Quality Manual SUPPLIER QA REV 13
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CAPSONIC SUPPLIER QUALITY MANUAL
Supplier Manual
Release Date: 8/28/2018
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Revision: 13
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TABLE OF CONTENTS
DESCRIPTION
PAGE
4. Context of the Organization
4
4.1 Understanding the Organization and its Context
4
4.2 Understanding the Needs and Expectations of Interested Parties
5
4.2.1 Capsonic Forever Requirements
5
4.3 Scope of Capsonic Quality Management System
6
4.3.1 Competitive Bidding
7
4.3.2 Customer Directed Suppliers
7
4.3.3 Suppler Profile/Non-Disclosure Agreement
7
4.3.4 Approved Supplier List
7
Supplier Checklist
8
Acknowledgment Sheet
9
4.4 Quality Management System and its Processes
10
5. Leadership
10
5.1 Leadership and commitment
10
5.1.1 General
10
5.1.2 Corporate Responsibility
10
5.2 Policy
10
5.2.1 Establishing the Quality Policy
10
5.2.2 Communicating the Quality Policy
10
5.3 Organizational Roles, Responsibilities and Authorities
10
6. Planning
10
6.1 Actions to address Risk and Opportunities
10
6.2 Quality Objectives and Planning to Achieve Them
11
6.3 Planning of Changes
11
7. Support
11
7.1 Resources
11
7.1.1 General
11
7.1.2 People
11
7.1.3 Infrastructure
11
7.1.3.1 Plant, Facility Planning
12
7.1.4 Environment for the operation of processes
12
7.1.5 Monitoring and Measuring the Resources
12
7.1.5.1 General
12
7.1.5.2 Control of Capsonic Supplier/Owned Equipment
13
7.1.5.3 Gage Instructions
14
7.1.5.4 Equipment Identification
14
7.1.5.5 Measurement System Analysis
15
7.1.5.6 Inspection, Measuring and test equipment records
15
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7.1.5.7 Tool/Mold Management
16
7.1.6 Organizational Knowledge
19
7.2 Competence
19
7.3 Awareness
19
7.4 Communication
19
7.5 Documented Information
20
7.5.1 Control of Design Records
20
7.5.2 Control of Specifications
21
7.5.3 Control of Procedures
21
7.5.4 Record Retention
21
8. Operation
22
8.1 Operational Planning and Control
22
8.1.1 Advanced Product Quality Planning (APQP)
22
8.2 Requirements for products and services
22
8.2.1 Customer Communication
22
8.2.2 Determining the requirements for products and services
22
8.2.3 Review of the Requirements for Products and Services
22
8.2.3.1 Process Characteristics Notes
22
8.2.4 Changes to Requirements for Products and Services
23
8.3 Design and Development of Products and Services
23
8.3.1 General
23
8.3.2 Design and Development Planning
23
8.3.3 Design and Development Inputs
24
8.3.4 Design and Development Controls
25
8.3.5 Design and Development Outputs
30
8.3.6 Design and Development Changes
30
8.4 Control of Externally Provided Processes, Products and Services
30
8.4.1 Conditions of Business Placement and Purchase Orders
30
8.4.5 Compliance of Business and Purchase Orders
31
8.4.6 Duration of Supply
33
8.4.7 Counterfeit Control Process
33
8.4.8 Scheduling and Releases
33
8.4.9 Cumulative (CUM) and Material Authorization
34
8.5 Production and Service Provision
35
8.5.1 Control of Production and Service Provision
35
8.5.2 Identification and Traceability
38
8.5.3 Property Belonging to Customers or External Providers
41
8.5.4 Preservation
41
8.5.5 Post Delivery Activities
47
8.5.6 Control of Changes
47
8.6 Release of Products and Services
49
8.7 Control of Non-Conforming Outputs
49
9 Performance Evaluation
51
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9.1 Monitoring, Measurement, Analysis and Evaluation
51
9.1.1 General
51
9.1.2 Customer Satisfaction
52
9.1.3 Analysis and Evaluation
55
9.2 Internal Audit
55
9.2.1 Supplier/Sub-Contractor Internal Audits
55
9.3 Management Review
56
9.3.1 General
56
9.3.2 Management Review Inputs
56
9.3.3 Management Review Outputs
56
10 Improvement
56
10.1 General
56
10.2 Non-Conformity and Corrective Action
56
10.2.1 Warranty
56
10.3 Continual Improvement
56
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4. Context of the organization
4.1 Understanding the Organization and its Context:
Capsonic Automotive and Aerospace (“Capsonic”) is committed to the continuous
improvement of its people, its products, its processes, and its support of end
customer programs. Growth of our business, and therefore growth of business with
our supply base, is dependent upon becoming the market leader for cost, quality,
delivery, and innovation. We recognize the effect of our Supply Base on our ability
to accomplish this strategy at a pace that matches this plan. Following industry
standards, Capsonic expects zero defects from our suppliers. In order to do so we
must establish a consistent set of requirements/ expectations that define the
necessary performance elements. Further, Capsonic must commit to its suppliers to
support all areas of supply coordination that such a shared relationship entails.
Capsonic is, therefore, establishing this manual. This outlines the policies,
procedures, documents, communications, and expectations that Capsonic has in
each of the key supply disciplines. It also defines the procedures and
documentation that Capsonic will use to support the supplier in their commitment of
zero defect supply. Due to the diverse markets that Capsonic supports, the
requirements in this manual have been written to reflect the procedures common to
all product lines, as well as define requirements that are unique to a specific end-
market use. Unique requirements, as applicable, will be referred to on Purchase
Order.
This manual will be openly available to all existing and new potential suppliers
commonly through the Capsonic Website. Capsonic seeks clearly defined
relationships of the highest integrity with its suppliers, and this manual, along with
the Terms and Conditions of Purchase Order, will provide the defined basis in
which the supply relationship will be conducted. Unless included on Purchase
Order, no exceptions, or additions to the requirements of this manual are allowed.
Any request made to a supplier that is not defined in this way should be referred to
Capsonic Management.
We will hold suppliers accountable to the expectations outlined here, and
understand that suppliers expect to do the same in return. We will be open in citing
supplier performance, and will use same to make business decisions about the
sourcing of new business opportunities. Uncorrected lack of performance by
suppliers to these expectations may lead to loss of business.
In addition to the procedures and policies outlined here, Capsonic further intends
each supply relationship to be conducted in a logical, professional, and honest
manner, yielding a long and valuable relationship for both parties. We ask suppliers
to proactively identify & communicate problems and opportunities in order that we
can logically weigh choices and execute correctly. Ultimately, we ask that each
supplier conduct its business with Capsonic using the philosophy of Continuous
Improvement.
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GENERAL INFORMATION
Capsonic Operating Locations
Corporate Address: 260 South Second St. Elgin, IL 60123
260 South Second St. Elgin, IL 60123
Sales Office Address:
3121 University Dr. Suite 120, Auburn Hills, MI 48326
Phone: 248-754-1100 Fax: 248-754-1104
Engineering Office Address:
1595 Highpoint Drive Elgin, IL 60123
Phone: 847-888-7212
Fax: 847-888-8124
Distribution Center Address:
Vista Corporate Center # 2
7B x Grey Street , El Paso TX 79906
Phone: 915-872-3590 Fax: 915-872-3501
Manufacturing Address:
6551 Hermanos Escobar - Parque Industrial Magnaplex Juarez,
Chihuahua 32320, Mexico
General email inquiries:
capaa@capsonic.com
Internet Address:
www.capsonic.com
Any questions or concerns with information that has been supplied by Capsonic should be
immediately addressed with the appropriate the Capsonic personnel. See the Capsonic Website for contact
information.
4.2 Understanding the Needs and Expectations of Interested Parties.
4.2.1 Capsonic “Forever Requirements”
The foundation of a good relationship with our suppliers is based on open, effective,
and proactive communication. The occurrence of non-conforming product,
unauthorized changes and related supply or capability issues present risk to both
Capsonic and to our customer when not communicated and managed effectively.
This risk also generates when these occurrences happen at the Tier 2, 3 or 4
suppliers or sub- contractors facilities.
Our “”Forever Requirements” are as follows:
Proactively communicate with your Customer Sites/Location(s). Know
when to raise the “red flag”.
Notify the Customer of proposed material or process changes.
Notify the Customer of proposed manufacturing location changes.
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atch for Internal issues within your company that could affect supply
and tell your Customer about them.
Notify the Customer of potential supply and/or capability issues.
Compliance with the Environmental, Regulatory and Government entities
of the country in which the productive activity is performed.
Supplier is responsible to maintain compliance to this manual and all its
posted updates.
The intent of these requirements is to eliminate surprises and special cause events
that can impact upon Capsonic’s customer(s). The requirements apply to ALL
suppliers and sub-contractors included as part of the process of manufacturing our
components, and it is expected that you will manage your entire supply base with
these principles.
We consider these requirements paramount in establishing a relationship of trust
with our suppliers. Violation of any requirement will result in escalation to the
Supplier Quality and Purchasing organizations within Capsonic. If deemed
necessary, a Supplier’s ISO/IATF/AS Registrar will be contacted and asked to
conduct the appropriate investigations and assessments, at the Supplier’s expense.
Continued non-compliance could lead to loss of business. If you are uncertain when
or for what reason(s) Capsonic should be notified, you are asked to contact your
Capsonic Supplier Quality Engineer for guidance.
4.3 Scope of Quality Management System
Vendors approved to supply products or services to Capsonic will be
authorized during the Sourcing Meetings and will have as a minimum the
authorization of the Plant, Purchasing and Supplier Quality Managers. The supplier
is to provide Capsonic with current copies of their registration certificates.
Additionally, the supplier will notify Capsonic of any change in registration status.
The Purchasing Manager will require an evaluation of a potential supplier’s quality
system from the Quality Manager when it has been identified. Following a
satisfactory assessment, potential new suppliers will be added to the Approved
Supplier List for consideration of future business awards. Supplier Quality System
assessment will be performed having as baseline the requirements from the
ISO9001, ISO14001, IATF16949, and/or AS9100 Rev D standards. During this
assessment, Materials Management and Logistics structure will be evaluated by
using the criteria described in the MMOG/LE (Materials Management
Organization Guidelines and Logistics Evaluation), in which Capsonic
encourages suppliers to use to comply with Capsonic requirements.
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Capsonic Specific Requirements will supersede the OEM requirements, if and only
if the Capsonic requirements are more stringent or are in addition to the OEM
requirements.
If Capsonic not have defined requirements on some clauses, a legend "No Capsonic
Specific Requirements for this Section" must appear. This legend means that
Requirements for ISO9001/IATF16949/ISO14001 and/or AS9100 are applicable,
and there is no additional requirements by Capsonic.
4.3.1 Competitive Bidding
Potential New Suppliers follow the competitive bidding process
as the method for receiving business awards from Capsonic,
therefore supplier must submit quotations consistent with the
instructions provided by Capsonic Purchasing group, this must occur
through initial submission of a Request for Quotation for goods or
services not previously supplied to Capsonic.
4.3.2 Customer Directed Suppliers
In those instances where sources are directed by Capsonic’s
customer for a specific part or commodity, the directed sources shall
meet all requirements as specified in this Supplier Manual and may
also undergo an assessment review.
4.3.3 Supplier Profile/Non-Disclosure Agreement
All suppliers are required to furnish a supplier profile consisting of
general information, company contacts, etc. Other data may also be
required, such as financial and technical information and union
contract status as a means for supplier consideration and monitoring.
It is the supplier’s responsibility to provide an updated profile
whenever there is a change in the reported information . CAPSONIC
has developed a JADE Portal for managing supplier’s information.
Suppliers must keep their data updated.
All suppliers must have an active approved Non-Disclosure
Agreement in place with Capsonic in order to receive Requests for
Quotation and documentation associated with parts that have
proprietary restrictions.
4.3.4 Approved Supplier List
An Approved Supplier List exists for production suppliers and is
utilized by Capsonic for strategic sourcing decision-making by
commodity or service performed. The listing is updated on a
continuous basis in order to reflect input from the assessment,
development and performance monitoring systems maintained by
Capsonic
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SUPPLIER
CHECKLIST
Supplier Name: Date Submitted:
Along with the signed acknowledgment page, the following documents are posted in the JADE library.
Supplier Capability Survey or Supplier Profile*
Supplier Design Review Checklist QAF-010-033
Feasibility Commitment Form QAF-SQM-001
Packaging Specifications Form QAF-010-032
Non-conforming material QAP-8.7.1-001
Air Shipment Control PRF-003-006
Premium Freight PRF-003-008
Sample Labels for Each Part Number
ISO 9001 :2015 Certificate *
IATF 16949 : 2016 Certificate *
ISO 14001 :2015Certificate *
Certificate of Liability Insurance
Minority Status Certificate (if applicable)
Tooling Standards Form QAF-SQM-002
Duns #
Please enclose this checklist with the required information and note below reason(s) for any omission(s).
*Note: It is the supplier’s responsibility to provide updated copies of the certificates of registration
and supplier profile whenever there is a change in the reported information
Supplier is responsible to maintain compliance to this manual and all its posted updates.
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ACKNOWLEDGMENT SHEET
Please retain this sheet and return a signed copy to the appropriate Buyer, indicating that you have
received, reviewed and accepted in principle the contents of this manual. All communications with
respect to the contents of this manual are to be addressed initially in writing to your designated
Capsonic Buyer. Comments or concerns should be noted below prior to returning your
acknowledgment sheet copy. Updates to this manual will be posted on the Capsonic website.
Comments (Please Type):
Supplier Name, Address, Telephone Number, E-Mail Address (Please Type):
Authorized Signature
Authorized Signature
Date Signed (Please Type)
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4.4 Quality Management System and its Processes
No Capsonic Specific Requirements for this section.
5. Leadership
5.1 Leadership and commitment
5.1.1 General
No Capsonic Specific Requirements for this section.
5.1.2 Corporate Responsibility
Supplier shall comply with the required on this Supplier Manual, and
with the Required on Purchase Order Terms and Conditions
http://www.capsonic.com/CA2/#/terms_conditions.
5.2 Policy
5.2.1 Establishing the quality policy
No Capsonic Specific Requirements for this section.
5.2.2 Communicating the quality policy
No Capsonic Specific Requirements for this section.
5.3 Organizational roles, responsibilities and authorities
Supplier shall notify to Capsonic any changes to senior management
responsible for Product Quality or company ownership.
6. Planning
6.1 Actions to Address Risk and Opportunities
Suppliers will be accountable for all costs associated with an interruption in
material supply to Capsonic resulting in a shut-down, due to labor, utility
disruptions or equipment failures.
Suppliers must maintain an effective contingency plan, in order to mitigate
undue risk to Capsonic, in the event of utility disruption, labor disruption
and/or equipment failure. The intent of the contingency plan is to
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reasonably protect the procuring division from disruption of supply in the
event of an emergency.
Material forecasting information will be communicated to the supplier
through weekly scheduled releases. While this information is an indication
of future material requirements, it is not considered binding on the part of
Capsonic unless supported by a specific purchase order.
The supplier must maintain the ability to absorb a 15% volume increase
(measured with reference to the nominal quoted volume) at all times without
additional cost to Capsonic.
Material authorization will typically include three to six weeks (combined
finished goods, work in process and raw material) and is determined by
Capsonic. In any case, additional material lead times require specific
approval from Capsonic's Purchasing Department.
The supplier is expected to maintain sufficient safety stock and finished
goods inventory to accommodate 100% on-time delivery. Short shipments
must be communicated immediately, along with a Corrective Action/
Recovery Plan.
Suppliers will abide by and provide all required documentation for progress
tracking as spelled out in the purchase order and this supplier manual.
6.2 Quality objectives and planning to achieve them
No Capsonic Specific Requirements for this section.
6.3 Planning of changes
No Capsonic Specific Requirements for this section.
7. Support
7.1 Resources
7.1.1 General
No Capsonic Specific Requirements for this section.
7.1.2 People
No Capsonic Specific Requirements for this section.
7.1.3 Infrastructure
No Capsonic Specific Requirements for this section.
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7.1.3.1 Plant, Facility Panning
As a condition of business, all suppliers/sub-contractors must be
prepared, on request, to provide information required to substantiate
the capacity to provide necessary products, commodities and
services.
This shall include, but is not limited to, technical capability
systems/procedures to evaluate key product characteristics, price
structure, and financial information.
Suppliers will hold a meeting with Capsonic SQE to complete a
design review, to obtain a supplier commitment that product or
component and service can be provided as described in the
drawing/specification. Suppliers must provide evidences derived
from this review and sign off completion will be provided by fulfill
the information required in SDR form (Supplier Design Review
QAF-010-033). In addition, the supplier must be prepared to provide
proactive initiatives such as cost reduction proposals and recycling
programs to Capsonic.
7.1.4 Environment for the operation of processes
No Capsonic Specific Requirements for this section.
7.1.5 Monitoring and Measuring Resources.
7.1.5.1 The supplier must have a documented system for the control,
calibration, analysis, use and maintenance of all gages, fixtures,
measuring/testing instruments and equipment. This system must
include a register of the monitoring, measurement and inspection
equipment, as well as to define the process for the recall for
calibration or verification.
7.1.5.1.1 Gages, fixtures, and measuring/testing
instruments/equipment are to be calibrated and adjusted at
prescribed documented intervals or prior to each use, against
certified equipment having a known valid relationship to
nationally recognized standards.
7.1.5.1.2 All gages and test equipment must be calibrated /
verified for accuracy annually at a minimum.
7.1.5.1.3 Gages, fixtures, and measuring/testing
instruments/equipment are to be assessed for accuracy and
repeatability /reproducibility (R&R) at prescribed
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documented intervals. Paying special attention to Inspection,
Measurement and test equipment used to confirm a critical
dimension/characteristic documented in Capsonic Drawings.
Max 10% R&R will be accepted by CAPSONIC. Refer to
MSA AIAG Manual.
7.1.5.1.4The environmental conditions must be suitable for
use and calibration/verification of the equipment.
7.1.5.1.5 Handling, preservation and storage is to be such that
accuracy and fitness for use is maintained.
7.1.5.1.6 Documented procedures and instructions for the
control, calibration, analysis, use and maintenance of all
gages, fixtures and measuring/testing instruments and
equipment are to be available at the point(s) of use.
7.1.5.1.7 Records associated with the control of inspection
gages, fixtures and measuring/testing instruments and
equipment are to be properly maintained and available for
review upon request.
7.1.5.1.8 Control, acceptance criteria and procedural
requirements are to be in accordance with the latest released
edition of the AIAG Measurement System Analysis
Guideline (MSA).
7.1.5.1.9 If supplier maintain the scheme of using
employee own gauges, these should be calibrated too as
per previous paragraphs description.
7.1.5.1.10 The calibration certificate must be on file at the
supplier’s facility, and be traceable to the actual gage
identification information. Calibration service provider must
be accredited in ISO/IEC 17025 and / or A2LA.
7.1.5.2 Control of Capsonic Supplied/Owned Equipment
7.1.5.2.1 All tooling and equipment provided by, and/or
property of, Capsonic provided for use at the suppliers/sub-
contractors facility shall be monitored with respect to the
latest product engineering change level for which each piece
of equipment is used.
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7.1.5.2.2 Capsonic shall monitor the recall, modification,
update, verification, return and/or replacement of all such
equipment, through the use of status forms that Suppliers are
required to supply and keep updated
7.1.5.2.3 All suppliers/sub-contractors shall have a
documented system in place for monitoring all changes to the
Capsonic supplied/owned tools and/or equipment. The
system shall address an annual verification procedure.
Suppliers should provide evidence of their verification
procedure to Capsonic.
7.1.5.2.4 All tooling, inspection and test fixtures supplied by
and/or property of Capsonic are to be permanently marked
with clear identification indicating ownership and Capsonic
Asset Number assigned.
7.1.5.2.5 Pictures of changes performed to all tooling,
inspection and test fixtures must be submitted to CAPSONIC
Purchasing personnel as well as a description of the change,
as evidence of this activity performed. These documents and
pictures must be approved by CAPSONIC SQE.
7.1.5.3 Gage Instructions
Operating instructions must be displayed at every inspection station
requiring the use of a gage or other measuring /testing device used in
the process, control, or checking of product manufactured for
Capsonic. The operating instruction must describe the proper
methodology for use the instrument during inspection. These
instructions must include a reference to the gage identification
number, and revision level, and be approved by appropriate
management. Whenever there is any change to the inspection
procedure that affects the use of the gage, or when any identification
information is revised, the operating instructions must be updated to
reflect the current status.
7.1.5.4 Equipment Identification
All tooling, general equipment, gages, fixtures, measuring devices
and test equipment, including employee owned must be identified as
follows:
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•Unique identifier
•Revision level (when applicable)
•The calibration date and the next calibration due date.
•Name/initials of the person who performed the calibration.
7.1.5.5 Measurement System Analysis
7.1.5.5.1 Evidence is required that appropriate statistical
studies have been conducted to analyze the variation
associated with each type of measuring and test
equipment system. Analytical methods and acceptance
criteria must conform to the latest released edition of the
AIAG Measurement System Analysis (MSA) manual.
7.1.5.5.2 The supplier must have a documented system in
place to control, calibrate, and maintain the proper function
and accepted level of gage repeatability and reproducibility
(R&R) of all inspection fixtures, gages, measuring / testing
instruments and equipment.
7.1.5.5.3 Supplier must demonstrate Measurement,
Inspection and test equipment used to confirm proper control
of Critical, Major and minor Characteristics are capable and
adequate for the intended use, linearity and bias must be
determined in the MSA.
7.1.5.5.4 Supplier must use Measurement, Inspection and
Test Equipment with variable data output
to determine the capability of the processes to meet the
Critical, Major and Minor characteristics identified in
Capsonic drawings.
7.1.5.6 Inspection, Measuring and Test Equipment Records
Records of calibration, verification, maintenance and statistical
analysis activities must be traceable to the part revision level
demonstrating conformance to standards and corrective actions taken
where applicable. Records must include:
•Device identification number and change level (when
applicable).
•Date of calibration/analysis and identification of the person
performing the activity.
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•Conditions and readings as received and prior to calibration.
•Calibration results and actions taken (i.e. replace, repair,
etc.)
•Gage R&R results.
•Action taken on products measured with out of calibration
and/or non-capable equipment.
Note: Capsonic must be notified if suspect or discrepant product has
been shipped as a result of out of calibration gages, fixtures,
measuring or test equipment.
7.1.5.7 Tool/Mold Management
7.1.5.7.1 Tool/Mold Development.
Suppliers must have a systematic process in place to ensure Tool
Quoting and development processes ensures the end product must
comply with Capsonic/Customers expectations. These processes
must make considerations that include information managed at
supplier’s shop by incorporating common design standards and
strategies into the quoting process, such as, material shrinkage
parameters, part rotation and tip positions, and the use of standard
components and machine configurations in such manner that will
ensure the quote reflects how design and engineering will approach
the job.
Capsonic purchasing department will request the basic information
to supplier developing a tool using the form QAF-SQM-002
submitted to Capsonic SQE for analysis of content. This information
will be used by Capsonic team to determine the supplier and tool
structure quoted.
The Supplier (Mold/Tool Quality Planning Team) should address the
development requirements by adding the key/critical items required
to be completed into a Timing Chart. This chart should ensure that
the activities planned for the new mold and tooling to be developed
are capable to meet Capsonic expectations and deliver the mold/tool
on time. Supplier progress should be monitored to assure completion
to surpass planned production tryout.
The above requirement will be flow down to sub-tear when supplier
uses a third party to develop the tool required by Capsonic
product/processes. Capsonic reserves the right to access sub-tiers
when progress of the tool/mold development is not presented to
Capsonic according to the original plan.
Suppliers must first establish a streamlined process that covers all
deliverables and milestones from the initial price quotation to the
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finished product samples. Inputs and outputs for each step in the
process need to be clearly identified, along with quality expectations
and the value added to the finished product. Once the entire process
has been laid out, specific technologies and methods must be
considered based on their impact on the process outcome.
Suppliers must be using Capsonic Mold Design Specification
Guidelines for tool under construction. These standards will be
assessed by Capsonic Engineering, SQE, and Buyer.
Supplier must use the proper 3-D software tools (no 2-D model will
be acceptable) during the design process to achieve standardization
and synchronization across design and manufacturing, to minimize
errors that may impact delivery. Software used must be able to
identify manufacturing issues proactively. These issues must be
documented as part of the potential failure modes that will be used
during the PFMEA development. Examples of these conditions are
detect potential collisions, verify correct shrink values and determine
whether parting surfaces are able to be manufacture.
Supplier must maintain the model obtained from this software
throughout the design and manufacturing processes, if changes are
required these must be controlled and validated (before the
incorporation in the tool) from design to manufacturing and
assembly. These changes /alterations must be approved by
CAPSONIC Design Engineer that will be performed through
CAPSONIC SQE assigned.
7.1.5.7.2 Tools/Molds Approval and Identification.
Using documented timeline provided by Capsonic SQE, supplier
must identify dates for production of samples required to confirm the
tools will produce the product required by Capsonic. Supplier must
make the considerations to run a minimum of 300 pieces or 8 hours
of production rate to consider an acceptable sample size to be
submitted as part of the PPAP process requirement (Automotive),
and FAI (Aerospace Market) the sample size of this trial will be
agreed with Capsonic SQE. Supplier will provide all the
documentation generated to obtain the final status of the tool, as well
as the documents required in the PPAP/FAI package. To obtain full
Capsonic approval of the tool supplier must provide the following
but not limited to:
- CAD Modeling files used to develop the tool/mold and that
describes the final status of this (such as is approved in PPAP
or FAI).
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- Pictures of the mold properly identified with the asset tag
provided by Capsonic personnel. Pictures my include legends
describing final property of the tool/mold.
- Presentation with pictures describing the product and
cavities for the mold (if applicable) or tool progressions.
- Pictures must be legible enough and can include key
features/characteristics that demonstrate the tool in the
picture is the same producing the component required.
Highlights of these features can be described and
communicated in these documents/pictures.
7.1.5.7.3 Tools/Molds Repair and Corrections Process.
Supplier must notify CAPSONIC Buyer /SQE of any identified
problem in a tool/mold that is derived in a quality issue in the
component provided to Capsonic, and that is not subject to warranty.
The causes of the problem that can be associated to; tool/mold not
developed by the supplier, or the life of the tool and it use caused to
be worn.
7.1.5.7.4 Supplier must complete the supplier tool modification
approval form QAF-06-070 to include all the activities that are
required to be performed to the tool if a problem is identified to
operate in an efficient manner the tool or suffers damage. This form
must by filled out by a supplier and approved by a Capsonic SQE
any time a production tool is scheduled to be taken out of production
for more than 48 hours for service, modification, or engineering
change.
7.1.5.7.5 Supplier must provide completed form with the need to
repair/correct molds tools to Capsonic SQE. Supplier must appoint
the area that requires correction/repair in the tool and correlate this
condition in the component produced, via business case for the tool
in concern with Capsonic buyer when required. This activity will be
documented including tooling photos as applicable.
7.1.5.7.6 Capsonic SQE and buyer must make considerations based
on component demand and how critical the item is for the finished
good/ customer requirements. They will use the input from
purchasing, production, and engineering to make the decision to
repair/correct the tool, after this is agreed with in Capsonic
organization. This authorization is officially communicated to
supplier through purchasing department to correct the tool.
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7.1.5.7.7 Purchasing will request to supplier to respond to the RFQ.
This will be supported with the previous form submitted to SQE and
including the Supplier Tools Form QAF-06-071 to describe the cost
of the service.
7.1.5.7.8 After tool is repaired PPAP or FAI documents will be
submitted by supplier to SQE for approval when applicable.
7.1.5.7.9 Tooling build suppliers will need to provide weekly status
updates on the Capsonic provided timeline and to work directly with
the Capsonic appointed SQE to fulfill the update requirements and
abide by the Capsonic Tooling Standards form.
7.1.6 Organizational Knowledge
No Capsonic Specific Requirements for this section.
7.2 Competence
No Capsonic Specific Requirements for this section.
7.3 Awareness
No Capsonic Specific Requirements for this section.
7.4.Comunication
7.4.1 General Communication
An essential ingredient to a successful partnership is clear and concise
communication. At
Capsonic, our means of communicating direction, expectations, guidelines
and systems include:
•Purchase Orders
•Supplier Performance Data
•Letter of Intent
•Authorized Request for Quote (RFQ) forms
•Capsonic’s Internet site www.capsonic.com
•Regular scheduled meetings
•Cross Functional Launch Team meetings
•Performance Review meetings
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•The Supplier Manual
•JADE Capsonic Portal
Details are noted in the appropriate sections of this manual. Refer to the
Table of Contents.
Although we communicate in numerous ways, Supplier Performance
Ratings are indicative of a suppliers overall performance and is the main
input of new business sourcing.
7.4.2 Revisions to the Supplier Manual
This manual will occasionally require revision as requirements, expectations
and systems change. It is the suppliers’ responsibility to ensure they have the
latest released edition. Suppliers will be able to access the most current
edition at www.capsonic.com and the JADE portal with access assigned to
each supplier. It is the supplier’s responsibility to contact the appropriate
Capsonic personnel with any questions regarding the requirements contained
within the Supplier Manual.
7.4.3 Suppliers must be capable to work with the JADE portal
https://capsonic.jadeinnovations.com
All material, purchased components, assemblies, and associated services
will be ordered by issuance of an individual Purchase Order or Blanket
Purchase Order. Suppliers will be issued production material requirements
weekly at a minimum, or as need dictates. Schedules will be communicated
through JADE.
It is the supplier’s responsibility to respond via JADE or contact the
Capsonic Buyer if a weekly release was not received or if unable to meet all
requirements for delivery date, time, quantity or quality.
7.5 Documented Information
7.5.1 Control of Design Records
All suppliers/subcontractors must have a documented system in place for
monitoring receipt, control, and obsolescence of all Capsonic supplied
design records. Suppliers will be responsible for being able to read math
data files in the appropriate language (NO Translations, i.e. IGES), and have
the ability to print files which include wire frame, GD&T, and notes (i.e.
performance and material requirements).
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Note: Confidentiality applies to all customer supplied drawings, math data
media and specifications.
7.5.2 Control of Specifications
Specifications noted on drawings and/or sketches supplied by Capsonic, and
subsequent specifications referred to within the body of those specifications
not supplied by Capsonic shall be obtained by the supplier/sub-contractor
directly from the controlling authorities (i.e. ASTM, SAE, etc.)
All suppliers/sub-contractors must have a documented system in place for
obtaining the latest released editions of required specifications. The system
shall address annual verifications by suppliers/sub-contractors to the
controlling authorities.
7.5.3 Control of Procedures QUALITY
7.5.3.1 Suppliers/sub-contractors shall establish documented quality
practices for all areas of the quality function based on AIAG
Advanced Product Quality Planning (APQP) Guidelines.
7.5.3.1 A multi-disciplined approach shall be utilized for approval of
quality documentation.
7.5.3.1 A documented method shall exist for revising, approving, re-
issuing and implementing policies, procedures and work instructions.
7.5.3.1 All procedures and supporting documentation shall be
controlled, maintained and available on site for review, upon request
by Capsonic personnel.
7.5.4 Record Retention
Suppliers are expected to maintain applicable retention periods to the
records derived from the manufacture processes as well as the inspection
activities that show compliance with the specification, these retention
periods are based on the nature of product, process and the sector of use. All
records must be retained by suppliers as a minimum of 10 years for
Automotive, and 15 years for Aerospace product and/or records that
demonstrate compliance with Government and/or regulatory agencies.
Disposition of these records must meet OEM Specific Requirements when
applicable, unless otherwise specified by Capsonic. Legal or government
requirements prevail. Suppliers must make this requirement extensive to
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sub-suppliers to make sure the information generated by sub-suppliers are
kept and supportive to the Capsonic Supplier Quality System.
8. Operation
8.1 Operational Planning and Control
8.1.1 Advance Product Quality Planning (APQP)
All suppliers are required to utilize the methodologies defined in the latest
released editions of AIAG Core Tools manuals, including:
•Advanced Product Quality Planning and Control Plan (APQP).
•Failure Modes and Effects Analysis (FMEA)
•Statistical Process Control (SPC)
•Measurement System Analysis (MSA)
These manuals are tools intended to assist the suppliers in meeting the
requirements necessary to produce a world-class product.
It is the responsibility of each supplier to ensure that their subcontractors
(Tier 3 suppliers to Capsonic) are meeting similar expectations and
requirements.
8.2 Requirements for Products and Services
8.2.1 Customer Communication
After part approval, Supplier shall use the SREA (Supplier Request for
Engineering Approval) process to submit approval requests for supplier
initiated process change proposals. This form is needed to be submitted to
Casponic SQE, for proper approbation.
8.2.2 Determining the Requirements for Products and Services
No Capsonic Specific Requirements for this section.
8.2.3 Review of the Requirements for Products and Services
8.2.3.1 Process Characteristics Notes
SUPPLIER is obliged to monitor and document the
manufacturing process by using suitable statistical methods
so that the continuous process capability as per the following
criteria:
Critical characteristics (Cpk >= 1.67) Δ 1
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Major characteristics (Cpk >= 1.33) Δ 2 can be verified over
the entire production time. Critical characteristics shall be
monitored 100%.
Major characteristics without process capability shall be
monitored 100%.
Minor characteristics can be verified with audit or boundary
checks (GO/NO-GO).
If any of these are not possible (for example because only
destructive testing is possible), the parameters controlling the
process have to be clearly identified by means of statistical
test planning and to be displayed as control parameters. Once
the process intervention
parameters have been defined and documented the process
concerned shall be controlled using these parameters.
Capability studies performed must meet the SPC
criteria, through the evaluation of the capability of at least
125 readings of the characteristic to be evaluated. The
instrument used to obtain the Cpk value must be able to
deliver variable data and meet the criteria for the R&R
defined in the MSA.
8.2.4 Changes to Requirements for Products and Services
No Capsonic Specific Requirements for this section.
8.3 Design and Development of Products and Services
8.3.1 General
No Capsonic Specific Requirements for this section.
8.3.2 Design and Development planning
The organization should consider Incoming inspection when to prevent the
use of non-conforming incoming material.
8.3.2.1 Control Plan Requirements
Suppliers must utilize appropriate APQP techniques as
identified in the AIAG Advance Product Quality Planning
and Control Plan reference manual or similar techniques.
8.3.2.2 FMEA Requirements
All suppliers are required to utilize the methodologies
defined in the latest released editions of AIAG Core Tools
manuals for FMEA development.
8.3.2.3 APQP/PLP Kick-Off
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An APQP / PLP kick-off meeting will be scheduled upon business
award. Personnel representing the supplier’s Program Management
and Quality Assurance shall participate to establish and outline
requirements, timetables, and contacts. All immediate technical
concerns will be addressed at this time. CAPSONIC SQE and Buyer
will obtain the supplier commitment to comply with CAPSONIC
requirements, a documented timeline (Microsoft Project Desirable)
will be provided by supplier with specific dates to meet key dates
(Milestone), Program progress review (meetings Capsonic-Supplier),
PPAP/FAI due date, and define run @ rate requirements.
Management supplier is required to appoint a responsible function
within their organization to review, submit/provide status of launch
activities to CAPSONIC SQE/Buyer in a periodic manner and to
reflecting process assumptions as well as key launch events,
associated timing and progress to plan.
8.3.3 Design and Development Inputs
Capsonic, its customers and regulatory authorities expect to have access to
Capsonic’s supplier facilities and records at reasonable times for the
purposes of audits, assessments, inspection of goods and associated control
systems.
8.3.3.1 Suppliers are expected to share with Capsonic detailed cost
data. Suppliers are also expected to use a fair and consistent method
of applying the profit factor and distribution of overhead expenses in
support of Capsonic requirements, consistent with goals of long-
term financial viability.
Suppliers must be willing to extend the benefits of cost reduction
efforts with Capsonic.
As a condition of business, all suppliers must be prepared, on
request, to provide any information required by the Capsonic
Purchasing Department to substantiate the ability to provide the
necessary products, commodities and services. This shall include, but
is not limited to:
Quotes provided on Capsonic developed cost model,
Technical capability and systems/procedures to evaluate key
product characteristics and
Financial information.
In addition, the supplier must be prepared to provide proactive
initiatives such as cost reduction proposals and recycling programs to
Capsonic.
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8.3.3.2 It is expected that a target for compliance of zero
discrepancies be set for all goods and services to be supplied to
Capsonic.
Warrants and certification requirements will be stated on Capsonic
purchase orders or on Product Drawing(s) defining the Product to be
supplied to Capsonic by Supplier. Annual validations for raw
material must performed by supplier (Dimensional layout, material
confirmation) are to be carried out by an independent accredited
testing when required by Capsonic.
Suppliers will be held accountable for warranty costs due to
negligence, process and supplier design issues.
8.3.3.3 Products/processes that are jointly developed between
Capsonic and its suppliers will be
Considered to have co-ownership and be royalties free unless
otherwise negotiated.
8.3.3.4 Reporting Material Composition (IMDS)
Automotive suppliers are required to provide evidence that the
Material/substance Composition reporting for each part has been
completed and complies with requirements. Material is to be reported
in the International Materials Data System (IMDS) unless another
system or method is pre-approved by Capsonic authorized personnel.
Note: IMDS is available through mdsystem.com. Capsonic
Automotive company ID is 8304.
8.3.4 Design and Development Controls
8.3.4.1 Manufacturing Process
If the supplier manufacturing process assumptions are based on new
technology, or on new processes for the supplier, the supplier must
document how and when the processes will be proven out in a pilot program
prior to production launch. The pilot program must provide for the
manufacture of a sufficient quantity of parts so that the program production
launch curve is based on the experience of the pilot program rather than
unproven assumptions.
If a pilot program cannot be accomplished, the supplier must provide a
detailed back-up manufacturing plan based on proven processes; to be
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implemented in the event problems are encountered during the launch of the
new technology or processes that may impact supply to Capsonic.
Regardless of process assumptions, the supplier must submit periodic launch
plans (Timing report with specific due dates) reflecting process assumptions
as well as key launch events, associated timing and progress to plan. The
due date for the first submission will be discussed at the APQP / PLP kick-
off. These will be confirmed and authorized by CAPSONIC SQE.
8.3.4.2 Process Sign-Off Requirements
Process Sign-Off (PSO) must be performed on all new or modified parts
determined by Capsonic to be high or medium or initial risk. Products that
have a high or medium Initial Risk Evaluation will require that the PSO be
led by Capsonic personnel. Parts with a low risk evaluation will have a
supplier led PSO.
Any product or process change that occurs during the lifecycle of a part or
system must be reviewed by the product team to determine whether a new
PSO is required. Submission for full PPAP/FAIR approval will not be
accepted unless PSO sign off approval is achieved.
It is the responsibility of the supplier to submit PPAP/FAIR documentation
for review and approval prior to shipping products to Capsonic. Failure to
obtain PPAP/FAI approval from CAPSONIC SQE may impact supplier
scorecard, due to a documented DMR.
8.3.4.3 Sample Submission Requirements
These will be communicated to suppliers by Capsonic SQE/Buyer via the
Capsonic JADE portal based on requirement level submission documented
in Capsonic PO provided to supplier. These requirements will be based on
final customer/program requirements.
Capsonic Supplier Quality Manual requires the compliance of PPAP and
FAI requirements to address the drawing design characteristics generated by
Capsonic from the supplier and their sub-tiers. In all instances PPAP and
FAI requirements applies to each bill of
material or parts list item with in a CAPSONIC part number that is invoked
in the product design. Capsonic or Customer PPAP/ FAI approval does not
relieve the supplier of the responsibility and/or liability for full compliance
with all Drawing/Contract requirements.
Capsonic will be using the JADE Portal to communicate PPAP/FAI when a
new product is released or when a change in product feature, process,
location is performed at supplier location.
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Capsonic requires its suppliers to annually perform and provide to Capsonic
a product validation. Also, Capsonic reserves the right to validate multiple
production lots if needed to determine overall process capability.
8.3.4.4 General Sample Submission Requirements
8.3.4.4.1 Suppliers are to meet all requirements of the latest
released edition of the AIAG Production Part Approval Process
(PPAP) and for Aerospace product the First Article Inspection report
(FAI) defined on SAE AS9102 manual. These requirements extend
to all commodities supplied by the supplier’s subcontractors and
third tier suppliers.
8.3.4.4.2 All submissions for production part approval must include
the required information as specified for a Level 3 submission,
unless otherwise instructed in writing. All submissions for prototype
part approval must include the requirements specified for Capsonic
verification package unless otherwise instructed in writing.
8.3.4.4.3Regardless of submission level, all documentation
defined in the AIAG PPAP/FAI manual and Capsonic specific
requirements are to be on file and available for review upon request.
8.3.4.4.4 Suppliers working with OEM programs are required to
perform an annual validation of the component produced for
Capsonic, as a proactive activity to identify variation in the supplier
manufacture process. Results of the validation must be filed in
supplier premises and these will be provided to Capsonic.
8.3.4.4.5 Suppliers are responsible for costs incurred by Capsonic
resulting from late or incomplete submissions.
8.3.4.5 Specific Sample Submission Requirements
8.3.4.5.1 When requested, PPAP/FAI submissions must be made
in accordance with OEM specific requirements. Examples of
OEM specific PPAP/FAI Submission requirements can be provided
to suppliers when these are requested to SQE’s.
8.3.4.5.2 All supplier PPAP or FAI submissions will be made in the
JADE portal where the checklist for required items is found as
selected by the SQE. All necessary files for the part submission are
to be uploaded in JADE. Part submission warrant must be filled out
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completely, indicating the finished part number(s) that are being
submitted. Only parts within the same product “family” (i.e. multiple
colors of the same product) and of the same revision level may be
submitted on a single warrant. All part numbers must be listed on the
warrant. Unless otherwise instructed, five (5) sample parts per cavity
will be required to be measured 100% on the feature/characteristics.
8.3.4.5.3 FAI sample must be obtained from same condition of
manufacturing process configured for production releases, therefore
samples must be provided according to the following criteria:
•Stamping metal parts.- From a 300 pcs produced continually
or 8 production hours. 5 pcs measured to be measured 100%
on the feature/characteristics from a sample obtained
randomly.
•Die Cast.- A sample from each cavity.
•Machining Parts.- 1 Pc.
•Molded Components.- a Sample from each cavity.
8.3.4.5.4 Dimensional layout data must be provided for each
drawing dimension and note. A ballooned reference drawing
provided by Capsonic showing the relationship between the layout
results and drawing specifications must accompany the layout report.
Graphical math data plots are acceptable for profile dimensions. A
sufficient number of inspection points to adequately define the
surface are required. Prior approval by Capsonic of inspection points
is required.
8.3.4.5.5 Only PPAP/FAI approved raw material sources may be
used. Material certifications must include a copy of the OEM
customer color and/or construction approval (e.g. General Motors
Material Evaluation Form). Material certifications must indicate lot
numbers and dates as certification that these approved materials were
used in the manufacture of the submitted samples.
8.3.4.5.6 Laboratory testing, when applicable, must be conducted by
an accredited facility (ISO / IEC17025 and / or A2LA). A copy of
the accreditation with scope of testing is to be included with the
submission.
8.3.4.5.7 Appearance approval, when required, must be submitted
via an Appearance Approval Report (AAR). The AAR is to be
completed in its entirety. On occasion, the supplier may be requested
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to obtain appearance approval directly from the end customer.
Suppliers will be notified in writing when this is the case.
8.3.4.5.8 Restricted and reportable chemicals contained in the
raw materials and parts used in the manufacture of supplied
components must be reported based on the IMDS (International
Material Data System) requirements. This form must be
submitted to CAPSONIC AUTOMOTIVE company ID 8304,
with packages whether reportable chemicals are contained in
components or not.
Note: All questions regarding PPAP/FAI submission should be
directed to the appropriate Capsonic Supplier Quality Engineer.
8.3.4.6 Supplier Prototype Product Requirements
The requirements noted below pertain to prototype submissions received
from suppliers providing component parts during the Design Verification
and Prototype builds. If for any reason the Supplier cannot meet these
requirements, they are required to notify Capsonic Supplier Quality in
writing, prior to shipment. The supplier is to use the appropriate program
documentation to note discrepancies.
8.3.4.6.1 Prototype Submission: The following verification package
documentation must be completed and provided with each shipment
supplied for the prototype build. Capsonic customers may also
require additional documentation such as a Prototype Control plan
and Pre-Production Sample Report. All documentation must
reference the product number and the drawing date/level.
•Capsonic provided balloon Drawings
•Dimensional Results
•Sample Parts
•Material Certification
•Proper Identification
8.3.4.7 Automotive Product Submission Disposition Status
8.3.4.7.1 FULL Approval
Full approval indicates that ALL engineering design record and
specification requirements have been satisfactorily met.
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8.3.4.7.2 CONDITIONAL Approval
Conditional approval MAY be granted under the following
conditions:
•Product is from production tooling and meets all Appearance,
Dimensional, & Test Specifications.
Exceptions/examples: Document missing/incomplete, Capability 1.0
to < 1.67 - Action Plan Required
•Product is not from production tooling or production tooling is off-
site, but product meets all customer requirements.
Exceptions/examples: Production tooling not complete or off-site,
low volume tooling used, conveyors not in place, automation not
complete – Action Plan Required.
SQE should indicate on the PSW when a Conditional or interim
approval is granted and the reason for the conditional approval as
well as the timing for its expiration.
8.3.4.7.3 REJECTED
Rejected status indicates that the product does not meet the
required customer specifications
8.3.5 Design and Development Outputs
No Capsonic Specific Requirements for this Section
8.3.6 Design and Development Changes
No Capsonic Specific Requirements for this Section
8.4 Control of Externally Provided Processes, Products and Services
8.4.1 Conditions of Business Placement and Purchase Orders
The extent of the purchase contract and order of precedence shall be:
1) Compliance with all relevant local, provincial, state and federal
government legislation with special emphasis on hazardous waste
and other environmental requirements
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2) General Supply Agreement [GSA] (if applicable)
3) The Purchase Order terms and conditions
4) Capsonic Request for Quotation Form
5) Requirements as stated in the Supplier Manual
6) Letter of Intent
7) Statement of Requirements
8.4.2 All suppliers/sub-contractors must provide Country of Origin
Certification and other documentation required under the US/Canada Free
Trade Agreement and the North American Free Trade Agreement (NAFTA).
All customs requirements must be met in a timely manner to ensure efficient
transportation of goods. These documents must be posted in JADE portal.
8.4.3 All suppliers shall have documented procedures for assessing,
selecting, monitoring and developing their suppliers/sub-contractors with
adherence to a continual improvement philosophy geared to complete
customer satisfaction and cost reductions.
8.4.4 Suppliers / sub-contractors are expected to sign up to a Long Term
Agreement (LTA), Productivity Program or other type of cost savings
agreement. This LTA is to provide cost savings through, but not limited to,
raw material price decreases, value analysis, or productivity improvements.
8.4.5 Compliance of Business and Purchase Orders
8.4.5.1 Purchase Order / Letter of Intent
Capsonic will issue purchase orders to suppliers for awarded programs. In
advance of receipt of purchase orders, suppliers to Capsonic may receive a
letter of intent from the Purchasing Department providing the following
information pertaining to Supplier conditions, requirements, and
responsibilities:
•Design, development, prototype and production source award.
•Pricing
•Packaging (Expendable and Returnable)
•Tooling design and timing
•Freight and Customs
•Pre-Production Activity
•Cost Reduction
•Currency
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It is the intent of Capsonic, that the supplier be the product supplier for the
related program provided, the supplier meets commercial, design, program
support, quality, and delivery requirements. Where Capsonic or OEM
dictated program changes necessitate adjustments to the purchase order or
Letter of Intent, the Supplier will be required to quote and substantiate such
adjustments.
The supplier will be required to conform to Capsonic and/or OEM tooling
documentation and audit requirements. Capsonic reserves the right to audit
tool costs incurred by the supplier in support of awarded programs. Such an
audit may include, but not be limited to, a review of quotes, purchase orders,
invoices, and other documentation.
Business award is conditional upon the supplier’s concurrence with the
requirements of Capsonic’s process procedures and terms and conditions.
8.4.5.2 Product / Program Changes
Capsonic will not accept cost increases due to process-oriented
developmental changes that are necessary to meet the design requirement.
The supplier will be reimbursed only for approved costs associated with
product/program changes mandated by Capsonic or the applicable OEM. If
Capsonic initiates product/program changes that result in reduced production
tooling or manufacturing costs, Capsonic will expect piece price or tooling
costs to be reduced to reflect the entire amount of the reduction.
8.4.5.3 Quotation Response Requirements
When Capsonic is considering a product or program change, a RFQ
(Request for Quote) form will be generated and forwarded to the supplier.
Suppliers are expected to respond by the due date identified in the RFQ,
with documentation as defined by the Capsonic initiator. The information
on the RFQ Form, once signed by the vendor’s responsible agent, obligates
the vendor to all the information provided, supporting documentation, and
terms and conditions (found at http://www.capsonic.com/Auto/Suppliers/).
Any deviations to the RFQ Form must have prior approval from the
Capsonic initiator. These will be represented in the Notes section on the
RFQ Form. RFQ response is a measurable for supplier performance. Failure
to meet response expectations may result in new business hold or removal
from the Approved Supplier List.
When supplier receives RFQ a Feasibility Commitment form QAF-SQM-
001 must be completed. With this form supplier must be satisfied that
proposed product can be manufactured, assembled, tested, packaged and
delivered in sufficient quantity to Capsonic. All the RQF are provided
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electronically to suppliers, and suppliers are expected to respond in the same
way through the portal.
8.4.6 Duration of Supply
The supplier must meet program commercial, design, support, quality, and
delivery requirements to be selected as Capsonic’ production source for
awarded program component(s). The supplier must remain fully cost
competitive with qualified alternate suppliers throughout the life of the
program.
8.4.7 Counterfeit Control Process
Authorized Manufacturers usually have a list of their authorized distributors.
All the distributors of Capsonic shall demonstrate that are an authorized
distributor for the initial manufacturer. This to assure that no counterfeit
parts are received in Capsonic.
Supplier shall provide a Material Certification on each shipment, if material
certification is not received Material cannot be used on the products
manufactured on Capsonic, until cert was provided by supplier.
Supplier shall ensure that the materials used to produce raw material sell to
Capsonic was manufactured with no Counterfeit Parts.
The requirement for Counterfeit Control shall apply to sub-suppliers.
Suppliers that provide to Capsonic components for Aerospace business shall
comply with the requirements for counterfeit control on SAE AS5553 and
SAE AS6174.
8.4.8 Scheduling and Releases
8.4.8.1 Raw material may be ordered by issuance of individual
purchase orders or releases under
a “blanket” Purchase Order.
8.4.8.2 Suppliers who have been issued a “blanket” Purchase Order
will typically receive weekly releases; however some suppliers may
receive less frequent, depending on the product type and/or volume.
The notification of these releases will be performed via JADE portal.
8.4.8.3 The supplier is to ship only those quantities that have been
released unless the Material Representative has authorized other
arrangements. If deviations are made, a revised release will be issued
as documentation of scheduling deviation approval. Over shipments
may be subject to return at supplier’s expense and without receipt of
a return material authorization. Excess Transportation Charges
resulting from unauthorized multiple shipments; past due
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requirements and/or unauthorized truck lines will be debited in full
to the supplier.
8.4.8.4 Suppliers who are unable to meet all delivery requirements
including date, time, quantity and quality must notify the Buyer
immediately, and officially confirm the condition using JADE portal.
Note that this communication does not alleviate the supplier of any
of the related costs and penalties associated with being past due or
shipping defective material.
8.4.8.5 Telephone calls noting schedule deviations, while appreciated
for planning purposes, do not result in allowances for deviation of
the requirement schedule. If a shipment is missed or is incomplete,
an expedited carrier must be set up at the supplier’s expense.
8.4.9 Cumulative (CUM) and Material Authorization
8.4.9.1 CUMs that do not match is an indication that an error has
been made either in receipt history or ship history. CUMs must
match to ensure the correct release of parts. It is recommended that
the supplier review CUMs daily. At a minimum, CUMs should be
reviewed weekly.
8.4.9.2 In the event the received and the shipped CUMs do not
match, the supplier must immediately notify the appropriate
Materials Representative. Until the CUM discrepancy is resolved,
the supplier should consider the Capsonic CUM to be correct, and
shipper the current release. It is the supplier’s responsibility to
provide proof of delivery when a discrepancy is found.
8.4.9.3 The supplier will have 30 calendar days after product
shipment receipt to resolve invoice CUM discrepancies. Failure to
resolve discrepancies may result in non-payment of open invoices
items. CUM discrepancies must be communicated in writing to the
Materials Department.
8.4.9.4 Unless otherwise specified, standard FAB authorization is
2 weeks and RAW authorization is 4 weeks. Exceptions to these
authorizations require written approval by the appropriate Materials
Representative.
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8.4.9.5 Capsonic will not be responsible for material beyond the
CUMs as authorized above. Quantities on release beyond the RAW
cum are for planning purposes only.
Capsonic’s release requirements may change on a daily basis due to
fluctuations of customer requirements. Capsonic is committed to
meeting these requirements without exception or assistance from our
customer. Excess freight or labor costs incurred by Capsonic in order
to meet delivery requirements are not passed on to our customer, no
matter the circumstance. Because of this, we require our supply base
to provide the same level of flexibility and support. This is the basis
for FAB and RAW authorizations as stated
8.5 Production and Service Production
8.5.1 Control of Production and Service Provision
When so directed, suppliers will be required to certify product after a lot rejection
has occurred. Two types of controlled shipping actions are employed when this
situation occurs.
•Supplier conducted sort and certification of subsequent part shipments
(CS1).
•Third party sort and certification (CS2).
8.5.1.1 The level of inspection (CS1 or CS2) will be determined based on
one or more of the following reasons:
•Repeat quality issues and/or failure to resolve a quality issue.
•Severity or risk to the organization.
•Incapable supplier process(s).
•Line disruption.
•High PPM level.
•Customer complaints.
•Other factors deemed applicable.
8.5.1.2 The Controlled Shipping Process will be applied as follows:
•The Capsonic SQE will initiate controlled shipping as deemed
necessary based on a review of the quality concern(s).
•The supplier will be notified of their Controlled Shipping status.
Additionally, Capsonic’s customer and/or the supplier’s quality
system registrar may be notified of Controlled Shipping Level 2 as
deemed necessary.
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•Controlled Shipping status will be reflected in the Supplier
Performance Rating
System.
•Capsonic SQE will develop and review the Controlled Shipping
expectations and exit criteria with the supplier, and Capsonic buyer.
•Capsonic Purchasing, Supplier Quality Engineer will monitor
the supplier’s
progress to plan.
•When the supplier has met the exit criteria, the Controlled Shipping
status will be removed. Capsonic’s customer and the supplier’s
quality system registrar will be notified of the change in status as
applicable.
•Failure to exit from Controlled Shipping status may result in New
Business Hold or de-sourcing.
8.5.1.3 Coordination and follow up of all controlled shipping actions are the
sole responsibility of the supplier. Part supply to Capsonic must meet
released quantities without supply interruption.
8.5.1.4 The supplier and Capsonic SQE will mutually define the certified
material identification requirements.
8.5.1.5 Delivery Non-conformances
8.5.1.5.1 A Delivery Performance Report (DPR) will be issued to the
supplier via JADE portal, for any delivery related nonconformance.
If the supplier does not agree with the reported discrepancy, the
supplier must document this decision though JADE within 24 hours
from receipt of the DPR notification of the discrepancy via JADE.
8.5.1.5.2 A DPR may be issued for any of the following reasons, but
is not limited to:
Under, over, late or early shipments
No ASN or late ASN
No documentation or inaccurate documentation
Damaged freight
No label or inaccurate label
Incorrect packaging
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8.5.1.5.3 A corrective action report detailing immediate actions taken
to address the reported discrepancy is to be submitted via JADE
within 24 hours.
8.5.1.5.4 A completed corrective action report including root cause
and preventive action is required within 3 business days.
8.5.1.5.5 At the discretion of Capsonic’ Purchasing or Materials
Representatives, the supplier will be required to submit a detailed
plan addressing behind schedule situations (as applicable). The plan
is subject to Capsonic Purchasing and/or Materials Representatives
approval and will be closely monitored for adherence.
8.5.1.5.6 The supplier is to immediately notify the Capsonic Buyer
of an inability to ship to schedule requirements. Notification is to be
followed by documented corrective action as previously described.
8.5.1.5.7 The supplier is expected to automatically expedite shipment
should they foresee or incur a past due situation. In addition, it is the
supplier’s responsibility to contact the Buyer to ensure availability of
a receiving dock.
8.5.1.6 Premium Freight
8.5.1.6.1 All requests for premium freight (PRF-003-008) must be submitted
to the Purchasing Manager for approval. Reasons for air freight must fall in
the following categories:
Capsonic placed the order late (not enough lead time)
Supplier is late (in this case supplier will pay shipping cost)
8.5.1.6.2 All approved requests for premium freight must be logged into
the Air Shipment Control (PRF-003-006). Those that are prepaid by the
supplier must also be logged into The Air Shipment Control Log.
8.5.1.6.3 Copies of the Air Authorization form will be kept on file by
supplier and available for clarifications if these are required by Accounts
Payable. All unauthorized shipments will not be paid.
8.5.1.6.4 If the shipment was not authorized, the Purchasing Manager
will instruct accounting to reverse the payment.
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8.5.1.6.5 Air freight charges due to supplier late shipment, should be
approved by supplier, via JADE for their approval.
8.5.1.7 Downtime Costs
8.5.1.7.1 The supplier is responsible for all costs associated to
downtime at Capsonic and/or downtime costs billed to Capsonic by
their customer when such costs are deemed to be the fault of the
supplier due to quality, delivery and/or other incidents of
nonconformance.
8.5.1.7.2 The supplier is responsible for all costs associated with
downtime at Capsonic and/or downtime costs billed to
Capsonic by their customer when such costs are deemed to be the
fault of the supplier due to quality, delivery and/or other incidents of
nonconformance
8.5.1.7.3 These costs will be published and updated as soon as these
are documented in the JADE portal.
8.5.2 Identification and Traceability
8.5.2.1 Lot Traceability
8.5.2.1.1 All material received by Capsonic must contain a lot code,
or serial number, clearly identified on each label and container,
ensuring full traceability of all material. Material must be traceable
from receipt of raw material, to each processing stage and through
final assembly and shipping to Capsonic.
8.5.2.1.2 The supplier shall communicate, to Capsonic, the
traceability method used (e.g. date and shift of manufacture along
with sequential processing number). In some cases the component
may be critical enough so as to warrant part identification; these
instances will be communicated through the appropriate quality and
engineering groups.
8.5.2.1.3 A lot should contain a specific quantity of parts, and should
not exceed eight hours or one day of production, at a maximum. In
the event of certain commodity-based material, methods such as “dye
lots” or steel coils will be acceptable.
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8.5.2.1.4 The supplier shall ensure implementation and management
of an effective FIFO (First In First Out) method of stock rotation.
Failure to comply with traceability requirements may lead to
rejection of material and issuance of non-conforming material
reports.
Traceability Records shall be maintained and accessible for the life
of the product, including Service, plus one year.
8.5.2.2 Labeling
8.5.2.2.1 Container Label Requirements
8.5.2.2.1.1 All materials for prototype, PPAP, or production
consumption, shipped to divisions of Capsonic, must be
identified with labeling containing human-readable text /
graphics, and machine- readable bar coded symbols.
Containers shall be identified with the following, as
applicable:
•Container labels
•C of C Enclosed
•master labels
•mixed load labels
•primary paper labels
•part labels when specified by design records,
specifications, or other written requirements
All labels must be legible and scan able to AIAG
Standard and unobstructed from banding and other
packaging materials.
8.5.2.2.1.2 Characters and symbols shall comply with the
Capsonic requirements of the AIAG, B-8 standard – Quality
Assurance Guide for Shipping Labels and Other Bar
Code Applications, to ensure consistency of supplier meeting
these requirements JADE portal have included the ability to
print labels according to these specifications.
8.5.2.2.2 Parts Shipping Labels (container, master, and mixed load),
shall comply with the layout formats defined in the AIAG, B-3
standard – Parts Shipping Label. Custom formats may be specified
by a Capsonic via a Customer Compliance Specification Sheet.
Supplier must use JADE portal to print out labels using CAPSONIC
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formats, this feature in the system allows the supplier to provide the
basic information required by CAPSONIC.
8.5.2.2.3 Primary labels shall comply with the layout format defined
in the AIAG, B-5 standard – Primary Metals. These labels can be
found in JADE Capsonic portal.
8.5.2.2.4 Label placement, orientation, quality and quantities shall
follow the guidelines contained in the AIAG, B10 standard – Trading
Partner Labels Implementation Guide.
8.5.2.2.5 Each container must have two AIAG bar-coded labels
(formatted as described above); this also includes any items not in
cartons such as rolls, bundles, drums, etc. The labels must be affixed
to the upper RH corner of at least two adjacent sides. If the container
is returnable, the supplier is to ensure that old labels are removed and
replaced.
8.5.2.2.6 Labels formats posted in JADE Capsonic portal will
include the following information:
•Part Number
•Revision Level
•Description (the description must exactly match the
description on the Purchase Order and Releases).
•Quantity (the quantity must be as per the standard Unit of
Measure
•Unit of Measure (UOM).
•supplier lot number, or lot code
•manufacture date
8.5.2.2.7 Pre-production and/or trial material must be clearly
identified by Program and Purchase Order Number, as well as any
other information defined by Capsonic. The use of JADE Capsonic
portal is required to print out labels identifying these parts.
8.5.2.2.7.1 PPAP samples will be identified with a label
QAF-001-060 orange color describing the PPAP shipment.
Prototype samples use the QAF-7362-001 yellow color label.
These can be printed from JADE Capsonic portal, or
provided by Capsonic Supplier Quality Engineer upon
request.
8.5.2.3 Part Barcode Labels
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8.5.2.3.1 When required that a barcode label be affixed to each part,
such labels must be affixed in an area as not to interfere with the part
function or appearance. Exceptions to part labeling requirements are
made for components that are restricted in size (i.e., fasteners).
Contact the appropriate Capsonic Division Material Manager for
requirements and exception details.
8.5.2.3.2 Part labels shall comply with the requirements defined in
the AIAG, B-4 standard – Parts Identification and Tracking
Application Standard, unless otherwise specified by design records
or Capsonic division specific requirements.
8.5.2.3.3 Typical Part Barcode Labels will include, at a minimum the
following information:
•Part Number
•Part Revision Level
•Part Description
The supplier shall submit a sample label for each component that is
to be barcode labeled to
Capsonic for approval.
8.5.2.4 Label Approval
Suppliers must obtain approval of newly introduced label formats from
Capsonic prior to implementation.
8.5.3 Property Belonging Customers or External Providers
Supplier must have a documented procedure to perform the Preventive maintenance
activities for the tools property of Capsonic that are required for the production of
components. The procedure must include a program to make sure the condition of
these assets are properly maintained, therefore the quality of the components
produced will be consistently in specification. Records of these activities must be
available and submitted to CAPSONIC SQE when these are required.
8.5.4 Preservation
8.5.4.1 Packaging
8.5.4.1.1 Packaging Suitability
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It is the supplier’s responsibility to provide any product sold to Capsonic in
approved packaging as determined by Capsonic’s APQP / PLP (Product
Launch Process) process. The criteria necessary to determine suitability may
include:
•Robustness to ensure integrity of product
•Compliance with health and safety guidelines
•Compliance to Capsonic Operations requirements
•Compliance to AIAG standard guidelines
•Compliance to MMOG/LE Chapter 4.2
•All expendable packaging should be recyclable.
8.5.4.1.2 Suppliers are encouraged to confirm with Capsonic any
additional requirements such as:
•Container fill and identification for a “balance out” or “final
release” situation
•Foamed plastics or expanded polystyrenes (EPS)
•ISO Modular Packaging Requirements for import/export
product
•Maximum weight for manually and mechanically handled
goods
8.5.4.1.3 All goods sold to Capsonic that are considered to be
“controlled” under Workplace Hazardous Material Information
Systems must comply with appropriate legislated regulations for
packaging and shipping.
8.5.4.2 Returnable Containers
Returnable containers may be recommended as the primary packaging method
considered on new programs. On an individual basis, Capsonic may assess current
production part packaging feasibility using returnable containers. Suppliers are
encouraged to consider conversion to reusable containers.
Capsonic has developed and implemented returnable containers with many
suppliers. As a result, specific styles of containers best suited to shipping, storage
and manufacturing requirements have been identified. Any inquiries regarding
this packaging may be submitted to the Capsonic Packaging Engineer or
designated Buyer.
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8.5.4.2.1 The Supplier shall be responsible to maintain the
cleanliness of all returnable containers.
This requirement extends to removing all prior container labels.
8.5.4.2.2 The supplier shall is responsible for all maintenance
and logistical tracking of the returnable. The supplier shall notify
Capsonic when repairs are necessary.
8.5.4.2.3 Financing of returnable packaging will comply to mutually
agreed upon terms.
8.5.4.3 Pallets
Pallets are to meet the following specifications:
•Pallets are to be banded and/or stretch wrapped.
•Boxes must fit on pallet, without any overhang.
•Pallet height limit is 48”, unless otherwise authorized.
•“DO NOT STACK” sticker is to be affixed to 2 adjacent sides
(when applicable).
•Pallets must be 4-way entry.
•Like parts may be mixed on a skid only if less than a skid quantity
of each part is required. Otherwise, all cartons for the same part
number must be on the same skid(s).
•All mixed pallets must be clearly labeled as “MIXED SKID” on 2
adjacent sides.
•Parts should be palletized by program and by part number.
•DO NOT mix RH/LH, FRONT/ REAR or programs together on a
pallet, unless otherwise authorized.
Pallet information must be included on the Packaging Specifications
Form.
8.5.4.4 Transportation
It is important that Capsonic suppliers are aware of transportation and
delivery requirements, as it is one of the key performance metrics upon
which they will be assessed. Capsonic supports the industry initiative of
inventory reduction, recognizing however the importance this places on
accurate and timely delivery of quality product. It is our expectation that
suppliers will deliver 100% on time to our locations, in compliance to
schedules.
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In an effort to support On Time delivery, we expect our suppliers to
constantly strive to reduce lead times with their suppliers, improve
flexibility and minimize changeover times. If necessary to support On
Time schedules, the supplier may be asked to support local warehousing or
supply terms providing for FOB Capsonic Distribution Center location.
The supplier must refer to MMOG/LE for guidelines to meet Capsonic
requirements.
8.5.4.5 Schedules, Routing and Carriers
8.5.4.5.1 All appropriate scheduling, routing, FOB points and
delivery requirements will be communicated early in program award,
typically through the Supplier Statement of Work or similar
documentation. All transportation arrangements and requirements
must be signed and agreed to by both organizations.
8.5.4.5.2 Specified truck lines along with customs and brokerage
information, if required, will be detailed on Capsonic Routing
Instructions.
8.5.4.5.3 All goods imported into the USA must show the Capsonic
Custom Bond Number and Importer Number on all required
documentation. Contact your Logistics and Packaging
Representative to ensure that you have the correct numbers.
8.5.4.5.4 Any changes to carrier or delivery frequency must be
approved in writing by the Capsonic
Materials Department, unless it is for an expedited shipment.
8.5.4.6 Transportation Routing Information
8.5.4.6.1 Suppliers will receive routing information including
transportation method, and pick-up and delivery window times.
Routing information will be communicated using a Routing Control
Notice, Transport Routing Information Sheet, Routing Instruction, or
similar document used by Capsonic. Capsonic will make certain that
all transportation and routing details are clearly specified. Suppliers
shall question any ambiguous instructions. All costs incurred as a
result of missed or late shipments that are clearly the responsibility
of the supplier, shall be recovered from the supplier.
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8.5.4.6.2 All material entering from a foreign country must have
“Country of Origin” clearly marked on the Pro forma Invoice, as
well as on the original Commercial Invoice. Brokerage fees for all
imported product is typically the responsibility of Capsonic, unless
otherwise negotiated. All fees and charges resulting from the export /
return of defective product shall be the responsibility of the supplier.
8.5.4.7 Packing Slip and Bill of Lading
8.5.4.7.1 Packing Slip
It is required that all material shipped be identified on a Packing Slip
or Bill of Lading. The Suppliers must use JADE portal to print out
the packing slip required in each shipment, This is required during
receiving process to acknowledges that supplier shipped the material
required, however information typically required includes:
•Ship date
•Invoice/Packing Slip number
•Ship to and Sold to Addresses
•Separate line item for each part number shipped
•Part number(s) and descriptions
•Engineering change level of each pert number
•Purchase Order number for each part
•Order release number
•Quantity ordered and Quantity shipped of each part
•Manufacture date and/or code lot for material shipped
•Number of cartons/skids/containers/weight per part
•Supplier Code
•Ship via
•Indicate whether freight is prepaid or collect
The packing slip is to be attached in a clearly visible location.
8.5.4.8 Bill of Lading
The Bill of Lading must include the following information:
•Total Number of Containers Shipped.
Examples of Containers Shipped:
20 cartons on 1 skid -or- 1 skid @ 20 cartons
50 cartons on 3 skids -or- 2 skids @ 20 cartons ea + 1
skid @ 10 cartons
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70 cartons on 4 skids + 3 loose cartons -or- or 3 skids
@ 20 cartons ea+ 1 skid @ 10 cartons + 3 loose
cartons
•Number of Cartons Per Skid and/or the Number of Loose
Cartons
•Total Weight
•Proper NMFC Description, Item Number, and Class
Example:
OEM PLASTIC AUTOMOTIVE COMPONENTS,
NM18850, CL 85.
•Indicate whether freight is prepaid or collect
Questions regarding the correct NMFC description, item number, or
class should be directed to the designated carrier. Because this
information affects freight rates, it is critical to ensure its accuracy.
This information is also to be included on the Packaging
Specifications Form.
8.5.4.9 Advance Shipping Notice (ASN)
8.5.4.9.1 The ASN must be sent within 1 hour of the shipment
leaving the supplier’s facility. ASNs
may NOT be sent early. This process must be completed via JADE
portal.
8.5.4.9.2 In the event of a known shortage or late shipments, the
supplier must immediately notify Capsonic by using JADE portal,
and advise them of the shortage or late shipment. The supplier shall
also indicate the anticipated time of delivery of the expedited
material required to complete the original schedule.
8.5.4.9.3 The supplier must communicate directly to Capsonic buyer
when ASN’s cannot be transmitted via JADE portal. The Capsonic
Materials Representative must be in agreement with the change by
confirming in writing de acknowledging of the change.
8.5.4.10 Hazard / Non-Hazard Chemical Requirements and Material
Certifications
8.5.4.10.1 Capsonic suppliers/sub-contractors considered to be
“controlled” under W.H.M.I.S. (Workplace Hazardous Material
Information Systems) must be familiar with and comply with all
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such regulations, for packaging and shipping. Chemical and
Hazardous substances with a “shelf life identification” must be well
specified and with enough active life.
8.5.4.10.2 Material Safety Data Sheets (M.S.D.S.) must accompany
all initial shipments from all suppliers/sub-contractors and marked to
the attention of the Environmental Health and Safety Coordinator.
8.5.4.10.3 Where required, Material Certifications are to be placed in
a separate envelope and addressed to the using division’s Materials
Department.
8.5.5 Post-Delivery Activities
No Capsonic Specific Requirements for this section.
8.5.6 Control of Changes
8.5.6.1 Initial Packaging Approval/Change Requests
Capsonic must approve all packaging prior to the first shipment. Approval is
required for packaging type (i.e. returnable, expendable), container size,
container quantity and pallet quantity. The supplier must submit a completed
“Supplier Packaging Proposal” form QAF-010-032 to the applicable
Capsonic SQE. Any changes or deviations from the approved packaging
require written approval.
Note: Packaging is also part of the PPAP/FAIR submission.
8.5.6.2 Capsonic and Customer initiated Changes
8.5.6.2.1 All potential, proposed and/or mandated engineering
changes affecting purchased product, will be submitted to the
supplier for impact and timing. These engineering change/change
request documents will be processed via Capsonic Engineering
Change Notification and supplier request for quote (ECN/RFQ)
procedures. Documentation for approved engineering changes will
be forwarded to the supplier for execution as defined in the Capsonic
ECN/RFQ procedures. All changes are required to be approved in
accordance to the PPAP/FAIR requirements before production
implementation.
8.5.6.2.2 The supplier is required to:
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•Respond to ECN/RFQ requests within 5 business days
or as otherwise arranged with the designated Buyer.
•Itemize applicable cost and timing in the required format.
•Manage and report all applicable engineering changes of the
Lower
Tier supply base.
•Once concerns are cleared, official updated drawing is
provided by buyer to supplier.
•Submit samples of all executed changes, in accordance
with Production Part Approval Process (PPAP/FAIR)
requirements prior to production implementation. Report Tier
3 sub-supplier changes as part of the PPAP/FAIR process.
•When PPAP submission includes the use of developed
Tools, Molds, Fixtures and/or Test Equipment in which these
are considered CAPSONIC assets, or those of Capsonic’s
customers. Pictures of such items must be submitted as well
as PPAP information to CAPSONIC SQE, to obtain the
PPAP approval.
8.5.6.2.3 Supplier Proposed Engineering Changes
Supplier proposed changes must be submitted for approval
consideration via the Capsonic SREA (Supplier Request Engineering
Approval) form PRF-8.4-002. All proposed changes, including but
not limited to the following are to be communicated as applicable:
•Proposed material changes.
•Proposed process changes.
•Proposed tooling and/or fixture changes.
•Proposed manufacturing location changes.
•Proposed Tier 3 sub-supplier changes.
•Any other changes as defined in the AIAG PPAP/FAIR
manual, including Customer
Specifics.
8.5.6.2.4 Rejected Supplier Change Requests will be returned to the
supplier with an explanation and/or request for additional
information.
8.5.6.2.5 Approved Supplier Change Requests will be communicated
to the supplier through Capsonic CN process documentation. The
SQE will communicate sample submission expectations and timing
requirements via the JADE portal. Other instructions and required
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documentation, when applicable, will also be communicated at this
time.
8.5.6.3 Engineering Change Notification and Control
All applicable documents and data to support engineering changes will be
forwarded to the affected supplier(s) by Capsonic buyer. This will be
controlled as defined in the Document Control Requirements section. All
executed engineering changes are to be submitted and approved in
accordance with Production Part Approval Process (PPAP/FAIR)
requirements prior to production implementation.
8.5.6.4 Engineering Change Product Identification
The first shipment of engineering change products is to be identified as
directed by the applicable Capsonic Quality Engineer or other authorized
Capsonic Representative. Subsequent shipments may also require
engineering change identification when deemed necessary by Capsonic.
Each container of engineering change product is to include this
identification. Failure to properly identify engineering change materials may
result in the issuance of a Defective Material Report. Related DMR charges
may apply.
8.5.6.5 Product Obsolescence
Suppliers must submit obsolescence claims resulting from engineering
changes within 30 days of the change implementation date. Suppliers must
use the Obsolescence Claim form posted on Supply Web, and submit via
email to the appropriate Capsonic Material Planner. Claims received outside
of the 30 days will not be processed. Submission of claim does not
guarantee validity of claim nor assure approval and payment of the claim.
8.6 Release of Products and Services
No Capsonic Specific Requirements for this section.
8.7 Control of Nonconforming Outputs
8.7.1 Quality Non conformances
8.7.1.1 Due to industry requirements the Capsonic Automotive and
Aerospace Inc. goal is to receive zero defective materials from suppliers, for
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that reason, suppliers must consider all the necessary actions to protect
Capsonic Automotive and Aerospace Inc. from receiving defective material.
8.7.1.2 When a defect is detected at Capsonic derived from an out-of-control
process condition from a supplier, the discrepancy will be documented in
JADE portal by Capsonic SQE, in which the defect will be communicated to
the supplier via automated JADE email:
8.7.1.2.1 Supplier will be communicated of the quality problem
through the JADE portal, in which suppliers are required to access
once the email notification alert them of the defect.
8.7.1.2.2 Supplier must evaluate the condition reported and confirm
their stock is free of that defective situation.
8.7.1.2.3 Supplier must respond with interim activities and
confirmation/acknowledge of the problem via JADE portal. If
supplier does not agree with the rejection this decision must be
addressed via JADE portal too.
8.7.1.2.4 Supplier must provide a plan to minimize the impact in
production based on the analysis of the discrepant condition and
inventory available, via JADE portal.
8.7.1.2.5 Supplier may contact Capsonic SQE, in case of additional
clarification / information is required. However official information
must be originated/posted into JADE Portal.
8.7.1.3 The Supplier must initiate the actions needed to contain the problem
at its facilities as well as the actions required to avoid the Capsonic
Production Department to stop due to a quality issue arising at the supplier’s
facilities.
8.7.1.4 Some of the actions performed to keep Capsonic production
requirements are to sort, rework or replace suspected stock at the supplier’s
premises. If this is not possible, the supplier must send a representative to
the Capsonic facilities to perform the actions required to keep the Capsonic
Production Department running.
8.7.1.5 If the supplier requires performing the interim actions at the
Capsonic installations, the supplier must observe the safety rules established
at Capsonic.
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8.7.1.6 The supplier must make the necessary arrangements with the
Supplier Quality Engineer (SQE) to coordinate the activities that could
include sorting or material rework to be performed by the supplier. The
supplier must be responsible for coordinating the activities and the personnel
designated to perform the job. No unattended personnel will be accepted at
any Capsonic facility.
8.7.1.7 Actions derived from these types of contingencies must be agreed to
by the Supplier Quality Engineer responsible for the product. If sort and/or
rework is performed by Capsonic personnel, supplier will be charged with
$20.00 dollars per hour per person required to support Capsonic production
demand.
8.7.1.8 A Return Material Authorization (RMA) must be provided to
Capsonic via JADE Portal by suppliers to return and/or scrap defective
material resulted from a defective shipment or/and sorting operation
performed at Capsonic premises.
8.7.1.9 Supplier must be charged with a fee of $150.00 U.S. dollars due to
Administrative activities and $150.00 U.S. dollars fee due to customs
charges originated from crossing material from El Paso TX and Juarez.
8.7.1.10 These charges will be submitted by Capsonic SQE via JADE based
on supplier performance and support provided.
8.7.1.11 Supplier must be contacting Buyer as well as SQE when quality
problem is reported by Capsonic to make the arrangements necessary to
replace defective/suspicious material with certified components and support
Capsonic production requirements.
8.7.1.12 If extended periods of bad quality of components are delivered to
Capsonic, the supplier will be hiring external services for sorting/reworking
material to ensure the quality of the product delivered to Capsonic.
8.7.1.13 All of the above activities must be documented in JADE portal and
suppliers must be using this system as an official communication method to
address the quality issues reported by Capsonic and to document out the
corrective actions derived from activities performed by suppliers to avoid
eliminate quality problems from their quality system.
9. Performance Evaluation
9.1 Monitoring, Measurement, Analysis and Evaluation
9.1.1 General
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No Capsonic Specific Requirements for this section.
9.2 Customer Satisfaction
9.2.1 Evaluating Vendors
9.2.1.1 Each vendor listed on the authorized vendor listing will be
evaluated every month.
9.2.1.2 A report will be generated by the Purchasing Department,
rating the vendors will be referred to as the monthly Vendor
Performance Rating Report (VPRR).
9.2.1.3 The goal established for each vendor will be based on 100%
on-time delivery and an overall VPR score of 95%.
9.2.1.4 Each vendor will be provided appropriate planning
information and purchase commitments to enable vendor to meet the
100% rating.
9.2.1.5 At the end of the rating period, the Purchasing Manager will
run the Vendor Performance rating on JADE Portal. A report will be
generated for each vendor providing information based on on-time
delivery; quantity received versus quantity ordered, and the quality
of the components received.
9.2.1.6 Based on the information received from JADE Portal, a
consolidated VPR report will be generated.
9.2.2 Supplier Evaluation Report
Capsonic suppliers will be evaluated in these areas following these criteria:
9.2.2.1 Quality (ppm’s); up to 25 Total points with the following
reductions if these situations take place:
Ten points will be deducted for the first DMR and/or corrective
action requested during the month. i.e. one Corrective Action (8D’s)
= -10 points, Two corrective actions (2 8 D’s) = -25 points, etc.
Reoccurrence = - 5 points
PPM’s greater than 1 = -5 points
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9.2.2.2 Delivery ; 100% delivery = 25 points,
95% = 7.25, 90% = 12.5 points, 80% = 0 points
9.2.2.3 Cost- If yearly improvement is demonstrated = 25 points.
9.2.2.4 Technical and Service Support; If proactive actions and
Corrective Action Response (CAR) effectiveness is demonstrated =
25 points awarded.
9.2.2.5 A total of 100 points can be awarded meaning that 100%
score has been given to this supplier.
9.2.3 Vendors Qualifications:
9.2.3.1 A letter from the Purchasing Manager will be sent to each
vendor notifying them of their rating every month.
9.2.3.2 In the letter sent to the vendors, details of what is to be
expected such as 100% on-time deliveries and maximum 20 ppms is
to be reinforced in the letter.
9.2.3.3 Each Buyer will also be given a copy of the VPRR.
9.2.3.4 Each vendor has the opportunity to appeal his rating. The
appeal must be addressed to the Purchasing Manager. If sufficient
grounds can be provided by the vendor, the Purchasing Manager can
adjust the rating accordingly.
9.2.3.5 Part of the Vendors Qualifications will be the Onsite Supplier
Audit which will be documented on the Supplier Audit report, and
follow up to any findings thru the open items list as well as timing
for closing open items.
9.2.4 Unsuitable Ratings
9.2.4.1 The Purchasing Manager will contact and request corrective
actions for those vendors that have an unsuitable rating over a two
month period.
9.2.4.2 The vendors that continue to have unsuitable ratings over a
three month period will be placed on probation. A letter will be sent
to them notifying them of such action. If the vendor cannot obtain a
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suitable rating over the next six months, that vendor will be removed
from the authorized vendor listing.
9.2.4.3 Supplier Rating Category & Action.
Supplier rating category & action taken will be based on the table as
follow:
Supplier
Category
Percentage /
Performance Remark
Actions
Green
(Best Supplier)
95-100%
Outstanding performance,
During 6 consecutive
months.
Post supplier as Green
Status in Bid List.
Blue
(Good Supplier)
90 ~ 94.9%
Satisfactory performance,
During 6 months.
Communicate to Sourcing
committee of potential
supplier in new businesses
(Require an assessment
before sourcing new
business).
Yellow
(Moderate Supplier)
85-89.9%
Below average
performance, improvement
required.
Issue Supplier Corrective
Action Report (SCAR) to
suppliers.
SQE, Buyer & Material
Management Sections
shall monitor corrective
action plan from supplier.
If remain at same category
during 3 consecutive
months, Purchasing issue
acknowledgement letter to
supplier’s top management
for action.
If remain at same category
for 6 consecutive months,
supplier will be
recommended to be
removed from bid list.
RED
(Very Poor Supplier)
Below 84.9%
Very unsatisfactory
performance, immediate
action plan is required
Issue Supplier Corrective
Action
Plan (SCAR) to supplier.
On Site Audit is required
QE, SOM & Material
Management Sections
shall monitor corrective
action plan from supplier.
Issue acknowledgement
letter to supplier’s top
management for action.
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If remain at same category
for 9 consecutive months,
supplier will be removed
from bid list.
9.1.3 Analysis and Evaluation
No Capsonic Specific Requirements for this section.
9.2 Internal Audit
9.2.1 Supplier/Sub-Contractor Internal Audits
9.2.1.1 Suppliers and sub-contractors will perform internal audits to verify
the continued effectiveness of the Quality and Environmental Management
Systems.
9.2.1.2 The internal audit will be performed at least once per year in
accordance with a documented audit schedule. The audit schedule will
be revised to increase audit frequency when warranted by internal and/or
external performance issues.
9.2.1.3 Internal audits are to be conducted by personnel who are
independent of the organizational or functional activity that is being
audited.
9.2.1.4 Documented internal audit procedures will be in effect indicating:
•Audit system review for effectiveness and continuous improvement.
•Defined responsibilities for personnel conducting the audit.
•Content/questions within the audit.
•Documented audit schedule and frequencies.
•Follow-up procedures to monitor and confirm that corrective
actions are completed and verified for effectiveness.
9.2.1.5 Internal audits and corrective action activities are to be maintained
on file for three years and are to be available for review, upon request by
Capsonic.
9.2.1.6 Capsonic may perform an audit review anytime a supplier/sub-
contractor falls within the unsatisfactory supplier performance guidelines
as previously established in the Supplier Manual.
9.2.1.7 Capsonic may review the suppliers’ internal and/or third party audit
results when based on just cause and reason.
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9.2.1.8 Capsonic may perform audits of the suppliers’/subcontractors’
Quality and/or Environmental Management Systems as deemed appropriate
based on supplier performance issues and/or for supplier development
purposes.
9.3 Management Review
9.3.1 General
No Capsonic Specific Requirements for this section.
9.3.2 Management Review Inputs
No Capsonic Specific Requirements for this section.
9.3.3 Management Review Outputs
No Capsonic Specific Requirements for this section.
10. Improvement
10.1 General
No Capsonic Specific Requirements for this section.
10.2 Nonconformity and Corrective Action
10.2.1 Warranty
A primary focus of OEM Customers is expenses attributed to product
performance after vehicle sale. Financial liability associated with
warranty is more significant now due to consumer awareness and
extended warranty coverage. Extensions of warranty periods from the
traditional 12-months to 36-months and beyond have emphasized the need
to deliver reliable and durable product or face warranty costs and owner
dissatisfaction.
OEM’s have stipulated that warranty costs will be shared with their supply
base. As such, with respect to new and carryover programs, suppliers
will be required to participate in warranty activities including:
•Warranty return reviews/analysis
•Improvement actions
•Warranty cost responsibility
When a supplier’s component is clearly implicated in a warranty issue with
financial consequences, the supplier will accept these costs. Currently
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purchase orders contain terms relative to warranty cost. The Statement of
Work will specifically define details of the supplier participation.
10.3 Continual Improvement
No Capsonic Specific Requirements for this section.
History Changes Log
Document:
Supplier Quality Manual
REVISION
DATE OF
REVISION
SECTIONS
DESCRIPTION OF CHANGE
APPROVED BY
1
5/24/2010
ALL
NEW MANUAL
J.A./ S.A.
2
2/24/2012
Supplier Check
List
Supplier Commitment Form was added
2.1
Removed sourcing meeting every week
Change BT to Plant Mgr.
4.1.1
Added process for recall equipment under calibration
4.1.3
Added MSA AIAG Manual reference
4.1.4
Added controlled conditions for
Calibration/verification
8.2.4
Added the feasibility form in the RFQ process
10.1.7
Added 20.00 dls per hour per person when Capsonic
Personnel perform the intermin activities.
11.1 and 11.3
Defined buyer responsibility to provide revised
drawing.
12.3.8.
Added the requirement for Cpk, R&R study for
instrument used and MSA.
3
3/23/2012
12.2.5
Annual dimensional layout requirement included.
J.A./ S.A.
4
5/14/2012
4.2.5
Requirement for tool pictures was added
J.A../ S.A.
10.2.7.1
Changed the method to measure quality
11.2.2
Added PPAP checklist
12
PPAP Checklist added and SQE responsibility
12.3.2
PPAP Checklist added and SQE responsibility
11.1
Requirement for tool pictures was added
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5
6/11/2012
12.3.8
Process requirements added for Key and Major
Characteristics
J.A./ S.A.
6
8/1/2012
13
Added general, lot control and FIFO
J.A./ S.A.
15.1
Right to access supplier premises.
15.2
Cost Policy
15.3
Quality of Products and Services
15.4
Product and Processes developed with suppliers
15.5
NAFTA was added
15.6
Interruption in Material supply
15.7
Tool development Report
7
11/20/2012
1.2
Change from www.capsonic.com to B2B for SQM
access
3.4
Record retention for aerospace product increased
from 10 to 15 years
9.1
Change from EDI to B2B to communicate with
Capsonic.
10.1.11
and 10.1.12
Added to contact buyer and SQE when a rejected
material is identified at Capsonic. Make reference to
QAP-13-002 procedure.
10.1.13
Actions for extended periods for bad quality
components delivered to Capsonic was added.
10.1.2.1
Added the detail of activities and communication to
be followed by suppliers when a quality issue is
documented.
17.4-17.8
Added details for processing mold forms
8
9/30/2013
Supplier Check
List
Added hyperlinks to forms
3.4
Added record retention criteria for Sub-suppliers
4.1.3
Added the criteria for performing the R&R studies.
4.1.9
Calibration is required for employee own gauges
4.3.3
Change from Guide 25 to ISO17025
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4.5.3 and 4.5.4
Added to determine MSA requirements for linearity
and bias
12.3.3
Added the amount of samples required for PPAP and
FAIR
9
3/3/2014
ALL
Change of Logo
12.3.9
Correction of IMDS Number 8403 to 8304
10
6/22/2016
12.3.2
Change number of parts to be inspected, from 6
pieces to 5 pieces per cavity.
11
10/20/2016
10.3.5
Added paragraph "Part of the Vendors Qualifications
will be the Onsite Supplier Audit which will be
documented on the Supplier Audit report, and follow
up to any findings thru the open items list as well as
timing for closing open items"
12.6.2
Added paragraph "SQE should indicate on the PSW
when a Conditional or interim approval is granted
and the reason for the conditional approval as well as
the timing for it’s expiration"
12
5/25/2017
15.1
"regulatory authorities" was added
2.1
4.1.11
"IATF 16949" Replace "ISO/TS 16949"
13
8/28/2018
All
Rearrange Manual to match with ISO9001:2015
structure.
4.1
Distribution center address: 7B Zane Grey street
79906 replaces 12120 Esther Lama Suite #120
79936
All
Material Engineer and Business Team Manager was
replaced by "Buyer"
8.4.7
Requirements for Counterfeit Parts was included
8.5.6.2.3
Format QAF-SQM-004 changes to PRF-8.4-002
