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Supplier Quality Assurance Process
Edition 2, April 2006
DaimlerChrysler
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
April 2006
EDITION 2
Confidential and Proprietary to DaimlerChrysler Corporation
Reproduction is not permitted
SQAP Version – Issued September 2004
SQAP Version - Issued July 2005
SQAP Edition 2 - Issued April 2006
Copyright @2004, @2005, @2006 by DaimlerChrysler
Endorsed by DaimlerChrysler Global Supplier Quality Council
James Gajda – DaimlerChrysler International Quality
Joseph Nguyen – DaimlerChrysler International, China Project
ⅰ
供应商质量保证程序
(SQAP)
2006年4月
第二版
版权归戴姆勒•克莱斯勒公司所有，侵权必究
未经允许，不得翻印
SQAP 版本 –2004年9月出版
SQAP 版本 - 2005年7月出版
SQAP 版本 2 - 2006年4月出版
版权 @2004, @ 2005, @2006 属于戴姆勒•克莱斯勒
戴姆勒•克莱斯勒全球供应商质量委员会认可
James Gajda –戴姆勒•克莱斯勒国际质量部
Joseph Nguyen –戴姆勒•克莱斯勒国际部 - 中国项目
ⅰ
FOREWORD
MISSION:
Implement Best in Class quality processes to ensure process performance improvements in the supply Base.
Our goal was to develop a comprehensive manual FAST, SIMPLE and LEAN to ensure world-class quality to “Be the Best in class by 2007”.
SCOPE:
This SQAP specifies the minimum suppliers’ activities to satisfy the Quality Assurance requirements of production parts for DaimlerChrysler.
OBJECTIVE & TARGET:
The objective of this SQAP (Supplier Quality Assurance Process) is to define the requirements of the Advanced Quality Planning.
By implementing this process, we and suppliers will strive for zero defects.
GUIDING PRINCIPLES:
Clearly define customer expectations.
Communicate clearly and consistently with our suppliers
Work with our suppliers as a one team
Pay attention to details
Concentrate on process
Reduce process variation
Focus on problem prevention
Be Proactive
Have flawless pilots and launches
PROCESS:
This SQAP consists of 20 key elements; this process is based on benchmark against the best practices in the industry. Some of the elements are divided in the SQAS (Supplier Quality Assurance Schedule) as “a” and “b” (Plan vs Implemented/Approved) – see page ＃5a and #5b
The SQAP timing is structured such that it begins after the supplier selection, however, elements of GPMA (Global Procurement Market Analysis), Source Evaluation and Quote Packages (RFQs) are integral to the quality planning processes at both DaimlerChrysler and the supply base. Purchase orders should be issued for SQAP to be initiated.
Source Evaluations are conducted to ensure that suppliers possess the necessary engineering, development, facility, manufacturing, quality and logistic capabilities to supply world class product to DaimlerChrysler. New buildings, building expansions and capital equipment that are specific to a new product shall be managed and monitored within the SQAP process with updates provided at DaimlerChrysler’s request.
[Reference element 12]
The Quote Process (RFQs) ensures that the best source is chosen with regards to the source evaluation criteria, unit pricing and the strategy for the particular product and commodity.
Potential volume and mix changes may affect tooling, production, capacity and logistics after the initial quote and business placement. The supplier shall manage the capacity/delivery risks and program requirements and alert DaimlerChrysler to any program timing risks these changes may affect. [Reference element 17]
ⅱ
前 言
使命:
通过运行同行最佳的质量过程来实现对供应基础过程绩效的改进。 我们希望借助于本手册，确保以“快速，简洁，精益”的方式 “于2007年实现同行最佳”的世界级质量。
范围:
本SQAP手册明确了供应商为满足戴姆勒•克莱斯勒对零部件生产的质量保证要求所需采取的最基本的行动。
目的和目标:
SQAP（供应商质量保证程序）的目的是确定先期质量策划的要求。
通过实施本程序，我们和供应商共同争取实现零缺陷。
指导方针:
明确顾客期望值
与供应商保持顺畅与和谐的沟通
与供应商同心协力
注重细节
以过程为核心
减少过程变差
重心放在问题的预防
具有前瞻性
试装和投产无缺陷
程序:
SQAP包含了20个关键要素，本程序的制订借鉴了行业标杆企业的最佳实践经验。SQAS（供应商质量保证 计划进度）中的某些要素被拆分为“a”和“b”（计划－已实施/已批准）－详见第 5a页和第5b页。
SQAP在供应商选定后开始启动，然而，全球采购市场分析GPMA 的要素包括货源评估（SE）及报价文件包（RFQs）也是戴姆勒•克莱斯勒和供应基础质量策划过程的组成部分。采购订单发出SQAP即同时启动。
开展货源评估以确保供应商具有必要的工程 、开发、 设备、生产、质量和物流能力从而为戴姆勒•克莱斯勒提供世界级的产品。如戴姆勒•克莱斯勒有要求，为新产品而投入的新厂房， 厂房扩充，资产设备也应被纳入SQAP过程进行监控，管理和更新。[参考要素#12]
报价过程（RFQs）确保以货源评估(SE)准则，单价及特殊产品商品的战略为依据从而选择最好的货源。
潜在的产量和混合变化可能影响初始报价和业务给予后的工装、生产、产能以及物流。供应商应管理产能/交付风险和项目要求并警示戴姆勒•克莱斯勒这些变化可能影响的项目进度风险。[ 参考要素#17]
ⅱ
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
April 2006
All customer reference manuals shall comply with:
AIAG manuals -MSA, FMEA, SPC and PPAP.
ORGANIZATION:
Authors: James Gajda and Joseph Nguyen Version , and Edition 2
The authors gratefully acknowledge the contributions of individuals for edition 2 from:
DaimlerChrysler GP&S
NEA (North East Asia Office), GP&S
BBDCA (Beijing Benz DaimlerChrysler Automotive)
FORMS, AND EXAMPLES FOR SOME OF THE SQAP ELEMENTS ARE INCLUDED ON THE CD,
ATTACHED TO THE LAST PAGE (COVER) OF THIS MANUAL.
SQAP edition 2 includes the following changes:
- Revised SQAP cover page
- Revised page 5a and page 5b to meet CDS ( Chrysler Development System ) Quality Gates timing
- Incorporated two new Quality Gates: “G2” and ”S2 start”
- Elements 8, 10, 11, 16 and 18 were split into "a" and "b" segments ( see page 5a and 5b) due to the CDS Gate timing changes.
- Modified page #33a
The attached CD for SQAP edition 2 includes the following changes:
- New Forms: SES (SQAP Executive Summary)
MSR (Meeting Structure Requirements)
Divided elements into folders
New Customer Specifics
PREPARED AND ISSUED BY:
James Gajda Joseph C. Nguyen
DaimlerChrysler International Quality DaimlerChrysler International
China Project
ⅲ
供应商质量保证程序
(SQAP)
2006年4月
所有顾客参考手册应符合:
AIAG手册-MSA, FMEA, SPC 和PPAP.
组织:
作者: James Gajda 及 Joseph Nguyen 第 , 版及第 二版
作者感谢以下团队为第二版所作出的贡献：
戴姆勒·克莱斯勒全球采购与供应（GP&S）
全球采购与供应 东北亚采购中心（GP&S NEA）
北京奔驰－戴姆勒·克莱斯勒汽车有限公司（BBDCA）
手册最后一页（封底）附带CD，含SQAP其中一些要素的表格和举例。
SQAP第二版中的修改之处有：
- 修改了SQAP 封面
- 修改了第5a页和第5b页, 使其符合CDS（克莱斯勒开发体系）质量门的时间节点
- 引入了两个新的质量门“G2”和“S2 开始”
- 由于CDS质量门时间节点变化，要素8, 10, 11, 16 和 18被拆分为"a" 和 "b" 两部分 ( 参见第5a页和第5b页)
- 修改了第33a页
SQAP第二版附带的CD有以下变更：
- 新增表格：SES (SQAP执行概要)
MSR (会议组织要求)
- 将要素按文件夹分类
- 新版的顾客特殊要求
筹备发行人:
James Gajda Joseph C. Nguyen
戴姆勒•克莱斯勒国际质量部 戴姆勒•克莱斯勒国际部 - 中国项目
iii
Table of Contents page #
MANAGEMENT:
ELEMENT “1”– DESIGNATE SUPPLIER REPRESENTATIVES AND QUALITY GATE PART RISK ASSESSMENT. …. …………………………………………………………………….…… 1
ELEMENT “2”– SUPPLIER QUALITY ASSURANCE SCHEDULE (SQAS) ………………………… … 3
ELEMENT “3”– QUALITY ASSURANCE FOR TIER II & III SUPPLIERS …………………………. …… 6
STANDARDS:
ELEMENT “4”– ENGINEERING STANDARDS ………………………………………………………. … 7
ELEMENT “5”– DFMEA ………………………………………………………………………………... …… 8
ELEMENT “6”– PARTS IDENTIFICATION, TRACEABILITY, PACKAGING & SHIPPING
SPECIFICATIONS …………………………………………………………………….. … 9
ELEMENT “7”– KEY PROCESS & PRODUCT CHARACTERISTICS …………………………………… 11
ELEMENT “8”– PARTS INSPECTION STANDARD …………………………………………………. …… 12
ELEMENT “9”– BOUNDARY SAMPLES AND APPEARANCE APPROVAL …………………………… 13
PROCESS QUALITY ASSURANCE:
ELEMENT “10”– PROCESS FLOW & PFMEA; OPERATOR WORK INSTRUCTIONS AND
OPERATOR TRAINING ……………………………………………………………. …… 14
ELEMENT “11”– ERROR MISTAKE PROOFING ………………………………………………………… 18
ELEMENT “12”– TOOLING, EQUIPMENT AND GAGES; PREVENTIVE MAINTENANCE ……. …… 20
ELEMENT “13”– PROCESS CAPABILITY STUDY …………………………………………………. …… 22
ELEMENT “14”– CONTROL PLAN: INCOMING AND OUTGOING MATERIAL PLAN;
SAMPLES SIZES AND TEST FREQUENCIES ……………………………………. 24
ELEMENT “15”– CORRECTIVE ACTION PROCESS ………………………………………………... …… 28
ELEMENT “16”– PROCESS MONITORING AND LAYERED PROCESS AUDIT (LPA) ………….. …… 29
ELEMENT “17”– PROCESS CHANGE REQUEST APPROVAL …………………………………….. …… 31
PRODUCT QUALITY ASSURANCE:
ELEMENT “18”– LINE SPEED DEMONSTRATION, PRODUCT VALIDATION (PV) TESTING AND
PART SUBMISSION WARRANT (PSW) …………………………………………. …… 33
ELEMENT “19”– FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC) …………………... …… 37
FIELD:
ELEMENT “20”– SUPPLIER WARRANTY PARTS ………………………………………………….. …… 38
Index ………………………………………………………………………………………………………. …… 39
Attached CD
FORMS
EXAMPLES
ⅳ
目录 页码
管理:
要素 “1”– 供应商代表指派及质量门零件风险评估…………………………………………………… 1
要素 “2”– 供应商质量保证进度计划 (SQAS) ……………………………………..…………………… 3
要素 “3”– 二三级供应商的质量保证 …………………………………………………………………….. 6
标准
要素 “4”– 工程标准………………………… .……………………………………………………………. 7
要素 “5”– 设计失效模式及后果分析DFMEA ……………………………………………………….. 8
要素 “6”– 零件标识、可追溯性和包装及发运规范…………………………………………………. … 9
要素 “7”– 关键过程与产品特性………………………………………… ………………………………. 11
要素 “8”– 零件检验标准………………………………. …………………………………………………. 12
要素 “9”– 边界样品和外观批准…………………………………………………. ……………………… 13
过程质量保证:
要素 “10”–过程流程和过程失效模式及后果分析PFMEA; 操作者作业指导书和操作者培训…..… 14
要素 “11”– 防误防错………………………………… …………………………………………………… 18
要素 “12”– 工装、设备与量检具；预防性维护保养……………………………………………………. 20
要素 “13”– 过程能力研究……………………………..…………………………………………………. 22
要素 “14”– 控制计划：进出料计划；样本大小和试验频次……...……………………………………. 24
要素 “15”– 纠正措施程序…………………………………… ………………………………………… 28
要素 “16”– 过程监控和逐层过程审核 (LPA) ………………………………………………….........… 29
要素 “17”– 过程更改申请……………………………………. …………………………………….. ….. 31
产品质量保证:
要素 “18”– 生产线节拍演示、产品验证试验 (PV) 和零件提交保证 (PSW) ………………………… 33
要素 “19”– 首次生产发运鉴定 (FPSC) ……………………………………………...………………... 37
售后服务:
要素 “20”– 供应商保修件…………………………. ………………………………………………...….. 38
索引 ……………………………………………………………...………………………………………… 39
附带CD
表格
举例
ⅳ
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “1”– DESIGNATE SUPPLIER REPRESENTATIVES AND QUALITY GATE
PART RISK ASSESSMENT
PURPOSE: To define the roles and responsibilities of the Supplier Representative and other personnel
and to explain the procedure for notifying the customer operation of the individuals names/
titles/phone #, and e-mails addresses.
SCOPE: Applies to all suppliers.
A. DESIGNATE SUPPLIER REPRESENTATIVES
SUPPLIER RESPONSIBILITIES:
The supplier shall provide the following information (names, titles, mailing address, telephone #, fax# and e-mail), to the Customer Supplier Quality and to Quality organization.
NOTE: Customer’s Supplier Quality Engineer is the primary contacts for quality issues.
A1. Supplier Representative:
This person is the primary contacted for all quality matters. It is Quality Engineer or/and Quality Manager. Responsibilities include:
Maintaining operating system
Reporting and providing Problem Resolution
Coordinating of containment
Representing the supplier during meetings/pilots/launch with the customer personnel
A2. Supplier Quality Manager or equivalent
A3. First, Second and Third shift contact:
The production quality control staff personnel that can be contact directly by the customer. They are responsible for preventing the non-conformances and to provide corrective action to the customer within a few hours.
A4. Non-conformances contact:
This individual is the primary contact point for returning non-conforming product.
A5. New Project Quality contact:
This person is responsible for coordinating new projects for pilot and Launch.
A6. Warranty contact:
This individual is responsible for receiving, investigating and providing reports for Warranty
return parts sent from the customer.
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供应商质量保证程序
(SQAP)
要素 “1”– 供应商代表指派及质量门零件风险评估
目的: 规定供应商代表和其他人员的角色和职责，解释如何通知顾客每个人的姓名/职务/电话号码和邮箱地址
的程序。
范围: 适用于所有供应商。
A.供应商代表指派
供应商职责:
供应商应给顾客供应商质量和质量部提供以下信息(姓名、职务、通信地址、电话号码、传真号码和邮箱地址)。
注: 顾客的供应商质量工程师是质量问题的第一联系人。
A1.供应商代表：
此人是质量工程师或/和质量部经理，他是所有质量问题的第一联系人。
职责包括:
保持运行系统
报告并提出解决方案
协调遏制问题
在与顾客进行的会议/试装/投产过程中代表供应商
A2. 供应商质量经理或同等职务人员
A3. 一班，二班，和三班的联系人:
顾客可直接联系生产质量控制人员。他们负责防止不合格产品并在几个小时内向顾客提交纠正措施。
A4. 不合格产品联系人:
此人为不合格产品退货的第一联系人。
A5. 新项目质量联系人:
此人负责协调新项目的试装和投产。
A6. 保修联系人:
此人负责接收、调查顾客退还的保修零部件，并作出报告。
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It is acceptable for the same contact name to appear more than once but there shall be at least two contacts.
The supplier shall provide quality contact information to the customer with names, titles, office phone numbers, pager numbers, home phones numbers and e-mail addresses. The contact list shall be provided to the customer within one week of being informed that have been selected to provide the parts/components.
The supplier shall create and maintain an organization chart and provide copy to the customer.
The supplier shall notify the customer within three working days of any changes to contact information.
B. QUALITY GATE PART RISK ASSESSMENT
B1. At each Quality Gate and as requested, Supplier Representative will submit a Status Summary of the required SQAP elements for each part or family of parts. At a minimum the supplier shall complete the elements listed for each quality gate, to support the vehicle program schedule.
PART Green, YELLOW and Red Risk Assessment
“G” - Green – Pass: Complete fulfillment of all deliverables. Continue to next gate as planned
“Y” – Yellow – All requirements/objectives not met and issues exist. A corrective action plan is
secured and have confidence toward a successful outcome.
X “R” - Red – Does not pass: The current status of the Deliverable does not fulfill the target
Need a detail Action Plan for each ‘Red” deliverable.
For “Does not Pass”, identify root cause of process failures, identify systemic process issues, and review with the Customer the action plan.
REPORTS:
Supplier shall develop status reports listing each of the elements for the regular team and management assessment meetings.
Some of the report assessment questions are listed in the key elements that includes (Part Inspection Standard, PFMEA, Error Mistake Proofing, Control Plan, Layered Process Audit, Line Speed Demonstration and Part Submission Warrant.
At the minimum, there shall be a Management Status Review at each of the Quality Gates.
In addition, the Customer will prepare reports for the Quality Gates Review using the appropriate TIP LEVELS applied to the CDS Quality Gate Criteria.
FORMS:
Supplier Contact form is included in the attached CD
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同一个联系人可以出现一次以上，但应至少指派两个联系人。
供应商应为顾客提供质量联系人的各种信息，包括姓名、职务、办公室电话、呼机号码、家庭电话和邮箱地址。供应商在被选中后一周内应向顾客提供联系人信息。
供应商应制作并保存组织机构图，并提供复印件给顾客。
若联系人信息有任何变动，供应商应在三个工作日内通知顾客。
B. 质量门零件风险评估
B1. 当位于每个质量门上，供应商代表将按照要求提交每个零件或每套零件的SQAP要素状态概要。供应商应至少完成每一质量门包含的要素以支持整车项目进度。
零件 绿色、黄色和红色风险评估
“G” – 绿色 –通过：完全实现所有输出要求，按计划向下一个质量门推进。
“Y” – 黄色 –所有要求/目标未满足且存在问题。 纠正行动计划被引入并有信心产生成功的输出。
X “R” – 红色 – 未通过：目前输出未达到既定要求，需要为每个“红色”输出制定详细的措施计划。
对于“未通过”项，将识别过程失效的根本原因，识别系统性的过程问题并与顾客一起评审措施计划。
报告:
供应商应向定期举行的小组及管理评估会议提交各要素进展状态报告。
报告中所应评估的某些问题已在一些关键要素中列出，这些要素包括零件检验标准、PFMEA、防误防错、控制计划、逐层过程审核、生产线节拍演示和零件提交保证。
至少，在每个质量门应进行管理状况评审。
此外，顾客将用CDS 版质量门标准所应用的适当可接受水平为质量门评审准备报告。
表格:
供应商联络清单在附带CD中
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SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “2”– SUPPLIER QUALITY ASSURANCE SCHEDULE (SQAS)
PURPOSE: The purpose of the (SQAS) is to provide a schedule of the manufacturing and quality control
activities necessary to assure the quality of parts for Volume Production. This schedule shall show the relationship of the supplier production preparation activities to the customer’s master schedule.
This schedule should be prepared by a cross-functional team that includes at minimum Supplier, Supplier Quality and Engineering organizations.
SCOPE: Applies to all suppliers.
The schedule should span the time between the issuance of the production drawing to three months after the start of volume production or Part Approval, whichever occurs later.
For parts manufactured for export from China the time schedule may be different
SUPPLIER RESPONSIBILITIES:
Suppliers are required to prepare a Supplier Quality Assurance Schedule (SQAS) for each Tier I, as well as
direct supply sub-components.
The SQAS shall include the following:
Header: Includes:
Supplier Information (Supplier name, Supplier Code, Part Number, Contact name, Model Code and Revision Record). This information except Revision record will be provided by the Customer.
Build Phase and MRD (Material Required Date) dates and includes the following:
Name of build (S-0, S-1, S-2, and V1), Build Dates, MRD (Material Required Date), # of vehicles that will be built during the build phase, and # of days of the build. This information will be provided by the Customer.
Customer Master Schedule:
Build Phases and the Quality Gates and includes the following:
Timing for S0, S1, S2, V1 and the Quality Gates. This information will be provided by the Customer.
SQAP Divisions:
The divisions are: Management, Standards, Process Quality Assurance, Product Quality Assurance and Field.
Legend: Includes Customer Lead and Customer phase.
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供应商质量保证程序
(SQAP)
要素 “2”– 供应商质量保证进度计划(SQAS)
目的: SQAS即为供应商制定的必要的生产及质量控制活动的进度计划，以此来确保批量生产中的零件质量。此进度计划应体现供应商生产准备活动与顾客总计划的相互关系。
它由横向跨部门职能小组制定，该小组至少由供应商、供应商质量管理部门和产品工程部门组成。
范围: 适用于所有供应商。
此进度计划应包括自生产图纸发放到批量生产或零件批准后三个月，以两者中的较迟者为准。对中国生产的出口零件， 时间进度可能不同。
供应商职责:
要求一级供应商和向其直接供货的分供应商制订供应商质量保证进度计划（SQAS）。
SQAS应包括以下内容:
标题： 包括：
供应商信息（包括供应商名称、供应商代码、零件号、联系人姓名、车型代码和更改记录）。除了更改纪录外，其他信息均由顾客提供。
生产阶段和物料需求日期（ MRD）：包括以下内容：
试装阶段的名称 (S-0, S-1, S-2 和V1)、 试装日期、 MRD (物料需求日期)、试装生产期内即将生产的车辆数和试装天数。这些信息由顾客提供。
顾客主要进度计划：
试装阶段和质量门，包括以下内容：
S0、S1、S2、V1时间安排和质量门。 这些信息由顾客提供。
SQAP 划分：
分为：管理、标准、过程质量保证、产品质量保证和售后服务。
图例：包括顾客交付日期和顾客阶段。
- 3 -
Approval Signature Block:
Supplier Quality field that has to be approved by the Supplier Management.
Supplier’s Master Schedule
Timing for each of the elements. Black lines indicate required element timing and green – dotted line indicates actual progress.
Supplier Department/Person Responsible & Dates:
To be used by the Supplier, that indicated the following:
Supplier responsible department/person (could have different names and departments, that depend on the individual element), Build Dates, MRD (Material Required Dates- this will be provided by the Customer), Begin (plan/actual) and End (plan/actual) dated for each element.
Progress Indicator: Red line indicates current date.
Remarks/Assessment:
This column is to be completed by the Supplier.
Supplier will provide comments if necessary and shall provide the Assessment for each of the element (green or red). See element # 1 for Assessment guidelines.
Comments:
This column can be completed by the supplier or by the customer.
A. Management Status Reviews
Shall be conducted to encompass each of the master schedules (customer & supplier). These should show on the SQAS as periodic milestones which allow for adequate “target vs. actual” reviews of process, tooling,
countermeasure activities, etc.
At the minimum, there shall be a Management Status Review at each of the Quality Gates.
B. Quality Gates- Definitions
Quality Gates are control points process to ensure that all exit criteria have been met, and that product and process have achieved the appropriate levels of maturity at each stage. The SQAP schedule shows elements that shall be completed prior to each gate.
In our SQAP schedule we indicated the following gates:
Final Program Specifications (Lastenheft) – All program objectives and specifications completed. Comprehensively feasible product and process defined. All verification, validation and production plans defined.
SHAPE \* MERGEFORMAT
Product & Process Design Complete (PPDC) –100% production feasible product & process design is complete. All verification, validation and production plans confirmed.
SHAPE \* MERGEFORMAT
S0 Start Readiness – First pilot build program based on product components and systems that meet design specification produced off tools and equipment allowing build to production process intent. Vehicles are properly built that verify product and process design, and train key plant personal.
SHAPE \* MERGEFORMAT
S0 Confirm – Ride & Drive – Ride and Drive evaluation of S0 vehicles.
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批准签字处：
供应商管理层应在供应商质量的位置签字批准。
供应商总进度计划：
每个要素的时间计划。黑线表示要素所要求的时间计划，绿色虚线表示实际进度。
供应商负责部门/负责人和日期：
供应商使用，含以下内容：
供应商负责部门/负责人（视不同要素，可以为不同的部门或人）、试装日期、MRD(物料需求日期，由顾客提供)、各要素的开始（计划/实际）和结束（计划/实际）日期。
进展指示：
红线表示当前日期。
备注/评估：
该栏由供应商填写。
必要时，供应商应标明备注，且应对每个要素做出评估（绿色或红色）。 见要素1，评估指南。
备注：
此栏可由供应商或顾客完成。
A. 管理状况评审
该评审应围绕总进度（顾客的和供应商的），并应作为阶段性里程碑体现在SQAS上，它们涉及到对过程、工装、解决措施等的“目标与实际”的情况作出充分的评审。
至少，每个质量门应有管理状况评审。
质量门—定义
质量门是一些过程控制点，该控制点确保产品及过程达到各阶段所期望的成熟度并满足所有的通行(EXIT)原则。 在SQAP进度计划上体现了在各质量门通行前应完成的要素活动。
在 SQAP进度计划中，我们指出了以下质量门：
.
最终项目标准 – 所有项目目标和标准完成。可行性的产品和过程定义完成。所有验证、确认和生产计划定义完成。
SHAPE \* MERGEFORMAT
产品和过程设计完成(PPDC) – 具备100%生产可行性的产品和过程设计完成。确定所有验证、确认和生产计划。
SHAPE \* MERGEFORMAT
S0开始准备 – 首批试装是基于满足设计规范要求的产品零部件和系统，它们是使用可以用于批量生产的工装和设备生产出来的。实施整车组装以验证产品和过程设计并培训关键的工厂员工。
S0 确认– 驾乘 – S0 车辆的驾乘评估。 - 4 -
SHAPE \* MERGEFORMAT
S1 Start Readiness – Home plant build to validate tooling, equipment and verify facilities. Build vehicles for certification test plan.
S2 Start Readiness – Home plant facility validation. Build of saleable vehicles for fast feedback and rental fleet feedback programs, and dealers.
S2 Confirm– Ride & Drive – Ride and drive evaluation of S2 vehicles.
V1 – Plant Review – Initiate production ramp-up of units for direct sale to the dealer network.
Post V1 Lessons Learned – Identify, share and apply lessons learned.
- 5 -
S1 开始准备：在整车厂生产线进行整车试装用于验证批量工装、设备和设施。组装用于认证试验计划的车辆。
S2 开始准备－主机厂生产设备验证。组装可售车辆，租售给有合作关系的汽车租赁公司及分销商以获得该批车辆质量的快速反馈。
S2 确认－驾乘－S2 车辆的驾乘评估。
V1－工厂审核－启动进入分销网络的可直接销售车辆的生产爬坡。
V1之后 经验总结－识别、分享和应用所总结的经验。
- 5 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “3”– QUALITY ASSURANCE FOR TIER II, AND III SUPPLIERS
PURPOSE: To define the minimum Quality system requirements of tier II and below.
SCOPE: Applies to Tier I suppliers.
SUPPLIER RESPONSIBILITIES:
Tier I suppliers are responsible for the tier II and below. This shall include the following:
A1. The tier I supplier shall have a system in place to evaluate and select tier II and below.
A2. The Tier I supplier shall establish objective means of evaluating their suppliers performance.
A3. The tier I supplier shall maintain a record of acceptable tier II suppliers based on objective
measures. This record shall be available for the customer.
A4. The tier I supplier shall develop quality requirements with the tier II to support the customer
requirements.
A5. Tier I suppliers shall involve tier II and below suppliers in planning, problem solving and communication.
A6. Tier I shall explain the “Forever Requirements” to all tier II and below suppliers and maintain records demonstrating compliance.
A7. Tier I suppliers on request from the customer will provide evidence of quality audits and AQP
(Advanced Quality Planning) plans from tier II suppliers including:
Copies of tier II supplier PSW’s (Part Submission Warrant)
Copies of tier II supplier ISO certifications (ISO 9001-2000 and/or TS).
NOTE 1: Tier II shall be third party registered to ISO 9001-2000 by an accredited third-party
certification body.
A8. In order for tier I supplier to change or add a tier II or below, they shall obtain written approval
from the customer at least 3 months prior to the sub-supplier change. SEE “Forever
Requirements”, in the element # 17 “Process Change Request”.
A9. Tier II supplier initiated changes shall be formally communicated to the customer at least
three months prior to the change. SEE “Forever Requirements”.
NOTE 2: A diagram or indented list of the "supply chain" which reflects the Supplier/Sub-supplier
hierarchy under the "Extended Enterprise(" is required. The list shall identify down to the
Production material level (or in some cases raw material level) each Sub-supplier by
name, part or material produced, manufacturing plant location, and PPAP status of the parts supplied.
- 6 -
供应商质量保证程序
(SQAP)
要素 “3”– 二三级供应商的质量保证
目的: 规定二级及以下供应商的最低质量体系要求。
范围: 适用于一级供应商。
供应商职责:
一级供应商负责二级及以下供应商，包括以下职责:
A1. 一级供应商应形成一套评估和选择二级及以下供应商的体系。
A2. 一级供应商应建立评估供应商业绩的客观方法。
A3. 一级供应商应保留有关的二级供应商的相关记录，且对供应商的认可是基于客观的测评结果。
记录向顾客公开。
A4.一级供应商应和二级供应商共同制定质量要求，来保证达到顾客要求。
A5. 一级供应商应参与二级及以下供应商的策划、问题解决活动并与之保持沟通。
A6. 一级供应商应对所有二级及以下供应商解释“永久性要求”，保存证明其符合性的记录。
A7. 如顾客要求，一级供应商应提供质量审核证明和二级供应商的AQP计划(先期质量策划)，包括:
二级供应商PSW (零件提交保证)复印件
二级供应商ISO认证证书的 (ISO 9001-2000和/或 TS)复印件
注 1: 二级供应商应通过有资质的第三方认证机构的ISO9001-2000认证。
A8. 一级供应商若要更换或增加一个二级及以下供应商，变更前至少三个月应获得顾客的书面批准。参见要素#17“过程更改申请”的“永久性要求”。
A9. 二级供应商提出更改，更改前至少三个月应与顾客进行正式沟通。参见“永久性要求”。
注 2: 需要通过图表或用缩进方式表示的清单来说明“供应链”中供应商/分供商的隶属关系。该清单应追溯到提供生产材料(在一些情况下具体到原材料）的供应商，应标明各分供商的名称、生产的零件或材料、制造厂所在地以及所供零件的PPAP状态。
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SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “4” – ENGINEERING STANDARDS
PURPOSE: All applicable engineering standards with the latest change level shall be identified, listed
and available.
SCOPE: Applies to all parts.
SUPPLIER RESPONSIBILITIES:
NOTE1:
Supplier shall review the DVP&R with Customer Engineering
NOTE 2:
See Element "18" for additional DVP&R requirements (page 34-35)
A1. A system shall be in place to obtain revisions to the standards and to notify all applicable departments of
specification changes as they occur (see TS16949, section Engineering Specifications).
A2. The Supplier shall have a procedure for monitoring the customer applicable standards for revision level
changes.
This procedure shall include the frequency and responsibility for review of standards.
A3. Review CATIA comments page or drawing and notify the customer if all standards included in the Source
Package have not been included.
A4. For appearance standards suppliers need to refer to Limit samples (Design Boundary Samples), .,
grain, color, gloss, etc.
NOTE 3: Mercedes Car Group Specific Requirement
A5. Series/Volume releases related to Quality Gates (see SQAS):
Tooling Kick off from DCX – mid (6-11 months) and long lead tooling (>11 months).
Final release of Series/Volume level (short, mid and long lead tooling) is on schedule, with documentation provided.
FORMS:
Included in the ATTACHED CD
- 7 -
供应商质量保证程序
(SQAP)
要素 “4” – 工程标准
目的: 最新更该级别的所有工程标准应加以标识，形成清单并可供使用。
范围: 适用于所有零件。
供应商职责:
注1:
供应商应与顾客产品工程师一起评审DVP&R
注2:
附加的DVP&R要求参见要素 #18 (第 34-35页)
A1. 应具备一系统，当发生工程更改时，该系统确保获得该工程更改并将该更改通知到所有相关部门
(参见 TS16949, 工程规范 )。
A2. 供应商应有一套程序来监控顾客标准的更改级别。
此程序应规定评审标准的频次和职责。
A3. 查看 CATIA 说明页或图纸，如发现货源包中未包括所有相关的标准时，请通知顾客。
A4. 关于外观标准，供应商需参考限度样品（设计边界样品），如纹理、颜色、光泽等。
注3：梅塞德斯轿车特殊要求
A5. 批量/量产与质量门相关（见 SQAS）
戴姆勒•克莱斯勒 工装启动—中期（6~11个月）以及长期工装（>11月)。
最终批量放行/量产水平依据所提供的文件要求的时间表进行（短期，中期和长期工装）。
表格:
在附带CD中
- 7 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “5”– DFMEA
PURPOSE: The purpose of a Design Failure Mode Effects Analysis (DFMEA) is to define the risk
associated with potential process failures and to propose corrective action before these failures can occur.
SCOPE: Applies to all new or modified parts.
NOTES:
- DFMEA discipline requires a design FMEA for all new parts changed parts, and carryover
parts in new applications or environment.
- It is initiated by an engineer from the responsible design activity, which for a proprietary design may be the supplier.
- The responsible engineer is expected to directly and actively involve representatives from
all affected areas.
SUPPLIER RESPONSIBILITIES:
A1. DFMEA shall be created using the latest edition of AIAG guidelines and criteria.
A2. There shall exist an internal process, including documentation and data, which explains how the DFMEA was developed. The process shall include risking the design features or characteristics that risk medium and high to the DFMEA form.
This process shall be reviewed periodically for effectiveness.
This process shall include consideration of lessons learned.
A3. A recommended action is required for the highest RPNs regardless of value.
A4. Buzz-Squeak-Rattle (BSR) and Noise-Vibration-Harshness (NVH) issues should be addressed in the
DFMEA, if applicable.
A5. The DFMEA is a living document and shall be traceable to the engineering change level. This document should contain the special characteristics agreed to by the Customer.
A6. A DFMEA shall be created for the purchased parts (assembly, systems, etc) as well as for all sub-components.
A7. Obtain approval by customer for supplier initiated DFMEA’s.
FORMS:
AIAG forms
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供应商质量保证程序
(SQAP)
要素 “5”– 设计失效模式及后果分析DFMEA
目的: - 设计失效模式及后果分析(DFMEA)目的在于识别与潜在的过程失效相关的风险并在失效发生前提出纠正措施。
范围: 适用于所有新的或更改的零件。
说明:
- 对于所有的新零件, 更改的零件, 用途改变的延用件DFMEA小组需要进行DFMEA。
- DFMEA由设计工程师起草，供应商负责起草供应商拥有的设计。
- 要求负责的工程师直接和积极地参与与此相关的各项工作。
供应商职责:
A1. DFMEA应使用最新版本的 AIAG指导方针和标准来制定。
A2. 应具备解释DFMEA是如何制定的内部流程，包括文件和数据。此流程应当包括将DFMEA表格中的中高风险的设计属性和特性进行风险排序的步骤。
应定期评审流程的有效性。
流程应考虑以前的经验教训。
A3. 无论数值大小，对于那些最高的RPN值，要求有建议措施。
A4. 如适用，各种异响 (BSR) 和 噪音- 振动- 行驶不平顺 (NVH)的问题应在DFMEA中体现。
A5. DFMEA是一个动态的文件，应可以追溯到产品的工程更改级别。此文件应包括顾客认可的特殊特性。
A6. 应对所有采购的零件 (总成，系统等)，以及所有的分部件制定DFMEA。
A7. 供应商负责起草的DFMEA应获得顾客批准。
表格:
AIAG 的表格
- 8 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “6” – PARTS IDENTIFICATION, TRACEABILITY, PACKAGING &
SHIPPING SPECIFICATIONS
PURPOSE: Verify that the documents listed have the correct part number, description and change level
entered or cross-referenced (reference TS-16949 section Control of Documents).
To explain parts packaging and shipping plan.
SCOPE: Applies to all parts.
SUPPLIER RESPONSIBILITIES:
A. PARTS IDENTIFICATION, TRACEABILITY
A1. A procedure shall be in place to assure correct part number and revision level as changes occur.
An internal system of communication/notification for changes shall exist between the Supplier and all Sub-Suppliers. The Tier I is ultimately responsible to ensure product shipped to Customer is the latest revision level. (See Customer Forever Requirements in element # 17 “Process Change Request”.)
This system shall include the receipt of an approved DaimlerChrysler change authorization notification (. ODDBox or CN).
NOTE: Voicemail, email, or verbal authorizations are unacceptable forms of communication.
The Supplier shall make no changes without formal approval from the customer.
A2. When the Supplier uses their own part numbers, the Supplier and Sub-Suppliers shall provide a cross
reference which enables users to identify the customer part number and revision which corresponds to
the Supplier’s numbering and revision system.
A3. For each product/process changes the Supplier shall:
Identify which documents require updating, who is responsible for updating them and when the actual updates occurred.
Identify records when any required testing is performed.
Record the date and lot number of the 1st production shipment of parts with the change.
The Supplier shall not PPAP until all affected documents are updated.
NOTE: For additional part identification and traceability requirements, see element # 14.
FORMS:
Documents required:
Engineering standards
CATIA files, drawings and comment page(s)
Software level
Part number cross reference sheet (if applicable)
- 9 -
供应商质量保证程序
(SQAP)
要素 “6” – 零件标识, 可追溯性， 包装及发运规范
目的: 确认列出的文件有正确的零件号,描述和更改级别或对应的参考 (参考TS-16949 文件控
制)。说明零件包装和发运方案。
范围: 适用于所有的零件。
供应商职责:
A. 零件标识、可追溯性
A1. 应具备一程序来确保当发生更改时，可获得正确的零件号和更改级别。
在供应商和分供商之间应有内部沟通/通知更改的系统。一级供应商负责确保发运到顾客的产品为最新的更改级别。(参见要素 # 17 “过程更改申请”中的顾客“永久性要求”)。
此系统应包括经戴姆勒•克莱斯勒批准的更改授权通知函(例如 ODDBox或CN)。
注: 留言,电子邮件或口头批准为不可接受的沟通方式。
供应商在没有获得正式顾客批准前，不能进行任何更改。
A2. 如使用自己的零件号, 供应商和分供商应提供与顾客零件号的对照表，使用者借此来明辨顾客的零件号和更改级别与供应商的零件号和更改级别的对应关系。
A3. 对于产品/过程更改，供应商应:
确定哪些文件需要更新，谁负责更新，以及更改日期。
确定所需的试验记录。
记录更改实施后首次发运的生产零件的日期和批号。
供应商应在更新所有相关文件后提交PPAP。
注: 对于零件可追溯性和标识的附加要求，见要素 # 14。
表格:
文件要求:
工程标准
CATIA文件, 图纸和注释页
软件版本
零件号对照表(如果适用)
- 9 -
B. PACKAGING AND SHIPPING SPECIFICATIONS
NOTE 1: Applies to both types of containers: expendable and returnable that will be used to ship
product to the customer plants.
SUPPLIER RESPONSIBILITIES:
NOTE 2:
All test shipments and test methods shall assess the protection of the product from normal transportation damage and adverse environmental factors.
B1. The parts packaging and shipping plan shall include:
a)The types of containers (expendable or returnable) and their specifications including dimensions,
tare weight, type of material if applicable, etc.
b) Specifications on how the parts are packaged including part orientation, pack size, dunnage use,
total weight, etc.
c) Labeling instructions.
d) Shipping instructions.
e) Backup expendable packaging plan.
B2. All suppliers using expendable packaging as their primary packaging OR for returnable backup are
responsible for designing, manufacturing, and testing their packaging. Some suppliers may be
responsible for designing their own returnable packaging and part orientation.
B3. All packaging (including backup) shall either pass a laboratory shaker
test or actual test shipment with documented results. Suppliers designing their own packaging, as
noted previously, are responsible for the completion and documentation of the test. In order to ensure
these tests are completed prior to pilot build.
B4. If returnable containers are to be used, a Returnable Container Management plan shall be developed
which includes: Container Inventory Control.
B5. Container Maintenance
Need written documentation of the internal packaging maintenance plan.
B6. Backup Packaging
Expendable backup plan shall cover a shortage of returnables.
Several of the key requirements include: It shall be available at all times, in the event of a
shortage. Backup packaging shall maintain the same footprint (dimensions) as the returnable
container and where possible, hold the same number of pieces in the same orientation.
NOTE 3: Deviation from these requirements requires concurrence from customer Corporate Material
Handling Engineering.
B7. Packaging Labeling Requirements:
All shipments made to a customer facility shall have a shipping label that conforms to customer
standards both in format and placement.
DOCUMENTATION REQUIRED:
- Container inventory control process
- Maintenance and cleaning procedures
- Backup expendable plan
- 10 -
B.包装和发运规范
注1: 适用于两种容器: 把产品运输到顾客工厂的一次性的和可以循环使用的容器。
供应商职责:
注2:
应对所有接受发运测试的货物装运试验和及其测试方法进行评估，以确定在正常和恶劣运输条件下，包装对产
品的保护。
B1. 零件包装和发运计划应包括：
a)容器类型 (一次性或循环型) 及其技术规格，包括尺寸、毛重，如果需要，列出材料类型等。
b) 零件包装规范，包括 零件装箱方向、打包尺寸、托盘的使用、总重量等 。
c) 标签说明。
d) 发运说明。
e) 一次性包装备用计划。
B2. 将一次性包装作为主要包装或备用方案的供应商，负责该包装的设计、制造和测试。 某些供应商也可自行设计可循环使用的包装和零件装箱方式。
B3. 所有包装 (包括备用)应通过实验室振动测试或实际装运测试，并形成记录。如前所述，设计自己包装的
供应商将负责其包装的测试并形成记录，同时务必确保测试在试装之前完成。
B4. 如果使用循环容器, 应制定循环容器管理计划，包括容器库存控制。
B5. 容器维护保养
应有书面的内部包装维护保养计划。
B6. 备用包装
一次性包装备份计划应考虑到可回收包装的短缺 。
几个关键的要求包括：短缺时它应随时备用，如可能备用包装应与循环式容器占地面积 (尺寸)相同，且放置零件的数量和方向相同。
注 3： 如与上述要求有出入，则应征得顾客物料搬运工程部门的同意。
B7.包装标签要求：
所有发运给顾客的产品应有发运标签，标签的格式和位置按顾客标准执行。
文件要求:
- 容器库存控制程序
- 预防性维护保养和清洁程序
-一次性包装备用计划
- 10 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “7” – KEY PROCESS & PRODUCT CHARACTERISTICS
PURPOSE: The purpose is to define the key product, process characteristics and establish requirements
for process capability.
SCOPE: Applies to all parts.
NOTES:
A list of special product and process characteristics such as key, safety, noise, etc., shall be developed using Customer input as well as Supplier knowledge of the product and process. The design and process FMEAs should be used to help create the list.
Key <D>, emissions <E>, noise <N>, theft <T>, safety <S>, and homologation <H> characteristics shall be noted on the Control Plan, set-up sheets, and operator instruction sheets.
SUPPLIER RESPONSIBILITIES:
Supplier shall:
A1. Define and document the definition of special process characteristics and their requirements.
A2. All process characteristics shall be identified on the Control Plan.
A3. Safety <S> characteristics require SPC reporting that shall be made available to the Customer
representatives upon request (refer to Engineering Process Standard PF-SAFETY Definition: Special (Safety) Characteristic.
A4. A Special (Safety) Characteristic <S> is a specific aspect related to assembly or manufacturing
that requires special due diligence since the consequence of a likely assembly or manufacturing
variation may cause a non-conformance to vehicle safety/regulatory requirements. Special
(Safety) Characteristics are identified with a <S> and pertain to either the part, process or system
function. For example, Special (Safety) Characteristics relate to: torque, welding, correct part
usage, dimensions, routing, connections, part identification, system functioning.
A5. Special product and process characteristics identified by customer and/or supplier shall be included in the FPSC (see element #19 )
- 11 -
供应商质量保证程序
(SQAP)
要素 “7” – 关键过程和产品特性
目的: 确定关键产品和过程特性，制定过程能力要求。
范围: 适用于所有零件。
说明:
关键的、安全、噪音等的特殊产品和过程特性的清单应通过采用顾客的输入和供应商对产品和过程的认知来制定。设计和过程FMEA有助于确定此清单。
关键项<D>、排放<E>、噪音<N>、防盗<T>、安全项<S>和商检验证<H>特性应在控制计划、调试卡和操作者作业指导书上标明。
供应商职责:
供应商应：
A1. 确定过程特殊特性，将其定义及要求文件化。
A2. 所有过程特殊特性应在控制计划中加以标识。
A3. 安全 <S>特性需要有SPC报告并可随时提供给顾客代表 [ 参见工程过程标准 PF-安全
定义：特殊(安全)特性]。
A4. 特殊(安全)特性<S>是指在装配或制造中需要特别控制的产品特性，因为可能的装配或制造的偏差会导致不符合车辆安全要求和政府法规要求。 特殊（安全）特性用<S>来标识，适用于零件、过程或系统功能。 例如特殊（安全）特性涉及到： 扭矩、 装焊、正确的零件用途、 尺寸、 安装路线、 连接、 零件标识和系统功能。
A5. 顾客和/或供应商识别的特殊产品和过程特性应被纳入FPSC中（参见要素#19）。
- 11 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “8” – PART INSPECTION STANDARD
PURPOSE: To define the supplier’s inspection plan of finished product prior to shipping.
SCOPE: Apply to critical parts defined by the Customer.
SUPPLIER RESPONSIBILITIES:
A1. All Parts Inspection Standards will be approved by the Customer (Engineering, Supplier
Quality, Quality Control and Manufacturing).
A2. Part Inspection Standard lists all product characteristics, acceptance criteria, inspection methods, and inspection frequency to be inspected on the finished product prior to shipment to the customer.
A3. The Inspection standards shall also include: Datums, performance characteristics, weight, material, appearance requirements, function, color, and special inspection items.
A4. Inspection standards shall be considered:
Generated by supplier:
Supplier submits draft of Inspection Standard to the Customer for review and approval.
Supplier shall be responsible for updating based on design changes. Other reasons for revisions shall be discussed with Customer.
Generated by Customer
The customer drafts and discusses Inspection standards with the supplier.
A5. The supplier will review the part against the Part Inspection Standard with the customer before the
Line Speed Demonstration on-site visit (element #18)
A6. The supplier shall submit the part inspection Standard along with a marked up part drawing
identifying those special product characteristics listed on the form.
A7. Parts Inspection Standard does not replace current Process Control Plans.
FORMS & EXAMPLES:
REPORTS:
Reports will include the following:
Number of parts required Parts Inspection Standard
Number of Parts Inspection Standards completed
Number of Parts Inspection Standard approved
- 12 -
供应商质量保证程序
(SQAP)
要素 “8” – 零件检验标准
目的: 明确供应商成品发运前的检验计划。
范围: 适用于顾客规定的关键零件。
供应商职责:
A1. 所有零件检验标准将由顾客 (产品工程部门、 供应商质量管理部门、 质量控制部门和生产部门)来批
准。
A2. 具体零件检验标准应列出所有需检验的产品特性、 接收标准、 检验方法和检验频次。
A3. 检验标准还应包括： 基准点、 性能特性、重量、材料、外观要求、功能、颜色和特殊检验项目。
A4. 应考虑两种检验标准：
a) 供应商制定的：
i. 供应商提交检验标准的草案供顾客来评审和批准。
供应商按设计的更改负责更新。其他原因的修改应与顾客进行讨论。
顾客制定的：
i. 顾客起草并与供应商讨论检验标准。
A5. 在生产线节拍演示现场访问前（要素#18），供应商应和顾客一起参照零件检验标准评审零件。
A6. 供应商应提交检验标准及标识的零件图纸， 图纸上标识了清单上列出的产品的特殊特性。
A7. 零件检验标准未替代目前的过程控制计划。
表格和例子:
产品特性 公差 检验方式 检验频次
报告:
报告将包括以下内容:
1. 检验标准中要求的检验零件数量
2. 完成的零件检验标准的数量
3. 批准的零件检验标准的数量
- 12 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “9” – BOUNDARY SAMPLES AND APPEARANCE APPROVAL
PURPOSE: Boundary samples are actual parts representing acceptable quality limits, usually for appearance characteristics. Due to high level of subjectivity for appearance characteristics, the appearance approval is required.
SCOPE: Boundary Samples are required per the Inspection Standards.
Appearance Approval applies only for parts with color, grain, or surface appearance
requirements.
SUPPLIER RESPONSIBILITIES:
A. BOUNDARY SAMPLES
NOTE: See Element “4” Engineering Standards – A4
A1. Boundary samples represent current process capability.
A2. Boundary Samples are only used for a certain period (3 months). During these 3 months it is expected
that the process capability will improve.
A3. Initial Boundary Samples shall be reviewed and approved by the customer for pilot production.
Boundary Samples for the start of regular production shall be obtained during the Line Speed
Demonstration production and reviewed and approved by the customer.
A4. Supplier shall maintain the master boundary samples in a secure place and deliver three sets of the
samples to the Customer.
A5. Boundary Samples are valid based on approved process timing. Suppliers are expected to improve the
process thereafter.
B. APPEARANCE APPROVAL REPORT
SUPPLIER RESPONSIBILITIES:
B1. A separate Appearance Approval Report (AAR) shall be completed for each part or series of parts for which a submission is required if the product/part has appearance requirements on the design record.
FORMS:
Included in the ATTACHED CD
- 13 -
供应商质量保证程序
(SQAP)
要素 “9” – 边界样品和外观批准
目的: - 边界样品是代表了可接受质量极限的实际样件。由于对外观特性的判断具有很大的主观
性，所以要求进行外观批准。
范围: -根据检验标准要求确定是否需要边界样品。
-外观项批准仅适用于具有颜色、纹理或表面外观要求的零件。
供应商职责:
边界样品
注: 参见要素 “4” 工程标准 – A4
A1. 边界样品代表目前过程能力。
A2. 边界样品仅用于一定阶段 (3个月)。3个月内我们期待供应商能提高过程能力。
A3. 用于试装的最初边界样品应通过顾客评审和批准。
开始正常生产的边界样品应从生产线节拍演示运行中获得，并由顾客评审和批准。
A4. 供应商应把标准边界样品存放在安全的地方并向顾客提供三套样品。
A5. 边界样品在批准的时间内有效。 供应商应在批准的期限后改进工艺。
B.外观批准报告
供应商职责:
B1. 对于产品/零件在设计记录上有外观要求的零件或各系列零件，供应商应提交单独的外观批准报告（AAR）。
表格:
在附带CD中
- 13 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “10” – PROCESS FLOW & PFMEA; OPERATOR WORK INSTRUCTIONS AND
OPERATOR TRAINING
PURPOSE: - To describe the Manufacturing Process Flow and to define the risk associated with
potential process failures and to propose corrective action before these failures can
occur.
- To identify Suppliers Operator training program and its associated documents.
SCOPE: Applies to all parts.
A. PROCESS FLOW DIAGRAM AND MANUFACTURING PLAN
SUPPLIER RESPONSIBILITIES:
A1. The process flow chart shall be representative of the current or proposed process flow.
A2. To analyze sources of variations from the beginning to the end of a manufacturing or assembly
process.
A3. The flow chart will assist the team in analyzing the source of variations.
A4. The process flow diagram shall include the following:
Processing sequence, method, and equipment used at each station including inspection and repair/rework stations.
Number of operators, including float operators needed per station inspection and
repair/rework stations.
It shall include both main-line assembly processes as well as all off-line processes that supply it.
It should identify those stations which measure critical characteristics and/or stations which may contribute to significant customer issues as identified on the PFMEA.
- 14 -
供应商质量保证程序
(SQAP)
要素 “10” – 过程流程和过程失效模式及后果分析（PFMEA）, 操作者作业指导书和操作者培训
目的: -描述制造流程, 识别潜在过程失效风险，在失效发生之前提出纠正措施。
- 确定供应商操作者培训方案及其相关文件。
范围: 适用于所有零件。
A. 过程流程图和制造方案
供应商职责:
A1.过程流程图应代表目前或提议的过程流程。
A2.分析生产或装配过程从开始到结束的变差根源。
A3. 流程图有助于小组来分析变差根源。
A4. 过程流程图应包括以下:
包括检验和返修/返工工位在内的每个工位的加工顺序、方法和设备 。
操作者的数量,包括检验，返修/返工工位所需的流动操作者。
应包括主线装配过程及供应主线的所有旁支辅助过程。
对PFMEA中识别出的可能导致顾客重大问题的关键特性和/或工位加以标识。
- 14 -
B. OPERATOR WORK INSTRUCTIONS
B1. Operator, set-up, changeover, rework/repair inspection instructions and packaging instructions shall be
approved, signed, dated, traceable to the level of parts being produced, and shall include documented sample sizes and frequencies.
a) A procedure shall Exist that obtains cross functional signatures (. Quality, Engineering,
Manufacturing and Production Operators) for release of operating instructions.
b) A system shall exist which prevents non-standardized or out of date instructions from
existing on the manufacturing floor (. Document audit).
“Part loading and sequencing of operation” instructions shall exist for Gage R&R and in-process part loading into gages and/or fixtures.
B2. Any rework and repair operations and procedures shall be approved by the Supplier’s Engineering organization prior to the implementation.
The procedures shall include at a minimum:
a) All reworked/repaired products shall be clearly and uniquely identified.
b) All reworked/repaired product shall be re-validated utilizing production testing methods (if applicable) prior to packaging.
B3. All instructions, control charts, log sheets and reactions plans to out of control measurements
(if applicable) shall be located adjacent to the process, visible to the operator and legible.
Visual management techniques (displays & diagrams) should be used whenever possible.
a) Sample parts used as visual displays shall be properly identified and maintained to the
correct revision level and located at the applicable work station.
B4. Key <D>, safety <S>, noise <N>, emissions <E>, theft <T>, and homologation <H> characteristic parameters shall be addressed in the instructions. The instructions shall enable any adequately trained person to perform the described operation.
DOCUMENTATION:
Documents
Operator (Work) Instructions
Changeover Instructions
Rework/Repair Instructions
Packaging Instructions
Set-up sheets
Inspection Instructions
Inspection sheets (. checklists, logs, defect tracking sheets)
Visual displays/aids (. acceptance criteria displays, poke yoke charts/displays, and packaging)
Control charts (if applicable)
-15 -
B. 操作者作业指导书
B1.指导操作者操作、 调试、更换、返工/返修检测的作业指导书和包装指导书应经过批准、签字并注明日期，并与所生产的零件更改级别保持一致，应标明样本大小和频次。
应具备相关的程序，在操作作业指导书发放前，获得跨职能部门的签字认可。 (例如：质量部门，产品工程部门，制造和生产操作者。)
应具有一个系统，来防止非标准化的或过时的作业指导书在生产车间使用 (如文件审核)。
应具备“零件安装和操作顺序”的作业指导书来规定实施重复性和再现性分析Gage R&R的流程，以及在生产过程中零件在检具和工装上的安装流程。
B2. 任何返工/返修的操作和程序在实施前应经过供应商工程部门的批准。
程序应至少包括：
a) 所有返工/返修产品应有清楚的及唯一性的标识。
b) 所有返工/返修产品(如果适用)应在包装前应用生产检测方法进行重新验证。
B3. 所有作业指导书、 控制图、记录单和对失控状况的反应计划 (如果适用)应邻近工位存放，操作者一目了然。应最大限度地采用目视方式管理的方法(目视标志和图示)。
a)目视样件应正确标识并保持正确更改级别及放置在适用的工位。
B4. 关键<D>、安全 <S>、噪音<N>、排放 <E>、防盗 <T>和商检论证 <H> 特性参数应在作业指导书中标明。作业指导书应可以指导接受过足够培训的人员进行所描述的操作。
文件:
操作者(作业)指导书
更换指导书
返工/返修指导书
包装指导书
工艺卡
检验指导书
检验卡 (如：检查单，记录本，缺陷跟踪卡)
目视标志/辅具 (如接受准则的示图, 防错防误示图/标志和包装)
控制图 (如适用)
- 15 -
C. OPERATOR TRAINING
SUPPLIER RESPONSIBILITIES:
NOTE: Employee shall have comprehensive training in the SQAP process.
C1. Supplier shall identify training requirements for all levels of employees.
C2. Operator training shall be documented and a record of training for all operators shall be maintained.
C3. Supplier shall maintain assessment of the employees versus the competencies.
EXAMPLE: (Individual Assessment)
Included in the ATTACHED CD
D. PFMEA
SUPPLIER RESPONSIBILITIES:
NOTE: Process FMEA: - Identifies the process functions and requirements, and analyzes items that could go wrong
based on historical data.
- Provides feedback to the DFMEA to initiate a re-design if necessary.
- Identifies what process preventions or controls will be needed for occurrence reduction or detection ranking reduction.
D1. PFMEA shall be completed for each unique product or process and shall be reviewed by the Customer.
D2. PFMEA shall be developed as soon as the DFMEA and Process Flow charts are available.
D3. PFMEA drives the Error Mistake Proofing, the Process Control Plans, and Preventive Maintenance Plans.
D4. PFMEA is not an individual assignment but a team activity.
D5. The process FMEA (PFMEA) shall be developed for the entire process flow chart to assess the total risk.
D6. The PFMEA is a living document and shall be traceable to the engineering change levels and processing changes. These documents should contain the special characteristics agreed to by the Customer.
D7. There shall exist an internal process, to continually reduce the risk priority numbers.
Risk Priority Number (RPN) is used to ascertain robustness of the design or the process
RPN = Severity of failure (S) * Likelihood of Occurrence (O) * Detection ability (D)
- 16 -
C. 操作者培训
供应商职责:
注：员工应接受SQAP程序的全面培训。
C1. 供应商应确定各级员工的培训需求。
C2. 操作者的培训应文件化，并保存所有操作者的培训记录。
C3. 供应商应对员工的技能保持评估。
例子: (个人评估)
在附带CD中
D. 过程失效模式及后果分析PFMEA
供应商职责:
注： 过程失效模式和效果分析
- 识别过程功能和要求，并基于历史数据分析可能出错的项目。
- 如有必要，为DFMEA提供反馈以开展重新设计。
- 识别降低频度或探测度级别所需采取的过程预防或过程控制。
D1. 应制定每个特定产品或过程的PFMEA并应由顾客评审。
D2. 一旦过程流程图和DFMEA完成，则应进行PFMEA。
D3. PFMEA 推动防误防错，过程控制计划和预防性维护保养计划的建立。
D4. PFMEA不是个别人的任务，而是团队合作的结晶。
D5. 过程 FMEA (PFMEA)应覆盖整个过程流程以评估整体风险 。
D6. PFMEA 是动态文件，它应可以追溯到产品的工程更改级别和过程变更。此文件应包含顾客认可的特殊特性。
D7. 应具有不断减少风险顺序数的内部流程。
风险顺序数(RPN)是用来确定设计或过程的稳健程度
RPN = 失效严重度 (S) *频度(O) *探测度(D)
- 16 -
PFMEA TERM
DEFINITION
RATING SCALE
Severity (S)
It is an assessment of the seriousness of the effect of the potential failure mode to the customer. Severity applies to the effect only.
1 - 10
Occurrence (O)
It is how frequently the specific failure cause/mechanism is projected to occur.
1 - 10
Detection (D)
It is an assessment of the probability that the proposed current process control, will detect a potential cause/mechanism, or the probability that the process control will detect the subsequent failure mode, before the part or component leaves the manufacturing operation or assembly location.
1 - 10
Risk Priority Number (RPN)
For higher RPN’s the team shall undertake efforts to reduce this calculated risk through corrective action(s). In general practice, regardless of the resultant RPN, special attention should be given when severity is high.
1 - 1000
Follow-up action items should be geared towards reducing the raw score of Severity, then Occurrence. And then detection.
Suppliers shall use the AIAG supplemental manual “Potential Failure Mode and Effects Analysis” as a reference for proper methods and procedures for developing PFMEA
REPORTS:
Reports will include the following:
Number of processes that required PFMEA
Number of PFMEA completed
Pareto of RPN (highest RPN)
FORMS:
AIAG Form
- 17 -
PFMEA 术语
定义
分值
严重度 (S)
用来评估潜在失效模式对顾客影响的严重程度。严重性仅应用于后果。
1 - 10
频度(O)
指某一特定的失效起因/机理出现的频次。
1 - 10
探测度 (D)
对现行控制过程探测潜在失效起因/机理的可能性的评估，或者是对过程控制在部件离开制造及装配工位前发现潜在失效模式的可能性的评估。
1 - 10
风险顺序数 (RPN)
对于高风险顺序数的项目小组应努力通过纠正措施降低计算出的风险值。通常，无论RPN值高低如何, 当严重程度高时，就需要特别注意。
1 - 1000
跟踪措施应当首先立足于减少严重度的分值，然后是频度，最后为可探测度。
供应商应参考AIAG补充手册“潜在失效模式及后果分析”中方法和程序制定PFMEA。
报告:
报告将包括以下内容：
1.需要进行PFMEA的过程数量
2.已经完成的PFMEA数量
的排列图 (最高的RPN值)
表格:
AIAG 表
- 17 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “11” – ERROR MISTAKE PROOFING
PURPOSE: The purpose is to prevent mistakes from occurring. (reactive)
SCOPE: Applies to all processes.
KEY POINTS:
Mistake proofing identifies errors and prevents them from becoming a non- conformance.
Mistake Proofing approaches are used to improve the production processes reviewed during the Advanced Quality Planning, PFMEA, Pre-Line Speed Demonstration meeting and verified during the Line Speed Demonstration on-Site Visit.
SUPPLIER RESPONSIBILITIES:
NOTE 1：
Parts and processes should be designed so that:
Part can only be installed one way
Process is set up to check for factors that cause errors and not defects
Parts are not interchangeable (reduced complexity)
NOTE 2：
Tools, fixtures, equipment automatically:
Detects defects and shuts down operation
Sends a warning (visible or audible) to the operator when abnormality is detected
NOTE 3：
Visual aids:
Are used to help the operator in selecting the correct parts or placing part in the correct orientation
A1. Design error proofing features in product and process shall be incorporated at an early stage.
A2. The Mistake Proofing Plan shall describe how the organization addresses mistake proofing from the
organizational level.
A3. The plan shall explain how the verification frequency of “designated non-conforming product is determined”
A4. The plan shall describe how “designated non-conforming product” is labeled.
A5. Control Plan shall address mistake proofing verification (. frequency, # of parts).
-18 -
供应商质量保证程序
(SQAP)
要素 “11” – 防误防错
目的: 预防错误发生。 (采取行动)
范围: 适用于所有过程。
要点:
防错手段能识别失误并防止其演变成为不合格。
防错手段用于改进先期质量策划, PFMEA，生产线节拍演示预备会议中评审的生产过程，并在生产线节拍演示现场访问时进行验证。
供应商职责:
注 1：
零件和过程的设计应使:
零件只能按一个方向装配。
过程的建立是为了发现引起失误的起因，而不是去检查缺陷。
零件不可互换 (降低复杂性)。
注2：
工装、夹具、设备可自动：
发现缺陷并停止操作。
发现异常情况时，向操作者发出警告 (可视或可听)。
注3：
目视辅具：
用来帮助操作者选择正确的零件或把零件按正确的方向装配。
A1. 对产品及过程的设计性防误应在早期进行。
A2. 防错方案中应描述公司是如何从各个层面采取防错措施的。
A3. 此方案应说明“对所设定的不合格产品进行确定”的验证频次。
A4. 此方案应说明如何对“所设定的不合格产品”进行标识 。
A5. 控制计划应说明对防错的验证情况 (例如：频次, 零件数量)。
-18 -
A6. “Designated non-conforming product” shall be verified on the production line as frequently as needed to
ensure mistake proofing is operational. The frequency of verification should take into account such activities as start of shift, productions changeover, major disruptions, tooling maintenance’s, etc.
A7. Mistake proofing is mandatory for severity number of 8 or higher in the DFMEA and PFMEA.
A8. A contingency plan shall be developed and documented in the event the production mistake proofing is not operable. A visual or audible alert shall signify the mistake proofing is inoperable.
A9. In the event the mistake proofing becomes inoperable, the customer’s Supplier Quality Specialist shall be
notified per “The Forever Requirements”. The Potential Non-Conformance Process shall be used where applicable.
A10. Mistake proofing shall be addressed in the Preventative Maintenance Plan.
A11. Mistake proofing shall be addressed in the Layered Process Audit Plan.
A12. All critical processes will require Error-Mistake Proofing, Visual Controls at the station, and Layered Process Audit.
A13. Mistake Proofing in production shall provide immediate feedback and corrective action, should mistake occur.
REPORTS:
Reports will include the following:
Number of process that required Error Mistake Proofing
Number of processes completed Error Mistake Proofing
Breakdown of completed Error Mistake Proofing
Error Proofing %
Mistake Proofing%
Inspection %
Work Instructions %
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A6. 应按照所要求的频次在生产线上对“所设定的不合格品”进行验证以确保防错手段的可靠性。 验证频次的安排应考虑换班、生产换型、重大中断和工装维护等情况。
A7. 当DFMEA 和 PFMEA分析中严重程度值为8或8以上，应采取防错措施。
A8. 应制订应急计划来应对防错手段失效的情况 。此时，应具备可视或可听警示来告知防错的失效情况。
A9. 按“永久性要求”，应通知顾客的供应商质量专员防错失效的情况。如适用, 应使用潜在的不合格程序。
A10. 防错应在预防性维护保养计划中说明。
A11. 防错应在逐层过程审核计划中说明。
A12. 应对所有关键过程采取防误防错手段、 工位目视管理和逐层过程审核。
A13. 错误一旦发生，生产中所运用的防错手段应立即反应并采取纠正措施。
报告:
报告将包括以下内容：
1. 要求采取防误防错手段的过程数量
2. 已采取防误防错手段的过程数量
3. 对已采取防误防错手段的细分
防误 %
防错 %
检测 %
作业指导书 %
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SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “12” – TOOLING EQUIPMENT AND GAGES; PREVENTIVE MAINTENANCE
PURPOSE: To specify requirements for gages, test equipment calibration, and Preventive
Maintenance procedure.
SCOPE: Applies to all gages, fixtures, tooling, and test equipment for the manufacturing of the parts
and the finished product.
A. TOOLING EQUIPMENT AND GAGES
SUPPLIER RESPONSIBILITIES:
A1. All tooling, gages, fixtures, and test equipment required to produce a product shall be identified, tagged,
and appear on a tooling list (refer to TS-16949 section Customer Property).
A2. All DaimlerChrysler owned tooling or equipment shall be identified.
A3. All tooling, gages, test fixtures, and test equipment used in the manufacturing process from laboratory,
production, tool room, maintenance and quality areas shall be identified in the Supplier’s maintenance,
storage, and calibration programs. Any temporary or interim tooling or equipment shall be included in the
tooling list.
A4. All gages shall have acceptable R&R studies performed in conjunction with the Supplier Readiness
Evaluation Run (SRE) prior to the Pre-Line Speed Demonstration Meeting.
A5. Gage R&R studies shall be performed according to the Measurement Systems Analysis (MSA) manual
for both attribute and variable gages.
A6. Maximum of Gage R&R shall not exceed 10%. Customer shall give a written approval to use the gage
or measuring equipment with Gage R&R over 10%.
FORMS/DOCUMENTATION:
Supplier at the minimum needs the following documentation:
Gage R&R records
20 -
供应商质量保证程序
(SQAP)
要素 “12” – 工装设备量检具；预防性维护保养
目的: 规定量检具、试验设备校准和预防性维护保养程序的要求。
范围: 适用于所有量检具、夹具、工装和用于零件生产和成品制造的试验设备。
A. 工装设备和量检具
供应商职责:
A1. 对于所有用于生产的工装、量检具、夹具和试验设备都需要标识、挂标签并记录于工装清单中（参考TS-16949 顾客财产）。
A2. 应标识戴姆勒•克莱斯勒拥有的所有工装设备。
A3. 在供应商制造流程中所使用的来自实验室、生产车间、工具室、维修和质量区域的所有工装、量检具、试验夹具和试验设备，都应纳入供应商的维护保养、储存和校准流程。工装清单应包括所有临时或短期使用的工装设备。
A4. 所有的量检具应有可接受的重复性和再现性分析，此分析在生产线节拍演示的预备会议前，结合供应商准备情况评估运行（SRE）进行。
A5. 计数值和计量值量具的重复性和在再现性分析应依据测量系统分析 (MSA) 手册进行。
A6. 量检具R&R最大不得超过10%。使用R&R超过10%的量检具或测量设备应有顾客的书面批准。
表格/文件:
供应商至少需要以下文件:
量检具重复性和再现性Gage R&R分析记录
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B. PREVENTIVE MAINTENANCE
SUPPLIER RESPONSIBILITIES:
NOTE:
Calibration shall be traceable to a known source/standard.
Supplier needs Gage and test equipment calibration records.
B1. Supplier shall follow the requirements from the TS 16949 as follows:
Need to identify key process equipment and provide resources for machine/equipment
maintenance and develop an effective planned total preventive maintenance system
Preventive maintenance system minimally shall include the following:
planned maintenance activities
packaging and preservation of equipment, tooling and gauging
availability of replacement parts for key manufacturing equipment
documenting, evaluating and improving maintenance objectives
Supplier shall utilize predictive maintenance methods to continually improve the effectiveness of
its preventive system
B2. Preventive Maintenance (PM) plan shall exist for all equipment and tooling.
B3. Plans, schedules, frequencies and instructions for the periodic maintenance of equipment or
machinery, tools, dies, patterns, fixtures, etc., for each item of process equipment and tooling.
B4. Perishable tools and supplies. etc., shall have life expectancy and utilization parameters identified
including maintenance frequency and responsibility.
B5. All gages and test equipment shall be calibrated and reflect the last calibration date and expiration shall be traceable to a known source/standard.
B6. All gages shall be updated per latest engineering changes if required.
If required, supplier shall perform Gage R&R.
DOCUMENTATION REQUIRED:
Supplier shall have Preventive Maintenance (PM) plan
- 21 -
B. 预防性维护保养
供应商职责:
注：
校准应可追溯到一个被认知的标样/标准。
供应商需要有量检具和试验设备的校准记录。
B1. 供应商应遵循下列TS16949的要求:
- 需要标识关键过程设备和提供机器/设备维护的资源并建立有效的有计划的全面预防性维护保养系统。
预防性维护保养系统至少应包括以下方面：
有计划的预防性维护保养活动。
设备、工装和量检具的包装和保存。
备有关键制造设备的备件。
记录、评估和不断提高维修目标。
- 供应商应该使用预测性维护保养方式来持续提高其预防系统的有效性。
B2. 应具备针对所有设备、工装的预防性维护保养（PM）计划。
B3. 应对过程设备和工装涉及的各个方面，如设备或机器、工具、模具、胎具和夹具等的定期维护活动制定计划、时间、频次和维护保养指导书。
B4. 对易损工具及其相应配备的寿命和使用参数加以确定，同时也包括它的维护频次和职责。
B5. 应对所有的量检具和试验设备进行校准，并注明最新的校准日期和失效日期。校准应可追溯到一个
被认知的标样/标准。
B6. 如要求，所有的量检具应体现最新的工程更改级别。
如要求，供应商应进行量检具的 R&R分析。
文件:
供应商应有预防性维护保养计划 (PM)
- 21 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “13” – PROCESS CAPABILITY STUDY
PURPOSE: Is to demonstrate that the product meets the Customer statistical capability requirements, when a new product is introduced so product quality and variation reduction can be assessed.
SCOPE: Applies to all part characteristics identified as safety items, special process characteristics and all characteristics required by the Customer.
SUPPLIER RESPONSIBILITIES:
NOTE 1:
GOAL:
PP, PPK > (Initial Process Capability)
The difference between PP and PPK should be as small as possible.
Ideally PP - PPK = 0
A1. For multiple lines/tools/cavities, the data from each shall be identified and recorded separately.
- Pp and Ppk shall be calculated individually for each line/tool/cavity (each process stream).
- The selected characteristic, tolerance, type (attribute or variable), quantity processed, quantity accepted, and calculated performance values shall be recorded on the PRODUCTION DEMONSTRATION RESULTS form, Initial Process Study section. See attached CD for forms.
- 100% of the parts from the Line Speed Demonstration shall be included in the study. However, at least 100 parts in 25 sub-groups shall be checked from each production line/tool/cavity to satisfy PPAP requirements.
NOTE 2: The Customer shall note any deviation from the requirements on the COMMENTS/FOLLOW-UP
SHEET.
NOTE 3: For attribute studies, the performance calculations Pp and Ppk do not apply.
NOTE 4: Production Demonstration Results includes Line Speed Demonstration and Initial Process Study.
A2. Other calculations such as First Time Capability (FTC), station process quantities, rates and accepted quantities shall be included in the study and recorded on the PRODUCTION DEMONSTRATION RESULTS form.
-22 -
供应商质量保证程序
(SQAP)
要素 “13” – 过程能力研究
目的: 当引进新产品时，以此来证明产品是否满足顾客对统计过程能力的要求，同时对产品质量和变差的降低作出评估。
范围: 适用于所有安全特性、特殊过程特性和顾客要求的特性。
供应商职责:
注1:
目标:
PP, PPK > (初始过程能力)
PP和PPK 之间的差异应尽可能小。
理想状态： PP - PPK = 0
A1. 对多条线/工具/腔体各自的数据应分别记录和标识。
- 应分别计算每条线/工具/腔体（各个过程） 的Pp值 和Ppk值。
- 所选择的特性、公差、类型（计数或计量）、加工数量、接受数量和计算出的能力结果应记录在生产演示结果表上初始过程研究的部分。参见附带CD中的表格。
- 应将生产线节拍演示中生产的100%的零件纳入能力研究中。然而，为满足PPAP要求，应检测来自于每条线/工装/腔体的被分为25个子组的至少100个零件。
注2: 顾客应在评价/跟踪表上说明能力测评结果与要求之间的变差。
注3: Pp 和Ppk不适用于对计数值的能力测评。
注4: 生产演示结果包括生产线节拍演示和初始过程研究。
A2. 如首次交验合格率（FTC）、工位加工数量、节拍和可接受数量的计算结果应纳入分析研究并记录在生产演示结果表中。
- 22 -
NOTE 5: First Time Capability (FTC) is measured as the total number of items correctly processed, divided
by the total number attempted. These calculations shall be completed for each production line/tool.
Correctly processed means no repairs are required or allowed. Repaired parts are not to be used in
the FTC calculation.
-The Customer team shall determine the acceptable FTC percentage for the Production Demonstration Run.
NOTE 6: Any deviation from the Ppk requirement shall be approved in writing by the SQAP Team and
noted on the COMMENT/FOLLOW-UP SHEET (see attached CD).
A3. If Process Capability is less than the required Ppk > , then 100% verification of shipped parts is acceptable with Customer Team agreement. Initial Process Study shall be marked “unaccept” on the Line Speed Demonstration form.
- A recovery plan is required for all items on the Production Demonstration Results form, that do not have a “ Ppk >”.
- When Initial Process Study is marked “unaccept”, an on-site revisit is required by the Customer Team. This shall be noted on the Line Speed Demonstration Checklist.
- An Interim Approval Authorization (IAA), shall be issued until the supplier proves capability.
- The supplier shall identify and document the Root Cause and implement permanent corrective actions prior to the Line Speed Demonstration revisit being scheduled.
- For variable gages, tolerances used for 100% verification shall be reduced by the extent of Gage R&R (see MSA manual)
A4. When Line Speed Demonstration is met but the FTC percentage does not meet the Customer
Team’s requirement, the Customer Team shall mark “unaccept” FTC on the checklist.
- An on-site revisit is required by the Customer Team. This shall be noted on the Checklist.
- The supplier shall identify and document Root Cause and implement permanent corrective action prior to the revisit being scheduled. The Customer Team shall verify corrective action during the revisit.
A5. Parts made during the Production Demonstration Run may be used for PPAP, if and only if PPAP
requirements including the statistical requirements have been successfully completed.
A6. For on-going production after PPAP submission, the supplier shall maintain process capability with a
minimum Cp & Cpk of .
-23 -
注5: 首次交验合格率 (FTC) 用合格数量除以投入的总数。每条生产线/工具应单独计算。加工合格数量是指不必返修或不允许返修的数量。 返修过的零件不能放入FTC的计算中。
顾客小组应确定生产演示运行可以接受的FTC标准。
注6: 任何与Ppk要求有差距时，应经过SQAP团队的书面批准并在“意见/跟踪单”上注明。( 参见 CD ).
A3. 如果过程能力小于要求的Ppk > , 如果顾客小组同意，可以接受100%的出厂检验的方式。在生产线节拍演示的表上标明初始过程研究的位置注明“不接受”。
- 如果Ppk未达到，需要在生产演示结果表上注明所有项目的改进措施。
- 初始过程研究能力为“不接受”，顾客团队需要再次进行现场考察。该情况应在生产线节拍演示单上注 明。
- 在供应商证明其能力达到要求之前，顾客应签发一份临时批准授权 (IAA)。
- 供应商应识别分析根本原因并形成文件，并在安排再次考察生产线节拍演示之前实施永久纠正措施。
顾客小组将在再次现场考察中确认纠正措施的实施情况。
- 对于实施100%验证的计量型数据，其公差范围应视Gage R&R值的大小进行相应的紧缩。(见MSA 手册)。
A4. 当生产线节拍达到要求但FTC未达到顾客小组的要求时，顾客小组应在评价/跟踪表上注明FTC“不接受”。
- 应在“评价/跟踪表“上注明顾客小组需要进行再次现场考察。
- 供应商应分析根本原因并将其文件化，在再次安排生产线节拍演示之前，供应商应实施永久性纠正措施。顾客小组将在再次现场考察中确认纠正措施的实施情况。
A5. 当且仅当统计要求都得到完全满足时，生产演示运行的零件可以用于PPAP。
A6. 对于PPAP 提交之后的生产，供应商应维持过程能力Cp & Cpk ＞= .
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SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “14”– CONTROL PLAN: INCOMING, OUTGOING MATERIAL PLAN;
SAMPLES SIZES AND TEST FREQUENCIES.
PURPOSE: - To explain the manufacture of quality products according to customer requirements.
- Develop the Incoming and Outgoing material Plans.
SCOPE: Applies to a part, a group or family of products produced by the same process at the same source.
A. CONTROL PLAN
SUPPLIER RESPONSIBILITIES:
NOTE:
Control Plan shall be based on the PFMEA
Control Plan describes the actions required within the manufacturing process flow, gauging,
testing requirements and sample sizes, to assure that all process outputs will be in a state of statistical control
Control Plan shall:
A1. Summarize the entire control strategy for a system, subsystem or component.
A2. Communicate to operators and to the entire plant the methods and procedures that will be used to control
processes.
A3. Describe each step of the manufacturing process including: receiving, material handling and storage,
in-process operations, testing, inspections and shipping.
A4. Consolidate information from other documents, (at the minimum from Process Flow, PFMEA and SPC)
A5. Be used and maintained throughout the product life cycle.
A6. Not be a substitute for detailed operator instructions.
A7. Be used in Assembly, Mistake Proofing devices, Statistical Process Control/Process Capability, on-line
and off-line inspections, in-plant laboratory testing and PFMEA.
REPORTS:
Reports will include the following:
Number of Control Plans required (one Control Plan per part or family of parts)
Number of Control Plans completed
Number of Control Plans approved by the Customer
- 24 -
供应商质量保证程序
(SQAP)
要素 “14”– 控制计划：来料和发料计划，样本大小和试验频次。
目的： - 依据顾客要求来解释合格产品是如何制造的。
- 制订来料及发料的计划。
范围: 适用于由同一供应商按同一过程生产的某一零件、某一组件或一系列产品。
A. 控制计划
供应商职责:
注:
控制计划应在 PFMEA的基础上制定。
控制计划描述生产过程应具备的方方面面，诸如量检具、试验要求、样本大小所需进行的工作，以保证所有的过程输出在统计控制之内。
控制计划应:
A1. 汇总总成、分总成或零部件整体的控制策略。
A2. 就控制过程的方法和程序与操作员及整个车间进行交流。
A3. 描述整个制造过程的每个步骤，包括：接收、物料搬运和储存、工序间操作、测试、检验和发运。
A4. 从其他文件中收集信息 (过程流程、 PFMEA和 SPC)。
A5. 在产品的整个寿命周期中使用并保持。
A6. 不能替代详细的操作者作业指导书。
A7. 用于装配、防错装置、统计过程控制/过程能力、在线和离线检验、厂内实验室试验和PFMEA。
报告:
报告将包括下列方面:
要求的控制计划数量（一个控制计划用于一个零件或一系列产品）
完成的控制计划数量
已获顾客批准的控制计划数量
- 24 -
B. INCOMING MATERIAL PLAN
NOTE: Review the Incoming Material Qualification/ Certification Plan plus associated documents and
records (refer to TS-16949 element Verification of Purchased Product). The plan shall be
verified during the Line Speed Demonstration On-site visit.
SUPPLIER RESPONSIBILITIES:
B1. The plan shall describe operations and procedures used by incoming inspection to qualify and
certify incoming material prior to releasing into production.
B2. The plan shall include incoming acceptance sampling plans, for both attribute and variable data.
Two or more of the methods described in element of TS-16949 shall be used; otherwise,
the minimum requirements of Lot Acceptance Sampling shall be approved by the Customer.
The risk for the purchased component and material shall be taken into account when developing the incoming acceptance sampling plan.
B3. All parts require lot control and traceability within the organization’s manufacturing facility, these
shall be described in detail and verified (element & of TS-16949).
Parts required to meet the DaimlerChrysler Traceability Specification, PS-10125, shall adhere to all requirements therein. Product identification and traceability shall be maintained and recorded through all stages of production, delivery and installation. At a minimum, record keeping which tracks the usage of lots or batches back to the production date is mandatory.
All parts should be identified with Supplier Code, Part Number and Manufacturing Dates based on Engineering Standards PS-4480, if specified. When part design prevents compliance, then an alternate method shall be documented and approved by DaimlerChrysler Engineering.
B4. For lot traceability, the lot size shall be no more than one shift or one production run, whichever is
smaller.
B5. Special controls are required for sorted, reworked or repaired material to provide traceability to
the sorted, rework or repair process.
B6. The plan shall address containment of non-conforming material. This shall also include the use of
the DaimlerChrysler Supplier Notification of Potential Non-conformance process outlined in the
Forever Requirements.
B7. The plan shall address part handling and part identification for non-conforming product.
B8. The plan shall identify processes performed by sub-suppliers or any outside processor and shall
include records indicating inspection/test results that relate to the appropriate lot code.
B9. The plan shall identify sub-component processes performed in-house and shall include records
indicating inspection/test results that relate to the appropriate lot code.
B10. The lot acceptance date (or date the lot was inspected) shall be identified by the year, month,
day and numeric sequence.
- 25 -
B. 来料计划
注: 审核进厂材料验证/认证计划加上相关文件和记录 (参考 TS-16949 节 采购产品的验证)。应在生产线节拍演示现场访问时验证该计划。
供应商职责:
B1. 计划应描述在将来料被投入生产之前，对其进行质量验证和认证的操作和程序。
B2. 计划应包括计数和计量值的进厂接收抽样计划。应采用TS-16949的 描述的方式中的
两个或多种的方法；否则，批量接收抽样方案中的最低要求应得到顾客的认可。
在制订定来料进厂接收抽样方案样件计划时，应考虑被采购部件和物料的风险。
B3. 应对生产场所的所有零件进行批号和可追溯性管理，并将此流程加以详细描述和验证。(TS16949
& )。
戴姆勒•克莱斯勒的可追溯性标准为PS-10125，相关零件应完全遵循此标准。产品标识、可追溯性及其相关记录应贯穿整个生产阶段、以及之后的发运和安装过程。作为强制性要求，至少可以凭借相关记录从所使用的批次追溯到该批次的生产日期。
如有明确规定，应按工程标准PS-4480中的要求标识所有零件的供应商代码、零件号和生产日期。如由于零件设计原因而无法满足该标准的要求时，则应将其他标识方式文件化并提交戴姆勒•克莱斯勒工程部门进行批准。
B4. 在建立可追溯性批次时，批量的大小不能大于一个班次或一次生产运行的产量，以两者中较低者
为准。
B5. 对于挑选、返工或返修物料的可追溯性应予以特别控制。
B6. 计划应说明遏制不合格物料的方法。它也包括如何按照戴姆勒•克莱斯勒对供应商的“永久性要
求”运行“潜在不合格通知流程”。
B7. 计划应说明零件搬运和不合格品的标识。
B8. 计划应标明由分供商或者外部加工的过程，应包括对应批次的检验/试验结果的记录。
B9. 计划需要标明在厂内分总成的加工过程，应包括对应批次的检验/试验结果的记录。
B10. 批次接受日期(或批次检验日期) 应按年、月、日和数字序号构成。
- 25 -
B11. Components or production materials used in the assembly of parts for the Customer shall have
Full approval status. The PSW from tier II suppliers shall be on file.
B12. Certificates of Analysis shall comply with DaimlerChrysler Engineering Standard Requirements
identified on the CATIA comments page.
B13. The plan shall address returned assemblies or components from the customer.
B14. All incoming appearance sub-components shall meet the requirement outlined in the
DaimlerChrysler Appearance Standard AS-10119<A>.
B. OUTGOING MATERIAL PLAN
NOTES: Review the Outgoing Material Inspection Plan plus associated documents and records . Parts Inspection Standard. The plan shall be verified during the Line Speed Demonstration on-site visit. Applies to all parts.
SUPPLIER RESPONSIBILITIES:
B15. The plan shall describe the operations and procedures used by outgoing inspection to qualify
outgoing product prior to releasing to the customer.
B16. The plan shall include outgoing acceptance sampling plans, for both attribute and variable data.
NOTE: The PFMEA risk of the production part shall be taken into account when developing the outgoing
inspection sampling plan.
B17. Parts are required to meet the DaimlerChrysler Traceability specification PS-10125.
B18. All parts should be marked with Supplier Code, Part Number and Manufacturing Dates based
on Engineering Standard PS-4480, if applicable.
B19. For lot traceability, the lot size shall be no more than one shift or one production run, whichever
is smaller.
B20. Supplier shall have the ability to track a part back through all stages of the manufacturing to the
raw material.
B21. Supplier shall ensure systems that are in place to control traceability of all critical components.
Same shall be done at the sub-suppliers.
B22. The plan shall address containment of non-conforming material. This shall also include the use
of the DaimlerChrysler Supplier Notification of Potential Nonconformance process outlined in the
Forever Requirements.
B23. The plan shall address part handling and part identification for nonconforming product.
B24. The lot acceptance date (or date the lot was inspected) shall be identified by the year, month,
day and numeric sequence.
- 26 -
B11. 在顾客装配厂所使用的部件或生产材料应经过完全批准 。二级供应商的PSW应进行归档。
B12. 分析结果合格证书应满足在CATIA注释页上标明的戴姆勒•克莱斯勒工程标准的要求。
B13. 此计划应注明从顾客处返回的总成或部件。
B14. 所有入厂的外观件应达到戴姆勒•克莱斯勒外观标准AS-10119<A>中的所有要求。
发料计划
说明: 评审发料检验计划及其他相关文件和记录，如：零件检验标准。此计划应在现场考察的生产线节拍演示中进行验证。适用于所有零件。
供应商的职责：
B15.计划应描述出厂检验所使用的操作和程序，以证明出厂产品在发给顾客前已达到合格。
B16. 计划应包括对计数型和计量型数据的发料抽样计划。
注： 当制定发料检验抽样计划时，应考虑产品零件的过程失效模式及后果分析PFMEA的风险情况 。
B17. 零件应达到戴姆勒•克莱斯勒可追溯性标准PS-10125中的所有要求。
B18. 根据工程标准PS-4480（若适用），所有的零件应标明供应商代码、零件编号和生产日期。
B19. 对于可追溯性批次，批量的大小不得高于一个班次或一次生产运行的产量，以两者中较低者为
准。
B20. 供应商应有能力追溯零件生产的各个阶段直到原材料。
B21. 供应商应具备确保所有关键零件的可追溯性控制的系统。分供商也应满足此要求。
B22. 计划应说明对不合格品的遏制方式。它也包括如何按照戴姆勒•克莱斯勒对供应商的“永久性要
求”运行“潜在不合格通知流程”。
B23. 此计划应说明对不合格产品的零件处理和零件标识。
B24. 批次验收日期（或注明批次的检验日期）应按照年、月、日及数字顺序进行标识。
-26 -
C. TEST SAMPLE SIZES AND FREQUENCIES
NOTE: For regular production, refer to Part Inspection Standard for individual parts requirements of sample sizes and frequencies.
SUPPLIER RESPONSIBILITIES:
Frequency can be:
C1. Based on a unit of production (. parts, lbs, kg., etc.)
C2. Event driven: (. Change at start of each shift , a tool change, etc.)
Sample Size can be:
C3. Has to be specified according to the process and how critical is the part (.,
100%, Each, One reading at the end of line, First 5, Three pieces every 200
produced, etc.)
C4. See Note 1 element # 18 section B Product Validation (PV) Testing.
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C. 样本大小和试验频次
注： 对于正常生产，参考零件检验标准中的不同零件的样本大小和频次。
供应商的职责：
频次可以:
C1. 基于一次生产的单元量（如：件, 磅, 千克等）
C2. 由事件驱动 (如：每班开始时变更，更换工装时等)。
样本大小可以：
C3. 应根据过程以及零件的关键程度确定（如：100%，每件，线尾一次读值， 前五
件，每生产200件从中取三件，等）。
C4. 参见要素#18 B部分产品验证（PV）试验注1。
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SUPPLIER QUALITY ASSURANCE PLAN
(SQAP)
ELEMENT “15” – CORRECTIVE ACTION PROCESS
PURPOSE: The Corrective Action Process is a structured approach to problem solving which is required
of the supply base as a result of identification of product or process non-conformances within the supplier’s or customer’s facility.
SCOPE: Applies to all parts that are non-conformances.
SUPPLIER RESPONSIBILITIES:
NOTE: The customer provides the supplier representative an appropriate copy of the 7-Step Corrective
Action Plan form for completion.
A1. The supplier representative completes the form and submits it to the customer.
Partially completed forms may be used as progress reports.
A2. Containment shall be in place within 24 hours.
FORMS:
Included in the ATTACHED CD
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供应商质量保证程序
(SQAP)
要素 “15” – 纠正措施程序
目的： 纠正措施程序是在供应商或顾客场所处理不合格产品或过程不符合情况的结构化的问题解决方法。
范围： 适用于所有不合格品。
供应商的职责：
注：供应商代表填写一份顾客提供的7步纠正措施计划表。
A1. 供应商代表填写表格，并提交给顾客。
部分完成的表格可以随着措施的进展不断完善。
A2. 24小时内应制定出遏制措施。
表格：
在附带CD中
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SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “16” – PROCESS MONITORING AND LAYERED PROCESS AUDIT (LPA)
PURPOSE: A system of Process Monitoring shall exist which shall demonstrate the ability of the processes to achieve planned results.
The LPA is to be used as quality improvement business system involving multiple layers of
management.
It is to ensure continuous conformance by improving process stability and First-Time
through capability.
SCOPE: Applies to all critical components and processes identified by the Customer and by the
Supplier.
A. PROCESS MONITORING
NOTES: - When planned results are not achieved, correction and corrective action shall be taken, as
appropriate, to ensure conformity of the product per TS-16949, section ,Monitoring and
measurement of processes.
- Operator, set-up, changeover, and inspection instructions shall be documented and
be accessible for all work stations per TS-16949, section , Work Instructions.
A1. All out of control measurements shall have corrective action, documented and implemented.
A2. There shall exist a First Piece Approval Process which verifies product at all stations is being made
according to specification. It will also verify such things as proper machine set-up and/or parameters.
A3. Visual displays of process performance (. FTC, scrap and rework) shall be present on the
manufacturing floor.
a) These displays shall be frequently updated to reflect current quality data.
b) Targets shall be identified for each measurable.
c) A plan shall exist to achieve target for each measurable.
A4. Special product and process characteristics are identified by the customer in addition to those selected by the supplier through knowledge of the product and process.
B. LAYERED PROCESS AUDIT
NOTES:
There are two types of Layered Process Audits:
Process Control Audits
Error& Mistake Proofing Verification Audits
Customer shall review and approve LPA Plan with supplier (Required only for High and Medium Risk Parts). For low risk parts, suppliers will approve their own LPA plan.
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供应商质量保证程序
(SQAP)
要素“16” – 过程监控和逐层过程审核（LPA）
目的： 应具备过程监控系统来证明过程能力是否达到既定的目标。
LPA是一个涉及到多个管理层的质量改进业务系统。
通过不断提高过程稳定性和首次交验合格率来确保持续的符合性。
范围： 适用于由顾客和供应商确定的所有关键零部件和过程。
A. 过程监控
说明：- 当没有达到既定的能力时，供应商应采取适当的纠正和纠正措施以确保产品符合性，参见TS-16949，过程的监视和测量。
- 操作者操作、调试、更换和检验指导书应文件化且易于在各工位获取，参见TS-16949，的作业指导书部分。
A1. 所有测量结果反映失控情况时，应采取纠正措施，实施并将其文件化。
A2. 应有首件批准程序，以验证各工位生产的产品符合技术标准要求。当进行机器调试和/或参数设置时，也将运行此流程。
A3. 过程性能的目视展示（例如FTC，废品和返工）应布置在车间的生产现场。
a) 这些展示应经常更新，以反映当前质量信息。
b) 应确定可测量的目标值。
c) 应有达到每个目标值的计划。
A4. 产品和过程特殊特性包括由顾客规定的，以及供应商凭借对产品及其过程的认知而确定的特性。
B. 逐层过程审核
说明：
1．逐层过程审核有两种：
过程控制审核
防误防错验证审核
顾客应同供应商一起评审并批准LPA计划（适用于中高风险的零件）。对于低风险零件，供应商可自己批准LPA计划。
- 29 -
LPA is an ongoing system of process checks that verify proper methods, settings, operator craftsmanship, error proofing devices and other inputs are in place to ensure a defect free product.
LPA’s assures that defined methods and work instructions are utilized, problem solving solutions are held in place, and all process issues are identified and quickly corrected.
SUPPLIER RESPONSIBILITIES:
B1. Regularly scheduled reviews of all elements in a manufacturing/assembly process to ensure that:
Equipment is being properly maintained
Error Proofing is working
Standardized work instructions are being adhered to
B2. Process Control Audits shall be performed once per shift by supervisors.
Plant management shall perform the audit once per week.
B3. Error& Mistake Proofing Verification audits shall be conducted once per shift.
B4. Supplier shall develop the checklist for the LPA.
B5. Need to develop an Action Plan to identify all implementation steps.
NOTE: LAYERED PROCESS AUDITS ARE PROCESS BASED, NOT PART BASED.
B6. The area of highest risk should be the first area to implement the Layered Process Audit.
NOTE: Need to consider: Customer complaint history, Process stability, First-Time Through Capability, High RPN values from the FMEA, Operator influences, Error proofing/detection.
REPORTS:
Reports will include the following:
Number of LPA for Process Control
Number of LPA for Error& Mistake Proofing
Number of LPA approved by the customer (High and Medium Risk)
LPA for Process Control
LPA for Error& Mistake Proofing
FORMS:
Supplier shall develop forms for LPA.
EXAMPLES:
Included in the ATTACHED CD
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LPA逐层过程审核是一项持续的过程检查系统， 用来验证正确的方法、 设置、 操作员技能、防误装置和其他输入是否到位从而确保产品无缺陷产生。
LPA确保规定的方法，作业指导书得到运用，以及解决问题的方法有效实施和所有的过程问题得到确定及迅速纠正。
供应商的职责：
B1. 对制造/装配过程的所有要素进行定期地评审，以确保：
设备得到恰当地维护保养
防误方法有效
标准化的作业指导书得到遵循
B2. 班长应每班进行一次过程控制审核。
工厂管理层应每周进行一次审核。
B3. 防误防错验证审核应每班进行一次。
B4. 供应商应制定LPA检查清单。
B5. 应制定一个行动计划来确定所有实施步骤。
注： 逐层过程审核是以过程为基础进行的，而不是基于零件。
B6. 最高风险区域应首先进行逐层过程审核。
注： 需要考虑：顾客抱怨历史记录、过程稳定性、首次交验合格率、失效模式影响及后果分析中的高RPN值、操作者影响、防误/探测度。
报告：
报告包括下列内容：
用于过程控制的LPA数量
用于防误防错的LPA数量
顾客批准的LPA数量（高及中度风险）
过程控制的LPA
防误防错的LPA
表格：
供应商应编制LPA表格。
例子：
在附带CD中
- 30 -
SUPPLIER QUALITY ASSURANCE PLAN
(SQAP)
ELEMENT “17” – PROCESS CHANGE REQUEST
FOREVER REQUIREMENTS
PURPOSE : Suppliers shall proactively communicate with DaimlerChrysler regarding changes that may impact product quality.
SCOPE: Applies to all Suppliers.
SUPPLIER RESPONSIBILITIES:
A1. Notify the Customer of any changes to the approved production process.
A2. Notification to the DaimlerChrysler Supplier Quality Manager and Purchasing Manager shall be
completed verbally with written follow-up before implementation of proposed material changes,
process changes, and/or manufacturing location changes at the supplier or sub-supplier level. In addition, the supplier shall notify the DaimlerChrysler Supplier Quality Manager and Purchasing
Manager when they become aware of sub-supplier issues and/or potential supply or capacity issues.
Supplier shall:
Proactively communicate with DaimlerChrysler. Know when to raise the flag.
Notify customer of proposed material or process changes.
Notify us of proposed manufacturing location changes.
Watch for sub-supplier issues and tell the customer about them.
Notify customer of potential supply/capacity issues.
FORMS:
Included in the ATTACHED CD
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供应商质量保证程序
(SQAP)
要素 “17” – 过程更改申请
永久性要求
目的： 供应商应主动与戴姆勒•克莱斯勒沟通可能影响产品质量的更改。
范围: 适用于所有供应商。
供应商的职责:
A1.通知顾客对已批准的生产过程的更改。
A2. 供应商或分供商既定的材料更改、过程更改和/或生产地点发生更改前，应先口头通知戴姆勒克
莱斯勒供应商质量管理经理和采购经理，然后形成书面通知。另外，当意识到存在分供商问题和/
或潜在供应或能力问题，供应商应通知戴姆勒•克莱斯勒供应商质量管理经理和采购经理。
供应商应：
主动与戴姆勒•克莱斯勒进行沟通。并知道何时举旗提示。
通知顾客既定材料或过程的更改。
通知我们既定制造地点的更改。
关注分供商的问题，并将其告知顾客。
通知顾客其潜在的供应/能力问题。
表格：
在附表中
- 31 -
EXAMPLE:
- 32 -
例子：
使外围企业的过程运行…..
“永久性要求”
适用于所有戴姆勒•克莱斯勒供应商及分供商
附加非符合性的例子
·主动与戴姆勒•克莱斯勒及供应链进行沟通
• 知道何时举红旗提示
• 是义务
例1
• 安全件的供应商周一出现连续符合性试验失效。
• 直到周四才通知戴姆勒•克莱斯勒
• 当既定的生产地点变动时，通知戴姆勒•克莱斯勒及供应链。
例3
• 供应商变动了内部生产地点
• 未通知戴姆勒•克莱斯勒
• 新过程不稳定
• 导致零件失效
• 通知戴姆勒•克莱斯勒及供应链有关潜在供应/能力问题
例5
• 由于数月产量提高，供应商出现了过程瓶颈
• 达到最高产量
• 供应商未达到放行要求，但在最后一分钟才通知生产控制部门。
• 通知戴姆勒•克莱斯勒及供应链关于提议更改材料或过程事宜
例2
• 供应商通知戴姆勒•克莱斯勒有关材料更改事宜
• 没有全部通知
• 新材料出现早期失效
• 关注分供商问题，并告知戴姆勒•克莱斯勒及供应链
例4
• 供应商将某工序外包
• 未通知戴姆勒•克莱斯勒
• 未获得PPAP批准
• 新的分供商发运了不合格材料
供应商在外围企业中的角色…
• 以口头和书面形式通知供应商质量经理、采购代理及技术经理上述例子中的情况和其它质量、技术和能力问题。
• 遵循“永久性”要求
• 成为团队成员
• 关注细节和后续活动
- 32 -
SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “18” – LINE SPEED DEMONSTRATION, PRODUCT VALIDATION (PV) TESTING
AND PART SUBMISSION WARRANT (PSW)
PURPOSE: - To demonstrate to the Customer Team that the supplier is capable of producing quality parts at the Quoted Customer Tooling Capacity
- To explain the requirements of the Production Part Approval Process
SCOPE: Required for all new or modified parts or parts whose process/design has been modified.
A. LINE SPEED DEMONSTRATION
SUPPLIER RESPONSIBILITIES:
NOTE1: Line Speed Demonstration is a key process to ensure Quality at Production Volumes.
Production Demonstration Run includes the Initial Process Study.
NOTE2: The customer team shall witness a build as a part of the SQAP requirement.
The Team will review all 20 SQAP elements using the form on page 33a. (same form is on the CD disk). This form is used for the PROCESS APPROVAL. If one or more of the element is not approved, the team will not approve the SQAP on-site visit. The supplier shall provide detailed corrective action plan for each of the “not approved” elements. The customer and the supplier will schedule a follow-up visit
NOTE3: Process Approval – page 33a: “Z” approval - elements 1-18a have been completed; “A” approval- elements 1-20 have been completed. Both codes “A” and “Z” is an internal code within DaimlerChrysler
A1. The Production Demonstration Run shall be on the production line(s) of record, using production tools,
processes and trained operators.
A2. The Production Demonstration Run consists of a minimum 300 pieces or two hours of production
whichever is more stringent. For multiple production lines or tools this requirement applies for each
production line/tool.
The Customer has the authority to adjust the quantity of parts based on the parts complexity and cost.
Any deviations from the minimum quantity of 300 pieces or two hours of production shall be approved in
writing by the Customer and documented on the PRODUCTION DEMONSTRATION RESULTS form.
If the line is empty at the start of the Production Demonstration Run, line fill time should not be counted in
the two- hour requirement. The count will begin with the first completed unit off the production line.
A3. The Customer shall witness the Line Speed Demonstration build and monitor the Line Speed during the Product Demonstration Run and record the value on the PRODUCTION DEMONSTRATION RESULTS form. In the case of multiple production lines/tools, the line speed for each line/tool will be recorded and the production line identified.
A4. The Customer will also indicate on the form whether the production line is a “shared” line with additional
production requirements for other DaimlerChrysler, or other customers’ products and will enter the DC
Tooling Capacity as well as the Total Tooling Capacity. If it is a shared line they will additionally enter
Other Customer Capacity and Excess Capacity.
Process studies shall be performed using part data from the Production Demonstration build.
Process constraints (bottlenecks), which may impact quality or production schedules shall be
documented on the COMMENT/FOLLOW-UP SHEET and contingency plans established.
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供应商质量保证程序
(SQAP)
要素“18” – 生产线节拍演示，产品验证（PV）试验和零件提交保证（PSW）
目标 - 供应商向顾客组证明其在顾客工装能力定额下，有能力生产出高质量的零件。
- 解释生产件批准程序的要求
范围： 适用于新的或修改过的零件或过程/设计发生变更的零件。
A.生产线节拍演示
供应商的职责：
注1： 生产线节拍演示是确保批量生产质量的一个重要过程。
生产演示过程包括初始过程研究。
注2: 作为SQAP要求的一部分，顾客小组应亲临一次生产现场观察生产过程。
小组将使用33a的表格评审SQAP所要求的20个要素。（在CD中也有此表）。此表格用于过程批准。如果一个或多个要素未获批准，顾客小组现场审核将不批准SQAP。对每个未获批准的要素，供应商应提交详细地纠正措施计划。顾客和供应商将另安排再次现场审核的时间。
注3：过程批准--第33a 页：”Z”批准--要素1-18a 已完成；”A”批准--要素1-20 已完成。“A” 和 “Z” 是戴姆勒•克
莱斯勒内部编码。
A1. 生产演示过程应在规定的生产线上，使用生产工装、工艺及经培训的人员进行操作。
A2. 生产演示过程应至少生产300件零件或运行2小时的生产，以多的为准。对于多条生产线或多个工装，每一条生产线/每一个工装都按此要求进行。顾客有权视零件的复杂性和成本来调整零件的数量。如达不到上述要求的数量，则应得到顾客书面批准，并在生产演示结果表格上加以说明。
如果生产线在生产演示运行开始阶段是空线，那么跑线的时间不能算入两小时要中。计时应从首件下线开始计算。
A3. 顾客应在生产演示过程中亲临现场并监测生产线的节拍，在将结果记录在“生产演示结果”表上。在多条生产线/多个工装的情况下，记录每条生产线/每个工装的生产线节拍并标注对应的生产线。
A4. 顾客要在表中说明生产线是否承担生产其它戴姆勒•克莱斯勒工厂（或者其它顾客）的产品，并将填入DC工装能力及总工装能力中。如果生产线是一条共享生产线，应填入其它顾客产品的能力和过剩的能力。
过程研究应使用生产演示运行中生产的零件的数据。有可能影响质量或生产进度的过程瓶颈应在评价/跟踪表上做出说明，并制定应急计划。
-33 -
FORMS:
Included in the ATTACHED CD
Line Speed Demonstration Comments/Follow-Up sheet
Measurement System Verification Report
Production Demonstration Results
B. PRODUCT VALIDATION (PV) TESTING
NOTES: Buzz, Squeak and Rattle (BSR) and Noise, Vibration and Harshness are part of the
Production Validation Testing.
. Buzz, Squeak and Rattle (BSR) and Noise, Vibration and Harshness (NVH) issues shall be addressed, with potential causes evaluated and documented.
Analyses should include evaluations of interactions with mating parts. To reduce/eliminate and/or monitor any unacceptable BSR/NVH characteristics, potential causes shall be addressed in the DFMEA, PFMEA, DVP&R, and the Control Plan.
Supplier-responsible component level Production Validation (PV) test plan and test results shall be reviewed and approved by the Customer.
SUPPLIER RESPONSIBILITIES:
NOTE 1:
PV testing shall be preceded by successful DV testing.
Samples for PV testing shall be taken from the Production Demonstration Run and manufactured on production tooling and processes at the production rate and off the home line.
All PV testing is to be completed per the DVP&R.
Customer Engineering shall review and approve PV testing according to the DVP&R.
Design Verification Plan and Report (DVP&R) shall be used for all PV testing and the RESULTS shall be reviewed with the customer.
B1. The Supplier shall have detailed procedures and/or test methods to:
Properly detect BSRs without subjectivity
Define boundary samples
B2. The Supplier shall have training/certification for BSR operators (. hearing tests, etc.)
B3. For PV approval the followings shall occur:
Component level PV testing shall have been successfully completed on all test samples.
The PV test samples shall be taken from the Production Demonstration Run. The PV test part selection process depends upon the Customer strategy. If a single production line/tool will be qualified, the PV test components should be selected randomly from the Demonstration Run. If multiple production lines/tool will be qualified simultaneously, a portion of the PV test components should be randomly selected from each production lines/tools in proportion to that line’s contribution to the total production. If multiple production lines/tools will be qualified separately, the PV test components may be randomly selected from the first production line’s/tool’s Demonstration Run.
- 34 -
表格:
在附带CD中
生产线节拍演示评价/跟踪表
测量系统验证报告
生产演示结果
B. 产品验证 (PV) 试验
说明: 嗡嗡声、吱吱声、卡喀声（BSR）与噪声、振动和不平顺性是产品验证试验的一部分。
.
应查明嗡嗡声、吱吱声、卡喀声（BSR）还有噪声、振动和不平顺（NVH）问题的原因并进行评估和记录。
分析应该包括对匹配件的影响评估。为了降低/消除和/或监控任何不可接受的BSR/NVH特征，应在DFMEA, PFMEA, DVP&R和控制计划中说明潜在的原因。
供应商负责的零部件级的产品验证（PV）试验计划和试验结果应由顾客进行评审和批准。
供应商的责任:
注1:
应在设计验证DV试验成功完成后再进行PV试验。
PV试验的样品应是在生产演示运行中抽取的并且是用批量生产的工装和过程以批量生产的线速生产出来的产品。
所有PV试验将按照DVP&R来完成。
顾客工程部门应根据DVP&R来评审和批准PV试验。
对于所有PV试验，应使用设计验证计划与报告 (DVP&R) ，并且应与顾客共同对试验结果进行评审。
B1. 供应商应具备详细的程序和/或试验方法以：
客观恰当地检测BSR。
定义边界样品。
B2. 供应商应为BSR操作人员提供培训/认证 (例如： 听力测试等)。
B3. 进行PV批准时应含如下内容：
在所有试验样品上应成功通过了零部件级的PV试验。
PV试验样品应从生产演示运行中抽取. 根据顾客策略来确定PV试验零件选择程序。如果对单条生产线/工装进行认证，PV试验所用零部件应从演示运行中随机抽取。如果对多条生产线/多台工装同时进行认证，应该从每条生产线/工装上按照那条线/工装的比例分别随机地抽取部分PV试验零件。如果对多条生产线/多台工装分别进行生产认证，可以从生产线/工装的首次演示运行中随机抽取PV试验零部件。
- 34 -
However, the Customer and the Supplier shall place special emphasis on all
characteristics that could effect the outcome of PV testing and ensure that subsequent production lines/tools maintain average & capability comparable to the first line/tool qualified. Otherwise, a separate PV test may be required for each production line/tool.
The DVP&R shall be updated with the component level PV test results.
B4. Validation testing shall be completed annually (each model year) as specified in the DVP&R, unless waived in writing by the Customer. A waiver shall be obtained each model year that the annual validation will not be performed.
NOTE 1: For addition information refer to DaimlerChrysler TS16949, section , Validation of process for productions and service provision.
NOTE 2:
Production Validation Testing refers to engineering tests that validate that products made from production tools and processes meet engineering standards.
C. PSW (PPAP)
SUPPLIER RESPONSIBILITIES:
C1. 100% PPAP approval required by S1 (Quality Gate C) for all critical components and all modules.
C2. At the successful completion of all 20 elements including the Line Speed Demonstration and PV
testing, the Supplier is required to submit to the customer a Part Submission Warrant (PSW).
Submission Levels -
The supplier shall submit the items and/or records specified by the level as requested by the customer:
DaimlerChrysler Specific requirements ONLY recognize Level 2 and Level 4:
Level 2 – Warrant with product samples and limited supporting data submitted to the customer
Level 4 – Warrant and other requirements as defined by the customer
NOTE: See attached CD for forms and PPAP table.
NOTE: In some instances the customer may require different PPAP submission level. Refer to the AIAG
PPAP Fourth Edition manual for specifics.
Full Approval - Indicates that the part or material meets all customer specifications and requirements. The supplier is therefore authorized to ship production quantities of the product subject to releases from the Customer scheduling activity.
Production Part Approval Process (PPAP) is always required prior to the First Production Shipment of product in the following situations:
1. New parts or modified carry-over products.
2. Parts resourced from one supplier to another
3. Parts or product modified by engineering change to design, specifications, or materials.
4. Source change for sub-contracted parts, materials, or services (plating, heat treat, etc.).
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无论如何，顾客和供应商应格外关注所有可能影响PV试验结果的特性，并且要保证后面的生产线/工装能够维持在平均水平并且能力与第一条认证过的生产线/工装可比。否则，需要对每一条生产线/工装进行独立的PV试验。
• 当零件级PV试验产生结果后，设计验证计划与报告（DVP&R）应随之更新。
B4. 应按照DVP&R的要求开展年度(每个车型年)验证试验，除非获得顾客的书面豁免。某年度验证试验的免除应依据该年的顾客书面豁免。
注1： 关于额外信息，可参考戴姆勒•克莱斯勒 TS-16949第部分：生产和服务提供过程的验证。
注2:
产品验证试验指的是为了验证生产工装和过程生产出来的产品能否满足工程标准而进行的工程试验。
C. 零件提交保证PSW (PPAP)
供应商的责任:
C1. S1（质量门C）时，100%完成所有关键零件和所有总成件PPAP批准。
C2. 在包括生产线节拍演示和产品验证试验在内的20个要素成功完成时，供应商应该向顾客提交一份零件
提交保证 (PSW)。
提交级别 －
供应商应按照顾客要求的级别提交文件和/或记录：
戴姆勒•克莱斯勒的特殊要求仅仅认可级别2和级别4：
级别 2 – 向顾客提交保证书和产品样品及有限的支持数据
级别4 – 提交保证书和顾客规定的其它要求
注：参见附带CD中的表格及PPAP手册中的表格。
注：在某些情况下顾客可能要求不同的PPAP提交等级。 详情参照AIAG PPAP第四版手册。
完全批准 -
指零件或材料满足顾客所有技术标准和要求，供应商才能得到授权按顾客进度及数量要求发运产品。
在下列情况下，在首批生产的产品发运前总要进行生产件批准程序(PPAP)：
1. 新零件或更改的过渡产品。
2. 零件供货厂家更改。
3. 零件或产品的设计、技术标准或材料发生工程更改。
4. 外协零件、外协材料或外协服务发生了更改 (如电镀、热处理等)。
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5. Use of optional material or construction different from initial part approval.
6. Production from new or modified tools.
7. Production following refurbishment, rearrangement or relocation of existing tooling or equipment,
(including new or additional manufacturing locations).
8. Production following a change in process or manufacturing method.
9. Product released after tooling has been inactive for 12 months or more.
REPORTS: Line Speed Demonstration
Reports will include the following:
Number of Line Speed Demonstration:
Required.
Scheduled
Completed
Approved
Number of Line Speed Demonstration on-site visit failed:
Once
twice
REPORTS: PSW (PPAP)
Reports will include the following:
Number of PSW (PPAP) required
Number of PSW (PPAP) completed
Number of PSW (PPAP) approved
FORMS:
PSW form is included in the ATTACHED CD
- 36 -
5. 使用了可选的材料或与最初获批零件的结构不同。
6. 使用新的或更改了的工装进行的生产。
7. 目前的生产工装或设备被翻新、重整（布置）、工装设备搬迁后再进行生产（包括在新的或其他的制造地点进行生产）。
8. 在过程或制造方法更改后进行的生产。
9. 生产工装停用了12个月或更长时间后再次投入生产。
报告: 生产线节拍演示
报告包括下列内容：
生产线节拍演示的数量：
要求的
计划的
完成的
已批准的
现场考察时生产线节拍演示失败的次数：
一次
两次
报告: 零件提交保证PSW (PPAP)
报告包括下列内容：
要求的零件提交保证 PSW (PPAP)数量
完成的零件提交保证PSW (PPAP)数量
批准的零件提交保证 PSW (PPAP) 数量
表格:
零件提交保证PSW表格包含在附录中。
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SUPPLIER QUALITY ASSURANCE PROCESS
(SQAP)
ELEMENT “19” – FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC)
PURPOSE: The purpose of FPSC is to verify that initial production shipments meet customer drawings
and Engineering Standards requirements. It is intended to prevent potential part problems at selected suppliers during first production shipments to ensure a successful launch.
SCOPE: The FPSC program requires the Supplier to provide statistical evidence of conformance to
special product and/or process characteristics for parts that were requested by the customer prior to the shipment of components to the customer.
SUPPLIER RESPONSIBILITIES:
A1. Ensure that the First Production Shipment Certification (FPSC) documents and the initial
production shipments meet DaimlerChrysler drawing and Engineering Standards requirements.
A2. First Production Shipment Certification (FPSC) documents that initial production shipments meet all DaimlerChrysler drawing and Engineering Standards requirements . The FPSC program requires the Supplier to provide statistical evidence of conformance to special process characteristics prior to the shipment of components to DaimlerChrysler receiving plants. Certification is for a minimum of 2000 parts or for a specific time period specified by the customer.
100% of the FPSC parts shall be inspected for conformance to special product characteristics and key process characteristics shall be included. Customer shall approve # of certified parts below 2000.
A3. All parts/components regardless of risk shall be held to FPSC requirements. It is the responsibility of the Customer to identify those requirements.
A4. All completed FPSC forms shall be made available for review by the Customer at the
Customer’s request.
FORMS:
Included in the ATTACHED CD
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供应商质量保证程序
(SQAP)
要素 “19” – 首次生产发运鉴定 (FPSC)
目的: 首次生产发运鉴定的目的是验证最初发运的生产件是否能够满足顾客图纸和工程标准的要求。 它的目的是对选定的供应商在首次发运生产件期间防止发生潜在零部件问题，保证成功投产 。
范围: FPSC程序要求供应商在向顾客发运零件之前，对顾客要求的某些特殊产品和/或零件的过程
特性提供符合性统计证据 。
供应商的责任:
A1. 保证首次生产发运鉴定（FPSC）文件能够满足戴姆勒•克莱斯勒的图纸和工程标准要求。
A2. 首次生产发运鉴定(FPSC)记录了首次生产发运满足戴姆勒•克莱斯勒图纸和工程标准要求。 FPSC 程序要求供应商在向戴姆勒•克莱斯勒收货工厂发货之前，应提供统计证据表明其过程特殊特性符合要求 。
鉴定针对至少2000件零件或针对顾客指定的一段特殊时间。100%FPSC零件应检验特殊产品特性的符合性并且应包括关键过程特性。当鉴定数量低于2000件时，应经由顾客批准 。
A3. 所有零件/零部件，无论风险大小， 都应该满足FPSC的要求。明确这些要求是顾客的职责。
A4. 当顾客要求时，所有已经完成的FPSC表可随时得到以供评审。
表格:
含在 附带CD中。
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SUPPLIER QUALITY ASSURANCE PLAN
(SQAP)
ELEMENT “20”– SUPPLIER WARRANTY PARTS
PURPOSE: To understand the Failure Modes occurring in the field and enable implementation of the Corrective Action Process to eliminate the issue on vehicles built today and on vehicles that will be built in the future.
SCOPE: Applies to all parts supplier warranty.
SUPPLIER RESPONSIBILITIES:
A1. Retrieve parts from the Customer.
A2. Perform Root Cause Analysis.
A3. When Root Cause is determined to be Supplier responsible, supplier is required to submit a completed
Corrective Action Plan within two days of identification of the Root Cause.
A4. Participate in resolution of non-supplier responsible warranty issues with the customer Engineer.
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供应商质量保证
(SQAP)
要素 “20”– 供应商保修件
目的: 了解在最终用户处发生的失效模式，采取纠正措施以避免在现在和未来生产的车辆上重蹈覆辙。
范围: 适用于所有的供应商保修件。
供应商的责任:
A1. 从顾客处追回零件。
A2. 进行根本原因分析。
A3. 如根源归咎于供应商时，供应商应在根源确定的两天内提交一个完整的纠正措施计划。
A4. 参与顾客工程部对非供应商责任的保修问题的解决过程。
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INDEX
A
Appearance ……………………………………………………………………………………….13
Approved by (Endorsed) ...……………………………………………………………………… i
Assessment Report …………………………………………………………………………..…. 2
____________________________________________________________________________
B
Boundary Samples ………………………………………………………………………………13
Buzz-Squeak-Rattle (BSR) ………………………………………………………….………… .8, 34
____________________________________________________________________________
C
CATIA …………………………………………………………………………………………… 7
Containers ………………………………….…………………………………………………… 10
Control Plan ……………………………………………………………………………………...18, 24
Corrective Action Process ……………………………………………………………………....28
____________________________________________________________________________
D
DFMEA ……………………………………………………………………………………………8
DVP&R (Design Verification Plan and Report)………………………………………………..34
____________________________________________________________________________
E
Engineering Standards ………………………………………………………………………….7
Error Mistake Proofing…………………………………………………………………………..18
Examples ……………………………………………………………………………….………...Attached CD
____________________________________________________________________________
F
First Production Shipment Certification (FPSC) ……………………………………………..11, 37
First Time Capability (FTC) …………………………………………………………………….23
Forever Requirements ………………………………………………………………………….26, 31, 32
Forms ………………………………………………………………………………….………….Attached CD
Forward ……………………………………………………………………………………..…….ii
____________________________________________________________________________
G
Gages …………………………………………………………………………………………….20
Guiding Principles ……………………………………………………………………………….ii
____________________________________________________________________________
I
Incoming Material Plan …………………………………………………………………………25
____________________________________________________________________________
L
Layered Process Audit (LPA) Plan ……………………………………………………………19, 29, 30
Line Speed Demonstration …………………………………………………………………….33
Line Speed Demonstration Form ………………………………………………………………33a
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目录
A
外观 …………………………………………………………………………………………………………….……13
批准人 ……………………………………………………………………………….……………………………….i
评估报告 ………………………………………………………………………………..…….. …………….…… ..2
B
边界样品 ……………………………………………………………………………….……. …………….…. …. 13
嗡嗡声-吱吱声和卡喀声(BSR)……………………………………………….………………….……. …………..8, 34
C
CATIA …………………………………………………………………………………………….……. …………..7
容器……………………….………………………………………………….…. ….……. …………………… .. 10
控制计划 …………………………………………………………………………………....... . …………….…. .18, 24
纠正措施程序 …………………..………………………………………………………..….. . ……………. …. 28
D
DFMEA 设计失效模式与效果分析……..……………………………………………..……. …………….…. ….8
DVP&R (设计验证计划与报告)…………………………..…………………………………. . …………….…. ..34
E
工程标准…………… …………………………………………………………………………. …………….… ….7
防误/防错 ……………….…………………………………………………………………. …………….… .18
举例 ……………………………………………………………………………….……….…. . …………….…. …附CD
F
首次生产发运鉴定(FPSC) ………………………………………………………….…. . …………….………….11, 37
首次交验合格率 (FTC) ………………………………………………………………………….…. . …………….23
永久性要求 …………………………………………………………………………………... ….…. . ……………26, 31, 32
表格 ……………………………………………………………………………….……….. ….…. . ………………附 CD
发运 ……………………………………………………………………………………..….... .…. . ……………….ii
G
量检具………………………………………………………………………………………………………………...20
指南……………………………………………………………………………………………………………… ….ii
I
来料计划 ………………………………………………………………………………….…. . ………………….. .25
L
逐层过程审核(LPA) 计划……………………………………………………………………. .…. . …………...…19, 29, 30
生产线节拍演示 ……………………………………………………………………………….…. . ………… ..….33
生产线节拍演示表 …… …… ……………………………………………………………….…. . ..……33a
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M
Management Status Review …………………………………………………………………….4
Mission ………………………………………………………………………………………….. ii
____________________________________________________________________________
O
Objective & Targets …………………………………………………………………………….. ii
On-Site Line Speed Demonstration Form ……………………………………………………33a
Operator Instructions …………………………………………………………………………….15
Operator Training …………………………………………………………………………………16
Organization ………………………………………………………………………….…………. ii
Outgoing Material Plan …………………………………………………………………………. 26
____________________________________________________________________________
P
Parts Inspection Standards (PIS)……………………………………………………………… 12, 13, 26
Packaging and Shipping …………………………………………………………………………10
Part Identification ………………………………………………………………………………… 9
PFMEA ………………………………………………………………………………………….. 16, 17, 26
Preventive Maintenance Plan …………………………………………………………………. 19, 21
Process ……………………………………………………………………………………………..ii
Process Capability …………………………………………………………………………………22, 23
Process Change Request ..…………………………………………………………………… ..31
Process Flow ………………………………………………………………………………………14
Process Monitoring ………………………………………………………………………………..29
Production Demonstration Run ……………………………………………………………….....33, 34
Product Validation (PV) Testing …………………………………………………………………34
PPAP …………………………………………………………………………………………….....35
PSW ………………………………………………………………………………………………...35
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Quality Gates ……………………………………………………………………………………...4, 5
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Safety Characteristics ………………………………………………………………………….. .11
Scope ……………………………………………………………………………………….……. ii
Sub-Supplier ………………………………………………………………………….………….. 6
Supplier Quality Assurance Schedule (SQAS) .………………………………………………3, 5a
Supplier Contacts …………………………………………………………………………………1
Supplier Representative …………………………………………………………………..……..1
Supplier Warranty Parts………………………………………………………………………… 38
Support from DaimlerChrysler ……………………………………………………….…………..ii
Special Characteristics ………………………………………………………………………… .11
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Table of Contents…………………………………………………………………………………..iv
Test Samples Size and Frequencies …………………………………………………………...27
Tier I ………………………………………………………………………………………………..6
Tooling Equipment and Gages ………………………………………………………………….20
Traceability ………………………………………………………………………………………...9, 25, 26
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管理状态评审……….. ………………………………………………………………………………………....4
任务 ……………………………………………………………………………………………………………...ii
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目的与目标…… …………………………………………………………………………………………….…..ii
现场生产线节拍演示表………………………………………………………………………………………... 33a
操作指导书…… ……………………………………………………………………………………………….. 15
操作者培训 ………………………………………………………………………………………………….... .16
组织 ………………………………………………………………………….…………………………………..ii
出料计划 ………………………………………………………………………………….. ……………………26
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零件检验标准(PIS)…………………………………………………………………….……………………..…12, 13, 26
包装与发运 ……………………………………………………………………………………. ……………….10
零件标识 …………………………………………………………………………………………………………9
过程失效模式与后果分析 ………………………………………………………….. ………………16, 17, 26
预防性维护保养计划 …………………………………………………………………………………………. 19, 21
过程 ……………………………………………………………………………………………………………. ii
过程能力 ………………………………………………………………………………………………..…. …. 22, 23
过程更改申请…………………………………………………………………………………………………... 31
过程流程………………………………………………………………………………………. …………….. 14
过程监控 ………………………………………………………………………………………………………. 29
生产演示运行 ……………………………………………………………………………..………………….. 33, 34
产品验证(PV)试验 ………………………………………………………………………….…………………. 34
生产件批准程序PPAP …………………………………………………………………………………………35
零件提交保证PSW …………………………………………………………………………………………….35
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质量门 ………………………………………………………………………………………………………….. 4, 5
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安全特性 …………………………………………………………………………………………………….…..11
范围 ……………………………………………………………………………………….……. …………. …..ii
分供商 ………………………………………………………………………….……………... ………………. 6
供应商质量保证进度计划(SQAS) .…………………………………………………………………………. .3, 5a
供应商联系方式 …………………………………………………………………………………………………1
供应商代表 ………………………………………………………………….……………..……. ………….….1
供应商保修件….…………………………………………………………………………..…….. ……………. 38
戴姆勒•克莱斯勒支持……………………………………………………….…………. .…….. .. ………........ii
特殊特性 ………………………………………………………………………………………. ……….. …… .11
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目录…………………………………………………………………………….…………………………. .. iv
试验样本的大小与频次 ……………………………………………………………………..…. ………………27
一级供应商……………………………………………………………………………………………………... .6
工装设备与量检具 …………………………………………………………………………….... ……………..20
可追溯性………………………………………………………………………………………………………….9,25,26
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