Business Survey
GENERAL BUSINESS
Organization and Management
Support Questions:
1. Provide updated organization chart for your business including global organizations.
?Identify who would be designated to GEA account.
?Will they be fully dedicated or part-time?
?What is the tenure of the Engineering organization?
?Who is the ultimate owner of a project with GEA?
2. Identify key staff members and responsibilities.
3. Outline responsibilities of key staff relative to operation objectives.
4. Does supplier have a centralized purchasing organization? No_____ Yes_____
Explain:___________________________________________________________________
Scoring:
1. Limited organization with roles of key players not clearly defined. Company would have difficulty supporting a new
program start-up without significant staffing and/or plant and equipment expenditures.
3. Organization appropriate for scope of current business. Roles are clearly defined and key players have ability to lead
company to current objectives. Company has ability to grow, but would have to expand staff and facilities to
accommodate.
5. Organization is currently staffed to handle additional business. Roles are clearly defined and top positions are staffed
with leaders capable of successfully growing the company. Company is capable and willing to make expenditures to grow business.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____4_____) (Category Score__________) = Total Score __________ Operational Goals
Support Questions:
1 What is your company mission? Rank in priority order your company?s key measurements (sales, availability, etc.,
2. What are your current year business objectives?
3. Compare current year objectives to historical performance.
4. Discuss business reinvestment. Give examples of domestic and international reinvestment.
5. Discuss your long term business strategy.
6. Are there any outstanding legal issues facing your company that could potentially hamper your ability to supply
product under quoted circumstances?
7. What countries outside the U.S. do you currently conduct business in?
8. Does your company have a legal and policies compliance program?
9. Do you use or have you ever used child, forced or prison labor in the manufacture of any products?
10.Are there any outstanding regulatory or safety complaints still pending?
Scoring:
1. Key measurements are neither defined nor communicated beyond staff level. Individual roles and
responsibilities not defined to include accountability for meeting objectives. Goals are limited to
short term with little long term planning evident.
3. Key measurements are defined and communicated to all levels, and there is clear accountability for all
key measurements. Long and short term strategic planning is part of total business plan.
5. Key measurements are defined in detail and communicated and integrated into work plan of each
employee. Progress to goals are updated on regular basis to entire business. Strategic long term
growth is an important part of business plan.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score__________) = Total Score _________
Industry
Support Questions:
1. Describe your major competencies.
2. What type of global competition do you have? Who are they?
3. Who are major custo mers and what % of suppliers? business do they represent?
4. Who are major countries/markets of distribution and what % of business does each represent?
5. What are the brand names, market share, and average annual growth rate over the past five years
for major products sold in the United States?
6. What is the market share for supplier?s major channels of distribution?
7. What is supplier?s major new product and growth initiatives? (Line extensions, new lines/features/technologies)
8. What are your plans to capitalize on these growth opportunities?
9. What % of your sales is OEM/private label?
10. Name OEM customers and length of time served.
- Do you dedicate resources to serve these customers?
Scoring:
1. Business positioned to maintain small share of total market or niche business, with little funding for planning
for future growth or acquisition. Current product offerings provide limited growth potential.
2. Business is positioned well relative to others in industry, although they may not be one of the key suppliers within
the industry. Product line offerings could provide opportunities for future growth potential.
5. Company is clearly an industry leader and accounts for an above average proportion of the total industry output
Product line offerings are innovative and varied enough to assure their market place leadership.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score__________) = Total Score __________ Program Execution
Support Questions:
1. What major programs are currently underway in your facility?
2. What was the last major program your company completed?
How long from start to finish?
3. What is your history for on-time, on-budget programs?
4. Are there any other major programs currently under consideration by your company?
5. Outline program management personnel and resources available for program implementation.
1.Does supplier utilize a New Product Introduction (N.P.I.) process with scheduled technical and product reviews? Scoring:
1. Company has not implemented a mid/major program in recent past. Resources would limit scope
of any program undertaking. GEA would have to lend considerable resources to be assured of
successful implementation.
3. Company has successfully implemented mid/major programs in recent past. Resources would limit
Programs to small or mid-sized. GEA would require a detailed implementation plan along with
corrective action program before business could be awarded.
5. Company successfully implements mid/major programs on a continuing basis. Resources are either
available or could be obtained to assure successful execution of program. GEA?s resource involvement
would be limited primarily to program management interface.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score__________) = Total Score __________ Customer Interface
Support Questions:
1. Who are your major customers? Break down sales % by customer.
2. How do you service your key customer accounts?
3. Do you measure each customer on a separate profit and loss (P&L) statement?
4. Do your customers measure you? How?
5. How do you measure yourself?
6. Give examples of current reports and company performance.
7. Do you track the following data internally?
a. On-time ships
b. Availability by product
c. After-market parts availability
d. SCR tracking
Scoring:
1. Company works primarily through blanket orders and has minimal contact with customer and supplier base.
Quality, delivery and/or other issues are generally reactively handled on case by case basis.
3. Company employs a representative who, as the primary customer contact. Personally handles most quality,
delivery or customers questions. The representative will involve his plan resources on an as needed basis.
Customer/supplier relationships are recognized as being important and are handled in a professional and amiable
manner.
5. Customer satisfaction is a key operational objective, and Company has systems in place to measure customer
approval as well as supplier performance. Company has established programs that proactively address customer
satisfaction as well as supplier performance.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____3_____) (Category Score__________) = Total Score __________
Pricing - Also see ‘Productivity’ in Technology section
Support Questions:
1. Are you willing to share your cost structure with your customers?
2. What types of productivity or cost savings programs do you engage in?
3. Do you pass on cost savings to your customers?
4. Describe the size, organizational structure, and role of your purchasing department.
5. What are your primary goals and objectives of your purchasing department and how is it measured?
6. What are the qualifications of the personnel in the purchasing department?
7. Describe your deflation/cost savings history during the past few years.
8. Supply pricing history on several core models.
Scoring:
1. The current structure and strategy of the company does not support being a low cost producer.
3. Company goals include productivity and cost saving initiatives, but efforts are not fully maximized.
5. The company aggressively pursues productivity and costs saving initiatives internally and with their supply base by
providing the structure and training to accomplish.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____4_____) (Category Score__________) = Total Score __________
QUALITY
Management & Goals
Support Questions:
1. What are the Corporate Quality Objectives? How are they communicated to all employees?
2. How is Quality Department organized? (See organization chart from General Business Survey)
?Is Quality department organization well defined/functionally sound?
?Are there good lines of responsibility among all functions?
?Who has key contributor expertise and experience?
3. What are Quality Goals for the business? Are they documented? Are they challenging?
4. What is Service Call Rate (SCR) goal for products?
5. What is the SCR for products shipped to the United States?
6. What is the SCR of products shipped within the country where products are manufactured?
7. How is SCR determined/calculated?
8. Is there a long term strategy to achieve SCR goals?
9. Has a 6 sigma philosophy been incorporated into new designs and used for problem solving and to identify
opportunities?
10. Is there a 6 Sigma movement in the business?
11. What level of involvement does the management team have in dealing with quality issues?
12. Are quality costs tracked?
Scoring:
1. Quality organization in place, but there is no evidence of authority, vision, or a strong relationship to business
measurements
3. Appropriate quality goals in place but the organization is largely inexperienced or not fully staffed. Management is
committed but resources are not available for needed upgrades.
5. Well defined goals and measurements in place; field data and quality costs are understood, acted on, and measured Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ___5____ ) ( Category Score _________) = Total Score __________
Planning & Documentation
Support Questions:
1.Is there a comprehensive Quality Manual? Is latest revision up-to-date?
2.Is it accessible to all employees, and approved by upper management?
3.Are there detailed quality instructions posted at the work stations in the appropriate language?
4.Is this facility ISO Approved? 9001? 9002? 9003?
5.Is this facility approved by another GE business?
6.Who reviews contracts prior to acceptance to ensure customer requirements are understood?
?Evaluate ability of personnel to interpret and communicate in English?
?Evaluate ability of personnel to communicate to GEA? Cross functionally?
?Does sales organization interface with Design Engineering? Manufacturing?
7.Are quality plans developed for each product? Who has responsibility?
8.Are critical specifications and characteristics identified and control plans developed?
9.Are critical processes identified and quality plans developed to 6 sigma process capability?
Scoring:
1. Quality manual exists but is not complete or primarily covers policies not procedures that can be executed. Minimal
quality planning evident.
3. Quality manual is well documented but there is little evidence of quality planning in the system and process controls
are not covered adequately.
5. Manual is well documented and followed. Quality system includes quality planning, process control, auditing, and
reliability testing.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ___5___) (Category Score ________) = Total Score _________
Change Control/Procedures
Support Questions:
1. What is product specification change procedure? Who is responsible? Is it documented?
2. What is process for change control in factory?
3. Who physically changes documents or computer files? Is there a master file?
4. How are manufacturing drawings and specifications controlled to the latest revision?
5. Who insures drawings and specifications from their suppliers are to the latest revision?
6. If Engineering and Sales organizations are located in another city/country, how are changes controlled?
Scoring:
1. There is no formal change control procedure and factory processes do not sufficiently document
3. Change procedures for internal changes and drawings only. Suppliers not controlled.
5. Well defined process for handling drawing, process, and material changes
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score __________) = Total Score __________
Process Control & Statistical Process Control
Support Questions:
1.List Major in-process inspections/tests
?Do process control plans include acceptance criteria? Characteristic Instrume (Refer to appropriate Product specific survey) __________
__________
__________
__________
__________
__________
__________
2. Are process instructions and equipment calibration procedures posted at appropriate locations?
3. What is the procedure to adjust process equipment between model changes?
4. What is the procedure to adjust test/measurement equipment between model changes?
5. Are control plans developed and maintained to monitor process outputs?
?Sub-assemblies?
?Finishes?
?Major fabrication?
?Primary assembly and test?
6. Do the control plans include:
?Critical-to-quality characteristics? Who is responsible for monitoring?
?Frequency?
?What type of measurements? Type gages used?
?Data recorded? Stat
6. Have short and long term capability studies been performed?
7. Are assignable cause variations investigated and corrected? Who has responsibility?
8. Are appearance standards in place? Is lighting adequate for inspection?
9. Are station aids used at CTQ and complex operations?
Scoring:
1. Ineffective process control system with no understanding or use of SPC.
3. Adequate process control techniques in place. Operators understand and work to station instructions.
5. Extensive evidence of effective use of statistical control of critical processes. SPC charts being utilized.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score __________) = Total Score __________
Metrology
Support Questions:
1. Is there a documented gage calibration program?
2. Is inspection, measurement, and test equipment capable of the required accuracy/precision?
?Measure at increments 1/10 of tolerance minimum?
?Are gages stored and handled to protect accuracy and fitness for use?
3. Are gage R&R (repeatability and reproducibility) studies performed?
?What percent of tolerance is considered acceptable?
4. Are calibration records complete for production test equipment?
Instrument/Tester
Location?
Frequency?
__________________________________ __________________
_________________
__________________________________ __________________
_________________
__________________________________ __________________
_________________
__________________________________ __________________
_________________
5. Have appropriate actions been taken when measuring and test equipment is found to be out of calibration?
?Have previous test results been checked for validity?
?Is upstream material held for retest?
?Customers notified if suspect material has been shipped?
6. Is there a documented gage maintenance program?
Scoring:
1. Inspection, measurement, and test equipment are not capable of required accuracy/precision and are not calibrated
regularly.
3. Inspection, measurement, and test equipment are capable of the required accuracy/precision, but documentation and
consistency lacking in some instances.
5. Inspection, measurement, and test equipment are capable of the required accuracy/precision and are strictly
monitored and changed as appropriate. Gages and instruments are scheduled for calibration and acceptance R&R
studies are performed and on file.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight___5____) (Category Score _________) = Total Score ________
Corrective Action / Problem Solving
Support Questions:
1. Is control provided for identification, documentation, evaluation, segregation and disposition of in-process non-
conforming product?
2. Is non-conforming finished product impounded? Is the customer notified?
3. Does written formal procedures exist for problem solving that defines the problem and root cause?
4. Do corrective actions have date of temporary fix, permanent fix, and owner?
5. Are corrective and preventative actions reviewed by management and the customer?
6. How does the Quality organization monitor long term issues - failures from 1-10 years?
7. How is field failure information accumulated, including repairs, defective parts, application, and installation?
Scoring:
1. Little formal procedures exist for corrective actions to resolve problems or control non-conforming material.
3. Procedures exist and responsibility assigned, but follow through apparently lacking. Minimal field failure information.
5. Formal problem solving and corrective action process is used with containment action, defining root cause, verifying
corrective action and system changes. Field failure data is obtained and acted on.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score ___________) = Total Score __________
Outgoing Quality Assurance
Support Questions:
1. What tests are performed after final assembly? (Refer to appropriate Product specific survey)
2. Is there an end-of-the-line audit for products? Characteristics measured? Frequenc
?Safety tests?
?Functional tests?
3. Is there a grading system? Describe?
4. Is product performance tested by lot? Is data provided to the customer?
5. Is product life tested or “stress” tested on a scheduled basis?What tests are performed?
6. Is a appearance standards board/room maintained to compare outgoing product versus established standards?
Scoring:
1. In-line and audit testing are inconsistent and do not ensure 100% function or safety.
3. Product is tested 100% in-line for basic functions, but critical characteristics are not formally audited.
5. Product is 100% tested in-line, critical tests and consumer cues are audited by sample plan, and product performance
is tested per GEA requirements.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score __________) = Total Score __________
Personnel/Training
Support Questions:
1. What is average factory personnel turnover rate?
2. What is minimum educational level for factory personnel? Average?
3. What is the training process for new personnel? Hours? Type
Training?
4. Who is responsible to ensure training is documented, accurate, complete, and up-to-date?
5. Are there any factory Quality Awareness Programs? Quality Circles?
6. Is there a training program for quality personnel?
?Type training? SPC? Scoring:
1. Minimal …on job training? with limited or no supervision
3. Good …on job training? with supervision and experienced operators, but little formal quality/gage instruction.
5. Formal and mandatory training program in company policies/procedures and normal and specialized job training.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________
________________________________________________________________________________________________________
________________________________________________________________________________
(Category Weight ____5_____) (Category Score __________) = Total Score __________
PRODUCTION SUPPORT
Inventory Management
Support Questions:
1. How is inventory measured and tracked? How is it controlled?
2. How is schedule attainment measured?
3. How many days of RIP (raw, in-process) and finished goods inventory are carried?
4. What is the supplier?s capability to inventory finished goods? How many units?
Location?
5. What is the supplier?s capability to inventory components? Quantify.
6. What is supplier?s inventory turns?How are turns calculated?
7. What is supplier?s willing to consign finished inventories at customer?s location? Is this a current practice?
8. How is Materials Department organized? (See organization chart from General Business Survey)
9. What training is provided for materials personnel?What type experience or certification is required? e.g. APICS -
American Production Inventory Control Society.
Scoring:
1. Minimal inventory control processes and inability to inventory finished products, minimal manpower
and inventory management focus.
3. Inventory control processes being used, some capability to inventory finished products, sufficient
staffing and focus on inventory management.
5. Inventory control processes in place and fully utilized, highly capable of storing and managing finished goods
inventories, well organized staffing with focus on meeting business objectives.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score__________) = Total Score __________ Scheduling/Quick Response
Support Questions:
1. What procedures/processes and systems are used to schedule your manufacturing facility? What is the frequency of
schedule updates? What software packages are used?
2. Does the supplier have Electronic Data Interchange (EDI) and Internet capability? If yes, what is it used for? If not,
are plans in place to implement?
3. Does supplier understand which components, materials, subassemblies, and manufacturing processes restrict their
flexibility to respond to customers mix and volume changes?
?What are issues and what actions are being taken to address them?
?Are safety stocks carried - provide any studies performed.
4. What is the supplier?s customer on-time fill rate (quantity ordered versus quantity shipped)?
5. What is supplier?s customer on-time delivery (order date versus date product received)?
6. How flexible is supplier?s factory?
a. What is supplier?s manufacturing cycle time for products?
b. What is supplier?s response time to make product volume or mix changes after notification?
c. How often does supplier cycle product? Daily, weekly, monthly?
6. How is obsolescence controlled and measured?
Scoring:
1. Scheduling performed manually with no use of material systems, Electronic Data Interchange (EDI), or the Internet. Limited
understanding of issues restricting flexibility or capability to correct. Not capable of meeting customer needs.
3. Material systems, Electronic Data Interchange (EDI), and the Internet being used adequately. Supplier plant is
reasonably flexible and issues impacting are understood, but only limited actions are taken. Customers needs met
frequently.
5. Highly proficient and evident use of material systems, Electronic Interchange Data (EDI), and the Internet. Supplier?s
factory is flexible and issues impacting are fully understood and proactively addressed. Customers needs fully met.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________
(Category Weight _____5____) (Category Score __________) = Total Score
Facility/Equipment/Layout/Capacity
Support Questions:
1.What are the primary processes performed in supplier?s factory - e.g. assembly, metal fabrication, injection molding
2.What waste, practices, and inefficiencies are evident when walking the flow of the plan from incoming materials
to outgoing product shipments?
3. How would you rate the layout, cleanliness, lighting, and work environment of the plant?
4. What expansion capabilities does the supplier have?
5. Does supplier have any current plans to expand or upgrade the manufacturing facility?
6. Does supplier have any plans to purchase or upgrade equipment? Why and when?
7. Would products from other customers impact su pplier?s ability to support GE production needs, e.g. seasonal
products.
8. Does the supplier have a documented capacity plan which includes overtime capability and supplier and internal
limitations?
9. What is the annual capacity of the manufacturing facility and what is currently being utilized?
10. What is the typical age and condition of supplier?s equipment, fixturing, and tooling?
11. How much of supplier?s production capacity would be allocated to GE?
12. Has the supplier identified and formalized tooling, equipment, and labor constraints relative to capacity? Is a plan
developed in the event additional capacity is needed?
13. How many days/week and shifts do assembly and support operations work?
14. Does supplier have a formalized and comprehensive preventative maintenance program? Are records kept on
maintenance, repairs, and modifications?
Scoring:
1. Inefficient plant layout with poor material and process flow and cleanliness. Limited understanding of factors
restricting production and no contingency plans to address increased or spiked demands from customers. Lack of
preventative maintenance reflected in tools and equipment condition.
3. Plant layout and material/process flow adequate. Understand factors effecting production and generally have some
plans in place to respond to changing customer volumes, although not always timely. Preventative maintenance
routines in place and tools and equipment in acceptable condition.
5. Upgrade or new facility with state-of-the-art and efficient material/process layout and flow. Excellent lighting,
cleanliness, and work environment. Supplier thoroughly understands and documents factors restricting production
and actively works issues. Contingency plans are in place to quickly respond to changing customer volumes. Well
documented preventative maintenance program that is strictly adhered to results in tools and equipment being in like
new condition.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________
(Category Weight ____5_____) (Category Score __________) = Total Score __________
Tooling
Support Questions:
1. Who is responsible for managing all tooling activities?
2. Does supplier design and build its own tooling or purchase from external suppliers? What type tooling does supplier
build?
3. How many tool designers and builders does supplier employ? What are their qualifications?
4. Does supplier have a formalized sourcing and review process to ensure customers tools are highly capable, durable,
and purchased at the most economical cost?
5. Who is responsible for purchasing tooling and equipment and what are their qualifications?
6. What is the typical age and condition of supplier?s equipment to produce tooling?
7. Does supplier have a well documented preventative maintenance program in place?
8. What type software package are used to design and build tools?
9. What is the typical age and condition of supplier?s in-house tooling?
10. Are records maintained on supplier held tooling?
11. What is your tooling design review procedure?
Scoring:
1. Supplier does not have a formal sourcing process and minimal tooling expertise. Tooling in poor condition.
3. Supplier uses a sourcing process and has adequate expertise and equipment (if applicable) for either constructing or
purchasing tooling. Preventative programs for in-house tooling and through suppliers resulted in tooling
being well maintained.
5. Supplier has a formalized and well documented sourcing process that is strictly adhered to. High caliber in-house
experts that are highly trained. Disciplined use of a sourcing process and preventative programs result in capable
and durable tools that meet customer specifications.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight _____4____) (Category Score __________) = Total Score __________
TECHNOLOGY
Technical Capability
Support Questions:
1. Does supplier have technical capability to design products?
2. What are the qualifications of supplier?s technical staff?
3. Are your designers trained in CAD systems? To what degree?
4. To what degree have you been involved in the development of products you currently manufacture?
5. How is the technical department organized. (See organization chart from General Business Survey)
6. Does supplier have experience in dealing with performance specifications?
Scoring:
1. No Computer Aided Design (CAD) systems used. Minimal design capability/experience.
Engineering staff lacks adequate training/qualifications or is non-existent.
3. Uses CAD. Design experience/capability limited. Moderate number of engineers with degrees. Some training
available in design tool (FEA, FMEA, DFX, etc.) and process technology.
5. Broad application of CAD. Excellent design capability. Extensive experience designing complex products.
Most engineers have degrees and extensive experience in process technology and use of latest design tools.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight _____5_____) (Category Score __________) = Total Score
Evaluation/Testing/Qualification Capability
Support Questions:
1. Is there a documented product evaluation program in place? Obtain copy if available?
2. Where in the introduction cycle is the testing performed? What location?
3. What is being tested (components, products, systems) and what type testing is performed (reliability, environmental,
shipping, etc.)?
Item Tested Testing For?
How Tested?
______________ _______________________________________
____________
______________ _______________________________________
____________
______________ ________________________________________
____________
______________ ________________________________________
____________
4. Are there adequate product performance testing facilities?
5. What is the evaluation testing output?
6. What is the data analysis capability?
7. Is there a correlation/calibration procedure?
?To GEA standards?
?To industry agency?
?To government agency
Scoring:
1. Minimal evaluation capability and inadequate or non-existent testing facilities.
3. Product evaluation program I place but overall capabilities and test facilities need upgrading.
5. Completely documented evaluation program with well equipped testing facilities, detailed and complete test procedures, and
highly qualified staff.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ___5____) (Category Score __________) = Total Score ___________
Product Safety
Support Questions:
1.What is the process for screening new products for potential safety issues?
2.Do documented guidelines exist for properly conducting a product safety review?
3.Are completed product safety reviews conducted and archived for convenient retrieval?
4.Are regular audits conducted to test the quality and safety of finished products?
5.Are product safety reviews required before the implementation of a change to a product?
6.Is there a process in place that gathers information concerning safety issues encountered by customers? Describe.
7. Are timely decisions made concerning appropriate actions following the identification of a safety issue?
Scoring:
1. Minimal documentation, processes, reviews, and audits to ensure product safety.
3. Adequate documentation, processes, reviews, and audits to meet customer and regulatory requirements.
5. High documented and proactive procedures, processes, reviews, and audits that are rigidly adhered to ensure all safety
requirements are met.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ____5_____) (Category Score __________) = Total Score __________
New Product Introduction
Support Questions:
1. Is there a documented New Product Introduction (NPI) process? Obtain
copy of flowchart if available?
2. Who is responsible for program management of new programs?
Tracking?
3. Describe critical stages:
?Prototype development:
?Pre-pilot stage:
?Engineering, Quality Control, Adv. Mfg. Eng., Production involvement?
?Are specifications and quality objectives defined?
?Pilot stage:
?Are tooled parts used?
?Who is responsible for first piece approval?
?When is Underwriter?s Laboratories Approval required? Who is responsible?
?Initial production stage:
?When is program review completed?
?Who insures a production quality assurance plan is in place? When?
4. Do you have a process for screening new products for potential safety issues? No____ Yes____
5. Do you have a documented process for properly conducting a product safety review?
No_____ Yes_____
6. Are regular audits conducted to test the quality and safety of finished products? No___ Yes___
7. Are product safety reviews required before the implementation of a product change? No__ Yes__
Scoring:
1. No formal NPI program. Has no program management structure and little experience with major projects.
3. Formal NPI program but not complete rigidly executed. Some program management and major project experience.
5. Has documented and comprehensive NPI program. Extensive program management experience with dedicated managers for
key programs. Process includes appropriate assignment of responsibility, cross-functional reviews and approvals, and
tracking.
Comments/Deficiencies:____________________________________________________________________________________
________________________________________________________________________________________________________
________________________________________________________________________________________________________ (Category Weight ____5____) (Category Score __________) = Total Score ___________
Productivity
Support Questions:
1. Does supplier have a documented productivity program that is championed by senior management with
defined goals and measurements that are clearly communicated?
2. Does supplier target productivity goals for all appropriate business areas?
3. Are goals communicated throughout the organization? Are team members regularly updated on progress?
4. Who owns and leads supplier?s productivity efforts? Are owners assigned to each approved project?
5. How are projects tracked and driven to completion?
6. What methods, processes, and tools does supplier use to generate productivity opportunities? What facets of the
business are reviewed?
7. Does supplier utilize Rolled Through Put Yield analysis to identify areas of opportunity?
8. How does supplier productivity gains shared with customers?
9. Has supplier passed on material increases/decreases during the past three years?
10. How are employees involved in supplier?s productivity program? Are they rewarded? How?
Scoring:
1. Productivity is not a business priority and supplier does not have formal plans or organization structure in place.
Increases are typically passed along to customers.
3. Supplier has a formalized productivity plan and organization structure in place and has demonstrated adequate
capability to identify and implement opportunities. Supplier often absorbs increases and offsets with productivity
gains.
5. Supplier has a formalized and proven productivity plan and organization structure in place that understands the need
for continuous improvement and aggressively pursues and delivers sustainable gains to its customers. Increases
always offset with productivity gains made in other areas.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________
(Category Weight ____5_____) (Category Score __________) = Total Score __________
Packaging
Support Questions:
1. Does supplier have engineers on staff to design product packaging to meet customers minimum packaging
requirements?
2. Does supplier have in-house test facilities to evaluate and approve the adequacy of packaging design?
3. Does supplier utilize returnable containers with its customers or suppliers?
Scoring:
1. Supplier does not have experience or expertise to design or test packaging methods.
3. Supplier has adequate experience or expertise either in-house or through its sub-tier suppliers to design and test
packaging methods.
5. Supplier has experienced and highly trained engineers for designing packaging. Modern in-house facilities and
qualified technicians for testing packaging methods.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ (Category Weight ____3_____) (Category Score __________) = Total Score __________
RELIABILITY GROWTH, QUALIFICATION AND AUDIT TESTING
Support Questions:
1.Who is responsible for managing your reliability process?
2.What are your reliability goals for products similar to ours, and how are they established?
3.What reliability tests do you presently conduct on products similar to ours? Including Growth, Qualification and Audit tests.
4.What are your top five failures, root causes and corrective actions?
5.What is your process for reliability test development and failure reporting? (i..e., Failure Modes and Effects Analysis and
FRACAS)
6.Do you conduct these tests in-house or sub-contract them out? What is the capability and capacity for both?
7.What are your customer?s top 5 failures in the field, root cause, and corrective actions? Are reliability plans developed an d
reviewed with the customer?
Scoring:
1. Conducts only reliability growth and qualification testing and shows no evidence of root cause analysis or documented corrective actions. Does not request customer failure data.
3. Conducts all three reliability tests, evidence of root cause analysis and corrective actions but no link shown to subsequent improvement. Requests customer data, no measure system in place to link corrective action with product improvement.
5. Conducts comprehensive reliability testing, linking internal and customer data with root cause analysis, corrective actions and subsequent measurable improvement.
Comments/Deficiencies_____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ____________________________________________________________________
(Category Weight____5______) (Category Score_____________) = Total Score
SUPPLIER MANAGEMENT
Support Questions:
1. Does supplier have a documented quality program for purchased materials, components, assemblies, finishes, and purchased
services?
2. What is staffing for purchasing and quality organizations to deal with supplier issues and opportunities? (See organization
chart from General Business Survey)
3. Define the responsibilities of the purchasing and quality organizations as it relates to suppliers.
4. Supplier Surveys:
?Are all new suppliers surveyed and approved before business is placed with them?
?If not, what is required to do business with supplier?s company?
?What is the frequency of surveys on an ongoing basis?
?Provide an example of a recent survey.
?Who completes the survey?
5. What areas and criteria are suppliers rated on? How does a supplier become approved?
6. Do you have an approved supplier list?
7. Do you establish annual supplier goals and evaluate them in the areas of quality, cost, delivery and other business initiatives?
Give an example of a goals for a given year.
8. Is there a formal supplier performance program that provides feedback for performance? What is frequency of feedback? If
not, how is performance evaluated and fed back to suppliers?
9. What processes and methods are used to drive improvement in the areas of cost, quality, and cycle time?
10. Are quality control plans required from suppliers? Do you evaluate and approve them? Are they kept on file?
11. How is process capability monitored?
12. Are critical processes identified with suppliers and quality plans developed to 6 Sigma process capability?
13. Is a 6 Sigma philosophy and movement being driven through supply base?
14. Do you perform and maintain first piece reports on your suppliers?
15. Who reviews first piece parts and determines if they are acceptable?
16. Who is responsible for follow-up on corrective action items?
17. Does supplier have an Incoming Inspection operation and are materials and components inspected?
18. Are incoming materials and components held until inspections and/or audits are complete?
19. What procedures/processes and systems are used to communicate schedules to your suppliers?
20. What is the frequency of schedule updates? What software packages are used?
21. Do you schedule major suppliers using EDI?
22. Have you communicated your customer?s change control notification procedure to your
suppliers?
?Do you require suppliers to notify you prior to change?
?How do you enforce?
16. How many sources do you have for each component? What is your purchasing philosophy
for sole sourced suppliers - where you only buy from one source and it would take more 6-12 months to qualify
a new supplier.
17. Do any of your suppliers consign components/materials to you? How does this operate?
18. What programs and training are provided to suppliers to drive continuous improvement?
19. Are suppliers required to have documented capacity plans?
20. Are suppliers responsible for maintaining the condition of tooling they hold on your behalf?
21. List the following information on major material, component, assembly, and finish suppliers and those providing
services on a separate spreadsheet.
?Component Description
?Supplier Name
?Year Started Doing Business With
?Manufacturing Location
?Lead -Time
?Weeks of Buffer Stock
?Minimum Order Quantity
?Supplier Rating: 1-10, 10=Best
Scoring:
1. Limited resources, no supplier measurements, supplier first pieces are not maintained,
change control does not apply to suppliers.
3. Some supplier suppliers first piece reports on file, limited PPM tracking of supplier parts
limited feedback to customer on supplier performance.
5 . Outstanding - Fully staffed for supplier monitoring, to conduct surveys, and to take needed
actions to drive continuous improvement.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ _________________________________________________________________________
(Category Weight ____5_____) (Category Score__________) = Total Score
FINANCIAL
(Financial Information to be provided as part of the Supplier Pre-screen Application)
Scoring:
1. Company has limited financial strength and is unable to support major investments for new programs. Comprehensive
financial review appropriate prior to placement of any business with this company.
3. Company is financially strong, but could have difficulty supporting major program investments.
5. Company has a high level of financial strength and can provided needed levels of investment to support GEA
programs/business.
Comments/Deficiencies:____________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________
(Category Weight ____5_____) (Category Score__________) = Total Score
REPUTATION RISKS
Complete this section only during an onsite inspection of the supplier?s facilities. Any question answered “no” must be revi ewed with GEA?s EHS General Manager . If permitted, take digital photographs of the condition causing the “no” answer. Answer all questions and have a copy of the “Employment Practices”, “Environmental and Worker Health and Safety” and “Employee Housing” sections of the supplier?s Pre-Screen Application in hand when conducting a Business Survey to qualify a supplier or to review an existing supplier to comply with Policy 30.13 Guidelines. Answer questions noted with a * during every visit to the supplier?s facilities.
Employment Practices
1. Does local management recognize the HR policy or procedures provided with the supplier?s Pre-Screen Application, or
provide updated HR policies/procedures during the inspection? (If the supplier has no written HR policy or procedures answer “No.”.) No _____ Yes _______
2. Does the supplier?s written hiring policies comply with applicable laws and make children under age 16 ineligible for
employment? (If the supplier has no written hiring policy answer “No.”) No _____ Yes _____
3. Does the supplier?s pay for overtime, weekend or holiday work comply with applicable laws? No ____ Yes _____.
4. Does the supplier maintain copies of documents it requires from employees to prove their age? (If the supplier does not
require or maintain copies of age docu mentation, answer “No.”) No ____ Yes ____
5.* Do all employees look to be above the applicable age limit, or age 16, which ever is higher? No _____ Yes _______
6.* Do all employees appear to be present voluntarily (e.g. not an unusual number of guards present and employees appear free to
enter and leave dorm facilities except during nighttime curfew hours)? No _____ Yes _______
Environmental and Worker Health and Safety 1.* Is the general housekeeping of the facility good (e.g. restrooms, break areas, aisles, and doorways are clean and uncluttered
and trash is in containers)? No ______ Yes ______
2.* Does the facility have good lighting (for example it is easy to see across the facility or to the nearest exit and workers do not
appear to be straining to see their work)? No ____ Yes _____
3.* The facility has no visible haze or chemical mist in the indoor shop work areas. (Answer “Yes” if true.) No _____ Yes
____
4.* There are no objectionable odors in indoor shop work areas (Objectionable odors include very irritating, acrid odors that in
some cases make your eyes water as you walk through the area or cause you to have a strong negative reaction) (Answer “Yes” if true.) No_____ Yes ____
5.* The work areas are kept at a reasonable temperature (e.g. not dangerously cold or hot). (Answer “Yes” if true). No _____
Yes ______.
6.* The exits (including emergency exits) are clearly marked and they lead to an area clear of the building without obstructions
such as locked doors. (Answer “Yes” if tr ue.) No ______ Yes ______.
7.* Do chemicals and wastewater get treated prior to going to a sewer or drainage system (e.g. no dumping buckets or containers
of chemicals down a drain, sinks and tank discharges are not connected to storm sewer or floor drains)? No _____ Yes _____
8.* There are no waste materials, scrap metal or garbage stored outside directly on the ground, in badly corroded containers or in
direct contact with rainfall runoff (e.g. open top, overflowing containers). (Answer “Yes? if true.) No ______ Yes ______ 9.* The vegetation on site appears to be normal (not distressed due to unnatural causes). (Answer “Yes” if true.) No ______
Yes _____
10.* A re air emissions ordinary in appearance (e.g. not visibly dark or strong yellow)? No ______ Yes ______
11. Is first aid equipment available to employees? No ______ Yes ______
12. Is there an alarm system to notify employees of an emergency situation? No _____ Yes _____
13.* A re there fire extinguishers or fire fighting equipment in the facilities? No ______ Yes ______
14.* D o the work practices and work equipment used in the manufacturing process appear to be safe? No _____ Yes _______
(The following six questions ask about typical unsafe activities that you may observe.)
15.* A re employees using eye protection in areas where there are risks that chips or particles may be flung from the machinery or
they could be splashed with chemicals.? No _____ Yes _____
16.* D o machines appear to be guarded so that employees cannot reach into machines with rotating or moving parts, or under or
into devices that stamp, cut or punch metal? No ______ Yes _____
17.* A re employees wearing shoes appropriate for a manufacturing environment (sandals and bare feet are not appropriate on a
shop floor)? No ______ Yes ______
18.*Are employees wearing hearing protection in all areas with high noise levels (areas where you cannot be heard without yelling).
No _____ Yes _______
19.* A re employees in high dust or vapor areas wearing breathing protection? (Note that cotton surgical masks or scarves
wrapped around the face are usually not sufficient in these areas.) No _____ Yes ______
20.* D oes all wiring appear to be in good condition (e.g., not frayed, appears to have been installed professionally and does not rely
excessively on extension cords)? No _____ Yes _______
Employee Housing
1.Do housing facilities have fire alarms that can be activated on every floor and emergency lighting? No ____ Yes _____
2.Are there two ways to exit the building available to every floor (doors locked so they cannot be opened from the inside during
any part of the day may not be counted as an exit)? No _____ Yes _______
3. 3. Is first aid equipment available to employees ? No _______ Yes _______
4.Food is not prepared in sleeping rooms and areas were food is prepared or served appear to be clean and sanitary. (Answer
“Yes” if true.) No _____ Yes _____
5.Is clean drinking water available to employees at or nearby the housing facilities? No ____ Yes ____
6.Is the building heated during cold weather? No _____ Yes ______
7.There are no activities close to the building that might create a health hazard for employees living in the facility (e.g., burning
waste or venting chemical emissions). (Answer “Yes” if true.) No ____ Yes _____
Score from Survey: ________
Commodity Specifics Score: ________ If required by selection team
Technology Specific Score: ________ If required by selection team
Total Score: ________
Any required corrective actions to be made by supplier must be documented using the form located @ Supplier Corrective Action Requirements 8-01 Update.doc