Transcription of Tokai Eastern Rubber (Thailand), Ltd.
1 supplier Quality Improvement ManualTechnical supplier ManualRevision 10 Effective date : 20 May 2011 Approved byTechnical SectionTokai Eastern Rubber (Thailand), byChecked bySupplier Quality Improvement ManualContentsItemPage1. Quality assurance ideality12. Purpose13. Scope14. Requests for Initial Control Approval Initial Part of Production Preparation SPTT Inspection Initial Delivery PPAP Reason to submit PPAP Retention / Submission Requirement for TER PPAP Record Process Change Reason to information of process change24 Submission requirement for Delivery requirement after PCN Change Control Record Guideline for Environmental Hazardous Substance Control of initial nonconforming products(NC)325. Attachment List33 Technical supplier Manual Change NotificationTechnical supplier ManualSupplier Quality Improvement Manual1. Quality assurance supplier shall produce parts that meet to TER satisfaction as purchasing agreement.
2 TER would approve parts that shall be controlled quality supplier shall improve production process to achieve condition and requirement and prepare quality assurance of part have not problem after delivery Especially for problems in TER shall be corrected and prevented TER shall audit QA system of supplier including monitoring and advising in order to assure quality of supplier efficiently and To conduct coordination between TER and supplier shall apply ISO9000 or ISO/TS16949 to implement in Quality Assurance Initial part of supplier shall approved by TER before start Mass PurposeThis guide to Technical supplier Manual is defined a standard of quality assurance for new or changed product as supplied to " Tokai Eastern Rubber (Thailand),Ltd."3. ScopeThis manual applies to the quality assuarance activities of suppliers for new or change, which related to TER in assembly product. If it difficult to carry out them please contact to Technical section, QA&Technical department of TERPage 1 of 34 Technical supplier Manual10 supplier Quality Improvement Manual4.
3 Requests for Initial Control OrganizationEstablish and maintain the quality assurance system. The supplier shall assign a person who responsible in quality and delivery for initial part. This assignment has aimed to ensure an establishment of a consistent quality assurance and delivery system to cover all processes of each supplied productfor TER and response in our satisfaction of requirements. supplier shall submit to Technical section within 7 days after received New Part Notice from Technical / TER.** If Contact person change. Please Review /Revise this organization and submit to Technical section within 7 2 of 34 Technical supplier ManualFactory ManagerName YoshidaE-mail :(038) 893-557-61 Phone :081-9496355< Manager > < Staff >Project Leader(Department):Project Leader(Department):Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone :Core Team # 1(Department):Core Team # 1(Department):Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone :Core Team # 2(Department):Core Team # 2(Department):Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone :Core Team # 3(Department):Core Team # 3(Department):Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone :Core Team # 4(Department):Core Team # 4(Department):Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone :Core Team # 5(Department):Core Team # 5(Department).
4 Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone :Core Team # 4(Department):Core Team # 4(Department):Name :Name :Position :Position :E-mail :E-mail :Tel :Tel :Mobile Phone :Mobile Phone (038) 893-557-61 (038) 893-557-61 EngineerProduction ControlProduction (038) 893-557-61 (038) 893-557-61 Engineering Production Div. Production Div. Engineering Div. Marketing Div. Marketing Div. Quality Div. Quality (038) 893-557-61 EngineerProduction 893-557-61 Engineer 893-557-61 893-557-61 (038) 893-557-61 893-557-61 & Technical 893-557-61 893-557-61 team4QA & Technical GMMarketing team6 Project Organization ChartCore team1 Project LeaderCore team2 Core team3 Project NameRT-50 supplier NameCore team51010 supplier Quality Improvement Production Preparation Schedule(PPS) supplier issue PPS which contains New Part Notice, TER master plan(TD0, TM0, TM1, MP), SPTT stage and detail of part preparation.
5 After received plan supplier shall issue supplier plan submit to TER within 2 week and update supplier plan in PPS submit to Technical every month. Technical will check progressive of part from shall issue supplier 's PPS to Technical / TER after received New Part Notice by7 working days. supplier shall update progressive of PPS by 25th of wery SPTT AuditTechnical set SPTT activity for1. 100% Quality meet to TER requirement2. 100% On time delivery in each stage3. Close communication between TER and SupplierSPTT activity has 3 steps and criteria as list below. Page 4 of 34 Technical supplier ManualSupplier :XXXXXXXXXXXXXXXX3 Part No. :XXXXXXXXXXXXXXXX2 ApprovedApprovedCheckedCheckedApprovedCh eckedIssuedPart Name:XXXXXXXXXXXXXXXX :XXXXXXXXXXXXXXXXPLAN0dd/ Material&CKDXXXC omponentLocal partsXXXP rocess planningXXXXXXXXXxProd. Of Tooling/EquipmentXXXXXXXXXxProd. Of Checking FixtureXXXXXXXXXxTry-outXXXXXXXXXxTurnin g & ModilicationXXXXXXXXXxTooling & Equipment TransferXXXXXXXXXxProd.
6 Of Tooling/EquipmentXXXXXXXXXxProd. Of Checking FixlureXXXXXXXXXxInstallationXXXXXXXXXxT ry-outXXXXXXXXXxTuning & ModificationXXXXXXXXXxLow Volume Production Trial (LVPT)XXXXXXXXXxHigh Volume Production Trial (HVPT)XXXXXXXXXxStart of Vulume ProductionXXXXXXXXXxDimension & AppearanceXXXXXXXXXxMaterial EvaluationXXXXXXXXXxPerformance Evaluation(Sample part)XXXXXXXXXxPerformance EvaluationXXXXXXXXXx(Re-comfirmation of Local Prod. Part)XXXXXXXXXxInspection StandardXXXXXXXXXxQC Process ChartXXXXXXXXXxProcess Standard (WI,QCS,etc.)XXXXXXXXXxPPAP Submit (SPSW Submit)XXXXXXXXXxEducation & TrainingXXXXXXXXX xsignsignsign20112010 supplier PlanTER PlanCUSTOMER PlanTokai Eastern Rubber (Thailand), Recordnew issuesignsignsignsignTHAIQ uality DocumentEvalutionProduction Preparation ScheduleMaster ScheduleProcess PreparationResponsibilityActivitiesJAPAN S upplier:_____S-LotETPT1PT2 SOPTM1TM0TD0 MPTM1TM0TD0MP1stSPTT3rdSPTT2ndSPTT10 supplier Quality Improvement ManualSPTT1st Audit2nd Audit3rd AuditSupplier shall control part follow Approval Initial Part of supplier supplier shall issue Inspection standard and record which identify all measuring itemsand specification for supplier product testing and submit to TER after received drawing within 2 weeks supplier shall maintain inspection item which TER approved.
7 (TER form)Page 5 of 34 Technical supplier ManualStagePart QualityQuantityReferenceActivitySPTT audit check sheet(Trial Dimension)(CKD or Local) -Co-check dimension of partTD0 Part Off Tooln=3 pcs/shots -Check tooling statusCan reworkTM0 Part Off ToolRefer to Pilot POTM1 Part Off ToolRefer to PO -Check production process -Confirm capacityPPAP ApprovedMPPart Off ToolRefer to PO -Confirm production processCan not rework -Confirm part before shippingSPTT audit check sheet(Trial mold at THA)Off Process -Check capacity(Trial mold at JP)Off ProcessCan not rework - supplier PPAP ApproveSPTT audit check sheet(Mass Production)Off ProcessDoc. No. TES-IY- DCR No. Rev. 0 (DATE) MFG. NO PART NO PART NAME MODEL ROUTE MATERIAL RANKINSPECTIONINSPECTIONSAMPLINGINSPECTI ONCRITERIONINSTRUMENTPLANMETHOD (MIN) QA DEPTD imen-sionTHREAD ACCURACYLENGTHBBTHREAD GAUGEM10 X ITEMRANK xxxxxx INSPECTION STANDARD xxxxxxxxxxxxx26 0 HEIGHT GAUGE / CMMCALIPER / ( MAX )PAGE OF( 1 / 2 )HEIGHT GAUGE / CMMSAFETY PART xxxxxxxxFINISHEDUNFINISHEDMETAL20-May-10 40 + = 5, c = 0 / METAL LOT n = 5, c = 0 / LOTSUPPLIER DATA CHECK ( MIN )HEIGHT GAUGE / CMMPROFILE ( MAX ) ( MIN )CHECKALL METAL LOTMATERIAL CERTIFICATEISSUEMATERIAL CERTIFICATECALIPERSUPPLIER QA DEPT (TER)APPROVE CHECKCHECKCUSTOMER Tokai Eastern Rubber (THAILAND), XXXXXXXXXXXXXXXXXXISSUEDATEREVISION RECORD n = 1, c = 0 / INITIAL OR PROCESS CHANGE / IF NECESSARYBALANCERn = 5, c = 0 / METAL LOTEVIDENCE33 gMATERIAL OF PARTNO USE OF 4 ENVIRONMENTAL SOCsA CONFORM TO TSZ0001 GVISUALn=10%,c=0 / METAL LOTALL( supplier )
8 TSH7903 GTSH6524G-BAppea-ranceSURFACE TREATMENTBZINC COATINGC harac-teristicWEIGHTRef+ Quality Improvement ManualInspection Rank List ControlFor(Safety)(Regulation)(Emission) Page 6 of 34 Technical supplier Manual S S - Test before shipping part to TER evey lot- Use SPC controlRankControl MethodDimensionAppearanceCharacteristicR emark -Visual 100% Inspection - Test before start production evey lot - Use SPC control -Sampling checkControl methodand frequencyrefer to TER'srequirementwhichagree together -Visual 100% Inspection -Test before shipping part to TER - Test before start production evey lot - Use SPC control -Test before shipping part to ACCURACYM10 X ( ~ )DueLENGTH+ ( ~ )DueDIMENSIONDueRADIUSDueDIMETERDueOUTER ( ~ )DueDIMENSIONDueDIMETER0 ( ~ )Due Keep period :EFFECTIVE DATE : DIMENSIONAPPEARANCECALIPER CALIPER ( MIN ) R ( MIN ) PCS ( MAX ) ( MIN ) ( MAX ) CALIPERPCSPROFILEHEIGHT GAUGE / CMMGOODGOODCALIPER/CMMHEIGHT GAUGE / CMMCALIPERPCSNGPCSCHECKED BYINSPECTED BYNGn=1 , c =0 / INITIAL OR PROCESS CHANGE & IF NECESSARYALL SUPPLIERn=10%,c=0/LOTTER SURFACE TREATMENTVISUALn=5,c=0/METAL LOTMATERIAL OF PART ( ) PLAN HEIGHT GAUGE / CMM THREAD GAUGEn=5,c=0/METAL LOTCUSTOMER NAMEPART NAMESHIPPING QT'YSKETCHNO USE OF 4 ENVIRONMENTAL SOCs (CONFORM TO TSZ0001G)EVIDENCE PART 's DATAINSPECTION DATEINSPECTION QTYSUPPLIER 's DATASHIPPING DATEQAINSPECTION RECORD ( METAL PART )NG QTYRECEIVING LOTSUPPLIER NAMESHIPPING LOTEVIDENCE supplier DATA CHECK ONLYCHARACTERISTIC WEIGHT: 33 g.
9 (REF.)*VICKER HARDNESSTESTERZINC COATING(TSH7903G, TSH6524G-B)Keep period :(GM)APPROVERECEIVING LOTINSPECTION QTYQASKETCHMFG 's DATATER 's DATAPART DATESUPPLIER NAMEINSPECTION RECORD ( METAL PART )SHIPPING DATESHIPPING LOTPART NAMEMODELCUSTOMER NAMESHIPPING QT'YNG QTYH istory RecordPICTERCHECKED(SUPV.)SUPPLIERISSUED CHECKEDAPPROVE(MGR.)APPROVEAPPROVE(ENGIN EER)(SUPV.)(MGR.)(MGR.)xx-xxxxxx-xxxxxxx xxxxxxxxTERxxxxxxxxxxxx-xxxxxx-xxxxxxxxx xxxxxxTERxxxxxxxxxxSupplier Quality Improvement SBSCSBSC is supplier Banned Substance Check SheetSuppliers shallcheck your material and reply to Technical by attach with TM0 Data. Concentration of banned substances calculate from MSDS or Chemical ingredient. (Attach sheet No. 18)SBSCPage 7 of 34 Technical supplier ManualTechTech SupplierSupplier Name : Address : Responsible person : Reason for submissionNew modelNew Materials / Chemical Change ECN no.. Current material Correction for previous discrepancywith.
10 Change Process .. fill form of your material or chemical name and concentation if it don't have these chemical Substanced, Pleases fill in that Cadmium and cadmium compounds11 Polybrominated diphenylethers (PBDE)21 Trinuvin 3202 Lead and lead compounds12 Other brominated organic compounds22 Dimethylfumarate ( DMF )3 Mercury and mercury compounds13 Organic tin compounds23 REACH (SVHC)4 Hexavalent chromium compounds14 Asbestos 24 Other5 Polychlorinated biphenyls (PCB)15 Azo compounds6 Polychlorinated naphthalenes (PCN)16 Formaldehyde7 Polychlorinated terphenyl (PCT)17 Polyvinyl chloride (PVC) and PVC blends8 Chlorinated paraffins (CP)18 Perfluorooctane sulfonate anion (PFOS)9 Other chlorinated organic compounds19 Recycled Meterial10 Polybrominated bihenyls (PBB)20 Polycyclic Aromatic Hydrocarbon(PAHs)* For specification refer to Sony Technical Standards SS-00259, Yano standards and Green Procurement Standard of Matsushita group and GGP-001 of Pioneer Group *For REACH refer to the European Chemical Agency has announced the latest SVHC Candidate List - please see information from UK.