康明斯质量手册

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1、精心整理CUMMINS INC.康明斯公司FILTRATION BUSINESS UNIT滤清器业务单元SUPPLIER QUALITY HANDBOOK供给商质量手册TABLE OF CONTENTS索引CORPORATE OVERVIEW公司简介1SUPPLIER QUALITY IMPROVEMENT PROGRAM (SQIP) INTRODUCTION1供给商质量改良工程介绍SUPPLIER MANAGEMENT供给商管理2-4A. SELECTION PROCESS选择流程B. DEVELOPMENT开发C. PRODUCTION PART APPROVAL PROCESS (PP

2、AP)生产件批准流程D. QUOTATION CRITERIA 报价准那么E. SHIP TO USE (STU) PROCESS发运至生产流程F. PERFORMANCE REPORT业绩报告SUPPLIER QUALITY SYSTEM REQUIREMENTS供给商质量体系要求5-11A. ORGANIZATION组织B. ADVANCED QUALITY PLANNING先期质量筹划C. WRITTEN PROCEDURES书面程序D. DRAWING AND SPECIFICATION CONTROL图纸和标准管理E. INSPECTION AND TEST检验和测试F. MATER

3、IAL CONTROL物料限制G. RECORDS记录H. MEASUREMENT AND TEST EQUIPMENT测量与测试设备I. STATISTICAL PROCESS CONTROL (SPC)统计过程限制J. DEVIATION REQUEST偏差许可申请K. PRODUCT VERIFICATION生产确认L. REJECTED MATERIAL拒收材料M. PACKAGING AND SHIPPING包装与发运N. CORRECTIVE ACTION订正措施O. COST CHARGEBACKS本钱降低PRODUCTION PART APPROVAL PROCESS (PPA

4、P)生产件批准流程11MAINTENANCE维护13CONTINUOUS IMPROVEMENT持续改良14APPENDIX附录 15-17A. ACRONYMS AND DEFINITIONS缩略语与定义精心整理CORPORATE OVERVIEW公司简介Filtration Business Unit (FBU) is a world leader in filtration and exhaust manufacturing for the truck, agricultural, small engine, shipping, and construction equipment in

5、dustries. We use a variety of purchased materials and components in our manufacturing processes, including: filter media, coil steel, tubing, expanded metal and screen, plastisol, coatings, clamps, nuts and bolts, fittings, mounting flanges, o-rings, gaskets and packaging. 滤清器业务单元FBU是卡车、农业机械、小发动机、船机

6、和建筑机械等领域的世界领先的滤清器和排气系统的制造商。我们在制造过程中运用各种选购原材料和零件，包括：过滤介质，钢板卷材，管材，编织金属网, 塑料，涂装，夹具，螺母和螺栓，装配，装配法兰, O型圈，橡胶件和包装材料FBU is a strategic Business Unit of Cummins Inc. Established in 1958 as The Seymore Filter Co., Fleetguard was a single filter production line dedicated to meeting the high performance filtrati

7、on needs of Cummins engines. In 1963, the Fleetguard brand was initiated and in 1967 manufacturing moved to Cookeville, TN. FBU是康明斯公司的一个战略业务单元，成立于己于1958年，当时名为Seymore滤清器公司。弗列加是一条单一的生产线，致力于满意康明斯发动机对滤清器的高品质要求。1963年弗列加商标起先运用并于1967年将制造场所迁至田纳西州的Cookeville。In 1986, Fleetguard began its US expansion with th

8、e acquisition of Kuss Corporation of Findlay, OH. Kuss specializes in in-tank and in-line fuel filters for the automotive and light truck industries. In 1997, Fleetguard continued its growth strategy with the acquisition of Nelson Industries headquartered in Stoughton, WI. Nelson specializes in exha

9、ust and filtration systems.1986年，弗列加起先在美国的扩张，收购了俄亥俄洲的库斯公司，库斯公司专业生产汽车和轻型卡车的燃油滤清器。1997年，弗列加接着其战略扩张，收购了总部位于威斯康森州斯托顿的纳尔森公司，纳尔森专业生产排气和滤清系统。In addition to its US-based entities, FBU has production or distribution facilities in Canada, Mexico, South America, Africa, Asia, Australia, and Europe. The Corpora

10、te headquarters for FBU is located in Nashville, TN.除了在美国的实体，FBU在加拿大，墨西哥，南美，非洲，亚洲，澳大利亚和欧洲有生产或分销基地。FBU的公司总部位于田纳西州的纳斯威尔。SUPPLIER QUALITY IMPROVEMENT PROGRAM (SQIP) INTRODUCTION供给商质量改良工程介绍The purpose of this “Supplier Quality Handbook” is to communicate the Quality requirements and expectations of FBU

11、to our direct material suppliers. These requirements and expectations, known as the Supplier Quality Improvement Program (SQIP) and depicted by the logo above, focus not only on the physical characteristics of a part, but also on the level of service, delivery, and cost containment provided by each

12、supplier. 本“供给商质量手册”的目的是与我们的干脆材料供给商沟通弗列加的质量要求和期望。这些在上面的索引里提到的被称为供给商质量改良工程SQIP的要求和期望，不仅仅关注于产品本身的特性，而且包括每一个供给商供给的效劳，交付和本钱限制的水平。The SQIP was developed with three basic principles in mind:SQIP主要包括如下三个根本原那么： Incorporate quality expectations as one of the considerations in new supplier selection总体的质量期望作为选

13、择新的供给商的一个考虑方面 Assure that quality tools are utilized by suppliers in the development of and revisions to their products, processes, and services 确保供给商在开发过程中运用质量工具并传递到他们的产品，过程和效劳中。 Provide a framework for sustaining and improving the quality of supplier products, processes, and services 供给一个支持和改良供给商产

14、品，过程和效劳质量的框架It is the policy of FBU to meet and exceed customer requirements. Suppliers play a vital role in our quest. Therefore, it is imperative that all suppliers share in our commitment to quality.满意和超越客户的期望是FBU的方针。供给商在我们这扮演了一个重要的角色。因此，供给商必需分担我们的质量承诺。SUPPLIER MANAGEMENT供给商管理FBU operates under t

15、he premise that the supplier is fully responsible for their products, and services as well as any damages resulting from said products/services. Further, we purchase parts with the understanding that they are defect free and processable in FBU processes. Finally, each supplier is required to develop

16、 an effective total quality system that encompasses business aspects based on defect prevention rather than defect detection. All suppliers to FBU are required to be, or provide a plan to attain, third party registration to ISO 9001:2000.FUB运作的根底是供给商对他们的产品，效劳和任何由他们的产品/效劳所导致的损害负全责。而且，我们认为从他们那选购来的产品是没

17、有缺陷的，并在FBU的过程中是可加工的。最终，每一个供给商都要求建立一个有效的全面质量管理系统，包括基于缺陷预防而不是缺陷发觉的企业运作。FUB的全部供给商都要求通过或供给打算通过第三方的ISO 9001:2000认证。A. Selection Process选择流程The FBU Supply Chain Management group is responsible for identifying potential suppliers. Basic investigation into the suppliers ability to meet contract requirements

18、 includes a review by FBU SCM group of the suppliers profile/capabilities. New suppliers are also provided with a copy of FBU Supplier Quality Manual and are asked to complete a Confidentiality Agreement. FBU供给链管理小组负责选择潜在供给商。为满意合同要求而进展的供给商实力的根底调查包括FUB供给链管理小组对供给商的总体状况/实力的一个概况了解。新的供给商将得到FBU的供给商质量手册复印件

19、并要求签署保密协议书。 Once identified, an appropriate cross-functional Supplier Selection Team will initiate a supplier selection and material approval process. The approval process can consist of the following steps:一旦确定，一个相关的跨部门供给商选择小组将发起供给商选择和材料批准流程。批准流程包括下面的步骤： Verification of third party registration. Yo

20、u will be asked to provide a copy of the certificate that covers the plant location and product proposed for delivery to FBU. If you are not yet third party registered you will be asked to submit a plan with timelines for becoming registered. SCM SQIE must approve this plan before work can continue.

21、确认第三方认证。你将被要求提交一份包括生产场地和将要提交给FBU的产品的认证证书。假如你没有通过第三方认证，你将被要求提交一份认证打算时辰表。在开展下面的工作前，SCM的SQIE必需批准该打算。 Suppliers completion of the Quality System Self-Assessment. 供给商完成质量系统自我评估。 Site Visit and “FBU Quality System Pre-assessment”. This assessment centers on selected elements of the system (vs. the entire

22、Quality System) and looks for evidence of routine execution and the capability of the manufacturing process to produce quality product appropriate for FBU. 访问工厂并进展“FBU质量系统预评审”。此评审关注于被选择的系统局部和整个质量系统和找寻满意FBU产品质量要求的日常限制和制造过程实力的证据 Process audits of similar product being run on the process proposed for F

23、BU (may be included as part of the Pre-assessment).和提交给FBU的产品类似的产品的过程审核可以作为预评审的一局部 Decision made as to whether to continue with this supplier or move to another candidate.确定接着与该供给商合作还是转到另一个供给商In addition to the quality of your products and processes, as part of the selection process you will also be

24、 evaluated on administration, attitude, company information and statistics, cost, delivery, materials planning, and technology.除了你的产品和过程，作为选择的一局部，你还将被审核到经营，看法，公司信息和统计，本钱，交付，物料打算和技术。 B. Development开发Supplier development is an evolving process through which FBU ensures that:供给商开发是一个绽开的过程，FBU通过此确保： Sta

25、ndards for suppliers are clearly defined给供给商的标准已被清晰定义 Suppliers quality systems meet requirements供给商的质量体系满意要求 Suppliers processes are in control, capable and product defect free供给商的过程受控，有实力，无缺陷产品 Suppliers commitment to provide a total quality product 供给商承诺供给全面质量产品 Supplier practices continuous cost

26、 improvement供给商实践持续的本钱改良The FBU Supplier Selection Team will conduct an initial evaluation of the supplier and begin work with that supplier towards a Ship-To-Use (STU Status). This status is in support of the FBU to reduce the Receiving Inspection process. Initial efforts will be directed toward:FB

27、U供给商选择小组将进展一次初始的供给商评估，工作起先于供给商发运的产品到达运用状态STU状态。该状态旨在支持FBU削减进货检验。初始的效果将 Encouragement of open communication and partner-like relationships between the supplier and FBU.鼓舞在FBU和供给商之间建立开放式的沟通和合作伙伴关系 The supplier is required to follow the Advance Product Quality Planning process and continuous quality sy

28、stem improvement.供给商将被要求遵照APQP流程和持续的质量体系改良 Explaining the function of the part(s) or process (es) to be provided as it relates to the performance of the final product. This includes descriptions of the product into which the part is assembled subsequent processing performed on the part, handling met

29、hods etc., where such information is not considered confidential or proprietary.说明产品或过程的功能，因为这些将关系到最终产品的表现。这包括在不涉及到机密和全部权的状况下描述后续的装配过程和操作方法。C. Production Part Approval Process (PPAP)生产件批准流程All new or changed product supplied to FBU must meet AIAG PPAP. It is the responsibility of the supplier to not

30、ify FBU, SCM SQIE or facility SQIE, of the need to submit PPAP per AIAG PPAP Manual. Unless otherwise approved or specified the required submission will be a Level 3 PPAP. See Production Part Approval Process (PPAP) later in this manual for more detail.全部供给应FBU的新的或更改的产品必需满意AIAG PPAP的要求。供给商有责任通知FBU，S

31、CM的SQIE或工厂SQIE遵照AIAG PPAP要求提交PPAP的的须要。除非另有批准或规定，提交的等级为PPAP 3级。更多细微环节见此手册后面的PPAP流程。D. Quotation Criteria报价准那么When submitting a quotation, the following criteria should be addressed: 当提交报价时，必需遵守以下准那么： Clear understanding and agreement on product specifications, requirements and applications.清晰地理解和同意产品

32、标准，要求和应用 Internal capabilities sufficient to manufacture products at consistent, acceptable quality and performance levels. 内部实力足够以制造持续的，可承受的质量和表现水平的产品。 Recommendation of any changes that will prove advantageous to product quality, performance, price and delivery. 任何建议的更改都将证明有利于产品质量，表现，价格和交付 Notice

33、of any exceptions to be included with quotation bid.任何反对看法都必需包括在报价标书内 PPAP plan including timing to submit, run size planned筹划了包括提交时间，运行数量的PPAP打算E. Ship To Use (STU) Process发运至生产流程STUOur ultimate goal is to eliminate receiving inspections at all FBU facilities. To further this initiative, we have in

34、stituted a process in which all of the suppliers products by part number are expected to progress, through demonstrated quality performance, to a STU status. Inconsistent or poor performance will cause the product to ultimately become disqualified. The supplier should contact the SCM SQIE and active

35、ly pursue STU status for components and materials they supply. The progress path is as follows: 我们的最终目标是在任何的FBU工厂消退进货检验。为到达次目的，我们发起一个流程，在此要求全部供给商供给的产品都有产品编号，通过此流程证明质量表现，到达发运至生产的状态。不稳定的或差的质量表现将导致产品丢失资格。供给商应当联系SCM SQIE主动获得他们供给的零件和材料的STU状态表现。该过程路径如下：First Piece Status首件状态:Released part awaiting initial

36、 PPAP approval发放的产品等待首次PPAP批准Approved Status批准状态:PPAP has been approved for receipt and will begin quality and delivery history development. PPAP已被批准接收，将起先开发质量和交付表现统计流程STU Status / STU状态：Product has demonstrated consistently good delivery and quality with no rejections. Demonstration of on-going sta

37、tistical capability, for specified characteristics, may be required by the SCM SQIE for STU status.产品证明有持续的好的交付和质量表现，没有拒收。SCM SQIE可能会要求为STU状态供给指定特性的在线的统计实力。Note留意: A product is expected to advance and remain at STU Status. However, a rejection against a part number at STU Status will cause the part

38、number to be moved back to Approved Status. Continued rejections or chronic occurrence of rejections will result in the part number and consequently the supplier to be disqualified as an approved component and supplier. 产品将要求超过和保持STU状态。当然，一次在STU状态的产品的拒收将导致产品回到被批准的状态。连续的拒收或始终有拒收发生将导致产品和供给商失去资格成为批准的零件

39、和供给商。F. Performance Report表现报告FBU will categorize all suppliers into two groups: Primary, and Secondary. This categorization is determined using the FBU Supplier/Component Risk Profile Categorization Guide. The degree of supplier management will be based on this categorization.FUB将全部供给商分为两组：一级和二级。此分

40、类将依据FBU供给商/零件风险等级指导确定。供给商管理的程度将基于此分类。A major component of supplier management is the Supplier Scorecard. The Supplier Scorecard is a measurement and feedback system to suppliers on Quality and Delivery performance. Each category is evaluated independently and suppliers are required to perform well i

41、n both categories.一个主要的供给商管理手段是供给商计分卡。供给商计分卡是一个供给商质量和交付表现的衡量和反应系统。每一级都是独立的，供给商被要求两级当中都有好的表现。Primary and selected Secondary suppliers will periodically receive a “Supplier Scorecard”. The FBU performance expectations are zero (0) defects and 100% on-time delivery. Suppliers should reference the perfo

42、rmance matrix below to determine their performance rating. 一级和二级供给商都将定期收到一个“供给商计分卡”。FBU的表现期望是0拒收和100%准时交付。供给商应当参照下面的表现矩阵表来确定他们的表现等级RATING等级QUALITY质量DELIVERY交付PREFERRED首选的 99% On-timeKEY关键的500 15197 98.9%APPROVED批准的1200 50190 96.9%CONDITIONAL受控的 1200 PPM 90% On-timeWhile suppliers are rated in each o

43、f the categories, the overall rating is the lowest rating in any category. For example if you are “Preferred” on quality, but “Conditional” on delivery, then your overall score is “Conditional”. Suppliers attaining “Preferred” status may gain access to additional business opportunities provided you

44、also add value toward cost reduction efforts. Suppliers rated “Conditional” may be placed on the Special Emphasis Supplier Process (SESP) referred to in a previously distributed separate letter. 当供给商在各个类别中评定等级，总的等级是全部等级中最低的等级。比方说，假如你在质量方面是“首选的”，但在交付方面是“受控的”，那你总的等级就是“受控的”。假如供给商到达“首选的”，同时在本钱降低方面有增值表现，

45、你将可能获得额外的业务时机。供给商评级为“受控的”将在收到一封单独的信件后进入特殊关注供给商流程SESP。SUPPLIER QUALITY SYSTEM REQUIREMENTS供给商质量体系要求Third party registration to ISO 9001:2000 is a FBU requirement for suppliers of direct materials. These third party registrations are accepted as evidence that suppliers will comply with numerous custom

46、ers quality system requirements through one registration and will utilize universally recognized terminology and quality tools. The supplier is expected to operate to the requirements of their registration; however, the following references to a quality system are either in addition to the registrat

47、ion requirements or redundant reference to specific items of concern to FBU.ISO 9001：2000的第三方认证是FBU对干脆材料供给商的要求。此第三方认证将被作为证据，证明供给商能通过一个认证满意大多数客户的要求并将运用通用的术语和质量工具。当然，下面的质量体系的参考将是认证要求的补充或是FBU的特殊要求的补充。A. Organization组织The organizational structure of the company shall include a Quality Control function,

48、which promotes a commitment to continually improve processes and systems. The quality management position should report to a management level that provides authority to implement effective quality assurance and continuous system improvement.公司的组织构造应当包括质量限制功能，以促进对持续改良过程和系统的承诺。质量管理职位应当被授权执行有效的质量保证和持续的

49、体系改良并向管理层汇报。B. Advanced Quality Planning先期质量筹划Defect prevention rather than defect detection is accomplished by front-end quality planning. As such, suppliers are required to comply with the basic intent of AIAGs Advanced Product Quality Planning and Control Plan requirements. FBU will assist with t

50、he analysis and provide all information it considers critical to the form, fit, function and reliability of the product. 缺陷预防胜于缺陷探测将在前期质量筹划中完成。为此，供给商将被要求遵守AIAG关于先期质量筹划和限制打算的要求。FBU将帮助分析和供给关于产品的外形，安装，功能和牢靠性等方面的全部信息。Process Flow Chart, Process FMEA, Control plans and other documented instructions shoul

51、d be developed to provide consistent control of product quality. Statistical process control (SPC) techniques should be utilized to provide a clear understanding of process capabilities within the suppliers facility. 应当开发过程流程图，过程FMEA，限制打算和其他文件化的指导书以供给持续的产品质量限制。应当运用统计过程限制SPC技术以在供给商工厂内供给对过程实力的清晰的理解。C.

52、Written Procedures书面程序Written procedures defining all aspects of the manufacturing and quality functions should be available to FBU on request. Examples include, but are not limited to: Quality Control Manual, inspection documents, validation processes, gage calibration, machine operation, product r

53、ework, and disposition of scrapped material. All procedures shall be controlled and revised on a scheduled basis.定义了制造和质量限制功能的全部方面的书面程序必需在FBU要求时可得.包括但不限于：质量限制手册，检验文件，验证过程，量具校验，设备运行，产品返工和报废零件的处置。全部程序必需受控并按打算修改。D.Drawing and Specification Control图纸和标准限制Suppliers are required to maintain a documented s

54、ystem to control drawings, specifications, and changes to those documents. Suppliers will be notified of changes to drawings or specifications, at which time the supplier is responsible for the control and distribution of those changes. All obsolete drawings and specifications shall then be removed

55、from use. Suppliers must not make revisions or changes without prior written approval from FBU. 供给商必需维护一个文件化的图纸和标准限制和修改的系统。供给商将被通知到图纸或标准的更改，此时，供给商有责任限制和分发这些更改。全部过期的图纸和标准应当从运用场所移开。在没有得到FBU的书面批准前，供给商不得更新或修改图纸。E.Inspection and Test 检验和测试 Receiving - Suppliers shall have a system to ensure the quality o

56、f incoming materials, which assures that all specifications are met. 收货供给商应当有一个系统确保全部的选购材料的质量满意全部的标准要求。 In-process The supplier shall have a system to verify product quality compliance through-out the manufacturing operation. A method for first piece compliance to specifications and approval prior t

57、o parts being allowed into production shall be in place. 过程供给商应当有一个系统在整个制造过程中验证产品质量的符合性。.生产前进展首件检验和批准的方法应当运用。 Final When Receiving and/or In-process quality systems have proven ineffective, suppliers will provide 100% inspection and/or dock audits to assure product quality.最终当进货和/或过程质量无效时，供给商必需供给100

58、%的检验或成品审核以确保产品质量。F.Material Control物料限制The FBU requires that the supplier have a lot traceability method that ties the materials and processes to the date of production. It is also expected that the supplier will cascade appropriate requirements to sub-suppliers to FBU product including requirements

59、 for registration to ISO 9001:2000 or compliance to that standard at a minimum.FBU要求供给商有批次跟踪方法以记录生产当日的材料和过程。同样要求供给商针对供给应FBU的产品对他们的供给商提出同样类似的要求，包括ISO9001：2000的认证或至少符合该要求。G.Records记录Suppliers shall maintain records for all quality functions. These functions include but are not limited to calibration,

60、instruction sheets, inspection and test results, statistical data (if applicable), and corrective action reports. Records documenting inspection, test, and final audit data should indicate the nature and type of any deficiencies, disposition of material, inspectors name, and date of inspection. Reco

61、rds shall be maintained for a minimum of one (1) year unless otherwise indicated by FBU. Retention of PPAP records should be for the life of the production of that product plus one-year.供给商应当保存全部质量活动的记录。这些活动包括但不限于计量，指导书，检验和测试结果，统计数据如适用和订正措施报告。检验，测试和最终审核的书面记录必需显示缺陷类别，材料的处置，检验员名字和检验的日期。除非FBU另有规定，记录至少须

62、保存一年。PPAP记录必需保存产品生命周期再加一年。H.Measurement and Test Equipment测量和测试设备 All gages used for variable data on safety, critical, major, 6 sigma, and key control characteristics, final layout or SPC collection points shall be included in a Gage Repeatability & Reproducibility (GR&R) program. Total gauge error

63、 should be less than 30%. Gauge error that can not be reduced to less than 30% prior to PPAP should be approved by SCM SQIE prior to PPAP submission.全部用来测量平安、关键、重要、6、关键限制特性、最终产品特性或SPC数据收集等可变性数据的量具都必需进展GR&R探究。总的量具误差必需小于30%。全部没法到达小于30%的量具误差必需在PPAP提交之前得到SCM SQIE的批准。 Any FBU owned or specialty gages for

64、 FBU products only shall be indicated as such and may be subject to correlation with like gages at FBU locations.全部FBU全部或特地用于FBU产品的量具应当象FBU工厂的量具一样管理。I.Statistical Process Control (SPC)统计过程限制SPCFBU requires the use of SPC for dimensions or characteristics that are identified as safety, critical, major, 6 sigma, or as a key control characteristic of a product. This data and/or capability indices shall be maint