GKN Aerospace - St. Louis
Supplier Quality Assurance Manual
This manual contains requirements that are applicable when invoked by GKN
Aerospace – St. Louis Purchase Orders. Use of this manual is required
for Contract Review and Quality Planning Activities.
Revision date: 25 February 2014
Section 1 - Introduction
1.1
Section 1: Introduction
Table of Contents
5
1.1 Table of Contents 5
1.2 Mission Statement 9
1.3 Introduction to the Supplier Quality Assurance Manual 10
1.4 Goal of the GKN-STL Supplier Quality Assurance Manual 11
1.5 Anticipated Benefits GKN-STL Supplier Quality Assurance Manual
1.6 How to Use the Supplier Quality Assurance Manual
13
Section 2: Initial Approval of Direct Material Sources
2.1
Initial Approval of Sources
12
14
14
Search Function 13
Overview 14
Minimum Requirements for Inclusion on the GKN-St. Louis ASL 14
AS/ISO Registration
14
Compliance with AS 9003 Requirements 15
NADCAP Certification – Outside Processors Only 15
A Pre-existing Customer/Supplier Relationship 15
Customer-Directed Sources
15
Additional Suppliers “Approved” Only As Needed
Maintenance of “Approved Supplier” Status
Definitions and Links
15
15
18
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Section 3: Initial Production Part/Material Approval
3.1 Quality Requirements
19
19
Overview 19
Identifying Applicable Quality Requirements (QRs)
Integration of QRs into Production Processes
Process Flow Chart
20
21
3.2 First Article Inspection Requirements
Definitions and Links
19
23
22
Overview 23
Development of First Article Inspection Report Data
23
Submission of First Article Inspection Report & Associated Part 23
GKN Review and Approval of Individual Part First Article Submissions 24
GKN Review and Validation of Supplier First Article “Processes” 24
Process Flow Chart
25
Definitions and Links
26
Section 4: On-going Formal Communications
4.1 Supplier Requests For Specification Deviation Or Change
27
27
Overview 27
Temporary Specification Deviations
27
Permanent Specification Changes
28
Process Flow Chart
29
Process Flow Chart
30
4.2 Supplier Process Change Approvals 32
Definitions and Links
31
Overview 32
Initiation of Requests for Manufacturing Process Changes
32
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Production Shipment Approval for Authorized Process Changes 32
Process Flow Charts
33
4.3 Nonconformance Reporting 35
Definitions and Links
34
Overview 35
Recording & Reporting of Supplier-responsible Nonconformances
Supplier Responsibilities upon Notification
35
36
Supplier-responsible Nonconformance Cost Recovery
36
Post-Delivery Notification from Supplier to GKN 36
Process Flow Charts
37
4.4 Supplier Corrective Action Requests
Definitions and Links
39
38
Overview 39
Initiation of a Supplier Corrective Action Request
39
Supplier Corrective Action Request Response Development
39
Supplier Corrective Action Request Implementation & Closure
40
Probationary Status & CAST
Process Flow Charts
42
4.5 Supplier Performance Rating
Definitions and Links
41
44
43
Overview 44
Supplier Appeal Process 47
Process Flow Charts
48
Definitions and Links
49
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Section 5: Continuous Improvement
5.1 On-site Supplier Assessments
50
50
Overview 50
Scheduling of On-site Assessments
50
Supplier Preparation for an On-site Assessment 51
The Opening Meeting
51
Conducting the On-site Assessment
The Closing Meeting
51
51
Improvement Plan Review & Follow-Up 52
Process Flow Charts
53
5.2 Supplier Process Assessments (SPAs)
Definitions and Links
55
54
Overview 55
Initial Data Search & Review
55
Coordination & Scheduling of SPAs with Suppliers
Conducting the SPA
SPA “Out Brief”
55
56
56
Corrective Actions Based on SPA Findings
Process Flow Chart
57
Definitions and Links
59
56
5.3 Consultation, Action, Selection and Termination
Process Flow Chart
60
59
Overview 60
CAST Process Steps
60
Step 1 - Consultation Meeting
Step 2 - Action Meeting
60
61
Step 3 - Decision Meeting 61
Process Flow Charts
62
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1.2 Mission Statement
It is the responsibility of the GKN Aerospace - St. Louis Supply Chain
function to establish and develop a base of suppliers with the
demonstrated capabilities to consistently supply parts, raw materials
and processing services that meet all specified requirements while
minimizing total procurement-related costs. The cornerstone of this
effort will be the collective requirements and processes described
within this GKN Aerospace - St. Louis Supplier Quality Assurance
Manual.
Principal strategies essential to the achievement of this mission are as follows:
•
Source qualification based on compliance with established criteria.
•
Utilization of this Supplier Quality Assurance Manual as a tool for communicating GKN-St.
Louis expectations and for guiding supplier quality system development efforts in accordance
with AS9003.
•
Facilitation of effective corrective/preventive actions in concert with suppliers to ensure root
cause solutions to purchased part/material concerns identified by GKN-St. Louis and/or its
customers.
•
Performance monitoring and feedback to facilitate supplier improvement and as a basis for
GKN-St. Louis source selection decisions.
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1.3 Introduction to the Supplier Quality Assurance Manual
In supplying goods and services to its customers, GKN Aerospace- St.
Louis acknowledges its important obligation to assure compliance with all
specified requirements. Likewise, GKN Aerospace - St. Louis requires its
suppliers to accept full responsibility for the quality of the goods and
services they provide. In order to fulfill this obligation, it is necessary that
GKN suppliers develop, implement, and maintain management procedures
and related controls that will provide evidence that they are capable of
executing contractual responsibilities to the satisfaction of GKN. It is also
required that all GKN suppliers of direct parts/materials and processing services develop and maintain a plan
of the overall organization defining the responsibility and authority for the Assurance of Quality in the form
of a Quality Manual or similar document which at minimum encompasses those requirements outlined within
AS 9003 – Inspection & Test Quality System. Guidance for the development of this Quality Management
Systems Manual may be found in ISO 10013.
This Supplier Quality Assurance Manual contains prescribed methods for interaction between GKN
Aerospace - St. Louis and its suppliers. These methods are to be adhered to at all times in order to further
ensure the conformance of products and services to specified requirements.
This document is a contractual obligation of the supplier, when invoked in whole or in part by a GKN
Aerospace - St. Louis purchase order.
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1.4 Goal of the GKN-STL Supplier Quality Assurance Manual
GKN Aerospace - St Louis is proud of its heritage as a producer of high performance
structures to the aerospace industry. Maintaining and enhancing this reputation
demands a total commitment to continuous quality improvement and product
performance. In order to achieve these objectives, GKN expects no less than this
same level of commitment to product/service excellence and continuous quality
improvement from its suppliers.
In order to satisfy its customers and effectively compete in worldwide markets, GKN
must continue to aggressively minimize the occurrences of nonconforming
products/services and their related costs. Toward this end, GKN recognizes that
Quality and Continuous Improvement can only be managed effectively when
customers and suppliers share a partnership based on common objectives and
effective communication. It is the hope of GKN Aerospace - St. Louis that the systems, tools, and
expectations described within this manual will define these objectives and foster the communication
necessary to build such partnerships with its suppliers.
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1.5 Anticipated Benefits GKN-St. Louis Supplier Quality Assurance Manual
•
Minimization of supplied nonconformances and their related costs.
•
Enhanced customer satisfaction through consistent and cost-effective
conformance to requirements leading to optimal value for GKN and its
customers.
•
Implementation of efficient and effective problem reporting and
resolution methods.
•
Rapid and open communication between GKN it suppliers through the
use of defined systems, tools, resources and contacts for routine qualityrelated business practices.
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1.6 How to Use the Supplier Quality Assurance Manual
Table of Contents
The Table of Contents links the user to the topics in the text. Click on the topic to go
to the desired text.
Search Function
This Supplier Quality Assurance Manual is a Microsoft WORD® document. Use the Edit/Find functionality
within WORD® to locate various terms within the Manual.
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Section 2 - Initial Approval of Direct Material Sources
2.1
Initial Approval of Sources
Overview
GKN Aerospace - St. Louis maintains an Approved Supplier List (ASL) as a basis for identifying those direct
part/material and processing suppliers who meet the minimum standards necessary to fulfill its procurement
needs.
In order to be considered eligible for the GKN Aerospace - St. Louis Approved Supplier List (ASL),
prospective new suppliers must meet at least one of the following criteria:
Site registration to AS 9100, ISO 9000:2000
Compliance with AS 9003: Inspection & Test Quality System
Site certification to NADCAP (Processors only)
Demonstration of a pre-existing supplier relationship with GKN
Directed for use by a GKN customer
Purchases of direct parts/materials and outside processing services may be made only from those suppliers on
the Approved Supplier List (ASL). Once added to the ASL, the supplier must continue to demonstrate an
acceptable level of performance in order to remain eligible for new business and to maintain their approved
status.
Minimum Requirements for Inclusion on the GKN-St. Louis ASL
In order to be considered eligible for the GKN Aerospace - St. Louis Approved Supplier List (ASL),
prospective new suppliers must meet at least one of the following criteria:
AS9100 / ISO Registration
Prospective suppliers of direct parts/materials or outside processing services that can substantiate a current
site registration to AS9100 or ISO 9000:2000 through an accredited Registrar will be considered eligible for
addition to the GKN Aerospace - St. Louis ASL.
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Compliance with AS 9003 Requirements
Prospective suppliers of direct parts/materials or outside processing services that can substantiate compliance
with all quality system requirements outlined within AS 9003 Inspection & Test Quality System will be
considered eligible for addition to the GKN Aerospace - St. Louis ASL. In order to substantiate compliance,
prospective suppliers are required to complete a GKN-STL Supplier Self-Assessment including references
to their quality system documentation that supports each required element. Suppliers who fail to meet the
requirements outlined above may be offered the opportunity to improve or develop their systems and resubmit
their self-assessment at a later time. When warranted, GKN Aerospace - St. Louis may elect to conduct a
GKN-STL On-site Supplier Assessment prior to addition to the ASL.
NADCAP Certification – Outside Processors Only
Prospective suppliers of processing services who can substantiate a current site accreditation to NADCAP
(National Aerospace and Defense Contractors Accreditation Program) requirements will be considered
eligible for addition to the - ASL. Such suppliers will be required to provide a completed GKN-Aerospace –
St. Louis Supplier Self-Assessment for informational purposes.
A Pre-existing Customer/Supplier Relationship
Suppliers who provide direct parts/materials and/or outside processing services to an existing business
venture at the time of a transition to GKN Aerospace - St. Louis will be added to the Approved Supplier List
(ASL). Suppliers will be required to complete a GKN-STL Supplier Self-Assessment for informational
purposes.
Customer-Directed Sources
Suppliers of direct parts/materials and/or outside processing services who are directed for use by one or more
GKN customers will be added to the Approved Supplier List (ASL). Customer-directed sources are also
required to complete a GKN-STL Supplier Self-Assessment for informational purposes.
Additional Suppliers “Approved” Only As Needed
When there is a need to add a supplier to its ASL, GKN Aerospace - St. Louis Procurement personnel will
contact the supplier and invite them to substantiate their eligibility. GKN Supplier Quality Engineering
and/or Procurement Management will review the supplier’s eligibility and add the supplier to the ASL only
upon verification of compliance with one or more of the criteria outlined above. Suppliers will be added to
the ASL only when a specific sourcing need has been identified.
Maintenance of “Approved Supplier” Status
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Purchases of direct parts/materials and outside processing services affecting product quality may be made
only from those suppliers on the Approved Supplier List (ASL). Once added to the ASL, the supplier must
continue to demonstrate an acceptable level of performance in order to maintain their eligibility for new
business and their approved status.
GKN Supplier Quality Engineering and Procurement Management monitor suppliers’ performance on a
monthly basis. Suppliers who demonstrate continued unsatisfactory performance are subject to formal
Supplier Corrective Action Requests (SCAR’s) and/or other more extensive remedial action. In those cases
where supplier performance does not respond to this remedial action, suppliers may be removed from the
ASL.
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GKN Aerospace - St. Louis
Supplier Approval & Selection
Process Flow Chart
GKN IDENTIFIES
A NEED FOR A
SUPPLIER
GKN REVIEWS
ASL FOR AN
APPROVED
SUPPLIER
SUPPLIER
FOUND?
YES
SUPPLIER
SELECTED
NO
SEARCH FOR
NEW SUPPLIER
POTENTIAL
SUPPLIER
IDENTIFIED
NO
SUPPLIER
MEETS ASL
CRITERIA?
YES
SUPPLIER ADDED
TO GKN ASL
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Definitions and Links
GKN-STL Supplier Self-Assessment
A formal documented evaluation of the
supplier’s quality system in order to verify
compliance with minimum requirements (ref.
AS9003) for inclusion on the GKN Approved
Supplier List (ASL).
GKN-STL On-Site Supplier Assessment
An on-site review of a supplier’s processes,
systems, and capabilities as conducted by
GKN personnel.
Supplier Corrective Action Request (SCAR)
A request to a supplier for formal documented
corrective and preventive action in response to
a nonconformance or performance concern.
Supplier Performance Ratings – the GKN
Aerospace - St. Louis quantified measure of
supplier performance.
Supplier Performance Ratings
Approved Supplier List – a list of those direct
part/material and processing sources deemed
capable of supporting GKN-St. Louis
procurement needs.
ASL
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Section 3 - Initial Production Part/Material Approval
3.1 Quality Requirements
Overview
GKN Aerospace - St. Louis purchase orders for direct parts/materials and outside processing services will include a
number of clauses relating to specific quality assurance requirements. Applicable QR clauses are assigned on a part
number basis and are identified on GKN purchase orders by their unique alphanumeric identifiers (QC2098 = First
Article in accordance with AS9102, e.g.). In order to view the complete text of QR’s applicable to their individual
purchase orders, Suppliers are required to access the following web site:
http://www.gkn.com/aerospace/supplier-info/st-louis/Pages/Quality-Information.aspx
GKN Buyers will assist Suppliers in gaining the necessary access to this site for purposes of reviewing Quality
Requirements.
Identifying Applicable Quality Requirements (QR’s)
In addition to identifying the applicable technical requirements as specified
within engineering drawings/blueprints, material and processing
specifications, etc., GKN Aerospace - St. Louis purchase orders will
contain a number of additional Quality Requirement (QR) clauses.
QR’s encompass a broad range of additionally imposed contractual
requirements, including but not limited to:
•
Critical Part/Material Traceability and/or
Serialization Requirements
•
GKN Right of Entry for review of Products/Processes/Systems
•
Record Retention Requirements
•
Special Restrictions on the Use of Qualified Sources
•
Special Control and Disposition of Nonconforming Materials
• Program or Customer-specific Quality System Requirements
The Quality Requirements selected for individual purchase orders will vary based upon a number of factors
including the criticality of the procured part/material and the needs of individual programs and GKN customers.
Applicable QR clauses are assigned on a part number basis and are identified on GKN purchase orders by their
unique alphanumeric identifiers (QC2098 = First Article in accordance with AS9102, e.g.). In order to view the
complete text of QR’s applicable to their individual purchase orders Suppliers are required to access the following
GKN Virtual Community web site: GKN Virtual Community
GKN Buyers will assist Suppliers in gaining the necessary access to this site for purposes of reviewing Quality
Requirements.
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Integration of QR’s into Production Processes
Suppliers are expected to review all applicable QR's as a part of their Contract Review and Quality Planning
processes. Requirements imposed by QR’s should be integrated into the Supplier’s Quality Systems and/or productspecific planning and related controls to ensure consistent compliance for all parts/materials supplied.
Certificates of Conformance supplied to GKN indicating compliance with all purchase order requirements should
take into account and reflect compliance with all applicable QR's listed on the GKN purchase order.
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Process Flow Chart
Compliance with applicable Quality Requirements (QRs)
Supplier
GKN
START
Identification of appropriate Quality
Requirements (QRs) associated with
individual parts/materials.
Applicable QRs linked to GKN Purchase
Order.
GKN Purchase Order transmitted to
Supplier by GKN Buyer.
Contract Review initiated to identify all
GKN purchase order requirements
including QRs.
P.O.
Acceptance?
NO
STOP
YES
Planning developed to ensure
compliance with all GKN purchase
order requirements including QRs.
Manufacture and/or Processing in
accordance with all GKN purchase
order requirements including QRs.
Review and Confirmation of compliance
with all GKN Purchase Order
Requirements including QRs.
Certificate of Conformance issued
attesting to compliance with all P.O.
requirements including QRs.
Parts/Materials shipped to GKN.
STOP
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Definitions and Links
Quality Requirement – a defined special purchase order
condition relative to quality assurance needs for procured
direct parts/materials or processing services.
QR
GKN Virtual Community Web Site.
http://www.gkn.com/aerospace/supplie
r-info/st-louis/Pages/QualityInformation.aspx
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3.2 First Article Inspection Requirements
Overview
GKN Aerospace - St. Louis requires its suppliers of direct production
parts to employ a First Article Inspection process in accordance with
AS9102. The purpose of this requirement is to develop objective
evidence to support that all engineering design and specification
requirements are properly understood, accounted for, and verified. A
copy of the completed First Article Inspection Report and the sample
part from which First Article data were obtained are to be provided to
GKN Aerospace - St. Louis for its review and approval. GKN Quality
Assurance personnel will review the First Article part and associated data for compliance to engineering
requirements and for required content in accordance with AS9102. Suppliers will be notified in writing of the
acceptance or rejection of their First Article Inspection Report submission through their GKN Buyer. Until formal
GKN acceptance of the First Article is received, suppliers are not authorized to make on-going production
shipments. Partial or complete re-accomplishment of the First Article Inspection for affected characteristics is
required for changes in product design, any change in the supplier’s manufacturing process, or other events as
prescribed within AS9102
Development of First Article Inspection Report Data
Prior to shipment of production parts, GKN suppliers are required to conduct and submit for GKN review/approval a
complete, independent, and documented physical and functional inspection to verify that prescribed production
methods have produced an acceptable item in accordance with engineering drawings, planning, purchase order,
engineering specifications, and/or other applicable design documents. These data are to be developed and
documented in accordance with methods prescribed within AS9102 - Aerospace First Article Inspection
Requirement (revision 2000-08). Suppliers are to utilize the forms associated with this standard where possible.
Suppliers’ own equivalent forms may be used in place of those contained within AS9102, provided all content
prescribed within AS9102 is included. Suppliers may acquire copies of AS9102 and the associated forms at the
following web-site address:
www.sae.org
NOTE: This requirement applies to supplied castings & forgings but excludes supplied basic raw materials such as
metallic plate/sheet, chemicals, fibers, fabrics, and outside processing services unless otherwise a part of approval
processes administered by a GKN customer.
Submission of First Article Inspection Report & Associated Part
Suppliers are to coordinate the transmission of their First Article Inspection Reports and the associated part through
their GKN Buyer. Packaging associated with such parts should be sufficient to prevent potential damage during
shipment to GKN. To facilitate GKN identification and verification of First Article parts and data, suppliers are
required to attach a
GKN-STL Supplier First Article Label to applicable packaging in a manner that
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conspicuously identifies the First Article part as such. On-going production shipments for such parts are not to
proceed until authorization from their GKN Buyer indicating that their First Article has been successfully verified
by GKN.
NOTE: For critical and other select parts, GKN may elect to have the supplier withhold their First Article
submission in order to allow GKN Supplier Quality Engineering to conduct a verification of the First Article part
and data at the supplier’s production facility. Arrangements for this review will addressed by a specific Quality
Requirement (QR) and be coordinated well in advance between GKN Supplier Quality Engineering and the supplier.
GKN Review and Approval of Individual Part First Article Submissions
GKN Quality Assurance personnel will review the First Article part and associated inspection report data for
compliance to engineering requirements and for required content in accordance with AS9102. Suppliers will be
notified of the acceptance or rejection of their First Article submission through their GKN Buyer. Until informed of
the acceptance of their First Article by their GKN Buyer, suppliers are not authorized to make on-going production
shipments. Rejected First Articles will require resubmission of complete or partial First Articles part and data.
Partial or complete re-accomplishment of the First Article Inspection for affected characteristics is required for
changes in product design, any change in the supplier’s manufacturing process, or other events as prescribed within
AS9102 and this Supplier Quality Manual.
GKN Review and Validation of Supplier First Article “Processes”
Where appropriate GKN Supplier Quality Engineering may utilize specifically tailored Supplier Process
Assessments (SPA’s) in order to validate the thoroughness and effectiveness of those processes developed and
deployed by individual suppliers for purposes of generating and verifying their First Article documentation in
accordance with AS9102. Those suppliers whose processes are successfully validated in this manner will still be
required to transmit their First Article Reports along with the labeled parts from which the data were derived but will
not be required to seek GKN First Article Verification approval for individual parts prior to commencing ongoing
production shipments.
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Process Flow Chart
Supplier First Article Submission
Supplier
GKN
START
Acceptance of GKN P.O. requiring
First Article Inspection Report
development per AS9102.
Supplier conducts and documents
First Article per AS9102.
GKN Supplier First
Article Part Label
affixed to applicable packaging.
First Article Part and
associated data shipped
to GKN.
Supplier's FA Process
validated by GKN?
NO
GKN Buyer coordinates First Article
Verification with BU Quality
Business Unit Quality conducts
First Article Verification.
FA Verified
successfully?
YES
YES
NO
Supplier notified
of Part FA
Verification
Rejection by
GKN Buyer.
STOP
Supplier notified of
Part FA Verification
Approval by GKN Buyer.
Supplier commences on-going
production shipments.
STOP
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Definitions and Links
First Article Inspection
The development of objective evidence to
support that all engineering design and
specification requirements are properly
understood, accounted for, and verified.
AS9102
The SAE Aerospace Standard (AS) that
establishes documentation requirements for
the First Article Inspection.
GKN-STL Supplier First Article Label
A specific label used to facilitate GKN
identification and verification of supplier
First Article parts.
First Article Verification
A review of supplied parts and associated
data to confirm compliance with AS9102 as
conducted by GKN personnel.
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Section 4: On-going Formal Communications
4.1 Supplier Requests For Specification Deviation Or Change
Overview
Suppliers are not to ship parts or materials that violate engineering specifications or
other contractual requirements without prior authorization from GKN Aerospace St. Louis. A deviation is a temporary modification to specifications as approved by
the appropriate design authority. In the event that a temporary specification
deviation is considered necessary, suppliers must submit a formal documented
request to their GKN Buyer and obtain documented approval prior to shipment to
GKN. If a permanent specification change is required, suppliers must also request
and obtain formal documented approval through their GKN Buyer prior to
shipment of such materials.
Temporary Specification Deviations
Temporary specification deviations are to be requested by Suppliers when there is a need for relief from engineering
specifications for a limited number of parts/material or for a limited time. Suppliers should initiate specification
deviation requests only after all efforts to meet GKN Aerospace - St. Louis purchase order requirements have been
exhausted. Suppliers must withhold shipment of production parts/materials that do not meet contractual
requirements pending receipt of an approved request for temporary specification deviation request that authorizes a
“use as is” disposition. Suppliers may also ship parts based on alternate dispositions such as rework at supplier,
rework at GKN, or ship to GKN for GKN Engineering analysis/review when documented within a GKN response.
When a supplier determines that a temporary specification deviation request is necessary, they are to complete a
GKN-STL Supplier Request for Specification Deviation/Change and transmit to their GKN Buyer. For deviations
to the Material Issue Card (MIC) for raw/prepped material, the GKN Buyer forwards the GKN-STL Supplier
Request for specification Deviation/Change Form to Manufacturing Engineering for review/approval. If
Manufacturing Engineering determines that a finished part can be produced from the material without deviating
from the engineering drawing/specification, then the Manufacturing Engineer shall approve the form and revise the
original MIC. If the raw/prepped material will deviate from the engineering drawing/specification, GKN will need
to submit a Request for Deviation to the customer and obtain approval. If the customer approves the deviation, then
the Manufacturing Engineer shall approve the form and revise the original MIC. The supplier shall note the material
size that is actually being shipped to GKN on their associated certification and shipper.
For requests other than deviations to the MIC for raw/prepped material the GKN Buyer will review the GKN-STL
Supplier Request for Specification Deviation/Change Form for completeness and link it to a
GKN
Nonconformance Tag for purposes of acquiring the necessary review by GKN Engineering and/or GKN customer
engineering personnel. The supplier will receive notification of the request disposition from their GKN Buyer in the
form of the copy of the approved or rejected request and the associated Nonconformance Tag.
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To facilitate GKN identification of deviated parts/materials, suppliers are required to attach a
GKN-STL Deviated Supplied Parts Cover Sheet to applicable packaging in a manner, which conspicuously
identifies the parts/materials as such. Such labels are also required for nonconforming parts/materials dispositioned
for rework at GKN, engineering analysis/review at GKN, or scrap at GKN. Supplier certificates of conformance
must also note the applicable GKN Nonconformance Tag number. Suppliers are authorized to ship deviated
materials only in accordance with the quantity or timeframe indicated on the approved deviation request.
NOTE: Materials shipped in accordance with approved specification deviations will not be charged against
Supplier Performance Rating.
Permanent Specification Changes
Permanent specification change requests are to be initiated only when the supplier has determined that established
processes are not able to produce materials in compliance with existing engineering requirements and that necessary
improvements to processes and/or appropriate control systems are believed to be prohibitive.
Suppliers are to submit permanent specification change requests to their GKN Buyer using a GKN-STL Supplier
Request for Specification Deviation/Change. The GKN Buyer will coordinate the review of the request by GKN
Engineering and/or applicable GKN customers. The supplier will withhold shipment of production parts/materials
pending receipt of the approved change request, the modified applicable engineering documentation from GKN
and/or its customer, and an updated GKN purchase order where appropriate.
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Process Flow Chart
Requesting a Temporary Specification Deviation
Supplier
GKN
START
Supplier identifies need for
temporary specification deviation.
Supplier completes a "GKN Supplier
Request for Temp. Deviation" and
transmits to GKN Buyer.
GKN Buyer links Request for Spec.
Deviation to a Nonconformance Tag &
routes for GKN Engineering review.
END
Yes
"Scrap at
Supplier" ?
GKN Eng. conducts coordination
internally at GKN & with customer as
required.
No
"Rework at
Supplier"?
No
Disposition (USE AS IS, SCRAP, REWORK AT
GKN, REWORK AT SUPPLIER, ETC.)
Yes
documented on NC TAG by GKN ENG.
Supplier carries
out prescribed
rework.
"Use as Is"
or
"Rework at GKN"
or
"Scrap at GKN" ?
GKN Buyer returns Request for Spec.
Deviation & associated GKN
Nonconformance Tag to Supplier.
No
Consult GKN
SQE
Yes
Supplier attaches Deviation label(s) to
subject parts/materials.
Supplier includes GKN
Nonconformance Tag number on
certificate of conformance.
Supplier ships deviated parts/materials
to GKN.
STOP
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Process Flow Chart
Requesting a Permanent Specification Change
Supplier
GKN
START
Supplier identifies need for
permanent change in specified
requirement.
Supplier completes a "GKN
Supplier Request for
Specification Change" and
transmits to GKN Buyer.
GKN Buyer transmits request
to GKN Engineering for review.
GKN Business Unit Eng. review
Approved
Approved or
Rejected?
GKN Buyer returns
approved Request
to Supplier along
with modified
Engineering
documentation.
Supplier ships parts/
materials in accordance
with modified GKN P.O.
and approved change
request..
Rejected
Disposition for
subject parts/
materials
identified by GKN.
GKN Buyer updates
P.O. as necessary to
incorporate modified
Engineering
documentation.
STOP
Supplier carries
out disposition.
GKN Buyer
returns rejected
Request to
Supplier.
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Definitions and Links
Temporary Specification Deviation
A temporary modification to any specified
product requirement (blueprint,
specifications, etc.) as approved by the
appropriate design authority. Deviations are
typically bounded by a timeframe or quantity
of parts/material.
Permanent Specification Change
A modification to any specified product
requirement (blueprint, specification, etc.) as
approved by the appropriate design authority
which is unbounded by quantity or time.
Nonconformance Tag
An internal GKN tool used for documenting
conditions that violate specified
requirements.
Supplier Request for Specification Deviation or
Change
A formal request for a temporary deviation
or permanent change to a GKN-STL
purchase order specification requirement.
GKN-STL Deviated Supplied Parts Cover Sheet
Label to be affixed by supplier in order to
facilitate GKN identification of deviated
parts/materials.
Supplier Performance Ratings – the GKN
Aerospace - St. Louis quantified measure of
supplier performance.
Supplier Performance Ratings
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4.2 Supplier Process Change Approvals
Overview
Once an approved First Article Inspection Report and part have been provided to, and
approved by GKN Aerospace - St. Louis, suppliers are not to make any changes to the
process that produces the part (i.e. methods, materials, machinery, etc.) or the location at
which the part is produced without prior written authorization from GKN. In the event that
it becomes necessary or desirable to modify the process or location, suppliers are required to
submit a
GKN-STL Supplier Process Change Request to their GKN Buyer through the
GKN Virtual Community web site or via fax. Any manufacture of parts from changed
processes without prior GKN approval will be done so at the supplier’s risk. Suppliers are
not authorized to ship parts from modified processes until they have:
•
Received documented authorization in the form of an approved GKN Supplier Process Change Request
from their GKN buyer and,
•
Achieved applicable First Article process validation or part approvals as described in section 3.2 of this
manual.
Initiation of Requests for Manufacturing Process Changes
In the event that a change to the established part process is desirable, suppliers are required to submit a GKN-STL
Supplier Process Change Request to their GKN Buyer. Completion of this form will require the supplier to fully
describe the nature and reasons for the proposed change including the benefit to be derived by GKN as a result of
the proposed change. It will also require the supplier to fully describe how the change will be verified as producing
materials in accordance with all specified requirements. Typically this will include a detailed description of a
proposed partial or complete First Article Inspection in accordance with AS9102. The GKN Buyer will review the
form for completeness and route it through GKN for the necessary internal review by GKN Supplier Quality
Engineering and Business Unit Quality Assurance. Suppliers will receive notification of acceptance or rejection of
the request from their GKN Buyer in the form of the approved or rejected request.
Production Shipment Approval for Authorized Process Changes
After a supplier has received the necessary approval to proceed with a proposed process changes, they may also be
required to develop and transmit appropriate First Article data (and labeled part as appropriate) prior to commencing
ongoing production shipments. This will enable the supplier and GKN to substantiate that the change has not had
any substantial detrimental impact on the supplier’s ability to produce parts in accordance with all specified
requirements. Any required First Article data and associated parts will be defined within the approved GKN-STL
Supplier Process Change Request.
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Process Flow Charts
Requesting a Process Change
Supplier
GKN
START
Supplier identifies need for a
change in a manufacturing process.
Supplier completes a "GKN Supplier
Process Change Request" and
transmits to GKN Buyer.
GKN Buyer transmits request
to GKN SQE and Business Unit
Quality Assurance for review.
SQE and Business Unit Quality review.
Approved or
Rejected?
Approved
Supplier conducts entire or partial
First Article per AS9102 where
directed by GKN on change request.
GKN Buyer returns
approved Request to
Supplier.
Rejected
GKN Buyer returns
rejected Request to
Supplier.
Supplier transmits First Article data
and subject parts to GKN Buyer.
STOP
GKN FA Approval?
NO
YES or Not Applicable
Supplier commences shipments of
parts/materials from modified process.
STOP
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Definitions and Links
Process Change
Any change to the materials, methods, machinery, or location
from that previously approved by GKN Aerospace - St. Louis.
GKN-STL Supplier Process
Change Request
A form used to document a supplier’s request for implementation
of a process change with respect to production of parts/materials
to be supplied to GKN - St. Louis.
First Article Inspection
The development of objective evidence to support that all
engineering design and specification requirements are properly
understood, accounted for, and verified.
AS9102
The SAE Aerospace Standard (AS) that establishes
documentation requirements for First Article Inspection.
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4.3 Nonconformance Reporting
Overview
Supplier-responsible nonconformances are defined as any violation of a specified
contractual requirement imposed by a GKN Aerospace - St. Louis purchase
order. Nonconforming parts/materials or related processing services will be
recorded on
GKN-STL Nonconformance Tag documents when encountered.
Such documents will be developed as a result of supplier-responsible
nonconformances encountered at any point in the value chain established between
GKN and its customers. Copies of “Nonconformance Tags” will be transmitted to appropriate supplier personnel
by their GKN Buyer via the GKN Virtual Community web site or fax. Upon notification, suppliers are required to
undertake immediate containment actions to minimize further impact to GKN and its customers. Suppliers will also
be expected to participate in discussions with their GKN Buyer regarding appropriate disposition options for
nonconformances encountered as well as the future availability of replacement stock as required. Suppliers may
request return of nonconforming parts/materials, at their expense, when they are not otherwise suitable for
immediate use or rework by GKN. Alternately, Suppliers may examine nonconformances at GKN prior to final
disposition in order to aid the development of timely and appropriate corrective/preventive actions provided
arrangements are made in a timely manner.
Recording & Reporting of Supplier-Responsible Nonconformances
Supplier-responsible nonconformances are defined as any violation of a specified contractual requirement imposed
by a GKN Aerospace - St. Louis purchase order. This includes technical engineering requirements defined on
blueprints, specifications, etc. as well as requirements for Certificates of Conformance, quantified test results, use of
appropriately qualified sources, special part/material identification requirements, or any other requirement imposed
by GKN Quality Requirements (QR’s) applied to the subject purchase order.
Nonconforming parts/materials or processing services will be recorded on GKN Aerospace - St. Louis
“Nonconformance Tag” documents when encountered. Such documents will be developed as a result of supplierresponsible nonconformances encountered at any point in the value chain established between GKN and its
customers. The GKN Buyer will transmit copies of GKN’s Quality Management Information System (QMIS)
generated “Nonconformance Tags” to the applicable Suppliers.
Nonconformances found by the supplier prior to delivery to GKN shall be documented on a Supplier
Nonconformance Record (Form MI 7.4-16 (b)) using Attachment Form (MI 8.1-11 (e) or MI 8.1-11 (f)), as
applicable. The GKN Buyer will consider processing such non-conformances, and if approved, will record the
nonconformance into GKN’s QMIS and provide the system generated GKN Nonconformance Number and
Nonconformance Tag to the supplier for inclusion on all documentation.
The supplier is required to attach Form MI 7.4-16 (d) to applicable packaging in a manner which conspicuously
identifies the parts/materials with the associated Nonconformance Tag. Supplier Certificates of Conformance must
also note the applicable GKN Nonconformance Tag Number. A copy of GKN’s Nonconformance Tag must also be
included within the documentation package. Suppliers are authorized to ship deviated materials only in accordance
with the quantity or timeframe indicated on the approved Nonconformance Tag.
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Supplier Responsibilities upon Notification
Suppliers are expected to immediately route GKN-STL Nonconformance Tag information internally to appropriate
Operations and Quality personnel. Once notified, Suppliers are required to undertake immediate containment action
to minimize or eliminate any further impact to GKN and its customers as a result of similar nonconformances, which
may be in-process, in inventory, or in-transit. Suppliers will also be expected to participate in discussions with their
GKN Buyer regarding appropriate disposition options for nonconformances encountered as well as the future
availability of known-acceptable replacement stock as required. Suppliers may request return of nonconforming
parts/materials, at their expense, when such parts/materials are not otherwise suitable for immediate use or rework
by GKN. Alternately, Suppliers are encouraged to examine nonconformances at GKN prior to final disposition in
order to aid the development of timely and appropriate corrective/preventive actions.
Supplier-responsible Nonconformance Cost Recovery
Suppliers are subject to charges for recovery of costs associated with any/all supplier-responsible nonconforming
parts/materials in accordance with QR # QC1900. Such charges will at minimum include:
•
An administrative charge for each nonconformance document generated by GKN-STL,
•
A rework charge for each part requiring rework by GKN or GKN customer personnel,
Part and/or material charges per P.O. or contract pricing for each part and/or material scrapped at
GKN or its customer.
Additional charges may also apply where parts or materials, as supplied by GKN and/or its customer, require
scrapping at the supplier as a result of the supplier’s actions.
•
Additional charges may also apply where supplied parts/materials require extraordinary rework at GKN or its
customer.
Post-Delivery Notification from Supplier to GKN
In the event that a supplier knows or suspects that it may have delivered nonconforming goods to GKN, they are
required to promptly notify their GKN Buyer in writing. Such notifications should describe the affected part
numbers, the specific nonconforming conditions, the quantities affected, applicable lot identification information,
and the dates delivered to GKN.
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Process Flow Charts
Supplier-responsible Nonconformances
Supplier
GKN
START
Supplier-responsible Nonconformance
encountered at GKN and/or its
Customer.
Nonconformance documented at GKN
on "Nonconformance Tag"
GKN Buyer transmits preliminary copy
of Nonconformance Tag to applicable
Supplier.
Supplier initiates immediate
containment actions and develops
corrective/preventive measures.
GKN Buyer and Supplier review availability of replacement stock and
potential disposition options.
Disposition determined and
Nonconformance Tag completed.
Copy of completed Nonconformance
Tag transmitted to Supplier by GKN
Buyer.
Supplier debited for related expenses
including, freight, material, rework, and
adminstrative efforts.
Formal Supplier Corrective Action
initiated by GKN Supplier Quality
Engineering.
Supplier responds to Corrective Action
Request within timeframe requested.
STOP
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Definitions and Links
Supplier-responsible
Nonconformance
Any violation of a specified contractual requirement imposed by
a GKN Aerospace - St. Louis purchase order.
Supplier Non-Conformance
Record
GKN template completed by the Supplier for submittal of
Supplier Non-Conformances to GKN.
Nonconformance Tag
An internal GKN tool used for documenting conditions that
violate specified requirements.
Disposition
Engineering determination of the appropriate further actions
associated with nonconforming parts/materials. Typical options
include Scrap, Rework, Use as Is, etc.
Form MI 7.4-16 (d)
GKN Nonconformance Tag and Instructions
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4.4 Supplier Corrective Action Requests
Overview
GKN Aerospace - St. Louis requires its suppliers to employ a closed
loop Corrective and Preventive Action methodology in order to address
product, process, and Quality System nonconformances. GKN Supplier
Quality Engineering initiates the Supplier Corrective Action Request
process by documenting an observed nonconforming product, process,
or Quality System condition on a formal Supplier Corrective Action
Request and transmitting it to the responsible supplier. Each Supplier
Corrective Action Request requires the supplier to utilize the following
multi-step approach in order to successfully and permanently resolve the condition:
(a) Description of the Problem or Nonconformance
(b) Interim Containment Action
(c) Root Cause Analysis
(d) Permanent Corrective Action
(e) Permanent Corrective Action Verification Plan
(f) Controls to prevent recurrence
(g) Preventive actions associated with similar products/processes/systems
Suppliers are required to respond prior to the deadline noted on the request (typically no more than 7 calendar days
from initiation) with a comprehensive action plan encompassing each of the above aspects. GKN Supplier Quality
Engineering will review the supplier’s response for completeness and timeliness. Late and/or rejected responses
will be documented and have an adverse impact on Supplier Performance Indicator Ratings. Suppliers who
demonstrate a consistent inability to provide acceptable responses to Supplier Corrective Action Requests or within
the deadlines established are subject to probationary status or CAST.
Initiation of a Supplier Corrective Action Request
GKN Supplier Quality Engineering initiates the Supplier Corrective Action process by documenting the
nonconforming product, process, or Quality System condition on a formal
GKN-STL Supplier Corrective Action
Request Cover Sheet. Also included in the request is a detailed
GKN-STL Supplier Corrective Action Response
Form upon which the supplier is to document the various actions taken to resolve the concern. These documents are
transmitted to the responsible supplier’s Quality Assurance Manager or other appropriate managerial representative
through the GKN Virtual Community web site or fax. GKN Supplier Quality Engineering subsequently contacts the
supplier to confirm receipt and to answer any questions they may have.
Supplier Corrective Action Request Response Development
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Receipt of a GKN Aerospace - St. Louis Supplier Corrective Action Request is an important event. It is a formal
notification that nonconforming supplied parts/material have created a significant unplanned disruption in the
manufacturing operations of GKN and/or its customer. A Supplier Corrective Action Request should be given the
highest priority within the supplier’s operations and thus requires the urgent and active participation of the
supplier’s management team. Response development should begin immediately upon notification and include the
identified actions, due dates, responsibilities and the resultant outcomes appropriate to each step in the process.
Suppliers are required to respond to the requestor (GKN Supplier Quality Engineering) via the GKN Virtual
Community web site or fax within the timeframe indicated using the GKN-STL Supplier Corrective Action
Response Form provided. A step-by-step
Supplier Corrective Action Guide is also available on the GKN
Virtual Community web site. Suppliers are strongly encouraged to utilize this guide as it reflects the expectations
that GKN has for acceptable content to Supplier Corrective Action Request responses.
GKN Supplier Quality Engineering reviews the Supplier Corrective Action Request responses for completeness and
timeliness upon receipt. The assigned GKN Supplier Quality Engineer will communicate the response acceptance
or rejection and compliance with established response timing.
Responses received after the response due date indicated are identified as late and will have a negative effect on
the supplier’s Performance Indicator rating as described in section 4.5 of this manual.
Extensions to the required due date may be granted by GKN Supplier Quality Engineering when warranted.
Suppliers are cautioned, however, not to rely on due date extensions because they are granted only in rare
circumstances.
Responses, which do not fully address appropriate content for all sections on the response form are rejected and
require supplier modification and resubmission. Such rejections will also have a negative effect on the supplier’s
Performance Indicator rating.
The due date for resubmission is established by the Supplier Quality Engineer on a case-by-case basis but is
typically no longer than 2-3 business days from the date of the initial rejection.
Suppliers who demonstrate a consistent inability to provide acceptable responses to Supplier Corrective Action
Requests or within the response deadlines established are subject to Probationary Status and/or CAST.
Supplier Corrective Action Request Implementation & Closure
Upon notification that a Supplier Corrective Action Request response is acceptable, suppliers are expected to
complete all actions within the timeframe indicated on the request. This is typically no more than 28 calendar days
from the date of the request initiation. Information/data supporting the implementation and effectiveness of actions
cited on Supplier Corrective Action Request responses must be provided to GKN Supplier Quality Engineering
before a Supplier Corrective Action Request is successfully completed.
Typical examples of evidence supporting the implementation and/or effectiveness of corrective/preventive actions
include but are not limited to: modified procedures or work instructions, training records, inspection/test records,
modified engineering planning, experimental data, and inspection results. Evidence supporting successful
implementation and effectiveness should be transmitted via the GKN Virtual Community web site to the requesting
Supplier Quality Engineer. Having developed and implemented an appropriate and comprehensive Supplier
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Corrective Action Request response, subsequent shipments of the subject part/material should then conform to all
GKN Aerospace - St. Louis purchase order requirements.
Suppliers will be notified by GKN Supplier Quality Engineering regarding the open/closed status of their assigned
Supplier Corrective Action Requests.
Probationary Status &
CAST
In those cases where suppliers demonstrate an inability to respond properly to Supplier Corrective Action Requests,
such suppliers will be placed on Probationary Status and will thus be considered ineligible for new business
opportunities unless otherwise directed by a GKN customer. Such suppliers will be removed from this probationary
status and returned to full ASL Approval status 90 days after the successful completion of the applicable Supplier
Corrective Action Request.
Thresholds for Probationary Status are as follows:
•
or more rejected responses to the same Corrective Action Request.
•
Failure to provide an acceptable comprehensive response within 14 calendar days of the SCAR
initiation date.
Failure to provide appropriate evidence of successful implementation and/or effectiveness within
45 days of the SCAR initiation date.
Suppliers who fail to address outstanding Corrective Action Requests after being placed on probation may be
subject to CAST as described in section 5.3 of this manual.
•
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Process Flow Charts
Supplier Corrective Action Requests
Supplier
GKN
START
Supplier-responsible Nonconformance
encountered at GKN
and/or its Customer.
Nonconformance documented at GKN
on "Nonconformance Tag" &
transmtted to Supplier by GKN Buyer.
Supplier initiates immediate
containment actions and develops
corrective/preventive measures.
GKN SQE initiates Supplier Corrective
Action Request (SCAR) via transmission
of GKWI 5.11 (A) and 5.11 (B) to Supplier.
Supplier develops comprehensive
response encompassing containment,
short and long term corrective actions,
etc. and responds to GKN SQE prior to
established deadline.
GKN SQE reviews response for
timeliness and completeness.
NO
Response
Acceptable?
Supplier implements defined actions in
accordance with targeted schedule.
YES
Supplier transmits evidence to
substantiate implementation &
effectiveness to requesting GKN SQE.
Supplier identifies 1st post-corrective
action shipment with required label.
GKN verifies effectiveness of Supplier's
Corrective Actions on subsequent
shipment.
STOP
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Definitions and Links
Actions planned and implemented to
contain, correct, and prevent the causes of a
product, process, or system
nonconformance.
Corrective & Preventive Action
Supplier Corrective Action Request (SCAR)
A request to a supplier for a formal
documented corrective and preventive
action in response to a nonconformance or
performance concern.
This forms describes the nonconformance
condition encountered, defines required
response and implementation dates and
provides GKN contact information.
GKN-STL Supplier Corrective Action
Request Coversheet
This form details the steps necessary for the
supplier to respond to the Request for
Corrective Action.
GKN-STL Supplier Corrective Action
Request Response Form
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4.5 Supplier Performance Rating
Overview
GKN Aerospace - St. Louis monitors the performance of its direct part/material and
processing suppliers on a monthly basis. When utilized Supplier Performance Rating
measure a supplier’s demonstrated performance with respect to product delivery, product
quality (percentage of supplied materials/services which meet all specified requirements)
and the supplier’s responsiveness to formal Supplier Corrective Action Requests
(quantity of late or rejected responses). These measures when weighted appropriately
may be combined to achieve an overall measure of each supplier’s performance on a
scale of 0-100. GKN Suppliers who do not maintain satisfactory Supplier Performance
Rating scores will be required to provide formal documented corrective action plans
and/or to participate in formal performance reviews at GKN. Where these remedial
activities are unsuccessful, suppliers may be subject to CAST and eventual removal from the Approved Supplier
List (ASL).
Delivery Performance Calculation:
4.5.1.Delivery performance will be calculated on a monthly basis as follows, numbers in parenthesis
are used in the sample calculations:
4.5.2.Traditional or Discreet Purchase Orders to be calculated as follows:
4.5.2.1.
Total Due = Current + Arrears + Lag
150 + 15 + 5 = 170
4.5.2.2.
On Time % = On Time / Total Due
145 / 170 = 85%
4.5.2.3.
Total Received = Total quantity received in a calendar month
4.5.2.4.
Current - Total open quantity on orders scheduled in the current month (150)
4.5.2.5.
Arrears - Total undelivered quantity on orders due prior to current month (15)
4.5.2.6.
Lag - Total quantity delivered against orders due prior to current month (5)
4.5.2.7.
Future – Total quantity delivered against orders scheduled in later months (10)
4.5.2.8.
On Time – Any quantity due within the month that is received 14 calendar days prior
to or 7 calendar days after the scheduled delivery date (145)
4.5.2.9.
The metric will be calculated 14 days after the month ends or the next business day if
the 14th day is not a business in order to allow for the +7 delivery window.
4.5.3.Min/Max orders to be calculated as follows:
4.5.3.1.
Total Due = The number of Opportunities in a month
4.5.3.2.
On Time % = Sum of the In Range occurrences / Total Opportunities in period
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37/55 = 67.3%
4.5.3.3.
Opportunities – Count of part numbers currently rated and managed by this order
method each Monday morning – (excludes parts with a metric effectivity date set in the
future) (e.g. 10, 15, 15, 15)
4.5.3.4.
In Range – when the inventory level for a part number is between the min and max
level as shown in the web portal
4.5.3.5.
On Time (Within Range) – Opportunities In Range on each (e.g. 5/10, 9/15, 8/15,
15/15 = 5+9+8+15 = 37)
4.5.4.Kanban or pull items to be calculated as follows:
4.5.4.1.
Total Due = Current + Lag + Arrears
400 + 50 + 50 = 500
4.5.4.2.
On Time % = On Time / Total Due
375 / 500 = 75%
4.5.4.3.
Current – Count of signals sent to supplier in the current month(400)
4.5.4.4.
Lag – Count of signals opened in prior months but satisfied in current month(50)
4.5.4.5.
Arrears – Count of unsatisfied signals open from prior months(50)
4.5.4.6.
On Time – Any signal satisfied in the current month that meets contractual obligations
(e.g. St. Louis cut to size is 14 calendar days) (375)
4.5.5.If a supplier is managed by a combination of the above methods the following formula should be
used to calculate the on time percentage:
4.5.6.Total On Time % = (On Time + On Time + On Time) / (Total Due + Total Due + Total Due)
4.5.6.1.1.
78% = (145 + 32 + 375) / (170 + 40 + 500)
4.6. Suppliers will be monitored on a monthly basis for quality rating. Suppliers will be categorized into
sub groups depending on quality rating and product will be subject to incoming receiving inspection
depending on the rating category and criteria set forth. Quality Performance will be calculated on a
monthly basis in the following manner:
4.6.1.Only nonconformances found at GKN Receiving Inspection (RI Tag Type), GKN Stock or Work In
Process (WIP) (EX Tag Type) and coded as the supplier’s responsibility will be counted in the
supplier’s quality rating. Nonconformances initiated and submitted by the supplier (SP Tag
Type) will not be counted within the supplier’s quality rating.
4.6.2.Item 2.11 will be calculated as follows:
4.6.2.1.
% Acceptable = (Total Received - Total Rejected) / Total Received
4.6.2.2.
Total Received - Total quantity received during the time period in question.
4.6.2.3.
Total Rejected – Total quantity rejected by a GKN representative (Escapes).
4.6.2.4.
Data shall be calculated and reported for the last month, last 3 months and 12 month
rolling time period.
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4.6.3.The SQE will evaluate all suppliers under the 98% for the 12 month rolling calculations and
document if any additional actions are required.
4.7. Service and Support Performance will be calculated in the following manner:
4.7.1.Containment Corrective Action Request (CCAR) Responsiveness (as referenced in Item 2.12) will
be calculated as follows:
4.7.1.1.
Initial CAR Responsiveness = On Time CCAR Responses/ (CCAR Responses Due +
CCAR Responses Past Due)
4.7.1.2.
On Time CCAR Containment Responses – count of GKN initiated corrective action
requests that are received or accepted by GKN within the site’s window of response time
(e.g. St. Louis = 7 Days)
4.7.1.3.
CCAR Responses Past Due – count of GKN initiated correction action requests that are
open beyond the window described above.
4.7.1.4.
CCAR Responses Due – count of GKN initiated corrective action requests that are due
(as defined by the window above) during the time period in question.
4.7.2.Corrective Action Request (CAR) Responsiveness (as referenced in Item 2.13) will be calculated
as follows:
4.7.2.1.
CAR Responsiveness = On Time CAR Responses/ (CAR Responses Due + Car
Responses Past Due)
4.7.2.2.
On Time CAR Responses – count of GKN initiated corrective action requests that are
received or accepted by GKN within the site’s window of response time (e.g. St. Louis = 7
Days)
4.7.2.3.
CAR Responses Past Due – count of GKN initiated correction action requests that are
open beyond the window described above.
4.7.2.4.
CAR Responses Due – count of GKN initiated corrective action requests that are due
(as defined by the window above) during the time period in question.
4.7.2.5.
Service and Support ratings will be calculated as 5% each of the total performance
rating.
4.8. Overall Supplier rating will be calculated as follows:
4.9. Total = (Delivery rating x 45%) + (Quality rating x 45%) + (Service and Support rating x 10%)
4.10.
Threshold levels for supplier performance.
4.10.1. The Quality Performance Rating will be grouped into the following categories:
4.10.1.1.
Gold: Equal to 100%
4.10.1.2.
Silver: Greater than or equal to 99.8% and less than 100%
4.10.1.3.
Bronze: Greater than or equal to 99.55% and less than 99.8%
4.10.1.4.
Yellow: Greater than or equal to 98% and less than 99.55%
4.10.1.5.
Red: Less than 98%
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4.10.2. The Delivery Performance Rating will be grouped into the following categories:
4.10.2.1.
Gold: Equal to 100%
4.10.2.2.
Silver: Greater than or equal to 98% and less than 100%
4.10.2.3.
Bronze: Greater than or equal to 96% and less than 88%
4.10.2.4.
Yellow: Greater than or equal to 90% and less than 96%
4.10.2.5.
Red: Less than 90%
4.10.3. The Overall Supplier Rating will be grouped into the following categories:
4.10.3.1.
Gold: Quality and Delivery Performance equal to 100%
4.10.3.2.
Silver: Quality greater than or equal to 99.8% and less than 100%.
4.10.3.2.1.1.1. Delivery greater than or equal to 98% and less than 100%
4.10.3.3.
Bronze: Quality greater than or equal to 99.55% and less than 99.8%
4.10.3.3.1.1.1. Delivery greater than or equal to 96% and less than 88%
4.10.3.4.
Yellow: Quality greater than or equal to 98% and less than 99.55%
4.10.3.4.1.1.1. Delivery greater than or equal to 90% and less than 96%
4.10.3.5.
Red: Quality less than 98%
4.10.3.5.1.1.1. Delivery Less than 90%
4.10.4. Suppliers with an Overall Supplier Rating of Red for 3 consecutive months will be evaluated by
Supply Quality Engineering and Supply Chain Management for appropriate actions. If the
Supplier does not meet the Supplier Performance criteria, corrective action per MI 7.4-23 may
apply and SCM may place the Supplier in CAST (Supplier Consultation, Action, Selection, and
Termination) per MI 7.4-14 or remove the suppler from the ASL.
Supplier Appeal Process
Suppliers may submit a written appeal to the Purchasing Manager within 10 working days of receipt of their
Supplier Performance Rating Scorecard. Purchasing and Supplier Quality Engineering Management will review the
appeal and respond within an additional 10 working day period.
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Process Flow Charts
Supplier Performance Indicator Ratings (SPIs)
Supplier
GKN
START
GKN SQE compiles nonconformance
and Suppier Corrective Action
Response data for
supplier on a monthly basis.
GKN SQE calculates and publishes
Supplier Performance Indicator Ratings
(SPIs) internally within GKN.
GKN Buyers transmit Supplier
Performance Indicator Ratings to
individual Suppliers.
SPI > 90?
YES
Supplier eligible for New Business.
NO
Supplier ineligible for
New Business.
YES
SPI > 80?
Supplier ineligible for New
Business and subject to formal
Corrective Action or CAST.
NO
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Definitions and Links
CAST
Consultation, Action, Selection, and Termination process
used to address unsatisfactory supplier performance.
SCAR
Supplier Corrective Action Request – tool used for
identifying and reporting supplier corrective actions in
response to product, process, or system
nonconformances/deficiencies.
Supplier Performance Rating
Supplier Performance Rating – the GKN Aerospace - St.
Louis quantified measure of supplier performance.
Supplier Performance Rating Scorecard
Report detailing the performance rating for the supplier
during each month.
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Section 5 Continuous Improvement
5.1 On-site Supplier Assessments
Overview
GKN Aerospace - St. Louis conducts periodic on-site assessments of its major
suppliers. Such assessments encompass a broad range of supplier performance
considerations including Quality, Operations, Delivery, Strategy, Capability,
and Total Value. These assessments are conducted using the GKN-STL Onsite Supplier Assessment. A team of GKN personnel encompassing a variety
of functional disciplines, including but not limited to Supplier Quality
Engineering and Purchasing, typically conduct these on-site assessments. Areas identified by the assessment team
as needing significant improvement will require suppliers to submit a formal action plan to GKN Supplier Quality
Engineering detailing activities, responsibilities, and timing for achieving the targeted improvements.
Scheduling of On-site Assessments
GKN Aerospace - St. Louis conducts periodic on-site assessments of its major suppliers. Such assessments
encompass a broad range of supplier performance considerations. These considerations are contained within 6
major assessment categories that include: Quality, Operations, Delivery, Strategy, Capability, and Total Value.
The purpose of these assessments is to conduct a comprehensive evaluation of suppliers’ strengths and weaknesses
and to provide direction regarding developmental needs and opportunities.
GKN Supplier Quality Engineering will notify those suppliers it wishes to assess, in advance, and coordinate
mutually agreeable dates and schedules for conducting on-site assessments. These schedules will include sufficient
time for an Opening Meeting in order to review the planned activities, as well as a Closing Meeting to review the
final assessment results. A team of GKN personnel encompassing a variety of functional disciplines including
Supplier Quality Engineering and Procurement typically conducts on-site assessments. The duration for an on-site
assessments varies depending on the size of the supplier’s facility, the scope of the work being undertaken for GKN,
the number of GKN personnel participating, and other factors. It should be noted that on-site assessments include
considerable time spent reviewing relevant manufacturing processes from receipt of raw materials through shipment
of finished goods. For the majority of supplier locations, 2 full days is required to achieve a satisfactory review of
all areas of interest.
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Supplier Preparation for an On-site Assessment
Suppliers are expected to prepare for a GKN On-site Assessment. To prepare suppliers are encouraged to assess
themselves with respect to each question contained within the on-site assessment form. In this manner, suppliers
will be able to identify and document all meaningful evidence necessary to substantiate their true plant-wide
performance relative to the established criteria. Documentation and operational evidence in support of performance
should be organized to facilitate timely presentation and review by GKN personnel. The importance of preparation
for the On-site Assessment cannot be over-stated. There is only a limited amount of time available to cover all the
elements within the assessment. GKN personnel will not conclude compliance unless they are presented with
substantiating evidence that criteria have been met.
The Opening Meeting
At the Opening Meeting, GKN and Supplier personnel will introduce themselves and review the final assessment
schedule. Individual GKN Assessors and their Supplier counterparts will be paired according to the assignments
outlined in the schedule. Finally, applicable safety precautions and any other site-specific considerations will be
reviewed.
Conducting the On-site Assessment
The following supplier representatives, at minimum, should be available for the on-site assessment for the times and
purposes noted below:
•
Operations Manager, Plant Manager, or General Manager to participate in both the Opening and
Closing Meetings.
•
Site Quality Director or Quality Manager to participate in the entire process.
Functional Managers of applicable areas such as Manufacturing, Engineering, and Purchasing will
be available for consultation during the assessment and to address assessment topics related to their
specific functional areas.
The assessment will proceed on a section-by-section basis in accordance with the schedule established in advance.
Applicable supplier personnel will be asked to provide evidence to GKN representatives in support of their
compliance with established performance criteria detailed within the on-site assessment form.
•
The Closing Meeting
Prior to the closing meeting, GKN personnel will seek a private office to quietly finalize the assessment scoring.
Comments will be prepared for individual questions as required.
At the closing meeting, GKN personnel will:
•
Summarize the results of the on-site assessment and identify areas that represent
strengths/weaknesses.
•
Discuss the final percentage score from the assessment results and provide a copy of the final
assessment report with scores and comments included.
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•
Discuss specific items that require Improvement Plans and the timing for submission of these plans
(typically 30 days from date of closing meeting). Improvement Plans must be specific as to the
activities being undertaken to resolve the performance issue, the individuals responsible for their
completion, and the anticipated completion dates.
Improvement Plan Review & Follow-Up
Upon receipt of the supplier’s Improvement Plan, GKN Supplier Quality Engineering will review the plan and
provide appropriate feedback. Improvement Plans that fail to appropriately address performance issues in a timely
manner will require resubmission.
GKN Supplier Quality Engineering will follow-up with suppliers to review the implementation of Improvement
Plans. This follow-up will occur through subsequent on-site assessments and/or a specific request to the supplier to
provide evidence to substantiate the successful implementation of targeted improvements.
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Process Flow Charts
GKN On-Site Supplier Assessments
Supplier
GKN
START
Supplier contacted by GKN
Procurement & On-site Assessment
date/schedule established.
Supplier conducts self-assessment and
conducts necessary preparation.
Opening Meeting
On-Site Assessment per established schedule
Closing Meeting
Identification of areas requiring
improvement plans.
Development and submission of
improvement plans detailing actions,
responsibilities, and targeted
completion dates.
Implementation of improvement plans.
Request evidence to substantiate
successful implementation of
improvements and/or review on
subsequent assessments.
STOP
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Definitions and Links
GKN On-Site Supplier Assessment
An on-site review of a supplier’s business
systems and capabilities as conducted by GKN
personnel.
Improvement Plan
A detailed plan describing specific actions,
responsibilities, and targeted completion dates
associated with areas requiring significant
improvement as identified through the on-site
assessment.
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5.2 Supplier Process Assessments (SPA’s)
Overview
GKN Aerospace - St. Louis conducts periodic detailed on-site
examinations of the manufacturing processes, procedures, and controls
used in the fabrication, assembly, inspection, and delivery of individual
purchased parts/materials. Successful FAI is a prerequisite for such
Supplier Process Assessments (SPA’s). The objective of such
examinations is to help improve the supplier’s manufacturing and support
processes and to achieve continuous improvement with respect to quality
and related costs. Supplier Process Assessments entail comparisons of
the supplier’s processes and controls against their internal procedures as
well as contractual requirements inclusive of AS 9003.
Nonconformances identified during SPA’s will require initiation of
formal Supplier Corrective Action Requests in order to document the
resolution. GKN will utilize SPA results as a basis for determining the amount and nature of additional supplier
oversight required.
Initial Data Search & Review
Prior to conducting the SPA, GKN Supplier Quality Engineering will undertake a review of the following data:
•
Formal Corrective Action Requests issued against the supplier and/or parts / processes targeted for
review.
•
GKN-STL Nonconformance Tags generated against the supplier and/or parts / process targeted for
review.
Customer escapes, i.e. nonconformances reported by GKN customers, against the parts/processes
targeted for review.
This information will be used as a basis for targeting specific areas of concern requiring more in-depth review and
evaluation during the SPA.
•
Coordination & Scheduling of SPA’s with Suppliers
SPA’s will be scheduled with suppliers in advance by GKN Supplier Quality Engineering in order to ensure that
appropriate supplier personnel can actively participate and support the process assessment activities. Coordination
will take place between supplier personnel and GKN Supplier Quality Engineering to ensure that subject
parts/materials are in production at the time the SPA is conducted. Suppliers will be asked to provide a process flow
chart in advance that depicts all process sequences, process inputs, process outputs, and applicable material,
machines, methods, manpower, and measurements. Process Flow Charts should encompass receipt of raw materials
through shipment of finished products. Upon review of the process flow chart, the full scope of the SPA will be
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established. Supplier Quality Engineering will also clarify any questions the supplier may have regarding the SPA
process at this time.
Conducting the SPA
The overall objective of the SPA is to help improve the supplier’s manufacturing and support processes and to
achieve continuous improvement with respect to quality and related costs. To accomplish this, a comparison of the
supplier’s processes and controls against their internal procedures as well as contractual requirements is conducted.
Each part/process shall be evaluated using the GKN-STL Supplier Process Assessment Checklist. This checklist
is based on the requirements outlined in AS 9003: Inspection & Test Quality System and incorporates those areas
from this standard that most closely pertain to the production environment. This checklist may also be tailored to
cover areas with unique or specific requirements.
Particular consideration will be given to the following aspects of the subject part/material processes:
•
The completeness and accuracy of work instructions,
•
The adherence to specified work and inspection instructions,
•
The appropriateness and thoroughness of process controls and related data analysis,
•
The depth and breadth of operator knowledge and experience, effectiveness of Corrective Action
efforts,
•
The application of preventive quality measures, and demonstrated continuous improvement
SPA “Out Brief”
At the conclusion of the SPA, the Supplier Quality Engineer will coordinate with the supplier to schedule sufficient
time to conduct an out brief of the findings. SPA out briefs will cover the following topics:
•
The detailed results as documented on the SPA Checklist
•
Generalized Strengths and Weaknesses
•
Review of those areas requiring formal Corrective Action and associated timing.
Corrective Actions Based on SPA Findings
GKN Supplier Quality Engineering will initiation Supplier Corrective Action Requests for those nonconformances
identified during SPA’s. Supplier responsibilities for response to these requests and subsequent substantiation of
effective implementation will be the same as the same as those outlined within the Supplier Corrective Action
Request section of this manual.
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Process Flow Chart
GKN Supplier Process Assessments (SPAs)
Supplier
GKN
START
Supplier Quality Engineering (SQE)
conducts review of supplier
performance data.
SQE contacts Supplier to initiate
Supplier Process Assessment (SPA).
Supplier develops and submits
Process Flow Chart to GKN SQE.
Scope of SPA and final SPA schedule established.
SPA Conducted on Schedule Date(s) for targeted parts/materials and processes.
SPA Outbrief Conducted to review findings and establish areas requiring Corrective
Action.
Development and submission of
Corrective Action plans detailing
actions, responsibilities, and targeted
completion dates.
Implementation of Corrective Actions
and submission of evidence to
substantiate successful
implementation.
Review/Approval of
supplied evidence.
STOP
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Example Process Flow Chart
Receive Router
Raw Materials
accepted per
XXX.
NC Machine
per Router
Tape No. XXX
Form per
Router
Clean & Apply
Primer per XXX
Chemical
Conversion
Coat per XXX
Clean &
Penetrant
Inspect per
XXX
Drill per
Router
REWORK per
Repair STD.
XXX
SCRAP
per XXX
Part Mark/
Identify per
XXX
PASS
Final Inspect
per XXX?
NO
YES
Package for
Shipping per XXX
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Definitions and Links
GKN-STL Supplier Process Assessment
Checklist
Periodic detailed on-site examination of the
manufacturing processes, procedures, and controls
used in the fabrication, assembly, inspection, and
delivery of individual purchased parts/materials.
Successful FAI is a prerequisite for such Supplier
Process Assessments (SPA’s).
Supplier Corrective Action Request (SCAR)
A request to a supplier for a formal documented
corrective and preventive action in response to a
nonconformance, system, or performance concern.
Process Flow Chart
A depiction of all process sequences, process inputs,
process outputs, and applicable materials, machines,
methods, manpower, and measurements. Process
Flow Charts should encompass receipt of raw
materials through shipment of finished products.
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5.3 Consultation, Action, Selection and Termination
Overview
CAST is a process used by GKN Aerospace - St. Louis to address
chronic and/or severe performance issues with approved suppliers.
CAST is an acronym for Consultation, Action, Selection, and
Termination. This acronym denotes the major steps in the process for
rectifying supplier performance issues, and where necessary, for
terminating business with such suppliers. Suppliers with an Overall
Supplier Rating of Red for 3 consecutive months will be evaluated by
Supply Quality Engineering and Supply Chain Management for appropriate actions. If the Supplier does not
meet the Supplier Performance criteria, corrective action per may apply and Supply Chain Management may
place the Supplier in CAST or remove the supplier from the ASL.
Once a supplier is placed in CAST, the supplier is ineligible for new work for a period of 6 months. If a supplier is
terminated as a result of CAST, the supplier will be removed from the ASL for a minimum of 12 months from the
date of termination. A
GKN-STL On-site Supplier Assessment is required before the supplier may be considered
for ASL reinstatement.
If a supplier is successful in resolving performance issues, the supplier is taken out of CAST and placed on
probation for a period of 12 months. Any recurrence of the same issues during the supplier’s probationary period
will result in the supplier being placed back in CAST.
CAST Process Steps
Step 1 - Consultation Meeting
GKN Supplier Quality Engineering initiates the CAST process with suppliers after 3 consecutive delivery months of
Supplier Performance Ratings below 80% or in the event of other particularly severe or chronic performance issues.
When a decision is undertaken to initiate CAST, GKN Supplier Quality Engineering will complete a
Supplier
Corrective Action Request documenting the specific concerns targeted for resolution. The applicable Business Unit
Purchasing Manager will then formally notify the supplier of their status in CAST using the CAST Letter with the
Supplier Corrective Action Request included as an attachment. A Consultation Meeting is then scheduled at the
Supplier’s facility.
GKN Supplier Quality Engineering will chair and document the initial Consultation Meeting with the supplier.
GKN attendees will include Sourcing and/or Purchasing Management, Supplier Quality Engineering Management
and affected Business Unit Quality/Operations personnel. Required Supplier attendees include: the Supplier’s
executive management, including but not limited to, senior leadership from the Operations and Quality functions.
Agenda items for the Consultation Meeting include:
Overview of the CAST Process
Problem Identification
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Development of a Preliminary Action Plan
Definition of Action Plan Deliverables
At the outset of this meeting, the CAST process is reviewed in detail. After this the specific performance problems
are reviewed and approved by both parties. Finally, a preliminary action plan and key deliverables are developed in
preparation for the next phase of the CAST process.
Step 2 - Action Meeting
Two weeks after the initial CAST Meeting, GKN will schedule an Action Meeting with
the supplier. The required attendees include those present at the initial Consultation
Meeting. At the Action Meeting, the Supplier will be required to present a detailed Action
Plan that includes the specific tasks, schedule, responsibilities, and deliverables identified
as necessary for resolving the performance problem. GKN will instruct the Supplier on
any necessary changes to the Action Plan and then set a date for the Selection Meeting.
Step 3 - Decision Meeting
GKN will convene this meeting at an appropriate interval to review the supplier’s
performance and progress with respect to identified action plans and deliverables. Based
upon the data presented, GKN will determine one of the following courses of action:
•
Supplier is to remain in CAST with continued monitoring of progress to the established
Action Plan.
•
Supplier is removed from CAST based upon complete resolution of identified concerns but placed
on probationary status for a subsequent 12- month period.
GKN Sourcing will initiate Selection of a new supplier and Termination of the existing supplier
based upon insufficient objective evidence of improvement.
GKN Supplier Quality Engineering will document the results of this meeting.
•
If the decision is for the supplier to remain in CAST a date will be set for a subsequent Decision Meeting.
If a decision is made to remove the supplier from CAST, GKN Purchasing Management will notify the supplier in
writing. GKN Supplier Quality Engineering and Purchasing Management will then continue to monitor the
supplier’s performance for an additional 12 months. At any time during this probationary period the Supplier
Quality Engineering Manager or Purchasing Manager may recommend that the supplier be returned to CAST or
terminated if sufficient evidence can be provided. If at the end of this 12- month probationary period the supplier
has demonstrated the ability to sustain an acceptable level of performance they will have their probationary status
removed and be returned to full ASL Approval status.
If the supplier is to be terminated and removed from the Approved Supplier List, Purchasing Management will
formally notify the supplier in writing.
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Process Flow Charts
Performance Remediation through CAST
Supplier
GKN
START
SPI Ratings < 80 for 3 consecutive
delivery months or other severe/chronic
performance concerns.
SQE Initiates CAST via a Supplier
Corrective Action Request documenting
the performance history.
Business Unit Purchasing Manager
formally notifies Supplier of CAST
status via CAST Letter.
Consultation Meeting convened to review performance history
and establish preliminary action plans.
Action Meeting convened to review Supplier's detailed Action Plan
for achieving improved performance.
Action Plan Implementation
Supplier Performance Monitored
Decision Meeting Convened
Performance
Improved ?
NO
Select new
supplier and
remove
existing
source from
ASL
YES
Remove from
CAST. Supplier
in probationary
status.
Trending
Positively
Continue to
monitor.
Supplier
retained in
CAST
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Definitions and Links
CAST
Consultation, Action, Selection, and
Termination. GKN Aerospace - St. Louis
process for resolving significant supplier
performance concerns.
CAST Letter
Formal document notifying the Supplier of
the initial of CAST proceedings.
GKN-STL On-Site Supplier Assessment
An on-site review of a supplier’s processes,
systems, and capabilities as conducted by
GKN personnel.
Supplier Corrective Action Request (SCAR)
A request to a supplier for formal
documented corrective and preventive
action in response to a nonconformance or
performance concern.
Supplier Performance Ratings
Supplier Performance Ratings – the GKN
Aerospace - St. Louis quantified measure
of supplier performance.
Supplier Performance Ratings Scorecard
Report detailing the Supplier Performance
Rating for the supplier. This report
combines the Supplier Quality Rating and
the Supplier Responsiveness Rating.
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