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					Supplier Production Readiness Cover Sheet                                                                                                                               Control #                                                                                                               Revision 01 6/1/05                                            Mass
                   Project:                                                                                Total Score                                                                                                SUPPLIER APPROVAL                                 Innotec Group APPROVAL
                                                                                                                                                                                                                                                                                                  SUPPLIER DEV. /
                                                                                                                                                                                                                                                                                                                                                           Production
                                                                                                                                                                                                             PROJECT MANAGER     PRESIDENT / SR. LEVEL MGR.   AUDITOR         CELL MEMBER
          Supplier Name:                                                                                                                                                                                                                                                                             PURCH.                After Review                     Direction
               Location:                                                                                     0%                                                       Supplier Code           Signature
                                                                                                                                                                                                                                                                                                                           with PM MGT
                                                                                                                                                                                                                                                                                                                           (circle one)

              Visit Date :                                                                                                                                                                                                                                                                                                                                  Go            NoGo
                                                                                                                                                                                                Date
          Summary
                                                                                                     Audit Priority
Quality                                                                                        (ie stamping, welding, paint, all)
                                                                                                                                                                                                                                                                                                 M/P FORECAST                                              Follow-up




                                                                                                                                    Classification
                                                                                                1                                                                                                                                                                                   Supplier                             Follow-up
                                                                                                                                                                                                                                                                                                                                                          Survey / Visit
                                                                                                                                                                 Process Check Items                      Actual Results From Evaluation (comments)                                Evaluation                            Required
                                                                                                2
                                                                                                                                                                                                                                                                                     rating                     X        (Yes/No)                           required
                                                                                                3

                                                                                                4
                                                                                                                                                                                                                                                                                                                                                           Yes               No
Production                                                                                      5                                   1                              Receiving Inspection
                                                                                                6
                                                                                                                                                                                                                                                                                                                                           Date
                                                                                                7

                                                                                                8                                   2                           In-process Parts/Materials
                                                                                                9                                                                                                                                                                                                                                         Supplier Evaluation Rating:
                                                                                                10
                                                                                                                                    3                              In-process Equipment                                                                                                                                                   1. All check items are NG.
                                                                                                                                                                                                                                                                                                                                          Safety/Regulation concerns exist.
                                                                                                       Attendance                                                                                                                                                                                                                         Impact to M/P.
                Mass Production Line Situation At a Glance
                                                                                                                                    4                          In-process Manufacturing Jig                                                                                                                                               2.N/G and level-up items exist &
                                                                                                S                                                                                                                                                                                                                                         extensive temp c/m's are required to
                                                                                                                                                                                                                                                                                                                                          prevent impact to M/P.
                                                                                                U
                                                                                                P
                                                                                                P                                   5                              In-process Manpower                                                                                                                                                    3. Level-up items exist but temp
                                                                                                L                                                                                                                                                                                                                                         c/m's will prevent impact to M/P.
                                                                                                I
                                                                                                E                                                                                                                                                                                                                                         4. Level-up items exist, but present
                                                                                                R                                   6                             In-process Performance                                                                                                                                                  no impact to M/P.
                                    Receiving Inspection
                 Leadership/development   6          In-process Parts/Materials
                            General                         In-process Equipment                I
                                                                                                                                                                                                                                                                                                                                          5. 100% check items are ok.
                                            4
                                                                                                N
                                                                                                                                    7                            In-process Q.A. Machine
                 Documentation                                  In-process Manufacturing Jig    N
                                            2
                                                                                                O
                                                                                                T
            Inspection fixtures             0                    In-process Manpower
                                                                                                E
                                                                                                                                    8                                Final Inspection                                                                                                                                                                  Production
                                                                                                C
                     Packaging                                  In-process Performance                                                                                                                                                                                                                                                           M/P ready
                                                                                                G
                     Off-line testing                       In-process QA Machine               R                                                                                                                                                                                                                                                OK with temp C/M's
                           Part Inspection            Final Inspection                          O                                   9                              Non-conforming Parts
                                      Non-conforming parts                                      U                                                                                                                                                                                                                                                NG Immediate action
                                                                                                                                                                                                                                                                                                                                                    required
                                                                                                P
                                                                                                                                                                                                                                                                                                                                            X
                                                                                                # of Hours Required to
                                                                                                    complete Audit                  1
                                                                                                                                                                      Part Inspection
                                                                                                                                    0

                                                                                                                                                                                                                                                                                                                                                If unclear of judgement level,
                                                                                                                                    1                                                                                                                                                                                                           error to concern rather than
                                                                                                                                                                      Off-line Testing                                                                                                                                                                         OK
                                                                                                                                    1

                                                                                                                                    1
                                                                                                                                                                        Packaging
                                                                                                                                    2
No.         Parts Name                                      Parts Number

                                                                                                                                    1
                                                                                                                                                                    Inspection Fixtures
                                                                                                                                    3

                                                                                                                                    1
                                                                                                                                                                      Documentation
                                                                                                                                    4

                                                                                                                                    1
                                                                                                                                                                         General
                                                                                                                                    5

                                                                                                                                    1
                                                                                                                                                                 Leadership/Development
                                                                                                                                    6


            Critical Open Issues and Countermeasures
                                                                                                                                                                                                                                                                   Total Score         0
                                                                                                                                                                                                                                                                                                          When
No.                                               Issue                                                                                              Temporary Countermeasure                                            Permanent Countermeasure                                    Who           Temp C/M   Perm C/M




                                                                                                                                                                                                                                                                                                               C:\Docstoc\Working\pdf\[b1c47956-adf6-4068-9114-b0cfe0f69057.xls]Cover Sheet
                                                                                                                                                                                                                           Control #
                                                                                                     INNOTEC GROUP SUPPLIER SOURCING ASSESSMENT                                                                                                .
                                                                                                                                                                                                                                                  Special note: It's
Assessment Date:                                                                                                                                                                                                                              OK, & expected to have
Supplier Name:
                                                                                                                    CHECK SHEET                                                                                                               many yellow Triangles.
                                                                                                                                                                                                                                              Please record the
Parts Evaluated:                                                                                                    COMMODITIES                                                                                  LEGEND:       OK             issues and apply C/M
                                                                                                                                                                                                                               Minor issues
Project:                                                                                                                                                                                                                                      as nescessary.
                                                                                                                                                                                                                           .   only
                                                                                                                                                                                                                           X   NO GOOD


      Receiving Inspection                                                                                                 Check Method                                             Supplier                               JUDGMENT
 1           Item                                                                                                             Suggestion                                          Resp. Assoc.   Actual Result                          X
 1    Is the correct part Raw Material being used?                                        Material Cert. Sheets, (Dwg VS actual Material Code #) (on file, approved, tracking)

 2    Is there lot control for critical all raw materials/component parts?                Heat #/Date

 3    As per the control plan, are quality checks being done? Recorded?                   Receiving Inspection Data Sheet

 4    Are non-conforming materials placed in a quarantine area?                           Non-conforming material area

 5    What is the frequency of tool calibration?                                          Check procedure


 6    How are in coming first run after change tags controlled?                           Check flow to assembly from tracking & roll-up (fifo/cage/Assy)
      How does supplier confirm they have the correct part #'s and Design Change or       Compare to P.O., D/C status list. Confirm that first run after change policy is being
 7    Document Control (D/C) #'s? For Innotec Supply parts, others?                       followed

 8    Who passes judgment on the non-conforming material? How is it documented?           Review Non-Conforming material process
      Is there a system for Identifying 'first run after changing product/process' to
 9    guarantee delivery of correct product and marking as such?                          Confirm system and marking strategy

 10   Where are documents stored and who stores/retrieves them?                           Document control / D/C associate


      In-process parts/materials                                                                                           Check Method                                             Supplier                               JUDGMENT
 2           Item                                                                                                             Suggestion                                          Resp. Assoc.   Actual Result                          X
      Are the In-process materials in an appropriate area? Mixing concerns? Smooth
 1    flow?                                                                               Check actual area.

 2    Are there any material handling concerns (part damage)?                             Check for method of part transport.

 3    Contamination from foreign material?                                                Check raw and in process material

 4    Are parts/materials being used on a FIFO basis?                                     Check actual flow (Push/Pull System)

 5    How are cage parts controlled/updated?                                              Check organization of parts

 6    Are the locations to where the parts go properly labeled and/or organized?          Check cage

 7    Do any of the parts have a shelf life? If so, how is it controlled?                 Check method

 8    How do the associates know what parts to deliver to the assembly line?              Check method

 9    How is lot control managed in this area?                                            Best = Label affixed to container. Tag in parts.


      In-process - Equipment (Molding Mach./Assy Equip)                                                                    Check Method                                             Supplier                               JUDGMENT
 3           Item                                                                                                             Suggestion                                          Resp. Assoc.   Actual Result                          X
 1    Is there a preventative maintenance plan in place?                                  Preventative Maintenance Plan
      After preventative maintenance, are quality levels/conditions recorded? How is part
 2    quality re-verified?                                                                Review a previous work order

 3    Are machine setting conditions checked at each run?                                 Machine set-up sheets

 4    Are all Poke Yokes/sensors working properly?                                        Test a NG sample at each station

 5    How often are the Poke Yokes calibrated?                                            Check calibration frequency

 6    If more than (1) piece of equipment, are part quality results the same?             Part data confirmation (Line 1, 2...)

 7    Are machine/equipment critical characteristics monitored?                           SPC, run charts

 8    How is the material mated to the machine (type, color, grade etc)?                  In-process check sheet

 9    Are first off samples approved by QC before a production run?                       First off sample

 10   Are critical part quality controls recorded by the equipment (ie. Torque)?          In-process check sheet, check control plan controls

 11   Are the Poke Yoke test samples outside the spec, but near the upper/lower limits?   Check actual N/G sample condition

 12   How is the PM plan organized on a day-to-day basis?                                 Check plan

 13   Are the poke yoke masters clearly identified?                                       Check masters
      Does a process stop if an automatic process is not finished? How many attempts
      are made before a machine says NG? What is the procedure for restarting the
 14   line?                                                                               Confirm process logic




                                                                                                                                                           Page 2 of 10
                                                                                                                                                                                                                        Control #
                                                                                                           INNOTEC GROUP SUPPLIER SOURCING ASSESSMENT                                                                                       .
                                                                                                                                                                                                                                               Special note: It's
Assessment Date:                                                                                                                                                                                                                           OK, & expected to have
Supplier Name:
                                                                                                                          CHECK SHEET                                                                                                      many yellow Triangles.
                                                                                                                                                                                                                                           Please record the
Parts Evaluated:                                                                                                          COMMODITIES                                                                         LEGEND:       OK             issues and apply C/M
                                                                                                                                                                                                                            Minor issues
Project:                                                                                                                                                                                                                                   as nescessary.
                                                                                                                                                                                                                        .   only
                                                                                                                                                                                                                        X   NO GOOD


     In-process - Manufacturing Fixture                                                                                           Check Method                                   Supplier                               JUDGMENT
 4          Item                                                                                                                   Suggestion                                  Resp. Assoc.   Actual Result                          X
     Can the parts be repeatedly set without possibility of mis-nesting? Are the parts
     nested on the jig without looseness? Checks datum points? Can the part be
     assembled upside down, right/left or other model mixing? Does the jig damage the
 1   part in any manner?                                                               Set the actual parts on the jig and evaluate

 2   If more than (1) jig, are part quality results the same?                                 Part data confirmation (Line 1, 2 ...)

 3   Are datum locations adequate for a good manufacturing conditions?                        Check datum locations

 4   Do they have spare parts for the equipment?                                              Check parts inventory status

 5   Are the jigs identified as to what model they are for?                                   Check jigs

 6   Are the parts easily removed from fixtures after process is complete?                    Remove several parts with no binding


     In-process - Manpower (Line associates)                                                                                      Check Method                                   Supplier                               JUDGMENT
 5          Item                                                                                                                   Suggestion                                  Resp. Assoc.   Actual Result                          X
 1   Do the operators understand their job function/critical control points?                  Ask them their job responsibility
     Has each associate achieved their targeted level of training? Does the training
 2   matrix explain who has been trained for which processes?                                 Review training Matrix (Plan vs Actual)

 3   Are they following approved Operation Standard procedures?                               Observe the operator activity. Confirm sign-offs
     Do the operators understand how part defects impact the Customer (internal and
 4   external)?                                                                               Ask them if they understand their job.

 5   All appropriate manpower in place?                                                       Check full production manning requirements.

 6   Is it clearly understood who has what process at a given time?                           Confirm documentation method

 7   What is the procedure if someone has to leave the line during production?                Confirm procedure; Method to deal with abnormal

 8   What is the company policy related to low manpower? (vacation, temp's, etc)              Confirm if extra quality checks are used
                                                                                              Confirm production team members running the line, as indicated & signed-off on
 9   Are the mass production operators in place?                                              Training Matrix.


     In-process - Performance                                                                                                     Check Method                                   Supplier                               JUDGMENT
 6          Item                                                                                                                   Suggestion                                  Resp. Assoc.   Actual Result                          X
 1   Does cycle time target equal actual results (each manufacturing process)?                Check actual cycle time (stop watch)

 2   Does the scrap rate target equal actual results?                                         Check actual scrap rate
     Are statistical process controls being used? ( X, R, Run charts - for critical control
 3   points)                                                                                  Check control plan and actual

 4   Are the parts within Innotec's capability standard (Cpk 1.33)?                           Check actual CPK on critical points (data sheet points)

 5   Do they have a quality improvement system?                                               Check system (ie. Kaizan system)

 6   Is management aware of quality performance?                                              Check for management awareness (signatures etc)

 7   Do they record downtime & reasons?                                                       Confirm record keeping method

 8   Is there a reward system for associates catching defects?                                Confirm program (to result in a better product)

 9   Do the associates place a mark which corresponds to their quality checks?                Confirm requirement and actual




                                                                                                                                                           Page 3 of 10
                                                                                                                                                                                                        Control #
                                                                                                    INNOTEC GROUP SUPPLIER SOURCING ASSESSMENT                                                                              .
                                                                                                                                                                                                                               Special note: It's
Assessment Date:                                                                                                                                                                                                           OK, & expected to have
Supplier Name:
                                                                                                                   CHECK SHEET                                                                                             many yellow Triangles.
                                                                                                                                                                                                                           Please record the
Parts Evaluated:                                                                                                   COMMODITIES                                                                LEGEND:       OK             issues and apply C/M
                                                                                                                                                                                                            Minor issues
Project:                                                                                                                                                                                                                   as nescessary.
                                                                                                                                                                                                        .   only
                                                                                                                                                                                                        X   NO GOOD


      In-process Q.A. Machine (Function tester etc.)                                                                      Check Method                           Supplier                               JUDGMENT
 7           Item                                                                                                            Suggestion                        Resp. Assoc.   Actual Result                          X
 1    Is the QA machine checking all features as specified on the control plan?          Confirm control plan

 2    How is the operator notified of a defect (NG part)?                                Light, Horn, Alarm

 3    Does the line stop when a NG part is detected?                                     Run a NG part through machine

 4    Who is authorized to re-start the line? Management?                                Review the policy/Management Signature

 5    Are NG parts quarantined in a hold area?                                           Non-conforming In-process area

 6    Is the part labeled signifying that it passed QA Machine testing?                  Part label application timing

 7    Do they have non-conforming tags close to the QA machine?                          Check tag location for ease of access

      Is there a Potential Problem Analysis (PPA) plan if the Q.A.. machine is not
 8    functioning (out for service)?                                                     Check reaction plan/policy.

 9    Is there qualified personal to do Q.A.. machine maintenance?                       Ask who does the machine maintenance.

 10   Are there poke yoke masters for the QA machine?                                    Check for masters

 11   How are repair parts controlled? Flow?                                             Confirm with QA machine

 12   Is the specific part failure identified? (to focus the repair)                     Confirm identification method

 13   How are part variations handled in the machine at changeover?                      Master parts should be used to confirm components


      Final Inspection                                                                                                    Check Method                           Supplier                               JUDGMENT
 8           Item                                                                                                            Suggestion                        Resp. Assoc.   Actual Result                          X
 1    Is the Inspection area clean and well lit?                                         Inspect area

 2    Does the associate know what to inspect for?                                       Ask the associate/Check Op. Stnd

 3    Are limit samples posted?                                                          Check actual board

 4    Are defective parts put in a non-conforming area? Are they tagged?                 Check non-conforming parts area

 5    Are the parts identified as passed final inspection area (stamped with code)?      Check actual system

 6    Does the final inspection check the critical control points?                       Confirm actual situation


      Non-Conforming Parts                                                                                                Check Method                           Supplier                               JUDGMENT
 9           Item                                                                                                            Suggestion                        Resp. Assoc.   Actual Result                          X
 1    Can repair parts be mixed with production ok parts?                                Confirm flow & repair location

 2    Are parts labeled as being repaired, once the repair is complete?                  Check labeling policy

 3    Are the parts re-routed back through the production line for re-inspection?        Confirm flow

 4    Are non-conforming material releases signed by QA management?                      Review actual non-conforming label

 5    Is there a non-conforming part repair flow/procedure?                              Non-Conforming Flow Chart

 6    Are daily rework items recorded? (Plan VS Actual)                                  Confirm tracking mechanism

 7    If rework actual above target, is feedback system in place?                        Check gaps (target vs actual) and corrective action

 8    Do non-conforming tags clearly identify part status?                               OK/In Process/NG Parts

 9    How does the supplier prevent part mixing? Other variations/model types parts etc. Review part identification system
      How is repair handled? Who does it? How is part marked? Are parts identified
 10   with defect to be repaired?                                                        Confirm method

 11   Are rejects or scrap reviewed before product is released for shipment?             Confirm scrap and rejects before product is released




                                                                                                                                                Page 4 of 10
                                                                                                                                                                                                                            Control #
                                                                                                        INNOTEC GROUP SUPPLIER SOURCING ASSESSMENT                                                                                              .
                                                                                                                                                                                                                                                   Special note: It's
Assessment Date:                                                                                                                                                                                                                               OK, & expected to have
Supplier Name:
                                                                                                                       CHECK SHEET                                                                                                             many yellow Triangles.
                                                                                                                                                                                                                                               Please record the
Parts Evaluated:                                                                                                       COMMODITIES                                                                                LEGEND:       OK             issues and apply C/M
                                                                                                                                                                                                                                Minor issues
Project:                                                                                                                                                                                                                                       as nescessary.
                                                                                                                                                                                                                            .   only
                                                                                                                                                                                                                            X   NO GOOD


      Part Inspection                                                                                                         Check Method                                           Supplier                               JUDGMENT
10           Item                                                                                                                Suggestion                                        Resp. Assoc.   Actual Result                          X
 1    Is the part within Innotec specifications (as per data sheet)                           Measure a sample of parts

 2    Is the part at the correct Innotec Design change level?                                 Confirm design change level part

 3    Is there a design change tracking control method?                                       Confirm system thru production process

 4    Is there a method to confirm visual inspection was completed?                           Check control plan visual inspections

 5    Are parts within limit boundaries?                                                      Check part to limit samples

 6    Are quality checks built into the process (assoc. double checks)                        Check inspection flow, redundancy

 7    Is the part color within acceptable limits? Is lot to lot color variation controlled?   Innotec Master Plaque

 8    Is the gloss within acceptable limits?                                                  Must meet Innotec approved master sample

 9    For parts needing specialized Lot Traceability, is the system effective?                Check component and raw material traceability

 10   For all other (non designated parts) is the lot control system effective?               Check component and Raw Material traceability

      Do the production parts meet the master samples (IE. Feeling/Illumination
 11   Masters)?                                                                               Confirm parts with master sample

 12   Are inspection criteria identified and posted?                                          Confirm posting


      Off-line testing                                                                                                        Check Method                                           Supplier                               JUDGMENT
11           Item                                                                                                                Suggestion                                        Resp. Assoc.   Actual Result                          X
 1    Are test samples segregated away from production line flow?                             Check test part holding area?

 2    Is the testing completed and recorded as per control plan?                              Check control plan

 3    Are all results recorded and on-file? How long are they retained?                       Confirm past testing results?

 4    Are the results signed by QA management?                                                Confirm past testing results?

 5    Are test samples put back into production or scrapped?                                  Should be scrapped. If not they must be marked.


      Packaging                                                                                                               Check Method                                           Supplier                               JUDGMENT
12           Item                                                                                                                Suggestion                                        Resp. Assoc.   Actual Result                          X
 1    How does the operator guarantee that the box is labeled correctly?                      Computer tags printed depending on model variation

 2    How are the outgoing first run after change's controlled?                               Confirm Procedure
      How does the first run after changing product/process guarantee delivery of correct Is there a special marking system (IE. Initial Production Part - IPP tagging system or
 3    product and marking as such?                                                        Barcode Scan system)

 4    How does the associate know how to pack the parts?                                      Confirm control plan

 5    Sample board available for Part Distinction? Mixing concerns?                           Check Sample Boards

 6    What does associate do with partials at the end of a run?                               Designated associate to identify and re-introduce partials




                                                                                                                                                           Page 5 of 10
                                                                                                                                                                                                                       Control #
                                                                                                    INNOTEC GROUP SUPPLIER SOURCING ASSESSMENT                                                                                             .
                                                                                                                                                                                                                                              Special note: It's
Assessment Date:                                                                                                                                                                                                                          OK, & expected to have
Supplier Name:
                                                                                                                   CHECK SHEET                                                                                                            many yellow Triangles.
                                                                                                                                                                                                                                          Please record the
Parts Evaluated:                                                                                                   COMMODITIES                                                                               LEGEND:       OK             issues and apply C/M
                                                                                                                                                                                                                           Minor issues
Project:                                                                                                                                                                                                                                  as nescessary.
                                                                                                                                                                                                                       .   only
                                                                                                                                                                                                                       X   NO GOOD


     Inspection Fixtures/Tools                                                                                             Check Method                                         Supplier                               JUDGMENT
13          Item                                                                                                             Suggestion                                       Resp. Assoc.   Actual Result                          X
 1   Is the fixture certified with supporting data?                                      Fixture certification report

 2   Is the fixture at the correct D/C level?                                            Fixture cert. Report and ident.

 3   Is the fixture being used at intervals specified by the control plan?               Check actual data recording timeline

 4   Are all measuring tools calibrated?                                                 Check plan & actual dates on tool tags

 5   What is the frequency of tool calibration?                                          Check procedure

 6   What happens while the measuring tools are being calibrated?                        Confirm if 2nd set exists

 7   How is the calibration of the measuring tools organized?                            Confirm method-computer software

 8   Does the supplier use certified gauges?                                             Check part with gauge

 9   How was the frequency of calibration established?                                   History, data, testing


     Documentation                                                                                                         Check Method                                         Supplier                               JUDGMENT
14          Item                                                                                                             Suggestion                                       Resp. Assoc.   Actual Result                          X
 1   Is the control plan accurate and include all critical quality checks?               Confirm control plan content

 2   Do the Operation Standards reflect the actual processes?                            Compare Op. Standard content; confirm approval sign offs
     Are quality documents updated when defect is found or when the process has
 3   changed or been improved?                                                           Check Non-Conforming Part Flow;

 4   Are all documents at the latest Design Change level?                                Confirm Innotec Drwg D/C level to Documentation

 5   Is the first run after change system being used correctly?                          Review first run after change control system (flow chart etc)

 6   Is there a system to control op stnd's updates?                                     Confirm system and line side temporary vs permanent document

 7   Is there an actual changeover procedure?                                            Confirm procedure with proper signatures


     General                                                                                                               Check Method                                         Supplier                               JUDGMENT
15          Item                                                                                                             Suggestion                                       Resp. Assoc.   Actual Result                          X
                                                                                         Confirm PTC status (IE. Trend, Pareto, Paynter or other type Issue/Action tracking
 1   Are Problem Tracking Charts (PTCs) reflected into the process?                      sheets)

 2   Are machines/work area clean and orderly?                                           Visual inspection (Relative to mfg environment)

 3   Are all Problem Tracking Sheet items closed?                                        Check PTC status
     Are there any open 8Ds? If so, are they on track to be effectively closed in a timely
 4   manner? Does the supplier system insure effective & timely closure?                   8D tracking system. Review examples of both closed and open 8Ds

 5   Was the trial run at production speed?                                              Confirm cycle time plan vs actual
                                                                                         Confirm system in-place and active.
 6   Is there an active Cost Reduction System?                                           Check for open VA/VA items and implementation schedule).



     Leadership/Development                                                                                                Check Method                                         Supplier                               JUDGMENT
16          Item                                                                                                             Suggestion                                       Resp. Assoc.   Actual Result                          X
     Does leadership have a short and longer term plan for the organization is this
 1   communicate to all employees?                                                         Confirm there is a organizational plan
     Is there an incentive for employees to improve quality, delivery, efficiency, and see
 2   out new innovations?                                                                  Confirm the incentive programs exists and is used
     Does the company currently track performance measures like quality performance,
 3   delivery performance, inventory turns, changeover times, etc.                         Review current performance measures are they easily identified

 4   Are employees encouraged to continue their education?                               Review the incentive to continuing ones education
     Is there on-going training programs to keep employees informed of current
 5   technology changes or developing employees into leadership?                         Confirm development and training exists
     Are employees crossed trained so during absence of employees manufacturing,
 6   quality performance, and delivery performance will not change?                      Confirm cross training system exists

 7   Are employees evaluated on performance and quality of their work.                   Review evaluation process

 8   Are there any Best Practices that can be learned from Supplier?                     Find, review & document Best Practice (s)




                                                                                                                                                            Page 6 of 10
Quality Assurance Visit Gap Analysis Worksheet
                                                               Status Key:
Model:                                                            O          Complete / OK
Supplier Name:                                                    D          In-process / Pending
Part Number(s) / Name(s):                                         X      Complete / No Good
                                                               Update date:
   No.       Item           Gap Explanation   Countermeasure     Who       Schedule
                           Control #

Complete / OK
n-process / Pending
Complete / No Good

                      Status
Supplier Mass Production Readiness Cover Sheet                                                                                                                Control #                                                                                                                  Revision 01 6/1/05

                        Project:                Honda SJC Flr Cnsl Rr Garnish                              Total Score                                                                                       SUPPLIER APPROVAL                                   Innotec Group APPROVAL
                                                                                                                                                                                                                                                                                                                                              Production
                                                                                                                                                                                                    PROJECT MANAGER       PRESIDENT / SR. LEVEL MGR.   AUDITOR         CELL MEMBER         SUPPLIER DEV. /
              Supplier Name:                            'Wish I was better' Plastics                                                                                                                                                                                                          PURCH.           After Review
                                                                                                                                                                                                                                                                                                                                               Direction
                    Location:                                  Somewhere, USA                              79%                                             Supplier Code             Signature
                                                                                                                                                                                                                                                                                                               with PM MGT
                                                                                                                                                                                                                                                                                                               (circle one)

                 Visit Date :                          3,4 Feb 04 Revisit March 1, 2004
                                                                                                                                                                                       Date
                                                                                                                                                                                                                                                                                                                                              Go
           Summary
                                                                                                    Audit Priority
'Wish I was better' Plastics specializes in injection molding, paint and assembly.             (ie stamping, welding, paint, all)
                                                                                                                                                                                                                                                                                          M/P FORECAST                                       Follow
Honda SJC program will utilize mold and assy. Rear Garnish tooling not complete,                   Assembly




                                                                                                                                    Classification
                                                                                          1
                                                                                                                                                                                                                                                                             Supplier                         Follow-up                     Survey / Visit
so audit performed on surrogate program "air outlet".                                                                                                  Process Check Items                       Actual Results From Evaluation (comments)                                  Evaluation
                                                                                                                                                                                                                                                                                                         X    Required
                                                                                                                                                                                                                                                                              rating                          (Yes/No)                        required
                                                                                          2        Molding
4 audit categories found 100% compliant.                                                  3

                                                                                                                                                                                    Issues with Lot Control, Material Certs & Material / Spot ID
                                                                                                                                                                                                                                                                                                                                              Yes
                                                                                          4
Various errors noted in other areas will require immediate CMs.                           5                                         1                    Receiving Inspection       Procedure revised to incorporate Material Cert verifications. Process needs to be          3                                 Y
                                                                                                                                                                                    verified over time for effectiveness.                                                                                                      Date         Mar '04
                                                                                          6
Major areas of concern include: Receiving Insp., In-process Equipment (Pokayoke                                                                                                     Mixing concern (Molding resin package ID)
                                                                                          7
INOP), In-process Performance (corrective action for out of spec conditions), and
Inspection Fixtures
                                                                                          8                                         2                 In-process Parts/Materials    FIFO system established and in place, work instructions incorporated. Process              3                                 Y
                                                                                          9                                                                                         needs to be verified over time for effectiveness.                                                                                         Supplier Evaluation Rating:
                                                                                          10                                                                                        PokaYokes INOP, need Fixing and Verification system implemented immediately.
                                                                                                                                                                                    Tolerances needed for molding 'Job Setup' requirements                                                                                    1. All check items are NG.
                                                                                                                                                                                                                                                                                                                              Safety/Regulation concerns exist.
                                                                                                                                                                                    Update: Pokayoke fixed and verified as operational. Requires monitoring (audit)                                                           Impact to M/P.
                   Mass Production Line Situation At a Glance
                                                                                                                                    3                   In-process Equipment
                                                                                                                                                                                    on a daily per shift when in use basis for the next thirty days, with random audits
                                                                                                                                                                                                                                                                               4                                 Y
                                                                                                   Attendance                                                                       performed weekly after the thirty day time frame. Poke Yoke functional and                                                                2.N/G and level-up items exist &
                                                                                                                                                                                    checks are performed as given in procedure                                                                                                extensive temp c/m's are required to
                                                                                                                                                                                                                                                                                                                              prevent impact to M/P.


                                                                                                   Jim Smith                        4                In-process Manufacturing Jig                                                                                              5                                 N            3. Level-up items exist but temp
                                                                                                                                                                                                                                                                                                                              c/m's will prevent impact to M/P.
                                                                                                   Al Widget
                                                                                                                                                                                    Need verification of team member training to specific job assigned                                                                        4. Level-up items exist, but present
                                                                                          S
                                          Receiving                                       U                                         5                   In-process Manpower         Completed for manpower need to have supervisors added to the training per job              4                                 Y            no impact to M/P.

                                         Inspection                                       P                                                                                         matrix.
                                            6               In-process                    P
                                                                                                                                                                                    X_Bar R procedure error and Gaging concern
                                                                                                                                                                                                                                                                                                                              5. 100% check items are ok.
                  Documentation                                                           L
                                            5             Parts/Materials
                Inspection                                       In-process
                                                                                          I                                                                                         Procedure modified and retraining accomplished. Process needs to be verified
                                            4                                             E
                  fixtures                                      Equipment                                                                                                           over time for effectiveness.
                                            3                                             R                                         6                  In-process Performance
                                                                                                                                                                                    Gauges fixed and verified via Gauge R/R as OK for Nissan.                                  3                                 Y
                                            2                            In-process
           Packaging                                                                                                                                                                Innotec gauges will be per G, D, and T data with Gauge R/R targeted for <10%
                                            1                          Manufacturing…
                                                                                                                                                                                    with no more than 20% to be acceptable for use.
                                            0
                                                                                          I
                                                                       In-process                  Gunter Audit
       Off-line testing                                                                   N
                                                                       Manpower           N                                         7                  In-process Q.A. Machine                                                                                                 5                                 N
                                                                                          O
                                                     In-process                           T
          Part Inspection
                                                    Performance                           C
                Non-conforming                In-process QA                                                                         8                      Final Inspection                                                                                                    5                                 N                       M/P Forecast
                     parts                       Machine                                  G
                              Final Inspection                                            R                                                                                                                                                                                                                                         M/P ready
                                                                                          O                                                                                         Receiving and Molding need 5S work (note Assy area ok)
                                                                                          U
                                                                                                                                                                                                                                                                                                                                    OK with temp C/M's
                                                                                          P
                                                                                                                                    9                   Non-conforming Parts        5s continuing footprints starting to be introduced around the presses, progress            4                                 Y
                                                                                                                                                                                                                                                                                                                                    NG Immediate action
                                                                                                                                                                                    continuing with verification required over time.
                                                                                                                                                                                    Some parts beyond spec reqs. (I.E. Nissan Vane - length short)
                                                                                                                                                                                                                                                                                                                                X      required
                                                                                          # of Hours Required to
                                                                                              complete Audit                        1
                                                                                                                                    0
                                                                                                                                                           Part Inspection          Refer to item 6 above. Verification to be over time. Parts within specification but        3                                 Y
                                                                                                                                                                                    control limits need attention.

                                                                                                     18                             1
                                                                                                                                    1
                                                                                                                                                           Off-line Testing                                                                                                    5                                 N
                                                                                                                                                                                                                                                                                                                                    If unclear of judgment level,
                                                                                                                                                                                                                                                                                                                                    error to concern rather than
                                                                                                                                                                                                                                                                                                                                                  OK


                                                                                                                                                                                    Labeling procedures need upgrade to insure all boxes checked for proper labeling
                                                                                                                                    1
                                                                                                                                    2
                                                                                                                                                              Packaging             after pack                                                                                 4                                 Y
 No.            Parts Name                                         Parts Number                                                                                                     New procedure in place, training accomplished.
        Surrogate Program Air Outlets / Components audited                                                                                                                          Inspection Fixtures need improvement to insure print/datum intent compliance;
                                                                                                                                    1                                               certification; Design Change level upgrade and Gage R & R
                                                                                                                                    3
                                                                                                                                                         Inspection Fixtures
                                                                                                                                                                                    Refer to item 6 above. Verification to be over time. Completed with rev. level,
                                                                                                                                                                                                                                                                               4                                 Y
        (SJC Flr Cnsl. Rr Garnish production design release not yet complete)                                                                                                       R&R and calibration.
                                                                                                                                                                                    PQCT (Control Plan) needs clarification to resolve frequency of gaging confusion.
                                                                                                                                    1                                               Need 1st part shipment after change system (IPP system established)
                                                                                                                                    4
                                                                                                                                                           Documentation                                                                                                       3                                 Y
                                                                                                                                                                                    On Going. Control Plan clarified with frequency of gaging/inpection.

                                                                                                                                                                                                                                                             Total Score       55
                Critical Open Issues and Countermeasures


                                                                                                                                       LAST UPDATE; 4/27/04                                                                                                                                                                                                                                                               When
No.                                                              Issue                                                                                                           Temporary Countermeasure                                                                                                              Permanent Countermeasure                                                           Who      Temp C/M    Perm C/M
                                                                                                                               1.- 'Wish I was better' Plastics will review all of the existing programs for deficiencies in the areas of Prints, Material Specifications,   1.- 'Wish I was better' Plastics will insure upon acceptance of ANY program that all required information is available
                                                                                                                               Operational Specifications and Gauging Requirements by 2/15/04. DONE                                                                          through the drawings, statements of work and contract stipulations. DONE

                                                                                                                               2.- 'Wish I was better' Plastics will inform the customers of missing or conflicting information and obtain the missing documentation         2.- In the event that information is found to be lacking or conflicting a resolution to the concern will be required to be
                                                                                                                               from customers and vendors by 3/1/04. DONE                                                                                                    documented before moving forward with the program.DONE

                                                                                                                                                                                                                                                                             3.- In the event 'Wish I was better' Plastics is unable to obtain confirmation or guidance. 'Wish I was better' Plastics
                                                                                                                                                                                                                                                                             will inform the customer of our intentions regarding the concerns noted and request Interim Approval based upon our
        1) Need released customer Print, and/or Deviation for direction, material used in accordance with E-mail to Customer                                                                                                                                                 intended actions
1.1.1   only.                                                                                                                                                                                                                                                                                                                                                                                                      1.1.1 3/15/04
                                                                                                                                                                                                                                                                             4.- Interim Approval will be required for production based upon the 'Wish I was better' Plastics stated conditions.
                                                                                                                               3.- 'Wish I was better' Plastics will obtain the missing information or request Interim Approval for production by 3/1/04. DONE
                                                                                                                                                                                                                                                                             Shipment or production of product shall not occur without this Interim Approval. DONE

                                                                                                                                                                                                                                                                             5.-Interim Approval to proceed will be obtained and production will not occure without Interim Approval. DONE
                                                                                                                                                                                                                                                                                                                                                                                                          Jim S.                   15-Apr-04
                                                                                                                                                                                                                                                                             6.- These Permanent Countermeasures will be incorporated into Operational Procedure OP 2.001 at revision level "E".
                                                                                                                               4.- 'Wish I was better' Plastics will define the parameters it will produce the 829 Outlet against to the customer (BAP) by 3/15/04.          DONE
                                                                                                                               These parameters will define materials and certain dimensional criteria deemed critical or esential to the production of a part if drawings
                                                                                                                               are not available. DONE.

                                                                                                                               1.- Material certifications for all materials will be obtained and in-house no later than 2/13/04. Effective immediately, material
                                                                                                                                                                                                                                                                             1.- Mother Co. will supply material certification for all future shipments. DONE
                                                                                                                               certifications will accompany all future shipments. DONE

                                                                                                                                                                                                                                                                             2.- Operational Procedure OP 10.002 has to be revised at revision level "Q" to cover the action required upon receipt of
1.1.2   2) No material certs to insure raw material meets spec reqs for mat received from Mother Co.                           2.- 'Wish I was better' Plastics will not place material in inventory that does not have material certification as of 2/9/04. DONE                                                                                                                                                  1.1.2 2/13/04
                                                                                                                                                                                                                                                                             material without an attached certification. Will also incorporate Tops Team Raw recommendations. DONE

                                                                                                                               3.- 'Wish I was better' Plastics will obtain from Mother Co. the material certifications for all of the materials supplied to NPC prior to
                                                                                                                               2/9/04 by 2/13/04. DONE

				
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