Manual.desbloqueado

2001 Ford Motor Company 2001 Ford Motor Company

Q1 2002

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What is Q1 2002Q1 2002

z Ford Motor Company exclusive designation

z Set of fundamental quality and manufacturing disciplines

z Drives suppliers continual improvement

z Put tools in place to maintain excellence

z Improve each passing year

z Q1 not achieved independently - guides cooperation - Ford/Supplier relationship Q1---- qjing


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Supplier Benefits of Q1Q1

z Recognition (Q1 flag, Q1 plaque)Q1

z Publicity and Advertising Privileges

z World Excellence Award (acknowledges the best of the best)

z Preferred Status with Changan Ford (Ideally only Q1 facilities are considered in source selection)Q1

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Whats Changed-Q1 2002 2ndQ1-2002

1.Comm. PPM PerformancePPMa) Industry comm. PPM has been revised to a 12-month fixed PPM.

PPMPPMb) Process for deducing points from suppliers for poor performance to the

industry comm. PPM has changed.PPM

c) The overall site PPM maximum threshold has been reduced to 110PPM (from 120)PPM120110

2. Six-month Site PPM( Production only)6PPMSite will no longer receive negative points when 6-month PPM exceed 100 6PPM100 qjing


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3. Low-volume Site PPMPPM

4. Stop Shipment Wavier

5. Site Assessment

Full site assessment requires as follow:

z Segment 1 and 2 sites every 6 months

z Segment 3 and 4 sites every 12 months

The process will be triggered when the:z Site assessment is late to the required 6 or 12 month frequency

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z Corrective action plan is not submitted to the Ford STA site engineer within 30 days of the site assessment

STAz Site action plan is ineffective in its execution

6. Violation of Trust

7. Plant Endorsement

8. Service- Ford of Europe

----9. Warranty Performance (production only - 3rd quarter 2003)

-200310. Launch Performance (production only)

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Q1 2002 RequirementsQ1 2002

z Any external suppliers manufacturing facility that currently supplies parts to Ford is eligible for consideration

z Suppliers facility has to achieve excellence in five key areas::

z Capable Systems

z Ongoing Performance

z Site Action Plan

z Satisfied Customers

z Continual Improvement qjing


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Whats New-Q1 2002-2nd Q1-2002

Same

Same

Ford of Europe service PPM is newPPM

Ford of Europe service delivery is new

Shipping History- six months which includes:----No Field Service Actions (with supplier responsibility) No Stop Shipments (with supplier responsibility) PPM less than 150% of Industry Commodity PPM for both production and servicePPM150%Minimum Delivery Rating of 81 points for both production and service 81

Site Assessment criteria enhanced

Acceptable Manufacturing Site Assessment

Same Third-Party Certification-QS-9000 or TS 16949, and ISO 14001; compliance to MS 9000, MMOG, or Odette

Compared to Q1 2002 Q1 2002What It Takes to Get Q1 2nd EditionWHATS NEW?

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Whats New-Q1 2002-2nd

Launch performance, warranty performance, QR trend and Customer Plant endorsement added to Site Assessment. Site Assessment frequency revised from 6 to 12 months for Quality segment III and IV sites QR

Includes both performance metrics and Manufacturing Site Assessment

Was 120 PPM 120PPMSite PPM performance threshold raised to 110 PPM PPM110

Continuous Improvement

Same Q1 overall score at least 800 points Q1800

Endorsement is clarified to include Q1 performance criteria and six-month QR trend at the Customer PlantQ16QR

Endorsement-STA and Customer STA

Compared to Q1 2002 Q1 2002What It Takes to Get Q1 2nd EditionWHATS NEW?

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1) Capable Systems

Third-party certification::z QS-9000 (or TS 16949)z ISO 14001 (environmental management

system)ISO 14001()

z MS-9000, MMOG or Odette (materials management system assessment)MS-9000, MMOG Odette()

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2) Ongoing Performance

Suppliers performance history with Ford::

z Field Actions

z Stop Shipments

z PPM PerformancePPM

z Delivery Performance

z Monthly Q1 2002 overall scoreQ1

Q1 suppliers are responsible not just for their own sites, but for controlling the quality of any suppliers that provide them with product.Q1,

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3) Site Action Plan

Site assessments supplier tools to gage their performance to address:----:

z Planning & Demonstration of Manufacturing Process Capability

z Variability Improvements

z Manufacturing Efficiencies (Lean, FTT, OEE)(,FTT,OEE)

z Customer Satisfaction (documented in QOS)(QOS)

All suppliers must perform a Manufacturing Site Assessment by June 1, 2003 and re-assess every 6 months.20036

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4) Satisfied Customers

z Each supplier site must provide customer endorsements of::

Supplier Technical Assistance (STA)STA

Each Ford plant that receives product

Material Planning & Logistics (MP&L)

Ford Customer Service Division (FCSD)

z Each of those customer must provide the supplier with an endorsement qjing


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5) Continual Improvement

Q1 2002 thresholds for performance metrics and site assessment will be raised annually to drive overall continual improvement.Q1 2002

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Applying for Q1 2002 1Q1 2002-1

z Suppliers should contact their STA site engineer, who will help/guide the suppliers through the Q1 processSTAQ1

z Conduct and submit a self-evaluation to ensure meeting Q1 2002 criteriaQ1 2002

z Once the supplier believes the facility is ready obtain necessary customer endorsements (valid for 6 months)

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z Formal application to Ford STA with documentation of certification to QS-9000/TS 16949, MS-9000 (or MMOG, Odette) & ISO 14001QS9000/TS16949MS-9000ISO14001STA

z A Q1 on-site evaluation may be scheduled to review qualifications to Q1 2002Q1Q1 2002

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z Responsible STA Commodity Manager provides a final recommendation based on Q1 2002 criteriaSTAQ12002

z Minimum six-month shipping history for production and/or service

z If a supplier location has not shipped to Ford within prior 12 months is no longer considered Q1Q1qjing


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Overall Q1 Score 1Q1 -1

z Every Supplier site begins with a 1000 point Q1 scoreQ11000

z Suppliers must maintain an overall score of at least 800 points for Q1 statusQ1,800

z Sites must maintain certification to QS-9000/TS 16949, ISO 14001 and compliance to MS-9000/MMOG/OdetteQS9000/TS16949,ISO14001MS-9000/MMOG/Odette

z Sites gain or lose points based on their performance metrics.

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Overall Q1 Score 2Q1-2

z Sites must meet all Q1 manufacturing site expectations & implement effective corrective action plans,.

z Not meeting Q1 2002 requirements or fail to implement effective action plan: lose 250 points & Q1 will be revokedQ1 2002,250,Q1

z Suppliers on Q1 revocation:Q1: cannot gain points for positive performance cannot regain Q1 status for 6 consecutive months. 6Q1 qjing


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Overall Q1 Score 3Q1-3

The final Q1 score is tabulated for:Q1:z Capable Systemsz Ongoing Performance

z Site Action Plan

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Capable Systems

Prerequisites that must supplier maintain:z ISO 14001- Environmental Management System

ISO 14000----z QS-9000/TS 16949 - Quality Management System

QS-9000/TS16949----9 suppliers are required to be third-party certified to QS-

9000 or TS 16949 by Job#1QS-9000/TS16949

z MS-9000/MMOG/Odette - Material Management SystemMS-9000/MMOG/Odette---- qjing


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Ongoing Performance 1Scoring Thresholds:

-1z Field Action (-250 points)in a 6 month period in which supplier hasresponsibility (Tier 1, 2, 3 ):(-250)

()Supplier site loses 250 points250Q1 status is immediately revokedQ1

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z Stop Shipment (0 to -250 points)2 or more Stop Shipments in a 6 monthperiod:0-2502

Supplier loses 250 points250Q1 status is immediately revokedQ1


-2

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z PPM (+100 to -250 points)PPM+100-250

6 month PPM (production or service) exceeds the ongoingcommodity PPM by 100% or more and site PPM >120: 6PPM100%PPM120

Supplier site loses 250 points250Q1 status is immediately revokedQ1Gain up to 100 points by outperforming the commodity

PPM PPM100Gain up to 100 points by achieving 60 or less PPM PPM60100


-3

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Low Commodity Comparison

SIM calculates a 6 month PPM for each of a suppliers commodities.SIM6PPMSIM calculates the industry commodity 6 month PPM.SIM6PPMSIM calculates the site commodity performance to the industry commodity performance for the last 6 mature months.Sim6SIM assigns points to each comparison based upon the metrics.SIM qjing


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Low Commodity Comparison

SIM determines all of a suppliers commodities with 6-month receipts greater than 10% of the suppliers 6-month total receipts.SIM6610%SIM determines which of those commodities(>10% of receipts)have the lowest commodity comparison pts. If commodity PPM10%),PPM10%) is found, then the site receives 0 points.,Q1.,0

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z Delivery Rating (+100 to -250 points)falls below 81 metric points :+100-25081

Supplier loses 250 points250Q1 status is immediately revokedQ1Gain 50 points when 97-99 metric points 97-9950Gain 100 points when 100 metric points 100100


-4

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PPM120

Q1

+100 +75 +50 +20 +10 0 -25 -50 -100 -150 -150 - 250

100 %75 % 99%50 % 74%25 % 49%11 % 24%0 % 10%

-1 % - 24%-25 % -49%-50 % -74%-75 % -99%-100%

PPMPPM

PPM a)

Q1

0-100-250

0, 6 1, 6 2, 6

-25061

Q1

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()Q1

-150-250

+100 +50 0 -250

10097 9981 96 81

+100 +50 0 -20 -40 -60 -80 -100 -125

0 PPM1 PPM 60 PPM

61 PPM 100 PPM101 PPM 250 PPM251 PPM 500 PPM501 PPM 750 PPM751 PPM 1000 PPM

1001 PPM 1500 PPM> than 1500 PPM

6PPM b)

a) PPM 110b) 2 qjing


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Site Action Plan 1-1

z Scoring Thresholds: (-250 points)250

z Full site assessment annually, partial assessment every 6 months (see areas asteriksed *)*

I. Planning for Manufacturing Process Capability

I. Demonstration of Manufacturing Process Capability

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z Suppliers must demonstrate fundamentals based on objective evidence

z Assessment can be done as: a self-assessment by the supplier

an on-site assessment conducted by the

STA engineerSTA

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I. Planning for Manufacturing Process Capability1Quality Procedures, QS-9000/TS 16949, QOS

QS9000/TS 16949QOS2 FMEAs/Control Plans *

FMEA/*3 Employee Readiness/Training Review

/4 PPAP Review and Run@Rate Review

PPAP5 Manage the Change


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II. Demonstration of Manufacturing Process Capability1Sub-supplier Quality Management *

*2Control of Incoming Quality

3Control Plans/Operator Instructions *

/*4Process Variability Monitoring *

*5Gage Calibration and Use *

6Part Identification, Nonconforming Parts, Packaging, Shipping


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II. Demonstration of Manufacturing Process Capability

7) Testing, Engineering Specifications

8) Preventive Maintenance (PM)/ Housekeeping *PM/*

9) Manufacturing Flow, Lean Manufacturing Metrics **

10) Problem Solving, Corrective Actions


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Revocation of Q1 2002 1Q1 2002-1

zWhen a problem is identified, STA will work with a supplierto identify the root cause of a problem and develop a corrective action plan.Q1,STA

zIf, however, a supplier has not satisfactorily addressed theperformance or customer satisfaction problem, thesuppliers Q1 status will be affected.Q1

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zInitial 1000 Q1 pointsQ11000zOverall Q1 score will be updated monthly

Q1zEffect on Q1 status cannot be offset by positive performancein other areasQ1zRegain Q1: supplier must satisfy all requirements for 6

consecutive months, incl. all endorsementsQ1

Revocation of Q1 2002 2Q1 2002-2

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What it takes to lose Q1 2002 2nd

Same Stop Shipments two or more (with supplier) ---2

Same Field Service Action (with supplier responsibility)

Site Action is ineffective

Site Assessment or Site Action Plan is late or Site Action is ineffective

Same Lack of Third-Party Certification - QS-9000 or TS 16949 and ISO 14001; compliance to MS 9000, MMOG or Odette

Compared to Q1 2002What It Takes to Lose Q1 2nd Edition

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What it takes to lose Q1 2002 2ndQ1 2002

Same Q1 overall score falls below 800 points Q1800

Violation of Trust is new Violation of Trust

Ford of Europe Service Delivery is new

Delivery Rating less than 81 points for either production or service81

Site PPM is greater than 120 for either production or service and Commodity PPM exceeds Industry PPM by 100%PPM120PPM 100%Ford of Europe Service PPM is newPPM

Site PPM is greater than 11o for either production or service and any Comm. PPM exceeds Industry PPM by 100% and any Comm. PPM exceeds the monthly Industry PPM in any month during the subsequent five months PPM110PPM100%PPM

Compared to Q1 2002Q1 2002

What It Takes to Lose Q1 2ndEdition Q1 2002

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Q1 Status Codes

Recommended Q1 StatusQ1

z R Q1 Revoked Q1z X Q1 Approval Denied Q1z R, X All Non-Q1 Q1

If present Q1 status = Recommended Q1 Status,then the Q1 At Risk = NoQ1Q1Q1Q1Q1Q1STA

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Q1 Formal ApplicationQ1

Supplier meets all Q1 prerequisites and performance metricsQ1Supplier obtains all required customer endorsementsThe Q1 petition package shall be prepared by the supplier and shall include:Q1

z Supplier information Supplier name Manufacturing location code and street address

GSDB Primary contact Primary contact address Telephone number qjing


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Matrix of current part number(s) supplied to Ford and Ford receiving plant(s)Copy of QS-9000 certificate/TS-16949 CertificateQS-9000/TS-16949Copy of MMOF/MG-9000/Odette Self-Assessment performanceMMOG /MG-9000/Odette Copy of ISO 14001 CertificateISO 14001

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If supplier does not have GSDB ON-LINE access to input certification information, it must submit the following information for each certification:GSDB ON-LINE

z Certificate Date z Registrar Name z Certificate # z Registration Champion Name, Phone, Fax, E-mail z

Copy of current SIM Site Q1 Performance Screen which supports the site Q1 conformanceSIM

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Copy of customer endorsement form(s)Note: endorsements are not acceptable if dated more than 6 months prior to the Q1 petition date.Q16Supplier turns in Q1 petition to STAQ1STASTA engineer makes Q1 determination and either send Q1 letter or contacts supplier with deficiency.STAQ1Q1 qjing


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Next Step WorkSet up company Q1 achievement plan and get management approval, the plan send to related STA within 2 weeks.Q1STASet up Q1 training plan, perform the plan within company.Q1Q1Site assessment can combine with internal audit, planed date report to STASTA

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Manual.desbloqueado