TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SQAM
Supplier Quality Assurance Manual
PARTS & COMPONENTS
(ISSUE 4C, JANUARY 2007)
**IMPORTANT DOCUMENT CONTROL INFORMATION**
Any printed copy of this document is considered an uncontrolled
version and may not be current. This electronic version located at
Toyotasupplier.com is the controlled and current version.
© 2006, Toyota Motor Engineering & Manufacturing North America
Click for Forms TOC
TABLE OF CONTENTS
Chapter I
Introduction and General Requirements
1.0 Executive Level Expectations
1.1 Coordinating Manufacturer for Common Parts
1.2 Inspection Control Responsibility
1.3 Safety, Emission, Regulation and MVSS Parts
1.4 Identification and Traceability
1.5 Field Quality Assurance
1.6 Confidentiality
1.7 Service Parts Quality
Chapter II
Production Preparation
2.0 Milestone Overview
2.1 Supplier Parts Master Plan (SPMP)
2.2 Designated Control Characteristics ([Pc], PpK, CpK)
2.3 Part Evaluation Plan (PEP)
2.4 Part Inspection Standard (I/S)
2.5 Boundary Samples
2.6 Manufacturing Quality Chart (MQC)
2.7 Checking Fixtures, Gages, & Test Equipment
2.8 Mating Part / Component Request
2.9 Sample Part Submission
2.10 Color and Grain Approval Activities
2.11 Part Approval (PA)
2.12 Quality Readiness Checksheet (QRC)
2.13 Final Approval (FA)
2.14 Quality Improvement Request (QIR)
Chapter III
Mass Production
3.0 Mass Production Overview
3.1 Non-Conformance Handling
3.2 Quality Tuning Request (QTR)
3.3 Process Change Request (PCR)
3.4 Field Quality Improvement
Chapter IV
Appendix
4.0 Acronyms
4.1 Symbols
4.2 Definitions
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TABLE OF CONTENTS
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SECTION 1.0 – EXECUTIVE LEVEL EXPECTATIONS
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: To provide an overview of Toyota’s quality assurance expectations to supplier
executive management and communicate Toyota’s commitment to partnering
with our supplier to ensure the highest quality products for our customers.
EXPLANATION:
1. Toyota’s philosophy is to develop and maintain a collaborative relationship with suppliers
based on mutual prosperity, excellent communication and joint problem solving.
2. Toyota’s Supplier Quality Assurance Manual (SQAM) is the governing quality
requirement document for parts and components (includes metallic threaded fasteners,
fabric and leather) that expresses Toyota’s internal quality assurance philosophy, rules,
and policy to suppliers. The SQAM applies to all suppliers and the suppliers are
expected to comply with stated requirements.
3. Toyota provides several directive manuals, documents, etc. to suppliers, but SQAM is
the top level policy for supplier quality assurance.
4. As SQAM secretariat and authorizer TMMNA QD will revise SQAM contents as business
needs dictate and develop SQAM training and content interpretation. Corresponding
revision levels will be noted on appropriate page(s), and a revision record will be
maintained for reference.
5. Each Toyota NAMC Quality Control General Manager is responsible to consistently
administer SQAM requirements to Toyota’s North American supply base.
6. Toyota Motor Manufacturing North America recognizes the benefit for suppliers to
comply with other domestic or international quality standards (i.e. TS16949, QS 9000,
ISO9000, etc.) and to utilize reference manuals and/or tools from the Automotive
Industry Action Group (AIAG). Toyota encourages all participating suppliers to ensure
proper and consistent application of these standards and tools to enhance their quality
assurance activities and management methods, as long as there is no conflict with the
SQAM requirements.
REQUIREMENTS:
1. The supplier’s executive management must clearly define, document, and effectively
deploy their quality assurance system (e.g. policies, procedures, standardized work,
etc.) to achieve Toyota/Lexus quality targets from the part development/production
preparation stage through mass production, including customer warranty and service
parts.
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SECTION 1.0 – EXECUTIVE LEVEL EXPECTATIONS
***** INTRODUCTION AND GENERAL INFORMATION *****
2. A permanent management level position must be established or designated as the
executive management representative for overall quality assurance. This position will
be responsible for comprehension, deployment, and ongoing internal training of SQAM
requirements. A succession plan must be in place to insure smooth transition and
retention of SQAM knowledge.
3. A proactive approach to quality assurance and improvement initiatives (e.g. built-inquality, effective communication, response to the customer voice, etc.) aimed to achieve
zero defects and prevent flow-out of non-conformances is required from all suppliers.
4. Achievement of quality targets prior to the start of mass production and stable quality
through the mass production life cycle is required from all suppliers.
5. All suppliers are required to manage nonconforming or suspect parts quality with a
system that includes prompt (time of discovery) notification to Toyota, containment
leadership and recurrence prevention.
6. The supplier is fully responsible for carrying-out supplemental operations such as
special inspections, product sorts, rework, etc. when quality targets and standards are
not being achieved consistently, regardless of location.
7. Printed copies of SQAM must be maintained in a controlled and secure manner and
identified as “FOR REFERENCE ONLY”. The e-SQAM located on Toyotasupplier.com
is considered the only current version.
8. All suppliers of North American sourced parts must identify and maintain their key
quality contacts information through the Toyota Centralized Contact Information (CCI)
database via ToyotaSupplier.com. Toyota contact information for each NAMC can also
be obtained through CCI. All printed copies should be utilized for reference only, as
daily changes to the CCI database may occur.
9. All suppliers must have a document retention policy for all SQAM related information
(i.e. records, reports, data, etc.) that complies with Toyota policies and government
regulations/requirements.
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SECTION 1.1 –COORDINATING MANUFACTURER for COMMON PARTS
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: If more than one NAMC will use a supplied part, one of them will be designated
as the Coordinating Manufacturer to help simplify and streamline SQAM related
communications.
EXPLANATION:
1. Common parts are those provided to more than one NAMC (includes Toyota overseas
manufacturing locations) by the same supplier, with the same part number,
manufactured at the common facility, and using common tooling.
2. The main role of the Coordinating Manufacturer is to provide the supplier with a primary
window contact to facilitate activities related to SQAM documentation between the other
NAMCs for direction or approval.
3. One specific NAMC QC/QE Department will be designated by TMMNA Quality Division
as the Coordinating Manufacturer and this information will be communicated to the
supplier.
REQUIREMENTS:
1. The supplier must follow the document routing and responsibilities indicated in Table
1.1 -1: Documentation Flow for Common Parts.
2. The supplier may receive communications or instructions from either the Coordinating
Manufacturer or another NAMC, but all part changes or quality standard changes must
first be approved by the Coordinating Manufacturer.
3. The supplier should provide all information to each using NAMC location.
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SECTION 1.2 – INSPECTION CONTROL RESPONSIBILITY
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: To describe the supply chain business flow, and identify quality assurance
responsibilities therein.
EXPLANATION:
Self Procured Parts
Parts / components sourced and purchased by the tier 1 supplier for use in a
level 1 part. The tier 1 supplier is totally responsible for assuring level 2 and
below part quality.
Controlled Self Procured Parts
Toyota specifies the source for the part / component, but the tier 1 supplier
purchases the part for use in a level 1 part. The tier 1 supplier is totally
responsible for part quality. Includes all raw materials brokered by Toyota
under the Centralized Purchasing System (CPS) Program.
Direct Supply Parts
Parts /components sourced and purchased by Toyota, and provided to the tier 1
supplier for use in a level 1 part. The NAMC QC/QE Department is primarily
responsible for part quality, with support from the tier 1 supplier to manage daily
quality related items.
REQUIREMENTS:
The supply chain inspection control responsibility for suppliers is defined by two basic business
cases; self procured parts and direct supply parts.
Case A: Self Procured Parts (includes “controlled” self procured parts)
Tier 1 Controls Total Quality
Level 1 Parts
Self Procured Parts
(Level 2 and below)
Contract
Contract
Tier 1
Tier 2/3
Sourcing / Pricing Decision*
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SECTION 1.2 – INSPECTION CONTROL RESPONSIBILITY
***** INTRODUCTION AND GENERAL INFORMATION *****
1. The supplier (tier 1) has total responsibility for part quality, and is expected to coordinate
and manage activities with their suppliers (tier 2/3) to ensure consistency from
production preparation through the mass production life cycle.
2. Activities to assure self procured part quality must be in accordance with SQAM
requirements, and the lower tier supplier must have basic QA/QC systems and methods
in place that are consistent with SQAM.
3. Self procured parts must achieve all quality targets and not impact production
preparation or mass production launch schedules.
4. The supplier (tier 1) is expected to have a formal policy and system in place to select
and periodically evaluate the performance of their suppliers.
5. The supplier (tier 1) has responsibility to notify their suppliers (Tier 2 and below) that
Toyota has the authority to participate in any quality audit or visit to their facility.
Case B: Direct Supply Parts
Direct Supply Parts
(Level 2 and below)
Level 1 Parts
Contract
Tier 2/3**
Tier 1*
Toyota NAMC
Contract
* Tier 1 controls quality of level 1 part, plus specified items of Tier 2/3 parts
** Toyota controls quality of level 2 and below parts
1. NAMC QC/QE Department has Inspection Control Function (ICF) responsibility and
assumes primary responsibility for all quality assurance activities from sourcing
decision through mass production. For additional clarification, reference Table 1.2 -1:
Documentation Flow for Direct Supply Parts.
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SECTION 1.2 – INSPECTION CONTROL RESPONSIBILITY
***** INTRODUCTION AND GENERAL INFORMATION *****
2. Direct supply parts must achieve all quality targets and not impact production
preparation or mass production launch schedules.
3. The tier 1 supplier must insure the daily quality activities for the direct supply part as
required by the level 1Toyota Part Inspection Standard or other inspection criteria
provided by Toyota.
4. The supplier (tier 1) must issue a monthly quality performance report to Toyota
Purchasing, the NAMC QC/QE Department, and the direct supply part supplier. This
report must include the total number of parts received, the total number of nonconforming parts, and a description of non-conformances.
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SECTION 1.3 – SAFETY (
), EMISSION ( ), REGULATION (
MVSS PARTS
) and
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: All North American sourced parts that have raw materials and/or manufacturing
methods designated or identified as safety ( ), emission ( ), regulatory ( )
and/or MVSS as specified on the drawing or other documents created by Toyota
or the supplier must comply with specific quality assurance requirements.
EXPLANATION: The acronym MVSS will be used throughout this section and the manual to
represent the following symbols:
•
= Federal Motor Vehicle Safety Standard for United States
destination vehicles
•
= Canadian Motor Vehicle Safety Standard for Canadian
destination vehicles
•
= Japan Ministries of Land, Infrastructure and Transportation for
Japan destination vehicles
REQUIREMENTS:
1. At a minimum, Design Review Based on Failure Mode (DRBFM) or DFMEA and
Machine/Process Failure Mode Effects and Analysis (PFMEA) or equivalent document
must be developed for all parts. A PFMEA or equivalent document must include
reviews of both the equipment and the process. These activities should be completed
prior to drawing release, tooling/process design, Manufacturing Quality Chart (MQC),
part Inspection Standard, and Inspection Plan development.
2. Significant product failure items identified through DRBFM or DFMEA development that
are not corrected with a design change, must be indicated on the PFMEA or equivalent
document with sufficient inspection and detection capabilities to prevent flow-outs.
3. Additional analytical “tools” such as Quality Chain Management System (QCMS), QA
Network, etc. may be required or requested to be carried out in order to more fully
evaluate the capability of the total manufacturing process including the supply chain.
4. Equipment / process capability deficiencies identified based on the results from
analytical studies such as machine FMEA/PFMEA, QCMS, QA Network, etc., must be
represented in the inspection plans and associated documents (i.e. Manufacturing
Quality Chart (MQC), Part Inspection Standard, etc.) as required inspection criteria to
insure consistent achievement of quality requirements.
5. The supplier must assign a responsible person to conduct annual audits (at a minimum)
to verify and assure their QA System’s effectiveness for safety, emission, and regulation
parts.
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SECTION 1.3 – SAFETY ( ), EMISSION (
MVSS PARTS
), REGULATION (
) and
***** INTRODUCTION AND GENERAL INFORMATION *****
6. Lower tier suppliers (tier 2, 3, etc.) that provide materials or components that impact the
tier 1 part safety, emission, or regulation requirements must develop, submit, and gain
approval from the tier 1 supplier of a specific quality control plan that assures
conformance of their material or component. In the case of direct supply the
responsible NAMC QC/QE has approval responsibility.
7. The supplier must ensure that documented systems are in place at all sub-suppliers to
control traceability and confirm specification compliance for all critical components
(
, MVSS, etc.) including raw materials, parts and components.
8. Safety, emission, regulation and MVSS related processes must be continuously
monitored and controlled in regards to capability utilizing industry accepted methods of
statistical control. Reference SQAM Section 2.2 for process Cpk requirements.
9. The supplier must submit MVSS data for the first month of mass production shipments
by the 15th of the month utilizing the MVSS Regulation Item Data Submission form.
10. Process supervisors, operators, and other key staff must be fully trained to understand
the significance of the related equipment and processes, abnormality handling, and non
compliance impact to assure required safety, emission, or regulation requirements are
achieved.
11. Appropriate symbols to designate safety ( ), emission ( ), regulation ( ) or MVSS
must be applied to all related documents such as; QC process charts, standardized
work instructions, part inspection standards, control charts, check sheets, problem
reports, etc.. These same symbols must also be posted at all affected work sites in
order to clarify management priorities to enhance control / correction of abnormalities.
12. An effective change management system is required to manage ECI implementation,
tooling or equipment changes and process changes that impact safety ( ), emission
( ), regulation ( )or MVSS parts. Reference SQAM Section 3.3 for specific Process
Change Request (PCR) criteria.
13. Specific plans and methods must be developed and utilized to assure lot identification,
first-in-first-out material control, traceability, quality approval & verification of repair,
emergency / abnormality handling, and containment assurance.
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SECTION 1.4 - IDENTIFICATION AND TRACEABILITY
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: Identification and traceability of raw material, parts, components and
machine/process control parameters, through all stages of manufacturing from
receipt of raw materials to the delivery of completed parts, is required to quickly
ascertain the location of non-conforming product.
EXPLANATION: Identification and traceability strictly apply to , , , MVSS parts,
components, raw material and specified drawing requirements at a
minimum, but Toyota encourages suppliers to implement a system for all
parts.
REQUIREMENTS:
Identification
1. The supplier must develop an identification system that begins during production
preparation prior to the 1st draft of the part Inspection Standard.
2. The supplier must adhere to all identification requirements specified on the part
drawing, inspection standard or applicable regulation.
3. If no specification exists, the supplier should determine the appropriate level of
identification based on past experience and industry standards.
4. The supplier must clearly document the details of the identification method on the
original draft of the Approval I/S before submitting to the NAMC QC/QE for approval. In
the case of NAMC issued part I/S when the identification mark is not specified on the
drawing, then negotiation with the NAMC QC/QE prior to part I/S issuance is required.
Traceability
1. The supplier must develop a traceability system that begins from mass production
through the life of the part.
2. If no specification exists, the supplier should determine the appropriate level of
traceability based on past experience and industry standards
3. Traceability must be considered based on the following two criteria;
a. Process and Machine Control Parameters
This includes operation control parameters, maintenance, and calibration, repair
records, manpower changes and other data that documents machine or process
control criteria.
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SECTION 1.4 - IDENTIFICATION AND TRACEABILITY
***** INTRODUCTION AND GENERAL INFORMATION *****
b. Material and Product Flow
This includes material certification and date of receiving, date of manufacturing,
specific production equipment number, inspection date, and other data that
records the flow through the process.
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SECTION 1.5 – FIELD QUALITY ASSURANCE
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: To provide suppliers with an understanding of their responsibility to continuously
monitor and improve field quality performance.
EXPLANATION:
1. An effective field quality management policy and system is an essential element to
promote continuous quality improvement that will ensure the highest customer
satisfaction. Field quality encompasses, but is not limited to, warranty data and parts.
2. TMMNA Quality Division is the window group for supplier warranty data, warranty parts,
and supporting analytical tools provided to suppliers.
3. Warranty data and supporting analytical tools will be provided by Toyota through the
Supplier Quality Information Delivery System (SQIDS) accessed through
Toyotasupplier.com.
REQUIREMENTS:
1. All suppliers must have warranty management systems in place for all warrantable
commodities from mass production release through the life of the part.
2. The supplier’s field quality management system shall include:
a.
b.
c.
d.
Defined targets and measures gauging warranty performance against targets
Plan for achieving field quality targets (including future products)
Cross-functional working groups to address issues as they arise
Periodic forums (management review) to discuss field quality issues (internal &
external) and performance against established targets
e. Documented procedures that include the following elements for disciplined
problem solving and corrective action:
1) Tracking and control of incoming field information and parts
2) Analysis, identification and verification of root cause
3) Further flow-out prevention (field issue containment)
4) Countermeasure implementation and effectiveness verification
5) Determination and confirmation of recurrence prevention
6) Check of similar processes and application of needed controls or
countermeasures
7) Reporting of results to all impacted groups (internal & external)
3. Suppliers are responsible for requesting specific warranty parts needed for their
investigation, reference SQAM Section 3.4 for details.
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SECTION 1.6 – CONFIDENTIALITY
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE:
To ensure that the confidentiality requirements identified in the Toyota
Purchasing Terms & Conditions Contract will be enforced with all suppliers and
Toyota staff.
REQUIREMENTS:
1. The supplier must establish a system to manage confidentiality that begins at sourcing
decision and continues through the life of the part.
2. Any data, information, or knowledge (general and specific) obtained through activities
with Toyota must be securely controlled, treated with strict confidence, and properly
disposed of when no longer necessary.
3. Any breach of confidentiality, or concerns, must be reported with specific details to
Toyota management immediately.
4. Review of supplier designated proprietary or confidential documentation and/or data
maybe requested by the NAMC QC/QE. All suppliers are required to comply with the
request.
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SECTION 1.7 – SERVICE PARTS QUALITY
***** INTRODUCTION AND GENERAL INFORMATION *****
PURPOSE: To communicate Toyota’s expectations for service parts quality.
TIMING:
From the production preparation stage through the life of the part.
EXPLANATION:
1. Service part quality requirements for part development and production are unique
and compatible with the mass production requirements.
2. TMMNA Production Control Division is the Inspection Control Function (ICF) for past
model service parts and final authority for assuring the following:
a. Shipping quality requirements are met
b. Service part inspection operations are implemented
c. Taking action to analyze, reflect and address field and in-house quality problems
3. Service parts quality milestones are defined and communicated in the N-7 master
schedule found on Toyotasupplier.com in the Production Control section. Part
specific quality requirements are defined and communicated through the Notice of
Parts Change (NPC).
4. Service part inspection standards are unique from mass production part inspection
standards and are required for each service part.
REQUIREMENT:
1. The supplier’s executive management is responsible for supporting service part
development, production and quality improvement activities. Specific quality
requirements are defined in Toyota’s Service Parts Requirements Manual.
2. The supplier is required to support service parts trial activities. These trials will occur
as necessary to ensure service part quality.
3. The supplier is required to maintain the same process controls used during mass
production for past model service parts production. If changes to past model service
parts (process) are needed, then a Process Change Request must be submitted to
TMMNA Production Control Department, reference the Service Parts Requirements
Manual for details.
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SECTION 2.0 – MILESTONE OVERVIEW
***** PRODUCTION PREPARATION *****
PURPOSE: To provide suppliers with an understanding of the activities necessary to achieve
part quality targets prior to mass production.
TIMING:
From part sourcing decision through initial mass production.
SCHEDULE:
After the sourcing decision is made, Toyota (NAMC QC/QE, Design, Purchasing and
Production Control) will rank each part number, communicate the timing for key events on the
Toyota Parts Master Schedule (TPMS) and issue to supplier. Upon receipt of the TPMS,
the supplier will be required to develop and submit to Toyota their detailed quality related
preparation schedule as part of the Supplier Parts Master Plan (SPMP). Additional
information may be obtained through the appropriate Toyota Project Management Group.
PROJECT MILESTONE OVERVIEW:
Shown below is Toyota’s general timing philosophy as related to project milestones, NAMC
key events, and SQAM production preparation requirements. Specific project timing
requirements will be communicated using the TPMS.
Quality Preparation
Phases
Phase I
II
Parts
Sourcing
& Risk
Assess
I
Key
Milestones
(Gates)
Phase II
CE Image
(Planning)
VI
IV
V
Off-Tool
st
1 Quality
Assessment
Off
Process
and PA
III
SE
Activity
Phase III
HVPT /
Supplier
SQCS
VII
Mass
Production
&
Reflection
st
¿Ë 1
Drawing Release (all)
Tooling
2nd
Production Production
Trial
Trial
Phase IV
C/F
NAMC
Key Events
SOP
TPMS
2.1 - SPMP
Recurring Submissions (as required)
2.2 - Designated Control Characteristics [Pc]
SQAM
Key Requirements
Chapter II Section 2.1- 2.14
2.3 - PEP
2.5 - Boundary Samples
2.4 - Part I/S
2.10 - Color & Grain Approval
2.6 - MQC
2.7 - Checking Fixtures / Gages & 2.8 - Mating Parts & 2.9 - Sample Parts
2.11 - PA
2.12 - QRC
2.13 - FA
2.14 - Quality Improvement
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***** PRODUCTION PREPARATION *****
COMPLETION EXPECTATION:
All requirements as specified in the TPMS and as defined by SQAM, must be achieved per
plan in advance of mass production start, but not limited to:
•
Part durability / reliability verification
•
Quality assurance verification
•
Process capability verification
•
Sample part submission
•
QA related document completion
•
QA / QC related requirements
DOCUMENT SUBMISSION:
All quality related project documents as required by SQAM must be completed, maintained,
and managed by the supplier in accordance to the TPMS.
QUALITY PREPARATION PHASES:
Quality assurance preparation has 4 main phases:
Phase 1:
Planning
Phase 2:
Initial Evaluation
Phase 3:
Final Verification
Phase 4:
Mass Production Launch
Phase 1 – Planning
A. Main Objective:
To assure clear expectation and understanding of quality requirements prior to
drawing release and tooling kick-off meeting.
B. Supplier Responsibilities:
The quality planning stage must commence immediately after sourcing decision
through drawing release, SPMP issuance, and tooling K/O meeting. The quality
planning phase includes the following key requirements:
1) Study/establish design quality requirements including critical quality criteria
2) Communicate [Pc], Cpk, and boundary sample characteristics and
expectations (Reference SQAM Sections 2.2 and 2.5)
3) Establish critical sub-supplier quality control criteria
4) Develop Part Inspection Standard (Reference SQAM Section 2.4)
5) Develop Manufacturing Quality Charts (Reference SQAM Section 2.5)
6) Develop initial Part Evaluation Plan (Reference SQAM Section 2.3)
7) Develop tool to evaluate potential process failure modes (i.e. PFMEA)
8) Suppliers may be requested to join Simultaneous Engineering (SE) Activity
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***** PRODUCTION PREPARATION *****
Phase 2 – Initial Evaluation
A. Main Objective:
To assure part design intent can be achieved off “hard tooling” and mass production
equivalent process prior to Supplier Quality Confirmation Stage (SQCS) / line fill
production.
B. Supplier Responsibilities:
1) Assure that mass production tooling and equivalent processes produce parts
that conform to design and part Inspection Standard criteria.
2) Final drafts of required SQAM documentation such as; SPMP, Part Evaluation
Plan, part Inspection Standard, PFMEA or equivalent document, Manufacturing
Quality Chart (MQC) must be submitted and approved as required.
3) Short term [Pc], Ppk studies completed (Reference SQAM Section 2.2)
4) Initial boundary samples submitted as required (Reference SQAM Section 2.5)
5) Initial checking fixture capability studies completed (Reference SQAM Section 2.7)
6) Part dimension, function, and regulation requirements are achieved.
7) High confidence for part durability / reliability requirements.
8) Critical sub-supplier processes are certified as capable, including raw material
certification.
9) Issuance of Approval Request (AR) to obtain Part Approval (PA) (Reference
SQAM Section 2.11)
Phase 3 – Final Verification
A. Main Objective:
To assure that part design intent and quality requirements can be consistently
achieved at volume production off “hard tooling” and finalized processes.
B. Supplier Responsibilities:
1) Final submission of all required SQAM production preparation documentation for
approval.
2) Achievement of PA (Reference SQAM Section 2.11)
3) Final PFMEA (or equivalent document) and [Pc], Cpk studies must be completed.
Based on study and analysis results, enhancements to the MQC, tooling, or
process must be implemented to assure quality target achievement.
4) Critical sub-supplier process capability has been verified, including MQC
enhancement as necessary to insure no flow out of any sub-supplier quality
issue.
5) All process trials completed, including production volume trials.
ISSUE
4
REVISION
August 2005
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MOTOR
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MotorMANUFACTURING
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AMERICA,
INC.
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SECTION
PAGE
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3 of 4
SECTION 2.0 – MILESTONE OVERVIEW
***** PRODUCTION PREPARATION *****
6) Part dimension, function, and regulation requirements verified to be consistently
achieved at volume production requirements.
7) Develop special inspection plans to assure initial launch quality as required.
8) Complete all long term durability / reliability testing as required
Phase 4 – Mass Production Launch
A. Main Objective:
To assure part design intent and quality requirements are consistently maintained
through initial mass production launch and volume ramp-up.
B. Supplier Responsibilities:
1) Deploy special inspection plans as required to assure initial launch quality targets
are achieved.
2) Closely monitor internal and external quality indicators, and immediately respond
to assure quality requirements are consistently achieved.
3) Adjust tooling, process, or MQC as necessary to assure quality requirements are
consistently achieved.
4) Request Final Approval (FA) if required (Reference SQAM Section 2.13)
5) Conduct Reflection Activity based on production preparation and initial mass
production results and yokoten all lessons learned.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH
AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.0
4 of 4
SECTION 2.1 – SUPPLIER PARTS MASTER PLAN (SPMP)
***** PRODUCTION PREPARATION *****
PURPOSE:
To assure supplier understanding of the comprehensive development plan used
for parts and components that includes process, quality and operation
readiness schedules.
TIMING:
From receipt of the Toyota Parts Master Schedule (TPMS) to three months
after NAMC Start of Mass Production (SOP).
REQUIREMENTS:
1. The supplier must create and submit a Supplier Parts Master Plan (SPMP) at the
designated frequency to the appropriate Toyota Project Management Group.
2. The SPMP must include all items listed on the TPMS, as well as expanded supplier
activities and related timing that is necessary to achieve TPMS requirements.
3. Supplier should establish cross-functional teams to develop and approve the SPMP
content.
4. Upon receipt, the NAMC QC/QE Department will review the SPMP and feedback any
concerns to the supplier for correction.
5. The supplier top management must verify and approve the SPMP and conduct periodic
status reviews to ensure timing requirements are fully achieved.
6. Any changes or deviations from the approved SPMP, regarding quality related items
must be reviewed by to the responsible NAMC QC/QE before implementing the change.
The NAMC QC/QE will feedback any concerns to the supplier for correction.
7. The supplier is required to contact the appropriate Toyota Project Management Group
to obtain details regarding the SPMP. The intent of this section is to provide an
overview of the quality related items.
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.1
1 of 1
SECTION 2.2 - DESIGNATED CONTROL CHARACTERISTICS [Pc] /
PROCESS CAPABILITY STUDIES (Cpk / Ppk)
***** PRODUCTION PREPARATION *****
PURPOSE: Defines statistical control requirements for specific critical part characteristics as
designated by Toyota or suppliers. In order to achieve the highest possible
capability (initial quality), minimize scrap, and the potential for shipping defects
while maintaining a reasonable level of investment and technology.
TIMING:
From part / component drawing release through the life of the part.
REQUIREMENTS:
1. Normal Industry Cpk requirements apply except as specified by Toyota. For unique
cases based upon design criteria and supplier process capability, specific Cpk
requirements may be designated. For these special cases, feasible Cpk targets will be
established through joint Toyota x Supplier consultation considering vehicle
performance, benchmarking, part manufacturing, part quality and process view points.
Toyota Design, NAMC QC/QE, and Supplier QC, manufacturing, and tooling/process
engineering will confirm and adjust on an individual basis prior to tooling or process
development.
2. Cpk requirements, targets, projections, and studies must be specified / designated after
drawing release and prior to tooling and process design finalization.
3. [Pc] Cpk requirements may be added or removed throughout the part life as required by
design criteria, process capability results, or customer expectations.
4. [Pc] designation and Cpk requirements must include all, , , , MVSS related
process controllable items as designated by Toyota or the supplier. Reference SQAM
Section 1.3 for more details.
5. [Pc] designation and Cpk requirements may be established for additional specific part
characteristics that significantly affect performance, fit, function, installation workability,
or other identified FMEA items.
6. [Pc] items with corresponding Cpk requirements must be specified on the Part
Inspection Standard, MQC, and other related documents (standardized work, data
sheets, etc.) and processes.
7. For all [Pc] designated items, short term Ppk capability studies must be carried out
during production trials to establish outlook for consistency of Cpk target achievement.
ISSUE
4
REVISION
August 2005
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TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.2
1 of 4
SECTION 2.2 - DESIGNATED CONTROL CHARACTERISTICS [Pc] /
PROCESS CAPABILITY STUDIES (Cpk / Ppk)
***** PRODUCTION PREPARATION *****
8. If short term Ppk studies indicate that final Cpk requirements are unachievable,
adjustments to the design criteria, tooling/process, inspection plan, or Cpk requirements
must be developed, proposed, approved, and re-verified prior to line-fill/ mass
production start. Any changes to initial targets must be communicated and approved by
Toyota.
9. Appropriate data must be developed for each [Pc] designated item during the
production trials and submitted to Toyota as requested. Industry standard statistical
tools for conducting capability studies must be utilized except for specific Toyota
requirements.
10. Continuous long term Cpk verification must be carried out for each [Pc] item, with
acquired data maintained and utilized for continuous improvement. Toyota may request
data submission.
11. Initial process capability study requirements, long-term process capability verification /
inspection sampling requirements, and sampling size requirements must be established
and communicated to Toyota with approval prior to production trials and mass
production start. Related guidelines are designated in Tables 1, 2, and 3.
12. Inspection frequencies must be in conjunction with Cpk results. Depending on machine
or process capabilities, the inspection requirements may increase or decrease. Any
changes to the inspection frequency must be communicated with and concurred by the
responsible NAMC QC/QE Department and all related documents (e.g. Manufacturing
Quality Chart (MQC), Inspection Standard, etc.) revised and approved.
Table 2.2 -1: Initial Process Capability Study Guidelines
Short Term (Ppk)
Long Term (Cpk)
20 minimum*
50 or as required to determine
sources of variability
3-5
3-5
Stable
Stable
2) Cpk / (Ppk)
1.67 or greater** / ***
1.33 or greater ***
If expectation is not
achieved:
Provide C/M using Sample
Data Sheet Format
See Table 2
# of Subgroups
Parts/Subgroup
(X-bar, R Charts)
Expectation:
1) Process
* Or as negotiated with NAMC QC/QE
** Short-term Cpk calculations shall be referred to as Ppk
*** Refer to requirement #1 for unique cases where feasible Cpk differs from
standard
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
MANUFACTURING
Toyota
Motor Engineering
&
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.2
2 of 4
SECTION 2.2 - DESIGNATED CONTROL CHARACTERISTICS [Pc] /
PROCESS CAPABILITY STUDIES (Cpk / Ppk)
***** PRODUCTION PREPARATION *****
Table 2.2 - 2: Long-Term Process Capability Inspection Sampling / Guidelines
The most recent point
indicates that the
process (see below):
ACTIONS ON THE PROCESS OUTPUT
Based on the Historical Process Capability (Cpk)
Is in control *
Has gone out of
control in an adverse
direction. All
individuals in the
sample are within
specification.*
Less than 1.33***
1.33 - 1.67***
Greater than 1.67***
Contact NAMC QC/QE
to discuss appropriate
countermeasure
Accept product.
Continue to reduce
process variation.
Accept product.
Continue to reduce
process variation.
IDENTIFY AND CORRECT SPECIAL CAUSE
Contact NAMC QC/QE
to discuss appropriate
countermeasure.
Accept product and
a) Perform
correct cause of
sampling** on
instability.
existing product,
construct histogram
from those samples,
take appropriate
action.
b) Increase sampling
frequency until
stability is reestablished.
Has gone out of
IDENTIFY AND CORRECT SPECIAL CAUSE
control and one or
Inspect 100% from Inspect 100% from the
Inspect 100% from the
more individuals in
last in-control point.
the last in-control
last
in-control
point.
the sample are
point.
outside specification.*
* Control refers to the status of process stability. An “out of control” condition is defined by
evidence of special causes of variation on the Shewhart Control Chart with control limits
defined by the data. A process is considered “in control” when no evidence of special
causes of variation is detected or identified.
** Refer to Table 2.2 - 3 for sampling size determination guidelines
*** Refer to requirement #1 for unique cases where feasible Cpk differs from standard
ISSUE
4
REVISION
August 2005
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TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH
AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.2
3 of 4
SECTION 2.2 - DESIGNATED CONTROL CHARACTERISTICS [Pc] /
PROCESS CAPABILITY STUDIES (Cpk / Ppk)
***** PRODUCTION PREPARATION *****
Table 2.2 - 3: Sampling Size Determination Guidelines
LOT SIZE
OR
SHIPMENT SIZE
SAMPLE SIZE PER
CHARACTERISTIC CLASSIFICATION
ACCEPTABLE NUMBER = 0*
0 - 25
26 - 50
51 - 75
76 - 125
126 - 425
426 and up
100% Inspection
25
35
40
45
50
*If one or more individuals in the sample are out of specification, inspect
100% from the previous “in-control” point.
ISSUE
4
REVISION
August 2005
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TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.2
4 of 4
SECTION 2.3 - PART EVALUATION PLAN (PEP)
***** PRODUCTION PREPARATION *****
PURPOSE: The supplier’s plan and results for component testing and verification in order to
demonstrate achievement of requirements for all drawing and related Toyota
standards.
TIMING:
From drawing/RDDP release through final part approval.
REQUIREMENTS:
1. The Part Evaluation Plan (PEP) and Sample Data Sheet (SDS) must be submitted to
the NAMC QC/QE for approval by the date indicated on the Toyota Parts Master
Schedule (TPMS) and the Supplier Parts Master Plan (SPMP).
2. The lack of lab or test equipment / facility does not exempt the supplier from completing
the specified test requirements.
3. During the initial part development a complete validation of all drawing and Toyota
standards must be conducted, by the supplier.
4. The PEP must include the following part drawing and part inspection standard (I/S)
requirements for validation / submission, divided into the following part completion
categories.
a.
b.
c.
d.
e.
Regulation Related
Durability & Reliability
Function & Performance
Dimension
Sensory (Appearance, Sound, etc.)
5. The PEP and Sample Data Sheet must include all drawing and/or Inspection Standard
specifications. All parts must be tested in accordance to the latest Toyota Test
Standard.
6. The required submission data must utilize off tool and off mass production equivalent
processes parts (e.g. die or mold cavity, welding, heat treatment, coating, assembly
processes, etc.).
7. The minimum sampling quantity should be according to Toyota Standard. If not
specified the supplier must decide the quantity with NAMC QC/QE concurrence.
8.
Special regulation or inspection requirements must be indicated on the Sample Data
Sheet with the appropriate symbol
.
9. The supplier must develop/maintain a system to verify all Toyota Standards are the
highest or most current revision level prior to each prototype and production preparation
part test evaluation, and on-going periodic mass production evaluations.
ISSUE
4
REVISION
August 2006
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SECTION
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SECTION 2.3 - PART EVALUATION PLAN (PEP)
***** PRODUCTION PREPARATION *****
10. The PEP and Sample Data Sheet must be updated and re-submitted to reflect any part
Inspection Standard or ECI changes/revisions.
11. Parts must be evaluated from each trial per PEP and the Sample Data Sheet with
results submitted to NAMC QC/QE in advance of sample part shipment (e.g. fax, e-mail)
and included with the sample part shipment.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
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SECTION
PAGE
2.3
2 of 2
SECTION 2.4 - PART INSPECTION STANDARD (I/S)
***** PRODUCTION PREPARATION *****
PURPOSE: A document consisting of part critical characteristics, their acceptance criteria
and the method and frequency by which the part must be monitored and
controlled by the supplier.
TIMING:
Begins at the initial request by the NAMC QC/QE and continues throughout the
life of the part.
REQUIREMENTS:
Type A: Toyota Issued Part Inspection Standard (Toyota NAMC developed & issued)
An Inspection Standard Request Cover Sheet and Inspection Standard draft will be
issued to the supplier for review and approval per the timing indicated on the Toyota Parts
Master Schedule (TPMS).
Note 1: NAMC QC/QE retains the original document
Note 2: A request to fabricate checking fixtures may be included.
1. After any revisions have been made to a Toyota issued Inspection Standard the
supplier must:
a. Acknowledge the receipt.
b. Specify an implementation date.
c. Return the signed originals to NAMC QC/QE.
2. The NAMC QC/QE must manage revisions for all Engineering Change Instructions
(ECI) and Application Sheets for Approval (ASA) issued by Toyota Design
Type B: Approval Part Inspection Standard (Supplier developed & NAMC approved)
The supplier will receive an Inspection Standard Request Cover Sheet from the NAMC
QC/QE that requires them to develop the part Inspection Standard per the Toyota Parts
Master Schedule and the Supplier Parts Master Plan.
Note: A request for specific quality requirements and/or to fabricate checking fixtures may be included.
The supplier may be requested to modify the Inspection Standard draft, but once approved,
the original will be returned to the supplier and a copy retained by the NAMC QC/QE.
1. The Part Inspection Standard (I/S) cannot conflict with the drawing specification, but is
intended to clarify and enhance quality assurance related requirements.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
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SECTION
PAGE
2.4
1 of 4
SECTION 2.4 - PART INSPECTION STANDARD (I/S)
***** PRODUCTION PREPARATION *****
2. The part inspection standard, at a minimum, must define the following items:
a. Datum Structure
f.
Weight
b. Dimension and Tolerance1
g. Color
c. Appearance
h. Identification Method / Label
d. Performance
i.
Material
e. Function
j.
Special Inspection Items2
Notes:
(1)
The supplier must meet the drawing or inspection standard tolerance, whichever is
tighter. The tolerance must be considered in process design.
(2)
These items are critical part characteristics that must be controlled to satisfy special
inspection or governmental regulation requirements
.
3. The Inspection Standard must consider and include inspection related criteria as
indicated on the MQC (reference SQAM Section 2.6), PFEMA studies, etc., and the
identified frequency of inspection must be developed from process capability studies
and results.
4. The approved Inspection Standard criteria, subject to revision, must be consistently
complied with for the life of the part without exception.
5. Requirements on the drawing not stated on the part Inspection Standard must be revalidated annually at a minimum.
6. Suppliers with MVSS parts are required to maintain critical performance data based on
the testing requirements outlined in the part Inspection Standard. This data may be
submitted to the appropriate NAMC QC/QE utilizing the MVSS Regulation Item Data
Submission form.
7. The supplier must initiate revisions for all Engineering Change Instructions (ECI) and
Application Sheets for Approval (ASA) issued by Toyota Design.
8. The supplier must submit an Inspection Standard Change Request form for all
revision requests to the Inspection Standard after negotiating initial approval.
Note: The original Inspection Standard must not be marked on, prior to approval. Attach a
separate paper, copy, etc. to indicate any proposed changes.
9. In the case of an Approval Inspection Standard, the NAMC QC/QE may request a
change to the Inspection Standard by submitting an Inspection Standard Change
Request form to the supplier
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
2.4
2 of 4
SECTION 2.4 - PART INSPECTION STANDARD (I/S)
***** PRODUCTION PREPARATION *****
FLOW CHART 2.4 - 1: Toyota Issued Part Inspection Standard (Issued by NAMC QC/QE)
NAMC QC/QE
SUPPLIER
• Develop Inspection Standard
•Check for error and discrepancy to drawing
• Review accuracy, completeness, and
capability to meet all requirements
• Complete Section B of Cover Sheet and
return originals to NAMC QC/QE
INITIAL DRAFT
• Complete Section A of Inspection
Standard Request Cover Sheet
• Issue original Inspection Standard and
Cover Sheet to supplier per timing
indicated on
Toyota Project Master Schedule (TPMS)
Accept
Maintain Originals
cc:File
Negotiate Revisions
Not Accept
REQUESTED BY SUPPLIER
• Evaluate request and complete bottom
of form and return original to Supplier
ISSUE
• Submit Inspection Standard Change
Request to NAMC QC/QE
Original Request
• If accepted, revise original Inspection
Standard and attach to Cover Sheet with
Section A completed
• Submit both to supplier
• Complete Section B of Cover Sheet
indicating implementation date, sign
revised Inspection Standard and return
both originals to NAMC QC/QE
Maintain Originals
REQUESTED BY NAMC
REVISION
• Revise Inspection Standard and re-issue
to supplier with new Cover Sheet
• After negotiating with the supplier, revise
original Inspection Standard and attach to
Cover Sheet with Section A completed
• Issue both to supplier
cc:File
• Complete Section B of Cover Sheet,
indicating implementation date
• Sign revised Inspection Standard and
return both originals to NAMC QC/QE
Maintain Originals
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA, INC.
cc:File
SECTION
PAGE
2.4
3 of 4
SECTION 2.4 - PART INSPECTION STANDARD (I/S)
***** PRODUCTION PREPARATION *****
FLOW CHART 2.4 - 2: Approval Part Inspection Standard (Issued by Supplier)
NAMC QC/QE
SUPPLIER
• Complete Section A of Inspection
Standard Cover Sheet and send to
supplier
• Complete Section B of Cover Sheet
acknowledging request and indicating
implementation date
• Return original to NAMC by date indicated on
Cover Sheet
INITIAL DRAFT
Original Request
• Review Inspection Standard
• Complete Section B of Cover
Sheet and return both originals to
the supplier
• Develop Inspection Standard
• Complete Section A of a new Cover
Sheet, requesting NAMC by date
indicated on original request
Accept
cc:File
Not Accept
Maintain Originals
Negotiate Revisions
REVISION
REQUESTED BY NAMC REQUESTED BY SUPPLIER
Revise Inspection Standard and re-issue to
NAMC with new Cover Sheet
ISSUE
4
• Review request and accept or reject
• Sign both originals and return to
supplier
• After negotiating initial approval from the
NAMC QC/QE, modify Inspection Standard
and submit to NAMC with Inspection Standard
Change Request attached
cc:File
Maintain Originals
• Submit Change Request Form
indicating desired revision
• Sign original Inspection Standard
and return to supplier
REVISION
• Modify and sign revised Inspection
Standard
• Submit revised Inspection Standard and
signed request form to NAMC
Maintain Originals
cc:File
August 2006
• Review request
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA, INC.
SECTION
PAGE
2.4
4 of 4
SECTION 2.5 – BOUNDARY SAMPLES
***** PRODUCTION PREPARATION *****
PURPOSE: Boundary samples are used as a supplement to the part inspection standard
(e.g. visual or sensory) when the characteristics are difficult to define or
communicate by any other method.
TIMING:
From the production preparation through the life of the part.
REQUIREMENTS:
1. Boundary samples must be prepared and submitted for approval for all items noted on
the Inspection Standard as “per boundary sample”.
2. Preliminary boundary samples should be discussed prior to tooling and process
development to determine quality expectations and process capability.
3. Preliminary boundary samples or expectation achievement should be verified through
the production trial activity with final boundary sample approval prior to supplier QCS.
4. Boundary samples may also be created to define problems discovered in both
production preparation and mass production stages. When submitting boundary
samples for this purpose, the supplier must be prepared to discuss process capability
and previously tried countermeasures.
5. Proposed boundary samples must be representative of the supplier’s confirmed process
capability and be consistently achieved.
6. Boundary sample approval is based on internal Toyota/Lexus quality standards,
consumer acceptance impact, part design characteristics, and supplier process
capability.
7. A minimum of three equivalent sets of boundary samples must be prepared and sent to
the NAMC QC/QE for review. A completed Boundary Sample Tag is to be affixed to
each sample submitted for approval. After approval, two sets will be returned to the
supplier; one to be used as a master, the other to be used as a working set. In the
case of multiple NAMCs using the same part, additional sets must be submitted to the
Coordinating Manufacturer for distribution to the using NAMCs. In the case of direct
supply parts, an additional set must be provided to the appropriate NAMC QC/QE for
review, approval and distribution to the Tier 1 supplier.
Note: Certain commodities may require additional samples, please consult with the NAMC
Q/QE for specific quantity requirements.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.5
1 of 2
SECTION 2.5 – BOUNDARY SAMPLES
***** PRODUCTION PREPARATION *****
8. Supplier must provide sufficient lead time for the boundary samples to be evaluated,
shipment authorization will not be granted until all boundary samples have been
approved by NAMC QC/QE.
9. The supplier must maintain the master boundary samples in a location where it is not
susceptible to damage, aging, etc. The working boundary samples should be located
at the point of decision and should also be protected from damage or degradation.
10. In certain situations, the NAMC QC/QE will issue a boundary sample that the supplier
must enforce. If these boundary sample results in excessive scrap, rework or sort, due
to process capability, then the supplier may renegotiate with NAMC QC/QE.
11. The supplier may request approval of a temporary boundary sample that deviates from
the approved boundary sample for a specific lot or time period. Temporary boundary
sample requests are intended to be utilized for extraordinary circumstances where all
other considerations have been exhausted. Approval for a temporary boundary sample
must be achieved prior to subject parts being delivered to the NAMC.
12. Revisions or change requests to approved boundary samples must be handled the
same as original submission.
ISSUE
4
REVISION
August 2005
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TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.5
2 of 2
SECTION 2.6 - MANUFACTURING QUALITY CHART (MQC)
***** PRODUCTION PREPARATION *****
PURPOSE: To identify and establish process parameter controls at the supplier for the critical
characteristics of the parts from receiving inspection through shipment.
TIMING:
Constructed after a process flow, part Inspection Standard and PFMEA or
equivalent document have been developed and potential failure modes have
been identified and utilized through the life of the part.
REQUIREMENTS:
1. The supplier must develop and submit for review a Manufacturing Quality Chart
(MQC) and process flowchart or diagram per the date(s) indicated on the Toyota Parts
Master Schedule and the Supplier Parts Master Plan. In addition to the part I/S Toyota
may request specific requirements relating to the product or process to be included in
the MQC.
Note 1: Parts with identical processes (i.e. left hand and right hand parts, etc) can be combined
into one form submission.
Note 2: An effective MQC involves the Manufacturing Department in the development and the
Quality Department in the confirmation.
2. Part, machine, and process potential failure modes must be identified and utilized to
develop the MQC in order to ensure that the potential failure causes and mechanism
can be controlled and monitored. For all critical ( , , & MVSS) related items
DFMEA or DRBFM and PFMEA practices or equivalent must be utilized.
3. The MQC must focus on the process parameters and encompass or make reference to
specific items on the part inspection standard (I/S).
4. Process parameters and related inspections for all , , and MVSS related items
must be detailed and clearly identified in the MQC.
Note: All delta and MVSS items ( , , , , , ) must be listed individually on the
MQC.
5. During the pre-production trials, the supplier must conduct testing, process analyses,
and verification to support the contents of the MQC. The MQC must be revised to
correct any deficiencies found during the production preparation trials.
6. If changes are made to the MQC during production preparation, a copy of the revised
MQC, and the process flowchart or diagram must be submitted to NAMC QC/QE for
review.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.6
1 of 2
SECTION 2.6 - MANUFACTURING QUALITY CHART (MQC)
***** PRODUCTION PREPARATION *****
7. After Part Approval (PA), the supplier must notify NAMC QC/QE in advance of any
changes to the MQC based on the following judgments;
a. Change meets process change request issuance criteria (reference SQAM
Section 3.3); then issue a Process Change Request (PCR) form prior to
implementation to the NAMC QC/QE.
b. Change does not meet process change request issuance criteria; then provide
the revised MQC for NAMC QC/QE review and approval.
c. If unclear about the proposed change; consult with NAMC QC/QE first.
8. A method to identify revisions must be developed (e.g. revision symbols, bold or italic
text, separate internal revision log, etc.), along with the capability to explain reasons for
the changes.
ISSUE
4
REVISION
August 2005
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TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH
AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.6
2 of 2
SECTION 2.7 – CHECKING FIXTURES, GAGES AND TEST EQUIPMENT
***** PRODUCTION PREPARATION *****
PURPOSE: Devices used to evaluate production parts for compliance to drawings, inspection
standard, process control requirements or other quality standards.
TIMING:
From production preparation through the life of the part.
REQUIREMENTS:
1. The supplier must provide a means to verify quality characteristics specified on the
drawing and part Inspection Standard (I/S).
2. The supplier must develop, utilize, and maintain the required inspection related tools
such as checking fixtures, gages, or other inspection/test equipment that Toyota
specifies.
3. During the initial production preparation planning stage, the NAMC QC/QE will indicate
on the Inspection Standard Request Cover Sheet the requirements for checking
fixtures, gages or inspection/test equipment development.
4. The equipment development, delivery, trial, etc. plan must be clearly indicated on the
SPMP.
5. If the supplier is responsible for obtaining and preparing the necessary checking fixture,
gage and test equipment, the supplier should meet with NAMC QC/QE to establish the
design concept and obtain approval prior to starting the check fixture build.
6. The completion date and price quote must be indicated on the Checking Fixture,
Gage, and Test Equipment Approval Request form. The gage drawing must specify
the build tolerance and clearly indicate part features that will be checked.
7. The supplier must receive final approval for the checking fixture, gage, or inspection/test
equipment from the NAMC QC/QE Department prior to utilization for part inspection.
For final approval, the supplier must submit the following information with the Checking
Fixture, Gage, and Test Equipment Approval Request form to the NAMC QC /QE
Department.
• Calibration certification data
• GRR study results for [Pc] characteristics
• Maintenance and re-certification schedule
• Instructions on how to use gage
• Photo of device
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.7
1 of 4
SECTION 2.7 – CHECKING FIXTURES, GAGES AND TEST EQUIPMENT
***** PRODUCTION PREPARATION *****
8. Checking fixtures, gages and test equipment are to be completed, qualified, and
available to evaluate no later than first off-tool sample parts as required by the TPMS
and SPMP. Any deviations from the approved plans and schedules must be
communicated to the NAMC QC/QE Department.
9. Suppliers may select the equipment fabricator, and must assure all SQAM requirements
are achieved.
10. Checking fixtures, gages, and inspection/test equipment must be accurate according to
recognized automotive industry standards (reference http://aiag.org MSA Manual at
AIAG). The word accurate in this context refers to the relative degree of errors
associated with bias, repeatability, reproducibility, stability, and linearity. The device
should include documentation to the appropriate national/international standard.
11. The supplier must ensure that parts are located on checking fixtures and gages per the
datum scheme specified on the Part Inspection Standard. Fixtures must reference
Height, Width, Length (H.W.L.) car position if the drawing references or specifies car
position.
12. Gage repeatability and reproducibility (GRR) must be conducted and maintain a target
of ≤10% error to total variation (TV). If the supplier cannot achieve this target, they
must consult NAMC QC/QE. GRR to be verified by the supplier no later than first-off tool
sample using production metrology equipment and gage operators. At minimum, all
characteristics designated on the Inspection Standard as [Pc] must be evaluated for
GRR.
13. GRR study for variable gages shall be conducted using the long method; three
operators, three trials and ten samples. This criterion enables separation of error due to
the gage and operator. GRR study for attribute gages shall be conducted using the
short method. GRR data shall be submitted using the Gage Repeatability and
Reproducibility Data Sheet and the Gage Repeatability and Reproducibility Report.
14. The checking fixture, gage, or test equipment must be identified with the part number,
ECI level, certification date, and re-certification due date.
15. The supplier is responsible for maintenance and calibration of checking fixtures, gages
and inspection/test equipment, including recertification on a planned basis and GRR
studies for [Pc] items. Certification must be traceable to a national or international
certifying body.
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.7
2 of 4
SECTION 2.7 – CHECKING FIXTURES, GAGES AND TEST EQUIPMENT
***** PRODUCTION PREPARATION *****
16. If during maintenance or calibration of the checking fixture, gage or test equipment, it is
found to be out of calibration, the supplier must:
A. Notify the NAMC QC/QE Department using a Notice of Suspected Shipment of
Non-Conforming Product form*.
B. Repair/adjust the device back to specification standard including record and
traceability of repair/adjustment.
C. Have a method to assess the effect on parts measured on an out of calibration
device.
D. Notify the NAMC QC/QE Department of the results of the above assessment*
*Note: Requirements A and D are required only when the supplier thinks that it is possible, non-conforming
product has been sent to the NAMC as a result of an out-of-calibration checking fixture, gage or test equipment.
17. Checking fixtures, gages and inspection/test equipment must not be altered or
changed without written approval from the NAMC QC/QE Department. The supplier
must submit a Checking Fixture Change Request form and obtain approval prior to
implementing any changes. Changes may be needed as a result of:
A. Engineering Change Instruction (ECI)
B. Problem countermeasure activity
C. Part Inspection Standard change
D. Fixture workability
E. Process change
F. Repair (major damage; outside of normal maintenance)
18. Resubmission of gage studies and a Checking Fixture, Gage & Test Equipment
Approval Request form may be required for gage features that are affected by
significant changes as a result of any of the above listed items.
19. Before disposal of checking fixtures, etc., the supplier must contact the Toyota
Purchasing Department for instruction and approval.
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.7
3 of 4
SECTION 2.7 – CHECKING FIXTURES, GAGES AND TEST EQUIPMENT
***** PRODUCTION PREPARATION *****
FLOW CHART:
Flow Chart 2.7 - 1: Inspection/Test Equipment Development, Approval, & Use Responsibility
NAMC QC/QE
SUPPLIER
DESIGN
Identify need for Checking
Fixture, Gage or Test
Equipment and confirm
[Pc] points on the
Inspection Standard
Review
If not acceptable
If acceptable
Issue approval to build
Discuss concept
with NAMC QC/QE
When concept
Is agreed upon
Submit Checking Fixture,
Gage and Test Equipment
Approval Request form:
1. Drawing
2. Specifications
3. Completion date
4. Price quote (copy)
BUILD
Checking fixture, gage or test
equipment must be identified with:
1. Part number
2. ECI level
3. Certification date
4. Re-certification due date
If not acceptable
USE
Review
If acceptable
Submit Checking Fixture, Gage & Test Equipment
Approval Request:
1. Calibration Certification Data
2. Copy of Gage Repeatability & Reproducibility
results for [Pc] characteristics
3. Maintenance and re-certification schedule
4. Gage use instructions
5. Photo of device
6. Sample data sheet containing results from at
least 1 part measured on the gage
*Issue approval for use
Put into service
* Should be completed by 1st off-tool sample
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.7
4 of 4
SECTION 2.8 - MATING PART / COMPONENT REQUEST
***** PRODUCTION PREPARATION *****
PURPOSE:
An aide to be used for part fitting and/or testing.
TIMING:
From initial production preparation through the life of the part.
REQUIREMENTS:
1. The supplier must submit a Mating Part / Component Request form to the NAMC
QC/QE Department to obtain desired parts or components.
2. These parts or components must not be used as gages or for reference in making
design changes unless directed and concurred by the NAMC QC/QE Department
3. All mating parts or components received from Toyota must be kept confidential,
controlled, and maintained in a secure location.
4. If the supplier encounters any problems, issues, or concerns with the provided parts or
components the NAMC QC/QE Department must be contacted immediately.
5. The supplier is responsible to verify through the NAMC QC/QE Department that the
utilized mating part or component is the most current level.
6. The supplier is responsible to assure disposal of the mating part or component through
confidential destructive scrap.
7. The supplier may be requested to purchase any parts needed for continuous/on-going
testing.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.8
1 of 1
SECTION 2.9 - SAMPLE PART SUBMISSION
***** PRODUCTION PREPARATION *****
PURPOSE: To assure supplier understanding of responsibility to prepare and submit
production preparation evaluation parts.
TIMING:
From initial part submission through the life of the part.
REQUIREMENTS:
1. The supplier must provide sample parts in accordance with the timing indicated on the
TPMS and SPMP, at a minimum. Any change from the approved schedule and plan
must be communicated to and approved by the NAMC QC/QE and Production Control
Departments.
2. Detailed results of the sample part evaluation must be recorded on the Sample Data
Sheet (SDS) including the evaluation judgment indicated on the Part Evaluation Plan
(PEP).
a. The actual value must be recorded for all variable evaluation items (e.g.
dimensional, performance, etc.) per the part I/S.
Note: During production preparation when go-no-go gages are used, actual gap data
must be taken.
b. Data judgment must be expressed on the Sample Data Sheet using the
following format:
{
∆
r
⊗
= Meets requirement (all parts meet requirement)
= Meets requirement, but needs improvement (all parts meet, but
are clustered near upper or lower specification limits)
= Does not meet requirement* (1or more parts do not meet
requirement)
= Reworked to meet requirement*
(1 or more parts reworked to meet the requirement, but extent
of rework must be explained)
* NAMC QC/QE Department must be contacted prior to shipping
c.
An explanation and countermeasure plan must be provided for all "∆", “r”,
and “⊗” judged items on the Sample Data Sheet at the time of submission.
d.
Tear down analysis must be performed on all functional parts that do not
achieve performance test requirements. For functional part achieving
performance test requirements and the test is not run to failure, a tear down
analysis must also be performed to identify and analyze wear tendencies and
trends.
Note: Prior to the tear down activity the NAMC QC/QE must be contacted to verify
their attendance.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
2.9
1 of 3
SECTION 2.9 - SAMPLE PART SUBMISSION
***** PRODUCTION PREPARATION *****
3. The submitted samples, which were evaluated for dimensional characteristics on the
drawing or inspection standard, must be identified with sequential numbers (1, 2, 3, etc.)
which corresponds to the columns on the Sample Data Sheet. Toyota expects the
supplier to randomly select the sample parts used for submission.
4. All sample parts submitted to NAMC must have a Sample Submission Cover Sheet
and evaluation results attached. One cover sheet should be utilized for each part
number. The part completion summary portion of the Sample Submission Cover Sheet
must include the drawing and inspection standard quality characteristics arranged
according to the part completion categories shown in Table 2.9-1. After the initial
submission and NAMC QC/QE approval the arrangement of the drawing and inspection
standard quality characteristics to the part completion categories should not change.
Table 2.9 - 1: Explanation of Part Completion Categories
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
2.9
2 of 3
SECTION 2.9 - SAMPLE PART SUBMISSION
***** PRODUCTION PREPARATION *****
5. The sample part data package submitted to NAMC QC/QE Department must include :
• Sample Submission Cover Sheet
• Reference comparison of the parts to the final mass production intent
• Part Evaluation Plan
• Sample Data Sheets with results (including process capability if required)
• Raw material certifications
• ECI Implementation Log / Tracking Sheet
Note: All raw material certifications and performance test results must include the actual
testing data. All parts and materials must be tested to the appropriate current level Toyota
standard with part completion ratio.
6. The supplier must include an explanation of any significant change or deviation from the
mass production level part (e.g. sub-component or material substitution, tool/die
substitution, process, etc.) when submitting the Sample Data Sheet (SDS).
7. One copy of the sample submission data package must be included in the sample parts
container. If more than one container is used per part number, the container that
includes the data package must be clearly identified.
8. One copy of the sample data package should be provided to the NAMC QC/QE
Department in advance of the sample part shipment arrival.
9. In all cases, sample parts and Production Preparation Trial parts must be packaged and
labeled in accordance with the instructions from NAMC Production Control Department
10. After the SDS have been reviewed, the supplier will be informed of any problems,
issues, concerns promptly by the NAMC QC/QE Department with request for
investigation or resolution.
11. After NAMC mass production start, the NAMC QC/QE Department may request
additional Sample Data Sheets be provided on a regular basis for a set period of time.
12. Some inspection items require actual data or data summaries to be submitted regularly
to NAMC QC/QE after SOP. These are indicated in the part Inspection Standard.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
2.9
3 of 3
SECTION 2.10 - COLOR & GRAIN APPROVAL ACTIVITIES
***** PRODUCTION PREPARATION *****
PURPOSE: To ensure that the established part color and grain requirements defined by
Toyota Design are met.
TIMING:
From production preparation sample submission through the life of the part.
REQUIREMENTS:
All color and grain approvals must be achieved prior to mass production line fill and
in accordance to the TPMS and SPMP. Any change from the approved schedule
and plan must be communicated to and approved by the NAMC QC/QE
Department
I. Color Approval Requirements
1. The supplier is responsible for developing the color with the raw material
supplier and confirming the color to standards prior to NAMC QC/QE review,
reference Flow Chart 2.10 -1 for details.
2. The supplier must provide visual and colorimeter data showing parts achieve
color standards or boundary samples including their judgment. The data is to
be recorded on the Color/Grain Matching Follow Sheet.
3. The numerical data forms a basis for benchmarking and tracking process
variation. Preference should be given to the scale which best replicates the
visual technique (L*a*b* , L*C*h* , CMC, etc.).
E
E
4. Visual color matching activity utilizing mating parts, components, etc. is the final
or ultimate decision making method as to standard to target achievement and
tuning or adjustment direction.
5. Unless otherwise indicated by NAMC QC/QE Department, the supplier must
attach a Color Matching Follow Sheet to the part submission and provide to
NAMC QC/QE Department per the timing indicated on the TPMS and SPMP.
6. Suppliers are required to request their master color/grain plaques through
Toyotasupplier.com, concerns regarding color/grain plaques should be directed
to Toyota Purchasing. Working color standards may be issued by the NAMC
QC/QE Department for exterior parts only.
7. It is the supplier’s responsibility to establish a color and gloss management
program which controls part variation and sub-supplier quality (i.e. part and
material variation). The confirmation frequency for these items must be listed
on the MQC.
ISSUE
4
REVISION
August
August2006
2005
B-
Toyota
Motor MANUFACTURING
Engineering &
TOYOTA
MOTOR
Manufacturing
North America
NORTH AMERICA,
INC.
SECTION
PAGE
2.10
1 of 4
SECTION 2.10 - COLOR & GRAIN APPROVAL ACTIVITIES
***** PRODUCTION PREPARATION *****
FLOW CHART(S):
Flow Chart 2.10 - 1: Color Development and Approval Process
SUPPLIER
NAMC QC/QE
Supplier brings or sends parts,
standard, and Color Follow
Sheet to NAMC
PRODUCTION PREPARATION
Run samples in color
Visual color match to standard
Visual color match
Tune
NG
OK
Check on color
computer
Record results on the Color/Grain
Matching Follow Sheet
MASS PRODUCTION
TIMING
NG
OK
Instruct supplier
modification direction
< 2A
Approve
Color
Issue working standard
(if applicable)
Supplier makes parts & records data on
the Color/Grain Matching Follow Sheet
SOP
Check
Monitor trend with color
computer using
established boundary
samples
SUPPLIER PREPARATION
1st Color Trial
1) Run parts in all colors using mass production process
2) Check visually at supplier
3) Check by color computer at supplier (benchmarking)
4) Fill in Color/Grain Matching Follow Sheet (include sketch)
5) NAMC to set-up specific time for color matching
6) Items to bring to NAMC
a. Parts (2 per color per mold per material)
b. Color/Grain Matching Follow Sheet - completed for 1st Trial
c. Supplier color standards
7) At each color matching meeting NAMC QC/QE will give supplier instructions for the next meeting
NOTE: 1) Visual color matching is the ultimate controlling method
2) Numerical data is the basis for benchmarking
ISSUE
4
REVISION
August 2006
August
2005
B-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
Manufacturing
North America
NORTH AMERICA,
INC.
SECTION
PAGE
2.10
2 of 4
SECTION 2.10 - COLOR & GRAIN APPROVAL ACTIVITIES
***** PRODUCTION PREPARATION *****
II. Grain Approval Requirements
1. Toyota Design may issue an ECI to change the grain instruction based on
review of the Grain Memo, reference Flow Chart 2.10 - 2 for details.
2. NAMC QC/QE Department will issue a Grain Authorization Sheet to the
supplier when:
a. Production preparation samples satisfy all dimensional, appearance, and
fit requirements, for both individual parts and upon assembly into the
completed vehicle.
b. No further changes will be made or are planned to materials or mold
(cavity side).
3. The supplier can initiate graining of the tool, mold, die, etc. only after receiving
a Grain Authorization Sheet from the NAMC QC/QE Department.
4. The supplier must review the Grain Authorization Sheet adding the date by
which grained parts will be provided to NAMC QC/QE Department for approval,
then sign the sheet and return it to NAMC QC/QE by the date indicated.
5. The supplier must request grain approval using the Color/Grain Matching
Follow Sheet from the NAMC QC/QE Department as indicated on the SPMP
and in advance of mass production line fill.
6. The supplier must only utilize a Toyota approved graining source and should
consult with the related Toyota Design Engineer regarding their choice.
7. Grained parts from all mold cavities must have NAMC QC/QE approval.
8. Suppliers are required to request their master color/grain plaques through
Toyotasupplier.com, concerns regarding color/grain plaques should be directed
to Toyota Purchasing.
ISSUE
4
REVISION
August 2006
August
2005
B-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
Manufacturing
North America
NORTH AMERICA,
INC.
SECTION
PAGE
2.10
3 of 4
SECTION 2.10 - COLOR & GRAIN APPROVAL ACTIVITIES
***** PRODUCTION PREPARATION *****
Flow Chart 2.10 - 2: Grain Development and Approval Process
TOYOTA DESIGN
SUPPLIER
Issue Grain Concept
Memo
NAMC QC/QE
SE Study / Provide Feedback
DESIGN / SE
1) Review Results
2) Changes Needed
YES
NO
1) Issue Grain Instruction Memo
2) Issue Production Drawing
Receive and Review
1) Receive Grain Memo
2) Confirm specification to
the drawing*
Conduct Parts Fitting Trials
PRODUCTION PREPARATION
OK
1) Provide Grain Authorization
Sheet
2) Approval to proceed
1) Select approved Grain
Source (w/ Design)
2) Grain Tool(s)
1) Collect Data
2) Report results with
examples
3) Submit for Grain Approval
1) Review
2) Approve
MASS PRODUCTION
NO
ISSUE
NG
YES
Monitor the grain quality to the
drawing requirements
4
REVISION
August
2006
August
2005
B-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
Manufacturing
North America
NORTH AMERICA,
INC.
SECTION
PAGE
2.10
4 of 4
SECTION 2.11 - PART APPROVAL
***** PRODUCTION PREPARATION *****
PURPOSE: Part approval (PA) demonstrates the supplier’s capability to produce limited
volume parts utilizing off-tool and mass production equivalent processes that
meets the specified quality standard.
TIMING:
From off-tool and off mass production equivalent process raw materials prior to
Supplier Quality Confirmation Stage (SQCS).
REQUIREMENTS:
1. The supplier must request Part Approval (PA) by submitting the Approval Request (AR)
form to the NAMC QC/QE Department for approval based on the timing indicated on the
TPMS and SPMP. PA is not the ultimate authority to ship parts without notifying the
NAMC QC/QE Department.
2. PA cannot be requested until all design and part Inspection Standard criteria have been
achieved and verified.
3. Prior to submission for PA, qualified sample parts (reference SQAM Section 2.9) that
were produced off tool and mass production equivalent process must be submitted to
the NAMC QC/QE Department for evaluation and verification.
4. Mass production equivalent process is defined as the machine, equipment, process,
and manpower used to produce the parts evaluated for PA request, represents the final
manufacturing process in terms of critical control characteristics and that the final
manufacturing process will not have any significant differences that impact design or
quality requirements.
5. An Approval Request (AR) for each part number, drawing, or part family (i.e. LH / RH)
listing all level one part numbers indicated on the drawing must be submitted. The AR
must be completed in its entirety including all designated supplier approval signatures.
6. The following latest revision level documents and information must be on record and
submitted as requested by the NAMC QC/QE Department prior to request of PA.
a. Supplier Parts Master Plan (SPMP)
b. Manufacturing Quality Chart (MQC)
c. Machine / Process FMEA or equivalent document (as required)
d. Process Capability studies and results (Cpk)
e. Part Inspection Standard (I/S)
f. Raw Material Certification
g. Part Evaluation Plan (PEP)
h. Sample Data Sheets (SDS) and related evaluation / test results
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.11
1 of 2
SECTION 2.12 – QUALITY READINESS CHECKSHEET (QRC)
***** PRODUCTION PREPARATION *****
PURPOSE: To verify the supplier’s capability to produce high quality products utilizing mass
production tooling and processes at mass production quantities.
Note: The Quality Readiness Checksheet (QRC) is one of the three elements contained
in the Production Readiness Confirmation System. The other two elements are; the
Process Readiness Checksheet (PRC) and the Operations Readiness Checksheet
(ORC)
TIMING:
Initial trial stage to initial mass production line fill (typically N-2 months).
REQUIREMENTS:
1. The supplier must plan and initiate all mass production readiness activities as required
by the Toyota provided check sheet, theTPMS, and the SPMP without exception. Any
change or deviation must be communicated to the NAMC QC/QE Department and
concurrence or approval must be achieved.
2. The supplier must verify during the Final Verification Phase that final quality assurance
must be verified as required by the TPMS, SPMP, and SQAM. The specific quality
reportables will be listed on the Quality Readiness Checksheet (QRC).
3. The production trials carried out during the Final Verification Phase must be utilized to
verify quality assurance capability.
4. The results of the quality requirements specified by the QRC must be submitted to the
NAMC QC/QE Department for review and approval per the timing required on the
TPMS and SPMP. A Sample Data Sheet and/or process capability data may be
required for each submission of the QRC, please consult with the NAMC QC/QE for
details.
5. During the Final Verification Phase, if all required quality targets are not consistently
achieved the supplier must develop and deploy special inspection plans (indicated on
the MQC) at a minimum, if the problems cannot be corrected. Additional items may be
added by the NAMC QC/QE. These inspections must occur in advance of mass
production to fully assure no flow-out of non-conforming product.
6. Toyota will communicate to the supplier when it is acceptable to ship mass production
parts based on their Production Readiness Confirmation results.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
2.12
1 of 1
SECTION 2.11 - PART APPROVAL
***** PRODUCTION PREPARATION *****
7. The NAMC QC/QE Department will review the request for PA, all related documents
and information, sample part quality achievement, and verify status of achievement of
design and quality criteria. After review, the NAMC QC/QE Department will provide
notification of granting PA, or denying PA and the requirement for obtaining FA
(reference SQAM Section 2.13).
8. Granting PA authorizes that the part achieves all design and quality criteria under the
current known conditions from a design and quality perspective. The supplier should
proceed to verify ability to achieve consistent quality criteria through final production
preparation activities as defined by the TPMS and SPMP.
9. Conditional PA may also be granted pending completion of specific quality assurance
requirements as noted on the Approval Request form. The supplier must achieve
completion of the specific items as noted prior to requesting FA.
10. If the request for PA is denied, the supplier must urgently respond to the reasons for
denial before proceeding to full mass production preparation activities.
ISSUE
4
REVISION
April 2006
A
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.11
2 of 2
SECTION 2.13 - FINAL APPROVAL
***** PRODUCTION PREPARATION *****
PURPOSE:
To assure supplier understanding of their responsibility to obtain Final Approval
(FA), to signify that the tool and final mass production process is capable of
consistently producing product that achieves all design, quality and production
volume requirements.
TIMING:
90 days after the start of Mass Production.
REQUIREMENTS:
1. To achieve Final Approval (FA), all quality requirements must be achieved as required
on the TPMS, SPMP and PRC with no significant unresolved quality issues from initial
mass production.
2. As designated by the Part Approval (PA) requirement, the supplier may be required to
resubmit the Approval Request (AR) form to the NAMC QC/QE Department to request
FA. The earliest that this submission can be made is 30 days after the start of mass
production. The earliest that this request for FA can be approved is 90 days after the
start of mass production, pending no discovery or occurrence of unresolved significant
quality issues.
3. After PA is approved, if any significant quality issue develops and remains unresolved,
the NAMC QC/QE Department can void the automatic granting of FA requiring
resubmission to obtain FA.
4. If request for AR is required, a form must be submitted for each level 1 part number,
indicated on the drawing must be submitted. The AR request must be completed in its
entirety including all designated supplier approval signatures.
5. The following latest revision level documents and information must be on record and/or
submitted as requested by the NAMC QC/QE Department prior to request of FA.
a. Supplier Parts Master Plan
b. Manufacturing Quality Chart
c. Machine / Process FMEA or equivalent document
d. Process capability studies and results (Cpk)
e. Part Inspection Standard
f. Raw material certification
g. Part Evaluation Plan
h. Sample Data Sheets and related evaluation / test results
6. The NAMC QC/QE Department will review the AR, all related documents and
information, sample part quality achievement, and verify status of achievement of
design and quality criteria. After review, the NAMC QC/QE Department will provide
notification of granting FA, or denying FA.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.13
1 of 2
SECTION 2.13 - FINAL APPROVAL
***** PRODUCTION PREPARATION *****
7. If the request for FA is denied, the supplier must urgently respond to the reasons for
denial and achieve the necessary requirements to obtain FA.
8. Toyota Purchasing may base their payment system for Toyota property on several
factors that include, but not limited to the following:
a. Issuance of part approval (PA)
b. Closure of all provisions or open items for PA
c. QRC evaluation result of “Ù“ or closure of any issues related to the Production
Readiness Confirmation
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.13
2 of 2
SECTION 2.14 QUALITY IMPROVEMENT
***** PRODUCTION PREPARATION *****
PURPOSE:
To communicate quality improvements needed on parts and components.
TIMING:
From first sample submission to initial mass production line fill.
REQUIREMENTS:
Type A: Quality Non-conformance
1. When a part is discovered not to conform to the current quality requirements as defined
by the drawing, Part Inspection Standard, or checking fixture data a Quality
Improvement Request (QIR) form may be issued.
2. The supplier is expected to respond with urgency and priority to QIR requests.
3. The supplier is expected to respond by the date requested on the QIR with the following
information:
a) If the problem is clearly supplier responsibility;
•
Root cause and countermeasure detail and date
•
Arrival timing of countermeasure sample part
b) If the responsibility for the problem is not clear;
•
Conduct investigation and provide the results
4. In the case that the drawing, Part Inspection Standard or checking fixture quality is
unclear and requires definition or revision, a QIR may also be issued. In case of any
change or revision established Toyota procedures must be followed.
Type B: Quality Tuning Request
When the sample part meets the current quality requirements as defined by the drawing,
Part Inspection Standard, or checking fixture data and a quality improvement is desired to
improve fit, function, appearance, workability of mating part a Quality Tuning Request
(QTR) will be issued to the supplier details indicated in SQAM Section 3.2.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
2.14
1 of 1
Next Section
SECTION 3.0 – MASS PRODUCTION OVERVIEW
***** Mass Production *****
PURPOSE: To identify key quality assurance activities required during mass production.
TIMING:
From supplier quality confirmation stage (SQCS) through life of the part.
REQUIREMENT:
The quality assurance responsibility for mass production parts is defined by five key activities.
•
Continuous and consistent quality assurance
•
Notification of pending or potential quality non-conformance
•
Response to correct and prevent recurrence prevention of quality nonconformance flow-out
•
Continuous quality improvement activity
•
Effective communication
1. Continuous and consistent quality assurance
The supplier is required to have policies, systems, and methods (designated by the
MQC & part I/S) in place, as developed during the production preparation stage,
that will monitor and assure all required quality criteria are consistently achieved.
Executive management must periodically audit and improve the effectiveness of
the mass production quality assurance systems and methods.
2. Notification of pending or potential quality non-conformance.
The supplier is required to notify the affected NAMC QC/QE Department on an
urgent basis of any suspected, pending, or potential flow out of non-conforming
product utilizing the Notice of Suspected Shipment of Non-Conforming
Product form.
3. Urgent response to correct and prevent recurrence of non-conformance
When notified by the NAMC QC/QE Department of quality non-conformance flow
out, either by Quality Problem Report (QPR) or by other means, the supplier must
urgently respond with priority to contain, correct, and assure recurrence prevention
of the non-conformance issue. The supplier is responsible to identify suspect nonconformance range and carry out any necessary supplemental activities that
assure containment and availability of conforming product. These activities
include, but not limited to sort, rework, special inspection, etc. regardless of
location, reference SQAM Section 3.1 for additional detail.
4. Continuous quality improvement activity
The supplier must have systems and methods in place to monitor internal and
external performance indicators as well as utilize this information to improve overall
quality. Warranty data and parts must also be considered a key quality
performance indicator (as applicable).
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
MANUFACTURING
Toyota
Motor Engineering
&
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
3.0
1 of 2
SECTION 3.0 – MASS PRODUCTION OVERVIEW
***** Mass Production *****
5. Effective communication
Through the life of the part the supplier must ensure effective communication to
the NAMC QC/QD Departments and related Toyota divisions (e.g. Design,
Purchasing, and Production Control). Reference Table 1.1 - 1: Documentation
Flow for Common Parts and Table 1.2 - 1: Documentation Flow for Direct
Supply Parts.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
3.0
2 of 2
Next Section
SECTION 3.1 NON-CONFORMANCE HANDLING
***** Mass Production *****
PURPOSE: To ensure that countermeasures, containment and rework are implemented for
non-conforming parts/components.
TIMING:
From Supplier Quality Confirmation Stage (SQCS) through the life of the part.
REQUIREMENT:
1. Non-conformance discovered by supplier
a) If the supplier finds actual or potential flow out of non-conforming product, the
supplier is required to submit a Notice of Suspected Shipment of Nonconforming Product to the NAMC QC/QE and Receiving Inspection
Departments and confirm receipt by telephone. The form must be completed in
its entirety before submittal, reference Table 3.1-1: Non-Conforming Parts
Communication Flow for Suppliers.
b) A Quality Problem Report (QPR) will not be issued if the supplier initiates and
leads all activity to contain and control the non-conforming product at the NAMC
prior to being found on the line or installed on the vehicle or unit assembly.
c) The supplier must report the non-conformance cause and corrective action to
prevent recurrence to the NAMC QC/QE Department within 15 days by utilizing
the Countermeasure Reply Form. The form must be completed in its entirety
and address both the why made and why shipped factors and include approvals
from the Quality Control and Production Engineering Departments.
2. Non-conformance discovered by the NAMC
a) The supplier will be notified of all non-conforming product discovered at the
NAMC. The supplier may be notified using a Quality Problem Report (QPR)
according to the issuance criteria indicated in Table 3.1-2: QPR Ranking and
Issuance Criteria. The supplier would then be provided advanced notification
and/or an advance copy of the QPR, reference Table 3.1-3: Non-conforming
Parts at NAMC for details.
b) QPR issuance and response will be included in mass production supplier quality
performance indicators.
c) QPR issuance will be ranked by severity and non-conformance type delta “ ”
ranked QPRs must have the highest level of supplier management attention.
Urgent response and verification of recurrence prevention must be addressed by
the supplier’s upper management, reference TABLE 3.1-2: QPR Ranking and
Issuance Criteria.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
3.1
1 of 5
SECTION 3.1 NON-CONFORMANCE HANDLING
***** Mass Production *****
d) Upon receipt of the advance QPR notice, the supplier must immediately contain,
and correct all non-conforming products at the affected NAMC(s), in transit, and
at the supplier facility. The supplier is fully responsible to provide the necessary
direction, equipment, and manpower necessary to contain and correct all nonconforming products. The supplier must respond to the NAMC QC/QE
Department’s request or direction to initiate a sort, reference Summary of
Supplier PPM Application Standard for additional information.
e) The supplier must provide a response within 24 hours by completing the
Temporary Countermeasure Plan section and providing it to the NAMC QC
Receiving Inspection Department. The plan must include:
1) Sorting results
2) Temporary countermeasure details
3) Plan implementation date
4) Ship date, shipment ID #, (e.g. FRS, order #, manifest #, etc.) and
identification method for temporary countermeasure parts
f) The supplier must identify each container of temporary countermeasure parts
with a securely attached 5”x7” yellow Certified Stock Tag located near the
standard Toyota KANBAN indicating date of part certification and the QPR
tracking number and non-conformance description. This temporary identification
labeling must be applied to all containers until the permanent countermeasure is
implemented.
g) The supplier must submit to the NAMC QC/QE Department a Countermeasure
Reply Form as soon as available, but no later than the due date indicated on
the QPR. The Countermeasure Reply Form must be completed in its entirety,
address both the why made and why shipped factors and include approvals from
the QC and Production Engineering Departments.
h) The supplier must respond to the QPR by the due date even if the permanent
countermeasure has not yet been determined. In this instance the supplier is
expected to provide a summary of activities, schedule of completion and a
follow-up date. Resubmission of the Countermeasure Reply Form is required
upon completion of countermeasure.
i) If the permanent countermeasure requires a process change that meets PCR
requirements (reference SQAM Section 3.3), the supplier should submit a PCR
with the reply form and indicate on the reply form PCR submission
implementation timing.
j) The supplier must identify the first shipment of permanent countermeasured
parts with a securely attached 5”x7” green Certified Stock Tag located near the
Toyota KANBAN indicating the related QPR #, non-conformance description,
and ship date of countermeasured parts.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
3.1
2 of 5
SECTION 3.1 NON-CONFORMANCE HANDLING
***** Mass Production *****
k) The supplier is responsible for removal of all yellow and green temporary
identification labels on returnable containers, before reuse at supplier facility.
l) In cases where QPR issuance criteria is not met by incident of non-conforming
parts, a Quality Improvement Request (QIR) may be issued by the NAMC
QC/QE Department notifying the supplier of an emerging or sporadic quality
issue. The supplier is expected to investigate and initiate action to improve or
correct the identified non-conformance. If directed on the QIR the supplier must
respond to the NAMC QC/QE Department by the due date.
3. Sort, rework, special inspection support
a) The supplier, at its cost and as directed by the NAMC QC Department, must
rework nonconforming parts, replace the non-conforming parts with new parts,
or perform any other additional work necessary to bring the nonconforming parts
into full compliance with all Toyota requirements. All nonconforming
containment activities must be coordinated with and approved by the NAMC
QC/QE Department.
b) The NAMC at their discretion may rework or sort any nonconforming products to
prevent interruption of the production line. In this case, the supplier may be
charged for the rework or sort activity.
c) Proposed rework instructions must be reviewed by the NAMC QC/QE
Department in advance of initiation.
d) The supplier must insure conforming parts are available without interruption to
planned NAMC production requirements.
e) The supplier must place priority to containment of non-conforming product at
their location and simultaneously support NAMC on site containment and
recovery.
f) The supplier may elect to utilize an NAMC approved flexible work force to
supplement NAMC on site containment and recovery activities.
g) If utilization of a flexible work force is elected, the supplier is responsible for the
flexible work force. This includes their training, management and approval of
their sort/rework method and the quality of the resulting part.
h) A supplier representative or designate must be available at all times when a
flexible work force is on site at an NAMC. This supplier representative is
responsible to supervise, and assure completion of directed activity.
ISSUE
4
REVISION
August 2006
B
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
3.1
3 of 5
SECTION 3.1 NON-CONFORMANCE HANDLING
***** Mass Production *****
i) All sort and rework activity must be recorded and approved by the supplier
representative. Recorded data must include quantity sorted, OK/NG results,
number reworked, etc. This data must be provided to the NAMC QC/QE
Department on a shift by shift basis on the format required by the NAMC.
j)
The supplier must continue containment activities until certified
countermeasured product is available and the NAMC QC/QE Department has
concurred that the containment activity has been effective and can be
discontinued.
4. eQPR
a) eQPR, a non conforming document web site, is utilized to communicate mass
production QPR and QIR to the entire supply base. All guidelines and rules in
SQAM apply to mass production QPR and QIR in eQPR.
Suppliers are required to respond to mass production QPR and QIR in eQPR.
FLOW CHART(s):
Table 3.1 - 1: Non-Conforming Parts Discovered Supplier
SUPPLIER
NAMC
QC/QE
QC R/I
Discover non-conformity; suspect
shipment to NAMC
•
•
Immediately fax a Notice of
Suspected Shipment of Nonconforming Products
Confirm receipt by telephone
Confirm if non-conforming parts exist on
production line or on completed vehicle
Yes
•
•
Prevent additional non-conforming
parts from being manufactured or
shipped to NAMC
Support NAMC in replacing,
reworking or sorting parts at NAMC
Submit a “Countermeasure Reply
Form” within 15 calendar days of
original notification
ISSUE
4
REVISION
August 2006
B
Issue QPR
(Ref. Table 3.1 -2)
No
Don’t Issue
QPR
Review and confirm
countermeasure
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
3.1
4 of 5
SECTION 3.1 NON-CONFORMANCE HANDLING
***** Mass Production *****
Table 3.1 - 2: QPR Ranking and Issuance Criteria
RANK
S
A
B
C
C
CATEGORY
Delta or MVSS characteristics
CRITERIA
1 or more non-conformances
Essential vehicle function characteristics
(e.g. run, stop, steer, brake, etc.)
All other characteristics not specified
above except appearance and machining
(e.g. function, performance, abnormal
noise, wrong, missing, etc.)
Appearance related characteristics
Machining Process (Casting & Forging)
1 or more non-conformances
Based on Toyota Internal Standard
3 times PPM target
(3 part minimum / shift)
Table 3.1 - 3: Non-conforming Parts at NAMC
SUPPLIER
NAMC QC Receiving Inspection
(QC R/I)
NAMC QC/QE
Discover non-conformance
Provide temporary
countermeasure
information to QC R/I
within 24 hours
Submit
•
Copy
•
Prepare QPR, contact
supplier by phone and
fax an advanced copy
Forward original to
QC/QE
Forward
•
•
Forward supplier reply to
QC/QE
Reply
Complete a
“Countermeasure Reply
Form”, and submit to
NAMC QC/QE by due
date indicated on QPR
ISSUE
4
REVISION
August 2006
B
Forward
Review QPR and
temporary
countermeasure
plan
Issue official QPR
to supplier
Issue
Response
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
Review and confirm
countermeasure
SECTION
PAGE
3.1
5 of 5
Next Section
SECTION 3.2 Quality Tuning Request (QTR)
***** Mass Production *****
PURPOSE:
To initiate a tuning change for a part or component that is within specification,
but must be modified to achieve the desired vehicle quality.
TIMING:
From production preparation through the life of the part.
REQUIREMENTS:
1. When the part or component is in conformance to current quality requirements an
improvement is desired for the mating parts fit, function, appearance, or workability a
Quality Tuning Request (QTR) will be issued by the NAMC QC/QE.
2. The supplier must investigate the QTR and respond to the NAMC QC/QE by the date
indicated. As applicable, the following information must be included in the response.
a) Accept / Decline requested change
b) If applicable, ECR/ECI number,
c) Tooling cost estimate
d) Piece price change estimate (+/-)
e) Obsolescence/rework cost estimate
f) Implementation plan and date
g) Sample part availability date
h) Production volume implementation date
3. The NAMC QC/QE will review the response and notify the supplier to proceed with the
QTR and as required to provide sample parts for verification and final approval.
4. Sample parts must be verified and submitted with evaluation results as required by
SQAM Section 2.9. The supplier’s verification must include the change portion;
condition before change and after change.
5. The supplier must not implement any permanent changes until all applicable approvals
have been granted:
a) Part Inspection Standard revised (if applicable)
b) Toyota Purchasing approval of tooling, piece price, obsolescence, etc. costs.
c) QTR Approval
6. First parts delivery after QTR implementation must be labeled and identified in
accordance with instructions from the NAMC QC/QE.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
3.2
1 of 2
SECTION 3.2 Quality Tuning Request (QTR)
***** Mass Production *****
FLOW CHART:
Table 3.2 - 1: QTR Issuance and Implementation
SUPPLIER
NAMC QC/QE
1. Issue QTR to supplier
2. Forward a copy to the
NAMC PC Department*
3. Reevaluate QTR with
supplier (as required)
* For Inventory Management
Reject
Reject
1. Review and evaluate the
QTR (accept or reject)
2. Complete the response
section of the QTR form
3. Return to the NAMC
QC/QE by the date
indicated on the QTR
Review suppliers response
Accept
Supplier
Decision
NAMC
Decision
Accept
Implement the QTR change
1. Send copy of the approved QTR
to supplier
2. File original
3. Send copy to Purchasing**
** For information as needed
Produce, evaluate and submit
sample parts to the NAMC QC/QE
ISSUE
4
REVISION
August 2005
-
1. Confirm change
2. File with original
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
3.2
2 of 2
Next Section
SECTION 3.3 – PROCESS CHANGE REQUEST (PCR)
*****MASS PRODUCTION*****
PURPOSE:
To provide advance notification of any change that affects the Toyota
approved part design and quality requirements. This includes both the
supply chain and/or “direct” manufacturing process.
TIMING:
From achievement of QRC through the life of the part.
REQUIREMENTS:
1. The supplier must establish a cross-organizational system that prevents any
negative impact or results to the product design, quality requirements, or
production volume resulting from any changes to the supply chain or
manufacturing process.
2. Process changes are classified as Level I, II, & III based on their potential impact.
These classifications determine the requirements for submission and verification
as shown in Table 3.3-1: PCR Submission Requirement Guidelines. After
reviewing the guidelines, if the supplier is unable to determine the correct level
they must contact the NAMC QC/QE for direction.
3. A two step process is required for all Level I process changes.
Pre-Notification:
Pre-notification with joint (NAMC QC/QE, Supplier and Purchasing as
needed) determination is made for go-and-see verification, quality planning,
sample part submission, sample part testing, process capability studies,
inspection plan verification, and other quality requirements as determined
necessary. Guideline for pre-notice timing completion should be 10 working
days minimum prior to submission of a Process Change Request (PCR).
Process Change Submission:
Completion of PCR requirements, verification of quality requirements, revision
of all related documents, (MQC, Inspection Standards, standardized work
instruction, etc), and implementation and approval of the actual process
change may take anywhere from several weeks to three months or more,
depending on the scope and impact of the process change and related
verification activities.
4. Notification of PCR is through the designated NAMC QC/QE Department, with a
copy being provided to any related NAMC as shown in Flow Chart 3.3-2: PCR
Submission / Approval Process.
ISSUE
4
REVISION
JANUARY 2007
C
TOYOTA MOTOR ENGINEERING &
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SECTION
PAGE
3.3
1 of 4
SECTION 3.3 – PROCESS CHANGE REQUEST (PCR)
*****MASS PRODUCTION*****
5. Toyota Purchasing approval is required for sub-supplier changes (Tier I, Tier II,
etc.) and plant location changes and sub-supplier classification change from “self
procured” to “direct supply” (or reversed). An approved Sub-Supplier / Plant
Location Change Request (SSCR) form must be submitted with the PCR.
6. Mass production volume and quality requirements must be consistently
maintained while gaining PCR approval and implementing the process change.
The establishment of safety stock for the pre-change components / parts may be
required.
7. Notification and approval is not required for Level III process changes.
However, if the supplier forecasts or discovers any impact to quality or
productivity, Toyota must be notified immediately upon discovery. This includes
NAMC QC/QE, Production Control, and/or Purchasing based on the impact of
the issue.
8. Records of all process changes and related information must be maintained and
available for Toyota review upon request.
9. The supplier should reference the Toyota Technical Information Manual (TTIM)
to determine whether an Engineering Change Request (ECR) should be issued
prior to initiating the PCR process.
ISSUE
4
REVISION
JANUARY 2007
C
TOYOTA MOTOR ENGINEERING &
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SECTION
PAGE
3.3
2 of 4
SECTION 3.3 – PROCESS CHANGE REQUEST (PCR)
*****MASS PRODUCTION*****
FLOW CHART(s):
Table 3.3 - 1: PCR Submission Requirement Guideline
LEVEL
ISSUE
CHANGE TYPE / IMPACT
REQUIREMENT
I
• Any change affecting Ñ,Î,Ð and
MVSS parts
• Change of manufacturing location
(new or existing facility)
• Change of sub-supplier
(new or location change)
• Change of material
(supplier, specifications)
• Change of manufacturing method
(new technology, system, method)
• Removal or addition of permanent
inspection process due to technology
advancements
• Change of tool, die, mold, etc.
(modification, repair, type)
• Initial use of new machine
• Toyota ECI affecting performance,
function, durability or reliability
• Toyota Purchasing pre-approval
required (for items in bold text)
• Toyota approval required prior to
implementing any change
• Pre-Notification
• Joint quality assurance planning
including on-site verification (go &
see)
• PCR Submission
• Achievement of Toyota PCR &
SQAM requirements
• Assure that parts meet standard
before, during and after change
• FIFO and traceability of change
part
• Notification of first change part
delivery
II
• Relocation of equipment or process
within supplier facility
• Modification change or repair of machine,
equipment, tool, die, mold, etc.
• Addition or elimination of shift
• Removal of permanent inspection process
• Toyota ECI affecting dimension or
appearance
• Change of sub-supplier classification
(self-procured, direct supply)
• Toyota Purchasing
(approval as applicable)
• Toyota approval prior to change
• PCR Submission
• Achievement of Toyota PCR &
SQAM requirements
• Assure that parts meet standard
before, during and after change
• Internal quality verification and
tracking required
III
• Normal machine repair
• Wear replacement of tool, die, mold, etc.
(replace with expendable, not perishable
tooling)
• Change of cycle time, manpower, staff
• Addition or removal of temporary
inspection
process (does not affect Ñ,Î,Ð or
MVSS
parts)
• Minor day-to-day kaizen activity
• Toyota notification not required
• PCR submission and approval not
required
• Internal quality verification
and tracking required
• Assure that parts meet standard
before, during and after change
4
REVISION
JANUARY 2007
C
TOYOTA MOTOR ENGINEERING &
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SECTION
PAGE
3.3
3 of 4
SECTION 3.3 – PROCESS CHANGE REQUEST (PCR)
*****MASS PRODUCTION*****
PreNotification
STAGE
SUPPLIER
NAMC QC/QE
• Provide pre-notification of the proposed
change with a schedule
• Review the proposed change and
schedule with the supplier and other
related groups and feedback response
NAMC SOP
(C)
Mid-size Trial Production
(Supplier SOP)
(B)
Mid-size Trial Production
Approval
(A)
First Off-Tool Sample
Approval
(P)
Planning Approval
•For sub-supplier changes, submit Subsupplier Change Request to Purchasing
•Decide if changes requires PCR or ECR
(Note: for "gray area" changes of if the
supplier is unsure ,contact TTC Design)
If PCR
If ECR
Contact TTC/
Purchasing
•Prepare plan and submit PCR (App.AB)
with supporting documentation
•Produce and evaluate first off-tool sample
•Cross-check to current part (if applicable)
•Submit PCR with part shipping and NAMC
evaluation dates,ID method, and sign
•Review and issue approval or rejection
•If approved, return approved PCR
indicating implementation requirements
(process audits, sample
submission,meetings,ect.)and authorizing
supplier to continue to next page
PCR
•Evaluate submission package and
approve or reject
•If approved, supplier is authorized to
continue to next page
•Submit sample parts and data package*
•Run mid-size trial production and evaluate
parts
•Submit PCR with part shipping and NAMC
evaluation dates,ID method, and sign
PCR
•Submit sample parts and data package*
•Submit sample parts and data package*
•As negotiated with NAMC PC,stop shipment
of previous component and maintain safety
stock
PCR
Parts
Review
•Evaluate submission package and
approve or reject
•If approved, supplier is authorized
to continue to next page
Parts
•Run Mass Production Parts and confirm they
meet all drawing and Inspection Standard
requirements
•Submit PCR with part shipping and NAMC
evaluation dates,ID method, and sign
Review
Review
•Evaluate submission package
and approve or reject
•Monitor and confirm initial part
quality
* = If required by NAMC QC/QE
ISSUE
4
REVISION
JANUARY 2007
C
TOYOTA MOTOR ENGINEERING &
MANUFACTURING NORTH AMERICA
SECTION
PAGE
3.3
4 of 4
SECTION 3.4 – FIELD QUALITY IMPROVEMENT
***** MASS PRODUCTION *****
PURPOSE: Defines the methods to be utilized by suppliers to improve the quality of supplied
warrantable parts / components based on customer / field feedback.
TIMING:
From mass production release through the life of the part.
REQUIREMENTS:
Field Quality Problems:
1. A Field Quality Problem Report (FQPR) may be issued by the NAMC QC/QE
to communicate customer / field quality issues.
Note: Related warranty parts may be returned to the supplier for use during problem
solving.
2. The supplier is required to respond with their initial analysis results and
countermeasure proposal within the timeframe indicated on the FQPR.
3. The NAMC QC/QE will review the FQPR response:
•
If acceptable, the FQPR will be returned to the supplier as approved
•
If unacceptable, the FQPR will be returned to the supplier with a request
to resubmit with an approved countermeasure plan.
4. The supplier must implement their countermeasure plans and report the results
to the NAMC QC/QE.
5. The FQPR will be closed when the countermeasure can be confirmed by the
NAMC QC/QE.
Warranty Return Parts:
1. The supplier may request warranty return parts that they originally supplied by
submitting a Warranty Return Parts Request (WRPR) form to TMMNA Quality
Division / Warranty Administration.
Note: Toyota may decide to provide warranty return parts without a request.
2. Suppliers are required to analyze all warranty return parts and:
•
Report the results to the applicable NAMC QC/QE
•
Propose countermeasure
•
Implement countermeasure
•
Confirm countermeasure effectiveness
3. Suppliers must ensure that the appropriate contact person for warranty return
parts has been entered into the CCI database located on Toyotasupplier.com.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
3.4
1 of 2
SECTION 3.4 – FIELD QUALITY IMPROVEMENT
***** MASS PRODUCTION *****
Warranty Claim Information:
1. Suppliers are required to monitor their warranty performance monthly via the
Supplier Quality Information Delivery System (SQIDS) located on
Toyotasupplier.com.
2. If the supplier detects any potentially significant product concerns through review
of SQIDS data, they should contact the appropriate NAMC QC/QE to discuss
necessary action (regardless of whether the potential cause is supplier or
Toyota).
3. Quality improvement activities must be initiated based on warranty information
trends and analysis results.
4. Suppliers must ensure that the appropriate contact person for SQIDs has been
entered into the CCI database located on Toyotasupplier.com.
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
MotorMANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
3.4
2 of 2
Next Section
SECTION 4.0 – ACRONYMS
***** APPENDIX *****
Acronym
Initial Description(s)
AIAG
C/M
CAPTIN
CPS
CSP
DFMEA
DRBFM
ECI
ECR
FA
FQPR
GRR
HVPT
ICF
ISO
MQC
MVSS
NAMC
Automotive Industry Action Group
Countermeasure
Canadian Autoparts Toyota Inc.
Centralized Purchasing System
Controlled Self Procurement
Design Failure Mode and Effects Analysis
Design Review Based on Failure Modes
Engineering Change Instruction
Engineering Change Request
Final Approval
Field Quality Problem Report
Gage Repeatability and Reproducibility
High Volume Production Trial
Inspection Control Function
International Organization for Standardization
Manufacturing Quality Chart
Motor Vehicle Safety Standard
(Toyota) North American Manufacturing Company
(TMMK, TMMC, NUMMI, TMMI, TMMBC, TMMTX,
TMMWV, TMMAL, TABC, CAPTIN, Bodine)
NUMMI
New United Motor Manufacturing, Inc.
PA
Part Approval
PCR
Process Change Request
PFMEA
Process Failure Mode and Effects Analysis
PFS
Problem Follow Sheet
PRC
Production Readiness Confirmation
QCMS
Quality Chain Management System
QC/QE
Quality Control/Quality Engineering
QCS
Quality Confirmation Stage
QIR
Quality Improvement Request
QPR
Quality Problem Report
QRC
Quality Readiness Check sheet
QS 9000 / TS16949 Quality System (AIAG - Automotive Industry Specific
Requirements)
QTR
Quality Tuning Request
SE
Simultaneous Engineering
SEPM
Supplier Enhancement Project Management
SOP
Start of Production
SPMP
Supplier Parts Master Plan
SQAM
Supplier Quality Assurance Manual
SQCS
Supplier Quality Confirmation Stage
TABC
Toyota Auto Body Inc
TCI
Toyota Canada Inc
ISSUE
4
REVISION
August 2005
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
4.0
1 of 2
SECTION 4.0 – ACRONYMS
***** APPENDIX *****
TEMA
TTC
TOC
TPC
TMC
TMMAL
TMMBC
TMMC
TMMI
TMMK
TMMNA (QD)
TMMTX
TMMWV
TMS
TPMS
ISSUE
4
REVISION
August 2005
-
Toyota Motor Engineering and Manufacturing North
America
Toyota Technical Center
Toyota Operations Center
Toyota Planning Center
Toyota Motor Corporation
Toyota Motor Manufacturing, Alabama, Inc.
Toyota Motor Manufacturing de Baja California, S.
de R. L. de C. V.
Toyota Motor Manufacturing Canada
Toyota Motor Manufacturing Indiana
Toyota Motor Manufacturing Kentucky, Inc.
Toyota Motor Manufacturing North America, Inc.
(Quality Division)
Toyota Motor Manufacturing Texas
Toyota Motor Manufacturing West Virginia
Toyota Motor Sales
Toyota Parts Master Schedule
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
4.0
2 of 2
Next Section
SECTION 4.1 – SYMBOLS
***** APPENDIX *****
Description
Symbol
ISSUE
4
REVISION
August 2005
=
=
=
=
=
=
=
Safety Standard
Regulation Item
Emission Standard
Japan Export Regulations
Federal Motor Vehicle Safety Standards
Canadian Motor Vehicle Safety Standards
Purchased (out of house) stamped parts
X
=
Installation of measured or certified parts to a shell
body to identify or confirm body problems
-
TOYOTA
MOTOR
Toyota
Motor MANUFACTURING
Engineering &
NORTH AMERICA,
INC.
Manufacturing
North America
SECTION
PAGE
4.1
1 of 1
Next Section