康明斯质量手册.doc

CUMMINS INC.康明斯公司FILTRATION BUSINESS UNIT滤清器业务单元SUPPLIER QUALITY HANDBOOK供应商质量手册TABLE OF CONTENTS索引CORPORATE OVERVIEW公司简介1SUPPLIER QUALITY IMPROVEMENT PROGRAM (SQIP) INTRODUCTION1供应商质量改进项目介绍SUPPLIER MANAGEMENT供应商管理2-4A. SELECTION PROCESS选择流程B. DEVELOPMENT开发C. PRODUCTION PART APPROVAL PROCESS (PPAP)生产件批准流程D. QUOTATION CRITERIA 报价准则E. SHIP TO USE (STU) PROCESS发运至生产流程F. PERFORMANCE REPORT业绩报告SUPPLIER QUALITY SYSTEM REQUIREMENTS供应商质量体系要求5-11A. ORGANIZATION组织B. ADVANCED QUALITY PLANNING先期质量策划C. WRITTEN PROCEDURES书面程序D. DRAWING AND SPECIFICATION CONTROL图纸和规范管理E. INSPECTION AND TEST检验和测试F. MATERIAL CONTROL物料控制G. RECORDS记录H. MEASUREMENT AND TEST EQUIPMENT测量与测试设备I. STATISTICAL PROCESS CONTROL (SPC)统计过程控制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纠正措施O. COST CHARGEBACKS成本降低PRODUCTION PART APPROVAL PROCESS (PPAP)生产件批准流程11MAINTENANCE维护13CONTINUOUS IMPROVEMENT持续改进14APPENDIX附录 15-17A. ACRONYMS AND DEFINITIONS缩略语与定义August 2003 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 industries. 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。我们在制造过程中使用各种采购原材料和零件，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 filtration 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，致力于满足康明斯发动机对滤清器的高品质要求。1963年弗列加商标开始使用并于1967年将制造场所迁至田纳西州的Cookeville。In 1986, Fleetguard began its US expansion with the 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 exhaust and filtration systems.1986年，弗列加开始在美国的扩张，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，弗列加继续其战略扩张，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 Corporate 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供应商质量改进项目介绍The purpose of this “Supplier Quality Handbook” is to communicate the Quality requirements and expectations of FBU 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 supplier. 本“供应商质量手册”的目的是与我们的直接材料供应商交流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应商质量改进项目（SQIP）的要求和期望，不仅仅关注于产品本身的特性，而且包括每一个供应商提供的服务，交付和成本控制的水平。The SQIP was developed with three basic principles in mind:SQIP主要包括如下三个基本原则： Incorporate quality expectations as one of the considerations in new supplier selection总体的质量期望作为选择新的供应商的一个考虑方面 Assure that quality tools are utilized by suppliers in the development of and revisions to their products, processes, and services 确保供应商在开发过程中使用质量工具并传递到他们的产品，过程和服务中。 Provide a framework for sustaining and improving the quality of supplier products, processes, and services 提供一个支持和改进供应商产品，过程和服务质量的框架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.满足和超越客户的期望是FBU的方针。供应商在我们这扮演了一个重要的角色。因此，供应商必须分担我们的质量承诺。SUPPLIER MANAGEMENT供应商管理FBU operates under the 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 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运作的基础是供应商对他们的产品，服务和任何由他们的产品/服务所导致的损害负全责。而且，我们认为从他们那采购来的产品是没有缺陷的，并在FBU的过程中是可加工的。最后，每一个供应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现的企业运作。FUB的所有供应商都要求通过或提供计划通过第三方的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 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供应链管理小组负责选择潜在供应商。为满足合同要求而进行的供应商能力的基础调查包括FUB供应链管理小组对供应商的总体情况/能力的一个概况了解。新的供应商将得到FBU的供应商质量手册复印件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应商选择小组将发起供应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. You 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.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。如果你没有通过第三方认证，你将被要求提交一份认证计划时间表。在开展下面的工作前，SCM的SQIE必须批准该计划。 Suppliers completion of the Quality System Self-Assessment. 供应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 Quality System) and looks for evidence of routine execution and the capability of the manufacturing process to produce quality product appropriate for FBU. 访问工厂并进行“FBU质量系统预评审”。此评审关注于被选择的系统部分（和整个质量系统）和寻找满足FBU产品质量要求的日常控制和制造过程能力的证据 Process audits of similar product being run on the process proposed for FBU (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部分） Decision made as to whether to continue with this supplier or move to another candidate.决定继续与该供应商合作还是转到另一个供应商In addition to the quality of your products and processes, as part of the selection process you will also be evaluated on administration, attitude, company information and statistics, cost, delivery, materials planning, and technology.除了你的产品和过程，作为选择的一部分，你还将被审核到经营，态度，公司信息和统计，成本，交付，物料计划和技术。 B. Development开发Supplier development is an evolving process through which FBU ensures that:供应商开发是一个展开的过程，FBU通过此确保： Standards for suppliers are clearly defined给供应商的标准已被清楚定义 Suppliers quality systems meet requirements供应商的质量体系满足要求 Suppliers processes are in control, capable and product defect free供应商的过程受控，有能力，无缺陷产品 Suppliers commitment to provide a total quality product 供应商承诺提供全面质量产品 Supplier practices continuous cost improvement供应商实践持续的成本改进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:FBU供应商选择小组将进行一次初始的供应商评估，工作开始于供应商发运的产品达到使用状态（STU状态）。该状态旨在支持FBU减少进货检验。初始的效果将 Encouragement of open communication and partner-like relationships between the supplier and FBU.鼓励在FBU和供应商之间建立开放式的交流和合作伙伴关系 The supplier is required to follow the Advance Product Quality Planning process and continuous quality system improvement.供应商将被要求遵照APQP流程和持续的质量体系改进 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 methods etc., where such information is not considered confidential or proprietary.解释产品或过程的功能，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所有权的情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 notify 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.所有提供给FBU的新的或更改的产品必须满足AIAG PPAP的要求。供应商有责任通知FBU，SCM的SQIE或工厂SQIE按照AIAG PPAP要求提交PPAP的的需要。除非另有批准或规定，提交的等级为PPAP 3级。更多细节见此手册后面的PPAP流程。D. Quotation Criteria报价准则When submitting a quotation, the following criteria should be addressed: 当提交报价时，必须遵守下列准则： Clear understanding and agreement on product specifications, requirements and applications.清楚地理解和同意产品规范，要求和应用 Internal capabilities sufficient to manufacture products at consistent, acceptable quality and performance levels. 内部能力充足以制造持续的，可接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 of any exceptions to be included with quotation bid.任何反对意见都必须包括在报价标书内 PPAP plan including timing to submit, run size planned策划了包括提交时间，运行数量的PPAP计划E. Ship To Use (STU) Process发运至生产流程（STU）Our ultimate goal is to eliminate receiving inspections at all FBU facilities. To further this initiative, we have instituted 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 actively 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工厂消除进货检验。为达到次目的，我们发起一个流程，在此要求所有供应商提供的产品都有产品编号，通过此流程证明质量表现，达到发运至生产的状态。不稳定的或差的质量表现将导致产品丧失资格。供应商应当联系SCM SQIE主动获取他们提供的零件和材料的STU状态表现。该过程路径如下：First Piece Status首件状态:Released part awaiting initial 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，将开始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 statistical 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状态提供指定特性的在线的统计能力。Note注意: 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 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。连续的拒收或一直有拒收发生将导致产品和供应商失去资格成为批准的零件和供应商。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将所有供应商分为两组：一级和二级。此分类将根据FBU供应商/零件风险等级指导确定。供应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 in both categories.一个主要的供应商管理手段是供应商计分卡。供应商计分卡是一个供应商质量和交付表现的衡量和反馈系统。每一级都是独立的，供应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 performance matrix below to determine their performance rating. 一级和二级供应商都将定期收到一个“供应商计分卡”。FBU的表现期望是0拒收和100%准时交付。供应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 of 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 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. 当供应商在各个类别中评定等级，总的等级是所有等级中最低的等级。比如说，如果你在质量方面是“首选的”，但在交付方面是“受控的”，那你总的等级就是“受控的”。如果供应商达到“首选的”，同时在成本降低方面有增值表现，你将可能获得额外的业务机会。供应商评级为“受控的”将在收到一封单独的信件后进入特别关注供应商流程（SESP）。SUPPLIER QUALITY SYSTEM REQUIREMENTS供应商质量体系要求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 customers 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 registration requirements or redundant reference to specific items of concern to FBU.ISO 9001：2000的第三方认证是FBU对直接材料供应商的要求。此第三方认证将被作为证据，证明供应商能通过一个认证满足大多数客户的要求并将使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, 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.公司的组织结构应当包括质量控制功能，以促进对持续改进过程和系统的承诺。质量管理职位应当被授权执行有效的质量保证和持续的体系改进并向管理层汇报。B. Advanced Quality Planning先期质量