Guideline – Quality Supply Chain Management.

CLAAS KGaA mbH
Postfach 1163
33426 Harsewinkel
Tel.+49 (0)5247 12-0
www.claas.com
Guideline – Quality
Supply Chain Management.
CLAAS Fertigungstechnik GmbH,
Beelen
BRÖTJE Automation GmbH,
Wiefelstede
The CLAAS Group –
Locations worldwide.
AGROCOM GmbH & Co.
Agrarsystem KG,
Bielefeld
CLAAS U.K. Ltd.,
Saxham/Great Britain
CLAAS Selbstfahrende
Erntemaschinen GmbH,
Harsewinkel
CLAAS Service and Parts GmbH,
Hamm
CLAAS Vertriebsgesellschaft mbH,
Harsewinkel
CLAAS Global Sales GmbH,
Harsewinkel
Usines CLAAS France S.A.S.,
Metz-Woippy/France
CLAAS Industrietechnik GmbH,
Paderborn
CLAAS Automation GmbH,
Nördlingen
CLAAS Tractor SAS,
Vélizy/France
CLAAS Hungaria Kft.,
Törökszentmiklós/Hungary
CLAAS Saulgau GmbH,
Bad Saulgau
CLAAS Réseau Agricole S.A.S.,
Vélizy/France
CLAAS Tractor SAS,
Le Mans/France
CLAAS Omaha Inc.,
Omaha/Nebraska/USA
CLAAS France S.A.S.,
Paris/France
000 CLAAS, Vostok,
Moscou/Russia
000 CLAAS,
CLAAS of America Inc.,
Omaha/Nebraska/USA
CLAAS Ibérica S.A.,
Madrid/Spain
CLAAS Italia S.p.A.,
Vercelli/Italiy
CLAAS India Ltd.,
Chandigarh/India
CLAAS India Ltd.,
Faridabad/India
BRÖTJE Automation USA
Inc.,
Omaha/Nebraska/USA
CLAAS of America LLC.,
Columbus/Indiana/USA
CLAAS Argentinia S.A.,
Sunchales/Argentinia
Agr i cul t ur al
equi pment
Stand 28.08.2008
Agr i cul t ur al
equi pment
Product companies
Product companies
Sales companies
Sales companies
Pr oduct i on t echnol ogy
Pr oduct i on t echnol ogy
I ndust r i al
I ndust r i al
engi nee-
Stand 28.08.2008
engi neer i ng
CLAAS Group
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The system solutions, products and services of the
CLAAS group represent technical innovation, highest quality and absolute reliability.
Quality as a Principle.
Worldwide. CLAAS.
The image of the CLAAS products and the loyalty of our
customers provide evidence for extraordinary performances of CLAAS products and are also spur to continue
our effort for quality and our pursuit of progressive system
solutions. In particular the high customer satisfaction contributed to the continuous growth of the CLAAS group
worldwide.
Continuous improvement of our quality standards over the
entire supply chain process is our declared objective. The
competence and motivation of our suppliers influences
significantly the reliability and quality of our products and
services. Hence fundamental elements of our quality
understanding (philosophy) regarding our suppliers are
- robust processes and their permanent enhancement
- proactive, open and fast communication
- professional project management and
- the willingness for assumption of responsibility
Dr. Theo Freye
Speaker of the Executive Board
The following quality guideline for the entire CLAAS group
explicitly documents the valid QM elements for the buying
process to be applied. Effective adherence to the described procedures for identifying concerns early will make
error elimination possible.
Collaboratively we will agree to the relevant elements for
the respective business with you and use this as the base
for our common supply relationship. The rigid application
of this agreement leads to a continuous improvement of
the quality of our products and services. The achieved
customer satisfaction is a guarantee for both parties for a
long-term and positive business development.
Quality policy
We are determined to exceed the expectations of our customers. We are committed to maintain peak customer
satisfaction with faultless products and services. Quality is
the guiding principle in the way we do business.
Dr. Cornelius Weiß
Head of Corporate Quality Management
Rüdiger Mohr
Head of Corporate Purchasing
Editorial
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No Compromises.
Worldwide.
Content
I. General description .............................................................. 8
II. General criteria .................................................................... 9
Overview QM elements in the procurement process.......10
III. Selection and Qualification Process ...................................12
1. Self assessment/References .....................................12
2. Audit ........................................................................ 12
3. FMEA ....................................................................... 13
4. Process Control Plan ................................................14
5. First Samples ............................................................14
6. Process Capability ....................................................16
7. Product audit ............................................................17
8. Reliability Testing ...................................................... 18
Supplier qualification process Flow Chart ......................20
• Flow chart Component supplier...................................20
• Flow chart System Supplier.........................................22
IV. Series Monitoring ............................................................. 24
1. Continuous Evaluation ..............................................24
2. Processing of complaints ......................................... 24
V. Further Agreements ...........................................................26
1. Special Release ........................................................26
2. Logistic Agreement .................................................. 26
3. Emergency Plan ....................................................... 27
4. Quality Assurance Agreement (QAA) ........................ 27
5. Agreement of confidentiality ..................................... 27
VI. Appendix ......................................................................... 28
1. Definitions ................................................................ 28
2. Abbreviations............................................................ 29
3. Sources ................................................................... 29
Content
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I. General description.
II. General criteria.
Purpose
Responsibility
Supplier
CLAAS
This guideline explains the CLAAS quality standards to
suppliers. The individual elements between the contractual
partners will be fixed individually in our negotiation process.
The supplier is required to adhere to the demands as laid
out in the agreement and described in this guideline.
Documented and certified QM system conforming to:
• Clear and complete information to the supplier
• Clear communication channels and responsibilities
• Specific, clear and generally comprehensible
documentation according to product-specific
requirements
• Precise definition of volumes and delivery schedules
including the expected deviations
• Support and advice
The quality management standards, which are
documented here, are designed to ensure that:
- The produced components meet the CLAAS
specifications in every aspect
- The process capability and control of the supplier are
such that the specifications are adhered to consistently.
Area of Application
These requirements enter into effect with the agreement of
the establishment of a business between CLAAS and the
supplier.
The purchasing organisations of the individual locations
ensure that the agreed standards are implemented and
adhered to.
Support documentation
The processes and techniques referred to in the
guideline use defined standards as reference (VDA, QS
9000 regulations).
• ISO / TS 16949, DIN EN ISO 9001, VDA 6.1 or
upon approval by CLAAS Audit System
• Development of a “Zero-Defect-Strategy” within the
quality planning. Elaboration of measures to achieve
the quality objective “Zero-Defect”
• Understanding and acceptance of CLAAS
requirements
• Qualified QM personnel
• Carrying out of required planning and test procedures,
analyses, first samples, process control plan, process
capability, etc.
• Open communication and information in regard to
- Problems that arise
- Demands that cannot be met
- Capacity bottlenecks
• Qualification of sub-suppliers
If a quality assurance agreement (QAA) is concluded between CLAAS and the supplier, the supplier commits himself to provide a similar QAA with other CLAAS companies.
Premises
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Overview QM elements in the procurement process
II. Series monitoring
I. Selection and qualification process
QM elements in the
procurement process
1.
Sel f assessment /
r ef er ences
2.
Audi t s
- Syst em
- Pr ocess
3.
FMEA
4. Pr ocess cont r ol pl an
Information for
the supplier
Documents
Questionnaire Information
provided by supplier
Filled out by
supplier
CLAAS audit
catalogue
Basis VDA 6
Carried out by CLAAS
auditor at supplier
FMEA Analyses
VDA 4.1 / 4.2 or
QS 9000 FMEA
Risk analyses carried
out by supplier
Process control plan
(QM-Plan / Control plan)
To be produced by the
supplier to ensure
process reliability
5. Sampl es
VDA Volume 2
QS 9000 PPAP
To be produced by
supplier prior series
production launch
6. Pr ocess capabi l i t y
VDA Volume 4
QS 9000 SPC
To be carried out by
supplier for all marked * or
seperate aligned
characteristics
VDA Volume 6 (Part 5) /
audit system of the supplier
Certificate of effectiveness
of the QM system
7. Pr oduct audi t
8. Rel i abi l i t y
*Symbol 1:
Safety Critical Characteristic
VDA Volume 3
To be carried out by
supplier if requested by
CLAAS
QM elements in the
procurement process
1. Cont i nous eval uat i on
2. Pr ocessi ng of compl ai nt s
Documents
CLAAS Supplier
Assessment
8D-Report /
CLAAS Form "Problem
analysis"
Information for
the supplier
Supplier performance is
constantly monitored by
CLAAS
To be done by supplier
with every complaint
III. Additional agreements
1. Except i onal Appr oval
2. Logi st i c Agr eement
3. Emer gency pl an
4. QAA
5. Agr eement of conf i dent i al i t y
Exceptional Approval
CLAAS
Logistic Agreement
VDA 6.1
VDA 6.4
Request for
approval at CLAAS
before delivery
Agreement between
CLAAS and supplier
Supplier responsibility
CLAAS QAA
Agreement between
CLAAS and supplier
Agreement of confidentiality
Agreement between
CLAAS and supplier
*Symbol 2:
Key Characteristic / Functional Size
Premises
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III. Selection and
Qualification Process.
1. Self assessment/References
2. Audit
Self assessment
System audit
Process audit
Objective
Information about the supplier to complete the company
profile on following points.
- General company data
- Technical information
- QM-System
Objective
Evaluation of the QM system of the supplier in respect of
- Completeness
- Implementation
Objective
Assessment of process quality capability.
Support of the continuous improvement process.
References
Objective
• General information about the customer base of a
potential supplier
• Additional input based on information gleaned from
existing customers.
Note: only when both parties agree.
Implementation
Auditing of the QM system by CLAAS auditors
Basis:
- VDA Volume 6.1, Material Products
- VDA Volume 6.2, Service
Timing and scope of the audit will be mutually agreed
between CLAAS and the supplier.
3. FMEA
Implementation
Process audits can be carried out in agreement between
the supplier and CLAAS.
Basis:
- VDA Volume 6, Part 3
- CLAAS process audit questionary
Objective
Early recognition of potential for error in
design and/or production.
Implementation
The supplier is requested to carry out a systematic
analysis of potential errors within design and/or production
planning. (Basis VDA 4.1 / 4.2, QS 9000 FMEA)
After completion of the engineering- / process- and / or
system-FMEA the documented risk priority numbers
(RPN) may not be higher than 125.
A process audit is carried out either on individual components or on component families, if they are manufactured
using the same process.
Implementation
The questionnaire about supplier self-assessment is to be
filled out by the supplier and to be returned to the purchasing department.
Selection and
Qualification Process
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4. Process Control Plan
5. First Samples
Objective
Assurance that CLAAS quality standards are complied
with by describing the planned processes, methods and
checking procedures.
Objective
The supplier provides proof that the products have been
produced under series conditions and that they comply
with the CLAAS specification. Components for series production require a written approval for first samples.
Implementation
The supplier plans and documents the procedures for
parts and component groups (QM-plan / Control plan).
CLAAS supports the supplier with the review of CLAAS
documents (e.g. drawings, instructions, standards).
Preventive action
Manufacturing procedures must be checked beforehand
for possible errors (e.g. by use of FMEA or similar
weakness analysis).
Implementation
The supplier provides the samples and documents to
CLAAS quality organisation. (Based on VDA Volume 2)
Sample selection
Samples must be produced and tested under serial conditions (machinery, equipment, machining conditions)
Testing of production samples (Dimensions, Material
testing).
The supplier is responsible for checking all the parameters
on five parts.
The supplier is responsible for compliance to the material
specifications of the product (including labelling, physical
characteristics etc.)
All test results have to be recorded in the sample report.
The supplier has to assure for himself that all characteristics comply with CLAAS specifications.
Complete filled and signed sample report and, if requested
by CLAAS, inclusive process control plan.
The test samples are to be tagged clearly so that they can
be easily matched to the test results.
Even in cases where the supplier is not able to carry out
dimensional or material checks, the responsibility stays
with the supplier. Then the checks have to be carried out
by a suitably qualified, reputable organisation.
Clear matching of drawing parameters to test results by
markings in the drawings as well as clear matching of test
results to the proband.
When components have been pre-assembled the highest
level of completion has to be sent to CLAAS. If requested
the documentation for the single components has to be
marked accordingly and attached.
Any deviation from these specifications requires an
approval by CLAAS.
*Symbol 1:
Safety Critical Characteristic
*Symbol 2:
Key Characteristic / Functional Size
Supporting documentation for process capability for all
marked * characteristics and reliability data, if specified in
the drawings.
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Selection and
Qualification Process
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6. Process Capability
Objective
Proof of process capability by use of statistical methods
for the critical characteristics as defined * in the drawings
or separately aligned characteristics.
• Reduction of checking effort for customers
and suppliers
• Early recognition of process changes (Trends)
Implementation
At marked * or separately aligned parts, which have a
major impact on function, safety, assembly and reliability
of the product.
Proof
The supplier at least has to prove that all marked parts
have been produced under controlled process conditions
(controlled and stable).
*Symbol 1:
Safety Critical Characteristic
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7. Product audit
Minimum requirement
Machine Capability / Short term Capability – Cmk ≥1,67
Process Capability / Long term Capability – Cpk ≥ 1,33
The shape of distribution has to be checked, e.g.
Gaussian Distribution.
Process capability analyses
The supplier checks the capability on at least 125 production parts produced in sequence. Preferably the sample
batch should be produced in 25 lots of five units each.
The process capability calculation takes place with familiar
statistical methods (VDA Volume 4, QS 9000 SPC).
Documentation
During production, the documentation is provided by the
methods of statistical process control (SPC).
Attributive critical characteristics
In cases of attributive characteristics, which are marked
characteristics * in the drawings (“safety critical” or as
“important”), all of the samples selected for the capability
tests have to meet the specifications.
Objective
Inspection of the level of effectiveness of the QM activities
installed by the supplier in respect on components or
families involved.
Implementation
• The supplier is requested to plan and carry out product
audits. Basis: VDA Volume 6.5
• The results are to be analysed and documented in a
comprehensible manner, which includes target
definition
• Deviations have to be eliminated by fault analysis and
corrective actions
Variances
If the characteristic does not comply with the given criteria, a selection test has to be carried out until 100% compliance is reached. The planned and implemented corrective actions are to be documented in action plans with
schedules and responsibilities and made available to
CLAAS if requested.
*Symbol 2:
Key Characteristic / Functional Size
Selection and
Qualification Process
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8. Reliability Testing
Implementation
Reliability test procedures
The supplier refers to the specifications and drawings from
the CLAAS R&D function for the test procedure. In the
case that CLAAS R&D gives no clear specifications the
missing information has to be requested by the supplier.
Reliability tests
The supplier carries out reliability tests on the products
that have been attributed a specific lifetime in the CLAAS
drawings and documentation.
Reliability analysis methods
The analysis and interpretation of the results are analysed
using the Weibull method.
Basis: VDA Volume 3, reliability testing
Calibration of the reliability test equipment
The test rigs must be calibrated in accordance with the
manufacturer’s instructions with reference to the relevant
national norms.
Documentation
Test conditions and test results have to be recorded and
when required to be presented by CLAAS.
Objective
Confirmation that the product involved meets the lifetime
specified by CLAAS.
Minimum standards
A minimum product conformance level of 0.95 (95%) has
to be attained in order to carry out the reliability data analysis. Products, which fail to meet the minimum specified
lifetime would not be accepted under any circumstances.
Selection and
Qualification Process
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Supplier qualification process
Flow chart component supplier
1
Self assessment by supplier
Supplier information, no
further action
Not
O.K.
Checking of correction and
documentation
Not
O.K.
Supplier self assesment is
checked
2
3
Drawings are prepared for
quotation purposes
Negotiation with
supplier
Not
O.K.
5
11
Finalisation of quotation and time
schedule
13
Checking of quotation
and time schedule
14
Order of first samples
16
Samples are shipped
17
Not
O.K.
15
C*
Checking of process control
plan and drawings
O.K.
O.K.
4
10
1
12
3
Checking of drawings and
preparation of a process control
plan
Revision of the quotation
Quotation is checked
Not
O.K.
O.K.
6
O.K.
7
Responsible
1) Supplier
2) Supplier qualification team
3) Purchasing
4) Purchasing
5) Purchasing
6) Supplier
7) Supplier qualification team
8) Supplier qualification team
9) Supplier
10) Supplier
11) Supplier qualification team
12) Supplier
13) Supplier
14) Purchasing
15) Purchasing
16) Purchasing
17) Supplier
18) Supplier qualification team
19) Supplier
20) Supplier qualification team
QM system and /
or product audit
O.K.
8
Audit results checked
A*
* A, B, C – Supplier classification
1
B*
Corrective action defined
and carried out
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19
Release for
series production
Checking of first samples
18
Not
O.K.
O.K.
Release for
series production
20
Selection and
Qualification Process
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21
Supplier qualification process
1
Flow chart system supplier
1
Supplier self assessment
17
Supplier information,
no further action
3
Not
O.K.
Supplier self assessment
is checked
Corrective action
Not
O.K.
2
Checking of
documents
and drawings
16
O.K.
O.K.
4
QM System and / or product
audit
17
Checking of calculation
Corrective action
Not
O.K.
5
Review of audit results
C*
B*
O.K.
Definition and
implementation of
corrective actions.
6
A*
17
Agreement of confidentiality
concluded
18
Corrective action
Not
O.K.
7
Checking the test
results of the prototypes
19
O.K.
Handing over of required
specifications to supplier
8
17
Specifications are checked with
the supplier in order to clarify open
points and make quotation
Supplier information,
no further action
11
Not
O.K.
Feasibility evaluation
and costs
Responsible
1) Supplier
2) Supplier qualifiation team
3) Purchasing
4) Supplier qualifiation team
5) Supplier qualifiation team
6) Supplier
7) Purchasing
8) Purchasing
9) R&D / Purchasing
10) R&D / Purchasing
11) Purchasing
12) Supplier
13) R&D / Project Management
14) Supplier
15) R&D / Project Management
16) R&D / Purchasing
17) Supplier
18) R&D / Purchasing / Management
19) R&D
20) Supplier qualifiation team
21) R&D
22) Supplier qualifiation team
Corrective action
Not
O.K.
9
10
O.K.
17
Corrective action
Not
O.K.
First sample process
(see flow chart
component supplier)
20
O.K.
Evaluation of the results of
the field tests / pre-series
21
O.K.
Handing over of specification book
including detailed project plan is
given to CLAAS
12
Reworking of
specifications and / or the
project plan
14
Not
O.K.
Release for series
production
Checking of specifications
of the project plan
22
13
O.K.
Follow up of project plan including
defined development steps
15
* A, B, C – Supplier classification
1
Selection and
Qualification Process
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IV. Series Monitoring.
1. Continuous Evaluation
2. Processing of complaints
Objective
Basis for intensive and steadily improving business relationship is the optimisation of the testing process at CLAAS
and the supplier. It is important to give feedback to the
supplier on the level of quality supplied including improvement potential.
Objective
Rapid elimination of the fault at CLAAS.
Damage limitation by narrowing errors down.
Resolution of the problem, no repetition.
Implementation
• Continuous monitoring of the relevant data
- Quality
- Logistics
- Costs
- Innovation
- Motivation
• Analysis of the data and continuous information
to supplier
• In the event of unsatisfying evaluations the supplier is
required to formulate a written statement about cause
and corrective action including proof of efficiency
Implementation
• Rapid detailed information to the supplier by CLAAS
• Joint agreement about immediate measure
• Analysis of the problem by supplier
• Documentation by the supplier of at least
- Problem
- Cause
- Immediate measure
- Elimination measure
• Or conform to the VDA 8D - systematic
Series Monitoring
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V. Further Agreements.
1. Special Release
2. Logistic Agreement
3. Emergency Plan
4. Quality Assurance Agreement (QAA)
Objective
Avoid that components, which are nonconforming, get,
without a special release, into the production process.
Objective
• Minimal carrying costs by bundling of supply transports
and intelligent carrying concept
• Improvement of inventory by coordinated supply
frequency
• Improvement of the process by standardised container
concept and shipping documentation (according to
VDA recommendation 4902)
Objective
Continuity of supply in case of crisis, as for example may
result from:
- machine or tool breakdown
- breakdown of computer system
- power failure
- damage to buildings and equipment (natural disasters)
- supply bottlenecks of material
Objective
Approval of direct delivery to the place of use in the factories.
Decreasing of CLAAS goods incoming inspection.
Implementation
CLAAS Logistics Agreement
Implementation
Joint agreement on components that are essential for an
emergency programme.
5. Agreement of confidentiality
• Securing the delivery capability
Implementation
After detection of a deviation the supplier has to inform
CLAAS (purchasing / procurement) immediately in written
form. CLAAS decides on further action and informs the
supplier in written form.
Implementing of the decision
For the case of a delivery approval for a limited lot size
these lots have to be marked clearly and precisely in the
shipping documents regarding to the exceptional approval. Basically the delivery only can be carried out after submission of the approval.
• Development of an emergency plan
• Joint checking and approval of the emergency plan
Implementation
The QAA will be agreed as an addition of the basic supply
agreement. The QAA relevant products will be specified and
documented accordingly.
Objective
With this agreement both parties ensure the confidential
handling of all information and data, which will be exchanged
between CLAAS and the supplier.
Implementation
CLAAS Agreement of confidentiality.
Further Agreements
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VI. Appendix
1. Definitions
DIN EN ISO 9001
New certification norm for quality management systems,
which was edited by the German (DIN), European (EN)
and International Organization for Standardization (ISO).
Critical Characteristics
Characteristics of a product or production process that
have a considerable influence on safety, function, assembly, adherence to legal safety standards and customer
satisfaction.
Lifetime
Period from initial use to the point of failure after which the
product cannot be returned to a functional state.
Supply Reliability
Adherence to the requirements regarding on date of
delivery and delivery quantity.
3. Sources
2. Abbreviations
Capability of measurement
Measuring of the degree of inaccuracy in relation to the
tolerance of the characteristics to be measured.
System supplier
Takes responsibility for development and production of an
assembly, which can be separated functionally, such as
cutter bars, brakes, steering, hydraulics
Component supplier
Works on the basis of documents, drawings, specifications etc. provided to them with no development responsibility.
Cp/Cpk value
R&D
FMEA
PCP
QM
QAA
RPV
SPC
VDA
- Process capability value
- Research and development
- Failure potential and influence analysis
- Process control plan
- Quality Management
- Quality assurance agreement
- Risk priority value
- Statistical Process Control
- German Automotive Industry Association
VDA Volume 2:
VDA Volume 3:
VDA Volume 4:
VDA Volume 6 (Part 1):
VDA Volume 6 (Part 2):
VDA Volume 6 (Part 3):
VDA Volume 6 (Part 4):
VDA Volume 6 (Part 5):
QS 9000 PPAP
QS 9000 APQP
QS 9000 FMEA
QS 900 SPC
QS 9000 MSA
Quality Assurance of Supplies
Reliability assurance of car manufacturers
and suppliers
Quality assurance during product realisation
QM system audit Material Products
QM system audit Service
Process-audit
QM system audit Production Equipment
Product audit
Guideline Production Part Approval Process
Guideline Advanced Product Quality
Planning and Control Plan
Guideline Failure Mode and Effects Analysis
Guideline Statistical Process Control
Guideline Measurement System Analyses
Weibull media rank method
Statistical method used in calculating product and
component reliability.
Appendix
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29
Forward-looking.
Worldwide. CLAAS.
Future
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