postfach 1163 guideline – quality supply chain management. · · 2017-02-20guideline –...

Guideline – QualitySupply Chain Management.

CLAAS KGaA mbHPostfach 116333426 HarsewinkelTel.+49 (0)5247 12-0www.claas.com

32

CLAAS Group

The CLAAS Group –Locations worldwide.

Stand 28.08.2008Agr i cul t ur al equi pment

Product companies

Sales companies

Pr oduct i on t echnol ogy

I ndust r i al engi neer i ng

Agr i cul t ur al equi pment

Product companies

Sales companies

Pr oduct i on t echnol ogy

I ndust r i al engi nee-

Stand 28.08.2008

CLAAS France S.A.S.,Paris/France

CLAAS Ibérica S.A.,Madrid/Spain

CLAAS Réseau Agricole S.A.S.,Vélizy/France

CLAAS Italia S.p.A.,Vercelli/Italiy

CLAAS Saulgau GmbH,Bad Saulgau

CLAAS Hungaria Kft.,Törökszentmiklós/Hungary

CLAAS Industrietechnik GmbH,Paderborn

AGROCOM GmbH & Co.Agrarsystem KG,Bielefeld

CLAAS Tractor SAS,Vélizy/France

Usines CLAAS France S.A.S.,Metz-Woippy/France

CLAAS U.K. Ltd.,Saxham/Great Britain

CLAAS Vertriebsgesellschaft mbH,Harsewinkel

CLAAS Global Sales GmbH,Harsewinkel

CLAAS Fertigungstechnik GmbH,Beelen

BRÖTJE Automation GmbH,Wiefelstede

CLAAS Service and Parts GmbH,Hamm

CLAAS SelbstfahrendeErntemaschinen GmbH,Harsewinkel

CLAAS Automation GmbH,Nördlingen

CLAAS Tractor SAS,Le Mans/France

CLAAS Argentinia S.A.,Sunchales/Argentinia

CLAAS India Ltd.,Faridabad/India

000 CLAAS,

CLAAS Omaha Inc.,Omaha/Nebraska/USA

CLAAS of America Inc.,Omaha/Nebraska/USA

BRÖTJE Automation USAInc.,Omaha/Nebraska/USA

CLAAS of America LLC.,Columbus/Indiana/USA

CLAAS India Ltd.,Chandigarh/India

000 CLAAS, Vostok,Moscou/Russia

54

Editorial

The system solutions, products and services of theCLAAS group represent technical innovation, highest qua-lity and absolute reliability.

The image of the CLAAS products and the loyalty of ourcustomers provide evidence for extraordinary perfor-mances of CLAAS products and are also spur to continueour effort for quality and our pursuit of progressive systemsolutions. In particular the high customer satisfaction con-tributed to the continuous growth of the CLAAS groupworldwide.

Continuous improvement of our quality standards over theentire supply chain process is our declared objective. Thecompetence and motivation of our suppliers influencessignificantly the reliability and quality of our products andservices. Hence fundamental elements of our qualityunderstanding (philosophy) regarding our suppliers are- robust processes and their permanent enhancement- proactive, open and fast communication- professional project management and- the willingness for assumption of responsibility

Quality as a Principle.Worldwide. CLAAS.

The following quality guideline for the entire CLAAS groupexplicitly documents the valid QM elements for the buyingprocess to be applied. Effective adherence to the descri-bed procedures for identifying concerns early will makeerror elimination possible.

Collaboratively we will agree to the relevant elements forthe respective business with you and use this as the basefor our common supply relationship. The rigid applicationof this agreement leads to a continuous improvement ofthe quality of our products and services. The achievedcustomer satisfaction is a guarantee for both parties for along-term and positive business development.

Quality policyWe are determined to exceed the expectations of our cus-tomers. We are committed to maintain peak customersatisfaction with faultless products and services. Quality isthe guiding principle in the way we do business.

Dr. Theo FreyeSpeaker of the Executive Board

Dr. Cornelius WeißHead of Corporate Quality Management

Rüdiger MohrHead of Corporate Purchasing

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Content

Content

No Compromises.Worldwide.

I. General description .............................................................. 8II. General criteria .................................................................... 9

Overview QM elements in the procurement process.......10III. Selection and Qualification Process ...................................12

1. Self assessment/References .....................................122. Audit ........................................................................ 123. FMEA .......................................................................134. Process Control Plan ................................................145. First Samples ............................................................146. Process Capability ....................................................167. Product audit ............................................................178. Reliability Testing ...................................................... 18Supplier qualification process Flow Chart ......................20• Flow chart Component supplier...................................20• Flow chart System Supplier.........................................22

IV. Series Monitoring ............................................................. 241. Continuous Evaluation ..............................................242. Processing of complaints ......................................... 24

V. Further Agreements ...........................................................261. Special Release ........................................................262. Logistic Agreement .................................................. 263. Emergency Plan ....................................................... 274. Quality Assurance Agreement (QAA) ........................ 275. Agreement of confidentiality ..................................... 27

VI. Appendix ......................................................................... 281. Definitions ................................................................ 282. Abbreviations............................................................ 293. Sources ................................................................... 29

98

Premises

Supplier

Documented and certified QM system conforming to:

• ISO / TS 16949, DIN EN ISO 9001, VDA 6.1 orupon approval by CLAAS Audit System

• Development of a “Zero-Defect-Strategy” within thequality planning. Elaboration of measures to achievethe quality objective “Zero-Defect”

• Understanding and acceptance of CLAASrequirements

• Qualified QM personnel• Carrying out of required planning and test procedures,

analyses, first samples, process control plan, processcapability, etc.

• Open communication and information in regard to- Problems that arise- Demands that cannot be met- Capacity bottlenecks

• Qualification of sub-suppliers

CLAAS

• Clear and complete information to the supplier• Clear communication channels and responsibilities• Specific, clear and generally comprehensible

documentation according to product-specificrequirements

• Precise definition of volumes and delivery schedulesincluding the expected deviations

• Support and advice

I. General description.

Purpose

This guideline explains the CLAAS quality standards tosuppliers. The individual elements between the contractualpartners will be fixed individually in our negotiation pro-cess.

The quality management standards, which aredocumented here, are designed to ensure that:- The produced components meet the CLAAS

specifications in every aspect- The process capability and control of the supplier are

such that the specifications are adhered to consistently.

Area of ApplicationThese requirements enter into effect with the agreement ofthe establishment of a business between CLAAS and thesupplier.

If a quality assurance agreement (QAA) is concluded bet-ween CLAAS and the supplier, the supplier commits him-self to provide a similar QAA with other CLAAS compa-nies.

Responsibility

The supplier is required to adhere to the demands as laidout in the agreement and described in this guideline.

The purchasing organisations of the individual locationsensure that the agreed standards are implemented andadhered to.

Support documentationThe processes and techniques referred to in theguideline use defined standards as reference (VDA, QS9000 regulations).

II. General criteria.

1110

Premises

I. Selection and qualification process II. Series monitoring

III. Additional agreements

QM elements in theprocurement process

Documents Information forthe supplier

Overview QM elements in the procurement process

QM elements in theprocurement process

Documents Information forthe supplier

1. Sel f assessment /r ef er ences

2. Audi t s- Syst em- Pr ocess

3. FMEA

4. Pr ocess cont r ol pl an

5. Sampl es

6. Pr ocess capabi l i t y

7. Pr oduct audi t

8. Rel i abi l i t y

Questionnaire Informationprovided by supplier

CLAAS auditcatalogue

Basis VDA 6

FMEA AnalysesVDA 4.1 / 4.2 orQS 9000 FMEA

Process control plan(QM-Plan / Control plan)

VDA Volume 2QS 9000 PPAP

VDA Volume 4QS 9000 SPC

VDA Volume 6 (Part 5) /audit system of the supplier

VDA Volume 3

Filled out bysupplier

Carried out by CLAASauditor at supplier

Risk analyses carriedout by supplier

To be produced by thesupplier to ensureprocess reliability

To be produced bysupplier prior seriesproduction launch

To be carried out bysupplier for all marked * orseperate alignedcharacteristics

Certificate of effectivenessof the QM system

To be carried out bysupplier if requested byCLAAS

1. Cont i nous eval uat i on CLAAS SupplierAssessment

Supplier performance isconstantly monitored byCLAAS

2. Pr ocessi ng of com-pl ai nt s

8D-Report /CLAAS Form "Problem

analysis"

To be done by supplierwith every complaint

1. Except i onal Appr oval Exceptional ApprovalRequest forapproval at CLAASbefore delivery

2. Logi st i c Agr eement CLAASLogistic Agreement

Agreement betweenCLAAS and supplier

3. Emer gency pl an VDA 6.1VDA 6.4

Supplier responsibility

4. QAA CLAAS QAAAgreement betweenCLAAS and supplier

5. Agr eement of conf i den-t i al i t y

Agreement of confidentiality Agreement betweenCLAAS and supplier

*Symbol 1:Safety Critical Characteristic

*Symbol 2:Key Characteristic / Functional Size

1312

Selection andQualification Process

III. Selection andQualification Process.

1. Self assessment/References

Self assessmentObjectiveInformation about the supplier to complete the companyprofile on following points.- General company data- Technical information- QM-System

ReferencesObjective• General information about the customer base of a

potential supplier

• Additional input based on information gleaned fromexisting customers.Note: only when both parties agree.

ImplementationThe questionnaire about supplier self-assessment is to befilled out by the supplier and to be returned to the purcha-sing department.

2. Audit

System auditObjectiveEvaluation of the QM system of the supplier in respect of- Completeness- Implementation

ImplementationAuditing of the QM system by CLAAS auditorsBasis:- VDA Volume 6.1, Material Products- VDA Volume 6.2, Service

Timing and scope of the audit will be mutually agreedbetween CLAAS and the supplier.

Process auditObjectiveAssessment of process quality capability.Support of the continuous improvement process.

ImplementationProcess audits can be carried out in agreement betweenthe supplier and CLAAS.Basis:- VDA Volume 6, Part 3- CLAAS process audit questionary

A process audit is carried out either on individual compo-nents or on component families, if they are manufacturedusing the same process.

3. FMEA

ObjectiveEarly recognition of potential for error indesign and/or production.

ImplementationThe supplier is requested to carry out a systematicanalysis of potential errors within design and/or productionplanning. (Basis VDA 4.1 / 4.2, QS 9000 FMEA)

After completion of the engineering- / process- and / orsystem-FMEA the documented risk priority numbers(RPN) may not be higher than 125.

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4. Process Control Plan

ObjectiveAssurance that CLAAS quality standards are compliedwith by describing the planned processes, methods andchecking procedures.

ImplementationThe supplier plans and documents the procedures forparts and component groups (QM-plan / Control plan).

CLAAS supports the supplier with the review of CLAASdocuments (e.g. drawings, instructions, standards).

Preventive actionManufacturing procedures must be checked beforehandfor possible errors (e.g. by use of FMEA or similarweakness analysis).

5. First Samples

ObjectiveThe supplier provides proof that the products have beenproduced under series conditions and that they complywith the CLAAS specification. Components for series pro-duction require a written approval for first samples.

ImplementationThe supplier provides the samples and documents toCLAAS quality organisation. (Based on VDA Volume 2)

Complete filled and signed sample report and, if requestedby CLAAS, inclusive process control plan.

Clear matching of drawing parameters to test results bymarkings in the drawings as well as clear matching of testresults to the proband.

Supporting documentation for process capability for allmarked * characteristics and reliability data, if specified inthe drawings.

Sample selectionSamples must be produced and tested under serial condi-tions (machinery, equipment, machining conditions)

Testing of production samples (Dimensions, Materialtesting).

The supplier is responsible for checking all the parameterson five parts.

The test samples are to be tagged clearly so that they canbe easily matched to the test results.

When components have been pre-assembled the highestlevel of completion has to be sent to CLAAS. If requestedthe documentation for the single components has to bemarked accordingly and attached.

The supplier is responsible for compliance to the materialspecifications of the product (including labelling, physicalcharacteristics etc.)

All test results have to be recorded in the sample report.The supplier has to assure for himself that all characteri-stics comply with CLAAS specifications.

Even in cases where the supplier is not able to carry outdimensional or material checks, the responsibility stayswith the supplier. Then the checks have to be carried outby a suitably qualified, reputable organisation.

Any deviation from these specifications requires anapproval by CLAAS.



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6. Process Capability

ObjectiveProof of process capability by use of statistical methodsfor the critical characteristics as defined * in the drawingsor separately aligned characteristics.

• Reduction of checking effort for customersand suppliers

• Early recognition of process changes (Trends)

ImplementationAt marked * or separately aligned parts, which have amajor impact on function, safety, assembly and reliabilityof the product.

ProofThe supplier at least has to prove that all marked partshave been produced under controlled process conditions(controlled and stable).

Minimum requirementMachine Capability / Short term Capability – Cmk ≥1,67Process Capability / Long term Capability – Cpk ≥ 1,33The shape of distribution has to be checked, e.g.Gaussian Distribution.

Process capability analysesThe supplier checks the capability on at least 125 produc-tion parts produced in sequence. Preferably the samplebatch should be produced in 25 lots of five units each.The process capability calculation takes place with familiarstatistical methods (VDA Volume 4, QS 9000 SPC).

VariancesIf the characteristic does not comply with the given crite-ria, a selection test has to be carried out until 100% com-pliance is reached. The planned and implemented correc-tive actions are to be documented in action plans withschedules and responsibilities and made available toCLAAS if requested.

DocumentationDuring production, the documentation is provided by themethods of statistical process control (SPC).

Attributive critical characteristicsIn cases of attributive characteristics, which are markedcharacteristics * in the drawings (“safety critical” or as“important”), all of the samples selected for the capabilitytests have to meet the specifications.

7. Product audit

ObjectiveInspection of the level of effectiveness of the QM activitiesinstalled by the supplier in respect on components orfamilies involved.

Implementation• The supplier is requested to plan and carry out product

audits. Basis: VDA Volume 6.5• The results are to be analysed and documented in a

comprehensible manner, which includes targetdefinition

• Deviations have to be eliminated by fault analysis andcorrective actions

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Reliability test proceduresThe supplier refers to the specifications and drawings fromthe CLAAS R&D function for the test procedure. In thecase that CLAAS R&D gives no clear specifications themissing information has to be requested by the supplier.

Reliability analysis methodsThe analysis and interpretation of the results are analysedusing the Weibull method.Basis: VDA Volume 3, reliability testing

DocumentationTest conditions and test results have to be recorded andwhen required to be presented by CLAAS.

8. Reliability Testing

ObjectiveConfirmation that the product involved meets the lifetimespecified by CLAAS.

Implementation

Reliability testsThe supplier carries out reliability tests on the productsthat have been attributed a specific lifetime in the CLAASdrawings and documentation.

Calibration of the reliability test equipmentThe test rigs must be calibrated in accordance with themanufacturer’s instructions with reference to the relevantnational norms.

Minimum standardsA minimum product conformance level of 0.95 (95%) hasto be attained in order to carry out the reliability data ana-lysis. Products, which fail to meet the minimum specifiedlifetime would not be accepted under any circumstances.

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1

12

15

19

3

NotO.K.

NotO.K.

NotO.K.

NotO.K.

O.K.

O.K.

O.K.

O.K.

10

11

13

14

16

17

18

20

3

1

O.K.

1

2

6

9

4

5

7

8

A*

B*

NotO.K.

NotO.K.

O.K.


Supplier qualification processFlow chart component supplier

Responsible1) Supplier2) Supplier qualification team3) Purchasing4) Purchasing5) Purchasing6) Supplier7) Supplier qualification team8) Supplier qualification team9) Supplier

10) Supplier11) Supplier qualification team12) Supplier13) Supplier14) Purchasing15) Purchasing16) Purchasing17) Supplier18) Supplier qualification team19) Supplier20) Supplier qualification team

* A, B, C – Supplier classification

Self assessment by supplier

Supplier information, nofurther action

Supplier self assesment ischecked

Drawings are prepared forquotation purposes

Quotation is checked Revision of the quotation

QM system and /or product audit

Audit results checked Corrective action definedand carried out

Checking of drawings andpreparation of a process control

plan

Checking of correction anddocumentation Checking of process control

plan and drawings

Finalisation of quotation and timeschedule

Negotiation withsupplier Checking of quotation

and time schedule

Order of first samples

Samples are shipped

Release forseries production Checking of first samples

Release forseries production

C*

2322


1

1

NotO.K.

NotO.K.

NotO.K.

NotO.K.

NotO.K.

16

18

19

20

21

22

17

17

17

17

17

6

A*

B*

O.K.

1

2

4

5

14

11

3NotO.K.

NotO.K.

NotO.K.

C*

O.K.

7

8

9

10

12

13

15

Supplier qualification processFlow chart system supplier

Responsible1) Supplier2) Supplier qualifiation team3) Purchasing4) Supplier qualifiation team5) Supplier qualifiation team6) Supplier7) Purchasing8) Purchasing9) R&D / Purchasing

10) R&D / Purchasing11) Purchasing12) Supplier13) R&D / Project Management14) Supplier15) R&D / Project Management16) R&D / Purchasing17) Supplier18) R&D / Purchasing / Management19) R&D20) Supplier qualifiation team21) R&D22) Supplier qualifiation team

* A, B, C – Supplier classification

Supplier self assessment

Supplier information,no further action

Supplier self assessmentis checked

QM System and / or productaudit

Review of audit resultsDefinition and

implementation ofcorrective actions.

Agreement of confidentialityconcluded

Handing over of requiredspecifications to supplier

Specifications are checked withthe supplier in order to clarify open

points and make quotation

Supplier information,no further action

Feasibility evaluationand costs

Handing over of specification bookincluding detailed project plan is

given to CLAASReworking of

specifications and / or theproject plan

Checking of specificationsof the project plan

Follow up of project plan includingdefined development steps

Corrective action

Corrective action

Corrective action

Corrective action

Corrective action

Checking ofdocuments

and drawings

Checking of calculation

Checking the testresults of the prototypes

First sample process(see flow chart

component supplier)

Evaluation of the results ofthe field tests / pre-series

Release for seriesproduction

O.K.

O.K.

O.K.

O.K.

O.K.

O.K.

2524

Series Monitoring

2. Processing of complaints

ObjectiveRapid elimination of the fault at CLAAS.Damage limitation by narrowing errors down.Resolution of the problem, no repetition.

Implementation• Rapid detailed information to the supplier by CLAAS• Joint agreement about immediate measure• Analysis of the problem by supplier• Documentation by the supplier of at least

- Problem- Cause- Immediate measure- Elimination measure

• Or conform to the VDA 8D - systematic

1. Continuous Evaluation

ObjectiveBasis for intensive and steadily improving business relati-onship is the optimisation of the testing process at CLAASand the supplier. It is important to give feedback to thesupplier on the level of quality supplied including improve-ment potential.

Implementation• Continuous monitoring of the relevant data

- Quality- Logistics- Costs- Innovation- Motivation

• Analysis of the data and continuous informationto supplier

• In the event of unsatisfying evaluations the supplier isrequired to formulate a written statement about causeand corrective action including proof of efficiency

IV. Series Monitoring.

2726

Further Agreements

V. Further Agreements.

1. Special Release

ObjectiveAvoid that components, which are nonconforming, get,without a special release, into the production process.

• Securing the delivery capability

ImplementationAfter detection of a deviation the supplier has to informCLAAS (purchasing / procurement) immediately in writtenform. CLAAS decides on further action and informs thesupplier in written form.

Implementing of the decisionFor the case of a delivery approval for a limited lot sizethese lots have to be marked clearly and precisely in theshipping documents regarding to the exceptional appro-val. Basically the delivery only can be carried out after sub-mission of the approval.

2. Logistic Agreement

Objective• Minimal carrying costs by bundling of supply transports

and intelligent carrying concept• Improvement of inventory by coordinated supply

frequency• Improvement of the process by standardised container

concept and shipping documentation (according toVDA recommendation 4902)

ImplementationCLAAS Logistics Agreement

3. Emergency Plan

ObjectiveContinuity of supply in case of crisis, as for example mayresult from:- machine or tool breakdown- breakdown of computer system- power failure- damage to buildings and equipment (natural disasters)- supply bottlenecks of material

ImplementationJoint agreement on components that are essential for anemergency programme.

• Development of an emergency plan• Joint checking and approval of the emergency plan

4. Quality Assurance Agreement (QAA)

ObjectiveApproval of direct delivery to the place of use in the factories.Decreasing of CLAAS goods incoming inspection.

ImplementationThe QAA will be agreed as an addition of the basic supplyagreement. The QAA relevant products will be specified anddocumented accordingly.

5. Agreement of confidentialityObjectiveWith this agreement both parties ensure the confidentialhandling of all information and data, which will be exchangedbetween CLAAS and the supplier.

ImplementationCLAAS Agreement of confidentiality.

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Appendix

1. Definitions

DIN EN ISO 9001New certification norm for quality management systems,which was edited by the German (DIN), European (EN)and International Organization for Standardization (ISO).

Critical CharacteristicsCharacteristics of a product or production process thathave a considerable influence on safety, function, assem-bly, adherence to legal safety standards and customersatisfaction.

LifetimePeriod from initial use to the point of failure after which theproduct cannot be returned to a functional state.

Supply ReliabilityAdherence to the requirements regarding on date ofdelivery and delivery quantity.

VI. Appendix

Capability of measurementMeasuring of the degree of inaccuracy in relation to thetolerance of the characteristics to be measured.

System supplierTakes responsibility for development and production of anassembly, which can be separated functionally, such ascutter bars, brakes, steering, hydraulics

Component supplierWorks on the basis of documents, drawings, specificati-ons etc. provided to them with no development responsi-bility.

Weibull media rank methodStatistical method used in calculating product andcomponent reliability.

2. Abbreviations

Cp/Cpk value - Process capability valueR & D - Research and developmentFMEA - Failure potential and influence analysisPCP - Process control planQM - Quality ManagementQAA - Quality assurance agreementRPV - Risk priority valueSPC - Statistical Process ControlVDA - German Automotive Industry Association

3. Sources

VDA Volume 2: Quality Assurance of SuppliesVDA Volume 3: Reliability assurance of car manufacturers

and suppliersVDA Volume 4: Quality assurance during product realisationVDA Volume 6 (Part 1): QM system audit Material ProductsVDA Volume 6 (Part 2): QM system audit ServiceVDA Volume 6 (Part 3): Process-auditVDA Volume 6 (Part 4): QM system audit Production EquipmentVDA Volume 6 (Part 5): Product audit

QS 9000 PPAP Guideline Production Part Approval ProcessQS 9000 APQP Guideline Advanced Product Quality

Planning and Control PlanQS 9000 FMEA Guideline Failure Mode and Effects AnalysisQS 900 SPC Guideline Statistical Process ControlQS 9000 MSA Guideline Measurement System Analyses

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Future

Forward-looking.Worldwide. CLAAS.