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ISO/TS 16949:2002 Volvo 3P & Volvo Powertrain Customer Specific Requirements

ISO/TS 16949:2002 Element

Requirement

Volvo 3P & Volvo Powertrain

Introduction

 

ISO/TS16949 and this document define the fundamental quality system requirements of Volvo 3P and Volvo Powertrain (Hereafter referred to in this document as “Volvo 3P/VPT”)

0.1 General

0.2 Process Approach

 

0.3 Relationship with ISO

This document contains the customer-specific requirements supplemental to ISO/TS16949. These supplemental requirements shall be included in the scope of the registration/certification to ISO/TS16949 in order for the ISO/TS16949 certificate to be recognized as satisfying the Volvo 3P/VPT organization’s criteria for third-party certification by an IATF recognized and contracted certification body.

9004

0.3.1 IATF Guidance

0.4

Compatibility with other

management systems

0.5

Goal of this Technical

 

Specification

ISO/TS 16949: 2002 is applicable to manufacturing sites of organizations supplying to Volvo 3P/VPT (production and service parts and materials), and to assemblers of production parts or materials purchased by Volvo 3P/VPT.

Non-manufacturing organizations (example; distributors, agents) Such organizations (Tier 1), which by nature can not be certified to ISO/TS 16949: 2002 must be third party registered to ISO9001: 2000 by an accredited third party certification body. These organizations must contact their respective Volvo 3P/VPT Supplier & Quality Development Department for concurrence and authorization.

Service parts and materials applicability does not include aftermarket or remanufactured parts.

Volvo 3P/VPT Group Customer Specific Quality Requirements are referenced in:

- Purchasing Quality Procedures (PQP)

- Volvo Purchase Order

- Volvo Corporate Standards

1 Scope

This International Standard specifies requirements for a quality management system where an organization: Needs to demonstrate its ability to consistently provide product that meets customer and applicable regulatory requirements, and aims to enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable regulatory requirements.

 

1.1 General

Regulatory requirements are conveyed in the Volvo Technical Regulations, on the Volvo 3P/VPT drawing and or Part Version Report

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3 Terms and definitions

SQIP – Supplier Quality Improvement Process This is a four-stage elevation process used to focus on negative oranization’s performance. It is intended to focus activity to resolve quality performance problems and prevent recurrence.

Supplier Scorecard Located within Volvo’s Supplier Portal, the Supplier Scorecard is a secured website that contains commercial, financial and quality information and performance data.

PPM – (Parts Per Million) A method of stating the performance of a process in terms of actual nonconforming material. PPM data should be used to prioritize corrective actions.

QPM – (Quality Performance Measurement) QPM is a quality performance-prioritizing tool based on a points system comprising the four measuring criteria:

- Parts Per Million (PPM)

- Number of non-conforming parts (NCp)

- Number of Inspection Reports issued (IR raised)

- Volume Value of Rejected Parts (Vol.Val.)

QPM = PPM points + NCp points + IR Raised points + Vol Val points

PQP – Purchasing Quality Procedures

Purchasing Quality Procedures defined the Volvo Customer Specific Requirements to our organizations and sub-contractors

RTS – Review of Technical Specification The purpose for the Review of Technical Specification is to collect and handle organization product review analysis and comments on the Technical Specification. This is to ensure the total understanding of all Technical Specifications and confirmation of product manufacturability. The aim is that no Design Change Request takes place after the PPAP or Tool order.

The RTS checklist is signed by Volvo and the organization to ensure that all the Technical Regulations & General Specifications applicable to the part have been received, reviewed and

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understood by the organization

4.2.2 Quality manual

The organization shall establish and maintain a quality manual that includes

For Volvo 3P/VPT, the organization must have the Volvo product line included into the scope of the ISO/TS 16949 certification.

a) the scope of the quality management system, including details of and justification for any exclusions (see 1.2)

b) the documented procedures established for the quality management system, or reference to them, and

c) a description of the interaction between the processes of the quality management system

4.2.3 Control of

Documents required by the quality management

Where the organization uses Volvo 3P/VPT documents/instructions or other documents of external origin, the organization must insure that the appropriate revision level is used. This would be the most current revision available or as specified by Volvo 3P/VPT.

documents

system shall be controlled. Records are a special type of document and shall be controlled according

to the requirements given in 4.2.4

 

Volvo Group Engineering Standards may be obtained at the following Volvo Website:

A documented procedure shall be established to

http://www.tech.volvo.se/standard/eng/

define the controls needed:

a) to approve documents for adequacy prior to issue

b) to review and update as necessary and re- approve documents

Volvo Group Purchasing Quality Procedures (PQP) may be obtained at the following Volvo Website:

http://www.volvo.com/suppliers/global/en-gb/

c) to ensure that changes and the current revision status of documents are identified,

d) to ensure that relevant versions of applicable documents are available at points of use

e) to ensure that documents remain legible and readily available

f) to ensure that documents of external origin are identified and their distribution controlled

g) to prevent the unintended use of obsolete documents, and to apply suitable identification to them if they are retained for any purpose

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4.2.3.1

Engineering

The organization shall have a process to assure the timely review, distribution, and implementation of all customer engineering standards and/or specifications and changes based on customer- required schedule. Timely review should be as soon as possible, and shall not exceed two working weeks.

The organization shall maintain a record on which each stage each change is implemented in production. Implementation shall include updated documents.

Organizations are encouraged to utilize the Volvo Review of Technical Specification (RTS) when developing a quote for Volvo 3P/VPT.

specifications

An equivalent and effective Organization Contract Review process that includes the elements within the RTS is acceptable in lieu of the Volvo RTS.

Note: A change in these reference standards/specifications requires an updated record of customer production part approval when these specifications are referenced on the design record or if they affect documents of production part approval process, such as control plan FMEA etc.

4.2.4.1

Records retention

The control of records shall satisfy regulatory and customer requirements

Production Part Approvals (PPAP), tooling records, selection of Special Characteristics and purchase orders shall be maintained for the length of time that the part (or family of parts) is active for production and service requirements plus one calendar year unless otherwise specified by Volvo 3P/VPT.

 

Quality performance records (e.g. control charts, inspection and test results) shall be retained for one calendar year after the year in which they were created.

Records of internal quality system audits, product audits, layout inspection, functional testing and management review shall be kept for three years.

The above time periods shall be regarded as minimum. Retention periods longer than those specified above may be specified by an organization in its procedures.

These requirements do not supersede regulatory requirements.

5.2 Customer focus

Top management shall ensure that customer

Volvo 3P/VPT Quality Customer Specific Requirements are conveyed to organizations in

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requirements are determined and are met with the aim of enhancing customer satisfaction (see 7.2.1 and 8.2.1)

the form of our Purchasing Quality Procedures (PQP). The PQP can be obtained in the Volvo Supplier Portal at http://www.volvo.com/suppliers

5.4.1.1 Quality objectives - supplemental

Top management shall define quality objectives and measurements that shall be included in the business plan and used to deploy the quality policy.

Volvo 3P/VPT Supplier & Quality Development Departments will determine customer expectations with respect to quality objectives.

Organizations are encouraged to sign a PPM Target Agreement in order to secure commitment towards continual improvement.

Note Quality objectives should address customer expectations and be achievable within a defined time period.

5.5.2

Customer

Top management shall designate personnel with

The organization shall notify Volvo 3P/VPT within 10 working days of any changes to senior management (i.e. Quality, Product Development, company ownership etc).

representative

responsibility and authority to ensure that customer requirements are addressed.

This includes selection of special characteristics, setting quality objectives and related training, corrective and preventive actions, product design and development.

 

6.3.2

Contingency plans

The organization shall prepare contingency plans to satisfy customer requirements in the event of an emergency such as utility interruptions, labor shortages, key equipment failure and field returns.

Volvo 3P/VPT requires the organization to have a set strategy and well-known routines for Risk Management. Risk areas may include production process, fire protection, flooding, earthquake, etc. Also areas such as environmental hazards and computer system breakdown, etc. should also be considered.

 

Risk Management must also include sub-contractors.

The organization shall notify the respective Volvo 3P/VPT Purchasing Buyer and Volvo Receiving facility within 24 hours of organization production interruption. The nature of the problem shall be communicated to Volvo 3P/VPT and immediate actions taken to assure supply of product to Volvo 3P/VPT.

Note: Production interruption is defined as an inability to meet the Volvo 3P/VPT specified production capacity volume.

7.1 Planning of product realization

The organization shall plan and develop the processes needed for product realization. Planning of product realization shall be consistent with the

Volvo 3P/VPT organizations shall utilize the AiAG - Advanced Product Quality Planning Process (APQP) .

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requirements of the other processes of the quality management system (see 4.1)

 

In planning product realization, the organization shall determine the following, as appropriate:

a. Quality objectives and requirements for the product

b. The need to establish processes, documents, and provide resources specific to the product

c. Required verification, validation, monitoring, inspection and test activities specific to the product and the criteria for product acceptance

d. Records needed to provide evidence that the realization process and resulting product meet requirements (see 4.2.4)

The output of this planning shall be in a form suitable for the organization’s methods of operations.

NOTE1 a document specifying the processes of the quality management system (including the product realization processes) and the resources to be applied to a specific product, project or contract, can be referred to as a quality plan. NOTE 2 the organization may also apply the requirements given in 7.3 to the development of product realization processes.

7.1.2 Acceptance criteria

Acceptance criteria shall be defined by the organization and, where required, approved by the customer.

To determine if customer approval is needed for a specific process, contact the respective Volvo 3P/VPT Purchase Quality contact.

For attribute data sampling the acceptance level shall be zero defects (see 8.2.3.1)

7.2.1.1 Customer- designated special

The organization shall demonstrate conformity to customer requirements for designation,

For special characteristics, Volvo uses the term "Critical Characteristics”. This designation identifies product characteristics or process parameters that, due to their impact on the

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characteristics

documentation and control of special characteristics

fit/form/function of the part or process, must be controlled in a manner that variation is minimized.

Volvo Product Development will determine which characteristics are design consequence class

 

and will identify them on the drawing with a designation of class 1,2 or 3. Critical Characteristic features are applied when minimizing the variation and centering the distribution close to the

mean of the tolerance optimize the part function or reliability.

Specific Critical Characteristics

instructions for identification and grading can be found in the Volvo Standard 105-0001 which

can be located at the Volvo Standards Website: http://www.tech.volvo.se/standard/eng/

The Volvo Group also uses the term "Key Control of Characteristics" (KCC) for the Mack Truck product. This designation identifies product characteristics or process parameters that, due to their impact on the fit/form/function of the part or process, must be controlled in a manner that variation is minimized

7.2.2 Review of requirements related to the product

The organization shall review the requirements related to the product. This review shall be conducted prior to the organization’s commitment to supply a product to the customer (e.g. submission of tenders, acceptance of contracts or orders, acceptance of changes to contracts or orders) and shall ensure that

Organizations to Volvo are encouraged to complete a Review of Technical Specification and submit to Volvo Purchasing 3P/VPT. An effective and equivalent contract review process can be used in place of the Review of Technical Specification.

a. Product requirements are defined

b. Contract or order requirements differing from those previously expressed are resolved, and

c. The organization has the ability to meet the defined requirements.

Records of the results of the review and actions arising from the review shall be maintained (see

4.2.4)

Where the customer provides no documented statement of requirement, the customer requirements shall be confirmed by the organization before acceptance.

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Where product requirements are changed, the organization shall ensure that relevant documents are amended and that relevant personnel are made aware of the changed requirements.

 

NOTE In some situations, such as internet sales, a formal review is impractical for each order. Instead the review can cover relevant product information such as catalogues or advertising material.

7.2.2.1

Review of

Waiving the requirement stated in 7.2.2 for a formal review (see note) shall require customer authorization

Any request for waiver of formal review shall be directed to the respective Volvo Purchasing Buyer.

requirements related to

the product - supplemental

 

7.2.3.1

Customer

The organization shall have the ability to communicate necessary information, including data, in a customer-specified language and format (e.g. computer-aided design data, electronic data exchange).

It is preferred that organizations have CAD/CAE system interface capability with Volvo Engineering. Catia, Pro-E and IGES are acceptable. It is not mandatory at the present time. The appropriate Volvo personnel shall notify organizations that are required to obtain interface with Volvo systems.

When there is a Volvo prescribed format for communication, it is specified in the appropriate section or other Volvo documents.

communication -

supplemental

7.3.1.1

Multidisciplinary

The organization shall use a multidisciplinary approach to prepare for product realization, including:

Volvo requires all organizations to follow a formal advanced product quality planning process for new product programs and product/process changes (APQP).

approach

- Development and finalization of special characteristics

FMEA, as these are “Living Documents”, are designed to aid and document improvement. Volvo does not have review and approval requirements prior to production part approval, but does review FMEAs during the PPAP submission process and at other times as appropriate.

- Development and review of FMEA’s, including actions to reduce potential risks, and

- Development and review of control plans.

7.3.2.2

Manufacturing

The organization shall identify, document and review the manufacturing design input requirements, including:

- Product design output data

Organizations are encouraged to complete a Review of Technical Specification and submit to Volvo Purchasing 3P or demonstrate existence of an effective and equivalent contract review process

process design input

- Targets for productivity, process capability and

 

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cost

 

- Customers requirements if any, and

- Experience from previous developments

NOTE the manufacturing process design includes the use of error proofing methods to a degree appropriate to the magnitude of the problems and commensurate with the risks encountered.

7.3.2.3

Special

The organization shall identify special characteristics (see 7.3.3 d) and

Reference Volvo Corporate Standards below:

characteristics

- STD 5060,3 – Classification of Requirement (Designs prior to 04 Oct. 01

- Include all special characteristics in the control plan

- STD 105-0001 – Critical Characteristics of design products

- Comply with customer specified definitions and symbols

- Identify process control documents including drawings, FMEAs, control plans and operator instructions with the customer’s special characteristic symbol or the organization’s equivalent symbol or notation to include those process steps that affect special characteristics

NOTE special characteristics can include product characteristics and process parameters

7.3.6.1

Design and

Design and development validation shall be performed in accordance with customer requirements including program timing.

Specific design and development validation, other than specified in the Technical Regulation, including project timing will be determined by either the Volvo 3P/VPT Buyer, PD Engineer and or Corporate Project Manager.

development validation - supplemental

7.3.6.2

Prototype program

When required by the customer, the organization shall have a prototype program and control plan. The organization shall use, wherever possible, the same suppliers, tooling and manufacturing processes as will be used in production.

The appropriate Product Development representative shall determine the requirements for a comprehensive prototype program.

 

The organization is responsible for the quality of the parts it produces and for any subcontracted services, including suppliers specified by Volvo 3P/VPT. This applies to all phases of product development, including prototypes.

All performance testing activities shall be monitored for timely completion and conformity to requirements.

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While services may be outsourced, the organization shall be responsible for the outsourced services, including technical leadership.

 

7.3.6.3

Product approval

The organization shall conform to a product and manufacturing process approval procedure recognized by the customer.

Volvo 3P/VPT requires the use of the AIAG Production Part Approval Process (PPAP). In addition, organizations shall comply with Section II.4, Truck OEM-Specific Instructions.

process

NOTE Product approval should be subsequent to the verification of the manufacturing process.

Tier 1 organizations shall insure their suppliers utilized the PPAP process. Tier 1 organizations have total responsibility for managing PPAP for their suppliers.

This product and manufacturing process approval procedure shall also be applied to suppliers.

7.4.1.2

Supplier quality

The organization shall perform supplier quality management development with the goal of supplier conformity with this Technical specification.

Volvo 3P/VPT strongly recommends that all 2nd tier suppliers be 3 rd party registered.

management system development

In exceptional cases, when requested by the 1st tier organization, the respective Volvo 3P/VPT Supplier & Quality Development Department may grant a temporary waiver, accompanied by the an ISO9001: 2000 implementation plan. The waiver would stay in affect until the supplier obtains certification.

Conformity with ISO 9001:2000 is the first step in achieving this goal.

NOTE the prioritization of suppliers for development depends upon, for example, the suppliers’ quality performance and the importance of the product supplied.

 

Unless otherwise specified by the customer, suppliers to the organization shall be third party registered to ISO 9001:2000 by an accredited third- party certification body.

7.4.1.3

Customer

Where specified by the contract (e.g. customer engineering drawing, specification) the organization shall purchase products, materials or services from approved sources.

Volvo approved sub-contractors (suppliers that must be used by Volvo tier one organization) of relevant products, materials, and services, are identified in the commercial agreements, drawings, general engineering specifications or other written authorization, as required. This also includes transportation.

approved sources

The use of customer designated sources, including

In these cases, the organization has the full responsibility for quality assurance.

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tool/gauge suppliers does not relieve the organization of the responsibility for ensuring the quality of purchased products.

Certain categories of suppliers (tier 2) must be approved by Volvo 3P/VPT Purchasing. These are suppliers of:

- Surface treatment

- Supply of forgings for Volvo 3P/VPT designed parts

- Supply of ductile iron castings for Volvo 3P/VPT designed parts

Additional sub-contractors may be considered at the request of the organization. These requests shall be directed to the Volvo Purchasing Buyer and Product Development Engineer. The new sub-contractor is subject to all Volvo requirements and must undergo the appropriate sub- contractor and material component PPAP approval process.

7.4.3.2

Supplier

Supplier performance shall be monitored through the following indicators:

Included in the organization’s monitoring of 2 nd tier supplier performance, the following additional parameters should be measured:

monitoring

- Delivered product quality

-

Quality/Environmental Management System status

- Delivery schedule performance (including incidents of premium freight)

 

- Special status customer notifications relating to quality or delivery issues.

The organization shall promote supplier monitoring of the performance of their manufacturing processes.

7.5.1.1

Control plan

The organization shall

 
   

- Develop control plans (see annex A) at the system, subsystem, component and/or material level, for the product supplied, including those processes producing bulk materials as well as parts, and

Volvo Supplier & Quality Development Department does not require the approval of control plan revisions.

- Have a control plan for pre-launch and production that takes into account the design FMEA and manufacturing process FMEA outputs.

The control plan shall

-

list the controls used for manufacturing

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process control

 

- include methods for monitoring of control exercised over special characteristics (see 7.3.2.3) defined by both the customer and the organization

- include the customer required information, if any, and

- initiate the specified reaction plan (see 8.2.3.1) when the process becomes unstable or not statistically capable.

Control plans shall be reviewed and updated when any change occurs affecting product, manufacturing processes, measurement, logistics, supply sources or FMEA (see 7.1.4).

NOTE customer approval may be required after review or update of the control plan.

7.5.4 Customer property

The organization shall exercise care with customer property while it is under the organization’s control or being used by the organization.

For Volvo owned customer-supplied product that is consigned to a tier one organization, the tier one organization is expected to work with the supplying company to resolve low quantity, less significant issues.

The organization shall identify, verify, protect and safeguard customer property provided for use or incorporation into the product. If any customer property is lost, damaged or otherwise found to be unsuitable for use, this shall be reported to the customer and records maintained.

Where ongoing product problems lack resolution, Volvo SQA should be formally notified with the details.

Tier one organizations are responsible for reporting product damage and any other obvious non- conformance to the Volvo Supplier & Quality Development Department.

7.5.4.1 Customer owned production tooling

Customer owned tools, manufacturing, test, inspection tooling and equipment shall be permanently marked so that the ownership of each item is visible and can be determined.

The organization shall have a documented system for preventive maintenance. This shall include a timely review of planned maintenance activities and a documented action plan to address any backlog. Action plans are to be included in the Management Review process.

Records of maintenance are to be maintained for 1 year.

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Note: Predictive maintenance shall be used wherever possible, be based on appropriate statistical techniques.

All Volvo 3P/VPT owned tooling shall be permanently identified and shall include the Volvo tool number and Volvo part number. This shall be performed on all pattern equipment and dies. Other tooling shall be similarly identified in a practical manner. The organization can recommend practical or alternate identification.

Tooling maintenance, changes or modifications shall be documented and traceable. Maintenance, repair, and timely replacement of tooling are the responsibility of the orgnization unless otherwise negotiated. The organization shall notify Volvo 3P/VPT Purchasing when tooling conditions deteriorate. Notice shall allow adequate lead-time to rework, repair or produce replacement tooling to ensure continuity of supply of conforming products.

Organizations shall store and maintain all tooling and equipment used to produce product for Volvo in a manner to ensure conforming parts are produced. Volvo 3P/VPT reserves the right to review tooling and equipment at the organization’s location for condition and identification. Volvo 3P/VPT requires organizations to conduct an inventory of all Volvo owned tooling on an annual basis.

Volvo 3P/VPT owned returnable packaging that is lost, damaged or otherwise unsuitable for use shall be reported to the appropriate Volvo Corporate Materials organization location. The organization is responsible for safekeeping and cleanliness of the returnable packaging in their care and use

7.6.1 Measurement system analysis

Statistical studies shall be conducted to analyze the variation present in the results of each type of measuring and test equipment system. This requirement shall apply to measurement systems referenced in the control plan.

Gage R&R studies are required for each unique variable gage used to measure Critical Characteristics.

Volvo does not accept the use of Gage R&R studies on families of gages or equipment for these Critical Characteristics. Analytical methods and acceptance criteria shall be determined on a case-by-case basis during the advanced quality planning process.

The analytical methods and acceptance criteria used shall conform to those in customer reference manuals on measurement systems analysis. Other analytical methods and acceptance criteria may be used if approved by the customer.

Organizations shall use the most current AIAG Measurement System Analysis publication for this purpose.

7.6.2

Records of the calibration/ verification activity for all

Volvo requires notification of the shipment of any suspected nonconforming material resulting

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Calibration/verification

gauges, measuring and test equipment, needed to provide evidence of conformity of product to determined requirements, including employee and customer owned equipment shall include

from out of calibration gages, measuring, and test equipment. When the measured characteristic is a Critical Characteristic, Volvo must be notified if the resulting products would not meet special requirements as listed in 8.2.3.1.

records

- equipment identification, including the measurement standard against which the equipment is calibrated

The receiving Volvo Assembly Operations Customer Satisfaction Department shall be notified.

- revisions following engineering changes

- any out of specification readings as received for calibration

- an assessment of the impact of out of specification condition

- statements of conformity to specification after calibration/verification, and

- notification to the customer if suspect product or material has been shipped.

7.6.3.2 External laboratory

External/commercial/independent laboratory facilities used for inspection, test or calibration services by the organization shall have a defined laboratory scope that includes the capability to perform the required inspection, test or calibration, and either

- there shall be evidence that the external laboratory is acceptable to the customer, or

Laboratory facilities used by the organization to verify product conformance must use ASTM or other recognized industry standards and the appropriate Volvo Group established test procedures, where available, as testing criteria.

The Volvo 3P/VPT will accept laboratory analysis from any independent accredited laboratory. In the event of disputes between the Volvo Group and the organization's laboratory, the Volvo 3P/VPT reserves the right to specify an independent laboratory for arbitration.

- the laboratory shall be accredited to ISO/IEC 17025 or national equivalent.

NOTE 1 such evidence may be demonstrated by customer assessment, for example, or by customer approved second party assessment that the laboratory meets the intent of ISO/IEC 17025 or national equivalent.

NOTE 2 when a qualified laboratory is not available for a given piece of equipment, calibration services may be performed by the equipment manufacturer. In such cases, the organization should ensure that the

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requirements listed in 7.6.3.1 have been met.

 

8.1.2

Knowledge of basic

Basic statistical concepts, such as variation, control (stability) process capability and over adjustment shall be understood and utilized throughout the organization.

Cpk is to be measured on all characteristics that are classified by Volvo 3P/VPT Product Development as Critical Characteristic.

statistical concepts

If the process is under control, normally distributed and with no risk of unpredictable events, the following capability must be demonstrated:

 

Critical Characteristics Level 1 = Cpk > 1.67 and production followed up with SPC Critical Characteristic Level 2 and 3 = > 1.33 and characteristic checked at a regular frequency

Should the process not be under control and normally distributed, the organization shall contact their respective Supplier & Quality Development Engineer.

The organization shall follow the AIAG PPAP manual for specific instructions.

8.2.1

Customer

As one of the measurements of the performance of the quality management system, the organization shall monitor information relating to customer perception as to whether the organization has met customer requirements. The methods for obtaining and using this information shall be determined

NOTE consideration should be given to both internal and external customers.

There is no prescribed Volvo 3P/VPT methodology to measure customer satisfaction.

satisfaction

Organizations shall determine their best method to determine and measure Volvo 3P/VPT’s satisfaction with their performance.

8.2.1.1 Customer satisfaction - supplemental

Customer satisfaction with the organization shall be monitored through continual evaluation of performance of the realization processes.

Certification Body/Registrar Notification The organization shall notify its certification body/registrar of record in writing within five (5) working days if Volvo 3P/VPT places the organization’s site into Stage #3 (Alarm) of the Supplier Quality Improvement Process (SQIP). Being in this Stage #3 category is a violation of 8.2.1.1 of

Performance indicators shall be based on objective data and include, but not be limited to:

ISO/TS16949.

- Delivered part quality performance

Organizations are strongly encouraged to review their performance status in the Volvo Supplier Scorecard at least on a monthly basis. The Volvo Supplier Scorecard can be assessed through the Volvo Supplier Portal at the following website: http://www.volvo.com/suppliers

- Customer disruptions including field returns

- Delivery schedule performance (incl. incidents of premium freight) and

 

- Customer notifications related to quality or delivery issues.

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The organization shall monitor the performance of manufacturing processes to demonstrate compliance with customer requirements for product quality and the efficiency of the process.

 

8.2.3.1 Monitoring and measurement of manufacturing processes

The organization shall perform process capability studies on all new manufacturing (including assembly or sequencing) processes to verify process capability and to provide additional input for process control. The results of process studies shall be documented with specifications, where applicable, for means of production, measurement and test, and maintenance instructions.

These documents shall include objectives for manufacturing process capability, reliability, maintainability and availability, as well as acceptance criteria.

Volvo 3P/VPT capability requirements can be found in Volvo STD. 5060-21, which can be accesses at the Volvo Standards Website: http://www.tech.volvo.se/standard/eng/

If the Cpk does not meet minimum requirements, the organization must implement appropriate corrective actions to secure uninterrupted deliveries.

 

The organization shall maintain manufacturing process capability or performance as specified by the customer pert approval process requirements. The organization shall ensure that the control plan and process flow charts are implemented, including adherence to the specified

- measurement techniques

- sampling plans

- acceptance criteria and

- reaction plans when acceptance criteria are not met

Significant process events, such as tool change or machine repair, shall be recorded.

The organization shall initiate a reaction plan from the control plan for characteristics that are either

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not statistically capable or are unstable. These reaction plans shall include containment of product and 100% inspection as appropriate. A corrective action plan shall then be completed by the organization, indicating specific timing and assigned responsibilities to assure that the process becomes stable and capable. The plans shall be reviewed with and approved by the customer when so required.

 

The organization shall maintain records of effective dates of process changes.

8.3.3

Customer

Customers shall be informed promptly in the event that nonconforming product has been shipped.

See Volvo 3P/VPT Customer Specific Requirement in 7.6.2

information

8.3.4

Customer waiver

The organization shall obtain a customer concession or deviation permit prior to further processing whenever the product or manufacturing process is different from that which is currently approved.

Requests for concessions (temporary deviations) shall be submitted to the appropriate Volvo 3P/VPT Purchasing Quality Contact

 

The organization shall maintain a record of the expiration date or quantity authorized. The organization shall also ensure compliance with the original or superseding specifications and requirements when the authorization expires. Material shipped on an authorization shall be properly identified on each shipping container.

This applies equally to purchased product. The organization shall agree with any requests from suppliers before submission to the customer.

8.5.2.1 Problem solving

The organization shall have a defined process for problem solving leading to root cause identification and elimination.

Volvo requires a disciplined problem solving process. Organizations shall use common tools such as 8D & AiAG Seven Step, PDCA, 6 Sigma, etc. are some excellent examples.

If a customer prescribed problem- solving format

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exists, the organization shall use the prescribed format.

 

8.5.2.4 Rejected product test/analysis

The organization shall analyze parts rejected by the customer’s manufacturing plants, engineering facilities and dealerships. The organization shall minimize the cycle time of this process.

In the spirit of continual improvement, Volvo 3P/VPT requires the organization to conduct failure analysis on material returned by Volvo from our customers on an as requested basis. The results of this analysis shall be communicated to the respective Volvo representative requesting the analysis.

Records of these analyses shall be kept and made available upon request. The organization shall perform analysis and initiate corrective action to prevent recurrence.

NOTE: Cycle time related to rejected product analysis should be consistent with the determination of root cause, corrective action and monitoring the effectiveness of implementation.

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