Quality Brose Group/ Purchasing Brose Group Manual Supplier

Transcription

Function
Quality Brose Group/ Purchasing Brose Group
Document type
Manual
Document name
Supplier Management at Brose:
Escalation Procedure
(including CSL Program, TOP-Q Meetings)
Supplier Evaluation
Status
Issued
Released
17.01.13
Index: 111
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Mitteilung ihres Inhaltes ist nicht ohne unsere vorherige schriftliche Genehmigung
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der Patenterteilung oder Gebrauchsmuster-Eintragung vorbehalten.
Page: 1/19
17.01.2012
The copying, use, distribution or disclosure of the confidential and proprietary
information contained in this document(s) is strictly prohibited without prior written
consent. Any breach shall subject the infringing party to remedies. The owner reserves
all rights in the event of the grant of a patent or the registration of a utility model or
design.
Overview
Modifications
101
19.05.04:
1.1 and 1.2 amended, revised
PPM point deduction and logistics modified
102
13.08.04:
1.2 amended; 1.3 and 1.2.2 Logistics catalogue revised, 1.2.3 Purchasing criteria detailed
103
8.9.04
1.1 and 4 amended. 1.2.3 authorized > 9% was < 9%
104
01.04.05:
1.2.1 modified, 1.2.3. modified
105
24.04.06:
Sequence of chapters modified
Editorial revision
Escalation procedure fully revised
106
Supplier evaluation revised (Implementation of qualification and performance; criteria
Project management, Status Audit + certification and Status escalation level added
107
07.08.09:
Escalation procedure adapted
Supplier evaluation revised
26.10.09:
Escalation procedure adapted (actions of audits added)
20.08.10
CSL Process added, TOP-Q meetings added
17.02.12:
Escalation procedure adapted, supplier evaluation requalification added
17.01.13:
Disruptions adapted; Requalification adapted; Packaging and Documentation adapted;
Project management adapted and failure codes added, 5.2.7 project management bonus
system added, structure updated; Requalification (see Qualification / Status audit +
certification added
108
109
110
111
Source
Quality Brose Group/suppliers
Index: 111
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design.
SUPPLIER MANAGEMENT AT BROSE
4
1
INTRODUCTION
4
2
BROSE ESCALATION PROCEDURE
5
3
CSL PROGRAM
7
4
TOP-Q MEETINGS
7
5
SUPPLIER EVALUATION
8
5.1 Overview
5.1.1 Performance of supply to individual plants
8
9
5.2 Fault type catalogues
5.2.1 Quality
5.2.2 Requalification
5.2.3 Logistics
5.2.4 Part code
5.2.5 Purchasing
5.2.6 Project management
5.2.7 Project management bonus system
5.2.8 Status Audit +Certification
5.2.9 Influence of Escalation level
5.2.10 Influence of CSL-level
10
10
11
11
13
14
15
16
16
17
17
5.3
18
Transmission to suppliers
6
ANNEX 1
18
7
TERMS AND ABBREVIATIONS
19
Index: 111
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Supplier Management at Brose
1 Introduction
Reaching the corporate targets the global acting Brose group is dependant on suppliers that represent
themselves continuously at the highest stage in terms of Performance and Qualification
This will be measured by constant Brose supplier evaluation.
If the supplier fails to achieve the targeted objectives, measures will be adopted within the scope of the
Brose Escalation Procedure.
A description of the Brose supplier evaluation and Brose escalation procedure is given in the subsequent
chapters.
Index: 111
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2 Brose Escalation Procedure
To ensure seamless production and project flow and to identify problems early in time,
Brose will apply the following escalation procedure. In case of problems caused by the
supplier, this process allows you to define appropriate standardized remedial measures
and to apply these measures.
In this regard, Brose defines two phases:
•
Project phase (development and realization phase)
•
Series phase
Appropriate measures are defined for each level of the escalation procedure, that are to
be fulfilled within a stipulated period. On non-compliance with the agreed measures, the
escalation is automatically continued to the next level and can result in partial or
complete reduction of the supplier.
Efforts to manage supplier by Brose or its representatives as part of the escalation
procedure will be invoiced to the supplier.
As part of the block, the supplier will receive the “New Business on hold” status.
“New Business on hold” means for the supplier that for the stipulated period he will not
receive
•
•
any inquiries and
any new orders from Brose.
Any other rights of Brose provided by contract or by applicable law are in addition to this
Escalation Procedure and remain unaffected.
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Diagram of escalation process during project phase and series production stage
Possible tools / processes:
Escalation level 3
Change of supplier
Supplier is not qualified for Brose Group
New Business On Hold
Escalation level 2
Supplier needs Third Party to secure the
delivery capability
Top quality meetings
Supplier development program
CSL 2 / CSL 3
Escalation level 1
Extended action plan
Supplier is not successful to solve the
problems
Escalation meeting with supplier
CSL 1
Escalation level 0
Action plan
Supplier has problems
Index: 111
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3 CSL Program
At repeated failures, escalated product topics or escalated supplier development
programs the Brose Group has the possibility within the escalation program to call a CSLProgram. Following levels of the CSL-Program are possible:
CSL1:
The supplier verifies 100% the requested characteristics for a defined time period/ for a
requested quantity or as long as the corrective actions are effective at the supplier. The
processing is running in the context of the complaint processing in the plant. CSL1 status
is decided here.
CSL2:
An independent third party verifies 100% the characteristics for a defined time period/ for
a requested quantity or as long as the corrective actions are effective at the supplier. 21
points are deducted in the supplier evaluation for the period of the CSL2 program
(escalation level 2).
CSL3:
In addition to the actions of CSL2 there will be a supplier development programme done
by an independent third party. In the “Kick-Off-Meeting” the divisions for the
development are defined. 21 points are deducted in the supplier evaluation for the period
of the CSL2 program (escalation level 2).
4 TOP-Q Meetings
There are TOP-Q meetings with the supplier for example at not successful CSLProgrammes, escalated single topics (serial- as well as project phase), permanent
insufficient performance. The management of the supplier will be invited to a TOP-Q
meeting, if needed also spontaneously. To this meeting Brose expects a meaningful
action plan including the immediate actions as well as the planned actions to eliminate
failures effective. Participants of Brose are Quality Brose Group, Supplier Development
Brose Group, Quality Manager of the affected plant, as well as further participants if
needed.
Index: 111
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5 Supplier evaluation
Supplier Evaluation is an instrument to monitor achievement of targets of suppliers. It
contains the main criteria Performance and Qualification with sub criteria according to
following overview.
5.1 Overview
Performance
• Product quality/ reliability
• Logistics quality
The performance is evaluated on group level on basis of fixed indicators (quality- and
logistic notifications) that are determined out of the deliveries to the plants.
Qualification
• purchasing rating
• project management/ performance
• status from Certification and/ or Brose audit
• Escalation level within the Brose Escalation procedure
The qualification is evaluated on group level.
The supplier evaluation is based on Quality notifications (quality and logistic rejections)
which are raised at all Brose plants, Business divisions and Central functions.
Ratings are given according this table:
points
→
100 - 90
=
A
89 - 80
=
AB
79 - 60
=
B
59 - 0
=
C
Rating
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For each criterion 100 points will be given if there are no disruptions/ rejections. Possible
deduction points arise from fault type catalogues printed further down.
The overall evaluation is calculated out off all relevant notifications raised within the
whole Brose Group.
Relevant notifications are:
- Q2- notifications (for Quality or Logistics) from the evaluated time span
- L1- notifications (for Logistics) from the evaluated time span
- L1-notification (project management) from the evaluated time span
- L1- notifications (purchasing, audit and certification and escalation ) which are
“open” at the moment of evaluation
5.1.1
Performance of supply to individual plants
The evaluation of the quality performance of the deliveries to each individual Brose plant
occurs on basis of the fixed indicators (rejections and ppm).
Index: 111
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5.2
5.2.1
Fault type catalogues
Quality
The criterion Quality consists out of points for disruptions (100 points).
Disruptions
“Factor”
No fault or not suppliers responsibility, supplier
proactivly informing Brose about nok deliveries
The problem is processed within „normal daily
business”
The problem is classified as Top- Q- escalation
level 1 according to the Brose Top- Q- process
blank
Deduction
per
notification
0
1
4
2
11
3
21
4
41
PPM- figures are calculated by the system out of the delivered quantity and the ppm
relevant quantities noted on quality notifications. The ppm-figures do not run into the
rating. These values serve the determination of necessary corrective actions.
To ensure comparable figures there are some “Rules for recording defective parts in
suppliers' PPM evaluations“ which are listed at the bottom of this guideline (see
annex 1).
Relativisation-coefficient
Due to partly deliveries by logistic service providers in kanban-lots there was
introduced a relativisation-coefficient for balance.
Index: 111
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5.2.2
Requalification
Code* Event-description
deduction
1000
Deviation for part number
5
2000
Requalification for part number not done
10
5.2.3
Logistics
Delivery reliability
Code
Event-description
deduction
8108
Mispick at ESP (external service provider)
2
8110
Transport damage
0
8200
Critical arrear without del.-information
4
8201
Delay/under minimum stock with replenishment of assembly
without special transport (ST) to customer
10
8202
Delay/under minimum stock with replenishment of assembly
with special transport (ST) to customer
14
8203
Delay/under minimum stock with belt-stop at Brose without
special transport (ST) to customer
16
8204
Delay/under minimum stock with belt-stop at Brose with special
transport (ST) to customer
20
8205
Delay/under minimum stock with belt-stop at customer
70
8206
Anticipated/ exceeded delivery with return-shipment or not
acceptable stock increase
2
8207
Delivery outside defined time-gap
4
8208
Pick-up outside defined time-gap
4
One incident is related to one material (ID-No.) and one call off or minimum stock
Index: 111
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Service
Code
Event-description
deduction
8301
Partner at supplier almost not available
2
8302
Translation efforts (time/money)
2
8303
Intensive work to get information
4
8304
Non-reliable information
4
8305
Poor/wrong container account-management
4
8307
Insufficient tie down (operational safety, road safety)
4
One incident is related to one process ( e.g. e- mail about several ID- No. which is not
answered completely or partly )
Packaging and documentation
Code
Event-description
deduction
8401
Wrong (according instruction), dirty or damaged packaging
2
8402
Missing or wrong labels, mixed materials
4
8403
Missing/wrong delivery-documents
4
8404
Missing label of dangerous materials
2
8405
Missing/ wrong content
6
8406
4
8410
Use of environmentally compatible packaging or the redemption of
disposable packaging is not guaranteed
Customer-item number is missing on the depit note
8411
Change index on delivery note is missing
4
8412
Incorrect Avis
4
8413
Incorrect ASN
4
4
One incident is related to one delivery (delivery note/ Invoice)
Code = fault type according to the catalogue on the BROSE- SAP- system
Index: 111
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5.2.4
Part code
Part code
Code*
Event-description
8200
Part code general
8201
Part code is incorrect
8202
Part number is incorrect / not up-to-date
8203
Part number is missing / illegible
8204
Manufacturing date is incorrect / not up-to-date
8205
Manufacturing date is missing / illegible
8206
Part serial number
8207
Part label on the wrong position
8208
Part label bad readable
8209
Part label is missing
8210
Charge number wrong
8211
Marking is missing
8212
Marking paint on the label
8213
Wrong label
8214
Barcode / Datamatrix not readable
8215
Part serial number missing / not readable
8216
Part serial number double
8217
In the data bank not available
Factor
deduction
1
4
2
11
3
21
4
41
One incident is related to one delivery or ID-No
Code = fault type according to the catalogue on the BROSE- SAP- system
Index: 111
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5.2.5
Purchasing
Fault
Competitiveness /
Costs
Commercial
responsiveness
Cost transparency
Contract
acceptance
description
Factor
< 3% less competitive
Deduction
0
< 5% less competitive
1
10
≥ 5% less competitive
2
20
On time
0
Delayed response/ after
request only
1
10
Not according to
requirements
2
20
Complete cost-break-down
(A- and B- price)
0
cost-break-down not
complete
1
15
Total price
2
20
All Brose standards
completely accepted
0
Brose standards with
modifications but negotiated
1
10
Legal regulations (no mutual
acceptance of contract
conditions)
2
40
Index: 111
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5.2.6
Project management
Code* Fault
Description
8510
-
8511
Attitude at quotation
Technical dialog
Abzug
quotations complete
prices are plausible
competitiveness
use of Brose forms/ Brofis
5
- AQPs / Feasibility studies
5
- Quality of APQP
8512
8513
8514
8515
8516
Commercial dialog
Adherence to dates
Quality of parts
Quality of documents
General performance
of supplier
- Technical support / engineering support
- Willingness for negotiation
- Propose and realise cost reduction potentials selfcontained
5
- quotations
- Prototypes / samples / Initial samples
- Project documents (AQP / Control plans /
Dimensional measurement
reports / etc.)
5
- Prototypes / Samples / Initial samples
- Number of AWEs and Drawing changes (during
launch)
10
- quotation
- APQP
- dimensional reports
- tool data sheet
- Project management system is existing
- Preparation of meetings
- Availability
- active communication
- Presence / Customer care
- Flexibility / Reaction time
- Adherence to consents and agreements
- Deviation is caused by the supplier
8517
Deviation (AWE)
caused by supplier
8518
Drawing update
caused by supplier
- Drawing update caused by supplier
8519
Noncompliance to
APQP
- APQP commitments are not kept by supplier
8520
Full-Run-Test- result:
yellow
- Result of Full-Run-Test: Yellow
8521
Full-Run-Test-result:
red
- Result of Full Run Test: Red
10
5
10
10
10
10
21
Code = fault type according to the catalogue on the SAP- system
Index: 111
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5.2.7
Code*
8610
Project management bonus system
Bonus
Innovation
performance supplier
Describtion / Condition
- 1 – 3 submitted Innovation-Input
- first evaluation is done
- Input entered in Hype
- 1 Innovation-Input passed 1st Innogate
(Idea release)
Factor
1
Bonus
5
2
10
3
15
- 1 Innovation-Input passed 4th Innogate
(pre development release)
*Code = fault type according to the catalogue on the SAP system
5.2.8
Status Audit +Certification
Process audit
If Brose carry out a process audit the result will influence the qualification directly
according to this table:
Audit result
deduction
Leading to
“qualification”
“green”, “yellow”
0
„A“
“yellow” and insufficient progress in
processing corrective actions
21
„B“
“red”
21
„B“
“red” and insufficient progress in
processing corrective action
41
„C“
Status of certification
Suppliers status of certification will directly influence the „Qualification“ according to this
table:
Status of certification
deduction
Leading to
“qualification“
Certificate expired and no reaction to the
requisition of the certificates
21
„B“
Index: 111
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Requalification
If there is detected (during Requalification check) that the supplier has not implemented a
system for requalification, there will be a point deduction in supplier evaluation according
to the following table:
Requalification
Deduction
No requalification system available
41
5.2.9
Leading to
“qualification”
„C“
Influence of Escalation level
In the case a supplier gets on one of the Escalation levels of the Brose Escalation system
caused by ongoing problems there will be an influence on the Supplier evaluation
according to this table:
Escalation level
Deduction
Leading to
“qualification”
„0“
0
„A“
„1“
11
„AB“
„2“
21
„B“
„3 BSHD“
21
„B“
“3 degradation of the supplier”
41
“C”
5.2.10 Influence of CSL-level
In the case a supplier gets on one of the CSL-levels of the Brose Escalation system
caused by repeated failure, escalated product topics or escalated supplier development
programs there will be an influence on the Supplier evaluation according to this table:
CSL levels
Deduction
Leading to
“qualification”
„0“
0
„A“
„1“
11
„AB“
„2“
21
„B“
„3“
21
„B“
Index: 111
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5.3
Transmission to suppliers
The monthly evaluation is transmitted to the suppliers automatically via email.
6 Annex 1
Rules for recording defective parts in suppliers' PPM evaluations
PPM input:
1. Accumulated rejection parts/complaints:
a) Parts accepted by supplier:
100%
b) Parts rejected by supplier:
x1
c) No feedback after 10 WD
0%
x2
processing time :
100%
d) Supplier proves customer error within 30 WD x1 processing timex2,
that the failure is not in the responsibility of the supplier
Can be corrected
e) After 30 WD x1 processing timex2
Can not be corrected
2. Iincidents at Brose:
2.1. Reported by supplier:
a) Parts failed on assembly line prior supplier report:
100%
b) Defective parts which have to be assembled before the supplier can
sort (caused by supply bottleneck):
100%
c) All other parts:
0%
x3
2.2. Series production fault discovered by Brose :
a) Parts failed on assembly line prior to series production fault
discovered x3:
100%
b) Defective parts which have to be assembled before the supplier can
sort (caused by supply bottleneck):
100%
c) Defective parts at Brose's end:
100%
d) Stocks replaced (returned) for sorting by supplier:
0%
All other parts:
0%
2.3. Wrong deliveries
a) Wrong deliveries which will not affect the production process are
merely evaluated as incidents in logistics terms:
0%
b) All other wrong deliveries are treated as defective parts:
see 2.1 or 2.2
Index: 111
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3. Incidents at the customer:
If parts have already reached the Customer when a series production
fault x3 is discovered or the supplier reports one, the Customer and
Brose together with the supplier must decide on the required action.
a) Defective parts replaced or found by sorting:
100%
b) ppm-relevant quantities which customer charges to Brose are
passed on to supplier:
100%
c) All other parts:
0%
Explanatory notes:
x1
) WD:
working days
x2
) Processing time:
Processing time runs from the date on which defective parts are physically accepted from the
supplier. The date of acceptance is taken as:
a) The date on which goods are received at the supplier, if parts sent by Brose.
b) The date on which the supplier accepts parts at Brose.
x3
) Discovery of series production fault:
A series production fault applies at the latest under the conditions below:
a) 25 parts fail in succession, or
b) Maximum 1% failure rate is exceeded during a production shift.
Series production faults can also be established by goods inwards testing (QK), Quality Brose Group
(ZQU) or Electronics Quality (EQU).
7 Terms and abbreviations
8D method:
ppm
QAP:
FRT:
Problem solution methods in 8 steps that is used as standard
method and report form
parts per million
Quality Advance Planning
Full Run Test
Index: 111
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design.

Quality Brose Group/ Purchasing Brose Group Manual Supplier

Transcription

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