VP-105 Special Characteristics Identification Process (SCIP) For by marcjackson

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									                                      VP-105 Special Characteristics Identification Process (SCIP)
                                              For All Programs with Gate 3 after October 1, 2003

Purpose: The purpose of this document is to identify a consistent global process for Visteon to define, control, and track
Special Characteristics.

Activities Affected:
Visteon Staff Activities: Advanced Supplier Development Engineering, Supplier Development Engineering – Worldwide
Product Development – Worldwide
Manufacturing Locations - Worldwide
Glass Operations

Inputs:
Customer Requirements including Customer Designated Characteristics
Statement of Work
Design FMEA Severity Rankings
Manufacturing Process Flow Charts
Project Team Engineering/Manufacturing Knowledge


Outputs
SCIF = VF-105
FMEA Characteristic Classifications
Control Plans
Drawings or Models


Performance Indicators:
SCIF initiated in WERS or equivalent by Gate 3
% VS characteristics identified by Gate 3
SCIF released as Notice by Gate ER


Exclusions:
This process is to be followed for all new model programs with Gate 3 after October 1, 2003. Prior Model Years may follow
this process at the discretion of Program Management with PD and Manufacturing concurrence. Otherwise programs with gate
3 prior to October 1, 2003 must follow VP-003 Characteristic Classification.

Section 1 – What Are Special Characteristics:
The intent of identifying special characteristics is to callout product aspects and features, or process parameters that are
sensitive to variation, and for which Visteon's standard processes do not provide adequate control. The intent is not simply to
ensure that the correct symbol is placed on drawings, but rather to develop a special control in order to reduce, eliminate or
detect variation in that characteristic.




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Procedure VP-105
                                Product Characteristics Summary

              Standard Characteristics
                   •Do not affect Customer Satisfaction, Safety, Regulatory Compliance,
                   Scrap or Repair Shop Rework OR
                   •Are Insensitive to Variation, OR
                   •Are Controlled Adequately by Standard Processes



              Major Characteristics
                   •Affect Scrap and Repair Shop Rework, AND
                   •Are Sensitive to Variation, AND
                   •Cannot be Controlled with Standard Processes AND
                   •Have Special Controls determined to be Cost Effective
                                     Significant Characteristics
                                           •Affect Customer Satisfaction, AND
                                           •Are Sensitive to Variation, AND
                                           •Cannot be Controlled with Standard Processes
                                                                Critical Characteristics
                                                                     •Affect Safety or Regulatory Compliance, AND
                                                                     •Are Sensitive to Variation, AND
Procedure:                                                           •Cannot be Controlled with Standard Processes
       Responsibility                                  Process Map                                       Notes/Deliverables
(1) CBG                                                (1)
                                      CBG obtains Customer Requirements and
                                              forms Program Team.



(2)                                                                                          (2)The output from the DFMEA activity
Product Development                                       (2)                                will include the identification of
                                     Initiate DFMEA including the classification
Engineering leads Program                                                                    potential critical and significant
                                          of potential Special Characteristics.
Team                                                                                         characteristics. FMEA risk reduction
                                                                                             activities should be part of this task.

(3)                                                                                          (3) Potential special characteristics will
Product Development                                       (3)                                be documented on Special
Engineering leads Program            Document potential Special Characteristics              Characteristics Identification Form
Team                                and formally initiate through WERS process.              (SCIF) Worksheet. Visteon Purchasing
                                                                                             Agents will incorporate this worksheet
                                                                                             within the RFQ to subcontractors. PD
                                                                                             initiates a Visteon Concern in WERS as
                                                                                             a local record change base concern or a
                                                                                             Visteon local only concern. The
                                                                                             Concern must be routed to PD, Mfg, and
                                                                                             Supplier Quality when applicable.
                                                                                             Approval of the Concern is by PD only.
                                                                                             NOTE: Visteon organizations that do
                                                                                             not use WERS must use local equivalent
                                                                                             release system.
                                                                                             NOTE: If no potential special
                                                                                             characteristics are identified this must
                                                                                             still be documented on SCIF Worksheet
                                                                                             and filed with program documentation
                                                                                             NOTE: Glass Division may use their
                                                                                             own document that meets or exceeds the
                                                                                             SCIF.




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Procedure VP-105

                                                                            (4) Potential special characteristics
(4) Purchasing                                                              specific to externally purchased parts
                                                   (4)
                                                                            must be provided to the appropriate
                                  Purchasing to cascade to relevant sub-
                                                                            supplier via SCIF (VF-105) so that they
                                                suppliers.
                                                                            can be considered in their Advanced
                                                                            Product Quality Planning (APQP).
                                                                            Suppliers with design responsibility will
                                                                            address potential characteristics on the
                                                                            DFMEA, PFMEA & Control Plan.
                                                                            Suppliers building to print will address
                                                                            the potential characteristics on the
                                                                            PFMEA & Control Plan.

(5) Manufacturing Process                            (5)                    (5) Using the SCIF Worksheet, relate all
Engineering and/or Supplier's          Relate the potential Product         the potential special characteristics to
process engineering                characteristics to process operations.   the process operations that effect them.
                                                                            These operations will be the ones that
                                                                            create, modify or check the product
                                                                            characteristics in question.
                                                                            NOTE: Visteon External Suppliers may
                                                                            use an equivalent process.
                                                                            NOTE: Appendix E of Reference
                                                                            Manual may be used in addition to
                                                                            SCIF.

(6) Manufacturing Process                          (6)                      (6) A) Include all the potential special
Engineering and/or Supplier's       Initiate PFMEA and include the          characteristics identified by the DFMEA
process engineering                  identification and subsequent          and captured on the SCIF Worksheet
                                 confirmation of special characteristics.   B) Identify potential major special
                                                                            characteristics arising specifically from
                                                                            process operations on the PFMEA.
                                                                            C) Assess the needs for special controls
                                                                            for all VCs, VSs, and VMs. Initiate cost
                                                                            analysis for potential VM's to determine
                                                                            if cost effective solution exists. Confirm
                                                                            or reject special characteristics.
                                                                            D) Apply FMEA risk reduction
                                                                            activities.
                                                                            NOTE: Visteon External Suppliers may
                                                                            use an equivalent process.

(7) Supplier Development                                                    (7) Supplier APQP reporting must
                                                   (7)
                                                                            demonstrate that the risks associated
                                Supplier Development to monitor supplier
                                                                            with the applicable special
                                  performance through APQP reviews /
                                                                            characteristics are being adequately
                                                reports.
                                                                            managed. Pass Through characteristics
                                                                            (see page 7) must be controlled at the
                                                                            plant of manufacture.
                                                                            NOTE: If supplier is selected and
                                                                            sourced by Visteon, Visteon is
                                                                            responsible for this task. If the supplier
                                                                            is a directed source the OEM retains
                                                                            responsibility for monitoring supplier
                                                                            performance




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Procedure VP-105



                                                                             (8) Some customers may require review
(8) Project Leader                                 (8)                       and sign-off of FMEAs and Control
                                 Obtain customer concurrence of special      Plans e.g. Component review team
                                   characteristics (Where required).         (CRT) agreements or other customer
                                                                             equivalent documents. Also, some
                                                                             customers may mandate the inclusion of
                                                                             characteristics considered special by the
                                                                             OEM; document them on the SCIF.
                                                                             NOTE: Visteon may require signoff of
                                                                             our Suppliers documents.

(9) Product Development                             (9)                      (9) SCIFs are to be reviewed and
Engineering                     Review all process control documents with    correlated to control documents for all
                                Manufacturing and Suppliers to ensure all    components and assemblies within a part
                                   potential special characteristics are     number
                                                addressed.



(10) Manufacturing Process                                                   (10) The SCIF needs to be updated to
                                                    (10)
Engineering                                                                  show list of confirmed special
                                 Update the SCIF with confirmed special
                                                                             characteristics (Page 1 of SCIF). NOTE:
                                characteristics and release through WERS.
                                                                             The original information showing
                                                                             potential characteristics should be
                                                                             retained. Reasons for not confirming a
                                                                             potential product special characteristic
                                                                             must be given. Approval of the SCIF
                                                                             will be by Manufacturing & PD
                                                                             activities on Page 1 of SCIF, it must be
                                                                             distributed to the affected Visteon
                                                                             Suppliers. NOTE: The SCIF is a
                                                                             Visteon INTERNAL document only and
                                                                             should not be shared with the customer.

(11) Product Development                           (11)                       (11) Generate a Visteon Notice from the
Engineering                     Convert form to .pdf format and forward to   Visteon Concern developed in Step 2.
                                             CAD Services.                   (Unix users can use Framemaker for .pdf
                                                                             conversion; PC users can use a .pdf
                                                                             writer such as Adobe Acrobat. Either is
                                                                             available from IT.)

                                                   (12)                      (12) Affected product detail will
(12) CAD                             Design Services will document the       reference the SCIF number in the
                                    information and include in the CAD       General Note Column of the drawing. It
                                                 package.                    is a requirement that all critical product
                                                                             characteristics are identified adjacent to
                                                                             the feature / note on the product drawing
                                                                             and as a prefix to the part number with
                                                                             the appropriate symbol. Symbolism on
                                                                             Customer Drawings is determined with
                                                                             the Customer.Visteon CAD Standards,
                                                                             Section E-2 Special Controls.




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Procedure VP-105



                                                         (13)                              (13) Follow the Visteon Electronic
(13)                                   Process Design Release Package and close            Release Process and Post package to
Material Release Analyst                            Release Notice.                        Docman per ERP.



(14) All                                                                                   (14) Accessability is by part number
                                                        (14)                               and/or notice number.
                                           SCIF document is now available in
                                                     DocMan.




(15) Manufacturing                                        (15)                             (15) It is a requirement of special
                                           Ensure that all VC's, VS's and the              characteristics that there is a special
                                        additional VMs, if any, identified on the          control which is documented on the
                                         Special Characteristics Identification            control plan. Manufacturing process
                                        Form (SCIF), are addressed on PFMEA,               flow charts and operator work
                                          Control Plans, and Operator Process              instructions are annotated to show which
                                                         Sheets.                           process operations have special controls
                                                                                           applied.
                                                                                           PD is required to sign off on all Mfg
                                                                                           documents.


Visteon recognizes that there may be other Special Characteristics defined by our Customers. Where contractually required,
Visteon must monitor/process these characteristics, including the appropriate notifications to Visteon suppliers.
NOTE: Before processing customer unique special characteristics through FMEAs, ensure that Visteon is being compensated
by the Customer for this additional effort and that it is included in the Statement of Work (SOW).

Special Characteristics are identified at the level where the special control exists. If the special control is implemented during
the manufacturing of a component, then that component must be designated as containing a special characteristic. If the special
control is implemented during assembly of a system then the assembly that is delivered must be designated as containing a
special characteristic. With this process Visteon could provide assemblies to an OEM that are not designated as having Special
Characteristics, yet the assembly could contain components or sub-assemblies that do have Special Characteristics. Visteon
may be required to advise the OEM that lower assemblies or components contain Special Characteristics, but the designation
does not flow up to the higher assembly. e.g. Visteon delivers an instrument cluster to an OEM. The drawing for that
instrument cluster will indicate all of the dimensional characteristics of the cluster, as well as the part number of the sub-
assemblies that are part of the cluster. If the stepper motor for the speedometer contains a critical characteristic, then the
drawing for the stepper motor would indicate which characteristic was critical. The drawing for the instrument cluster cannot
identify the characteristics of the stepper motor and therefore would not carry a Critical Characteristic designation. However if
the attach process for the stepper motor to the cluster was designated critical, then those attach points would be designated
critical, and the drawing would carry a Critical Characteristic designation.

How Special Characteristics change
                                                  Re-Classification Process
           Responsibility                              Process Map                                     Notes/Deliverable
                                                                                            1. Product or Manufacturing
 (1)                                                         (1)                            Engineering will, from time to time,
 PD Engineer / Manufacturing             Note the need to review one or more of the         identify the need to make or record
 Engineer                                          special characteristics.                 changes that affect the special
                                                                                            characteristics listed against a
                                                                                            product.




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Procedure VP-105


                                                              (2)                             2. The original team, as near as is
 (2)                                     Assemble the team who were responsible for           possible, with substitute persons
 PD Engineer / Manufacturing           the confirmation of the special characteristics or     where appropriate, shall be
 Engineer                                   replacement personnel as appropriate.             assembled to address the change.




                                                                                              3. Using the FMEA process the team
 (3)                                                          (3)                             will review the affected failure modes
 PD Engineer / Manufacturing             Consider the change leading to the review            and re-score them.
 Engineer                                and re-score the appropriate failure modes           NOTE: To achieve a reduction in the
                                         for severity, occurrence, and detection.             severity score of a design failure
                                                                                              mode, a design change to the
                                                                                              characteristic concerned is required.
                                                                                              To achieve a reduction in the severity
                                                                                              score of a process failure mode, a
                                                                                              process change to the manufacturing
                                                                                              operation concerned is required. All
                                                                                              scoring, risk reductions shall be
                                                                                              supported with documented
                                                                                              evidence.

                                                                                              4. The team shall then re-enter the
 (4)                                                          (4)                             Special Characteristic process flow at
 Program/ Project Team                     Enter the Special Characteristic Process           step 3, for a product change, or step 6
                                          Flow at step (3) or (6) on Page 3-4 of this         for a process change. (See Page 3-4
                                                    Procedure. (see notes)                    of this Procedure).


General Rules:
Performance Indicators:
Required: related indicators that link to a metric on a scorecard
Recommended: all other indicators listed on a procedure
ISO/TS16949 Requires that process effectiveness be demonstrated and monitored. It is the responsibility of management or
each activity performing the process to ensure that required metrics are identified, compiled and reviewed. If the process has
no required performance indicators, a method must be established to demonstrate process effectiveness.

Definitions :
A Potential Critical Characteristic (YC) is identified in the DFMEA as having a severity of a 9 or 10 indicating that if the
characteristic is not controlled then the potential for impacting the product's safety or compliance with government standards
exists.
A Potential Significant Characteristic (YS) is identified in the Design FMEA as having a severity of a 5 through 8 and an
occurrence rating greater than 1, indicating that if the characteristic is not controlled then the potential for impacting customer
satisfaction exists. Exception:

When the occurrence is 2 or 3, in the Design FMEA, and there is historical evidence that the Visteon manufacturing facility has
experience producing similar components with the exact same process without the need for special controls. This exception
cannot be used for suppliers unless Visteon directs the processes or controls used.

(Note: Regardless of whether the characteristic is confirmed as special by the Process FMEA, the severity does not change, and
the classification remains a YC or YS on the Design FMEA. This is kept as an indicator for future design or process changes
that will require that the potential characteristic be reassessed.)

A Confirmed Critical Characteristic (VC) is a product feature or aspect or process parameter for which reasonably anticipated
variation could significantly affect the product's safety or compliance with government standards or regulations.




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Procedure VP-105

Critical Characteristic Symbols: Either the ISO symbol for critical characteristics, (§), or the customer designated symbol is
required on all customer drawings for confirmed Critical Characteristics. The ISO symbol, (§), is required on all Visteon
drawings.

A Confirmed Significant (VS) Characteristic is a product feature or aspect or process parameter for which reasonably
anticipated variation could significantly affect customer satisfaction with the product.

A Confirmed Major (VM) Characteristic is a product feature or aspect or process parameter for which reasonably anticipated
variation could adversely affect scrap or rework of the product in the repair shop, and for which a cost effective control exists.
Major Characteristics are both identified and confirmed in the Process FMEA. Identification of the characteristic is made when
a severity rating of greater than 5 is assigned due to the effect on manufacturing/assembly, and the characteristic is sensitive to
variation. Confirmation of the characteristic requires the responsible Manufacturing Engineer to review a cost / benefit
assessment to determine the cost effectiveness of controlling the characteristic. This analysis would need to consider the
occurrence rating of the variation and trade the cost of scrap/rework at Visteon versus the cost of implementing special controls.
Once considered, the Major Characteristic is either confirmed or rejected.

A Standard Characteristic is a product feature or aspect for which reasonably anticipated variation is unlikely to affect the
product's safety, compliance with government standards, customer satisfaction, scrap, or rework in the repair shop.

Appendix A contains a simple graphic depicting the tests to determine the classification of special characteristics.

Pass through characteristics are a unique subset of special characteristics – the underlying assumption is that pass through
characteristics are those special characteristics that are produced or manufactured by a Tier II Supplier (supplier to Visteon),
and are not subjected to a detection or validation process through Visteon's normal preventive/detection systems/processes.
Therefore, a component or assembly that is defective for a pass through characteristic will be "passed through" to our
Customer. Note that a pass through characteristic will also be classified as Critical or Significant (Major characteristics cannot
be pass through as they do not affect customer satisfaction nor safety).

The Visteon Special Characteristic Identification Process will adequately manage pass through characteristics.

Visteon has two responsibilities as the Tier I supplier. First, we must communicate any potential Special Characteristics
designated by the OEM to our suppliers to ensure that they are properly addressed. This can be accomplished with the
completed Special Characteristics Identification Form (VF-105). Second, Visteon must make the OEM aware of Special
Characteristics in sub-assemblies or components that are part of our delivered product. This is typically accomplished with
Design / Process FMEA reviews with the Customer. The Special Characteristics Identification Form (SCIF) is NOT to be
shared with Customers. For more information/clarification of pass through characteristics, contact your Supplier Quality
Program Team Member.

Controls for Special Characteristics
Each special product characteristic will have associated manufacturing or assembly process parameters that affect product
characteristic variability. In cases where identification of the relevant process parameter is not obvious, various engineering
tools (e.g., DOE) may be needed to identify the correlations between product characteristic and process parameter. Control of
the process parameter around some target value (e.g., with the use of SPC) will ensure that variation of the product
characteristic is maintained or minimized around its target value. Control of a process parameter is generally the most cost
effective method of controlling a product characteristic. When a process parameter cannot be identified for the product
characteristic, control can only be achieved by trial and error or by screening out bad products.

Special controls can include SPC, sampling with a containment plan, or 100% inspection. (Generally 100% inspection is
reserved for instances when either the process does not meet it's capability indices, or when a 100% inspection can verify
multiple characteristics at the same time. i.e. a leak test.) For more information on Controls for Special Characteristics, see the
SCIP Tutorial and Reference Manual.

References:
Special Characteristics Identification Process Tutorial & Reference Manual
Visteon Engineering CAD Standards, Section E-2: Special Controls
AIAG Potential Failure Mode and Effect Analysis (FMEA) Reference Manual – Third Edition




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Procedure VP-105

Visteon EBOM Process
Visteon Electronic Release Process
Visteon Product Development Process (VPDS)
Note: Appendix A Below
VF-105 Special Characteristics Identification Form (SCIF)

List of Quality Records: The following records are maintained in accordance with Visteon Retention Policy schedule as
indicated: SCIF VF-105 per drawings and specifications retention rules

Originating Activity: Visteon Quality Office

Record of Revisions:
Date               Description of Change
9/30/97            Initial Release
7/2/98             Raised to Visteon level procedure - previously CDP07-101
3/23/99            Removed all references to FAPs in “Exclusions” and “References”, deleted/changes references from
                   CRM to GIS, removed “FMEA SAE J1739” under “References”, made clarifications under
                   “Procedure” section 7.
1/7/00             Updated URL hotlink to VP02-002 - no approvals required.
4/3/00             Complete re-write of procedure. All changes identified in blue.
2/19/01            Complete re-write of procedure for applicability throughout Visteon Procedure also renumbered from
                   VP09-004 to VP02-012
6/15/01            Removed requirement for Team sign off by production personnel in section 9.2
3/7/03             Complete rewrite of procedure/New Procedure Number, and reference of GIS to Visteon Retention
                   policy
3/14/03            Re-numbered because VP02-012 (VP-003) was reinitiated for MY's prior to 2007.
5/15/03            Added hyperlink, minor clarification change, no approval needed.
5/16/03            Corrected the hyperlink requested on 5/15/03, incorrect URL provided,. Process Owner approved
9/13/03            Changed implementation date from June 1, 2003 to October 1, 2003; rewrote Performance Indicators
                   to align with PDOS; corrected hyperlinks requested on 6/30/03. Implemented changes to hyperlinks
                   for New VBOS Doc Repository and moved to new system.
11/18/03           Clarified Definition of Potential Significant Characteristic – added exceptions; reworded NOTE in step
                   3, 10 for clarification; reworded e.g. in step 8 to say “or other equivalent customer documents” for
                   clarification; Added note to Appendix A. Addition to General Rules Section clarifying performance
                   indicators
2/13/2004          Added Reference to Visteon Record Retention policy, no approval needed.
5/12/2004          Included specific examples of acceptable special controls. Modified instructions to convert SCIF to
                   .pdf format. Corrected typographical errors. Removed superfluous wording. Revised YS definition
                   and exceptions based on feedback from Product Development. Included definition for §. Added VF-
                   105 under Quality Records.
11/24/2004         Reworded Exclusions to clarify that VP-003 is the preferred process for programs with gate 3 prior to
                   October 1, 2003. Updated hyperlinks to reflect new addresses.




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 Appendix A


DFMEA                                        NOT a VC
                                       No    DFMEA Severity < 9
A) Can the
Characteristic affect       A
Safety or Regulatory
Compliance?                                                                               NOT a VS
                                Yes    DFMEA Classification YC
                                                                                 No       DFMEA Severity < 5, OR
B) Can the
                                                                                          DFMEA Occurrenc e = 1
Characteristic affect                                                   B
Customer
Satisfaction?                                                               Yes DFMEA Classification YS*
PFMEA                                                                             *See exception under
C) Can the                                                                                                                   No     Not a VM
                                                                                   definitions for low
characteristic cause                                                                                               C                PFMEA Severity < 6
                                                                                   occurrence ratings bas ed
rework in the repair                                                                                                                Standard Characteristic
                                                                                   on robust processes                 Yes
shop or cause
scrap?
                                       No
                                             NOT a VC                            No      NOT a VS                            No     Not a VM
D) Is the                   D                                           D                                          D
Characteristic                               Standard Characteristic                     Standard Characteristic                    Standard Characteristic
Sensitive to                     Yes                                        Yes                                        Yes
Variation?
                                       Yes                                       Yes                                         Yes
E) Can Variation be                          NOT a VC                                   NOT a VS                                    Not a VM
                            E                                           E                                          E
controlled by                                Standard Characteristic                    Standard Characteristic                     Standard Characteristic
standard proc esses?
                                 No                                         No                                         No

                                        Confirmed VC                                  Confirmed VS                           Potential VM
                                        DFMEA Classification YC                       DFMEA Classification YS                Final Determination made by
                                        PFMEA Classification VC                       PFMEA Classification VS                Manufacturing Engineering
                                        A § (or customer designated                                                          based on cost effectiveness of
                                          symbol), shall be added to                                                         implementing special controls
                                          drawings


     When a Special Characteristic is confirmed, Manufacturing and Product Design Engineers must concur on a Special Control to either
     control the variation (preferred), or contain the variation (acceptable when control is not feasible). This control must be entered in the
     control plan, and records must be maintained to document that the characteristic is being cont rolled. These Special Cont rols will be
     indicated in the PFMEA under either the Current Process Cont rols (if a special control from a similar process exists), or as a
     Recommended Action if a new Special Control must be dev eloped.


 Hard Copies of This Document are Uncontrolled                                              Appendix A

								
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