Psa
Psa
Psa
December 2006
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SUPPLIER QUALITY MANAGEMENT PRINCIPLES 1 Enquiry, supplier selection and contract stipulation
For each enquiry, PSA PEUGEOT CITRON places several potential suppliers in competition with one another. PSA PEUGEOT CITRON only issues enquiries to suppliers who have the prerequisites that are considered to be essential with respect to financial stability, quality, research and development, internationalisation, competitive advantage, industrialisation and logistics Supplier certification according to the automotive quality standard ISO/TS 16949 is a prerequisite for a business relationship with PSA PEUGEOT CITRON. For PSA PEUGEOT CITRON, the pilot of this phase is the production buyer who calls upon the services of the project manager, the quality guarantor from the Technical Area (GAQO) and the auditor from the Purchasing Division. The enquiry contains all the essential elements to enable the supplier to submit a complete and justified offer to PSA PEUGEOT CITRON. It contains the following information: - The technical specification containing all prioritised technical requirements that the product must satisfy in its various model life situations. It contains the product's quality objectives when new and used. - The Management and Quality Assurance Clauses (CMQ) specify the management measures and operating modes: during development and industrialisation: sharing and planning of tasks, deliverables and results expected from both parties and associated timing plans; during full production during the management of incidents in after-sales - The logistics specifications (logistics specifications and operating modes) - The general project data into which the enquiry fits (quantitative elements, key scheduling dates, location where the part is used...); - General purchase conditions
SUPPLIER QUALITY MANAGEMENT PRINCIPLES 2 Development of the Product and Production process
The two main objectives of this phase are: to develop products that satisfy the requirements in the technical specification to set up an industrial and logistic system to guarantee product conformity in the requested quantities and lead times. For PSA PEUGEOT CITRON, the pilot of this phase is the project manager of the Technical Area who calls upon the services of the quality guarantor of his technical area (GAQO) and the project buyer. The prioritised Technical Specification requirements dictate the product/process development structure. For all the requirements, the supplier and PSA PEUGEOT CITRON define the product/ process design justification and validation approach (calculations, manufacture and testing of prototype parts, product FMECA, process feasibility). The validation approach must be adapted to the level of criticality of each requirement. During the development phase, the supplier must elaborate and supply the following to PSA PEUGEOT CITRON: The product definition elements (drawings, bills of materials, list of materials used, list of components supplied by tier 2 suppliers, etc); The justification and validation elements of his product design; The process design (process layout drawing, production site, surveillance plan, process description and associated controls, list of tier 2 suppliers, etc) The justification and validation elements of his process design; The justification, validation and qualification elements for the products and manufacturing processes of his own suppliers for which he is responsible
SUPPLIER QUALITY MANAGEMENT PRINCIPLES 2.2 The supplier's product-process development phase
The work to be carried out by the supplier during this phase is characterised by a progressive construction of quality and by the simultaneous management of product / process development, associated performance indicators and surveillance plans. The progressive convergence of intermediate results towards the final result allows the qualification of the product and the production process: Develop a robust product definition: Establish a definition that satisfies the requirements in the technical specification and for which the industrial feasibility is verified. Define the measuring and monitoring system planned to control deviations from the production process and to ensure conformity of manufactured products Develop the production process: Define and set up the production system, manufacture and deliver products that comply with the definition (from a process that is representative of full production conditions) and finalise the production process. Qualify the product: Show that products that comply with the definition, which are manufactured according to a production-representative process and which possess in the technical specification. Qualify the production process: Show that the production process implemented is capable of producing products that comply with the definition (capable process) and in the required rates (process capacity). The tier 1 supplier must guarantee that the above actions are carried out by himself or by his suppliers for the whole technical perimeter.
Develop a robust product definition Qualify the product Define the measuring and monitoring system Qualify the production process Developp the production process EXPECTED RESULT: Compliant parts delivered in the planned quantity and leadtime
The production process is able to produce compliant parts under normal production conditions in accordance with industrial objectives
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Develop a robust product definition Qualify the product Define the measuring and monitoring system Qualify the production process Developp the production process EXPECTED RESULT: Compliant parts delivered in the planned quantity and leadtime
The production process is able to produce compliant parts under normal production conditions in accordance with industrial objectives
A Technical and Functional Characteristic (CTF) is: Physical magnitude that can be measured (length, mass, time, frequency...) or a qualifiable target parameter (e.g. material composition, colour with respect to master sample, OK/NOK criterion) of the finished product, the conformity of which is required to guarantee that the product, defined as such, satisfies all the requirements in the technical specification The Validation Plan describes the tasks which must be carried out in order to guarantee that the product / process solution meets all technical requirements. This plan is carried out by the supplier where he is responsible and by PSA PEUGEOT CITRON for the integration into the vehicle. It describes: the justification approach, calculations, tests the checking of results within tolerance limits The supplier: Proposes a product solution and flowchart of the associated production process Determines and prioritises the CTF for each requirement (nominal and tolerance) by modelling the functions required. produces the first part of the validation plan: carries out calculations, assessments or tests to justify the relevance of the solution with regards to the critical requirements, operating safety and reliability
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SUPPLIER QUALITY MANAGEMENT PRINCIPLES Define the measuring and monitoring system
The design satisfies technical requirements
Develop a robust product definition Qualify the product Define the measuring and monitoring system Qualify the production process Developp the production process EXPECTED RESULT: Compliant parts delivered in the planned quantity and leadtime
The production process is able to produce compliant parts under normal production conditions in accordance with industrial objectives
Based on the detailed product / production process design, for which risks have been analysed, the supplier determines all the characteristics to be monitored and the associated surveillance plan. In production, the surveillance plan guarantees the product complies with its design. Definition of a Monitored Characteristic: Characteristic of the finished product, or the product in the process of being transformed, or parameter of the manufacturing process that is expressed as a measurable physical magnitude of a qualifiable target parameter: that can be monitored in mass production to guarantee that the product complies with its definition at the lowest cost and/or manufacturing process performance. Definition of a Monitored Essential Characteristic (CSE): Monitored characteristic: conformity of which is essential so that in the manufacturing flow, the downstream flow stages (i.e. PSA PEUGEOT CITRON) can manufacture in compliance and thereby ensure that the completed component or vehicle complies with its definition, or for which non-conformity will be visible by the end customer. For a given part, a CSE should be a CTF as a matter of priority but may also be a characteristic of an intermediate product or exceptionally a process parameter. Based on the list of CTF , on the associated customer risks, on the provisional or known process complexity and variability, the supplier proposes a list of CSE.
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Develop a robust product definition Qualify the product Define the measuring and monitoring system Qualify the production process Developp the production process EXPECTED RESULT: Compliant parts delivered in the planned quantity and leadtime
The production process is able to produce compliant parts under normal production conditions in accordance with industrial objectives
The supplier: sets up his general production system and implements the specific tools necessary for the production of the part. puts in place verified and capable checking fixtures necessary for the development and for full production. begins to manufacture products from the production process, delivers parts from homogenous batches which comply with the definition. An inspection and measurement report is produced for each batch (in compliance with the measures planned in the PCP ), which gives the first process capability assessments for each measurable CTF . These results are part of the product validation in accordance with the validation plan. finalises his process by manufacturing the appropriate product quantities and assessing his production results. He updates the surveillance plan and the PCP in order to control production dispersion. delivers the requested quantities of compliant products to PSA PEUGEOT CITRON. The batches produced under homogenous conditions and which comply to the definition are accompanied by an inspection and measurement report . When product conformity has been obtained by reworking, this information is given in the inspection and measurement report. The proof required to qualify the process are progressively acquired during the course of the development. Progress is measured by the aptitude of the process to produce compliant products (particularly the convergence of process capability with respect to measured CTF)
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Develop a robust product definition Qualify the product Define the measuring and monitoring system Qualify the production process Developp the production process EXPECTED RESULT: Compliant parts delivered in the planned quantity and leadtime
The production process is able to produce compliant parts under normal production conditions in accordance with industrial objectives
The supplier checks for each CTF that the results are within tolerance limits. The supplier finalises the validation plan by showing that definition-compliant products, which are manufactured according to a production-representative process and which possess deviations in characteristics that are accepted by the definition, satisfy the requirements in the technical specification by carrying out the calculations and tests agreed with PSA PEUGEOT CITRON. In parallel, PSA PEUGEOT CITRON carries out tests and models the supplier solution into the system(s), evaluates the results and forwards them to the supplier if necessary. The progress of this activity is assessed jointly with PSA PEUGEOT CITRON by the percentage of requirements satisfied by the product. The deliverables for this activity are: The reports from performance or reliability tests and calculations. When all requirements are satisfied, the activity is complete and product qualification is delivered by the supplier.. Product qualification is required to deliver process qualification.
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Develop a robust product definition Qualify the product Define the measuring and monitoring system Qualify the production process Developp the production process EXPECTED RESULT: Compliant parts delivered in the planned quantity and leadtime
The production process is able to produce compliant parts under normal production conditions in accordance with industrial objectives
The supplier: completes setting up the production system, manufactures products from this system and measures and inspects his production at a frequency that is adapted to the state of progress of finalisation (capability). An inspection and measurement report is produced for each batch (in compliance with the measures planned in the PCP ), which gives the process capability assessments for each measurable CTF , completes process finalisation by manufacturing the appropriate product quantities and by assessing his production results when product compliance is obtained by additional checks and sorting operations, these elements are permanently included in the manufacturing process and the surveillance plan , assesses process capacity to produce compliant parts at the planned potential, delivers the requested quantities of compliant products to PSA PEUGEOT CITRON. The batches comply with the design and include the inspection and measurement report . When product conformity has been obtained by reworking, this information is given in the report. At the end of this activity, the proof required to deliver process qualification are acquired. The progress of this activity is measured by the convergence of process capability with respect to the CTF and by the ability of the process to produce compliant parts at the planned production rate.
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SUPPLIER QUALITY MANAGEMENT PRINCIPLES 2.3 Qualification confirmation for the supplier's manufacturing process
The supplier delivers products from the full production means under full production conditions. During the production ramp up phase at PSA PEUGEOT CITRON, the supplier carries out tighter checks in accordance with the PCP . The supplier provides proofs of conformity for all the characteristics within the specified tolerances over the time period agreed by PSA PEUGEOT CITRON and the supplier. The quality tracking at zero KM of products delivered as measured by PPM of defective parts is put in place.
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SUPPLIER QUALITY MANAGEMENT PRINCIPLES 2.4 Problem escalation and resolution process
Resolving problems that are encountered during development or industrialisation is based on open-minded communication, trust and working in partnership with the supplier. The purpose of the problem escalation and resolution process is to react efficiently in time to prevent or correct an unanticipated situation during development or industrialisation at a supplier's premises that may seriously compromise PSA PEUGEOT CITRON's vehicle or component project. At each of the meetings organised in the development and industrialisation management phase, the supplier will inform PSA PEUGEOT CITRON of the potential problems in the next phase. The supplier must alert PSA PEUGEOT CITRON of any problem that occurs between two meetings and process it immediately. If the problem cannot be resolved by the supplier's and PSA PEUGEOT CITRON's teams concerned, solutions with resources to match the specific problem will be implemented. To manage problem resolution, the level of hierarchical managers involved, both with PSA PEUGEOT CITRON and the supplier, increase based on the level of difficulties encountered and the risks involved.
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SUPPLIER QUALITY MANAGEMENT PRINCIPLES 4 Processing changes in the supplier's product and/or manufacturing process during mass production
For changes in the product and or manufacturing process at PSA PEUGEOT CITRON's or at the supplier's request, the measures planned in development and/or industrialisation apply to all the elements affected by the modification. Change refers to the following: a technical change to the product or a change of components, a modification in the manufacturing process at the supplier's premises, a change of supplier's production site or PSA PEUGEOT CITRON delivery site, a change in the supplier's procurement sources. When the change is initiated by the supplier: The supplier makes a written request to the PSA PEUGEOT CITRON buyer, supported by all the technical documents and all the measures that he plans to make the change safe. The PSA PEUGEOT CITRON buyer confirms his prior agreement to the supplier in writing. The measures implemented for the development and industrialisation of the change are adjusted to the scale of the modification to the product and/or process. The quality requirements in development and industrialisation must be satisfied. The product acceptance measures based on the procedures related to Initial Samples (EI) systematically apply. The changes never release the supplier of his responsibility to respect the performance levels in the specifications and the quality performance levels that were initially negotiated.
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SUPPLIER QUALITY MANAGEMENT PRINCIPLES 5 Mobilising suppliers on processing incidents occurring in the field
The supplier's active involvement in minimising the impacts of a quality failure both for PSA PEUGEOT CITRON and its customers is subject to particular care and attention. PSA PEUGEOT CITRON expects its suppliers to carry out the following actions: Continuously analyse the "warranty information" communicated by PSA PEUGEOT CITRON, alert the Purchasing Division of any change shown by this analysis and propose suitable actions to be implemented. Contribute to setting up and carrying out analysis procedures on vehicles with the aim of reducing, or even eradicating removal of unjustified parts. In a crisis situation: Appoint one representative who is capable of mobilising all the resources required to manage the crisis, guarantee the supplier's reactivity and to respect lead times. Check conformity of the characteristics of the supplies concerned and where appropriate, bring them into line as soon as possible by informing PSA PEUGEOT CITRON of the uncertain batches. Carry out all analyses required using the available design elements (cause and effect diagram, logs of known incidents, FMECA, validation results, part qualification). Carry out analyses on defective parts that have been returned to him and where appropriate, take part in analysis visits on customer vehicles. Propose and apply "immediate" robust solutions with the aim of eradicating all or part of the confirmed or probable causes identified in order to reduce and/or eliminate the customer effect.
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