actions for Minor Nonconformities Monitoring of Corrective Actions
26 26 26 26 26
11 11.1
Case Examples Case Example – Selector Shaft - Müller + Co.
27 27
11.2
Case Example Input Material (Sheet metal) - Thyssen Stahl AG
33
11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 11.3.7 11.4 11.4.1 11.4.2 11.4.3 11.5 11.6 11.6.1 11.6.2 11.6.3 11.6.3.1 11.6.3.2 11.6.3.3 11.6.4 11.6.5 11.6.6 11.6.6.1 11.6.6.2
Case Example Laser and Mash Seam Welded Tailored Blanks - Thyssen Stahl AG Selecting Samples for Inspection 38 Scope of Inspection 38 Process and Sequence of Operations 38 Product Audit Report 39 Procedure for Handling Nonconformities 39 Dispatch Audit 40 Responsibility 40 Case Example Bearing Bush - AG Kühnle, Kopp & Kausch Explanation Systematic Quality Evaluation Production and Purchasing (SQPP) Code Number System for SQPP Procedure using Bearing Bush as an Example
43 43 45 47
Case Example Valves - TRW Deutschland GmbH, Motor Components
54
Case Example Tires - Continental AG Scope and Frequency of Inspection Specifications, Inspection, Measuring and Test Methods Process Auditor Visual Inspection Machine Tests Documentation Evaluation Forms Visual Inspection Concentricity
59 59 59 60 60 60 60 60 60 60 60 60
7
11.7 11.7.1 11.7.2
Case Example Complete Vehicle - FORD AG Check of Conformity Complete Vehicle
63 63 63
11.8
Case Example – Complete Vehicle - Volkswagen AG
72
11.9 11.9.1 11.9.2 11.9.3 11.9.3.1 11.9.4 11.9.4.1 11.9.5 11.9.5.1 11.9.5.2 11.9.6 11.9.7 11.9.8
Example of a Product Audit Procedure - Mercedes Benz AG, Hamburg Works 79 Purpose 79 Scope 79 Terms and Definitions 79 Product Audit 79 Responsibilities 80 Product Audit 80 Description 81 Performing the Product Audit 81 Product Audit Plan 82 Additional Notes 82 Applicable Documents 82 Flow Chart of the Product Audit Process 83
12
Appendix: Reference to VDA 6.1
86
13 13.1 13.1.1 13.1.2 13.1.3 13.1.4 13.1.5 13.1.6 13.1.7 13.1.8 13.1.9
Bibliography Standards DIN EN ISO 8402 (1995) DIN EN ISO 9000, Part 1 (08/94) DIN EN ISO 9000, Part 2 (03/92) DIN EN ISO 9001 (08/94) DIN EN ISO 9002 (08/94) DIN EN ISO 9004, Part 1 (08/94) DIN ISO 10011 Part 1 (06/92) DIN ISO 10011 Part 2 (06/92) DIN ISO 10011 Part 3 (06/92)
89 89 89 89 89 89 89 89 90 90 90
13.2 13.2.1 13.2.2 13.2.3 13.2.4 13.2.5 13.2.6 13.2.7
Literature VDA Publications for the Automotive Industry Masing, Walter (Publ.) DGQ-Publication 11 - 04 (Status 1995) DGQ-Publication 12 - 62 (Status 1991) DGQ-Publication 12 - 63 (Status 1993) DGQ-Publication 13 - 41 (Status 1995) DGQ-Publication 14-18
90 90 91 91 91 91 91 91
13.3
References
92
8
1
Introduction
A product audit assesses the effectiveness of quality assurance through the examination of a small number of products and/or parts and confirms their quality capability based on the quality of the product. Thereby, it is checked, if the product complies with the given specifications, or respectively, with special customer/supplier agreements. The focus of the evaluation of deviations from the specification lies, depending on the given objective, on its technical significance, its significance for the subsequent process or customer reaction. During a product audit, the product properties in new condition, and not after long term use, are determined. It does not serve as a substitute for inspections during the production process. Product audits are carried out regularly. Irrespective of this, they can also be additionally carried out for a specific reason. They must be planned and prepared by qualified personnel, before they are carried out. Every audit, its results, improvement measures, as well as responsibilities are to be documented. Product audits can be carried out in all business processes like, product development – product manufacturing - product marketing.
This publication primarily deals with product audits in product manufacturing. The product audit identifies quality trends and nonconformity focal points. In certain cases, it can lead to the conclusion that system failures exist, which then initiates further audits such as process or system audits being carried out. Product audits are an integral part of a quality system according to VDA 6.1. The company management must identify with the duties and ob jectives of the product audit.
9
The following decision criteria can be useful for the application of product audits in a company: -
checking the compliance of development results with the inputs (e.g. prototypes, pilot production runs) verifying the uniformity of production recognizing deviations, changes and trends discovering risk potential illustrating customer reaction decision aid to customer expectations and requirements earliest reaction to field problems checking the effectiveness of measures taken legal requirements.
An important precondition for the performance of product audits is the availability of an appropriately organized structure, that allows audits to be systematically and independently carried out. The audit plan defines at which stage in the production process, product audits are carried out. In the audit plan, questions about the efficiency, complexity of the products and the number of production pieces are included.
10
2
Definitions and Purpose of a Product Audit
2.1
Definitions
2.1.1
Quality Audit (according. to ISO 8402 : 1994)
„Systematic and independent examination, in order to ascertain, if the quality activities and related results, comply with given instructions, and if these instructions are efficiently put into action and are suitable to achieve their objectives.„ Note:
A quality audit is typically carried out on a quality system or an element thereof, on processes or products (including services), but is not restricted to these. Such quality audits are often called „system audits„, „process audits„, product audits„, or „service audits„. One purpose of a quality audit is to assess the need for an improvement or corrective action. A quality audit should not be mistaken with quality monitoring activities or reviews, which are carried out for process control or product receiving purposes. Quality audits can be carried out for internal or external purposes.
2.1.2
Product (according to ISO 8402 : 1994)
„Result of activities and processes„. Note:
The term „product“ can include a service, hardware, processed materials, software or a combination thereof. A product can be tangible (e.g. assemblies, processed materials) or intangible (e.g. knowledge or concepts) or a combination thereof. A product can be intended (e.g. product offered to customers) or unintended (e.g. pollutants or undesirable effects).
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2.1.3
Product Audit
A p r o d u c t a u d i t is the planning, performance, evaluation and documentation of e x a m i n a t i o n s of on after and before
-
quantitative and qualitative characteristics material products completion of a production stage its forwarding to the next customer (internal/external) of reference values an independent auditor.
on the basis through
-
Note 1:
Material p r o d u c t s are the result of activities and processes and are, for example, raw materials, intermediate products of all types including components, assemblies, and subassemblies, as well as end products, which are to be delivered to the customer. During a product audit, the properties in new condition and not after long term use, are determined.
Note 2:
Both internal or external c u s t o m e r s can be meant. One can also understand „customer“ to mean a further process or a subsequent production machine.
Note 3:
The product audit is generally carried out by the product manufacturer (supplier). It is useful for the p e r f o r m a n c e o f a p r o d u c t a u d i t t o u s e DIN ISO 10011 Part 1. The auditor must know the product and its production process, or have access to information carriers. Furthermore, depending on the objectives, he has information that describe customer reactions to nonconformities.
The performance of the examinations follows a defined audit plan. Note 4:
According to the VDA publication Volume 6, Part 1, Question 15.1 the following points are to be established in the product audit plan: type and extent of samples or parts, type and number of the characteristics to be checked, inspection, measuring and test method and equipment, and evaluation of the examination results in comparison to the internal and/or external standards or specifications and drawings.
Note 5:
The r e s u l t of the evaluation of a product audit is to be regarded as a review of all quality control measures. When deviations from the specifications are found, corrective actions are to be taken. Immediate actions like e.g. stopping or re-sorting the entire production and, if necessary, in development, are required, when deviations from specified values and/or limit patterns of important characteristics − especially safety characteristics, are found.
12
Note 6:
Product audits can be carried out on prototypes and after all production phases until delivery. Audits at different production phases and, if applicable, the delivery product audit performed from a customer’s point of view, are methodically attuned to one another.
2.2
Purpose
It is the task of a product audit, to check normally delivery-ready products according to the audit plan for conformance with the technical documents, drawings, specification, standards, legal requirements and further set „quality characteristics“. This check is carried out on few products, but very comprehensively and from the customer’s point of view. As a priority, system faults, nonconformity focal points and long term quality trends are to be ascertained. For the elimination measures to be implemented, recognized nonconformities are to be separated into systematic and coincidental nonconformities. In serious cases, immediate actions in the production process are implemented. The respective check represents the momentary situation. The audit in it’s entirety over a time period, shall illustrate the quality potential of the production. The scope of inspection is determined by the complexity of the product and the number of production pieces. The purpose of a product audit, for a company, is to recognize deviations and to confirm compliance with drawing requirements and customer specifications. The results of reliability checks can also be included. Knowledge of all customer expectations of a product is necessary during a product audit. These should be externally evaluated and methodically integrated into the product audit. In this way, for example, noises could be evaluated to see if, and to what extent, they are regarded as disturbing by the customer. The supplier or manufacturer gains a comprehensive picture of the quality of his products and the acceptance of these products by the customer.
13
3
Product Audit at Car Manufacturers and Suppliers
3.1
Distinguishing a Product Audit from other Audit Types
The product audit shows only partial similarities to other audit types or with other product assessments. An exemplary distinction, which does not claim to be exhaustive, is shown in Table 1.
14
Product Audit
Process Audit
100%inspection, measuring and testing
Final inspection, measurement and testing in serial production
Inspection verification First sample
Works inspection certificate
SPC
acc. to plan, generally once a year
acc. to plan and as necessary
continuously
continuously
acc. to cust. requirements
acc. to cust. requirements
continuously
selected acc. to Checked characteristics customer requirements /expectations and important process and product characteristics
elements of the quality system
selected, as necessary for process evaluation
qualitative characteristics, incompetent characteristics
selected, product – related, acc. to customer expectations
acc. to cust. requirements
selected, and acc. to cust. requirements
selected, as required for process control
Capability parameters
short term capability of the product characteristics on the basis of the selected sample. Feedback to production
(degree of compliance with the system objectives)
short term capabilities of the process parameters
(qualitative characteristics e.g. cpk < 1,33)
short and long term capabilities of the product characteristics
acc. tocustomer requirements
automatic identification of the short and long term capabilities
Applied verification methods
selected, specific for the product
document review compared to the objective, the application in practice
selected, specific for the process
selected, specific for the product
selected standard method, specific for the product
selected with the agreement of the customer
selected, specific for the process or product
Qualification of knowledge of the product and production the auditors / process, also from the inspectors customer’s point of view
DIN ISO 10011, Part 2 + EOQ Certificate + VDA 6.1 Certificate
knowledge of the process
knowledge of the characteristics
knowledge of the characteristics and customer expectations
knowledge of the characteristics, customer requirements and relevant standards
knowledge and experience of control card technology
Performance frequency
acc. to plan, generally several times a year
System Audit
Necessary documents
drawings, specifications, work and inspection instructions, coding systems
quality manual, procedures and work instructions
process plan, process parameters, inspection instructions
catalog of deviations for qualitative characteristics, inspection instructions
catalog of deviations for qualitative characteristics, specifications, drawings, inspection instructions
specifications, drawings, inspection instructions, standards
quality control cards, inspection instructions
Documentation / records
inspection results, audit report
results according to questionnaire, audit report, nonconformity analysis with corrective actions
inspection record, audit report, nonconformity analysis with corrective actions
statisticstoinspection results, nonconformity analysis with corrective actions
inspection record and statisticstoinspection results, nonconformity analysis with corrective actions
first sample inspection report
control cards with evaluation
Table 1:
works inspection certificate
Distinction between a product audit and other types of audits and inspections
15
3.2
Process of a Product Audit
The process of a product audit is schematically shown in the following. Product Audit Process Company specific requirements
Au di t - date - responsible area
Planning and preparation of schedule audits
Kcustomer specifications
Inspection instructions - characteristics - inspection, measuring and test equipment - frequency
Drawings FMEA
Internal nonconformity Planning and preparation of unscheduled audits *)
Customer complaints
Market and customer information Drawings
Process Inform responsible department Product sampling Product inspection
Inspection instruction
Record with audit results
Au di t p la n
Aud it rep or t Protocol
Evaluation
Long term evaluation
No
Product Audit satisfactory
Corrective actions according to element18, VDA 6.1
Nonconformities according to audit report
Ye s
Ac ti on pl an Yes
Au di t r epo rt Long term evaluation
No
Inform responsible departents Inclusion of results in next audit planning
*) Unscheduled audits are specifically initiated. They must therefore not be included in the long term evaluation. If specific assesments are included in the long term evaluation, it is distorted, as a specific assesment does not represent a random sample.
16
4
Preparation and Planning of Product Audits
4.1
Preconditions and Responsibilities
A product audit must be carefully planned. Therefore, certain preconditions must be met: a) Inclusion of a statement regarding the carrying out of product audits in the quality manual b) raising of an audit program c) the translation of this into a binding work instruction for the auditors. Persons responsible for the planning of product audits, are those functioning units in a company assigned accordingly in the quality manual. It must be ensured that this area is independent of the producer. 4.2
Audit Program
Audit programs must be established for the products and must contain following information:
-
Purpose of the audit Reference documents Products to be audited Coding systems/Check lists Date / Frequency of the audit Auditors Report issuer with distribution list Responsibilities for following up of corrective actions.
During the raising of the audit plan details, amongst others, must be given about: -
the characteristics to be checked quantitative characteristics functional characteristics material characteristics life time characteristics qualitative characteristics
and the inspection and testing methods and equipment to be applied.
17
The selection of the products and characteristics to be assessed is made to, for example, the following criteria: -
4.3
lot size customer requirements product composition production line.
Reference Documentation
For a product audit, all technical documents containing integral parts of the quality requirements are consulted. With the help of these documents, it can be assessed if the quality requirements on the product are being complied with. In particular, it involves e.g. following documents: -
Drawings with amendment status Specifications FMEA Production process plans and process descriptions, Inspection and testing specifications Nonconformity catalogs Limit patterns Instructions to the analysis methods Evaluation / quality standard or references Material sheets Approved production deviations (concessions) Standards Legal requirements (e.g. federal laws) If applicable, nonconformity classification (in e.g. major and minor nonconformities) with evaluation Delivery agreements.
18
4.4
Inspection, Measuring and Test Methods and Equipment
When selecting inspection, measuring and test methods and equipment, the following basics and comments have to be considered: -
-
4.5
measuring uncertainty of the inspection, measuring and test equipment with alternative inspection, measuring and test methods, the one to be selected should be one not used in the serial inspection, in this way, weaknesses due to incorrect or uncertain inspection, measuring and test equipment can be recognized. with qualitative inspections, measuring and tests, limit patterns and constant training of the auditors is necessary in order to keep the basis of the evaluation universal and constant, it should be frequently compared to the requirements and/or the auditors changed and the above documented.
Auditor Qualification
The success of a product audit depends to a large extent, on the technical and human qualifications of the auditor. Hereto belong, amongst others: -
knowledge of the purpose of the product audit product and quality specific knowledge use of inspection, measuring and test specifications mastery of inspection, measuring and test techniques handling of nonconformity catalogs evaluating of products reporting physical suitability (eye sight test etc.) good intelligence good intuition personal reliability practical experience in manufacturing knowledge of production processes, and or their application knowledge of, and access to, information about customer expectations
19
5
Product Audit Questionnaire
5.1
General
In order to ensure the successful performance of a product audit, thorough planning must first be carried out. Therefore, it is necessary for the audit, irrespective of whether product audits are carried out regularly or for a specific reason, to establish a questionnaire related to the area of application in the form of a specified/actual value comparison. The majority of questions are to be worded in such a way, that the answer may not only be „Yes„ or „No„, but that detailed information must be provided. 5.2
Questions to the Physical Examination of a Product
This procedure is based mainly on the examination of geometrical and functional quality characteristics of products or individual parts (and to a limited extent, also material characteristics). 5.2.1
Review of all Documents
With the help of questions, the following, e.g. is to be clarified: 5.2.2
Has the accuracy of the drawing been checked? Are any more specifications and standards applicable? Which part is examined with which revision index? Does the part have a serial number? Where was the part taken from? Which production area does it originate from? When was it produced? Random Sampling
Following a fixed sampling instruction and after determining if the test subject complies with the quality requirements, the following, for example, should be clarified -
Which nonconformities have been established? What is their significance? How is each nonconformity to be evaluated?
20
6
Performing a Product Audit
6.1
Responsibility
It has to be ensured, that the product audits are performed by an independent body. Product audits can be carried out in the following areas: -
at the manufacturer at the customer.
The responsibilities for the performance of the product audit lies, primarily, with the product manufacturer. In exceptional cases, product audits may also be performed by the recipient (customer) or in special cases by neutral bodies (external testing laboratories). As and when necessary, the supplier and customer (internal, external) should coordinate, in order to make use of the findings to promote product quality.
6.2
Process
For the audit process, the following regulations have proven successful: -
During an audit, the relevant departments are informed only at short notice about the sampling of the products.
-
When an audit is carried out for a specific reason, an additional measure may be that the lot, from which the samples were taken, is placed on hold until completion of the audit.
-
Products which have been taken as samples during an audit, must be reallocated carefully, if reused, in order to prevent mix ups with similar products. Thereby, the products have to be brought back to their original status, i.e. corrosion risks, specified packaging and so on, have to be taken into account.
21
-
6.3
If nonconformities are found on safety features, immediate corrective action is to be taken. Thereby it has to be ensured, that no nonconforming products are returned to the system.
Reporting (Documenting)
The results of the product audit are documented by the auditor in an audit report: See also page 29 and subsequent pages – Case studies of various companies.
22
7
Analysis of the Data and Investigation of Causes of Nonconformities
The main aim of a product audit is to gain information about the quality niveau of a product or individual parts, to monitor it over an extended period of time and to draw conclusions from the results for the future. This can be done with quality value numbers. The course of the quality value numbers (QVN – QWZ in German) is, in practice, often split into and evaluated in three categories. These categories are: -
regular
Course of the QVN within two limits (controlled processes)
-
irregular
Course of the QVN slightly exceeds the upper and/or lower limit
-
strongly fluctuating
Course of the QVN indicates an uncontrolled production process
A nonconformity analysis allows conclusions to be drawn about the causes of the nonconformity according to the five „M‘s„ (Man, Machine, Material, Method, Means/Environment). In addition to the actual product audit report, evaluations of nonconformity focal point are gaining more importance. The product quality can be demonstrated by these, as well as by using the attached diagrams.
23
8
Evaluation of the Product Audit Results
The evaluation of the product audit results is individual, differs from one product to the next and depends on the use of the product. It is important, however, that the evaluation method is kept constant for an extended period of time to allow comparison. It is important for the systematics of the evaluation, that one differentiates according to the following characteristics: -
quantitative (measurable) characteristics functional characteristics material characteristics life time characteristics qualitative characteristics.
The evaluation of the results should be made from a statistical point of view. When evaluating quantitative characteristics, the presentation of the mean value in connection with the spread is a suitable method. Additional diagrams show the correlation even more clearly. Where possible, for example, Pareto-Analysis can be used to establish nonconformity focal points. The evaluation of the questionnaire provides an indication of the quality niveau of a product through -
compliance or noncompliance with the product characteristics type and location of the nonconformity extent of the nonconformity (e.g. critical, major, minor) detectability (e.g. probability of discovery high/low).
For evaluations summarizing quantitative and qualitative characteristics, weighting factors can be established and applied. Often, they are used to establish quality value numbers, which are listed for comparison and are drawn upon for product evaluations.
24
9
Product Audit Report
The product audit report encompasses: -
statements on the number of parts or end products examined and those found to be nonconforming.
-
All nonconformities found are to be classified, if stated.
-
The classified and weighted results of the product audit should be condensed to one or several Quality Value Number (QVN), depending on their objective, to allow comparative assessments and to continually record trend.
-
the reasons that led to production stop, including the comments to the noncompliance of the quality requirements.
The characteristics, that make corrective actions necessary, are to be pointed out in the audit report. In any case, the results are to be included in the long term assessment of the product quality. The auditor writes the audit report and co-ordinates the corrective actions with the person responsible for production. The audit report is to be distributed to the responsible departments as well as to the responsible product management. The audit reports are to be archived following given regulations (see also VDA Volume 1 and Volume 6, part 1).
25
10
Corrective Actions Resulting from the Production Audit
10.1
General
Corrective actions are to be introduced, based on the audit report. Thereby, the procedure described in the VDA Volume Part 1, Element 18 (Questions 18.01 to 18.04) is to be followed. The corrective actions to be taken have differing significance; they depend on the severity, frequency and type of nonconformity. Only by knowing the causes of the nonconformities, can efficient corrective actions be introduced. The following corrective actions, if given, can be distinguished at a product audit: 10.1.1
Corrective Actions for Major Nonconformities
Major nonconformities cause immediate action to be initiated to determine the cause of the nonconformity and to eliminate it. All affected components, semi-finished products or products must be put on hold immediately. If nonconforming parts are reworked, they must undergo reinspection. 10.1.2
Corrective Actions for Minor Nonconformities
Dependant on the impact of the nonconformity, a concession (internal/external) has to be obtained for the stock in circulation and dispatch. 10.2
Monitoring of Corrective Actions
Corrective actions to be implemented, are to be laid down in writing including a set date, e.g. when the actions have to have been taken. The auditor is not responsible for the implementation of the corrective actions. The monitoring of the implemented corrective actions may require an unscheduled product audit. In addition, unscheduled process and/or system audits may be required, if the causes of nonconformity cannot be clearly determined.
26
11
Case Examples
In the following, some case examples for product audits from practice are shown, which are meant as supplements to the theoretical explanations. The chosen products extend from single parts, complete assemblies through to finished vehicles. The differing procedures and evaluation methods illustrate the scope for the user. The varying products in the automotive industry and the partially differing objectives for the product audit, do not allow the use of a uniform system. However, from the multitude of given possibilities, a concept can be put together appropriate to one’s own requirements and objectives. Example No.
Company
Product
11.1
Müller + Co.
Selector shaft
11.2
Thyssen Krupp
Input material (Thin sheet metal)
11.3
Thyssen Krupp
Laser and mash seam welded tailored blanks
11.4
KKK
Bearing bush
11.5
TRW
Valves
11.6
Continental
Tires
11.7
Ford
Complete Vehicle
11.8
VW
Complete Vehicle
11.9
Daimler-Benz
Procedure
Table 2:
Summary of the Case Examples for Product Audits
11.1
Case Example – Selector Shaft - Müller + Co.
Explanations
The inspection guideline 013-1 (Fig. 11-1-1) is generally valid for selector shafts of the same design and contains the description of inspection, measuring and test activities to be carried out, as well as the assigned inspection sequence number. The test pieces are selected from the dispatch department in accordance with the sampling plan. Inspection plan/Log sheets 27/1095 (Fig. 11-1-2):
27
The inspection plan is raised specific to the part by the quality department, it serves additionally for the recording of the inspection results. Nonconformities found are classified according to their significance and registered with a corresponding code letter - A-, B- or C-Nonconformity. For the evaluation of the nonconformity points (NP), the three nonconformity categories are assigned with different nonconformity weighting factors: A - Nonconformity = 10 Critical nonconformity B - Nonconformity = 5 Major nonconformity C - Nonconformity = 1 Minor nonconformity The sum of nonconformity points (NP) = ∑ (no. of nonconformities x nonconformity weighting factor). The inspection report contains in essence: - sampling date - sampling location - completion date of the test pieces. Identifying the completion date of the test pieces is, above all, important for narrowing down the nonconformity and establishing the corrective actions. The identifying of the number of nonconformities and the nonconformity points (NP) is necessary for the overall evaluation. In the given field, the number of A-, B- and C-Nonconformities are noted against the inspection sequences, the number of nonconformities and nonconformity focal points are calculated. Identifying the Quality Code Number : (QCN)
QCN = 100 – Nonconformity points/Test pieces In the example, 4 test pieces showed 7 nonconformities with 51 nonconformity points. QCN = 100 - (51/4) =100 - 12,75 QCN = 87,25 Note:
As the views about the value of a quality code number for comparisons differ, the user must decide if he should state a QCN in a report. The QCN can also be calculated to a different formula to the one given in the example.
The following are represented: Fig. 11-1-1: Inspection Guideline 11-1-2: Inspection Plan 11-1-3 + 4: Inspection Report (Front page/Back page)
28
Müller + Co.
Product Audit
Quality Assurance
Inspection Guideline 013-1
Inspection Sequence
Description of the activity or inspection
100
Sampling of the test pieces Sampling is to be carried out at random, test pieces are to be taken from a delivery-ready lot of the latest production date.
200
Check of the packaging - Appropriate for the purpose in accordance with specification - Marking in accordance with specification - Safety against damage to the product - Inspection certificate available for the customer
300
Visual inspection -Preparation : Number the taken test pieces -Inspection : Appearance, surface, marking according to drawing requirements
400
Dimensional inspection – Selected dimensions according to customer and manufacturer drawing
500
Production , gauging , fitting checks
600
Check of physical properties - Strength, hardness etc. - Heat -, cold resistance. - Torque and other moments of force according to requirement - Inspection certificate of the supplier available and satisfactory
700
Check of chemical properties So far as required and so far as the usability of the product is influenced. - Material inspection - Inspection certificate of the supplier available and satisfactory.
800
Reliability checks – Long term tests according to specification – Abrasion test – If applicable, availability of the inspection certificate
900
Establishing the results after entry in the audit report - Discussion of the nonconformity points (NP), no. of nonconformities x weight - Discussion of the quality characteristic number (QCN)
Department
Name
Date
Revised on
by
WQ4
Meier
19.10.94
21.11.1994
Schulze
Fig. 11-1-1:
Inspection Guideline
29
Müller + Co. Quality Assurance
Product Audit Inspection Log sheet 27/1095 Plan
Description of part: Selector shaft Customer: Schulze GmbH Operation: Complete assembly sketch
Manufacturer part no. 123.156 Ind. 2 Customer part no. 189.101 Ind. 11
Insp. seq. 205 210 305
310 405 410 415 420 425 505
510 605 610 705 805
Inspection characteristics Specified values Marking/Identification Packaging according to specification Selector shaft perfectly riveted to the lever Pin perfectly pushed in, free of burrs 2 x Angle 90° ± 30´ Angle 15° ± 30´ Ø Shaft 12.894..12 Dimension 264 ± 0,25 Dimension 61 - 0,25 Lever position, location, countersinking Parallelism Hole spacing Torque 00 NM min. Case hardness Inspection certificate for chemical analysis Abrasion resistance acc. specification A40563 Auditor Ott
Fig. 11-1-2:
Insp. meas. & test equip n = Visual 4
1
2
3
4
5
6
7
8
9
v. 01.10.1995 v. 27.09.1995
10 NP
Visual
4
Visual
4
10
Visual
4
5
QCN
Goniometer
4 Goniometer 4 Dial gauge 4 Caliper gauge 4 Caliper gauge 4 Setting 4
6
30
gauge
Gauge
4
Torsional spanner
4
Hardness test Visual
4 4
Facility
4
Date 13.10.1995
Nonconf cat.
Nonconf. weight
∑ NP
51
QCN 87,3
Inspection plan
30
Müller + Co.
Product Audit
Quality Assurance
Inspection Report No.: 27 / 1095
Description of part: Selector shaft Customer: Schulze GmbH
Manufacturer part no. 123.156 Ind. 2 Customer part no. 189.101 Ind. 11
v. 01.10.1995 v. 27.09.1995
Goods extracted on: Goods extracted from: Completion date:
12.10.1995 Dispatch dept. 03.05.1995
Insp.
of Cat B
Nonconf. Cat C
No. of Nonconf.
Inspection performed
n
No. Cat A
200
Packaging
4
-
-
-
-
300
Visual inspection
4
1 (x 10)
1 (x 5)
-
2
15
400
Dimensional insp.
4
-
1 (x 5)
1x1
2
6
500
Gauging
4
3 (x 10)
-
-
3
30
600
Physical properties
4
-
-
-
-
700
Chemical properties
4
-
-
-
-
800
Reliability checks
-
-
-
-
seq.
900
Result
Decision:
∑ 7
Release
∑ 51= NP
87,3 = QCN
Placed on hold
p
Noncon f. points
x
Summary: Placed on hold due to nonconformities in the inspection sequence: 209: 419:
Riveting not satisfactory. The lever does not sit securely on the shaft. The hole spacing is exceeded according to the gauge.
Further action required: Stock placed on hold Corrective actions to be initiated Drawing/Work plan amendment to be ordered Comments see overleaf
Yes x Yes X X
Nop
No
X
through Q 12 through P 11
by by
through
by
from
on
Auditor : Ott
immediately immediately
Date: 13.10.95
Distribution: a 12, P 1, P 11, P 124
Fig. 11-1-3:
Inspection Report / Front Page
31
Back page Inspection Report No. 27/1095 Acknowledgement from: P 11
to: P 1 and Q 12
Agreement with the assessment Yes
Corrective action
Nonconformity eliminated Amendment record no. 511 Notice no. 012/1095 Concession no. 2/2/Q1
Stock check
Customer complaints
since production date 14.10.95 from P 124 from P 11 from a 1 reg. Insp. sequence 315 (C-Nonconformity)
X
Stock in store
X
Stock in circulation Goods exit
X X
Amendment s Drawing will be changed
No
Nonconformity share : 0,5% of 200 inspected pieces Nonconformity share 2% of 50 inspected pieces Nonconformity share 0 of 75 inspected pieces X
by ...
Production plan will be changed
X
by ...
Warranty complaints notified
X
from...
Actions at the customer premises X
on ...
Cause of nonconformity, corrective action or reason for rejection: CF 1:
Pressure plate and riveting device corrected Drilling device newly adjusted and new bushes fitted Personnel instructed Stock in store and circulation sorted and reworked
Date: 19.10.95
Fig. 11-1-4:
Name: Thiebel
Identification Symbol: P 11
Inspection Report Bac / k Page
32
11.2
Case Example Input Material (Sheet metal) - Thyssen Stahl AG
Explanation
Product audits are carried out in the form of an internal company re-inspection (Fig. 11-2-1). The scope of inspection amounts to 20 coils (rolls) monthly per working area. The product range consists of the following: -
cold rolled sheet metal (KB) hot galvanized sheet metal (Z) galvannealed (ZF) electrolytic galvanized sheet metal (ZE) hot aluminized sheet metal (AS) coil coated sheet metal (OC) other (SO).
The selection of the test pieces is carried out in accordance with the instructions of the responsible quality department. Generally, coils packed and ready for dispatch are examined. The characteristics to be inspected are laid down in a questionnaire. The inspection is carried out on the basis of the given characteristic specifications. The characteristics are assigned with position numbers (Pos.-No.) e.g. 011-Labelling, 301 – not sufficiently oiled (Fig. 11-2-1). The evaluation scheme is made up of a 5-stage grid, against which each nonconformity is evaluated. For each nonconformity given 5 or more nonconformity points, the cause and corresponding corrective action are to be named. (Fig.11-2-2) Reporting takes place monthly by the auditor. The monthly results are presented for each working area and supplemented with action plans. The audit result is represented in Fig.11-2-3 and 11-2-4.
33
Product Audit Process Input Material (Thin Sheet Metal)
Spezification
Planning international company re-inspection
Checklist (Inspection characteristics Work instructions - characteristics - inspection, measuring and test equipment - frequency
Selection of test pieces
Requirement Quality department
Process
Work instructions
Evaluation
>5 Nonconformity points?
No
Reporting
Yes
Immediate actions Corrective actions
Bild 11-2-1:
Product Audit Reinsepection Work Process
34
Page No.: ___ of _ Insp. Date _______
PRODUCT AUDIT – REINSPECTION Individual evaluation KW I / KW II Product: DIN-Quality:
Order / Pos.: Order Width:
Tol. Width +/Tol. Thickness +/SG Cust. Standard Surface finish
Surface type Evenness Protection Stamping Stable side
Customer: Order Thickness: SPECIFICED VALUES Pack. weight min Pack. weight max Type of packaging Inner-∅ Outer-∅
of labels Application Other + Source details Evaluation step n 55 n 15 n 5 n 3 n 0
Pos
Ident. No.: Packet No.: Edge trim Welding No. of labels min.
i:
o: Type
Outer-∅ max.
Explanation
Assessment
min. 1 nonconf. with 55 points min. 1 nonconf. with 15 points min. 1 nonconf. with 5 points min. 1 nonconf. with 3 points no nonconfs. equals 0 points
Inspected characteristic
Method
011 051 101 102 103 104 152
Labeling Packaging Coil status Coil edges Outer winding Inner winding Coil Inner ∅
153 201 251 301 351 352 401 402 404 451 501
Coil Weight Edge trimming Ident. / stamping Surface protection Coil width Coil thickness Surface finish/coat. Surface type/class Evenness Weld seam Stable side
visual visual visual visual visual visual tape measure scales visual visual visual automatic automatic visual visual visual visual visual
Rejection of the insp.unit, further processing at cust. premises not poss. Partial rejection, Repair/rework prior to delivery necessary Throughput at cust. premises only poss. with add.costs (e.g extra oiling) Throughput at cust. premises without difficulty, cosmetic faults Reinspection complies with the release results/ cust. requirements.
Nonconf. points n 55
15
5
3
Comments 0
Corrective actions for nonconformity points ≥ n 5: Reinspection carried out Name/Signature
Datum
Name/Signature
Date
Repair carried out
Fig. 11-2-2:
Product Audit – Reinspection: Individual Evaluation(Form)
35
Product audit - Reinspection
KW2 Month: September 1996
Monthly assessment - Individual representation Scope of insp. per product - Cold rolled sheet metal (KB) - Hot galvanized sheet metal (Z) - Galvannealed (ZF) - El. Galvanized sheet metal (ZE) Seq. No.
Iden No.
Pack No.
Cust.
H234535
AUTO
Specified
Actual
5 5 5 5
4 7 4 5
Dimensions
g n i l l e b a L -
g n i g a k c a P -
s u t a t s l i o C -
s e g d e l i o C -
g n g i n p i . . Ø t m m - h d d r a t g n i n e i i m S i n e t e r / w w n . c W t r r I a e e e i l l g n f t e r n o i o d d u n u A - E - S - I - C - C - I -
. n h t k c d i i h w t l i l i o o C - C -
. t a o c / . n i s f s e e c a f . n f n r r e u u v S - S - E -
Inspection scope per product - Hot alu. sheet metal (AS) e - Coil coated sheet metal (OC) m d a i s e s l e - Other d b l a e t W - S
S G
Prod.
Width Thick. 1270
6
ZF
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0 401: color uneven
0,70
84405-01
2
2R643-01
E236492
AUTO
1610
0,75
6
ZE
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
85307-12
G220290
AUTO
1530
0,90
8
Z
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
4
2R591-01
E213971
AUTO
1220
0,80
6
ZE
0
0
0
0
0
0
0
0
0
5
0
0
0
0
0
0
0 301: poorly oiled
5
08137-01
F210690
AUTO
1625
0,77
6
Z
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6
08111-11
F210672
AUTO
1170
0,90
6
Z
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
0 201: strong buring on edge trim
7
84421-01
H234591
AUTO
1200
0,75
6
ZF
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
8
2R766-01
E236594
AUTO
1580
0,75
6
ZE
0
0
0
0
15
0
0
0
0
0
0
0
0
0
0
0
0
0 103: Start of coil 150 m, binding band pressure marks
9
2R388-01
E236608
AUTO
1625
0,75
6
ZE
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
10
163873E
C239294
AUTO
1600
0,84
6
KB
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
11
163875E
C269300
AUTO
1600
0,84
6
KB
0
0
0
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0 102: Coil edges slightly damaged
12
14770-11
G220565
AUTO
1540
1,20
7
Z
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 0 011: Label dirty
0
13
163800X
C269236
AUTO
1805
0,80
8
KB
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
14
08110-11
F210669
AUTO
1170
0,90
6
Z
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0 402: Occaisional scale
15
84537-01
H234714
AUTO
1200
0,75
6
ZF
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 0 404: Medium waviness
16
158887E
C215741
AUTO
1433
0,80
6
KB
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
17
08494-01
F210906
AUTO
1625
0,77
6
Z
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0 401: Stripey surface after grinding
18
84505-01
H234729
AUTO
1600
0,71
6
ZF
0
0
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0 101: Inner 10 windings, 10 mm run off center
19
85974-01
G221059
AUTO
1500
0,60
8
Z
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
20
2S787-01
2S787-01
AUTO
1460
0,80
6
ZE
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Actual
0 0 0
0 0 0
Comments*
1
0
Required
*Comment: For every nonconforming evaluated with min. 5 nonconf. points, an action plan with details regarding the cause of the nonconformities and corrective actions must be raised!
Date/Signature Auditor / Company Inspectors
Bild 11.2.3:
Management / Head of Quality Dept.
Product audit - Reinspection: Monthly Evaluation
36
Internal Company Reinspection - Monthly Eval uation - September 1996 - KW2 QF-PD de Fries
Se q No .
8
4
Non Conf pt s
Ident No. Customer Dimension Product Application
SG
Aggr. Delivery insp.
15
2R766-01 AUTO 1580x0,75 ZE Side part
6
IA 2
5
2R591-01 AUTO 1220x0,80 ZE Roof
6
EBA 2
Bild 11.2.4:
Type of nonconformity
Cause
Im m e d i a t e a c t i o n
Corrective action
103: Start of coil 150m Fine adjusting of the new Nonconforming length Binding band pressure Automatic binding machine automatic binding machine was cut off marks in Inspection Plant 2
301: Poorly oiled
Fault in the nozzle beam
Coil was reoiled during the reinspection
Fitting of flow meters
Responsible
F i n i s h i n g Pl a n t 2
Finishing EBA 2
Internal Company Reinspection - Monthly Evaluation
37
11.3
Case Example Laser and Mash Seam Welded Tailored Blanks - Thyssen Stahl AG
The next section describes the planning, performance, and monitoring of product audits on laser and mash seam welded tailored blanks. The product quality of tailored blanks, already finally inspected and ready for dispatch, is checked in random samples for compliance with the requirements. 11.3.1
Selecting Samples for Inspection
When selecting samples of the blanks to be inspected, the following criteria are to be especially considered: customer complaints, problem parts, large lot sizes, high rework and rejection costs, not easily detectable faults, extremely large measuring uncertainty etc. The sampling is carried out as a random selection. 11.3.2
Scope of Inspection
From each series checked, the following number of pieces per product are to be inspected for all important characteristics. The auditor decides which characteristics will be checked. For characteristics which require a lot of inspection time, energy and money, the auditor can be satisfied with only a small number of samples (min. 10 pieces). A3 – plants LRV - plant T4 - plant LSA3 - plant 11.3.3
50 pieces min. 10 pieces min 10 pieces min. 10 pieces min. Process and Sequence of Operations
1. Take samples of the dispatch-ready tailored blanks to be inspected from the store or from the final inspection department. The auditor is responsible for their correct return. 2. Obtain all documents, such as drawings, inspection forms, inspection instructions etc.
38
3. Review the documents with regard to validity, correct revision status. 4. Measure the blanks according to customer drawing (Dimensional inspection). 5. Visual inspection of the blanks (see Nonconformity Classification). 6. Material testing (if required) to be carried out. 7. Prepare audit report. 8. If the tailored blanks are in perfect condition according to the audit report, then the inspected samples can be handed back to the store/dispatch, after they have been preserved and repacked.
11.3.4
Product Audit Report
The measured values are to be statistically analyzed. Cpk-values and statistical known quantities are to be shown in the audit report. The results are immediately transmitted to the production department. A copy of the product audit report is to be distributed to the works management, the Head of Production and the quality department.
11.3.5
Procedure for Handling Nonconformities
The nonconformities found during the audit are, depending on the severity of the fault (Fig. 11-3-5-1) immediately, or daily notified to the involved areas of responsibility for corrective actions. Immediate corrective actions are monitored by the quality department in parallel. Based on the results of the product audit, if necessary, nonconformity analyses are to be carried out by the production and quality department and actions to eliminate the cause of the nonconformities are to be initiated. Monitoring the effectiveness of the initiated actions lies with the quality representative of the respective works.
39
11.3.6
Dispatch Audit
At irregular intervals, deliveries ready for dispatch are to be checked according to the criteria of the Dispatch Audit Checklist (Fig. 11-3-6-1) prior to loading. If nonconformities are found, the dispatch department is to be immediately informed. They must then initiate immediate corrective actions.
11.3.7
Responsibility
Overall responsibility
W orks management
Processing responsibility /A /Auditors
Quality dept./Representative
Audit subject subject
Dispatch Dispatch ready ready blanks/De blanks/Deliver liveries ies
Determining scope, inspection characteristics and samples
Quality Dept.
Determining the weighting factors for the audited characteristics
Quality Dept.
Raising, maintaining and releasing checklists
Quality Dept.
Organizing the inspection procedure and sampling blanks
Auditor Auditor
Performing the dimensional inspections
Auditor
Performing the material testing
Auditor
Preparing audit reports (Nonconformity report/Monthly report)
Auditor Auditor
Reporting : Nonconformity report
to Production / Quality Dept.
Responsible ffo or ca carrying ou out co corrective ac actions
Production / Dispatch De Dept.
Check of the corrective actions
Quality Dept.
40
Product Audit – Nonconformity Classification
Major noncon- Nonconformities which can lead to failure/rejection. formity 1=
Overlay faults, holes in the weld seam, dimensional nonconformities Major noncon- Nonconformities which can lead to disruptions in formity 2= further processing
Stack geometry, oil deposit. Major noncon- Nonconformities which lead to minor impairments formity 3= but are not allowed according to the specification
Packaging faults, loosened binding band, pallet beams out of alignment Major noncon- Nonconformities which, very likely, will not lead to formity 4= any disruption and are not specified (cosmetic faults)
Dirty packaging, bent label, small surface faults, e.g. light scratches.
Fig. Fig. 11-3-511-3-5-1: 1:
Noncon Nonconfor formit mity y Classif Classifica icatio tions ns for Lase Laserr and Mash Mash Seam Seam Welded Tailored Blanks
41
Dispatch Audit Checklist
Dispatch Audit No.: Tailored Blank
Part Number
Internal Order Number
TFT Delivery Note No.
Customer Reference No.
Customer
On ___________ in the store and dispatch dept. ______________ a dispatch audit was carried out.
Following characteristics were checked and compared to the customer order: 1. Complete customer address with unloading area
o
2. Customer reference no.
o
3. TFT reference no.
o
4. Dispatch details
o
5. Dispatch no.
o
6. Labeling (Application, Legibility Legibility and compliance compliance with the customer order)
o
7. No. of pieces (compliance with the customer order)
o
8. Packaging (Required type and marking/identification) marking/identification)
o
9. Dispatch papers (compliance with the customer order)
o
10. Correct loading onto the forwarder’s vehicle v ehicle
o
During the dispatch audit the following /no* nonconformities were found:
*please cross non applicable
Fig. Fig. 11-3-6 11-3-6-1: -1:
Dispat Dispatch ch Audit Audit – Chec Checkli klist st Laser Laser and and Mash Mash Seam Seam Welde Welded d Tailored Blanks.
42
11.4
Case Example Bearing Bush - AG Kühnle, Kopp & Kausch
11.4.1
Explanation Systematic Quality Evaluation Production and Purchasing (SQPP)
The product audit system SQPP (SQFE in German), combines quantitative and qualitative characteristics, showing them as a quality code number and allowing a timed assessment and control of quality. The advantage here is, that these quality numbers can be used as a management tool, in order, on the one hand, to identify the improvement potential of the examined product and, on the other hand, to allow the comparison of differing products. To establish the quality code number, the tolerance area of quantitative characteristics is divided into different zones. The individual zones are allocated a number of minus points, depending on the significance of the nonconformity they represent. Categories of minus points according to the following criteria: Grading
55
Criteria
RECALL ACTION NECESSARY - A failure which results in the destruction of the superior subassembly (Motor, gears, etc.).
15
REWORK UNAVOIDABLE – Unacceptable cosmetic fault which will be identified by every customer - Functional failure – Major faults preventing assembly
5
REWORK RECOMMENDED – Cosmetic faults, which are criticized by most customers - Failure causing customer dissatisfaction - Fault disturbing assembly
3
- no visible direct impact on function - however, requires a readjustment of the characteristic to within tolerance limits - Cosmetic faults generally accepted by the customer
43
TT
Tu
To
two-sided characteristic Tm
10 %
17 %
66 %
17 %
10 %
3
2
1
2
3
4
one-sided characteristic 0 limited
TR = Tolerance range Tm = Tolerance mean
4
TR
83 %
17 %
10 %
1
2
3
4
Zone 1:
0 Minus points
Zone 2:
3 Minus points
Zone 3 and 4:
In this zone 5, 15 or 55 minus points are issued depending on the severity of the nonconformity.
For qualitative characteristics which are only evaluated according to „Nonconformity found„ or „ Nonconformity not found„, one proceeds in the same manner. Depending on the severity of the potential nonconformity, minus points are assigned. Example:
Minor damage Major damage
5 Minus Points 15 Minus Points
In the following example, only the large-scale manual calculation method to establish the code number is described.
44
For the continual application of SQPP, the use of a computer-aided calculation program is recommended, which, simultaneously allows the audit planning and statistical analysis to be carried out. The code numbers are hereby automatically established from the audit results.
11.4.2
Code Number System for SQPP
a)
NNC = Niveau of Nonconformity:
This known quantity is the most important code number and consists of four digits. This number shows how many characteristics were marked with 55, 15, 5, 3 minus points during the product audit. Example - Niveau of Nonconformity (NNC – NNQ in German) If the sum of a digit of the NNC is greater than 9, it is set to 9 for formal reasons. Characteristic No.
n55
n15
n5
n3
NNC
1
0
0
0
0
0000
2
0
1
2
1
0121
3
1
1
0
0
1100
4
0
0
0
5
0005
5
0
0
0
1
0001 1213
Explanation:
1 Characteristic has a minimum of a 55-Points-Nonconformity 2 Characteristics have a minimum of a 15-Points-Nonconformity 1 Characteristic has a minimum of a 5-Points-Nonconformity 3 Characteristics have a minimum of a 3-Points-Nonconformity n = number of nonconformities in the respective negative points category
45
b)
QCC = Quality-Capability-Coefficient
The Quality-Capability-Coefficient (QCC – CAQ in German) is a code number for variable characteristics. It shows what percentage of a tolerance area related to the tolerance mean is used. The smaller the QCC, the stronger the measured values are focused around the tolerance mean. If the QCC = 1, the measured values lie at the tolerance limit (in this case, the QCC is set to 0.99 for formal reasons). two-sided tolerance range
= Maximum of:
max-value - Tm
Tm - min-value
or
TR/2
TR/2
one-sided Tolerance area = 0 limited TR Tm TR
= =
max-value
Tolerance mean Tolerance Range
The QCCmax is the largest QCC across all characteristics. c)
NDQ = Niveau of the Delivery Quality:
The NDQ supplements the NNC by the maximum used tolerance of a characteristic. NDQ = NNC + QCCmax d)
Av = Average Minus Points:
A value that is monitored over a period of time, is the average minus points per product. A comparison of this value over time is only acceptable, if it concerns the same product and the number of characteristics has not changed.
46
The Av is the sum of the realized mean quality numbers, Amr, per characteristic. Ar
(55xn55)+(15xn15)+(5xn5)+(3xn3)
Amr = = m m = Sample size n3/n5/n15/n55 =
11.4.3
Ar = realized Q-number per characteristic
Number of assessment results falling into the respective minus points categories.
Procedure using Bearing Bush as an Example
Step 1: Determine the characteristics to be assessed, measuring and test equipment and frequency .
inspection,
3 2
4
1
Step 2:
Allocate the minus points per characteristic (see Appendix)
Step 3:
Assessment of 20 Parts
Minus Point Categories
variable:
1.) Length 2.) Inside diameter 3.) Surface roughness
attributive:
4.) Outside diameter 5.) Damage
5 15 15 5 5
47
Step 4:
Evaluating the Measured Results (m = 20) Characteristsic1
Characteristsic3
Characteristic 4 Characteristic 5
20.5210
20.4880
20.5280 20.5190 20.5060 20.5010 20.5110 20.5020 20.5190 20.5290 20.5450
20.5000 20.5060 20.5010 20.4850 20.5250 20.5170 20.4820 20.4990 20.4900
1.9800
1.8000
1.7200 2.2100 2.0100 1.9900 1.9000 2.1500 2.1900 2.2400 1.6700
1.9200 1.8700 2.1000 2.0400 2.0100 1.9900 1.7900 2.2200 1.9700
20 x 20 x
Characteristsic2
8.4010
8.3970
8.4020 8.4050 8.3950 8.3990 8.4000 8.3920 8.3920 8.4010 8.3980
8.4040 8.4010 8.3970 8.4050 8.4000 8.3970 8.3950 8.4010 8.4030
O.K. O.K.
48
Step 5:
Calculation
5.1)
Calculation of Ar, Amr and Av Ar
No. Characteristic 1
Ar =
Total Length
realized Q-Number per characteristic
Amr = m
0 + 0 + 0 + 1 x 3
Amr
3
0,15
20 2
Inside diameter
0 + 0 + 0 + 2 x 3
6
0,3
20 3
Surface roughness
0 + 0 + 0 + 0
0
0
4
Outside diameter
0 + 0 + 0
0
0
5
Damage
0 + 0 + 0
0
0
Av = 0,15 + 0,3 = 0,45
Calculation of NNC
5.2)
Characteristic
n 55 n 15 n 5
n3
NNC
1
Total Length
0
0
0
1
0
0
0
1
2
Inside diameter
0
0
0
2
0
0
0
2
3
Surface roughness
0
0
0
0
0
0
0
0
4
Outside diameter
0
0
0
0
0
0
0
5
Damage
0
0
0
0
0
0
0
No.
=> NNC= 0002
49
Calculation of QCC and NDQ
5.3)
Two-sided tolerance No Characteristic
min.
max.
Total Length
Tm - min QCC= TR / 2
max-Tm QCC= TR / 2
20,5 - 20,482 0,05
20,545 - 20,5 0,05
QCC
1 20,5 ± 0,05
2
20,482
Inside diameter 8,4 ± 8,392 0,01
20,545
= 0,36
8,405
8,4 - 8,392 0,01
8,405 - 8,4 0,01
= 0,80
0,50
= 0,90
0,90
0,80
One-sided tolerance No Characteristic
min.
max.
max-Tm
QCC
QCC= TR / 2
3
Surface roughness Rz 1,67 4,0
2,24
2,24 4,0
0,56
NDQ = NNC + QCC max => QCC max = 0,90 => NDQ=0002,90
50
Computer-aided Evaluation Aktiengesellschaft Kühnle, Kopp & Kausch Evaluation Form SQPP
Marnheimer Straße 85/87 67292 Kirchheimbolanden Commission-No.: 7000 1000 Machine-No.: 133 0000 No of pieces: 20 Description: Bearing Bush Part-No.: 5315 100 2000 P Description of characteristic 1 Total Length Inspected number : 20 (Height measuring gauge) quantitative Specified value: 20,5000 upper tolerance: 0,0500 lower tolerance: 0,0500 2 Inside diameter Inspected number : 20 quantitative --> Nozzle gauge
Customer: Work process: Component Responsible department: Date: Signature: 55 15 5 3 0 3 5 15 55 0 0 19 1 0 AMR = 0,15 QCC = 0,90
2
18 0
0
0
-
Specified value: 8,4000 upper tolerance: 0,0100 lower tolerance: 0,0100 3 Surface roughness Inspected number : 20 quantitative --> Measurement of surface AMR = 0,00 roughness QCC = 0,56
20 0
0
0
-
Specified value: 0,0000 upper tolerance: 4,0000 lower tolerance: 0,0000 4 Outside diameter Inspected number : 20 qualitative--> snap gauge 5 Damage Inspected number: 20 qualitative --> Visual NNC = 2
-
0
0
AMR = 0,30 QCC = 0,80
-
-
-
-
20 -
0
-
-
-
-
-
-
20 -
0
-
-
Total Evaluation SQPP NDQ = 0002,9 Av= 0,45
QCCmax = 0,90
51
Documentation
If quality deviations or nonconformities are found (NDQ ≥ 10), immediate corrective action must be taken. Parts No.: Work process: Description: Mash.-No.:
5315 100 2000 Component Bearing bush 133 0000
Comm.-No.: 7000 100.0 No. of pieces: 20 Responsible department: Date: 27.05.1996 Signature:
__ Av
NQ + QCCmax
0,45
0002,9
Du
25
9999
NNC 5000
20
1000 500
15
100 50
10
10 5 X
5
1
X X X
0
X
X
X X
0,5 X
Month
JFMAMJJASOND / A
Distribution:
X
0
Month JFMAMJJASOND / A
Date:
Signature
27.05.1996
52
K K K
A k t i e n g e s e l l s c h a f t Kühnle, Kopp & Kausch Parts-No..: 5315 100 2000 Work Process :Component Benennung:
Mach.-No.: Date: 27.05.96 Signature.: ______________
Lagerbuchse
Characteristics NC
Inspection, measuring and Test Equipment
Units examined
quantitative Micro-Hite
20
Summary of characteristics
55 15 5 0 0 0
5 1
Parts-No.: Comm.-No.: No. of pieces: Responsible Department.:
Total Length 20,5 ± 0,05
3
20,450
15 2
Inside diameter 8,4 ± 0,01
quantitativ barrel gauge
20 8,389
3
Surface roughness
quantitativ surface roughness measuring equipment
5
8,39
3
19
1
20,467
20,533
-0-
2
18 8,3934
8,4066
5
qualitaiv snap gauge
20
5
Damage
qualitativ visual
20
Name Date Signature
3
CAQ
0,15 0
0
0
1
0,9
0,30 0
0
0
2
0,8
8,411
5
15
20 4,0
Total sum of the characteristics
3
55 15 5 3 0 0 0 2
CAQ NNQ
0
0
0
0,56
0
0
0
0
0
0
0
0
0
0
0
0
5
20
55 15 5
0
4,4
20
Subtotal of the characteristics
0
5
-0-
Issue/Revision
Dmr 55 15 5
15
8,41
3
3,32
Outside diameter
May 96
20,550
-04
1
5
3
-020
Month
3 2
-0-
3
5315 100 2000 7000 100.0 20 AQI
0 0 0 2
Du
0,9 max 0,45
NQL
2 , 9 0
53
11.5
Case Example Valves - TRW Deutschland GmbH, Motor Components
Explanation
A minimum of 50 valves ready for dispatch are taken from storage and subjected to a product audit. Design drawings, inspection instructions and quality guidelines from the basis of the evaluation. The basic characteristics defined in the quality guidelines are measured to the drawing and statistically analyzed. Visual nonconformities, such as impact marks, grinding marks, scratches, material defect marks or pores, are inspected using a nonconformity catalogue and, depending on their functional impairment, differentiated into major and minor nonconformities. Major nonconformities are deviations from design drawings which can lead to impairment of the valve function in the motor. The results are documented in the audit report, where type and frequency of the found nonconformities are explicitly presented. If faulty parts are found, the quality control management is informed immediately. For minor nonconformities, it is then decided if the part will be reworked or a concession which must be approved in writing by the customer. For major nonconformities which impair function, stock is in the store is placed on hold and is subjected to a 100 % reinspection with regards to the nonconformity characteristics found. Based on product audit results, nonconformity analyses are carried out for nonconformities where the cause is unknown and actions to prevent recurrence are introduced. The quality representative is responsible for monitoring the effectiveness of the introduced actions. The main reason for carrying out the product audit, however, is to establish the quality niveau of the delivered valves. Hereby, the statistical analyses and their statement to the process capability of the variable main characteristics, are significant.
54
TRW Deutschland GmbH Motor Components Postfach 11 11, 30881 Barsinghausen
Product Audit Report-No. 501.929.016.96
Date: 09.09.1996 Pages: 3
A product audit was carried out on exhaust valves ready for dispatch, destined for company........ .
Attachments: 2 Statistic tables
Drawing-No.: 076.029.200.01.2
Customer: . . ..
Order-No. 80174-00
Customer-Ref. No. 90 289 198
Processor: VCQ / Tel.350
Summary
After final inspection, 100 valves with the Ref. No. 076.029.200.01.2 were taken as samples. The parts were manufactured in production line No. 3. During visual inspection, 3 major nonconformities and 2 minor nonconformities were found. During dimensional inspection, 13 characteristics were inspected of which 2 did not reach the required minimum capability index. Individual Result/Visual Inspection
1 1 1 2
Defect mark on the seat > 0,5 Impact mark on the seat (raised < 0,5) Impact mark on the seat (not raised > 0,5) Impact marks in the throat (not raised > 0,5)
Nonconformity weighting
1 2 2 3
55
Individual Result/Dimensional Inspection The following characteristics lie below the required index of 1,33
Plate edge height Seat angle
Cp-Value
Cpk- Value
P- Value
1,24 1,37
0,73 1,30
0,00% 0,00%
Pe- Value
1,287% 0,005%
For a detailed listing see Appendix.
Note: Quality control was informed immediately. Distribution:
Auditor:
inspected:
G, M, T, TQ, VC, VP, VPQ 2x, VCQ
56
Table to Product Audit No.: 501.929.106.96 Character.
Plate Ø
Shaft Ø
Shaft Ø
Insert
valve head
shaft side
shaft end
Insert Ø
Seat
Plate edge
shaft end
height
Seat concentr.
Meas. unit
mm
mm
mm
mm
mm
mm
mm
mm
Spec. size
31,0±0,15
6,985±0,007
6,985±0,007
4,08±0,07
5,8±0,1
103,0±0,15
2,0±0,2
max 0,03
100
100
100
100
100
100
100
100
ULV
31,15
6,992
6,992
4,15
5,90
103,15
2,20
0,03
LLV
30,85
6,978
6,978
4,01
5,70
102,85
1,80
0,00
Max. x
31,069
6,984
6,986
4,081
5,796
103,055
2,191
0,018
Min. x
30,929
6,981
6,980
4,045
5,751
102,908
1,915
0,000
Cp
1,77
4,04
2,00
3,44
3,42
1,52
1,24
Cpk
1,63
2,43
1,43
2,92
2,50
1,46
0,73
2,66
P%
0,00%
0,00%
0,00%
0,00%
0,00%
0,00%
0,00%
0,00%
Pe %
0,00%
0,00%
0,00%
0,00%
0,00%
0,00%
1,287%
0,00%
x-3s
30,9038
6,9805
6,9794
4,0488
5,7438
102,8982
1,9226
x
30,9878
6,9822
6,9830
4,0695
5,7732
102,9936
2,0816
0,0056
x + 3s
31,0718
6,9839
6,9866
4,0902
5,8026
103,0890
2,2406
0,0149
n
P% Pe %
= =
Nonconforming parts in % % of Nonconformity to be expected statistically
57
Table to Product Audit No.: 501.929.106.96 (Continued) Character
Seat roundness
Seat angle
Measuring unit
µm
Deg.
Spec. size
max.6.0
44
±
Surface roughness
Surface roughness
Surface roughness
Seat Ra
Shaft Ra
Mirrors Ra
Min
µm
µm
µm
07
max 0,5
max 0,2
max 0,4
30
30
30
n
30
ULV
6.0
44
07
0,5
0,2
0,4
LLV
0.0
43
53
0,0
0.0
0.0
Max. x
2,1
44
03
0,369
0,119
0,229
Min. x
0,9
43
57
0,175
0,078
0,049
Cp
1,37
Cpk
4,41
1,30
1,73
4,91
3,46
P%
0,00%
0,00%
0,00%
0,00%
0,00%
Pe %
0,00%
0,005%
0,00%
0,00%
0,00%
x-3s
43
55
x
1,4400
44
00
0,2604
0,0872
0,0707
x + 3s
2,4690
44
05
0,3989
0,1102
0,1658
P% Pe %
= =
30
Nonconforming parts in % % of Nonconformity to be expected statistically
58
11.6
Case Example Tires - Continental AG
Explanations : Extracts from the procedure
11.6.1
Scope and Frequency of Inspection
The tires to be inspected are taken from current production. There is a choice of various designs under consideration of -
the number of production pieces manufactured if applicable, varying customer requirements.
Tires from the store of the factory or - if not available - from the final inspection point (after completion of inspection has been completed) are to be examined. A minimum of 250 tires are to be examined, split across five or six differing designs. All tires are to be assessed visually. For two designs, the folowing additional tests are to be carried out: True running
−
Unbalance
−
X-ray examination
The product audit is to be carried out once a year.
11.6.2
Specifications, Methods
Inspection,
Measuring
and
Test
The same nonconformity catalogs and limit values apply as during final inspection of the tires. When checking the true running and unbalance, the measuring tolerance is also to be considered. The measurements are to be taken using the same testing machines as in the series.
59
11.6.3
Process
11.6.3.1
Auditor
The auditor is generally sent by the Quality Assurance Department. Trained auditors from other tire factories are also acceptable.
11.6.3.2
Visual Inspection
The visual inspection is carried out by the auditor himself. 11.6.3.3
Machine Tests
The machine tests are carried out by the respective operators in the presence of the auditor. 11.6.4
Documentation
The inspection, measuring and test results are recorded on forms and compiled into an audit report. The overall result is followed over a period of time. 11.6.5
Evaluation
During a product audit, no tires which exceed limit values or deviate from limit patterns should be found as a major nonconformance. Otherwise, immediate corrective actions, planned for such an instance, must be initiated. 11.6.6
Forms
11.6.6.1
Visual Inspection
11.6.6.2
Concentricity
60
QUALITY SPEZIFICATION
Aktiengesellschaft PRODUCT AUDIT
Plant:
XXXX
Tires off-standard for visual inspection
Date:
29. 05. 96
311
845
SIZE Off-standard tire category Numbers of tires inspected
4731 1
2
981 3
50
1
2 50
3
1
2 45
3
1
2
3
60
Tires on-standard Blisters
Rubber folds Lack of material
sidewall tread/belt miscellaneous sidewall miscellaneous sidewall bead miscellaneous
Bead condition Foreign matter (rubber in bead seat) Off-standard tires from curing
bladder miscellaneous
Circumferential flash
1
Lettering illegible or incomplete
Poor repair Poor trimming too severe not clean Dirty mold tire missing Inspector's stamp illegible Total off-standard tires units % Remarks: No made conformity Grinding
CONTINENTAL GROUP MC:
Date: 01.06.92
1 2,0
QUALITY CONTROL PLANT QUALITY AUDIT SYSTEM PAGE:
0 0,0
BOOK: 0.0 ISSUE: 5
61
QUALITY SPEZIFICATION
Aktiengesellschaft
SIZE: n=
PRODUCT AUDIT
Plant:
XXXX
Uniformity Passenger
Date:
29. 05. 96
981
Conicity (CON)
50 Radial Force Variation (RFV) (daN)
more than 20.0 19.1 - 20.0 18.1 - 19.0 17.1 - 18.0 16.1 - 17.0 15.1 - 16.0 14.1 - 15.0 13.1 - 14.0 12.1 - 13.0 11.1 - 12.0 10.1 - 11.0 9.1 - 10.0 I 8.1 - 9.0 7.1 - 8.0 IIIII II 6.1 - 7.0 IIIII IIIII III 5.1 - 6.0 IIIII IIIII II 4.1 - 5.0 IIIII IIIII I 3.1 - 4.0 IIIII 2.1 - 3.0 I 1.1 - 2.0 0.1 - 1.0 1st. Harmonic (RFH) (daN) more than 15.0 14.1 - 15.0 13.1 - 14.0 12.1 - 13.0 11.1 - 12.0 10.1 - 11.0 9.1 - 10.0 8.1 - 9.0 7.1 - 8.0 6.1 - 7.0 III 5.1 - 6.0 4.1 - 5.0 IIIII IIIII II 3.1 - 4.0 IIIII IIIII III IIIII IIIII III 2.1 - 3.0 1.1 - 2.0 IIIII III 0.1 - 1.0 I CONTINENTAL GROUP MC:
Date: 01.06.92
(daN)
more than 13.0 12.1 - 13.0 11.1 - 12.0 10.1 - 11.0 9.1 - 10.0 8.1 - 9.0 7.1 - 8.0 6.1 - 7.0 5.1 - 6.0 4.1 - 5.0 I 3.1 - 4.0 IIIII IIIII III 2.1 - 3.0 IIIII IIII 1.1 - 2.0 IIIII IIIII 0.1 - 1.0 IIIII III -0.9 - 0.0 -1.9 - 1.0 -2.9 - 2.0 -3.9 - 3.0 -4.9 - 4.0 -5.9 - 5.0 -6.9 - 6.0 -7.9 - 7.0 -8.9 - 8.0 -9.9 - 9.0 -10.9 - 10.0 more than -11.0 Lateral Force Variation (LFV) (daN) more than 15.0 14.1 - 15.0 13.1 - 14.0 12.1 - 13.0 11.1 - 12.0 10.1 - 11.0 9.1 - 10.0 8.1 - 9.0 7.1 - 8.0 6.1 - 7.0 5.1 - 6.0 II IIIII IIIII 4.1 - 5.0 IIIII IIIII IIII 3.1 - 4.0 IIIII IIIII III 2.1 - 3.0 IIIII IIIII I 1.1 - 2.0 0.1 - 1.0
QUALITY CONTROL PLANT QUALITY AUDIT SYSTEM PAGE:
BOOK: 0.0 ISSUE: 3
62
11.7
Case Example Complete Vehicle - FORD AG
Explanations:
11.7.1
Check of Conformity
A conformity review is a special type of product audit and serves as evidence for the manufacturer of complying with legal requirements towards authorizing agencies. The example shown, deals with the compliance of built parts with approved components listed in the system approval and approved by the applicable authorizing authority (in Germany, this is the Kraftfahrt Bundesamt [KBA]). The underlying legal requirement is a directive of the European Commission 70/157/EC „Extraneous Noise“ in the annex 96/20/EC.
11.7.2
Complete Vehicle
The examination of vehicles is carried out with the help of a checklist, whereby the user may decide on the scope with regards to nonconformity locations and types. The list can be customer, as well as production orientated. The outline of the checklist determines the sequence of the checks. The presented checklist can be used for a product audit of the manufacturer, as well as dealer. The evaluation of a product audit on complete vehicles should usefully be carried out using an EDP program, taking into account the complexity of vehicles. A coding system for parts, nonconformity locations and types serves those organizational areas which receive necessary information from it.
63
The use of the same terms for nonconformity locations and types serves organizational areas (e.g. customer services, warranty department, quality assurance, design and development) in continual product improvement of current and future models. The inspector / auditor indicates the found nonconformities in the checklist and explains the causes for complaint in the corresponding space provided. A nonconformity weighting can take place in the form of a points system, that reflects the share of customers who complain about this nonconformity (e.g. 90%, 50%, 10%, 1%). Other evaluation criteria are also possible. The evaluation can take place in the form of -
a Pareto-Analysis to clearly present the nonconformity focal points or a comparison with the previous month (first possibility to estimate the effectiveness of introduced corrective actions possible).
Furthermore, separate evaluation of individual production areas like press works/shell construction, coating, final assembly and others (suppliers etc.) is helpful when trying to find the cause of a problem. All evaluation examples can take place on the basis of differing time periods, daily, weekly, monthly or yearly. Longer evaluation periods serve the verification of corrective actions carried out.
64
QUALITY CONTROL LEGAL REQUIREMENTS
CONFORMITY – NOISE LEVELS
Page
1 of 1
PART INTEGRITY TEST
Issue:
17.10.95
Revised:
28.05.96
Country Code:
MODEL: Approval: Vehicle type: Chassis-No.: Version:
e13*70/157*96/20*4573*02
* W F 0 0 X X AJS 5-Door Sedan BJS 3-Door Sedan
ENGINE: Cubic capacity :
GEAR:
J CJS 5-Door St Wagon DJS 3-Door St Wagon
Petrol
Motor Code : H W A
1298 cm3
Output:
65
MANUAL
AUTOMATIC
4.27
3.84
Transmission ratio : Gear marking :
CATALYTIC CONVERTER
*
kW
FITTED
MUFFLER
AIR FILTER:
FRONT : MIDDLE : 1 0 5 2 9 2 2 4 REAR : 1 0 5 2 9 2 3 7 78896433
10629328
Tread radius -upper/lower limit
TIRES: Axle 1 / Axle 2 Axle 1 / Axle 2 Axle 1 / Axle 2 Axle 1 / Axle 2 Axle 1 / Axle 2
NOISE REDUCTION:
266 264 272 269 274
/ / / / /
2 66 2 64 2 72 2 69 2 74
Tires acc. to WVTA approval
mm mm mm mm mm
155/70 165/65 185/70 165/65 185/55
R13 R13 R13 R14 R14
Engine hood
Cowl top inside
Engine cladding Gear cladding
Cowl top outside Cowl bottom outside
Inspection result: Vehicle complies with the details listed in the approval and above: YES Date: Legend :
Name: 4
= to be noted for ok or deviation
NO Signature: = complete as necessary
= Change
65
Model: Variant:
Chassis Number:
Engine Code: Country Code:
Part 1: Lighting, Instruments and Controls Part 1 of the form contains functional tests regarding lighting, instruments and controls. Each position shown in the drawing is to be checked and marked in the corresponding box - " Ö " = O.K. or " X " when a repair or correction is necessary. Further details regarding the repair/correction are to be entered in the fields below.
Á
Function Lighting, Instruments and Controls
High Series shown; Deviations possible – not built-in or in different position in other variants
Seq. No.
Description
Eliminated
66
Á
Funktion Beleuchtung, Instrumente und Kontrollanzeigen Console upper – Lighting and switch, Mirror
Window winder mechanism; Window locks and catch hooks at side and rear
Sun shades
Seat adjustment
Side mirrors
Safety belt - front: Check belt for cleanliness and twists
Light switch: Headlights, Side lights
Door light switch
Multifunctionalswitch:
Door locks; incl. side sliding door and rear door or tailgate
Windshield wipers and washer Multifunctional switch: Horn, Headlights and Indicators
Safety belt – rear :
Headlight– washer
Passenger seats
Windshield washer (front and back)
Inside lights
Check belt for cleanliness and twists
Windshield wipers (front and back)
Seq. No.
Description
Eliminated
67
Part 2: Mechanics and Road Test
Part 2 of the form contains checks of the mechanical functions and the road test. Each shown position is to be checked and marked in the corresponding box - „ √ “ = O.K. or „ X “ when a repair or correction is necessary. Further details regarding the repair/correction are to be entered in the fields below.
Á
Mechanics O.K.
Repair
Repair O.K.
Battery charge status (recharge at 12,4 V or less) Cold start/Cold start system and control indication (Diesel) Vehicle underside Brake hoses / Brake lines - Leakage, damage or chafing Steering /Suspension connection./Ball and socket joint and collar - Damage/Safety Exhaust system - Leakage, damage and safety Electrical system (cables) - Safety, chafing and correct wiring Electrical connections - Damage, engagement and safety Leakage • Engine oil • Coolant • Gear lubrication / fluid • Steering /Power steering • Suspension • Brake fluid • Fuel lines and tank • Axle oil Vehicle exterior Tires incl. spare tire - Damage, correct size and air pressure Doors, engine hood, trunk/tailgate – Adjustment and fitting Headlights – Adjustment Engine space/trunk/loading space Engine hood - Unlatching, Lock and catch hooks Engine space – Signs of leakage /condition of the hoses • Engine oil • Coolant • Power steering fluid • Brake fluid • Fuel • Vacuum hoses, incl. vacuum pump (only Diesel) • Turbo supercharger Oil lines / hoses (only Turbo Diesel) Check and fill up • Engine oil • Brake fluid • Coolant (Check antifreeze – correct if leaking) • Power steering fluid • Washer water container
68
Part 2: Mechanics and Road Test
Á
Road Test
Ensure that the vehicle is tested under differing conditions and over different terrain; including hills, flat, even and uneven streets and different road surfaces. Consider the conditions on town and country roads; pay attention to any extreme and unusual noises, as well as vehicle reactions. Road test includes functional testing of :
O.K.
Repair Repair O.K.
P/N Start Accelerator pedal – acceleration Clutch and gear changes Handbrake Foot Brake Gear shifting and Kickdown (Automatic Gear) Steering / Power steering Temperature gauge Fuel gauge Speedometer / Tachometer Engine – performance Unacceptable noises • Rattling / Screeching • Vibrations • Wind noises • Mechanical noises Heating and operating control Smoke development - visual (Diesel) Further appliances After road test Warm start Automatic gear, oil level - check and fill up (engine warm) Adjust clock, enter radio code, check audio system, tune in local radio stations
69
Part 3: Vehicle Appearance Part 3 of the form contains checks regarding the interior and exterior visual appearance. Each shown position is to be checked and marked in the corresponding box - „ √ “ = O.K. or „ X “ when a repair or correction is necessary. Further details regarding the repair / correction are to be entered in the fields below.
Á
Damages / Condition
Damages / Condition
O.K.
Repair
Repair O.K.
Exterior – Damages / condition of paint work, metal and trim Interior - Damages / condition of trim and upholstery Interior – Water leakage Carpet – Laying, fit and fastening Loading space door/tailgate – fastening, fit and correct closing Window panes – Damages and fit Tools – available and complete Vehicle keys – complete and function in ignition, doors and fuel cap
Mark every found nonconformity with an " X " and a sequential number at the corresponding point on the drawing. Nonconformities and corrective actions are to be entered on the back page of this sheet using the sequential number.
Vehicle exterior
70
Part 3 : Vehicle Appearance Mark every found nonconformity with an " X " and a sequential number at the corresponding point on the drawing. Nonconformities and corrective actions are to be entered at the bottom of this sheet using the seq. number.
Vehicle interior
Part Affected
Description
Corrective Action
Eliminated
1 2 3 4 5 6 7 8 9 10
71
11.8
Case Example – Complete Vehicle - Volkswagen AG
The product audit for finished vehicles (Vehicle audit) serves to identify delivery quality and is carried out at car manufacturers on vehicles ready for delivery. It is orientated, on the one hand, to the buyer’s requirements, including those wishes not specifically expressed by the customer (such as, e.g. being waterproof). On the other hand, the results of the vehicle audit serve to recognize all nonconformities possible to identify and to initiate improvements for the benefit of the customer. The delivery quality is represented using a code number, the quality category (QC). It is the sum of the nonconformity points of a vehicle. The code number is thereby independent of the productive possibilities and conditions within a works and irrespective of the type of vehicle produced (passenger vehicles or trucks). It has proven useful in practice, that the quality category system is orientated to the school grading system. „Grades“ up to 7,0 are awarded. Thereby, it is possible that newly developed vehicles can be audited, additionally to auditing of the current series. Independent vehicle auditors are appointed to carry out the audits using an audit guideline describing the scale and procedure of the audit. The uniform use of the guideline is ensured by annual comparisons. The sample size per works is up to 1% of the daily production. The audit process is determined by the sequence in the checklist. A single checklist is used for all vehicle types, in order to ensure the comparability of the audit results. It includes the following: -
Engine space/vehicle underside check (as preparation to the test drive) Check headlight adjustment Test drive Engine space / vehicle underside check (Recheck) Check of waterproofing Assessment of the electronics, interior fittings, car body Assessment of the surface finish.
72
With the exception of the headlight adjustment check, no other measuring checks are made during the course of the vehicle audit. If the auditor discovers nonconformities, these are recorded according to type and location, severity of the characteristic (S = severe, M = medium, L = light) and for surface finishes, according to zones (e.g. Zone 1 especially high grade). After evaluation of the checklist, the audit results are regularly presented to the management and subsequently documented in the form of an audit report. Attached is an example audit report of an audited vehicle. This was raised using : -
the audit checklist the weighting / evaluation (A, B or C-Nonconformities) and curve to differentiate the quality category
Despite the simple evaluation method and graphic clarity of the quality category, the used „grading system“ also has disadvantages in practice: -
The „grade"-differences in the direction of poorer quality for equal steps in the points, get smaller so that the true deterioration is watered down (Reason: Exponential function of the differentiation curve).
-
For new production runs, the quality improvement, important for the production, is not always clearly recognizable. This can have a negative influence on employee motivation
73
Page 7 to 38
AUDIT - CHECKLIST
Nonconformity type/Weighting (S = Severe, M = Medium, L = Light) Surface Finish
Code
extrem nonconformity
Bulge / Dent
Scratches
Bumper front Zone 1
STF1A
S
L/S
L/S
Front wing Zone 1
FKL1A
S
L/S
L/S
Nonconformity
Motor/Engine
.........
Missing component
Incorrect component
Damaged
Test drive
.........
Noises when Sluggish dr iv ing
Waterproofing .. .. .. .. .
Extreme leakage
Water leakage
......... Cooling system
MKU10
S
S
S
- Piping -cooling system
MKU14
S
S
S
- Heating pulley
MKU15
S
S
S
......... A-Post cladding left top
DAP11
L/S
L/M /S
Exhaust system
MOT80
L/S
L/M /S
Glove compartment
HAK10
L/S
L/M /S
......... Rear left window
SSH31
S
L/S
Left front window
SSH11
S
L/S
.........
74
Weighting / Evaluation
Nonconformity points
Nonconformity evaluation
Effect on/reaktion of the customern
Detectable
> 100
90
70
A-Nonconformance
60
50
40
30
B-Nonconformance
20
10
C-Nonconformance
Safety risk, sluggish vehicle, breakdown vehicle
not acceptable, will certainly lead to customer complaints, extreme surface finish nonconformity
unpleasant, disturbing, complaint is to be expected, quality nonconformity present
requires improvement, complaints from demanding customers are to be expected, quality requirements are not fulfilled
Vehicle not available
Vehicle must make an unscheduled visit to the workshop
Customer will have the nonconformity corrected at the next planned visit ti the workshop
Customer partially expects a correction of the nonconformity
by all customers by demanding customers and trained auditors under consideration of the internal quality requirements
Correction of the nonconformity
Nonconformities to this extent must be corrected; ensure that no vehicle with this nonconformity reaches the customer
75
76
AUDIT-REPORT Type: A3 Prod. date: Chassis No.: Engine:
Market: USA 08.02.96 1HTM009903 2.0 l
Doors: 4 Insp. date: 20.03.96 Color: Special extras:
Required 1.5 523
Quality category: Points:
Assembly line: 2
Team: K Inspector: 005
Silver metallic Sliding sun roof
Gear: MQ
Actual 3.4 1390
Weighting of nonconformities No. of nonconformities : Points per nonconformity category :
A 3 230
B 1 40
C 90 1120
Nonconformity points per main group : 1. Electronics 90 2. Car body interior 180 3. Car body exterior 280 4. Surface finish 730 5. Engine/Gear 0 6. Test drive 40 7. Waterproofing 70
Indivi dual Res ults Nonconf location
Nonconf type
Comment
R esponsible Nonconf. pts./cat.
1. Electronics
Right rear light Left fog light ...........................
Assembly not satis. Cable bushing Assembly not satis. Not working A
T
10 70 A
C
A-Post Cladding left top
Assembly not satisfactory
Fit not satisfactory
T
10
C
AIRBAG Cover/ Strip
Assembly not satisfactory
Damaged
A
40
B
R
30
C
2. Car Body interior
Sheathing inside Dirty back right winding window ...........................
77
Nonconf location
Nonconf type
Comment
R esponsible Nonconf. pts./cat.
3. Car body exterior
Left front door
Fit not satisfactory
B
10
C
Protection strip left front door
Color difference
V
30
C
Left front window
Operating noise
R
30
C
P
10
C
Squeaks
...........................
4. Surface finish
Front wing Zone I
Paint inclusions
Front wing Zone III
Painting nonconformity
Paint run
P
10
C
Left front wing Zone I
Extreme surface nonconformity
Paint rip
B
90
A
A-post left Zone I
Dirty seal
Paint mark
P
20
C
Roof (car) Zone I
Dent/Bulge
B
30
C
...........................
5. Engine/Gear
...........................
6. Test drive
Tailgate
Noise when driving
Rattles
T
10
C
Selector plate
Noise when driving
Crackles
R
30
C
Water leakage
Bushing
T
70
A
...........................
7. Waterproofing
Tailgate
78
11.9
Example of a Product Audit Procedure - Mercedes Benz AG, Hamburg Works
11.9.1
Purpose
Determining the responsibilities and processes during a product audit.
11.9.2
Scope
Mercedes-Benz AG, Hamburg Works
11.9.3
Terms and Definitions
11.9.3.1
Product Audit
The product audit evaluates in a random sample the product quality of finally-inspected, ready for dispatch aggregates, with respect to their compliance with objectives from development, quality assurance, planning, legislation and customer expectations. The effectiveness of previous quality actions is assessed through the product audit, or respectively, the quality niveau of the production process is established. WM PRD QA QMT QWT DSP A
Works Management Production Quality Assurance Quality Assurance Measuring Technology Quality Assurance Material Technology Development, Sales and Purchasing Audit
79
11.9.4
Responsibilities
11.9.4.1
Product Audit
Overall responsibility
Head of QA
Responsibility for performance
Head of QA / Audit representative
Audit object
aggregates ready for dispatch
Auditors
employees assigned with auditing
Establish aggregates, inspection characteristics and number of random samples
Audit
Establish weighting factors for the audit characteristics
Audit
Raising and amending checklists
Audit
Release raised or amended checklists
Head of QA / Audit representative
Sampling of the aggregates and organization of the inspection procedure
Auditor
Carrying out of dimensional checks
Auditor, (QMT if required)
Carrying out of material tests
QMT
Writing of audit reports (Nonconformity report/Monthly report)
Auditor / QA/Audit
Reporting: Nonconformity report
to go to the person responsible for the audited aggregates
Monthly report
to go to WM, PRD, QA, EVE
Responsible for performance of corrective actions
Cost center of the audited aggregate
Controlling of corrective actions
Auditor, through audits in rotation
80
11.9.5
Description
11.9.5.1
Performing the Product Audit
The selection and determination of the random sample size and sampling frequency of the aggregate is to be assessed is carried out with the aim, to effectively identify the quality status of manufactured aggregates and, so far as necessary, to introduce corrective actions. The aggregates are taken as samples by the audit department from the production area, after final inspection/the last work process, without prior notice. The subsequent audit of the aggregates is carried out using a checklist. This includes all characteristics to be audited and evaluated. Following inspections are carried out on the aggregates, amongst others: -
visual and functional dimensional torque electrical material testing (if required)
Nonconformities found during the audit, are, depending on their severity, reported to each involved department immediately or daily for correction. Necessary immediate actions to eliminate nonconformities are monitored in parallel by the Quality Assurance Department. (see also flow chart of the product audit process). The quality evaluation summarizing the audited aggregate is presented in the form of a quality number (QN). The QN is obtained by taking the identified nonconformities and their weightings from the checklist and applying a given calculation within the EDP-aided product audit system. The QN is announced monthly for the aggregates.
81
The documenting of the audit results is carried out within the EDP-aided product audit system. A report is raised for each product audit carried out. Each month, a summary audit report about the audited aggregates is issued to the works management and responsible heads of department.
11.9.5.2
Product Audit Plan
In the product audit plan, all aggregates to be audited, the random sample size and sampling frequency are identified. Urgent quality problems are acted upon immediately. The audit plan is reviewed annually. New aggregates can be included in the product audit at any time. The product audit plan, currently applicable, is always on display in the audit area.
11.9.6
Additional Notes
11.9.7
Applicable Documents
-
Product Audit Plan for Aggregates Guideline No. 23 Product Audit of the Central Quality Assurance Department
82
11.9.8
Flow Chart of the Product Audit Process
START
1 Unscheduled audit for a specific reason
Scheduled audit according to product audit plan
Performing the audit QA
Any nonconformities etablished?
Yes
Critical nonconformity or substantial deficiencies found?
Yes
No
No Write and archive report QS
Information regarding results/deficiencies
END
Are corrective actions required?
No Write, distribute and archive report QA
END
Yes
Initiate corrective measures QA
Implement corrective actions PRD
Write, distribute and archive report QA
END
83
1
Assess further aggregates for the nonconformities/ deficiencies identified QA
Further nonconformities/ deficiencies found?
2
Yes
Introduce and implement immediate actions
No
Information about results/deficiencies
Initiate and implement corrective actions QA/PRD
Write, distribute and archive report QA
Monitor implementation in parallel QA
Further corrective actions required to eliminate cause of the nonconformity long term?
Yes
No
Write, distribute and archive report QA
END
END
84
2
Establish corrective actions, verbally or in writing QA/PRD
Implement corrective actions PRD
Monitor implementation in parallel QA
Write, distribute and archive report QA
END
85
12
Appendix: Reference to VDA 6.1
The following table provides a summary of product specific points from the VDA 6.1 questions in connection with DIN EN ISO 9004-1, which might need to be taken into account in a product audit. VDA 6.1 Question No.
Question Requirement/Explanation
Reference ISO 9004-1
01.2 b) b)
Quality o ob bjectives
4.3.1
Product-related objectives 01.6
periodical Management Reviews
5.5
02.5
Quality planning Process and product validation
5.3.3
02.6. B)
Quality plans Plans for production products
5.2.6
03.3
Internal quality audits Corrective actions Evaluation/weighting of deviations regarding risk/product safety
6.2.2
03.4
Product audit Audit plan ... ... after after final final inspection inspection
6.2.2
04.2
Training program in quality techniques Inspection and measurement techniques ... Product Audit
18.11
04..4 04
Introdu duc ction an and in instr structi ction pr programs fo for ne new or or al altered processes/prior to the introduction of self tests
18.1.3
04.5 04 .5
Qualiificat Qual icatio ions ns of em empl ploy oye ees nec neces essa sary ry fo forr leg legal al an and d/o /orr con conttract ractua uall requirements (Material tester certificate, Welder certificate etc.)
18.2
05.3
Internal losses ... through inadequate product quality
6.2.2
05.4
External losses ... through inadequate product quality
6.2.2
06.2
Identification of products (documentation duties)
19.
06.3
Procedure for recognition of product risks
19 a, b
06.4
Emergency plan for nonconforming products
19 d, e
86
VDA 6.1 Question No.
Question Requirement/Explanation
Reference ISO 9004-1
07.1 07 .1
Marrket Ma ket an anal alys ysis is of a prod produc uct’ t’s s qu qual alit ity y requ requiirem remen entts and expe expect ctat atio ions ns
7. 7.1 1 a-c a-c
07.3
Quotation Establishing technical and commercial costs (cost blocks)
---
07.4 07 .4
Qualiity requ Qual requir irem emen entts of the cust custom omer er towar owards ds the prod produc uctt an and d quality system
7.1 d
07..5 07
Produ roduct ct spe peci cifficat cation (Pe (Perfo rforma rmance spe peci cifficat cation ons) s) Performance characteristics, installation instructions, applicable standards, QA methods, packaging
7.2
08..1 08
Suitable product devel velopment plan for new products (milestones/network plans)
8.1, 8.2, 8.10
08..6 08
Resu esults of prod roduct development work ork docum cumented in speci ecifications
8.6, 8. 8.8 8
9.1
Suitable process development plan for new/altered products
8.1, 8.2 8.10
9.3.
Fulfilling product requirements through the process
8.2.4, 8.4.2a, b
10.1 10.1
Proc Proced edur ure e for for the the iden identi tifi fica cati tion on,, ma main inte tena nanc nce, e, revi review ew an and d rele releas ase e of quality relevant documents Identification: Clear classification of internal and customer specific basic data
17.1
11.1 11 .1
Qualiity requ Qual requir irem emen ents ts on the the prod produc uctts an and d serv servic ices es in orde order r documents for suppliers
9.2
11.3
Sample verification of purchased products
9.3 b
11.6 11 .6
Securi Secu ring ng of supp suppllied ied prod produc uctts an and d serv servic ices es// veri veriffying ying qu qual alit ity y evidence
9.7
11.7
Traceability of supplied products to suppliers
9.8
12.1
... Quality m me easures/activities o on n cu customer-supplied pr products
---
13.1.
Identification of products for internal processes
11.2
13..5 13
.. tth hat on only th those pr products wh which c co omply wi with tth he qu quality requirements reach the next process/process phase and dispatch
11.7
13.5
Data of products traceable, from dispatch back to entry
11.2
87
VDA 6.1 Question No.
Question
15.1 15 .1
Are Are all all insp inspec ecti tion on act activit ivitie ies s and and insp inspec ecti tion on proc proces ess s pla plans ns (pro (produ duct ct-related presentation) represented with inspection instructions?
10.1.3
15.3.
Are es established qu quality re records fo for de delivered pr products ma maintained?
12.1
15.5.
Are quality records maintained for end products?
12.3 a
21.2 21 .2
Pro Produ duct ct ob obse serv rva ation tions s an and d ea earl rly y warni arning ng syst system ems s reg regardi arding ng production failures in the operating phase
7.3 16.5 16.6
21.3
Analysis of production failures
7.3.
Table 3:
Requirement/Explanation
Reference ISO 9004-1
Product specific points in VDA 6.1 related to DIN EN ISO 9004-1
88
13
Bibliography
13.1
Standards
13.1.1
DIN EN ISO 8402 (1995)
Quality Management and Quality Assurance - Definitions
13.1.2
DIN EN ISO 9000, Part 1 (08/94)
Quality Management and Quality Assurance; Guidelines for selection and use
13.1.3
DIN EN ISO 9000, Part 2 (03/92)
Quality Management and Quality Assurance Standards; Generic Guidelines for Selection and Use of ISO 9001, ISO 9002 and ISO 9003
13.1.4
DIN EN ISO 9001 (08/94)
Quality Systems; Model for Quality Assurance in Development, Production, Installation and Servicing
13.1.5
DIN EN ISO 9002 (08/94)
Quality Systems; Model for Quality Assurance in Production and Installation
13.1.6
DIN EN ISO 9004, Part 1 (08/94)
Quality Management - and Elements of a Quality System – Guidelines
89
13.1.7
DIN ISO 10011 Part 1 (06/92)
Guidelines for Auditing Quality Systems; Auditing
13.1.8
DIN ISO 10011 Part 2 (06/92)
- Qualification Criteria for Auditors
13.1.9
DIN ISO 10011 Part 3 (06/92)
- Management of Audit Programs
13.2
Literature
13.2.1
VDA Publications for the Automotive Industry
Volume 1
Parts requiring Documentation at Car Manufacturers and their Suppliers – Documenting -, 1973
Volume 2
Quality Assurance of Supplies in the Automotive IndustrySupplier Selection/Sampling – Quality Performance in the nd Series -, 2 Edition 1995
Volume 3
Ensuring Reliability of Car Manufacturers and Suppliers – nd Procedures and Examples – 2 Edition
Volume 4
Quality Assurance prior to Serial Application Revised in two parts
Volume 6
Part A: Quality Audit - Basics -, 1997
Volume 6
Part 1: Quality System Audit, 1996
Volume 6
Part 2: Quality System Audit Services
Volume 6
Part 3: Process Audit, 1997
Volume 6
Part 5: Product Audit, 1997
90
Volume 6
Part 6: Product Audit Services
Volume 7
Basics for Interchange of Quality Data – Electronic Transfer of Quality Data, 1994
Volume 8
Guidelines for Quality Assurance of Trailer, Superstructure and Container Manufacturers, 1994
Volume 9
Quality Assurance – Emissions and Consumption -, 1995
13.2.2
Masing, Walter (Publ.) rd
Handbuch des Qualitätsmanagement, 3 Edition, 1994
13.2.3
DGQ-Publication 11 - 04 (Status 1995)
Quality Management Definitions
13.2.4
DGQ-Publication 12 - 62 (Status 1991)
Quality Assurance Manual/Guidelines for Preparation and Procedures
13.2.5
DGQ-Publication 12 - 63 (Status 1993)
System Audit
13.2.6
DGQ-Publication 13 - 41 (Status 1995)
Product and Procedure Audit
13.2.7
DGQ-Publication 14-18
Efficiency through Quality Management
91
13.3
References
-
Verband der Automobilindustrie e. V. (VDA) Westendstraße 61, 60325 Frankfurt
-
Carl Hanser Verlag, Munich
-
Springer-Verlag, Berlin, Heidelberg, New York
-
Beuth-Verlag GmbH, Berlin
92
Other VDA-FORMS FIRST SAMPLE TEST REPORT - new version • •
Cover Page, Order No. 2661 Test results, Order No 2662 Multipart form set, 5 copies (packed of 50 sets) • Outline form for process capability verification, Order No. 2663 Pad of 50 sheets - Minimum order 1 pad FIRST SAMPLE TEST REPORT - present edition First Sample Test Report - Report result, Order No. 5331 Multipart form set, 7 copies (packed of 50 sets) First Sample Test Report - Test result, Order No. 5332 Pad of 100 sheets SYSTEM - FMEA - new version Order No. 7422, DIN A3 format, Pad of 50 sheets FAILURE-POSSIBILITY- AND INFLUENCE-ANALYSIS (EMEA) - old Version Order No. 769, DIN A3 format, Pad of 50 sheets QUALITY SYSTEM AUDIT (Material products) Questionnaire (onIy questions) DIN A5, Pad of 10 sets á 12 sheets Evaluation documents Final evaluation of the quality system Summary of results Total grading Summary of evaluated questions Individual measures Corrective Aotions-Outline DIN A4, Pad of 10 sets of 5 sheets
The two pads form a unit and are only offered as a set Order No. 1749 Order: DRUCKEREI HENRICH GMBH Schwanheimer Straße 110, D-60528 Frankfurt Telephone (069) 96777-158, Telefax (069) 96777-159
93
