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1
Seating Systems DivisionSupplier Quality Meeting
April 7, 2006
2
Agenda
Opening Remarks & VTE Restructuring M. Lewis 9:00
Supplier Quality R. Mowad 9:152005 Performance Metrics2005 Systemic Opportunities2006 Supplier Goals
Supplier Communication V. Piner 9:30Scorecards / SRS / Diversity
SQTS S. French 9:45
Top Focus Process / DDW K. Kustron 10:00
Launch Readiness K. Alexander 10:15
Tool Moves R. Boyer 10:30
PPAP Changes B. Cooper 10:45
IMDS R. Spearot 11:00
Wrap Up / Closing Remarks M. Lewis 11:15
3
Agenda
Opening Remarks & VTE Restructuring M. Lewis 1:00
Supplier Quality R. Mowad 1:152005 Performance Metrics2005 Systemic Opportunities2006 Supplier Goals
Supplier Communication V. Piner 1:30Scorecards / SRS / Diversity
SQTS S. French 1:45
Top Focus Process / DDW K. Kustron 2:00
Launch Readiness K. Alexander 2:15
Tool Moves R. Boyer 2:30
PPAP Changes B. Cooper 2:45
IMDS R. Spearot 3:00
Wrap Up / Closing Remarks M. Lewis 3:15
Weld Supplier Requirements M. Lewis 3:30
4
Margaret Lewis
Welcome & Introduction
5
Lear Restructuring
Former Lear Organization Purchasing
Supplier
Quality
Customer
Group
Program
Mgmt
Product
Division
Engineering Operations Quality
6
VTE Restructuring
EngineeringEngineering
LPMPLPMP
PurchasingPurchasing BOMBOM
Supplier
Quality
Supplier
Quality
APQPAPQP
OperationsOperations
Vehicle
Team
Vehicle
Team
Restructured Lear Organization
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Vehicle Team Executives - Organization
Steven L. HayworthPresident
Kevin HobanHB / DR
Ryan BurnsGMX 222
Billy WilliamsE70
Dan GollesGMT 800 / 610 / H2
Elie GhazalAOEM
Art KennedyU251
Chris ClarkGMT900
Jim ClaypoolEN114 / S197J56 / Ford Car
Bill SchuelerGMX 211/231
8
VTE / VTD / Quality
Plant VTE VTD Quality
Kevin Hoban Gene Dudash Al Addesso
[email protected] [email protected] [email protected]
(248) 447-1269 (248) 447-5956 (248) 447-1902
Kevin Hoban Butch Staycoff Alma Beebe
[email protected] [email protected] [email protected]
(248) 447-1269 (248) 447-4414 (248) 447-1812
Billy Williams George Bowers
[email protected] [email protected]
(864) 433-6605 ext 605 (864) 661-1344
Elie Ghazal Drew Sturgeon Stacey Dodge
[email protected] [email protected] [email protected]
(248) 447-1202 (734) 207-6396 (734) 207-6413
Chris Clark Willie Richards Mike Sabiston - [email protected] (248) 447-5826
[email protected] [email protected] Paul Bhinder - [email protected] (905) 682-2052 ext 334
(248) 447-1208 (248) 447-5854
Bill Schueler Jason Scott Jamie Wilson
[email protected] [email protected] [email protected]
(248) 447-5584 (248) 447-4415 (905) 683-2052 ext 380
Ryan Burns Mike Watters Jeff Hill
[email protected] [email protected] [email protected]
(248) 447-5856 (248) 447-1209 (248) 447-1374
Dan Golles Matt Hicks Randy Breeding
[email protected] [email protected] [email protected]
(248) 447-4477 (248) 447-4479 (248) 447-1604
Art Kennedy Kirk Koenig Scott Peel - [email protected] (248) 447-5842
[email protected] [email protected] Susan Buchanan - [email protected] (248) 447-5684
(248) 447-1954 (248) 447-4151
Jim Claypool Mark Folkert Arnold Park - [email protected] (248) 447-1604
[email protected] [email protected] Maria Berezcki - [email protected] (519) 633-2100 ext 244
(248) 447-1472 (248) 447-5786
Jim Claypool Bob Dowell Arnold Park - [email protected] (248) 447-1604
[email protected] [email protected] Maria Berezcki - [email protected] (519) 633-2100 ext 244
(248) 447-1472 (248) 447-5785
Scott French Dale Perrault
[email protected] [email protected]
(248) 447-1238 (248) 447-1358
Newark
Bridgeton / Romulus
Duncan
Montgomery
Ajax / Arlington / FentonJanesville / Rochester Hills
Whitby
Lordstown / Mason /Windsor
Wentzville
Elsie / Kitchener / MorristownRoscommon / Walker
Hazelwood / Liberty / Louisville
Atlanta, Hammond
St. Thomas / Brownstown
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Supplier Quality
Rich Mowad
10
Expectations Of Supply Base (2005)
External PPM50% year over year improvement
Repeat Written Concern70% year over year improvement
Flawless Launch Performance0 Plant Disruptions0 Customer Incidents< 300 PPM over first 60 days
11
847
453
235 205
0100200300400500600700800900
2003 2004 2005 2006 YTD
Americas - External Production SuppliersRPPM 2003 - 2006 Feb YTD
PPM Trend
72% PPM Reduction
12
Repeat Written Concerns 2004 vs. 2005
4360
7500
1000
2000
3000
4000
5000
2004 2005
83% Reduction
83% Reduction
Written Concerns
13
Common Cause of Failure 2005
Lack of Effective APQP ManagementDid not adequately predict failure modeDid not validate process effectively Lack of visual quality standards with Lear seating plantsPoor error proofing
Poor Process ControlLack of standardized process change/adjustment proceduresLack of discipline to follow established procedures
Lack of Resources
Sub-Tier Supply Chain Management
Logistic Concerns
14
Common Cause of Failure 2005 (cont’d)
Poor Tolerance Development and Engineering Practice
Poor/incomplete GD&TMissed significant characteristic call outFailure to understand part/component/system interface
Holiday Startup Procedures
Poor Containment PracticeContainment breakPoor documentationLack of follow-up on voice of the process
15
Supplier Development Focus (2006)
Flawless Launch Performance from the Supply Base
Eliminate Supplier Related Pass Through Quality Issues
Eliminate Supplier Related Plant Disruptions
Validate and Improve Controls on Welding Processes
16
Expectations Of Supply Base (2006)
External PPM50% year over year improvement
Repeat Written Concern70% year over year improvement
Pass Through Quality Concerns70% year over year reduction
Plant Disruptions70% year over year reduction
Flawless Launch Performance
17
Keys to Success (2006)
Increased Stress on Manufacturing and Quality Discipline
Sub-Supplier Management and Control
Adherence to the Non NegotiablesBullet Proof PFMEA and Control PlansProcess Standardization and Control (Solid Containment)Boundary Samples and Inspection CriteriaRobust Data Collection, Analysis, and UseDisciplined Problem Solving and Response to Issues
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Supplier Development - Contacts
OFFICE CELL e-MailALEXANDER Ken 248.447.5196 734.658.1364 [email protected] Ranjit 248.447.5221 248.703.6783 [email protected] Doug 248.447.5850 313.995.6183 [email protected]
GROGAN Mike 915.787.5242 915.892.5910 Cell 248.550.9204 Pager [email protected]
HETHERINGTON Scott 248.447.5203 313.671.1734 [email protected] Tim 248.447.5575 248.701.0507 [email protected] Kathy 248.447.5233 248.231.6633 [email protected] Dave 248.447.5238 248.470.8618 [email protected] Ron 248.447.5237 810.824.7140 [email protected] Rich 248.447.5282 248.877.0505 [email protected] Frank 248.447.5631 248.388.0871 [email protected] Les 248.447.5256 248.259.0627 [email protected] Rodney 248.447.5179 313.282.6168 [email protected]
NAME
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Supplier Communication
Vickie Piner
20
Supplier Requirements
LEAR REPORTING AND CERTIFICATIONS
TS16949
SRS
eCPAST
Tier II Diversity Spend Tracking
21
Purchasing Requirements – TS16949
All Lear Suppliers are Required to be Certified to TS16949:2002
Suppliers That are Currently Certified to QS9000Expires December 14, 2006Must have a plan within time-line to Lear Purchasing to transition to TS16949:2002 by May 1, 2006
ISO 14001:2004 (E) Environmental Certification is required by December 31, 2006
Lear PETC Will Issue Customer Satisfaction QNs to any Supplier Location that has not Submitted Quality Certificates
Email address for certificates: [email protected] by fax: 248-493-5999
22
Scorecard Key Performance Metrics
SUPPLIER PERFORMANCE MEASURABLES
RPPM 30 pointsWritten Complaints 20 pointsDelivery 15 pointsService/Responsiveness 10 pointsCompetitiveness 25 points
TOTAL 100 points
23
2006 RPPM SRS Rating Scale
076 & Higher 366 – 75 655 – 65 946 – 55
1236 – 45 1526 – 35 1821 – 25 2116 – 20 2411 – 15
276 – 10 300 – 5
2006 RPPM ScoreActual RPPM
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SRS Supplier Scorecard
“Corporate” ScorecardSummary scorecard for the entire corporationContains summary information for each ship point and overall score for the company
“Common” ScorecardSRS generates one “common” scorecard for each ship pointShows individual performance for each Lear plant the location supplies and overall score for the ship point
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Supplier Registration Lear On-Line
eCPAST https://access2.lear.com
On-Line QuotingSubmitting RFQ & ECN quotes to Lear
Purchase Order RetrievalProduction PO’s
Supplier Diversity Reporting – SDR Quarterly Reporting
Supplier Rating System – SRS SRS Monthly Scorecards and Metric Charts
Supplier Quality Tracking System – SQTS Respond to Quality Notices issued by Lear Plants for Quality, Delivery and Customer Satisfaction Issues
ProFile – Supplier APQPSupplier Data for Program Launch Requirements
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SRS Help / Support Resources
All Questions Regarding SRS Scoring Must be Addressed to the Lear Plant that Provided the Rating
The SRS Supplier Manual is Available on eCpast at https://access2.lear.com
All Remaining Questions Should be Addressed via Email to:[email protected]
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Tier II Diversity Spend Tracking
Lear Corporation Requires Tier 2 Reporting from all Suppliers
2006 Diversity Reporting Schedule:1st Qtr. Due April 10th 2nd Qtr. Due July 10th
3rd Qtr. Due October 9th 4th Qtr. Due January 8tt 2007
Lear’s Requirements – Lear Requires all North American Tier I Suppliers to Purchase 5% of Total U.S. Purchases from MBE’s
Your minority sourcing percentage results in a Green/Yellow/Red ratingMinority sourcing performance is considered in making future sourcing decisionsThe Lear SDD office has resources to assist in the reporting system
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$250$317
$350 $325$375$402
$475
$442
$550
$745
$1,000
$773
0
100
200
300
400
500
600
700
800
900
1000
2000 2001 2002 2003 2004
Diversity Spend (MILS)
TargetActual
2005 Supplier Diversity Tracking
2007 Target - $1 Billion
2005
29
Web Applications
You are now viewing the “Public Site” on http://lear.covisint.comTo register your company, click on the Web Applications tab
30
SQTS
Sherri French
31
What is the SQTS?
The SQTS is Lear Corporation’s Global Supplier Quality Tracking System for Supplier Quality, Warranty, Delivery and Customer Satisfaction Concerns
The SQTS Provides a Standardized Method of Issuing Quality Notices (QN’s) to Suppliers
Suppliers Must Respond to QN’s by Entering Data in the System Fields that Follow a Disciplined Problem Solving Approach
Data Collected in the SQTS Database will be Linked to the Lear Purchasing SRS (Supplier Rating System) to Generate Supplier Scorecards and Metric Reports
32
What are the Benefits of the SQTS?
Improved Communication Between Lear Plants and Suppliers
Standardized Method of Issuing QN’s to Suppliers
Faster Resolution of Supplier Driven Quality Issues
Detailed Supplier Quality Information Available to the Lear Divisions, Corporate Quality, Purchasing and Suppliers
33
Access
The SQTS is Accessed Through eCPAST. (https://access2.lear.com) You can Also Access the SQTS Directly at https://learconnect.lear.com/sqts
Suppliers Must be Enrolled in the SQTS by their Corporate Supplier Administrators
System RequirementsInternet Explorer Version 5.5 or higherAdobe Acrobat Reader (latest free version)Internet AccessEmail Account
34
QN Process FlowLe
ar P
lant
Sup
plie
r
Problem identifiedCreate QN via
intranetapplication
System generatede-mail notification
of new QN tosupplier
Recieve e-mailnotification of new
QN
Submit initialresponse via
internet/intranetapplication
SQTS
System generatede-mail notificationof initial response
to Lear plant
Review initialreponse
Approveinitial
response?
System generatede-mail notificationof initial response
rejection tosupplier
No
Initial reponseclosed indatabase
Yes
Completeremaining QN
data
Completeremaining QN
data and requestsQN closure
System generatede-mail notificationof closure request
to Lear plant
Review correctiveactions / QN data
ApproveQN closure?
System generatede-mail notification
of closurerejection t o
supplierQN closed
No
Yes
1. Lear Plant creates a QN.2. Supplier plant replies with Initial Response (Containment) within 24 hours.3. Lear Plant accepts or rejects the initial response.4. Supplier plant replies with root cause, permanent corrective action and
preventive corrective action.5. Lear Plant accepts or rejects the final response and closes QN.
35
SQTS Link in e-CPAST (https://access2.lear.com)
36
Help / Support
Contact your Local Supplier Administrator
Contact Lear Supplier Development Team
Contact the Lear Plant
Email [email protected] for all Questions Regarding the SQTS
Email [email protected] for all Questions Regarding your supplier scorecard
Supplier SQTS Manual and SRS Manual Available on eCPAST
37
Top 5 Questions Asked by Suppliers
How do I get access to the SQTS?
If you have the wrong Supplier Administrator or any questions regarding your Supplier Administrator please email: [email protected] your company needs a Supplier Administrator, please visit Lear’s website at Covisint and click on the Web Applications tab. You can complete the section ‘Request Web Application Access’ to request a Supplier Administrator.
After scrolling down to bottom
of the page
38
Top 5 Questions Asked by Supplier
Why Can’t I reply to a QN?
39
Top 5 Questions Asked by Supplier
Why hasn’t the Lear plant received my Initial Response? I’ve clicked on the Initial Response button but they haven’t received it.
40
Top 5 Questions Asked by Supplier
Why is my Supplier Scorecard Incorrect?
Wrong Supplier Ship Point in SQTSWrong Number of Parts Received in SQTSSupplier Ship Point Not in SQTS
41
Top 5 Questions Asked by Supplier
My email address is incorrect in SQTS. How can I change it?
Only your Supplier Administrator can change your email address. Please contact your Supplier Administrator directly.
42
Top 5 Process / DDW
Kathy Kustron
43
Top 5 Process
Overview Top Five - New Process for 2006System to Provide a High Level of Focus on the Poorest Performing Portion of the Supply Base
Structure similar to the "Top Focus" process established by GMFormal Monthly Review of Those Suppliers who have Performed Poorly During the Past Three Months
Based on data pulled from SQTS / SRS (Supplier Quality Tracking System / Supplier Rating System)
BenefitsIdentifies the Improvement Processes by the SuppliersFocuses Lear Resources on Only the Poorest Performing SuppliersMonitors and Tracks Supplier’s Improvements
44
INPUT SUPPLIERDATA INTO LEAR
SQTS (as required)
LEAR ASSEMBLYPLANT
SUPPLIER
INPUT SUPPLIERDATA INTO LEAR
SQTS(Previous Month)
Monthly Day 5 Monthly Day 12
REVIEW DATA INSQTS
DATACORRECT?
CONTACTREPORTINGPLANT TOCORRECT
DATACORRECT?
UPDATE SQTS
YES
NO
CLEAN DATAACHIEVED
Ongoing
NO
YES
Data Input Lear Supplier Quality Tracking System, SQTS
45
Top 5 Identification to Supplier Quality Review Presentation
LEAR SUPPLIERQUALITY
SUPPLIER
CREATEEXCEPTION
REPORT IN SRS
ANALYZE PAST 3MONTHS OF
DATA
IDENTIFICATIONSUPPLIERS FORTOP WORST 10
OTHERFOCUS?
TOP 5 WORSTSUPPLIERSIDENTIFIED
ELIMINATE FORREVIEW
NO
TOP 5 PACKAGESENT TO EACH
SUPPLIERSEPARATELY
Monthly Exception Report.xls Top 5.xls
Quality Review Notification Letter.doc
Quality Review Presentation.pptDeep Deep and Wide Read Across.xls
FMEA Comparrision.xls
Top 5 Supplier Meeting Notice.doc
Supplier Audit - Rev 1 1.xls
Monthly Top 5 Supplier Quality Internal Meeting Notice.doc
CONDUCTINTERNAL AUDIT
RETURN AUDITRESULTS
COMPLETESUPPLIERQUALITY
PRESENTATION
RETURNSUPPLIERQUALITY
PRESENTATION
REVIEWSUPPLIER AUDIT
RESULTS
DISTRIBUTESUPPLIER
PRESENTATION
REVIEWSUPPLIER
PRESENTATION
SUPPLIER,LEAR SUPPLIER
QUALITYMANAGEMENT, AND
VTE EXTENDED TEAM
QUALITYREVIEW AND
PRESENTATION
SQTS UP TODATE FOR
PRIOR MONTH
LEAR PLANTS ANDSUPPLIERS
SEND OUTINTERNALMEETINGNOTICE
+ I DAY +2 DAYS +2 DAYS +7 DAYS +7 DAYSNot To Scale
+3 DAYS
YES
Top 5 Sign In Sheet.xls
Top 5 Calendar 2006.xls
Deep Drill Worksheet.xls
Each category assessed by a weighted ranking system
• 10% for PPM• 10% for combined sum for Level 0,
Level 1, and Level 2 issues • 50% for sum of Level 3 disruptions• 30% for sum of Level 4 customer
issues
46
Follow Up
LEAR SUPPLIERQUALITY
SUPPLIER
SUPPLIER,LEAR SUPPLIER
QUALITYMANAGEMENT, AND
VTE EXTENDED TEAM
QUALITYREVIEW AND
PRESENTATION
ASSESS TOP 5REPORT
IMPLEMENTIMPROVEMENTS
REVIEWSUPPLIER'SPROGRESS
ASSIGN /IDENTIFY SQE
SUPPLIER ANDSUPPLIER QUALITY
ENGINEER
ASSESSSUPPLIER'S
PROGRESS OFIMPROVEMENTS
LEAR SUPPLIERQUALITY AND
SUPPLIER QUALITYENGINEER
CHANGESCOMPLETE?
NO
YES
UPDATETRACKING
MATRIX
Top 5 Monthly Tracking.xls
FOLLOW UPCONFERENCE
CALL
SUPPLIER ANDLEAR SUPPLIER
QUALITYPOSITIVETREND?
IDENTIFYIMPROVEMENT
PLAN
MONITORPROGRESS
YES
NO
Monthly Exception Report.xls
Top 5 Calendar 2006.xls
+ 1 MONTH (ON GOING)Not To Scale
+ 1 MONTH (ON GOING)
47
Top 5 Process: Supplier Requirements
Self Audit
Quality Review MeetingPresentation
• Standardized Power Point templateAttended by:
• Supplier Management• Lear Quality Management• Lear Vehicle Team Executives and Quality Management
Follow Up Status Meeting(s)Supplier and Lear Supplier Quality Engineer
Follow Up Conference Call(s) Supplier and Lear Supplier Quality Management
48
Self Audit
Supplier Self AssessmentOne Week to complete
• Continuous Improvement
Organization / Process Review
ManagementQualityProductionMaterials
Automatic Scoring Based on Supplier InputsAction Plan
Coded “Yellow” or “Red”
Supplier XYZ Start Date: 4/2/06 Karol GerilynLocation Assembly, MI Close Date: 555.234.7890Representative Heather Andree Rev. Date: [email protected]
G Green - Requirements MetY Yellow - Requirements are not fully met. 3 month window for correction.R Red - Little to No evidence of meeting requirements. 6 month window for corrections.
TOTAL TOTAL
0 0 1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
DATE OPENEDTARGET
CLOSE DATEACTUAL
CLOSE DATE LAST UPDATE
Auditor:Auditor Phone:Auditor E-Mail:
STATUS HISTORY
STATUS
MATERIALS
COUNTER MEASURES/comments
PRODUCTION
QUALITY
MANAGEMENTOldest Most Recent
ITEM # ACTION ITEM ACTION LEADER
49
Quality Review Presentation
AgendaSupplier Data Review
Supplier Pareto of IssuesSRS Charts QN / Controlled Shipping Status
BackgroundDrill Deep Drill Wide FMEA and Control PlanFollow-up Plans
50
Drill Deep - Investigate
DEFECT
WHY DID THE PLANNINGPROCESS NOT PREDICT
THE DEFECT?
WHY DID THEMANUFACTURING
PROCESS NOT PREVENTTHE DEFECT?
WHY DID THE QUALITYPROCESS NOT PROTECT
LEAR FROM THE DEFECT?
P1
P2
P3
P4
Pn
WHY?
WHY?
WHY?
WHY?
PREDICT THE ROOT CAUSE
M1
M2
M3
M4
Mn
WHY?
WHY?
WHY?
WHY?
PREVENT THE ROOT CAUSE
Q1
Q2
Q3
Q4
Qn
WHY?
WHY?
WHY?
WHY?
PROTECT THE ROOT CAUSE
IMPLEMENT CORRECTIVE ACTIONS
51
Drill Deep - Investigate
Purpose of the Drill Deep Analysis is to Understand WHYthe System Failed to
Prevent the occurrenceProtect Lear and determine what allowed the non-conforming part to be shippedPredict the problem on the part
The Drill Deep is Not Used to Understand WHAT Failed
52
Drill Wide - Implement
The Drill Wide (Read Across) Matrix is Used to Assist in the Carrying Across the Lessons Learned to:
Similar productsManufacturing processesFacilities throughout your company
Prevent Similar Reoccurrences
Prod
uct /
Pro
cess
C
lass
ifica
tion
Part Name & Number
Lear Assy. Plant N/C CS
Status QN Number / Issue
ContainmentCause of Failure Mode CAPrevent Corrective ActionProtect Corrective ActionPredict Corrective ActionKey Findings Corrective Action
Part Name & Number
Lear Assy. Plant N/C CS
Status QN Number / Issue
ContainmentCause of Failure Mode CAPrevent Corrective ActionProtect Corrective ActionPredict Corrective ActionKey Findings Corrective Action
Part Name & Number
Lear Assy. Plant N/C CS
Status QN Number / Issue
ContainmentCause of Failure Mode CAPrevent Corrective ActionProtect Corrective ActionPredict Corrective ActionKey Findings Corrective Action
Corporate Champion Symbols
Cor
rect
ive
Act
ion,
CA
Customer Concern Failure Mode 5 Why Analysis 2
Corporate Champion Symbols
Cor
rect
ive
Act
ion,
CA
Customer Concern Failure Mode 5 Why Analysis 3
Corporate Champion1 Symbols
#1 LocationA.P.Q.P. #2 Location
Customer Concern Failure Mode 5 Why Analysis
Cor
rect
ive
Act
ion,
CA
SYMBOL & STATUS KEY:
O
XR
N/A
Not Completed
Repeat IssuesNot Applicable
Completed & 3rd Party / Lear verifiedCompleted & Supplier verified only
Original Product line and location
Product line and/or location with similar process
53
Top 5
SelectionIdentification of Worst Performing Suppliers Based on Data from Lear’s SQTS / SRS
Three month weighted average
Supplier ResponsibilitiesSelf AuditSupplier Quality Review Meeting and Presentation
Data reviewDrill Deep and WideImprovement and Implementation Plans
Follow-up ReviewsSupplier Quality EngineerStatus Conference Call
54
Launch Readiness
Ken Alexander
55
2006 Launches
Hyundai CM – Santa FeSOP April 10, 2006
BMW E70 – X5SOP October 6, 2006
GMT 900 – Pick Up TrucksSOP October 2, 2006SOP November 13, 2006
56
Deliver Flawless Processes at Launch
Process is Stable, Robust and in Control
No Major Quality Issues at Lear Plants
No Third Party Containment Required
No Supplier Related Customer Yard Holds or Other Significant Events
57
Non – Negotiable Items
Bullet proof PFMEAs and Control Plans
Process Standardization and Control
Boundary Samples and Inspection Criteria
Robust Data Collection, Analysis and Use
Disciplined Problem Solving and Response to Issues
58
Launch Readiness
Executive Engagement During all Phases of Product Launch Cycle
Sub-Supplier Management
Launch Containment Expectations
ProFile Usage to Assist in Advance Quality Planning
59
Executive Involvement
Accountable to Take Measures to Promote Flawless Launch
Drive Correct Resources and Focus Placed on Launch
Chair Supplier Launch Readiness Reviews
Raise “High Risk” issues to Lear VTE to Quickly Drive Resolution
60
Sub-Supplier Management
Review of Supply Base Establish High Impact vs. Low ImpactDrive a priority based management system
Adherence to APQP System Throughout all Sub Tier Levels
Monthly Review Meetings with Supply Base Validate timingDrive program information
Materials Reporting Issues (IMDS)
61
Off-Shore Management Expectations
Verify Capabilities and Quality Systems
Increase Inventory Based on Transit Times
Contingency PlanningCatastrophic DamageLack of Raw MaterialsTransportation Interruptions (Storms, etc.)
Extraordinary Inspection / Containment
62
Launch Containment Expectations
Protection for Lear Facilities
Data Driven Validation of Supplier Processes
Definition, Achievement and Validation of Exit Criteria
Supplier Executive Management Involvement
63
Key Attributes of Launch Containment
Proper LayoutLightingMaterial Flow
Reliable LaborLow TurnoverProper TrainingCorrect Skill Set
Voice of the ProcessCorrect DataCorrect AudienceCorrect Reaction
64
ProFile
Usage is Mandatory for all Suppliers
Supporting Documents Must be Uploaded to Close a Line Item
Timely Updating of Activities
Action Items Must be Inserted into Comments Section for REDItems
65
Tool Moves
Ron Boyer
66
Tool Moves
Supplier / Sub-Supplier Location ChangeSupplier/Sub-Supplier moving to new locationResourcing of Sub-Suppliers
CharacteristicsSupplier must complete “Supplier Notification of Production Change/Move” form located on the Lear Website www.lear.comSupplier submits to Lear Buyer and Lear Plant’s Quality RepresentativePurchasing reviews with Supplier Risk Management GroupSupplier Risk Management Group coordinates kick-off meeting with plants affected and program teams affectedPlatform Team (Plants, Program Management, Engineering, Purchasing) completes processSupplier Risk Management Group monitors process and supports as required
67
Tool Moves
68
Tool Moves
69
Tool Moves
70
Tool Moves
71
Tool Moves
72
Tool Moves
73
Tool Moves
74
PPAP Changes
Bill Cooper
75
Supplier QMS Certifications - Cooper
TS 16949 Requires Lear to Assure that all Immediate Suppliers are Either QS9000, ISO 9001:2000 or ISO/TS 16949:2002 Certified
On Dec 14, 2006, QS9000 will no longer be in effect By Dec 14, 2006 all Tier's of suppliers MUST either be ISO 9001:2000 or ISO/TS 16949:2002Should you need a 3rd party registrar, Intertek Systems Certification will offer lowered man day rates to any Lear suppliers to lower their cost to go to TS 16949 - Contact Merry Keating at [email protected] (Phone 616-299-2650)Before May 1, 2006 please send a copy of each of your manufacturing facility’s most current QMS certification to: [email protected] or Fax 248-493-5999
76
PPAP 4th Edition Effective Date
The PPAP Fourth Edition Replaces the Third Edition Effective June 1, 2006 - Unless Otherwise Specified by Your Customer
77
Changes in the 4th Edition
The Fourth Edition of PPAP Includes the Following ChangesIdentified issues in the application of PPAPRemoval of QS-9000 referencesIMDSRemoval of OEM customer specificsRearrangement of clauses to improve flow
78
PPAP Changes Overview
Alignment of PPAP to the ISO/TS 16949:2002 Process Approach Including:
Aligning the order of the PPAP requirements with the automotive product development and manufacturing processInclusion of an example process flow for PPAPRelocation of Customer Specific Instructions to appropriate websites, (e.g. OEM and IAOB, www.iaob.org) to provide current requirementsUpdate of Truck OEM requirements
79
PPAP Changes Overview
Revised PSW (Part Submission Warrant) to:Provide more logical flow for the part/design description fieldsMake the supplier address fields applicable to international locationsInclude IMDS materials reporting to indicate reporting status
80
PPAP Changes Overview
Updated Specific PPAP Requirements - Including:Materials reporting requirements in the design recordProcess capability index usage (Cpk and Ppk)Definition + approval of catalog parts + definition of black box partsModified customer notification + submission requirements to align with OEM requirements
81
Summary of OEM PPAP Customer Specifics
SPECIAL NOTE: All Speakers at the Recent AIAG PPAP 4th
Edition Rollout Conference Repeatedly Said:
“If any supplier makes a change to any of their products’ design or process, then those applicable changes MUST be resubmitted for PPAP to each applicable customer and through all supplier levels until the PPAP is fully approved by the applicable OEM(s).”
Hence, if you Make a Change, You Must get an Approved PPAP From Lear to Do So
82
Read the New AIAG PPAP 4th Edition Completely Before June 1, 2006Purchase the New Manuals Online from www.AIAG.orgRead Your Customers’ Customer Specific Requirements for PPAP and ISO / TS16949 at www.IAOB.org and/or www.covisint.com
** MOST IMPORTANTLY **When in doubt about what to do,
you should ALWAYS call your immediate Quality and/or VTE contact
Summary of What You Should Do
83
IMDS
Rebecca Spearot
84
Lear Corporation
Product Material Content and Recyclability Reporting International Materials Data System
(PMCRR-IMDS)
Supplier Requirements 2006
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Legal / Customer Requirements
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Legal/Customer Requirements
End of Life Vehicle (ELV) Directive adopted in EU in 2000Japan Automobile Recycling Law implemented in 2003Korean and Chinese Laws - futureMany state specific laws in the US, either in place or being debated, prohibiting use of many substances/ materialsRestriction on Hazardous Substances (RoHS) implemented in EU in 2004
It’s all About Material Content!
ALL LEAR CUSTOMERS HAVE ENGINEERING SPECIFICATIONS THAT FOLLOW THESE LEGAL REQUIREMENTS
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Legal/Customer Requirements
To Sell Vehicles in EU and Japan, OEMs MUSTSubmit:A Disassembly Manual starting 7/2002 in Europe
Certify Compliance to Substances of Concern (SoC) beginning 7/2003 – EU and beginning 2004 - Japan
Certify to Recyclability Target & Parts Marking beginning 7/2006 – EU, and
Comply with the EU “Type Approval Directive” (RRR), Which Mandates that Recyclability Must be Certified for Each New Product From Q4 2008 and Existing Products Must be Certified Before Q2 2010
85% reuse/recycle/recovery beginning 7/200695% reuse/recycle/recovery beginning 7/2015
No Type Approval Means no Sales Within EU
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Because of These Requirements Lear MUST:Report and Certify (Globally) Complete Materials Content Data onEvery Assembly Shipped to Customers’ per Respective Customer Specification.
and
Eliminate Substances of Concern (SoC) usage from productsand
Meet Customers Requirements for Product Recyclability (ISO 22628) CY2006 and Beyond
WHICH MEANS OUR SUPPLIERS HAVE TO DO THIS TO!
Legal/Customer Requirements
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Customer Reporting Requirements
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Customer Reporting Requirements
Part Submission Warrant – Effective March 1, 2006
Materials ReportingHas customer-required Substances of Concern information been reported? Yes No n/a
Submitted by IMDS or other customer format: __________________________________________
Are polymeric parts identified with appropriate ISO marking codes? Yes No n/a
ExplanationSubstances of Concern: Enter “Yes,” “No,” or “n/a.”IMDS/Other Customer Format: Circle either “IMDS” or “Other Customer Format” as appropriate. If submitted via IMDS include: Module ID#, Version #, and Creation Date. If submitted via other customer format, enter the date customer confirmation was received.Polymeric Parts Identification: Enter “Yes,” “No,” or “n/a.”
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Customer Reporting Requirements
Comply with Parts Marking RequirementPlastic parts (ISO1043/11469) weighing more than 100 gramsElastomeric parts (ISO1629) weighing more than 200 grams
Part Weight (Mass)Shall be in Kilograms to four decimal places (0.0000) unless otherwise specified by the customer
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Hyundai/Kia
VW & Audi
Toyota
Nissan
GM (Fiat, Opel, SAAB, & Vauxhall)
Ford (Aston Martin, Jaguar, Land Rover, Mazda, & Volvo)
DaimlerChrysler – NADaimlerChrysler – Eu
Internet Based Reporting; International Materials Data System (IMDS)
BMW
REPORTING TOOL/METHODCUSTOMER
Specific SpreadsheetsFrench OEMs
Honda Own web based system
Customer Reporting Requirements
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DCX
Ford
Customer Reporting Requirements
Engineering Specifications
General Motors GMW 3059
And Many Others!
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International Materials Data System (IMDS)A web-based (http://www.mdsystem.com) data collection system used by customers/suppliers to collect, create, and report product materials content and recyclability data“Bottom-Up” data collection systemFree of cost to suppliers – supported by customersA complete IMDS entry for an assembly includes
Part numberPart descriptionPart weightSub-components/assemblies details Each material compositionRecycled materials usage Complete substances disclosure - Not just the prohibited substances
Customer Reporting Requirements
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OEMs
Supplier <n>
Supplier 3
Supplier 2
Supplier 1
IMDS Database
Customer Reporting Requirements
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Substances of Concern
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Substances of Concern
Global Automotive Declarable Substances List (GADSL)
See http://gadsl.org
Pre-GADSL:Many lists for each OE, confused suppliers and was inefficient
Now: There is one list – that is consistent with each OEOne international committee “controls” this list with inputs from all OEs and SuppliersClear definitions of “prohibited” and “restricted”Consistent target dates for removal of prohibited substancesElimination dates not specified in GADSL but linked to EU Directives
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Substances of Concern
Lead (Pb)Lead in Solder and Contact Plating is Exempted
Usage is limited to 60 grams/vehicleSome Customers require Lear to provide Lead free products by 7/2006
Lead in Glass BulbsProhibited beginning 1/2005. Lear is required to get writtendeviations from customers
Lead in Pyrotechnic InitiatorsAllowed in vehicles type-approved before 7/2006
Lead in Copper AlloysUsage is limited to 4% by weight
Cadmium (Cd)No Lear product should contain Cadmium above 0.01% by weight
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Hexavalent Chromium (Cr6+)Hexavalent Chromium used for Corrosion Preventive Coatings
Prohibited beginning 7/2007 (Regulation)Prohibited beginning 7/2005 (Customers)
Mercury (Hg)Mercury in Instrument Cluster Lighting
Prohibited beginning 7/2004Mercury in High Intensity Discharge Lamps
Prohibited beginning 7/2006
Brominated flame retardantsBrominated Flame Retardants are Found in Plastic and Foam
Penta and Octa Brominated flame retardants prohibited beginning 8/2004
Substances of Concern
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FutureFor Lead
Bearing Shells and Brushes (July 2008)Aluminum for Machining Purposes with a Lead Content up to 1.5% by wt. (exemption ends July 2008)Pyrotechnic Initiators (July 2006)
For Hexavalent ChromeCorrosion Preventive Coatings (July 2007)Corrosion Preventive Coatings Related to Bolt and Nut Assemblies for Chassis Application (July 2008)
Substances of Concern
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FutureFor Cadmium
Thick Film Paste (July 2006) Optical Components in Glass Matrixes Used for Driver Assistance Systems (July 2007)Batteries for Electrical Vehicles (Dec 2008)
And – Our Customers May Have Very Specific Needs
Substances of Concern
FOR MORE INFORMATION ON WHAT MATERIALS ARE
ALLOWED AND PROHIBITED PLEASE REFER TO THE LEAR
SUPPLIER PORTAL ON COVISINT AND CUSTOMER
ENGINEERING SPECIFICATIONS
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The PMCRR-IMDS Reporting Process
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SuppliersSubmissions
to LearData Processing
By Lear
Philippines Engineering
Technical Center(PETC)
IMDS Submissions
to Customers
PAP Submissions
to Customers viaIMDS and other
Lear Uses ONE Reporting System Worldwide
The PMCRR-IMDS Reporting Process
EngineeringBill of
MaterialData
AdditionalInformation
to Customers
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Lear PETC IMDS Group - Roles & Responsibilities Validate incoming data from suppliers – no one else can validate this data
Send acceptance/rejection acknowledgment
Maintain data validation guidelines
Submit Lear IMDS data to customers
Notify suppliers and the requestor (engineering, quality or program managers) of any substances concern violation
Help desk for Lear, Suppliers and Customers [email protected]
The PMCRR-IMDS Reporting Process
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IMDS Acceptance
The PMCRR-IMDS Reporting Process
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IMDS Rejection
Click on “View” to see the reasons for rejection
The PMCRR-IMDS Reporting Process
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IMDS Rejection
If suppliers report prohibited substances, such submissions will
be Rejected and reviewed for materials
change with engineering/program
team
The PMCRR-IMDS Reporting Process
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The PMCRR-IMDS Reporting Process
SoC Report Acceptance (if using the AIAG Spread Sheet)
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SoC Report Rejection (if using the AIAG Spread Sheet)
The PMCRR-IMDS Reporting Process
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Supplier Requirements
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Suppliers Can Submit IMDS to Lear in ONE of 2 ways:1. If submitting through IMDS, the IMDS information should be sent to
Lear IMDS site ID 632 (Lear Southfield)
2. If submitting using the AIAG spreadsheet, the certified form should be submitted to [email protected]
IMDS Data Submission Instructions and Requirements for SuppliersPosted at Lear Supplier Portal in Covisint and eCPAST
Submissions for PPAPs, 15 Working Days Prior to Supplier PAP Dates are recommended
Other Submissions for LPMP or Other Reasons may be RequestedIf any Supplier’s Data is Rejected – the supplier MUST work to resolve the rejection issue and must resubmit when resolved so the submission may be accepted.
NO OTHER EVIDENCE OF ACCEPTANCE WILL BE ALLOWED
Supplier Requirements
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Supplier Requirements
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IMDS Training for SuppliersIMDS Site at www.mdsystem.com. This is the main IMDS site.
Select “Public IMDS page”. This will give FAQ, Training information, Contact information, etc. If you have not registered your company – go to “System” on the public page. The use of the IMDS site is free. If you are already a registered IMDS user, login from the main site.
Supplier Requirements
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IMDS Training“Teach Yourself IMDS” - an On-line Video by General Motors
"Teach Yourself IMDS" was developed to help automotive suppliersunderstand and implement the materials reporting imperative. This seminar lasts about one hour. It is available at www.gmw3059.com website and it is free. Initial login is required to register.
Supplier Requirements
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Wrap Up / Closing Remarks / Discussion
Margaret Lewis