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SQA Manual P2104 edition 7 - July 2005 (Chinese)

供应商质量保证第7版—2005年7月

零缺陷是法雷奥为达成顾客满意而实行全面质量的目标。只要我们的顾客确信法雷奥不会在质量上妥协,他们就会把合同交给我们,顾客的合同决定着我们的未来。在作为法雷奥企业文化基础的五轴心(5 Axes)中,供应商一体化(Supplier Integration)是保证供应商和法雷奥一起努力达到零缺陷这一共同目标的关键。

供应商质量保证手册描述了法雷奥对供应商的选择以及对采购平台的管理的方

针和工作流程。为了达成我们的目标以达到使顾客满意,我们必须严格执行这些方针和流程。

Jean Christophe Figueroa

法雷奥集团副总裁,采购

目录法雷奥的供应商质量保证过程分成三个部分:SQAE, PQA, CQI

I – SQAE (Supplier Quality Aptitude Evaluation):供应商质量能力评价 5

1 目的――――――――――――――――――――――――――― 5

2 SQAE 程序――――――――――――――――――――――――11

供应商预评价―――――――――――――――――――――――11

3 跟踪审核―――――――――――――――――――――――――12

4 审核频次―――――――――――――――――――――――――12

II-PQA (Product Quality Assurance):产品质量保证――――――――13

1 目的―――――――――――――――――――――――――――13

2 PQA 程序―――――――――――――――――――――――――14

产品质量保证计划(QAP.pp)――――――――――――――――14

PQA 程序―――――――――――――――――――――――――14

应用范围―――――――――――――――――――――――――-16

步骤1:供应商选择――――――――――――――――――――― 17

步骤2:与供应商确定法雷奥要求文件――――――――――――― 17

步骤3:确定和接受质量保证文件(QAF)――――――――――― 17

步骤4:生产过程认可(全天试生产/ 过程审核)―――――――17

步骤5:首样认可―――――――――――――――――――――18

步骤6:试用期――――――――――――――――――――――19

步骤7:PQA 管理―――――――――――――――――――――20

3 流程图――――――――――――――――――――――――――21 III-CQ I (Continuous Quality Improvement) :质量持续改进――――22

1 目的―――――――――――――――――――――――――――22

2 质量事故处理流程―――――――――――――――――――――23

质量事故的定义――――――――――――――――――――――23

质量事故的处理――――――――――――――――――――――24

3 质量,价格,交货情况监测―――――――――――――――――26

PPM,PQA率和服务率的定义―――――――――――――――26

4 价格,质量和交货改进合同―――――――――――――――――28

附件――――――――――――――――――――――――――――――29 附件1:QAP.pp导引―――――――――――――――――――29

附件1bis:电子版QAP.pp导引―――――――――――――――31

附件2:针对不同类别供应商,SQAE / PQA的应用范围――――32

附件3:价格,质量和交货改进合同―――――――――――――33

附件4:记分卡样本――――――――――――――――――――36

I - SQAE

(Supplier Quality Aptitude)

供应商质量能力评价1 目的

有效的的质量体系对生产优质产品十分重要。

它必须:

●保证完成的任务和传递的信息的可靠性(尤其是在与客户/ 供应商的结合界

面上),

●推动持续改进,

●确保企业的know-how延续下去。

它基于:

●一个明确规定和展示出来的的质量方针,

●一个有能力在产品寿命周期各个阶段(符合法雷奥项目开发各个步骤)保证产

品质量的组织,

●期望与法雷奥合作并一起进步

供应商质量能力评价是法雷奥对潜在的或已经在采购平台内的供应商进行质量评价程序。包括:

上述审核的结果会被存放在SuMo (Su pplier Mo nitoring)(集团内部的供应商管理数据库)的 “ Supplier Evaluation” 菜单下,审核的结果将得到法雷奥所有分公司的承认。

预选择程序将对供应商做出等级的评定:

* 供应商必须在12个月内达到Eval ≥80%,承诺并开始实际行动,以取得汽车行业的质量体系证书或V1000证书,并具备一个合格的生产过程。否则,将启动删除该供应商的程序。

对制造商和分包商的预选择流程图表

供应商未通过预选择

供应商未通过预选择

V1000 Ed.5 审核

选择条件

所有VIP的分包商和制造商都必须取得V1000证书。

对开发商的预选择流程图表

供应商未通过预选择

供应商未通过预选择

V1000 Ed.5 Suppliers审核

不能认可为开发商

选择条件

2 SQAE 程序

供应商分三类:

所有潜在的供应商与采购平台内现有同领域供应商作比较时必须接受实地的评价。评价标准如下:

?战略和管理

?概况:财务稳定性,最小生产量,产品/ 市场排位,等

?研发状况(仅对开发商)

?生产

?质量

?物流

?竞争力

?交流的能力

同样的,如果现有的供应商无法满足上述8项评价标准的要求,也将被从采购平台上剔除。使用EVAL 2004标准对这8个方面进行评价。供应商在每个方面的得分必须不小于50。总分必须不小于70并且所有问题都必须得到答复。

开发商:

开发商能力评价-SDAE (参见开发商能力评价程序VAQ 2107)将由采购部门和研发部门共同完成,以决定该供应商是否有能力成为开发商。此情况下使用SDAE2004进行评价,供应商必须在各方面得分不低于50。总分必须不小于70并且所有问题都必须得到答复。

3 跟踪审核

跟踪审核的目的(参见供应商质量能力评估程序VAQ 2101)是在首次审核后,确认纠正措施实施的进度。

下列情况下必须实施跟踪审核:

?在供应商被现场评价为“II”级后六个月内进行。如果跟踪审核确认所有的纠正措施都得到实施并能解决所有的关键问题,该供应商即被评价为“I”级。?如果有必要进行第二次跟踪审核,必须在供应商被现场评价12个月内进行。

4 审核频次

供应商现场至少每两年要接受一次EVAL 2004评审,至少三年要接受一次质量体系审核。

当供应商的组织结构发生重大变化或者明显由于质量体系失效导致发生严重的质量事故或重复发生质量事故,则将安排一次新的审核。

法雷奥建议所有的供应商得到ISO TS 16949质量体系证书,或采取必要步骤获得该证书。

II - PQA

(Product Quality Assurance)

产品质量保证1 目的

产品质量保证被用来确保产品质量的长期稳定。它将减少法雷奥工厂的进货检验工作,但并不减轻供应商对产品质量的责任。

法雷奥集团的目标是100%达成PQA供货

2 PQA 程序

QAP.pp (Quality Assurance Plan for product/process)

产品/过程质量保证计划

产品质量保证程序从草拟产品/过程质量保证计划(QAP.pp)开始,以确保法雷奥的产品质量。

QAP.pp 包括:

●法雷奥要求文件(VRF),

●质量保证文件(QAF),

●首样(I.S.)文件,

●质量监控文件(QMF)。

QAP.pp清单参见附件1。

PQA 程序

产品质量保证程序有7个步骤。这些步骤应用于主机厂新项目(法雷奥与供应商同时进行项目开发-译者注)及已经批量生产的零件(仅需法雷奥的供应商进行项目开发-译者注)。

对于主机厂的新项目,供应商的产品质量保证7步骤对应法雷奥的项目开发5个阶段,如下图:

法雷奥质量审核程序书:A 2104

-15 -

应用范围

* 同类工艺产品是指由同一供应商严格按照同样的生产流程甚至使用同样的工夹具,为法雷奥生产的功能相同的零件,视具体情况而定。

同类工艺产品的供货频次(如:每月一次)不免除供应商实施VPS要求的职责。步骤1:供应商选择

潜在供应商得到一套产品功能要求规格书(开发商)或技术要求规格书(制造商)。此阶段,相关的要求有:

●产品规格书

●目标价格

●质量与供货条件

均将被定义或重申。

即使某种零件已经在批量生产,如果有新的项目也要用到该零件,进行新项目时必须更新上述要求。

最能符合上述要求的供应商将得到合同。

步骤2:与供应商确定法雷奥要求文件

法雷奥要求文件细述了上述3点要求,并且列出在整个PQA过程中需要供应商和/或法雷奥提供的文件种类。法雷奥要求文件中所有的要求在步骤2阶段由法雷奥和供应商共同草拟并商讨。

步骤2结束时,法雷奥汇总编制法雷奥要求文件(VRF),发放给供应商,等待供应商确认。

步骤3:确定和接受质量保证文件(QAF)

质量保证文件是对法雷奥质量要求的正式的答复。质量保证文件由供应商出具,与法雷奥共同按照法雷奥要求文件进行审核。一旦审核认可后,供应商承诺遵守此文件。如果发生产品或工艺更改/ 改进,包括生产转移,供应商需提交法雷奥正式认可。

此步骤结束,供应商开始投入生产用工装。

步骤4:生产过程认可(全天试生产/过程审核)

认可的目的是确保制定的质量程序对该产品的整个生产寿命周期都是适合且有效的。生产过程的认可可能质疑已制定的质量程序文件。

本步骤包括:

●质保文件(QAF)的确认(如必要),

●全天试生产,

●全天试生产时进行过程审核。

过程审核仅在批量生产的工艺条件(工装,生产条件)下进行方才有效。

全天试生产后下列报告必须出具:

●全天试生产报告:状况、产品及废品数量、缺陷分析、生产线速度,等

●过程审核报告,

●试验报告(如果供应商是开发商或法雷奥要求文件(VRF)中有要求),

●检验报告,

●过程能力(Cmk≥2,Ppk>1.67, 目标Ppk≥2)

只有当过程审核的结果令人满意(参见VAQ 2102 过程审核程序)时,该工艺才被法雷奥认可。否则,供应商要提交纠正措施计划,法雷奥会再做一次跟踪审核。

首样必须在全天试生产时抽取,采用批量供货的包装,与法雷奥要求文件中规定要求的资料一起送到法雷奥。

全天试生产定义按程序文件VAQ 2102。

供应商必须按照控制计划中定义的频次定期进行过程审核。法雷奥有权随时要求查看审核报告和纠正措施计划。

法雷奥至少每两年要对供应商进行一次过程审核,并保留在认为合适的时间随时进行审核的权力。

步骤5:首样认可

首样(I.S.)认可的目的是检查产品(性能,特性,可靠性,过程能力,试验,等),生产线和工装设备是否符合规格书要求。

法雷奥按照认可计划对首样进行检验从而认可该产品。

只有内部认可合格后才可宣布法雷奥认可供应商首样。

如供应商首样未认可,不允许零件批量供货。

步骤6:试用期

对所有适用PQA的零件,本步骤是必须的。

它的目的是优化和验证进货检验方式,特别是对不适用PQA的零件。

首样认可后,在整个试用期内要对供货产品做进货检验。

试用期至少为2个月且涉及至少6个生产批*的零件。

*生产批的批量大小在制定QAF时与供应商一起确定。

试用期内法雷奥对按照QAP.pp要求生产的产品进行检查,确认是否没有任何不符合(无论何种原因造成)。

发生不符合后,供应商提交相应的纠正措施,经法雷奥认可,并由供应商有效实施后,该零件重新开始新的一轮试用期。

步骤6结束后,试用期内的检验记录将归入QAP.pp。

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春季学期小学校历表.doc

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