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TRANSCRIPT
Page 2 of 82
EXPECTATIONS FROM OUR SUPPLIERS .............................................................................. 4
0.1 General Information ................................................................................................................. 5
1.0 MATERIALS MANAGEMENT DOCUMENTATION .................................................................... 6
1.1 Supplier MMOG Assessment ................................................................................................... 6
1.2 Supplier Launch Readiness ................................................................................................... 10
1.3 Supplier Launch Plan .............................................................................................................. 13
1.4 Safety Stock and Change Response ................................................................................. 14
1.5 Supplier Bank Build Requirements ....................................................................................... 14
1.6 EDI Electronic Data Interchange ........................................................................................ 15
1.7 Packing Slip Requirements .................................................................................................... 19
1.8 ASN Advanced Shipping Notice ......................................................................................... 21
1.9 Supplier Performance Monitoring ....................................................................................... 23
1.10 Customs and Brokerage Information.............................................................................. 29
2.0 PACKAGING AND PART INFORMATION ............................................................................. 29
2.1 Part Identification and labeling ........................................................................................... 29
2.1.1 Sample Container Labels ................................................................................................... 31
2.1.2 Master Labels......................................................................................................................... 34
2.1.3 Labeling Detail of Steel Coils ............................................................................................. 36
2.1.4 Palletization ............................................................................................................................ 37
2.1.5 Mixed Skids ............................................................................................................................. 38
2.2 Supplier Packaging ................................................................................................................. 38
2.2.1 Returnable Containers ........................................................................................................ 39
2.2.2 Decanting Material Guidelines ........................................................................................ 40
2.2.3 Coil Packaging ..................................................................................................................... 41
2.2.4 Steel Coil Packaging and Unloading Requirements .................................................. 41
2.2.5 Pallet Requirements ............................................................................................................. 43
2.2.6 Load Stability ......................................................................................................................... 44
3.0 TRANSPORTATION INFORMATION ....................................................................................... 45
3.1 Carrier notification .................................................................................................................. 45
3.2 Shipment documentation ..................................................................................................... 45
3.3 Missed Shipments ..................................................................................................................... 47
3.4 Overseas and North American Routing Notice .............................................................. 47
3.5 Free Trade Agreement Customs Compliance ................................................................ 52
3.6 C-TPAT / PIP ............................................................................................................................... 53
4.0 SUPPLIER QUALITY ................................................................................................................... 53
4.1 Supplier Communication .................................................................................................. 53
4.2 Supplier Selection ............................................................................................................... 54
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4.3 Supplier Continuous Improvement ................................................................................. 55
4.4 Tooling .................................................................................................................................. 56
4.5 Control of Inspection Fixtures, Measuring/Test Equipment ........................................ 56
4.6 e-APQP (Electronic Advanced Product Quality Process) .......................................... 57
4.7 Defective Material Notice Reporting ............................................................................. 59
4.8 Lot Traceability .................................................................................................................... 61
5.0 ENGINEERING CHANGE ........................................................................................................ 61
5.1 SRCD ..................................................................................................................................... 61
6.0 SERVICE AND CLAIM INFORMATION .................................................................................. 63
6.1 Service Obligations ............................................................................................................ 63
6.2 Obsolescence Claims ............................................................................................................ 63
6.2.1 General Information for Claims ........................................................................................ 63
6.2.2 Claim Document .................................................................................................................. 64
6.2.3 Claimed Material Audit ...................................................................................................... 64
6.2.4 Claim Settlement .................................................................................................................. 65
7.0 ACCOUNTING INFORMATION .............................................................................................. 68
7.1 Supplier Invoices and Payments ......................................................................................... 68
Acknowledgement .......................................................................................................................... 80
Page 4 of 82
Expectations from our Suppliers
Magna Closures Dortec Industries is committed to maintaining its position as a Global
Leader within the Automotive Sector. We will continue to be the supplier of choice to our
Customers, through continued leadership and excellence in innovation, technology, cost,
quality and delivery.
Recognizing the integral role that each Supplier has in the value chain, it is our intent to
establish strategic, long-term relationships to bring lasting value and benefit. Those
suppliers demonstrating the desire and ability to support us through the appropriate
engineering, quality and manufacturing disciplines, focused on effective design
validation, mistake-proofing, process controls, delivery, service and continuous
improvement will continue to share in this partnership.
The relationship between Magna Closures Dortec Industries and its Suppliers shall be
managed to the highest degree of honesty, integrity and professionalism. Our standard of
conduct will ensure that we consistently make our decisions based upon optimization of
value and sound business principles. We will not allow any undue influence or
inappropriate activity to compromise those decisions. We are committed to managing
our supply base in a manner that continues to bring shared value, growth and reward.
In support of maintaining a professional business relationship with our suppliers, our
Divisional Senior Management encourages an open door policy to facilitate discussion
and resolution of issues through escalation, as appropriate.
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0.1 General Information
Where conflicts exist between this Magna Closures Dortec Industries Supplier Manual and
the Magna Global Supplier Requirements manual, this Magna Closures Dortec Industries
Supplier Manual shall take precedence.
As a supplier to Magna Closures Dortec Industries, it is imperative that you are aware of
our delivery expectations. We fully expect our suppliers to deliver 100% on time to our ship
schedules.
It is the supplier’s responsibility to ensure that the carrier has been notified for each
scheduled pick up. If there is a ‘dead run’ or no material available for shipment, the
supplier must give 24 hours’ notice to the Carrier. If for any reason suppliers cannot meet
the regular scheduled shipment, they must expedite at their expense to meet the
required dock date of the release. The Material Planner at Dortec must be notified of any
delays. Any delays may be reflected in your monthly Suppliers Delivery Performance
Rating.
If meeting the delivery schedule should become a chronic problem, a Recovery Plan will
be requested by Magna Closures Dortec Industries’ Material Planner.
1. During periods of holidays and shutdown at the suppliers’ facility, Dortec expects
the supplier to make arrangements to ensure that flow of material is not disrupted
at Magna Closures Dortec Industries.
2. After seeking assistance from Engineering regarding Engineering Changes,
Finance Department for AP issues, Quality for Quality concerns or Purchasing for
Commercial issues, you will need to contact your Materials Planner if any delivery
problems are expected.
3. As changes in personnel at your facility occur, please be sure to update the
Master Vendor Listing and forward to your Materials Planner Representative.
Failure to update will affect the supplier rating.
Suppliers that are on Weekly Releasing will have Authorization as follows:
2 Weeks Firm
1Week Fabrication
6 Weeks Raw material
10 – 36 Weeks Forecast (Based on Customer Authorizations)
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Overseas Suppliers that are on Weekly Releasing will have authorization as follows:
8 Weeks Firm
1 Week Raw material
10 - 36 Weeks Forecast (Based on Customer Authorizations)
NOTE
Suppliers must contact their Planner to advise of any potential shipping problems and
advise any alternate shipping methods.
1.0 MATERIALS MANAGEMENT DOCUMENTATION
1.1 Supplier MMOG Assessment
As a Magna Closures Dortec Industries supplier there are certain criteria that you are
expected to achieve. An MMOG Assessment
http://www.aiag.org/staticcontent/committees/workgroup.cfm?FC=SC&grp=CUSTOMS&
group=MMOG is an industry standard format used to identify a company’s ability to meet
specific standards that relate to Materials Planning & Logistics. It is the suppliers’
responsibility to purchase this document.
Within the MMOG there is a Self-Assessment Report, which each supplier will be required
to complete on a yearly basis. This will provide your company and Magna Closures
Dortec Industries with important information as to how well your company operates and
where there may be opportunities for improvement. All new suppliers are required to
submit completed MMOG prior to award of new business. All suppliers are required to
submit the completed MMOG Self-Assessment results to their Material Planner. Critical
suppliers may be notified of an earlier date to complete the assessment. Failure to submit
the MMOG Self-Assessment on time will affect your Supplier Performance Rating each
month until submitted.
This document provides recommended business practices for the Materials Planning and
Logistics process within the supplier’s facility and is intended to establish a common
definition of materials practices to facilitate effective communication between trading
partners. Once this is complete, a Magna Closures Dortec Industries Representative may
visit your facility to complete an onsite audit.
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Explanation of Evaluation Results Sheet
Although every question in the document is of great importance to develop Materials
Planning and Logistics performance, a weighted scoring system has been designed to
identify areas which should be given a higher priority. This will allow focus on the urgent
issues to avoid the risk of not meeting business partners’ requirements. Throughout this document, “shall” indicates a situation where adherence to the criteria is
mandatory to the materials management function. Non-compliance to any "shall"
statement will result in a "C" level on the self-assessment rating. Three levels of focus have been defined and weighted as follows: F3: If F3 requirements are not met, there is a high risk of interruption to customer
operations with additional costs to be incurred in the short term. F2: If F2 requirements are not met, customer satisfaction and the organization’s
performance will be seriously affected.
F1: If F3 requirements are not met, the organization’s competitiveness will be adversely
affected.
The weightings are an aid to prioritizing continuous improvement activity only and do NOT
necessarily signify importance of the area in question.
SCORING/WEIGHTING
Each question is multiplied by a weight factor:
F1 = Low (1 point each)
F2 = Medium (2 points each)
F3 = High (3 points each; any non-compliance will result in overall evaluation to be Level
C due to critical competency factor.
Enter "X" in each check box if process is effectively implemented at your organization
A-Level
Definition: The supplier far surpasses minimum standards in every aspect and can be considered at or near "world class" standards.
Deployment from evaluation: A-Level is achieved if 90% or higher is obtained overall. Non-compliance to fewer than 6 F2-questions and compliance to all F3-questions will result in Level A.
B-Level
Definition: The supplier is deficient in several areas that will impact its ability to support the needs of the customer. An action plan should be in place, and the corrective action SHOULD NOT require a significant amount of time (3 months or more) to implement.
Deployment from evaluation: B-Level is achieved if a score greater than 75% and less than 90% is obtained overall. Non-compliance to 6 to 12 F2 questions and compliance to all F3-questions will result in Level B.
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C-Level
Definition: The supplier is deficient in one or more critical/high-impact aspects of a given category. Action plans are required to ensure deficiencies do not result in serious or prolonged issues to the customer.
Deployment from evaluation: Noncompliance to ANY F3 question will result from any of
the following: 1.) Noncompliance to ANY F3 question, 2.) Noncompliance to 13 or more
F2 questions or 3.) A score less than 75% is obtained
Preparation 1. Read through the document carefully 2. Discuss with other people involved, gain commitment 3. Establish preliminary time frame 4. Collect data & information 5. In the Self-Assessment, place an 'X' in the box in column D to indicate that the criteria
has been met 6. Document Data 7. For each question it is necessary to have supporting documentation e.g. flow charts,
organization charts. Please ensure your company has an evidence binder that will be
reviewed by the Magna Closures Dortec Industries Auditor. Complete Evaluation
In order to automatically populate the Scoring Sheet and Gap Analysis, the results of
each question are recorded with an “X” in the box in column “D” into the self-assessment
portion of the Excel spreadsheet. Analyze the data
Analysis of the self-assessment and weighting criteria will give a clear indication of
priorities for improvement activities.
Develop an Action Plan
An action plan is required for all criteria not fulfilled. All criteria not fulfilled will be
automatically populated onto the gap analysis portion of the Excel spreadsheet. To use the gap analysis, the following steps are to be followed:
Click on (arrow) in Column "A" labeled, "Question #" under Gap Analysis tab
Click "non-blanks"
Follow the above each time an additional "X" is recorded in Self-Assessment tab.
It will then be necessary to analyze the problem and define a measure to solve the
problem and complete the Action Plan, e.g.
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1.2 Supplier Launch Readiness
Suppliers can gain access to the following labels via the Supplier Portal through
Magnaclosures.com in the Suppliers section.
All Prototype Material will be identified with appropriate Pink labels. “PROTOTYPE
MATERIAL” QSP-080.3 REV. LEVEL A
This label is to be used on Prototype parts.
Ensure that the label identifies the person the Prototype Material goes to.
Ensure that all the required details are completed on the label, such as part
number, Revision level, Program ECN# (engineering change notification number),
and anything else that will help identify these parts.
Place the label on at least the front and back of the container/box and the top:
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All Non-Production parts will be identified with appropriate Orange labels
“STOP
NON-PRODUCTION”
This label is to be used on non–production parts: PPAP Samples, Trial Parts, etc.
Ensure that the label identifies the person the parts go to.
Ensure that all the required details are completed on the label, such as Part
number, Supplier Name, Engineering Change Samples or New Supplier Samples
etc.
Place this label on at least the front and back of the container/box and the top:
Page 12 of 82
First Time Shipment Notice – Blue Label
This label is to be used on production parts: First Time Shipments
Ensure that the label identifies what the shipment is due to: Engineering Change,
New Supplier, etc.
Ensure that all the required details are complete on the label. Such as Part
Number, Supplier Name, Part Status, etc.
Place this label on at least the front and back of the container/box and the top (if
possible).
This label is to be used for only the first shipment of the part at that particular
revision:
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1.3 Supplier Launch Plan
A Ramp-up plan is a manufacturing plan which requires frequent updates. This usually
indicates your production ramp-up volumes by part family, in order to meet customer
requirements.
This plan is necessary to allow you to plan your production facilities and “ramp up” in a
linear fashion to ultimately support Magna Closures Dortec Industries requirements. The
following is a generic example of a Ramp Plan. The information entered in this Ramp Plan
should be based on Magna Closures Dortec Industries release quantities. Shipping transit
time and sub-suppliers’ lead-time needs to be taken into consideration when populating
this information.
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1.4 Safety Stock and Change Response
Fluctuations in demands have become commonplace in the automotive industry.
Suppliers must support any increases in demand up to 20% with no additional cost and
must be supplied within 5 working days or as negotiated with Magna Closures Dortec
Industries Materials Management. Increases that exceed 20% will require the supplier to
complete a “Supplier Action Plan” which will be reviewed by the Materials Planning Team
to ensure sufficient supply at Dortec. In order to prevent missed deliveries to Magna
Closures Dortec Industries, Suppliers must ensure they have the capability to maintain a
continuous flow of material, despite potential interruptions from the following:
Labour disruptions
Equipment failures
Material shortages
Capacity Shortfalls
Tool Transfers, etc.
This should be accomplished by maintaining a certain amount of safety stock. The
amount of safety stock will depend on many factors such a geographic proximity and
manufacturing processing time, but will typically amount to one week's supply.
1.5 Supplier Bank Build Requirements
Suppliers may be requested to build banks for engineering changes, moving of
equipment etc. When a bank is requested where the part up-suffixes or the tooling is
physically moving, the supplier must complete a Supplier Bank Build Plan and submit to
Magna Closures Dortec Industries Materials for approval. This form must be submitted on a
weekly basis to track the plan. As well, upon the bank being considered complete by the
supplier, a final sign off by the Magna Closures Dortec Industries Materials Manager is
required prior to any changes or moves.
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Supplier Bank Build Plan
1.6 EDI Electronic Data Interchange
Magna Closures Dortec Industries will supply the following Data:
830 Weekly Releases
E-Business Dortec Internet Application
Suppliers must be able to receive electronic release Requirements (830 or E-Business
transaction sets).
Suppliers shall transmit their release requirements (830 transaction set) via EDI to their Sub-
Suppliers.
These electronic data transmissions for product release must occur, at a minimum weekly.
Suppliers must be able to transmit these requirements to their supplier base daily. 830 -
Supplier must be capable of receiving weekly and daily updates. It is the supplier’s
responsibility to check daily for updates to their releases.
In the event that the Supplier cannot receive or send electronically, they will be required
to use Magna Closures Dortec Industries E-Business application. This is an Internet
application for suppliers to receive releases and send Supplier ASN’s.
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Sample E-Business Releases
Material Planning Releases – Missed Shipments
Supplier Responsibility
If you are unable to meet the quantities required for shipment per the weekly releases,
you shall contact your Magna Closures Dortec Industries Materials Planner and the
Magna Closures Dortec Industries Freight Forwarder (which is Ranger for North America
and Cargo Services for Off-Shore) immediately via email, etc. Your Material Planner will
be able to determine if the quantities can be shipped on the next scheduled load or if an
‘expedite’ will be required.
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For Overseas Suppliers ONLY - You are required to obtain authorization from your Materials
Planner prior to booking an air-expedite, prior to the shipment leaving your facility.
All FedEx shipments that were not pre-approved will be charged back to the Suppliers.
Supplier Action Plan – Behind Schedule
Suppliers that are unable to meet weekly release quantities will be required to provide to
their Material Planners’ a Supplier Action Plan, showing when they will be able to be
‘back-on-track’ to the releases.
The Supplier shall complete the Supplier Action Plan matrix, as well as the Supplier
Shipping Plan, and return it within 24 hours, to your Material Planner.
The Supplier will need to provide the following information:
Reason for Short Shipment
Immediate action required to cover the release requirements
Permanent Corrective Action to prevent any reoccurrences
You may be required to attend daily conference calls
Sample Supplier Action Plan
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Sample Supplier Shipping Plan – Shipping
1.7 Packing Slip Requirements
Magna Closures Dortec Industries requires that all material shipped be identified on a
Packing Slip or Bill of Lading. The following information must be noted:
Shipment Date
Packing Slip and/or BOL number
Sold to
Ship to
Line item for each part number shipped (where full part number must be shown)
Description of each part must be noted as per 830 Order Release descriptions
Purchase Order Number for each part number must be noted on same line as
part number and quantity
Quantity Shipped
Quantity Ordered
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Order Release Number
Lot number of Shipped quantities
Number of containers of each part number shipped with the extended quantity
noted. E.g.: Pc/Carton, #cartons, #skids
Gross Weight
Net Weight
Signatures of Shipper and Carrier
Sample Supplier Packing Slip
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1.8 ASN Advanced Shipping Notice
An Advanced Shipping Notice – (856 transaction) must be sent to Dortec at the time of
shipment. If an ASN does not arrive at Dortec prior to the supplier shipment, or if it is
incorrect, a Receiving Discrepancy Report (RDR) will be issued for non-conformance of
ASN and the monthly SPM delivery rating will be affected. For all International shipments,
a copy of the invoice and packing are to be faxed to your Material Planner when the
shipment leaves your facility.
NOTE
Payment delays may occur if incorrect ASN is received.
ASN’s must be sent by ALL Suppliers. For Production and Service shipments. No
ASN will be required for Non-Production or Prototype material.
Sample Supplier ASN
ASN – Required Information
ASN#: Enter ASN number. This should be the same as your invoice or packing slip number ASN Date: The date the ASN was created Process Time: Time the ASN was processed and sent to Dortec Shipped Date: Date the freight is picked up at your facility
Expected Date: Expected Delivery Date at Dortec Vendor: Enter your Dortec Vendor Number and Name SCAC Code: For Overseas suppliers PAL: For ocean shipment via Manitoulin Cargo Services PALA: For air shipment via Manitoulin Cargo Services
Page 22 of 82
FEDEX: For air shipment via FEDEX SUPP: For air shipment arranged by the Supplier Carrier Name: Name of Carrier, Ocean vessel or Air Cargo Services Transportation: Mode of Transportation – Ground, Ocean or Air Freight Bill#: Manitoulin Ocean confirmation number (HBL Number) Air Bill #: Manitoulin Air confirmation number (HAWB Number) or FedEx Tracking number Gross Weight: Total weight of the freight Net Weight: Weight of Product without the packaging
P/N Magna Closures Dortec Industries part number found on PO
Part Description Magna Closures Dortec Industries part description
PO# for Each P/N Purchase Order Number for each part number
Tot# of Cartons/Skids Total Number of Cartons and or skids
Qty Ordered Quantity Ordered
Qty Shipped Quantity Shipped
Order Release# Order Release Number
Address Sold To
Address Shipped To
Receiving Discrepancy Reports – RDR
Dortec uses an RDR Notice to communicate all receiving discrepancies. Your Customer
Service representative for Magna Closures Dortec Industries will be receiving this
notification via email. Depending on the severity of the issue, you will be asked to provide
an 8D, to clarify and ensure that the issue has been resolved and that there will be no
more occurrences. Through the RDR we will also be communicating to you any line-
downtimes attributed to short shipments or missed shipments.
General reasons for discrepancies:
Material Received without a packing slip
Incorrect Quantity received
Incorrect Part number received
Incorrect suffix level for part number received
Over or Under shipment Received
No EDI
ASN received prior to receiving product
Error in the EDI ASN
Incorrect Packaging Received (container or skids)
Incorrect Label format
Incorrect information on label
A $250 Administration fee will be charged with every RDR issued. You will have 48 hours to
dispute the RDR. Should a corrective action be sent within this 48hrs, the administration
fee may be waived.
Page 23 of 82
Sample Receiving Discrepancy Reports
1.9 Supplier Performance Monitoring
Magna Closures Dortec Industries tracks and measures the performance of its supply
base on a monthly basis (with new reports on the 15th of the month in question). This
includes Quality, Delivery and Commercial ratings per the report card. The Supplier
Performance Management Database is accessible through the Magna Closures Dortec
Industries Corporate web page. You can get access via your company’s Administrator.
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It will be the supplier’s responsibility to update and maintain the contact information for
your company through the Web Registration. Direct link is
http://iweb01ds.MagnaClosures.com/Web/WebRegistration.nsf or
http://www.Magnaclosures.com, click on “Suppliers” on the left hand side, then “Magna
Closures Supplier Portal” button. Then you login, click on “Applications” “WebReg &
Information Update”.
The Web Registration:
is an online tool that allows suppliers to manage their own information,
provides secure access to Magna Closures Dortec Industries online applications,
allows mass communications with suppliers,
allows automation of communication from Magna Closures Dortec Industries.
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40% for Quality:
o PPM: 5 for every 25 ppm;
o OEM issues: 20 per OEM issue;
o DMN: 5 per DMN;
o DMN Responsiveness: 5 per late;
o Repeat Issues: 10 per repeat;
o Launch Issues: 10 per issue;
o PPAP Performance: 5 per late;
Quality 40%
Delivery 40%
Commercial 20%
Page 26 of 82
40% for Delivery:
o On time #/mth x 5
o Customer Line Interrupt #/mth x 30
o Dortec Line Interrupt #/mth x 15
o ASN #/mth x 5
o Over / Under x 2
o Label / Packaging x 2
o MMOG (yearly) / mth x 10 (each month late)
o Supplier Manual x 5 (each month late)
20% for Commercial:
o 5 for TS/VDA/ISO/CQI
o 3 for NAFTA
o 2 for monthly login to SPM
o 6 LTA (yearly)
o 4 VAVE (yearly)
Suppliers must maintain a 6 month rolling average of 80% minimum in order to bid
on future business and remain on the Magna Closures Dortec Industries Preferred
Supplier Listing. Meetings will be scheduled for any Supplier falling under 80%.
OEM Issues: Any Prototype, Pre-Launch, Launch, Production or Service Quality
issues incurred by an Magna Closures Dortec Industries OEM Customer
attributable to a supplier caused or related issue.
DMN: The total number of Defective Material Notice Reports issued against a
supplier. DMNs can be issued for both product and system non-compliance.
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DMN Responsiveness: Supplier responds to a Magna Closures Dortec Industries’
request for corrective action, for a quality discrepancy, within the specified
timeframe. Initial response is 24hrs and a Permanent Corrective Action (Plan) is to
be received within five days.
Repeat Issues: The number of DMN reports issued against a Supplier, reflecting a
similar, systemic failure mode as a DMN previously issued, The failure must be of
the same mode, however it can be related to different part numbers and may
occur over an extended period of time.
Launch Issue: A DMN issued during the Launch period of a new component or
assembly. Launch period is typically considered from Job 1 through 90 days,
however may differ between divisions.
PPAP Performance: PPAP submissions that are submitted past the Program Due
Date as reflected in the Magna Closures Dortec Industries web-APQP electronic
database; PPAP submissions that are rejected for reasons such as incomplete,
insufficient data, incapable processes, dimensional errors, etc. Rejected status is
as reflected in the Magna Closures Dortec Industries’ web-APQP electronic
database.
On-Time Delivery: of Production shipments are received within the delivery
window specified, utilizing normal freight (no premiums). Unless you have been
advised by your Materials Planner and or Program Manager, Air Shipment Pre-
approval form will need to be completed and approved prior to shipping.
Line Interruptions (Major): Any line stoppage or interruption at a Magna Closures
Dortec Industries OEM Customer facility that is directly related to a supplier issue.
The interruption can be caused by a quality, delivery or any other supplier-
related issue.
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Line stoppage or any line interruption (Minor): at a Magna Closures Dortec
Industries facility, that is directly attributable to a supplier caused or related issue.
The interruption can be caused by a quality, delivery or any supplier-related issue.
ASN Compliance: Supplier complies with Magna Closures Dortec Industries
procuring Division requirements to send electronic Advanced Shipping Notice,
detailing transit method, quantities and time of departure. ASN shall be sent as
soon as the truck leaves the suppliers facility.
Over or Under Shipments: Suppliers shall ship only the quantities specified on the
material releases, or similar documentation, as directed by the Closures Division.
Any deviation from normal ship quantities shall have written authorization.
RDR 8D Response: Supplier responds to a Magna Closures Dortec Industries
request for corrective action, for a shipping discrepancy, within the specified
timeframe. Initial response is to be received within 48 hrs and a Permanent
Corrective Action (Plan) is to be received within 5 days.
Label/Packaging Compliance: Packaging and labeling on all prototypes,
production and service product must be labeled as per AIAG and Magna
Closures Dortec Industries requirements.
TS16949: Supplier has applicable TS16949certification, at minimum ISO9001:2008.
NAFTA: Supplier has applicable NAFTA documentation. See section 3.5 in this
manual.
Supplier performance data is monitored closely and is integral to sourcing
decisions. In the event a Supplier exhibits chronic performance issues, or systemic
deterioration of key performance metrics, they may be requested to attend and
IQ Meeting. It will be incumbent upon the Supplier Senior Management to
present to Senior Magna Closures Dortec Industries Management, the Supplier’s
plan to address the systemic drivers to deteriorating or unacceptable
performance levels.
Page 29 of 82
1.10 Customs and Brokerage Information
Brokerage fees for all importation of shipments are Dortec's responsibility, unless otherwise
specified. All exportation e.g.: Defective Material returned to supplier is the supplier’s
responsibility and are moved accordingly. The suppliers Broker will process customs
clearance and invoice the supplier directly.
Dortec’s Custom Broker into Canada: Buckland Customs Brokers
www.bucklandcustoms.com Phone: 1-800-991-4944
Dortec’s Customs Broker into the U.S.: Buckland Global Trade
Services www.bucklandcustoms.com Phone: 1-888-806-1156
2.0 PACKAGING AND PART INFORMATION
2.1 Part Identification and labeling
All product received at Magna Closures Dortec Industries must have approved
bar code labels which reflect Dortec and industry standards. Magna Closures
Dortec Industries abides by FIFO; therefore it is a direct requirement that our
Suppliers employ FIFO (First In, First Out) as well when they are shipping to Magna
Closures Dortec industries. All material must be labeled with an A.I.A.G. standard
format bar code label and Global REACH requirements. Label standard is “3 of
9”. Label must be submitted prior to first shipment to
Adhesives on Labels for Returnable Containers
SHALL be removable type, pressure sensitive adhesive based on synthetic elastomers
featuring moderately high initial tack, a high level of ultimate adhesive, clean and
removable
SHALL be wrinkle free and assure adherence to the package substrate; adhesive types
can be pressure sensitive or dry gummed. If the specified label cannot be affixed to the
package/container because of container size or design, special arrangements will be
required.
At a minimum the following information must be present on the designated areas of the
label in legible characters as well as bar code symbols.
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Expendable containers must have 2 labels; 1 on each adjacent corner.
Returnable containers must have 2 labels; 1 on each end
Full Magna Closures Dortec Industries part number (bar coded) (P)
Supplier Name and Dortec Supplier Code (bar coded) (V)
Part description
Part quantity (bar coded) (Q)
Part lot number (for traceability) (bar coded) (1T)
Ship to address
Unique serial numbers (bar coded) (S)
Purchase Order Number (bar coded) (K)
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Box or Carton Identical labels shall be
located on two adjacent sides (wrap
around label acceptable). The upper
edges of the labels should be as high as
possible up to 20 inches from bottom of
carton.
Cartons on Pallet
Each carton shall be individually labeled
as described above. One master label
may be used as described in Section 8.1
or one mixed load label as described in
8.2. Each pallet shall contain a master
label or mixed load label. Note: Mixed
Skids only- All boxes/tote labels must be
visible with labels facing outwards. There
shall be no boxes with in the center of the
skid that cannot be verified during the
receiving process. No more than 4 part
numbers per mixed skid.
Drums, Barrels, or Cylindrical Containers
Identical labels shall be located on the
top and near the center of the side.
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Bales
Identical labels shall be located at the
upper corner of an end and the adjacent
side (wrap around label is acceptable).
Basket, Wire Mesh Container
Identical labels shall be located on two
adjacent sides.
Metal Bin or Tub
Tag one visible piece near top, or use a
label holder.
Pallet Box
Identical labels shall be located on two
adjacent sides (wrap around label is
acceptable).
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Telescopic or Set-Up Containers
Identical labels shall be located on two
adjacent sides of the outer box. Some
applications may also require
identification of the inner box (wrap
around label is acceptable).
2.1.2 Master Labels
Every skid must contain a Master Label.
At the top of this label, the heading "MASTER LABEL" should be printed in bold. All skids will
have 2 labels, one on each adjacent corner. The following information must be legible
through the shrink-wrap
Dortec Part number (bar coded) (P)
Quantity (bar coded) (Q)
Dortec PO Number (bar coded) (K)
Supplier Number (Assigned by Dortec) (bar coded) (V)
Serial Number (Assigned by the supplier) (bar coded) (M)
Ship from location
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Sample Vendor Steel Coil Label
2.1.3 Labeling Detail of Steel Coils
Steel Labels must contain the following:
Each coil must have one label. See pictures for proper label location.
(P) Dortec part number (bar coded)
(V) Supplier Code (bar coded)
(S) Unique serial number (bar coded)
(K) Purchase order number (bar coded)
(1t) Heat number (lot number for traceability) (bar coded)
(2Q) Quantity (weight in lbs.) (bar coded)
Description and size of steel required
Press number required in special data field
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2.1.5 Mixed Skids
Suppliers may put up to four (4) unique part numbers on one skid. Every box of one part
needs to be on the same pallet, unless total is more than one full pallet. The skid must be
labeled with a mixed skid label, outlining part number and number of containers. Any
mixed skid not identified in this manner will affect your supplier rating.
Supplier is responsible to ensure shipments are secure and the pallet load meets the
following criteria:
Even level pallet (not a pyramid)
Proper securing e.g. Straps, stretch wrap etc.
Height of pallet does not exceed 50 inches.
Pallets must be stackable (unless approved through Supplier packaging proposal)
Excessive handling will be charged to the supplier if the shipment does not
conform to requirements.
2.2 Supplier Packaging
It is the responsibility of each supplier to provide all products sold to Magna Closures
Dortec Industries in approved packaging. The criteria necessary to determine suitability
include:
Initial packaging approval/change requests - A completed "Supplier Packaging
Proposal" form (see P150 supplemental section) must be submitted for approval to
[email protected]. Approval must be granted
prior to first shipment. Packaging is also part of the PPAP submission.
All returnable packaging submissions must have an expendable back-up packing
submission approved.
Robust to ensure integrity of product
Double-wall corrugated boxes are required (Triple wall for Non-North American
Suppliers)
Compliance with health and safety guidelines (no box shall be over 3 lbs.)
Compliance to AIAG standard guidelines
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Sample P150 Form Packaging Proposal
PLEASE PROVIDE ALL DATA IN POUNDS AND INCHES.
2.2.1 Returnable Containers
During the PPAP process, suppliers are required to submit packaging approvals. If you are
selected for a returnable program, you will need to obtain packaging approval for
returnable pack and also an expendable backup. Magna Closures Dortec Industries
Packaging Coordinator will then establish the amount of the returnable containers to be
in circulation. This is determined by volume, pack density, transit time and frequency of
pickup to support demand. New suppliers will be provided the initial start-up containers 2
weeks prior to SOP (start of production). Returnable packaging will be delivered to your
facility upon pick of product. If an issue arises regarding returnable packaging, suppliers
should contact [email protected] for.
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Suppliers are responsible for the removal of all expired labels and debris from containers
prior to packaging new material. Suppliers are responsible for ensuring that all containers
are clean and that all functional gates or hinges are operational and safe.
2.2.2 Decanting Material Guidelines
The Guidelines for decanting material for any product that requires totes that
Dortec supplies:
Packaging Information for decanted product:
All totes to be de-labeled as required by Supplier,
All totes require (2) standard AIAG BARCODE LABEL’s provided by Supplier
,
All material to be supplied on 30x32 or 48x45 Pallet(provided by Supplier),
All material must be to the standard pack as approved by Dortec
(Packaging FORM P150 to be filled out by Supplier),
All material decanted variance needs to be reported out weekly to
Magna Closures Dortec Industries Inventory Control by Supplier,
Supplier shall notify Magna Closures Dortec Industries planning team of
tote shortages 2 days in advance,
All ST 21 totes are 12 per layer 6 layers high (15x12x4.5),
All ST 26 totes are 12 per layer 6 layers high (15x12x7),
All ST 28 totes are 12 per layer 5 layers high (15x12x9),
All ST 39 totes are 6 per layer 6 layers high (24x15x7).
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2.2.3 Coil Packaging
Pallets must provide 2-way fork entry. Skids will have a minimum of four ¾” ID
(inside diameter) bands, and banded to the skid using two 1 ¼” bands unless
otherwise dictated by customer. 1 ¼” ID bands may be used depending on the
size and gauge of the material. All coils to be shipped standing up will have a
minimum of two ID bands. If spacers are required for stand up material, 48”
runners will be used. They may be either 2” x 4” or 3” x 3” depending on customer
needs. 1 ¼” OD (outside diameter) bands are applied to each coil. On light-
gauge material, ¾” bands may be used. When packaging material standing up,
the minimum single coil width is 18”. Narrower width coils can only be shipped
standing up if they are banded together to meet the 18” minimum width
requirement. Minimum 2” x 2” spacers required between two coils on a skid or
two coils standing up banded together. All skids will have waterproof paper or
plastic on top runners, and all spacers will be wrapped with waterproof paper or
plastic unless specified by customer.
2.2.4 Steel Coil Packaging and Unloading Requirements
20” ID (Inside diameter) required for all coils,
Maximum coil weight 20,000 lbs.,
Maximum skid weight 10,000 lbs.,
Maximum two coils per skid,
Max coil weight and max OD (Outside diameter)will be specified on P.O.,
Rear tow motor or overhead crane unloading,
No side unloading AVAILABLE.
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Examples of skidded and stand up material with proper label location.
Standard wood requirements for steel pallets (see picture) Two 3” x 3” bottom runners Two 2” x 4” top runners Standard skid size is 36” x 48”
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2.2.5 Pallet Requirements
Magna Closures Dortec Industries-approved pallet sizes are as follows (any use of non-
standard pallet sizes must be approved by Materials Dept. at Magna Closures Dortec
Industries):
North American: 48”Length x 45” Wide or 30”L x 32”W Heat-Treated Pallets
Offshore: 39” Length x 45” Wide (or 43” Length x 43” wide for Asia suppliers only) Heat-
Treated Pallets
Pallets must provide 4-way fork entry, and be of double-face, non-reversible wood
construction. A 3-1/12" (88 mm) under-clearance on two opposite sides with a minimum
of 2-1/12" (63 mm) under clearance on the remaining two sides is required. All pallets must
be constructed from hardwood. Plywood pallets are not acceptable. Pallets of other
than wood construction are to be reviewed and approved by Magna Closures Dortec
Industries Manufacturing Engineering of the receiving activity prior to use.
NOTE
Packaging failure is often attributed to a poorly constructed and/or sized pallet. Pallets
must be single stringer and spacing must be 12” or greater. Pallet height must not
exceed 6”. No product shall over hang the pallet. Only hardwood pallets allowed.
Sample Supplier Pallet Construction
Standard North American 48” x 45” x 5”
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Standard Overseas 39” x 45” x 5”
2.2.6 Load Stability
ALL PACKS MUST HAVE SUFFICIENT VERTICAL STRENGTH AND STABILITY TO WITHSTAND
TIERED HEIGHTS OF 100" IN TRANSIT FOR NORTH AMERICAN SUPPLIERS.
50"(l250 mm) would be tiered 2 skids high - Total height 100”
33" (838 mm) would be tiered 3 skids high - Total height 99”
25" (635 mm) would be tiered 4 skids high - Total height 100”
ALL PACKS MUST HAVE SUFFICIENT VERTICAL STRENGTH AND STABILITY TO WITHSTAND
TIERED HEIGHTS OF 90" IN TRANSIT FOR ASIAN OR OVERSEAS SUPPLIERS.
45"(1l43 mm) would be tiered 2 skids high - Total height 90”
30" (762 mm) would be tiered 3 skids high - Total height 90”
22" (558 mm) would be tiered 4 skids high - Total height 88”
Stretch/shrink wrap, banding, or other stabilizing techniques shall adequately secure
palletized loads. Nailing, stapling or gluing is not an acceptable method for securing the
loads. When banding is used, non-metallic banding is required. Horizontal or "belly"
banding corrugated boxes, in order to achieve load stability, is prohibited. Under these
circumstances an upgrade of the corrugated board and/or the additions of dunnage or
corner-posts are recommended. (The use of wood is discouraged if an economical
substitute becomes available.)
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For part identification, label legibility, stretch/shrink wrapped loads must have
identification labels on both the container and on the exterior of the wrap. Banding,
Stretch/shrink wrap should extend low enough on the single or double winged pallet to
secure the load to the pallet.
No container shall exceed 35 lbs.
No skid shall exceed 1600 lbs unless Supplier obtains specific approval from
packaging engineer on the p150 form. The loads >1600lbs. must contain
overweight load stickers.
All suppliers providing goods to Magna Closures Dortec Industries, that are considered to
be “controlled” under the Workplace Hazardous Material Information System (WHMIS),
must comply with appropriate legislated regulations for packaging and shipping,
including MSDS documentation. No material requiring MSDS approval shall be shipped,
without approval. All solid wood packaging/pallets and crates must comply with the
International Plant Protection Convention Standard ISPM #15.
3.0 TRANSPORTATION INFORMATION
3.1 Carrier notification
One day prior to the regular shipments. North American suppliers will have to
provide the carrier the details by email at [email protected] (# of skids,
weight and dimensions). Even if shipment is done by FedEx, DHL, UPS or other
carrier, the supplier still has to advise Hybrid. If the commercial invoices are
available at this time the supplier can send them to the carrier as well.
The closing date for the overseas suppliers will be advised by the agent listed
below and the supplier has to advise the shipment availability a week before this
closing date.
3.2 Shipment documentation
All shipments must be accompanied by appropriate paperwork to comply with
Dortec, Carrier and Transportation regulations. Cross Border shipments must have
the necessary custom documents to avoid any delay.
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Information required on the Bill of Lading is as follows:
Bill of Landing number
Total quantity of Shipment
Total boxes/skids
Total weight (Gross/Tare/Net)
Overall description of Goods
FOB Conditions
Ship from/Ship to
Packing slip number
Information required on the Commercial Invoice:
Date of Export
Shipper address and name
Recipient address and name
Country of origin of the goods
Full description of goods
Magna Closures Dortec Industries part #
P.O. number
HS Code to the 6th digit level
Quantity
Total number of packages
Total weight
Unit price
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Total price
Custom broker name, phone and fax number (refer to section 1.10)
All documentation will have signatures from the following:
Supplier shipper
Carrier
Magna Closures Dortec Industries Receiving
3.3 Missed Shipments
All missed shipments must be expedited the same day at the supplier’s expense.
If Magna Closures Dortec Industries is organizing the ‘Expedite’ on the Supplier’s
behalf, the Supplier will receive an email notification regarding the charges.
Note: It is the Suppliers’ responsibility to ensure that the carrier has been notified
for each scheduled pickup. If there is a ‘dead run’ or no material available for
shipment, the supplier must give 24-hrs notice to the carrier or a charge for a
rescheduled pickup will be sent to the Supplier.
3.4 Overseas and North American Routing Notice
Suppliers will receive a Routing Control Notice to support both North American
and Global supplier origin ship from locations. The various modes will be either via
Land, Sea or Air and all required information would be identified on the routing
Control Notice. It is imperative that the supplier follows the instructions, e.g.:
allowed window times for pick up, carrier selection etc. All related cost will be
charged back if deviated from the specific outline instructions. These notices
must be acknowledged, signed and returned with 48 hours.
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3.5 Free Trade Agreement Customs Compliance
Suppliers within the North American NAFTA region (Canada, Mexico, and United
States) must complete the NAFTA Certificate of Origin, as directed by Dortec on
an annual basis. The Certificate of Origin must contain the Dortec Part Number
and be provided to Dortec annually by December 31st of each year.
Suppliers outside the North American NAFTA region must complete a Declaration
or Statement of Origin. Both the NAFTA Certificate of Origin and the Statement of
Origin are available at http://supplier.magna.com
Suppliers in Korea must complete the Korean-Canada Certificate of Origin on an
annual basis. The Certificate of Origin must contain the Dortec Part Number and
be provided to Dortec annually by December 31st of each year.
At times, other documents may be requested to fulfill our obligations under the
North American Free Trade Agreement or other Free Trade Agreement.
IMPORTANT NOTE: It is your responsibility, as a supplier, to notify Dortec within 30
days of any change in the FTA status of a procured good. Failure to do so may
affect your rating and have potential impact on future business
opportunities. Suppliers shall be responsible for costs incurred as a result of
missing, late or incorrect reporting.
Suppliers must inform Dortec immediately in the event there is a change to the
origin of the goods supplied.
It is expected that suppliers maintain sufficient and required expertise to ensure,
in partnership with Dortec, all necessary NAFTA and other FTA are in compliance
with the regulations.
Documentation to support ALL Free Trade Agreement declarations must be
retained by the supplier for a period of no less than 6 years.
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3.6 C-TPAT / PIP
Dortec is a participant of the Canadian Customs Partner in Protection Security
program. Suppliers who are currently registered to PIP or C-TPAT will be required
to complete the appropriate sections of the PIP/CTPAT questionnaire on an
annual basis. Suppliers, who are not currently registered to PIP or CTPAT or other
recognized security program, will be required to complete ALL sections of the
PIP/CTPAT questionnaire on an annual basis as directed by Dortec.
Shipments that cross international borders should ensure that the truck container
shipments have a high security seal that meets or exceeds the standards outlined
in ISO/PAS 17712. The seal number MUST be included on the supplier’s ASN for
production and service shipments.
4.0 SUPPLIER QUALITY
4.1 Supplier Communication Magna Closures Dortec Industries communicates to its Suppliers in a variety of ways,
including through our website at www.magnaclosures.com. You can also access this site
directly at www.magna.com.
At this site, you will find important information relative to our business, as well as our
expectations of our Suppliers. While the Purchasing and Quality links are accessible to the
Public, you will require a Logon Identification and Password to access the “Suppliers
Applications” Link. Within this Link, you will find the Global Supplier Performance
Management Report as well as the Links to our Web-APQP and Web-Registrations
applications.
Magna Closures Dortec Industries’ reliance on electronic and web-based
communication and procurement tools is intended to maximize our effectiveness and
efficiency in dealing with our Suppliers. As a pre-requisite for doing business with Magna
Closures Dortec Industries, Suppliers are expected to complete our Supplier Request for
Information.
As a Supplier to Magna Closures Dortec Industries, you will also be required to access our
electronic applications for the purposes of updating key supplier contact information as
well as reporting Advance Quality Planning activities, via our electronic APQP site.
Although our manufacturing operations are global, and there may be unique
requirements dictated by regional needs, we have attempted to implement common
standards and practices across all our Divisions. Our reliance on our electronic and web-
based applications is intended to streamline our procurement process and ensure
effective communication with our supply base.
An essential ingredient to a successful partnership is clear and concise communication.
At Magna Closures Dortec Industries, our means of communicating direction,
expectations and guidelines may include, but not be limited to:
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Purchase Orders
Supplier Performance Data
Letter of Intent
Sourcing Commitment Documentation
Statement of Work (SOW)
Website Links
Newsletters
Memos
Scheduled Meetings
Revisions will be made to this manual, as appropriate, and the latest revision level will be
posted on the Magna Closures Dortec Industries website.
4.2 Supplier Selection
To become a supplier to Magna Closures Dortec Industries, a Supplier Request for
Information (RFI) should be completed. The Supplier RFI can be obtained by contacting
Purchasing at [email protected]. Once the RFI has been completed,
Magna Closures Dortec Industries will complete the “Supplier Assessment” if appropriate.
Business cannot be awarded to a potential new supplier to Magna Closures Dortec
Industries, unless Magna Closures Dortec Industries has completed the Supplier
Assessment or has an Assessment on file completed by another Magna Group.
In those cases where sources are directed by Magna’s Customer, for a specific part or
commodity, any and all directed sources shall be obliged to meet all requirements as
detailed within this Supplier Manual.
Current Suppliers
Current Suppliers listed within the Magna Closures Dortec Industries Supplier Management
Database must continue to meet performance objectives of the divisions. Supplier
performance will be monitored as specified in the “Supplier Performance Monitoring /
Evaluation” section (Section 1.9) whereby these performance measures will serve as the
basis for future sourcing decisions.
All suppliers are required to finish a supplier profile consisting of general information,
company contacts, etc. Some data may also be required, such as financial and
technical information, union contract status, etc. as a means for supplier consideration
and monitoring. The Supplier, on a quarterly basis via the web-Registration application,
will update critical information.
The Supplier Management Database exists for production suppliers and is utilized by
Magna Closures Dortec Industries for strategic sourcing decision-making by commodity or
service performed. The database will be updated on a continuous basis in order to
ensure the latest information, from all Magna Operating Groups, is included.
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TS16949 / ISO14001 Certification
As specified by TS16949, Magna Closures Dortec Industries will perform supplier quality
management system development with the goal of supplier conformity to TS 16949. At a
minimum, Magna Closures Dortec Industries requires suppliers be registered to
ISO9001:2008 and ISO14001:2004, by an accredited third-party certification body.
Magna Closures Dortec Industries specific requirements will supersede the OEM
requirements if and only if the requirements are more stringent or in addition to the OEM
requirements.
Where applicable, suppliers shall also maintain CQI-9 (Heat Treat System Assessment),
CQI-11 (Plating System Assessment), CQI-12 (Coating System Assessment), CQI-14
(Warranty), CQI-15 (Welding), CQI-17 (Soldering), CQI-23 (Moulding System Assessment)
and all other FMVSS Standards, including but not limited to FMVSS 302 (Flammability
reporting) requirements, if directed and in support of applicable OE Customer-specific
requirements (www.iatfglobaloversight.org). For all Ford suppliers, heat treatment must
comply with WHTX. PPAP submission for heat treated parts must be a full batch or load at
minimum,
Steel Suppliers that provide HSLA material must provide inspection plan to Magna
Closures Dortec Industries which includes at minimum:
inspection plan: must cover each coil/bundle
PPAP - original mill certification must be provided
General Motors’ GP-12 (Early Production Containment - GM1920) is a requirement for all
new product/suppliers regardless of the end-customer or model year. Magna Closures
Dortec Industries is mandating its suppliers to abide by the GP-12 procedure if there is a
new design, material, manufacturing method, history of poor performance of this
component, or if requested. GP-12 instructions must be approved by Magna Closures
Dortec Industries. GP12 will be stopped only upon Magna Closures Dortec Industries
approval. Per GP-12, section A2: Implement GP-12 with entry date, exit criteria, and exit
date as defined by the customer, namely Magna Closures Dortec Industries responsible
Quality/SQA personnel.
4.3 Supplier Continuous Improvement
Magna Closures Dortec Industries promotes the effective use of statistical applications
and we direct that our Suppliers monitor the performance of their manufacturing
processes, through appropriate techniques including Pp, Ppk, Cp, Cpk etc. (refer to
AIAG SPC Manual). Statistical tools, when combined with process audits, shall provide the
data necessary to support continuous improvement. Evidence of these activities shall be
supported by maintaining records for a two year period, at minimum, or as otherwise
dictated by the Record Retention Policy. Records shall be available for review by Magna
Closures Dortec Industries, upon request.
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4.4 Tooling
Tooling design and build is generally the responsibility of the supplier, however Magna
Closures Dortec Industries has developed detailed Tooling Standards to ensure Suppliers
manufacture tools that will provide high quality parts throughout the life of the tooling.
These tooling standards will be communicated to you via the procuring division, if
necessary. Tooling standards are also available at www.magnaclosures.com. Suppliers
are responsible for the maintenance of all tooling, testing and inspection equipment. All
tooling must be identified with the appropriate Asset Tags as provided by the Division
Purchasing Group. The supplier will also be required to complete Bailee Bonds for tooling
owned by Magna Closures Dortec Industries. Final payment of tooling will be contingent
upon verification of proper identification and completed Bailee Bond. Following
notification to the Supplier, Magna Closures Dortec Industries reserves the right to
complete on-site inspection of tooling owned by Magna Closures Dortec Industries.
4.5 Control of Inspection Fixtures, Measuring/Test Equipment
Monitoring
The supplier must have a documented system in place to control, calibrate, and maintain
the proper function and an accepted level of gage repeatability and reproducibility of
all inspection fixtures, measuring / testing instruments and equipment. The system used
must be in compliance with AIAG Measurement System Analysis Manual and any O.E.
specific requirements.
Updating Instructions
Operating instructions must be displayed at every inspection station with a gage,
describing the proper methodology for use in inspection. These instructions must include a
reference of the gage identification number, and revision level, and be approved by
appropriate plant management. When 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.
Validation
All gages and test equipment must at a minimum be calibrated annually. The calibration
certificate must be on file at the supplier’s facility, and be traceable to the actual gage
identification information. Calibration Services of equipment must meet the requirements
of the latest released edition of TS16949.
Equipment Identification
All gages and test equipment must have an identification tag affixed reflecting the gage
identification number, the gage revision level, the last calibration date, and the
calibration expiration date.
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4.6 e-APQP (Electronic Advanced Product Quality Process)
Supplier shall not ship production parts without either PPAP Approval, or PPAP Interim
Approval (IA shall only be active for three months maximum). If warranted, an APQP kick-
off meeting will be scheduled upon business award. Personnel representing the suppler
program management and quality assurance shall participate to establish and outline
APQP requirements, timetables, contacts, etc. All immediate technical concerns must be
addresses at this time.
The PPAP submission is a validation of the production process. It is not an isolated one day
event. Suppliers are expected to submit PPAP documentation in accordance with the
sequential development of their manufacturing process. This will ensure proactive
resolution of issues prior to the required final PPAP submission date. The expectation is that
all issues are resolved by the PPAP date.
It is the responsibility of all Suppliers to ensure that their subcontractors (Tier 2, 3, etc.
Suppliers to Magna Closures Dortec Industries) are meeting similar expectations and
requirements.
Suppliers must submit electronic Level 3 PPAP requirements, as defined in the web e-
APQP, unless specifically directed otherwise by the Magna Closures Dortec Industries
Division. Suppliers are required to report all APQP activities via the Magna Closures Dortec
Industries web-based e-APQP program. Submissions will be electronic via e-APQP or by
registered Courier, as directed by the Division. PPAP submissions will not be faxed.
Suppliers must retain physical Master PPAP Samples, reflecting the most recent approval
level. All PPAP submitted documentation must be completed / translated into English.
For OEM directed Suppliers: prior OEM Approval does not negate the need for initial
submission or for annual validation, to Magna Closures Dortec industries. All suppliers shall
submit annual validation PPAP (minimum complete annual layout including all sub-
components), as determined by the date of the original approval.
Web APQP (Level 2) PPAP must be submitted for service components that have not been
in production for a period of greater than 12 months.
Prototype PPAP will be submitted to meet all Level 2 requirements as defined in the AIAG
PPAP Manual, unless otherwise directed by Magna Closures Dortec Industries. Suppliers
shall submit the following items as a package for prototype submission, unless a deviation
is permitted by Dortec:
marked up (ballooned) drawing addressing all dimensions and notes
dimensional results
100% inspection and reporting of all defined significant or critical characteristics
(LV)
laboratory and functional results shall include: Material Certification, and
Performance Results (as per PPAP manual)
appearance approval (AAR) if required
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PSW level 2, etc.
For suppliers with reporting requirements as defined by IMDS Standards, IMDS
documentation shall be part of the Supplier’s PPAP Requirement. The IMDS number
should be included on the PSW (Part Submission Warrant) at the time of PPAP submission.
For dimension or product requirements that do not meet specification, the Supplier shall
obtain approval as documented on a “Supplier Request for Deviation (or) Change”
(SRCD) prior to submitting PPAP. The signed authorization must be included in the
submission. Failure to comply will result in rejection of the PPAP submission.
A Defective Material Notice (DMN) and resulting Administration Fee (up to $500) may
result for PPAP submissions that are:
Rejected for non-compliance
Rejected for non-conformance
Late or Incomplete
Critical characteristics shall be identified either on the part drawing, or on separate
documents as detailed in the Statement of Work (SOW). Suppliers shall establish, validate
and maintain acceptable short - and long – term capability on all critical characteristics.
The applicable Magna Closures Dortec Industries Division will communicate the
appropriate method of critical characteristic designation.
Run at Rate (R@R)
All production processes are required to have a completed Magna Closures Dortec
Industries R@R package submitted with the PPAP. Depending upon the risk associated
with the Supplier and Part Number, the R@R may be observed on site, by Magna Closures
Dortec Industries. If deemed to be low risk by Magna Closures Dortec Industries, the
supplier will complete the R@R without the presence of a Magna Closures Dortec
Industries representative.
R@R’s must be conducted on the production process, and parts made from the R@R shall
be used for the PPAP Submission to Magna Closures Dortec Industries.
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4.7 Defective Material Notice Reporting
This system is designed to prevent the use of suspect and/or non-conforming purchased
material. Purchased components found to be non-conforming through either line
rejections, testing failures, failed inspection results, customer concerns, warranty and
customer returns or obsolete material are handled through the following procedure:
Supplier will be notified of the concern via telephone and / or electronically. All
relevant containment actions will be handled at this time. This includes any
immediate containment activities to ensure adequate supply of material to keep
Magna Closures Dortec Industries’ manufacturing lines in operation.
Supplier will receive a Defective Material Notice for the issue and is required to
acknowledge receipt of the notice within 24 hours
Quality non-conformances will be reflected monthly on the supplier rating
Note: Should a response not be received from a supplier, any stated charges associated
with the notice will be considered accepted by the supplier.
A corrective action report is required to address the concern and must be
received within the following time frames:
o Initial response and containment plan must be received within 24 hours
o Interim corrective action must be provided within 3 days
o Full root cause analysis must be provided within 5 days
o Corrective and Preventive Action plan must be submitted within 10 days
o The Magna Closures Dortec Industries 7-step format must be used
Terms (e.g. length of time charges can be applied and factors such as sort costs and
methods of calculation) of any costs charged to the supplier as a result of a quality
concern are determined by the Magna Closures Dortec Industries manufacturing
location.
Charges that could be applied to a quality concern are as follows:
Division sort of supplier product on production line until certified stock arrives
Production line shutdown
Finished product sort and/or scrap of material
Any material movement/transfer of nonconforming supplier product
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Quality Department time for problem investigation
Testing if required
Any sort/rework charges incurred by the Division
Related transportation expenses
Any costs incurred by the Magna Closures Dortec Industries Division for disruption
of Magna Closures Dortec Industries’ customers
All charges incurred by the supplier will be documented on the DMN, discussed and
approved through the Quality Personnel of the Magna Closures Dortec Industries’ Division
and the designated personnel of the Supplier facility. If mutual agreement cannot be
reached, the issue will be directed to the appropriate Magna Closures Dortec Industries
buyer within 30 days of final notice of issuance.
It is expected and the responsibility of the supplier to notify the Magna Closures Dortec
Industries division in the event, that there is reason to believe, that a nonconforming
condition of supplier components exists in Quality, Delivery, Warranty etc. Notification
must be followed by:
Immediate containment action within 24 hours (e.g. new material, new lot
number, etc.)
Interim Corrective action within 3 days
Permanent corrective action plan within 10 days
Controlled Shipping
When directed by the Magna Closures Dortec Industries division, suppliers may need to
certify product after a lot rejection has occurred. Usually, two types of controlled shipping
actions are employed when this situation occurs:
Supplier conducted sort and certification of subsequent part shipments, and
Third-party sorting and certification
All controlled shipping actions are the responsibility of the supplier to coordinate and
follow-up on. Part supply to the Closures division must meet released quantities without
supply interruption. The supplier and Magna Closures Dortec Industries division will
mutually define the certified material identification.
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Defective Material Notices will be issued for both non-complying material and/or non-
compliance to requirements and standards. Repeat DMNs for the same failure modes
may be charged double the Administration Fee.
4.8 Lot Traceability
All material received by Magna Closures Dortec Industries 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 Magna Closures Dortec Industries.
The supplier shall communicate 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.
A lot code should contain a specific quantity of parts, and should not typically 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. For approval
of a traceability method exceeding eight hours, or one shift of production, the Magna
Closures Dortec Industries division’s quality group must be contacted. The supplier shall
ensure implementation and management of an effective FIFO method of stock rotation.
Failure to comply with traceability requirements may lead to rejection of material and
issuance of defective material notice. Traceability records shall be maintained and
accessible for the life of the product, including service, plus one year.
5.0 ENGINEERING CHANGE
5.1 SRCD
Please check Supplier Application website http://iweb01ds.magnaclosures.com/
for further information on SRCD’s.
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SRCD Sample
A processed SRCD is NOT an approval to ship parts. This can ONLY be achieved through
the following:
PPAP approval
Written approval from the applicable Magna Closures Dortec Industries Division
through an EDR (Engineering Deviation Request)
NOTE:
All part number(s) shipped under this must have EDR # on it.
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6.0 SERVICE AND CLAIM INFORMATION
6.1 Service Obligations
Suppliers will maintain the ability to support all service requirements for a minimum of
fifteen (15) years after the end of production or as notified by Purchasing, and as per PO /
RFQ:
Continuous maintenance of all tooling
Ensuring ongoing manufacturing capability
Ability to procure raw material
NOTE
The disposal of tooling must be pre-authorized in writing by Magna Closures Dortec
Industries Purchasing Management.
6.2 Obsolescence Claims
Follow the procedure and guidelines that are outlined below to submit an
Obsolescence Claim for a Production Part. All Suppliers must ensure inventory
levels are minimized at the end of production or during engineering changes as
claims will be based on release authorization only.
6.2.1 General Information for Claims
Allowable Claim
Only Production Parts discontinued or cancelled:
Only claims in excess of $500.00 Cdn. will be accepted,
Parts must be certified stock and not damaged or defective,
Claims must be submitted to Magna Closures Dortec Industries Materials with 30
calendar days from the final release issue date,
Claim quantities must be within release authorization (Incorrect quantities will
lengthen the approval process),
All claims must indicate a "Salvage Value" or "Recovery Cost.
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Un-allowable Claims:
Parts that were previously exhausted,
Service Requirements.
6.2.2 Claim Document
Only one Production Part per claim document,
Material must be claimed at the appropriate stage e.g. Production Part, Work in
Process (WIP), Raw Material,
It is the supplier's responsibility to ensure the claim has been received by the
inventory Planning Department,
Material location information must be completed,
Only one contact name on Copies of the release,
Fabrication and Raw Materials authorization documents must be included with
the claim,
The supplier must complete all data fields in the Claims Document. Completion
will be validated upon receipt. If discrepancies are found, claims will be returned
to the supplier and processing will stop. If the supplier does not resubmit within the
original 30-day time frame, claims will not be accepted.
6.2.3 Claimed Material Audit
Material identified on a claim must not be scrapped, disassembled or reworked in
any way without written authorization from Materials Department,
Magna Closures Dortec Industries reserves the right to physically audit all claimed
material at their Supplier and sub-supplier locations,
Dortec Auditor will arrange audit date, time and specify claims for auditing,
Weighing and handling equipment to be available as requested,
Supplier is responsible to be fully prepared when the Auditor arrives,
Supplier is expected to investigate all recovery actions prior to submitting a claim
and include any recovery opportunities with claim submission.
Supplier will segregate all material prior to audit,
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Magna Closures Dortec Industries auditor will notify the Supplier-Claim contact of
the audit date and time,
Material must be at location specified on the claim,
Verify quantity, stage of completion, condition of parts and material,
Verify work in process and raw material are correctly identified and priced,
Verify materials are labeled or tagged the same as reported on the claim,
Supplier will count and/or weigh each production part and/or material to be
verified on the claim,
Magna Closures Dortec Industries Auditor may ask to confirm actual piece cost
against invoiced piece cost,
Magna Closures Dortec Industries’ Auditor will record audit results on a "Physical
Audit Worksheet", This document to be signed by both Magna Closures Dortec
Auditor and supplier representative after the completion of the physical audit and
serves as an agreement of verified information
6.2.4 Claim Settlement
Claims reduction may occur for the following instances:
Actual quantity is different from claimed quantity,
Material is incorrectly identified on claim,
Material claimed is at the wrong stage in the process vs. raw material,
Piece cost discrepancies,
Material is damaged and is not certified stock (e.g. rusted, cracked, soiled,
deformed, and disassembled),
Open service requirements exist for current or forecast requirements,
Magna Closures Dortec Industries Auditor to issue a Final Disposition document to instruct
on the handling of material
Magna Closures Dortec Industries Auditor will mail the Final Disposition to the supplier
contact on the claim. The Final Disposition authorizes the supplier to invoice Dortec for
claims payment. If the Supplier is unable to comply with the disposition instructions, or has
any questions regarding these instructions, they should contact the Magna Closures
Dortec Industries Auditor for clarification. Invoices for claim payment should be submitted
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to Magna Closures Dortec Industries only after the supplier has complied with all the
disposition instructions specified on the Final Disposition.
NOTE
Magna Closures Dortec Industries reserves the right to witness the disposal actions of the
production parts. They also may elect to cancel the audit if the Supplier is not prepared
on the scheduled date and time.
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7.0 ACCOUNTING INFORMATION
7.1 Supplier Invoices and Payments
Magna Closures Dortec Industries Suppliers must follow these guidelines in order to avoid
delays in payment of outstanding invoices:
Supplier invoices must be submitted directly to the Accounting Department,
Supplier invoices must reference a valid Magna Closures Dortec Industries
purchase order number,
Supplier payments will be based on pricing as per Magna Closures Dortec
Industries' valid purchase order in effect at time of shipment, if different from
invoice price,
All production part purchases must be shipped to Magna Closures Dortec
Industries on a packing slip with a packing slip control number and purchase order
number clearly identified,
All sample shipments must be documented on a separate packing slip.
Production materials and samples cannot be combined on one packing slip,
Supplier's payments will be based on pricing as per Dortec's valid purchase order
in effect at time of transfer, for title of goods, if different from packing slip price,
All payment inquiries must reference the supplier packing slip control number
Suppliers must provide statements of account on a monthly basis, when
specifically notified.
Supplier invoices must contain the following information:
Full Supplier name,
Full Supplier mailing address and full remittance address (if different than mailing),
HST registration number (where applicable),
Suppliers must provide statements of account on a monthly basis, when
specifically notified.
NOTE
Payments will be withheld if Purchase Order requirements are not met.
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FCD0524 Rev1 PPAP Report / Checklist
Report Date:
(Date Of Review)
PPAP Submit Level:
(Level 1-5)
Supplier:
Part Number:
Part Name:
Drawing Date: Drawing Level: PCN:
PPAP Samples
Reject / Accept
Are part number, revision level and cavity number on part, if applicable?
1 pc per cavity or 1 pc from each side of 2 up die – Must be numbered part (s) from dimensional layout
Are PPAP samples properly identified?
Comments:
Drawing Reject / Accept
Is the drawing approved by the customer? (Should have customer’s engineering signatures.)
Is the drawing at the correct level? Check the ECN for release level on the ECN tracking matrix.
Is the drawing ballooned to indicate dimensions inspected standards and notes?
Comments:
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Warrant (Latest Edition) Reject / Accept
Correct part name (description) – check /drawing.
Correct part number – check drawing.
Mark box if this is a safety item – check drawing.
Correct engineering drawing change level – check drawing.
Correct drawing number – check drawing (drawing number may be different than part number).
Weight must be on warrant in “kg” (to three decimal places). Individually weigh ten randomly selected parts,
calculate &
report average weight. For parts weighing less than 0.100 kg, weigh ten parts together, calculate & report the
average
weight to four decimal places.
Correct supplier information.
Correct application (program name – model year) ‘ if specified ‘
Correct submission level.
Correct customer information.
All boxes checked.
Correct reason for submission.
Correct submissions results (inclusions: i.e., parts, CP, FMEA, FLOW, etc.).
Supplier signature and title must be present, and dated
Production rate Included?
IMDS and #
Comments:
Dimensional Results
Reject / Accept
Latest Edition format
The supplier’s name should appear on the dimensional sheet.
The part number and part description must match the drawing and the warrant.
Item number must correlate with marked drawing.
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Dimension / specification must be listed and match the drawing.
A minimum of six samples must be measured (For multi cavity tool / die, a minimum of 1 pc per cavity
totaling a minimum of 6 ).
All dimensions and notes must meet specification and should be marked ‘OK’.
Signature of inspector and date of inspection should appear on the inspection sheet.
Where bonus tolerance is used, add feature size, i.e. , etc.
Comments:
Material Test Results / IMDS Reject / Accept
Include specification number and revision date of the specification / standard.
The supplier’s name should appear on the material sheet.
The part number and part description should match the drawing and the warrant.
The material specification number / date / specification should be called out for each test and should be the
specification
called out on the drawing. (All material specifications on the drawing must be listed).
The tests listed along with the tolerances should match those in the material specification.
Test results should be listed on the material test results sheet AIAG 4th
edition and should meet the specification.
The Material Composition breakdown must satisfy IMDS requirements for submission ( Other or Misc must be <
10 % total)
IMDS submission complete
Copy of lab accreditation & scope must be submitted – Check expiry date.
Signature of inspector and date of inspection should appear on the inspection sheet.
Comments:
Note: IMDS breakdown for clarification or questions see product engineering.
Performance Test Results Reject / Accept
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The supplier’s name should appear on the performance test results sheet.
The part number and part description should match the drawing and the warrant.
The performance specification number / date / specification should be called out for each test and should be the
specification called out on the drawing.
The tests listed along with the tolerances should match those in the performance specification.
Test results should be listed on the performance test results sheet and should meet the specification.
Copy of lab accreditation & scope (when applicable) – Check expiry date
Signature of inspector and date of inspection should appear on the inspection sheet.
Comments:
Appearance Approval Reject / Accept
Appearance approval sheet is filled out as required.
Comments:
Control Plan Reject / Accept
Pages should be numbered and include a header in each page.
Correct part #, part name, eng. level
The AIAG control plan format should be used.
Process steps should match those in the FMEA and Flow diagram.
SC and CC characteristics should be addressed and controlled using SPC ( (See Special Char. Class)( if
required))
SC and CC characteristics should match those on the drawing.
Other toleranced dimensions should be addressed on the control plan at some specified frequency.
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Sample size and frequency of inspection should be adequate for the product and reflect RPNs in the FMEA
(Past history on similar product can be used to determine frequency).
Special Processes require identification and additional controls (See Process Flow section)
Lot traceability plan procedure must be made available and identified in the control plan.
If material used is High Strength Low Alloy, control plan must include HSLA requirement - "Rockwell
hardness of each coil must
be checked at the press"
Comments:
Process FMEA Reject / Accept
Correct part #, part name, eng. level
All SC’s related to the process should be identified.
The AIAG PFMEA (Latest Edition) format should be used. Prevention & Detection controls must be identified &
ratings in
compliance.
Process steps should match those in the control plan and flow diagram.
Special Processes must be identified with appropriate RPNs. See Process Flow section.
RPNs multiplied correctly
Comments:
Process Flow Reject / Accept
Process steps should match those in the control plan and FMEA. (Process steps should be numbered and
equipment
identified, i.e. Station # Press 351).
Customer’s part number and Revision Level to be identified and correct.
Key inspection points should be listed and match those that are in the control plan.
If Welding or heat treatment is included in the Process Flow, it must be identified as a Special Process
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and identified in the PFMEA and Control Plan.
Yes
No - If no, full approval cannot be given.
Comments:
Process Potential / Capability Study (Ppk or Cpk) Reject / Accept
Ppk / Cpk should be submitted for all CC and SC characteristics. This data should be submitted for each tool
cavity, and
be comprised of at least 100 data points
The Ppk / Cpk results should meet PPAP requirement ( Ppk ≥ 1.67, Cpk = 1.67 )
Corrective action including immediate containment must be in place for those products that are less than 1.67 but
greater
than 1.33 and 100% check for less than 1.33.
Actual results of each piece measured should be submitted with the capability report, histogram and x-bar & R
chart.
Comments:
Gauge R & R Reject / Accept
Gauge R & R must be less than 1 year old.
Gauge R & R must be present for all gauges used to measure SC and CC characteristics.
Gauge R & R must be less than 10% for SC and CC characteristics.
Gauge R & R must be submitted for all checking aids as per control plan.
Comments:
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Extended Enterprise Reject / Accept
If applicable, ie., DCX Product
Is it included and complete? Must include material and process supplier back to raw material.
Comments:
Supplier Containment Plan Reject / Accept
Is applicable? Yes or No
Is it included and complete as per Control Plan? Does it address previous Non-conformances / Issues?
Comments:
TS16949 / ISO 9000:2001 Certification / QSA Reject / Accept
Is the supplier TS16949 / ISO 9000:2000 certified? If not certified, check file for QSA.
Comments:
Special Process: Heat Treat System Assessment ( CQI-9 )
Reject / Accept / Not Applicable
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CQI-9 audit less than one year old
W-HTX survey less than one year old
Yes
No - If no, full approval cannot be given.
Comments:
Special Process: Plating System Assessment ( CQI-11 )
Reject / Accept / Not Applicable
CQI-11 audit less than one year old
Yes
No - If no, full approval cannot be given.
Comments:
Special Process: Coating System Assessment ( CQI-12 )
Reject / Accept / Not Applicable
CQI-12 audit less than one year old
Yes
No - If no, full approval cannot be given.
Comments:
Don’t forget to:
Ensure that Control Plans / Inspection Sheets are updated to the latest level.
Ensure that Receiving Inspection sheets is updated and released in QSI data base.
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Send a copy of the Part Submission Warrant to the Purchasing Department.
Update the PPAP data base.
Comments:
APPROVED
INTERIM APPROVAL REJECTED
Checked by: Date:
Title:
This checklist is a guideline only, and does not replace the AIAG PPAP Standard Requirements. For more details reference the
AIAG PPAP Standard. This record is retained with the PPAP for the part listed on the front page, and will be disposed of when the
PPAP is disposed of. See PPAP record retention on the record retention list.
Page 80 of 82
Acknowledgement
Please complete this form acknowledging you have read, understand
and agree to the procedures outlined in the Dortec Materials Supplier
Handbook, and submit it to your Material Planner at Dortec (please print)
Company Name: ___________________________
Name: __________________________________
Position _________________________________
Date: __________________________________
Signature: ______________________________
Page 81 of 82
Index
A
Accounting Information ................. 68
Acknowledgement .......................... 80
Adhesives on Labels for Returnable
Containers ....................................... 29
Allowable Claim ............................... 63
ASN Advanced Shipping Notice .... 21
ASN Required Information ............... 21
C
Change Response ............................ 14
Claim Document .............................. 64
Claim Settlement .............................. 65
Coil Unloading Requirements ......... 41
Customs and Brokerage Information
.......................................................... 29
D
Decanting Material Guidelines ...... 40
Dortec 830 Weekly Release, E-
Business ............................................ 15
E
Ebusiness Releases ............................ 17
Electronic Data Interchange .......... 15
Engineering Change ........................ 53
F
First Time Shipment Notice ............... 12
G
General Information for Claims ...... 63
L
Label Approval ................................. 29
Labeling Detail of Steel Coils .......... 36
Launch Plan ....................................... 12
Launch Readiness ............................ 10
Load Stability ..................................... 44
M
Master Vendor Listing ......................... 5
Missed Shipment ............................... 47
Mixed Skids ........................................ 38
MMOG Assessment ............................ 6
N
Non Production Parts ....................... 11
O
Obsolescence Claims ...................... 63
P
Packaging and Part Information .... 29
Packing Slip Requirements .............. 19
Palletization Rules ............................. 37
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Part Identification ............................. 29
Prototype Material............................ 10
R
RDR (Receiving Discrepancy Report)
.......................................................... 23
Receiving Discrepancy Reports- RDR
.......................................................... 22
Returnable Containers ..................... 39
S
Safety Stock ....................................... 14
Sample Container Labels ............... 31
Sample Mater label .......................... 35
Sample Obsolescence Claim Form 67
Sample of Label for Steel ................ 36
Sample P150 Form Packaging
Proposal ........................................... 39
Sample Supplier ASN ........................ 21
Sample Supplier Packing Slip .......... 20
Sample Supplier pallet construction
.......................................................... 43
Service and Claim Information ....... 63
Service Obligations........................... 63
SRCD Sample .................................... 62
Steel labels must contain the
following .......................................... 36
Supplier Action Plan ......................... 18
Supplier Bank Build Plan ................... 15
Supplier Bank Build Requirements .. 14
Supplier invoice must contain......... 68
Supplier Packaging .......................... 38
Supplier Shipping Plan ...................... 19
U
Unallowable claims .......................... 64
W
WEBREG (Web Registration) ............ 24
Weekly Release ................................. 16