tooling manual/08_isza_manuals...7 - 1 issued 6/01/2005 revised 2/01/2016 tooling basic policy •...

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7 - 1 Issued 6/01/2005 Revised 2/01/2016 TOOLING Basic Policy This policy applies to all tools, dies, molds, jigs and fixtures (collectively referred to as “tools or tooling”) which INAC purchases or consigns to suppliers for use in producing parts exclusively for INAC. INAC Purchasing is responsible for administration and decisions relative to all tools, including but not limited to the following: Ordering and Production Payment Manner of Usage Relocation Disposal For parts in production Purchasing’s approval is needed for disposal. For parts in service AIPDN approval is needed for disposal. Ordering and Production INAC Purchasing shall negotiate pricing of tools based on Tooling Quotation Sheet and Production Process Charts submitted by Supplier. INAC Purchasing will issue Manual Purchase Orders in cases where INAC owned tools will be required. INAC Purchasing may confirm the tooling process by holding supplier hearings, conducting supplier surveys, or by visiting the supplier plant. On supplier visits, INAC Purchasing may be accompanied by representatives from Quality Assurance and/or Engineering.

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  • 7 - 1 Issued 6/01/2005 Revised 2/01/2016

    TOOLING Basic Policy • This policy applies to all tools, dies, molds, jigs and fixtures (collectively

    referred to as “tools or tooling”) which INAC purchases or consigns to suppliers for use in producing parts exclusively for INAC.

    • INAC Purchasing is responsible for administration and decisions relative to all tools, including but not limited to the following:

    ◊ Ordering and Production ◊ Payment ◊ Manner of Usage ◊ Relocation ◊ Disposal For parts in production Purchasing’s approval is needed for

    disposal. For parts in service AIPDN approval is needed for disposal.

    Ordering and Production • INAC Purchasing shall negotiate pricing of tools based on Tooling Quotation

    Sheet and Production Process Charts submitted by Supplier. • INAC Purchasing will issue Manual Purchase Orders in cases where INAC

    owned tools will be required. • INAC Purchasing may confirm the tooling process by holding supplier

    hearings, conducting supplier surveys, or by visiting the supplier plant. On supplier visits, INAC Purchasing may be accompanied by representatives from Quality Assurance and/or Engineering.

  • 7 - 2 Issued 6/01/2005 Revised 2/01/2016

    Payment

    Full payment of tooling will not be made until parts are PPAP approved.

    Lump sum payment • Upon PPAP approval, Supplier should submit the following information to the

    INAC Purchasing Department: ◊ Invoice ◊ Tooling Notice (including address and county of tooling location) ◊ Production Process Charts (PPC) ◊ Signed Tooling Maintenance Agreement ◊ Copy of PPAP Approval

    • Payment is issued from INAC - Finance (Anaheim office). Any questions pertaining to tooling payment should be directed to INAC Purchasing Department (Plymouth office).

    • After Supplier Invoice is processed for payment, INAC Purchasing will issue the following to the Supplier:

    ◊ Asset tag numbers for each tool ◊ Tooling notice (with specific asset numbers assigned)

    • Supplier is required to attach asset tag numbers to tools according to the

    Tooling Notice. The supplier is also required to take a photo of the tool with the Isuzu tag attached. Supplier will return Tooling Asset Weight and Log form (www.iszapurchasing.com/purchasing_form.html ) with photos attached to INAC Purchasing Department.

    Amortization

    • Term and piece price will be negotiated between supplier and the INAC Commodity Buyer.

    • Prior to the amortization period, Supplier should submit the following: ◊ Completed Tooling Notice. Notice should indicate that tools

    are “amortized”. ◊ Tooling Quote ◊ PPC Charts

    • Supplier will keep title of ownership for amortized tools.

    http://www.iszapurchasing.com/purchasing_form.html

  • 7 - 3 Issued 6/01/2005 Revised 2/01/2016

    Manner of Usage • All tools owned by INAC and located at Supplier’s facilities will be used in

    accordance with the INAC Tooling Maintenance Agreement. • Tools owned by INAC will produce only parts designated by INAC unless

    otherwise directed by INAC Purchasing. • Suppliers using tools owned by INAC shall report the following to INAC

    Purchasing upon request: 1. Presence of tools, stating exact location (city, state, and county). 2. Current part number(s) manufactured by the tools. 3. Presence of transferred tools. 4. Presence of obsolete tools. • In case the tools need modification due to an engineering change from INAC,

    the supplier shall inform INAC Purchasing and comply with the instructions of INAC Purchasing.

    Relocation • If tooling must be relocated for any reason, the Supplier MUST notify INAC

    Purchasing in advance of the relocation and wait for authorization. • Supplier is required to submit completed Tooling Notice indicating “Transfer

    from” and “Transfer to” addresses, the effective date of the transfer and the INAC tool numbers affected, along with backup (i.e. shipping documents).

    Disposal of Tooling • Supplier must request tooling disposition with a written request (stating

    reason for disposal) and a completed Tooling Notice. This information should be submitted to INAC Purchasing.

    • Supplier is responsible for notification to INAC Purchasing of any relocation/transfer of tooling BEFORE said tooling is moved.

  • 7 - 4 Issued 6/01/2005 Revised 2/01/2016

    TOOLING FORMS**

    1. Tooling Notice 2. Tooling Asset Weight and Log 3. Tooling Maintenance Agreement 4. Product Process Chart 5. Tooling Quotation **Forms are periodically updated; please always confirm with INAC Purchasing that you are using the most current form.

  • www.iszapurchasing.com Updated: 8/24/11

    DATE:SUPPPLIERNAME: PROJECT:

    TRANSFER DATE:

    EFFECTIVE DATE:

    FULL ADDRESS, CITY STATE COUNTY

    1

    2

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    4

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    6

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    15

    -$ US DOLLARS

    XPURCHASING MANAGER APPROVAL SIGNATURE

    (City), (State), (Zip Code)

    (City), (State), (Zip Code)

    (Street Address)

    TRANSFER FROM:

    TOOLING NOTICE

    SUPPLIERCODE:

    SUPPLIERINVOICE #:

    ** TOOL TYPE: P=PRESS C=CASTING F=FORGING R=RESIN BM=BLOW MOLDM=MODEL J=JIG D=DIE CM=COMPRESSION MOLDING

    X

    ISUZUTOOL# PART#

    TOOLTYPE ** MOD NEW

    TRANSFER TO:

    SUPPLIERCODE:

    SUPPLIERNAME:

    TOOLLOCATION:

    SUPPLIER APPROVAL SIGNATURE

    TITLE

    TOOLNAME

    MODELYEAR

    Buyer or Scrap DealerNAME:

    ADDITIONAL INFORMATION FOR DISPOSAL

    PURCHASEPRICE

    PPAPDATE

    (Street Address)

    SALES DATE:SUPPLIERCODE:TOOLLOCATION:

    SUPPLIERNAME:

    LOCATION

    NO

    AMORTIZED

    YES

    ACQUISITION DISPOSAL TRANSFER

  • www.iszapurchasing.com Updated: 8/24/11

    TOOLING ASSET WEIGHT AND LOG

    Supplier Code: _______ Purchase Order No. _______ Page: of

    ASSET NUMBER:

    Asset Weight

    _______ lbs.

    ASSET NUMBER:

    Asset Weight

    _______ lbs.

  • THIS AGREEMENT MUST BE EXECUTED BY ALL SUPPLIERS IN POSSESSION OF TOOLS OWNED OR FURNISHED BY ISUZU

    TOOLING MAINTENANCE AGREEMENT

    The undersigned supplier (hereinafter “we” or “us”) hereby agrees to the following terms and conditions which shall apply to our possession, handling and use of Tools owned by Isuzu North America Corporation (“Isuzu”) or such other party as may be designated in writing by Isuzu (a “Designee"). As used herein, the term “Tools” means any tools, dies, molds, jigs, fixtures and other items of equipment currently in our possession or hereinafter furnished to us by Isuzu for use in manufacturing or assembling products for purchase by Isuzu or its Designee. We agree that the terms set forth herein are in addition to the terms set forth in Isuzu’s General Terms & Conditions. 1. Use of Tools. We agree to use the Tools solely for the purpose of manufacturing or assembling products for

    purchase by Isuzu or its Designee and for no other purpose. We agree not to sell to any party (other than Isuzu or its Designee) any products manufactured or assembled by use of the Tools without Isuzu’s prior written consent.

    2. Title to Tools. All Tools are and shall remain the sole and exclusive property of Isuzu or its Designee. We

    agree to execute such documents as may be reasonably requested by Isuzu from time to time to confirm such ownership, and we shall at no time represent to any third party, expressly or by implication that title to the Tools is held by any person or entity other than Isuzu or its Designee. We agree not to sell, loan or otherwise transfer the Tools to any party or to grant or allow any encumbrance or lien upon the Tools without Isuzu’s prior written consent. We agree to mark the Tools "Property of Isuzu North America Corporation", or in such other manner as may be designated by Isuzu. We agree not to co-mingle the Tools with our own property or with the property of any other person, to modify the Tools, or to remove the Tools from the location of record without Isuzu’s prior written consent. The Tools are and shall at all times remain personal property, notwithstanding that they may now be or hereinafter become in any manner attached to or permanently resting on real property or improvements thereon.

    3. Information Regarding Tools. Within 45 days following the date of this Agreement, and within 30 days

    following the date on which any additional Tools are hereinafter furnished to us, we agree to supply Isuzu with the following information:

    a. names of all Tools in our possession; b. description of the Tools; c. names and addresses of locations where the Tools are located; d. part names and numbers produced by the Tools; and e. such other information as may be reasonably requested by Isuzu. We also agree to promptly notify Isuzu upon any changes in the foregoing information. In the event that

    Isuzu furnishes us with tags containing asset numbers for the Tools, we agree to attach such tags to the appropriate Tools, and furnish photographs of the Tools to Isuzu with the asset number on the tag visibly displayed. Isuzu or its Designee shall have the right to enter our premises at all reasonable times upon prior notice to inspect such Tools, our records for the Tools and/or to remove the Tools from our premises.

    4. Safety Precautions. We agree at our own expense to take full responsibility for the possession, handling

    and use of the Tools and for compliance with all applicable laws governing same. We agree to initiate, maintain and supervise all necessary safety precautions in connection with our possession, handling and use of the Tools.

  • 2

    5. Care of Tools. We agree to maintain the Tools in good working order, condition and repair, reasonable wear and tear excepted, and to bear the risk of loss or damage to the Tools while they are in our possession or control. In the event that any of the Tools becomes obsolete or unusable, we agree to promptly notify Isuzu and dispose of such Tools in accordance with Isuzu’s instructions. The costs of changes or replacements to the Tools due to engineering changes shall be allocated in accordance with our mutual agreement.

    6. Taxes. We agree to assist Isuzu in making any necessary filings and registrations with applicable state and

    local taxing authorities, including any applications for exemption from sales and use taxes imposed in connection with the Tools.

    7. Accidents. We agree to assume the risk of, and to indemnify and hold Isuzu and its affiliates, agents,

    representatives and employees harmless from and against, all claims, damages, liabilities, cost and expenses (including reasonable attorneys’ fees) incurred as a result of or in connection with our possession, handling or use of the Tools. We also agree to maintain adequate insurance protecting both us and Isuzu from claims and liability for injury, death and property damage arising out of or relating to the possession, handling or use of the Tools, and upon Isuzu’s request, to furnish Isuzu with a certificate of insurance showing Isuzu as an additional insured under such insurance.

    8. Termination; Return of Tools. We agree that Isuzu shall have the right to terminate this Agreement at any

    time without Isuzu incurring any liability towards us. Promptly upon the termination of this Agreement, or earlier upon Isuzu’s demand, we agree to return the Tools to Isuzu or its Designee in such manner as Isuzu shall designate. We also agree to deliver to Isuzu all specifications, operating manuals and other documents furnished by the manufacturer relating to the construction, maintenance or operation of the Tools.

    _________________________________________ [NAME OF SUPPLIER]

    By: _____________________________________

    Title: ____________________________________

    Date:____________________________________

  • PRODUCTION PROCESS CHART - PLASTIC and RUBBER PARTS

    Updated 6/1/05www.iszapurchasing.com Page 1 of 2

    SKETCH OF PART (With Dimensions) PRODUCTION PROCESS CHART (B) 1/2 Sheet No.

    --- For Plastic & Rubber Part --- Date of Issue

    Name of Supplier

    Material of Part

    Thickness of Part mmSignature

    Weight of Part kg

    Production Volumeunits/

    monthBusiness Engineering

    Pieces(s) per carName of Subcontractor:

    Prototype or Volume Proto V.P.Sketch of tool (With Dimensions; R , L x F , B x H)

    Injection Type of MachineMolding

    Cycle Time: /sec

    Compression Pieces per Shot /shotMolding

    Number of Tool

    Vacuum Molding Material of Tool

    Blow Molding Weight of Tool kg

    Extrusion Tool Life shotsMolding Lead Time

    (Weeks)

    Others Tool Number: Estimated Tool Cost ($)

    0 1 2 3

    Estimate

    Assembly Eval Model Part Number Part Name Component Part Number Component Part Name Isuzu Approval

  • PRODUCTION PROCESS CHART - PLASTIC and RUBBER PARTS

    Updated 8/24/11 www.iszapurchasing.com Page 2 of 2

    Production Process Chart (B) 2/2For Plastic & Rubber Parts

    Sketches of

    1 2

    Production Process

    Item Modification Records Originated Isuzu ApprovalModel Part Number Part Name (Due to) Date Name Date Name

    0

    Component Part NumbeComponent Part Name 1

    2

    3

  • PRODUCTION PROCESS CHART - STAMPED and FORGED PARTS

    Updated 8/24/11www.iszapurchasing.com Page 1 of 2

    SKETCH OF PART (With Dimensions)PRODUCTION PROCESS CHART (A) 1/2 Sheet No.

    --- For Stamped & Forged Parts --- Date of Issue

    Name of Supplier

    Material of Part

    Thickness of Part mmSignature

    Weight of Part kg

    Production Volumeunits/

    monthBusiness Engineering

    Piece(s) per carName of Subcontractor:

    Prototype or Volume Proto V.P.Ite Production Process

    Type of Machine

    Number of Tools

    Pieces per Size of Tool (mm)

    Weight of Tool Estimated Tooling Cost ($)

    Est. Date of Compl

    m Shot (kg) 0 1 2 3

    Estimate

    1 Eval.

    Estimate

    2 Eval.

    Estimate

    3 Eval.

    Estimate

    4 Eval.

    Estimate

    5 Eval.Model Part Number Part Name Component Part No. Component Part Name Isuzu Approval

  • PRODUCTION PROCESS CHART - STAMPED and FORGED PARTS

    Updated 8/24/11www.iszapurchasing.com Page 2 of 2

    PRODUCTION PROCESS CHART 2/2-FOR STAMPED & FORGED PARTS-

    Sketches of

    1 2 3

    Production Process

    4 5 6

    Item Modification Records Originated Isuzu ApprovalModel Part Number Part Name (Due to) Date Name Date Name

    0

    Component Part Number Component Part Name 1

    2

    3

  • www.iszapurchasing.comIssued: 6/01/05

    Updated: 2/01/16

    Supplier's Name: Code:

    Date: This quotation is valid until:P/ No.: P/ Name: Est. Vol./Month: Complete for Tool Modification

    to previous P/ No. (if applicable)

    Tool Tool *Tool P/ No. CostTool Name Size (LxWxH) Weight (Kg) Type New Mod. Amount Suffix Variance **Reason

    123456789

    10111213

    Var.Total:

    Location (where tool will be used) Name of Tool Manufacturer Location Tool PreparationTool Name City State Manufacturer City State Lead Time

    123456789

    10111213

    - Production Volume Lead Time: Supplier Signature:

    Title:

    Remarks:

    * Tool Type: (P)= Press; (C)= Casting; (F)= Forging; (J)=Jig; (R)=Resin; (BM)= Blow Mold; (M)= Model; (D)= Die; (CM)= Compression Mold; (IM)= Injection Mold

    ** Reason Code: (A)=VA; (B)=Design Change; (C)=Specification; (D)=Volume; (E)=Supply Parts Change; (F)=Negotiation; (G)= Other (state reason in Remark section)

    (Provide more detail for Cost Variance Reason in Remark section)

    - Gantt Chart for production readiness must be submitted after Isuzu tool kick off

    INAC TOOLING QUOTATION SHEET

    RFQ or ECS No.:Old P/ No.:

    Total Tooling Cost: