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TRANSPORT

10/10/2010

Supplier Quality Manual

Quality requirements

SCG-STD-006-01

P 2

External parts from suppliers highly contribute to high quality products, solutions and

services we have to offer our customers.To achieve this high quality level , we are

determined to establish and develop close and long term relationships with our

suppliers .

Involvement of our suppliers is managed through this manual, describing AT

standardized global approach , setting out the minimum required basics tools &

requirements.

This AT worldwide policy is mandatory to achieve our targets, satisfy our customers

and to establish with our panel of suppliers common sustainable growth.

Jean-Michel Geffriaud Valérie Gallego

Senior Vice-President Sourcing & Components Sourcing Quality Vice-President

INTRODUCTION

P 3

Our Requirements / Our common basics

Our requirements:

¤ Quality targets achieved

¤ On Time deliverables during development & execution phases

¤ Partnership behaviour

Our common Basics:

¤ No Safety and Regulation concerns

¤ No issue impacting Alstom Transport premises & fields.

¤ No product/process change without AT agreements

¤ No delay in Project Quality deliverables

¤ Key product/process characteristics under control

¤ Cost Of Non Quality (CONQ) reduced year after year

¤ Customer Secure, reactivity when issues & root cause eradication

¤ Proactive quality mindset & improvement plan

P 4

Our Way or Working

Our Supplier Quality approach is aligned on our Sourcing processes, along the three

main steps of the relationship with the supplier :

¤ Panel entrance and management : Only qualified suppliers may deliver to AT

¤ Prevention in Product & Process before deliveries : to support Quality Built-up

¤ Performance management in execution : To meet defined Quality targets

This Supplier Quality Manual describes :

¤ AT requirements towards suppliers for each of these steps,

¤ Expected way of working and way of managing the activities,

¤ Associated Quality tools to be implemented,

¤ Key Performance Indicators (KPIs) that will allow to assess

achievement of targets.

P 5

Sourcing Quality Management Process & Quality Basics

PERFORM SUPPLIER

SELECTION

MANAGE SUPPLIER

INTEGRATION

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

PANEL ENTRANCE

PREVENTION - SPQD

PERFORMANCE in EXECUTION

SOURCING

QUALITY

BASICS

GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE

PANEL ENTRANCE : Process leading a supplier to be introduced in the AT panel, according to a list

of pre-requisites (system certifications, Co-development & industrial assessments, sustainable development criteria)

PREVENTION - SPQD (Supplier Product Quality Development) MANAGEMENT: Process held during the Product &

Process development phases, in order to guarantee the compliance of the Product to the Quality/Cost/Delivery

targets in a sustainable way

PERFORMANCE MANAGEMENT IN EXECUTION: Continuous process of assessment of the Supplier

according to the Quality performance of the deliveries.

GLOBAL PERFORMANCE MANAGEMENT AND UPGRADE: Continuous process of assessment of the Supplier

according to the performance in all the sectors of the relationship (Execution & Product/Process development)

This performance is synthesised by a colour code.

P 6

Sourcing Quality Management Process

PANEL ENTRANCE

PROCESS

PERFORM SUPPLIER

SELECTION

INDUSTRIAL CAPABILITY

QUALIFICATION

SYSTEM CERTIFICATION

SUSTAINABLE

DEVELOPMENT CHARTER

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK

SUSTAINABLE DEVELOPT

QUALIFICATION

P 7

PANEL ENTRANCE PROCESS

PANEL ENTRANCE PROCESS:

A supplier will be integrated into the vendor list with a “Panel “ status when complying with AT business

criteria, as financial strength, industrial footprint, technical expertise, and has successfully passed the

following items:

¤ Quality Management System ( 3 rd party certification or AT classification )

¤ AT Sustainable development charter sign-off

¤ Process qualification on technical know-how (including special processes)

¤ Sustainable development qualification

¤ Co-development qualification (if the supplier is requested to develop the design of the part)

¤ Capacity check ( if necessary )

AT Sourcing Quality is in charge of performing these assessments and to pronounce the GO/NOGO status

according to their results..

In case of NOGO, only a waiver signed-off by the Product Line Sourcing Quality Development Director can

authorize a temporary panel entrance.

P 8

PERFORM SUPPLIER

SELECTION


SUSTAINABLE

DEVELOPMENT CHARTER


PURPOSE:

To guarantee that the supplier has put in place a consistent Quality

Management System able to satisfy AT requirements in the scope of

the supply

CONTENT

The supplier shall be ISO 9001 certified.

For Rolling Stock and Components, for the safety or critical parts and

sub-systems, the supplier must be IRIS certified.

Certified or at least shall commit to get the IRIS certification within the

following year.

In case of the supplier not ISO 9001 or IRIS certified, AT keep right to

perform

a classification audit according to its own standard.


QUALIFICATION

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK


QUALIFICATION


P 9

SUSTAINABLE

DEVELOPMENT CHARTER

PURPOSE:

The Sustainable Development is a core value within Alstom.

It is a strong component of Alstom strategy and means responding strongly

and actively to Alstom stakeholders societal needs and anticipating new

environmental, social and economic developments.

As key actors in the development and production processes, suppliers has to

Commit to the same values, and cascade to their own suppliers.

CONTENT

The supplier is requested to sign-off the charter and commit to AT requirements

in terms of:

¤ Labour standards

¤ Ethics

¤ Environment

¤ Occupational Health and Safety

¤ Product and services life cycle

PERFORM SUPPLIER

SELECTION


SUSTAINABLE

DEVELOPMENT CHARTER


QUALIFICATION

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK


QUALIFICATION


P 10

PURPOSE:

The Process Audit is performed to assess the capability of the supplier to

manufacture and supply parts according to the AT standards and control its

special processes.

CONTENT

This audit is divided in two main sections, one is generic whatever the processes,

the other is related to the control of the special processes (a specific questionnaire

per type of process )

TARGET

To be qualified, the supplier shall get:

¤ Overall score above 80%

¤ No Critical “Corrective Action Request”


QUALIFICATIONPERFORM SUPPLIER

SELECTION


SUSTAINABLE

DEVELOPMENT CHARTER

Generic

1. Process Management, control of I/0 data

2. Purchasing , Procurement

3. Production, Workstations

4. Finished products checks and tests

5. Preparation, storage, handling & shipment of product

6. Non conformities management

7. Personneel, training, skills management

Casting Cabling Electronic Board

Forging Riveting Heat treatment

Extrusion Brazing Rubber-Metal

Machining Stratification Glazing

Welding Gluing

Painting Winding

Special Processes


QUALIFICATION

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK


QUALIFICATION


P 11

PURPOSE:

The Co-Development Audit is performed to assess the capability of the supplier to

¤ perform a product & process development according to the AT standards.

¤ bring innovation through a controlled process.

CONTENT

This audit is divided in three main sections:

¤ Project Management

¤ Product / Process Development

¤ Innovation Management

TARGET




PERFORM SUPPLIER

SELECTION


SUSTAINABLE

DEVELOPMENT CHARTER

CO-DEVELOPMENT

QUALIFICATION


QUALIFICATION

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK


QUALIFICATION


P 12

PURPOSE:

The “Quick Supply Chain Assessment” is performed to evaluate the ability of the

supplier to control its supply chain and production planning.

CONTENT

This audit is focused on the management of all the items related to the supply

Chain activity

¤ Long & Medium term planning

¤ MRP

¤ Scheduling of the production

¤ Change management

¤ Inventories

In case of high risk detected, this audit shall be followed by a full Supply Chain audit.

TARGET




PERFORM SUPPLIER

SELECTION


SUSTAINABLE

DEVELOPMENT CHARTER

CAPACITY CHECK


QUALIFICATION

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK


QUALIFICATION


P 13

PURPOSE:

The sustainable development audit is performed to assess the compliance of the

supplier to Alstom requirements as defined in the Sustainable Development Charter.

CONTENT

This audit is focused on the following items:

¤ Management involvement

¤ Labour standards

¤ Ethics

¤ Environment

¤ Occupational Health and Safety

¤ Product and services life cycle

TARGET




PERFORM SUPPLIER

SELECTION


SUSTAINABLE

DEVELOPMENT CHARTER


QUALIFICATION


QUALIFICATION

CO-DEVELOPMENT

QUALIFICATON

CAPACITY CHECK


QUALIFICATION


P 14


PREVENTION DURING

PRODUCT DEVELOPMENT (BEFORE FIRST DELIVERIES)

SPQD PROCESS

MANAGE SUPPLIER

INTEGRATION

PREVENTION - SPQD

P 15

SPQD PROCESS :

The target of the SPQD process is to achieve product and process maturity at FAI (or FAT) stage.

The supplier is requested, during the development phases of a new product, to align its development

schedule on the requirements of AT regarding the Quality deliverables.

The backbone of the Quality in development will be the SPQD PLAN, that will be defined jointly at the

beginning of the development, and will include all the steps for the risk prevention and the Quality

Assurance build-up.The schedule will be compliant with the overall Project master schedule.

The AT Supplier Part Quality Development representative will be in charge of tracking and monitoring the

supplier Quality performance plan on a regular basis, and ensuring the achievement of the targets, both

qualitatively and on time, from the business award to the FAI (or FAT).

A focus will be done on the Product & Process risk, and on the consistency & efficiency of the control plan.

The performance of the supplier in the development phase (ability to achieve the targets) will be an input

in the overall supplier ranking (see SUPPLIER PERFORMANCE DASHBOARD chapter).

The Rolling Stock & Components Way of Working and requirements are detailed in the Appendix 1.

SPQD PROCESS

P 16


SUPPLIER PERFORMANCE

MANAGEMENT DURING

EXECUTION

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT


DASHBOARD (colour status)

8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 17

SUPPLIER PERFORMANCE MANAGEMENT DURING EXECUTION

PERFORMANCE MANAGEMENT DURING EXECUTION :

During the execution phase, the performance of the supplier by commodity is consolidated and monitored

by the Supplier Quality representatives.

This performance is measured through the following indicators:

¤ Non Conformities results at AT premises (e.g.:NCR rate = Non Conformity Report rate, corresponding to

the number of Non Conformities over the number of deliveries) , and the reactivity to solve the issues.

¤ Number of issues during the revenue service, and the reactivity to solve the issues.

¤ Number of FAI/FAT GO on time and their number of non conformities

¤ Cost Of Non Quality (CONQ) generated by the supplier non-conformities

The result of this performance assessment is synthesized through a colour code: Black, Red, Yellow or Green.

The rules to attribute these colours are defined hereafter.

P 18

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT



PURPOSE:

Rank the suppliers in terms of Quality targets achievements and reactivity in the

Execution & Product Development phases.

CONTENT

The rules for ranking the suppliers is performed through a colour code (Green,

Yellow, Red or Black Quality status).

The following matrix describes the colour code assignment criteria, the AT owners

for the supplier management; and the AT required reaction rules.




8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 19


Criteria AT Owners Tools and Management

Requirements

Green

¤ Development and Execution results exceeding the

target

¤ Improvement plan ongoing

¤ Proven Reactivity

Yellow

¤ Punctual Quality issues

¤ Quality results at target

¤ Improvement plan ongoing

¤ Proven Reactivity

¤ Local Quality representative

¤ Local Sourcing representative

¤ 8D managed locally

¤ CONQ recovery

¤ Management review involving Supplier

management, local Quality and Sourcing

representatives

¤ Improvement plan managed by local

Quality and Sourcing representatives

Red

¤ Execution results at AT premises out of target or

in continual degradation over the last 3 months,

¤ Safety related issue linked to a lack of process

control at supplier.

¤ 2 major revenue service issues within the last 3

months.

¤ Product Development results out of target, ie:

§ At least 2 FAI NOGO on the same product, with

supplier responsibility

§ At least 3 successive FAI NOGO on various

products.

¤ AND in all cases, no proven reactivity, ineffective

action plan

¤ Commodity Manager or Domain

Director

¤ Sourcing Quality representative

¤ 8D managed locally

¤ Reinforced control plan managed

locally.

¤ CONQ recovery.

¤ Upgrade plan managed by AT Quality

and Sourcing representatives.

¤ Management review involving Supplier

management, Commodity manager or

Domain director, Supplier Quality

Development representative.

¤ Definition of the Red status exit

conditions (performance targets and

due date) by Supplier Quality

Development representative.

¤ NBOH (New Business On Hold) panel

status preparation.

Black

¤ Ineffective action plan to exit the Red position.

¤ No involvement from supplier management

¤ Product line Sourcing Top

management

¤ Sourcing Quality Top management

¤ Exit plan set-up.

¤ CONQ recovery

E

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C

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S

P 20

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

CHANGES MANAGEMENT

PURPOSE:

Alstom requests its suppliers to inform in writing AT of any Product or Process

changes that it wants to implement. AT formal acceptation is mandatory before this

change request can be considered as approved.

CONTENT

Before applying the change, the supplier will assess the risks in terms of impact on

QCD performance and contractual requirements, and submit for approval the

Product and/or Process validation plan.

Process modifications includes:

¤ Location of the production site (manufacturing transfer)

¤ Production process

¤ Tools

¤ Material

¤ Subcontractors.

The supplier will submit the updated Product and/or Process documentation, AT

keeps right to assess the modified process, either at Supplier or Subcontractor

premises.




8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 21

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

CHANGES MANAGEMENT

CONTENT (ctd)

After validation, the modification will be formalized in the contractual

documentation.

The configuration management of the Product is under Supplier’s responsibility.

The control and monitoring of the modification will be performed using the

following information:

¤ Reference(s) impacted

¤ Serial number of the first modified product (including sub-assemblies if

impacted)

¤ Production date

¤ If applicable, State of hardware and software (revision level)

¤ AT modification number

¤ If applicable, reference of the AT waiver.

The supplier will inform AT in case of obsolescence.




8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 22

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

8D MANAGEMENT

PURPOSE:

To guarantee an efficient problem solving approach, Alstom requires from its

suppliers to implement the 8D tool in the analysis and corrections of the issues.

CONTENT

The 8D will at least presents the following items:

¤ Description of the problem

¤ Team in charge

¤ Problem Characterisation

¤ Containment: curative actions (within 48 hours after the problem notification)

¤ Root causes definition and validation **

¤ Permanent corrective actions (within 30 working days after the problem

notification)

¤ Preventative actions

¤ Lessons learnt

** The root causes identification will integrate the causes of non-detection and

the causes of occurrence of the problem.




8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 23

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

QUALITY WALL

RESIDENT

PURPOSE:

In case of not secured control plan , reoccurrence of deliveries of defective parts

detectable at supplier premises, Alstom may require the temporary implementation

of a Quality Wall or a resident to secure the Quality of the delivered products

CONTENT

The Quality Wall is managed by a third party company, mandated to ensure the

checking according to a check-list validated by Alstom Supplier Quality.

The conditions to remove the Quality Wall are defined at the starting of the activity

(number of parts or duration without defect found)

The results of the checking are registered, and communicated to Alstom.

In the meantime, the supplier commits to implement the corrective actions to

tackle the internal issues.The Quality Wall is removed when the targets defined

initially are reached.

A resident is a person full time in charge of supporting the supplier in its

management or problem solving approach. The rule to remove the permanent

remains the same than for the Quality Wall.




8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 24

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

COST OF NON QUALITY

(CONQ) MANAGEMENT

PURPOSE:

Alstom requests its suppliers to be liable for the financial impact of a non

conforming deliveries, either when detected at AT premises (S1) or in the Revenue

Service (S2).

CONTENT

The financial impact of the non-conformities detected at AT premises will be

reported in the CONQ S1 account. They will include:

¤ a fixed fee

¤ the variable cost for the non conformity management (sort-out, rework, …)

¤ the variable cost for the AT impact on production (line stoppage, …)

The financial impact of the non-conformities detected during the revenue service

will be reported in the CONQ S2 account. They will include:

¤ the variable cost of the non conformity management (retrofit, rework, …)

¤ the potential penalties requested by the customer.




8D MANAGEMENT

QUALITY WALL

RESIDENT

COST OF NON QUALITY

(CONQ) MANAGEMENT

CHANGES MANAGEMENT

P 25


GLOBAL PERFORMANCE

MANAGEMENT AND

UPGRADE

GLOBAL PERFORMANCE

MGT & IMPROVEMENT

SUPPLIER UPGRADE

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

P 26

GLOBAL PERFORMANCE

MANAGEMENT & IMPROVEMENT

PURPOSE:

Alstom requests its supplier to develop a continuous Quality improvement plan aiming

at increase their performance all along the development and production steps.

CONTENT

The improvement plan will be based on the analysis of the typology of the defects and

the weaknesses highlighted during the development and production phases..

Besides, AT will re-assess the suppliers ability to be compliant with the AT panel

criteria every 3 years at minimum according to the” Panel Entrance” “ rules.

Any deviations following these audits will be managed through the improvement plan.

However, in case of too high risks for deliveries highlighted during this assessment,

Supplier Quality Development representative can ask for a Red status

The improvement plan will be challenged by the Alstom Sourcing Quality

representatives and reviewed during the management reviews held on a regular basis

with the key suppliers.


SUPPLIER UPGRADE

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

GLOBAL PERFORMANCE

MGT & IMPROVEMENT

P 27

SUPPLIER UPGRADE

PURPOSE:

Alstom requests its Red supplier to develop a strong upgrade Quality plan to

recover yellow status and be maintained in the Alstom Panel.

CONTENT ( specific Red )

For the RED SUPPLIERSRED SUPPLIERS, AT will request a robust action plan, aiming to leave

this status within the 6 following months.

AT Sourcing and Supplier Quality Development representatives will be in

charge of monitoring this plan at supplier premises, and validating the

effectiveness of the corrective and preventive action plans..

AT Sourcing and Supplier Quality Development representatives could support

this plan through training and workshops if necessary in the supplier area.

Regular meetings are required at supplier and AT management level to

measure the improvement .

Note : A Quality wall is mandatory for the start of production of any product

manufactured at a red supplier.


SUPPLIER UPGRADE

SUSTAIN SUPPLIER

QCD PERFORMANCE

& CONTRACT

GLOBAL PERFORMANCE

MGT & IMPROVEMENT

P 28


APPENDIX 1

PREVENTION DURING

PRODUCT DEVELOPMENT (BEFORE FIRST DELIVERIES)

SPQD Plan For

Rolling Stock & Components

MANAGE SUPPLIER

INTEGRATION


FEED-BACK (colour status)

RETURN OF EXPERIENCE

SUB-SUPPLIERS

MANAGEMENT

PRODUCT RISK ANALYSIS

PROCESS RISK ANALYSIS

PRODUCT & PROCESS

CONTROL PLAN

FAI

P 29

MANAGE SUPPLIER

INTEGRATION

SPQD Plan For Rolling Stock & Components




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

SPQD PLAN

PURPOSE:

The SPQD plan (Supplier Product Quality Development plan) summarizes

Way of monitoring the supplier Quality activities during the development of a

new Product, in line with the project schedule

CONTENT:

At the early beginning of the project, the SPQD plan is defined and agreed by AT

Quality representative and the supplier.

SPQD plan detailed items are described on the following sheets.

As a first activity, SPQD Quality specification contractualizes the project Quality

targets and agreed Quality specific requirements.

S

P

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A

N

P 30


INPUT DELIVERABLES

Quality Specification sent to the Supplier (clause by clause)

Quality Specification agreed between AT & Supplier (clause by clause)

Supplier Quality Status analysis (Red/Yellow/Green in Development or

execution)

Request for concession if necessary

Criticality assessment for governance

Detailed SPQD plan build-up with the supplier (SPQD FU sheet)

List of the previous S1 & S2 failures and

related analysis.REX analysis

Drawings / Specifications

RAMS study

Product Risk analysis (D-FMEA or other)

¤ Checking of the right implementation of the risk analysis outputs

¤ List of Critical Product Characteristics identified

List of Critical Product Characteristics

Process flow & lay-out

Process Risk analysis (P-FMEA or other)

¤ Checking of the right implementation of the risk analysis outputs

¤ List of Critical Process Characteristics identified

Sub-Suppliers CPF list


Validation of the critical sub-suppliers bought-out parts on

Product/Process.


List of Critical Process Characteristics

P.FMEA

Product/Process Control Plan consistent with the Process risk analysis.

Product validation plan results

Check that the design conformity files are available and validated by

Engineering

Product conformity to requirements Validation

PRODUCT FAI STATUS (see FAI sheet)

Product/Process Control PlanProcess qualification through audit on Product specifics

PROCESS FAI STATUS (see FAI sheet)

FAI Status Request for concession if necessary toward the PrQM

Criticality assessment of the supplierReinforced Final Inspection or Quality Wall (for red suppliers) at supplier

premises

NCR dataChecking of the 3 first deliveries performance vs target.

8D management if any deviation

All documents related to the SPQD activity SPQD file to transfer ans handover to SQA

Key suppliers SPQD activities

Supplier color status and reasons why

Colour status

Project schedule

Quality Targets per commodity

Quality Targets per supplier (if any)S

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7

P 31

MANAGE SUPPLIER

INTEGRATION


FEED-BACK

PURPOSE:

The monitoring of the supplier Quality activities during the development of a new

product will be adapted to its current and past performance during the execution

phase.

CONTENT

According to the product & supplier criticality, 3 levels of monitoring are defined

(from 1 to 3). The frequency of the follow-up will be adapted accordingly and

integrated.in Product & Process Quality assurance plan.

NB: Suppliers with non fully qualified processes will be followed-up as the “RED”

criticality ranking.


G/Y Red Purple

Safety A & B Class 2 1 1

Non Safety A & B+ Class 2 1 1

B- class or Safety C Class 3 1 2

Supplier Status

Product

Risk

1




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 32

MANAGE SUPPLIER

INTEGRATIONRETURN OF EXPERIENCE

PURPOSE:

This is the first level of the risk analysis.

To guarantee the non reoccurrence of issues already happened in the past, the

supplier will perform an analysis of the Product & Process Design failures and

Check that the new Product concepts gets rid of the risks

CONTENT

The supplier will present a preliminary analysis based on the previous issues

on the same type of products.

Based on the root causes analysis, It will demonstrate that the previous deviations

have been taken into account and will not be carried out on the new development.

It will allow to define the Quality targets for the projects


2




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 33

MANAGE SUPPLIER

INTEGRATIONPRODUCT RISK ANALYSIS

PURPOSE:

All along the life-cycle, prevent the risks on the product due to the design.

Define the design validation activities.

Determine the Critical Product Characteristics.

CONTENT

The supplier will give the evidence of a Product risk analysis integration in the

Design activity. The supplier will be able to demonstrate its identification of the

critical Product characteristics.

The Product risk analysis can preferably be performed through a Design Failure

Modes and Effects Analysis (D-FMEA).

The activity will be performed by the supplier, and validated by AT Supplier Quality

function.


3




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 34

MANAGE SUPPLIER

INTEGRATIONPROCESS RISK ANALYSIS

PURPOSE:

All along the production, prevent the risks on the product due to the manufacturing

conditions..

Determine the Critical Process Characteristics.

CONTENT

The supplier will give the evidence of a Process risk analysis integration in the

Design activity. The supplier will be able to demonstrate its identification of the

critical Process characteristics.

The Process risk analysis can preferably be performed through a Process Failure

Modes and Effects Analysis (P-FMEA).

The activity will be performed by the supplier, and validated by AT Supplier Quality

function.


4




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 35

MANAGE SUPPLIER

INTEGRATION

SUB-SUPPLIERS

MANAGEMENT

PURPOSE:

Insure that the supplier

¤ transmits AT Product and Process requirements to its own suppliers

¤ manages its own critical products/suppliers though a Quality Plan in line with AT

expectations

CONTENT

Requirements of AT regarding the sub-supplier management are described on the

following sheet.


5




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 36

Sub-Suppliers (Tier 2) Management Requirements

As a key process in the achievement of the supplier Quality targets, a special focus will be done on the management

of the Tier 2 suppliers

The reference to assess this activity will be the following:

¤ The list of critical Products/Suppliers is identified

¤ These critical suppliers are qualified for their process scope (focus on special processes)?

¤ A FAI process has been implemented for these products

¤ A waiver process exists in case of sub-supplier NOGO FAI (including containement too secure the deliveries)

¤ A list of required documents for each delivery exists

¤ The critical product characteristics are identified for bought-out parts?

¤ The Tier 2 product/process control plan are available and validated?

¤ The Incoming Inspection Insrtuctions are defined and consistent with the critical characteristics?

¤ The measurement means are defined and adapted?

¤ The rules for segregation of the producs according to their Quality status are defined and applied?

¤ The rules for Non Conformity management are defined and applied


P 37

MANAGE SUPPLIER

INTEGRATION

PRODUCT & PROCESS

CONTROL PLAN

PURPOSE:

Describe the Product/Process control activities during the manufacturing of the

Product, and the reaction rules in case of drift.

CONTENT

The Product & Process control plan is built from the Incoming Inspection

to the Dispatch activities.

It will detail the Product & Process control operations, their frequency, their

responsible and the related registration documents.

The Work-instructions and Quality instructions will be aligned on the control

plan.

The Product & Process Control plan will be submitted by the supplier, and

validated by AT Supplier Quality function..


6




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 38

Control plan Requirements Requirements

The control plan is the backbone of the operational Quality implementation all along the process steps.

It must describe, from Incoming Inspection to Dispatching the prevention and detection activities, either on process

or on product.

The requested elements to be detailed are the following:

¤ Process Type or Operation Description

¤ Machine, device or tool

¤ Product and/or Process Characteristics to put under control

¤ Product and/or Processspecifications and tolerances

¤ Evaluation/Measurement technique

¤ Person in charge

¤ Sampling (size and frequency)

¤ Records

¤ Control Methods

¤ Reaction rules in case of N/C detection


P 39

Control plan requested to the supplier

Process

Number

Machine,

device, jig,

tools, asset #,

etc

Product Process Evaluation

Measurement

Technique.

(gage # if

applicable)

Control

Method

Reaction

Plan

Freq.

Supplier Name:

Date of last revisionControl Plan Number Control Plan Revision Level Supplier Key Contact/Phone Written by

Approval datePart Number Part Revision Level Part Name Approved by

Characteristics Methods

Process Name/

Operation Description

Class Product/Process

Specification/

Tolerance

Sample

Size


P 40

MANAGE SUPPLIER

INTEGRATIONFAI

PURPOSE:

Validate the First Article according to the product definition and requirements,and

validate its manufacturing process.

CONTENT

Based on a Product check-list, the Product FAI will allow to check the

compliance of the product to the technical & documentation requirements.FAI will

also be performed for carry-over parts for which the validation has been performed

more than 1 year ago.

The validation of the Process will be performed according to FAI Process

validation check-list.

The final statement of the activity will be based on the Product & Process

qualification level, following a X-Y-N code, where:

X

Y

N

Letter linked to the qualification level of the manufacturing process of the FAI part.

Letter linked to the qualification level of the product conception validation of the FAI part.

Number linked to the ownership of the corrective action plan to be deployed.


7




SUB-SUPPLIERS

MANAGEMENT



PRODUCT & PROCESS

CONTROL PLAN

FAI

P 41


Ranking of X can take 2 levels, given by the SPQD representative:

A

R

Ranking of Y can take 4 levels, given by the Engineering representative:

A

E

I

R

Ranking of N can take 3 levels, given by the SPQD representative:

0

1

2

Product/Process FAI accepted, no need for additional action plan.

Action plan needed, suppplier ownership.

Action plan needed, AT ownership.

"Rejected", Product conception do not guarantee the function & the compliance to specifications.

"Accepted", Manufacturing process of the FAI part is qualified.

"Rejected", Manufacturing process of the FAI part is not qualified.

"Accepted", Prodcut conception is able to guarantee specifications compliance

"External use possible", Product conception is not able to guarantee specifications compliance on minor deviations, not

jeopardizing Safety, Reliability, Fitting.Nevertheless, correction expected.

"Internal use only", Product conception is not able to guarantee specifications compliance on major deviations (out of

Safety) or conformity not fully demonstrated (long term test results missing). Product can be accepted under concession.

P 42


Process

Qualification

status

Product

Conception

validation

status

Responsab ility

A 0

1

2

1

2

I

Major non conformity, not jeorardizing Safety & Regulation

items or long term test results missing

Corrective action plan to be

supplied by the supplier.

Concession by the SPQD

mgr, Engineering & PrQM

needeed.

Major non conformity, not jeorardizing Safety & Regulation

items or long term test results missing


supplied by AT. Concession

by the SPQD mgr,

Engineering & PrQM

needeed.

CriteriaComments

Reaction rules

A

Product conforming to the definition and specifications,

complying with the usage conditions.

FAI valided, no need for

additional action plan.

E

Minor non conformities, not jeopardizing Safety, Relaibility

or Fitting, but correction requested as soon as possible.



Concession by the SPQD mgr

& Engineering needeed.

Minor non conformities, not jeopardizing Safety, Relaibility

or Fitting, but correction requested as soon as possible.


supplied by AT. Concession

by the SPQD mgr &

Engineering needeed.

P 43


A 1

1

2

1

2

1

2

Concession by SPQD mgr,

TSS & PrQM needed.

Produit/Process corrective

action plan to be supplied by

the supplier.

Major non-conformities but not jeodardizing safety or

regulation, or long term test results missing. The process is

not capable to guarantee the reproducibility of conforming

parts. No delivery without reinforced Quality checkings &

Quality Wall.


TSS & PrQM needed. Produit

corrective action plan to be

supplied by AT, Process



R

Product not conforming to the definition or the

specifications (safety/regulation), and/or not complying to

usage conditions.

No delivery allowed

Product not conforming to the definition or the

specifications (safety/regulation), and/or not complying to

usage conditions.

No delivery allowed

R

Product conception guarantees the compliance to the

specifications, but the process is not capable to guarantee

the reproducibility of conforming parts. No delivery without

reinforced Quality checkings & Quality Wall.

Process corrective action

plan to be supplied by the

supplier. Concession by the

SPQD mgr, TSS & PrQM

needeed.

E

Minor non-conformities not jeopardizing safety, nor

reliability nor fitting but corrections needed asap.. The

process is not capable to guarantee the reproducibility of

conforming parts. No delivery without reinforced Quality

checkings & Quality Wall.


TSS & PrQM needed.

Produit/Process corrective

action plan to be supplied by

the supplier.

Minor non-conformities not jeopardizing safety, nor

reliability nor fitting but corrections needed asap.. The

process is not capable to guarantee the reproducibility of

conforming parts. No delivery without reinforced Quality

checkings & Quality Wall.


TSS & PrQM needed. Produit


supplied by AT, Process



I

Major non-conformities but not jeodardizing safety or

regulation, or long term test results missing. The process is

not capable to guarantee the reproducibility of conforming

parts. No delivery without reinforced Quality checkings &

Quality Wall.

P 44

FAI Requirements

FAI is split in Product conformance on one side, and Process validation on the other side:

Product conformance status, given by AT engineering representative, includes:

¤ Technical drawings & specifications.

¤ Functional tests results

¤ Configuration management

¤ Visual inspection

¤ Fire and smoke

¤ Marking and identification

Process validation, given by AT Sourcing Quality representative, takes into account:

¤ Supplier documents and Implementation : Quality Control Plan, Working & Inspection instructions

¤ Dies, fixtures, jigs

¤ Special processes control in accordance with norma (including the operators training level)

¤ Packaging

The final status of the FAI, including both Product & Process conformance status is given by the Sourcing Quality representative

Only Product with accepted FAI can be delivered to AT. Otherwise, deviation request is needed to allow the delivery.


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