PITTSBURGH GLASS WORKS. LLC.
30 ISABELLA STREET, SUITE 500
PITTSBURGH, PA 15212
WWW.PGWGLASS.COM
Supplier Quality Manual
QA1.OEM.00.03
Revision 6
Revised: November 2015
The purpose of this document is to communicate Pittsburgh Glass Works’ (PGW) Quality
Management Systems requirements to those companies that supply parts and services to
PGW.
Table of Contents
1. Quality Systems Requirements
1.1
Quality System Registration
1.2
Quality System Audit
2. Purchasing Requirements
2.1
Supplier Quotations and Background Information
2.2
Competitive Pricing / Payment
2.3
On-Time Delivery
2.4
Incoming Quality Methods
Manufactured Parts and Chemicals & Compounds
3.
4.
2.5
Suppliers Premises Inspection
2.6
Tooling
2.7
Packaging
2.8
Environmental, Health and Safety Requirements
2.9
“End of Life” (ELV) Regulations and IMDS
2.10
Contingency Plan / Risk Assessment
Supplier Performance
3.1
Supplier Measurement
3.2
Supplier Non-Conformance Notice (SNN)
3.3
Parts Certification Process for Defective Product
3.4
Continuous Improvement/VAVE (Value Add-Value Engineering)
Quality Requirements for OEM Programs
4.1
Launch Support
4.2
FMEAs
4.3
Control Plan
4.4
Engineering Change and / or Manufacturing Change
4.5
Product Validation
4.6
Process Capability Studies
4.7
Sample Submissions
4.8
Prototype / Pre-production Parts
4.9
Production Process Audit
4.10
Production Part Approval Process (PPAP)
Appendix A –Supplier Quality Forms
Appendix B – Revision Record
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I – Quality System Requirements
The purpose of this document is to communicate Pittsburgh Glass Works’ (PGW)
quality management systems requirements to those companies that supply parts and
services to PGW. The basis for PGW’s Supplier Quality Manual is the Quality System
Requirement ISO/TS16949 as the framework for the basic quality systems required for
all suppliers of parts and services.
1.1
Quality Registration
PGW is committed to providing products and services to our customers that fully meet
their present and future requirements. PGW’s suppliers are a critical strategic resource
in meeting this customer commitment. PGW requires suppliers to have an effective
Quality System. ISO/TS16949 requirements are an integral aspect of PGW’s purchase
order.
PGW requires that the supplier:





1.2
Manage facilities, processes, quality systems and personnel to consistently and
cost effectively produce product and furnish services that meet the needs of
PGW and its customers.
Develop, implement, document and maintain a Product Quality Planning process
to assure that product and service requirements are met.
Provide PGW and our customers, objective evidence that products sold meet all
defined and agreed on requirements; as well as implied functionally
requirements.
Meet PGW and PGW customer specific requirements (examples CQI audits,
Chrysler Elements of Manufacturing audits, etc.).
Be committed to continuous process improvement by emphasizing reduction of
part-to-part variation and waste through defect prevention.
Quality System Audit
The Quality System Audit consists of a visit to a specific supplier’s production site. This
is normally completed in one to two days. PGW will use a PGW Quality Management
System audit, ISO/TS 16949 quality systems audit or VDA 6.3 process audit. At the
discretion of PGW, designated potential suppliers be subject to an on-site audit by
Purchasing and/or Supplier Quality. The supplier audit is intended to help further the
supplier’s awareness of PGW’s quality requirements. It is also intended to verify that the
supplier has an adequate quality process and to confirm that it is functioning properly.
A formal response and follow-up action for all significant elements identified as needing
improvement during the audit is required on a timely basis. In some cases, adherence
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to a recognized standard such as ISO/TS 16949 or ISO 9001:2008 may eliminate the
need for all or part of a formal on-site audit by PGW. At PGW’s discretion, a full quality
system audit may be required.
PGW requires the following:
Suppliers to PGW’s ISO/TS 16949 registered facilities are encouraged to achieve
compliance to ISO/TS 16949; at minimum suppliers must achieve third party registration
to ISO 9001:2008, plus any requirements specified by PGW and our customers. Any
critical supplier who has not yet achieved third party registration shall have their QMS
reviewed by PGW annually.
Supplier assessments to ISO/TS 16949 and/or ISO 9001:2008 by the OEM Customer,
an OEM Customer-approved second party or an accredited third party registrar will be
recognized by PGW as supplier quality audits.
2. PURCHASING REQUIREMENTS
2.1
Supplier Quotation and Background Information
PGW requires new suppliers to complete the Supplier Qualification Background
Information form (QA4.SQM.01.02).In addition to this form, we also require a copy of
the Supplier’s Quality Policy, Organization Chart, and TS/ISO 16949 (or equivalent
certification)-In order for PGW to assess business risk, PGW may request financial
information to better understand that potential risk. Cooperation is mandatory and all
information provided by you will be held strictly confidential within PGW. If necessary, a
NDA (Non-Disclosure Agreement) would be executed.
All quotations for new business and proposed changes must be submitted to the PGW
Purchasing Manager and include detailed breakdowns for part cost, tooling cost and
delivery lead-times (minimum requirements). All supplier quotations must be submitted
on PGW forms or through PGW’s requested submission method.
2.2
Competitive Pricing / Payment
Suppliers are expected to be globally competitive and will be benchmarked by PGW
Purchasing Managers. PGW expects its suppliers to continually strive for increased
efficiency, and cost reductions in their processes in order to meet PGW’s customer’s
annual cost reduction initiatives. Refer to Section 3.4 Continuous Improvement for more
details on submitting your improvement opportunities.
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Payment terms are Net 60 days. All invoices, packing slips and correspondence must
reference PGW’s individual purchase order number, line item number, storeroom part
number, and releasers name, (if applicable).
Excessive or premium freight charges related to a PGW expediting requirement are to
be detailed in a separate line item on the supplier's invoice and previously approved by
PGW personnel. Excessive or premium freight costs related to the supplier’s issue and
necessary to meet the PGW delivery date will be at the supplier’s expense. The supplier
will be required to submit a premium freight report covering all excessive or premium
costs as requested by PGW.
PGW reserves the right to audit supplier's invoicing against agreed to pricing.
2.3
On-Time Delivery
All deliveries of requested materials will be made to the facility receiving dock and the
packing list will refer to the purchase order number, release number, line item number
and storeroom part number (if applicable) and releaser's name (if applicable).
100% on time full shipment deliveries are required. Supplier is expected to maintain, at
his own discretion, sufficient stock to achieve and maintain specified delivery, back
orders are not acceptable. Delivery lead times quoted by the supplier are as important
as price to PGW Deliveries made against releases are to be unloaded only at the
PGW's facility. Requests for deliveries elsewhere are to be approved in writing by
purchasing.
2.4
Incoming Quality Methods
Manufactured Parts:
Typically parts are received by PGW facilities utilizing the supplier’s TS16949, ISO
9000, or other recognized quality system certification. However, SPC data showing
process capability of Key Product Characteristics (KPC) may be required to accompany
each lot if the supplier is not certified to a recognized quality standard or it is requested
by the PGW Facility Quality Representative. The minimum acceptable long term CPK
value for KPC’s is 1.33.
Chemicals & Compounds:
A certificate of analysis or compliance must be sent with each shipment, each lot or
upon request to the PGW Facility Quality Representative. The certificates must show
any testing performed the acceptance criteria, and results.
2.5
Supplier Premises Inspection
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PGW, or PGW’s customer, reserves the right to perform inspections at the supplier’s
facility, and expedite material or product from the supplier’s facility when necessary. All
materials or services are subject to final inspection and acceptance by PGW at
destination, notwithstanding any prior payment or inspection at seller's source and
inspection shall be made within a reasonable time after delivery or completion of work.
2.6
Tooling
All PGW and customer-owned tooling must be identified with the owner’s name and
other information as required by PGW or our customer. Maintenance and refurbishing
of the tooling required to meet product requirements, shall be the sole financial
responsibility of the supplier, without liens being attached for any reason. The supplier
is prohibited from using this tooling to make any product for any company except for the
owner or its representative without written authorization from PGW.
2.7
Packaging / Labeling
PGW and supplier shall agree upon the packaging plan prior to PPAP approval All
packaging units shall be labeled with AIAG or equivalent format barcode label including
PGW’s purchase order number, storeroom part number, quantity, lot number,
manufacturing date, expiration date (if applicable) and supplier name (minimum
requirements). All unique parts must be shipped in separate packaging units and shall
not be mixed with other unique parts. These parts must be clearly marked utilizing
identification labels for unique materials PGW Identification Label for Unique Materials
(QA4.SQM.01.28).
The PGW Packaging Proposal Form (QA4.SQM.01.27) must be sent to Supplier Quality
for approval at the using PGW plant prior to PPAP approval with consensus of the PGW
using plant, no later than the submission of the PPAP package.
2.8
Environmental, Health, and Safety Requirements
Supplier must be in compliance with all federal and state policies as outlined in PGW’s
Purchase Order General Terms and Conditions as well government regulations in the
country of manufacture or sale. PGW encourages registration to ISO 14001.
2.9
“End of Life” (ELV), REACH Regulations and IMDS
The European Union (EU) introduced regulations, effective in 2003, to control the
design and recyclability of automobiles. This Directive, called End of Life Vehicle (ELV)
prohibits the use of lead, mercury, cadmium and hexavalent chromium in any
component of automobiles placed on the market after July 1, 2003. These regulations
apply only to cars and light commercial vehicles (<3.5 tonne gross weight) sold in
Europe. Since PGW and our suppliers are part of a long supply chain, our products
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sold to a customer in the USA may become part of an automobile sold in Europe.
Additionally, similar regulations are proposed in Japan and other parts of the world – so
it is probable for you as a supplier to get various requests related to end-of-life
requirements.
All suppliers must comply with the new EU REACH chemicals regulation (Reg. (EC)
No1907/2006). REACH is a new European Community Regulation on chemicals and
their safe use. It deals with the Registration, Evaluation, Authorization and Restriction of
Chemical substances. Manufacturers and importers will be required to gather
information on the properties of their chemical substances, which will allow their safe
handling, and to register the information in a central database run by the European
Chemicals Agency (ECHA) in Helsinki. PGW will require your assistance in using only
REACH materials in your products.
In addition, PGW requires that all suppliers submit to IMDS (International Material Data
System) at the website http://www.mdsystem.com/ to the Pittsburgh Glass Works ID
93347. All new parts and any Engineering changes require a new IMDS submission.
2.10
Contingency Plan / Risk Assessment
Suppliers shall develop a Disaster Recovery Plan for potential catastrophes or work
interruption that would jeopardize the supply of product to PGW. This Disaster Recovery
Plan shall include at a minimum: material, transportation, computer, sub-supplier, utility
disruptions, labor disruptions, key equipment failures and field return contingency plans.
Supplier must immediately notify PGW of the course of action during this period as well
as the chain of command contacts.
If organized labor is used at the facility, PGW must be notified 6 months prior to the end
of the term of the labor agreement. Six months prior to the term of the labor contract
your contingency plan must be reviewed with PGW Purchasing to ensure plant
operations are secure and adequate safety stocks of quality certified material are
available. Your plan must ensure safe secure transportation into and out of your facility
PGW requires you to develop a supplier risk management process which identifies
financial and operational supply chain risks, and pro-actively develops strategies and
contingency plans to avoid disruptions. This process should be an on-going monitoring
of suppliers to identify potential "at-risk" suppliers and allow for proper intervention
strategies. If contingency plans are required, the situation should be shared
immediately with the PGW Purchasing. Managing the total supply chain is critical to our
collective success.
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3. SUPPLIER PERFORMANCE
3.1.
Supplier Measurement
Supplier performance measurement is an important function in PGW’s quality process.
PGW evaluates suppliers through PGW’s Supplier Performance Reports. Suppliers
identified by PGW as critical suppliers will receive Supplier Performance Reports on a
monthly basis. Supplier Performance Reports will be used to provide feedback to key
suppliers and identify areas of opportunity for PGW and suppliers to continuously
improve. These reports will also be used for Supplier Selection and Supplier
Recognition .Input to this measurement process includes data from our quality and
logistics departments.
Quality Performance is provided in the form of reject PPM’s (Parts/Million units
received), and SNN’s (Supplier Nonconformance Notices). SNN’s are evaluated as
incidents/1000 receipts.
Delivery performance will be measured by a Fill Rate metric. Each line item on a
purchase order (PO) will receive a score of “one” or “zero”. A score of “one” is applied if
the line item is received by or before the agreed to lead time AND in full quantity.
Otherwise the score for a given line is “zero”. The Fill Rate Performance is the average
of the scores for all PO lines in a given period.
The Performance areas, targets and scoring process are summarized below.
Performance
Area
PPM
Target
Rating
0 – 100
A
B
C
A
B
C
A
B
C
101 - 150
151 or more
0-25
SNN/1000 receipts
26-50
Greater than 50
Fill Rate
(On Quantity + On
Time Delivery)
90%to 100%
80% to 89%
Less than 80%
Points
5
3
0
5
3
0
5
3
0
Perf.
Weight
20%
40%
40%
Score
1.0
0.6
0
2.0
1.2
0
2.0
1.2
0
A total score will be compiled by multiplying the point score in each performance area
times the performance weighting. The supplier’s total score is the sum of the scores for
PPM, SNN and Line fill rate. Total scores will be rated as follows:
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Status Total Score
A
4.0 to 5.0
B
2.0 to 3.9
C
0 to 1.9
Status
Acceptable/Grow business
Monitor and Potential Corrective
Action Plan, Develop to “A” Status
Implement Corrective Action
Suppliers with continued “C” rated or “Red” status for total score will be placed on a
formal “Supplier Performance Improvement Plan.” Plans will be submitted to Corporate
Supplier Quality and your Purchasing representative within two (2) weeks of receiving
notification of unacceptable Performance Status. Please recognize red status can
impact your sourcing status with PGW. Consistent poor performance can lead to “new
business hold” and/or disqualification of the supplier.
Suppliers who have one or more of the following:
1. Corrective action for six (6) consecutive months
2. Major spill
3. Reoccurring quality issues
4. Showing no improvement
The supplier must prepare a detailed presentation to present to PGW Executive
Management at a chosen PGW site. Supplier may also be requested to present for
other reasons than stated above at the discretion of PGW Purchasing and SQ. Based
on results, PGW Purchasing may begin reviewing the process to start resourcing
product/service.
3.2
Supplier Non-Conformance Notice (SNN)
If PGW receives a product or service from a supplier that does not meet requirements
and it is deemed to be non-conforming by the PGW receiving location, a Supplier NonConformance Notice (SNN) will be issued. SNN requires the supplier to immediately
contain suspect product and to complete an initial response using PGW corrective
action form or supplier’s equivalent form within 24 hours. Full root cause explanation,
investigation, correction verification and prevention must be submitted to PGW within 15
calendar days.
Prevention or Verification plans that require an extension are to be requested from the
supplier to the PGW SNN issuing plant PGW could conduct an on-site SNN audit or
require that the supplier do so and submit to PGW.
Supplier is required to organize the transport or inspection of the non-conforming parts
on-site within 14 days. If arrangements are not made within these 14 days parts will be
scrapped at the supplier’s cost.
3.3
Part Certification & Containment
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If PGW determines an incoming quality issue, or potential issue, poses a significant risk
to PGW manufacturing plants or our end customer, PGW may initiate containment
activities.
1. CS1 or GP-12 type containment requires the supplier conduct self-certification of
product at the supplier location as directed by PGW. The supplier is responsible for all
costs associated with the certification.
2. CS2 type containment requires an independent 3rd-Party certification of the product
utilizing PGW approved inspectors. At PGW’s discretion, this certification may be
conducted at the supplier location, the PGW receiving location, or an off-location site.
The supplier shall manage the containment including contracting of the 3rd party; and
provision of any necessary 3rd party defect acceptance training, work instructions,
visual aids, daily inspection results reporting, etc. The supplier is responsible for all
costs associated with the certification.
3. Certified containers will be conspicuously marked to denote the parts they contain
have been certified. In some situations, PGW may require that each part be marked
and will provide direction so that the part marking is acceptable to the PGW
manufacturing plant and end customer.
PGW Supplier Quality shall exit the supplier from the containment process.
3.4.
Continuous Improvement/VAVE (Value Add-Value Engineering)
PGW works to reduce costs through the effective use of the Quality Process. Suppliers
are challenged to implement annual value-added cost saving proposals equaling at
least five percent, or higher, as dictated by PGW’s business needs. The goal is based
on the supplier’s total company global annual sales to PGW.
PGW expects all suppliers to submit proposals to PGW Purchasing that will result in
significant, measurable cost reductions, including those that challenge traditional
thinking. These savings opportunities are designed to achieve added value and to
reduce costs for both PGW and the supplier. Although these savings opportunities
include direct (bottom line effect) and indirect value propositions, emphasis should be
placed on those opportunities where direct savings can be realized.
4. Quality Requirements for OEM Programs
4.1
Launch Support
PGW requires the supplier to commit to the following:
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PGW requires that the supplier reviews the risks associated with the new product
introduction and establish launch plans and risk analysis for the new product.
The supplier also is required to establish an internal cross-functional team that
coordinates their APQP activity and creates product launch timelines, with periodic
reviews, which are available to PGW upon request. Activities should be based on the
AIAG APQP manual and using PGW APQP Tracker (QA4.SQM.01.29) tool.
The supplier is required to maintain an Open Issues list to track open issues from
inception to completion/resolution. This is a living document that the supplier’s team
reviews to keep a pulse on the progress of the launch.
PGW actively supports launch activities at their customer facilities. The supplier is
expected to provide launch support at either the PGW facility or the PGW customer
facility.
Provide data as evidence initial sample requirements have been met and that
acceptable process capabilities for all key characteristics have been established.
The supplier must submit a PPAP to PGW prior to shipping any series production
product. PPAPs may not be required for production samples depending on intended
use, at the direction of PGW Supplier Quality. FMEA’s, Control Plans, and other quality
documentation shall be on the AIAG latest revision forms.
All documentation must be provided in English. Failure to do so will result in
rejection of PPAP and potential delay of launch which could have financial effect
on supplier.
4.2
Failure Modes Effects Analysis (FMEA)
Design FMEA:
For product design responsible suppliers, a DFMEA is required as an analytical
technique to assure that potential design failure modes and their associated causes
have been considered and addressed to the extent possible. The DFMEA should be a
catalyst to stimulate the interchange of ideas within a cross-functional team.
The DFMEA is a living document and should be initiated before or at the design concept
finalization, be continually updated as changes occur or additional information is
obtained throughout the phases of product development, and be fundamentally
completed before the production drawings are released for tooling.
Process FMEA:
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The Process Failure Modes Effects Analysis an analytical technique utilized by a
manufacturing responsible supplier to assure that potential process failure modes and
their associated causes have been considered and addressed to the extent possible. In
its most rigorous form, a PFMEA is a summary of the engineer’s or team’s concerns as
a process is developed.
The PFMEA is a living document and should be initiated before or at the feasibility
stage, prior to tooling for production, and take into account all manufacturing operations.
Early review and analysis of new or revised process is promoted to anticipate, resolve
or monitor potential process concerns during the manufacturing planning stages of a
new model or component program.
Each PFMEA shall include a revision block to document changes and additions. The
revision block shall cross reference revisions made to address PGW issued SNN’s
A Process FMEA is a required document needed for PPAP submission
4.3
Control Plan
The Control Plan (CP) defines how to control / monitor the process and product to
ensure final product quality. The CP provides a structured approach in the
manufacturing process to consistently produce quality products according to customer
requirements. The CP details the actions that are required at each phase of the
process. During regular production runs, the CP provides the process monitoring and
control methods that would be used to control key product or key process
characteristics. Since processes are expected to be continually updated and improved,
the CP reflects a strategy that is responsive to capturing these changing conditions by
reflecting the current methods of control and measurement systems used. The CP is
updated as measurement systems and control methods re-evaluated and improved.
Each CP shall include a revision block to document changes and additions. The
revision block shall cross reference revisions made to address PGW issued SNN’s.
PGW will approve/request changes to CP as part of PPAP submission/approval process
4.4
Engineering Change and / or Manufacturing Change
The supplier must have a system in place for the control and tracking of engineering
and manufacturing changes. An Engineering Change Log showing the history of
engineering changes must be maintained by the supplier. The Log must be made
available upon request by PGW Supplier Quality.
Engineering Changes:
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The PGW Program Manager will notify the supplier in writing via a PGW ECR/ECN
when an engineering change to the product being supplied is required. Prior to
implementation of the engineering change, the supplier is responsible for updating all
quality planning documents, inspection standards and checking fixtures to reflect the
new engineering change. PGW will require sample parts before the conversion to the
new engineering change as well as a new PPAP submission. Any additional
requirements will be communicated by PGW Supplier Quality.
Engineering changes must be incorporated in a timely manner, in accordance with the
instructions from PGW. All product shipped to PGW must be clearly marked with the
engineering change level and notification to PGW receiving plant prior to delivery.
Manufacturing Changes:
The supplier is expected to notify PGW Supplier Quality and Purchasing in advance of
any planned manufacturing process or product changes. The notification must be made
using the Supplier Request for Change Form (QA4.SQM.01.12). These changes
include, but are not limited to:





Product material changes or changes in product material suppliers
New or revised production tooling
New or upgraded production processes
Movement of product to a different production operation
Product design changes
PGW will review the proposed change and request samples for evaluation. Depending
on the extent of the manufacturing change, PGW may also request:




FMEA and Control Plan
Product Validation Test Plan
Capability analysis
PPAP submission
In all cases, the supplier is not to ship production quantities of the product produced
under the manufacturing change conditions until PGW has validated that the product
does not adversely affect overall product performance.
4.5
Product Validation
Product Validation refers to the development and successful completion of engineering
tests that validate products made from production tools and processes meet all
functional and reliability criteria. The Product Validation Test Plan itemizes the test
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description, acceptance criteria, test responsibility, sample size and timing
requirements.
Reliability of the product is paramount to the success of the overall program. PGW will
review and approve the Product Validation Test Plan for appropriateness of the planned
tests and the successful completion of the tests. This can be completed during PPAP,
Run at Rate, Production Process Audit or by way of other means deemed appropriate
by PGW Supplier Quality. The suggested format is shown on the Product Validation
Test Plan (QA4.SQM.01.09).
4.6
Process Capability Studies
Acceptable process capability is achieved through the study and control of key process
parameters (e.g. temperature, pressure, weight, resistance, etc.). Process capability
studies are required by PGW for all KPC (Key Product Characteristics) identified.
Process Capability Requirements are as follows:
Expectation
Process Capability
If Expectation is not met
and one or more parts
are beyond specification.
4.7
Short Term (30-50 pcs)
Stable
Cpk > 1.67
 100% inspection
 contact SQ
 Provide Corrective
Action
Long Term (300 pcs)
Stable
Cpk > 1.33
 100% inspection
 contact SQ
 Provide Corrective
Action
Sample Submissions
Sample submissions to PGW, other than PPAP samples will be guided by the PGW
Program Manager or PGW Plant Development Team leader. PPAP sample
submissions will be dictated by PGW Supplier Quality. The default number of PPAP
samples is five (5) pieces.
4.8
Prototype / Pre-production Parts
PGW requires each supplier to submit with each shipment prior to PPAP approval PGW
Prototype/Pre-Production Part Certification Form (QA4.SQM.01.23). This process has
been established to assure raw material and purchased components, meet dimensional
and functional requirements at the earliest stages of the launch. It is the responsibility of
all PGW suppliers to provide products, which meets dimensional, functional and
material requirements.
Any deviations, which do not meet design intent, must be clearly identified and
addressed on Prototype/Pre-Production Part Certification Corrective Action Plan
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(QA4.SQM.01.23 PGW) and sent to PGW using plant and PGW Supplier Quality for
review. Corrective Action Plan will be review by PGW team and direction will be given to
the supplier from the PGW using plant or PGW Supplier Quality. If the supplier provides
multiple submissions from a single fabrication run, PGW expects each separate
shipment will be documented in compliance with this procedure.
For each Prototype or Pre-Production Part Submission, PGW requires that 3 (three)
parts be certified by documenting measurements to all dimensional, material, and
functional characteristics on the part drawing.
The three (3) certified parts shall be packaged separately from the remaining parts
provided and sent to the PGW using plant with this submission.
These parts will not be utilized for PGW part submission, but will be maintained for
future review should questions arise regarding their compliance to design. This will aid
in any discussion or review that may be necessary with the supplier.
Note: If parts are produced in a multi-cavity operation, one (1) sample from each cavity
must be measured, documented and submitted to PGW. Example: Part XYZ produced
in a four (4)-cavity mold, therefore, 12 parts (3/cavity) are to be measured.
4.9
Production Process Audit & Run-at-Rate
The Production Process Audit is a systematic review of the supplier’s manufacturing
process prior to launch to verify the supplier’s production readiness.
The Production Process Audit will be conducted in advance of the Production Part
Approval Process (PPAP) submission at the discretion of PGW Supplier Quality. If
necessary, PGW Supplier Quality will visit the supplier’s facility to insure that PGW
requirements are clearly understood and activities will be put in place to comply with
requirements
A run at rate trial may be required to be completed on the supplier’s process. This run
at rate trial is a check to see if the production process can make enough good parts to
satisfy both PGW’s required peak demand and also a demand equal to 20% greater
than peak demand. The Run at Rate Verification Form (QA4.SQM.01.24) can be used
to document the trial. Run at Rate verification may not be required in situation where
supplier’s monthly production capacity is higher than PGW’s annual orders.
4.10
Production Part Approval Process (PPAP)
The default PPAP submission will be level 3 unless otherwise dictated by PGW and
shall be submitted 4 weeks prior to the PGW customer PPAP date. PPAP submission
requirements are dictated by PGW and can be changed (in agreement with supplier) to
meet particular requirements of a program. The PPAP will be comprised of those
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elements listed in the latest edition of the AIAG PPAP manual and other requirements
(see listed below).
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









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Part Submission Warrant (AIAG CFG 1001) - AIAG
Design Records, e.g. part print. –AIAG, PGW Drawing
Engineering Change documents, if any - AIAG
DFMEA, if applicable - AIAG
Process Flow Diagram - AIAG
PFMEA - AIAG
Control Plan (Pre-Launch and Production) -- AIAG
Dimensional Results - AIAG
Material Test Results - AIAG
Performance Test Results - AIAG
Supplier TS or ISO Certification - AIAG
IMDS - AIAG
Product Validation Results, if applicable - AIAG
Initial Process Study - AIAG
Measurement System Analysis Studies - AIAG
Qualified Laboratory Documentation - AIAG
Appearance Approval Report, if applicable - AIAG
Sub-supplier PSW – PGW specific
Delivery certificate, if applicable – PGW specific
Run at Rate Verification Form - PGW specific
Packaging Approval – PGW specific
Regrind Certification Letter, if applicable – PGW requirement for plastic parts
Sample product – AIAG, to be kept at supplier, unless otherwise noted by PGW
SQ Master Sample – AIAG, to be kept at supplier
Checking Aids – AIAG, to be kept at supplier
4.10.1 Bulk Material Suppliers
Suppliers of Bulk Materials to PGW must submit to SQ a Level 4 PPAP
with IMDS data and performance/material testing (when applicable) for
review/approval as well as supply PGW using plants ongoing Certificate Of
Analysis (COA) with each shipment of product.
Bulk Material suppliers shall determine PPAP requirements at sub-supplier
or at a minimum require COA which is to be retained at bulk material
supplier and available at PGW request.
PGW Engineering, Purchasing or using plant may request samples to
conduct trial runs and conduct testing prior to PPAP submission or
approval.
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The following publications are available from the Automotive Industry Action Group
(AIAG) at www.aiag.org. These documents contain additional reference information for
suppliers to PGW:








Quality System Requirements ISO 9001:2008
ISO/TS 16949 Technical Specification
Production Part Approval Process (PPAP)
Advanced Product Quality Planning and Control Plan Reference Manual (APQP)
Potential Failure Modes and Effects Analysis Reference Manual (FMEA)
Measurement Systems Analysis Reference Manual (MSA)
Fundamental Statistical Process Control Reference Manual (SPC)
Customer Specified Requirements
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Appendix A – Supplier Quality Forms
Reviewing the checklist items will help assure that the APQP requirements have been
completed to the satisfaction of both the supplier and PGW. PGW recommends that the format
of the quality planning documents follow the AIAG standards. However, a well-documented
system created by the supplier can be used if found acceptable by the PGW team.
SUPPLIER QUALITY FORMS
Document No.
Document Name
Revised
CFG-1001
SA 0100
Part Submission Warrant
Supplier Alert Form (Issued by PGW)
QA4.OEM.14.01
Supplier Nonconformance Notice (SNN) (Issued by PGW)
30-Oct-14
QA4.SQM.01.01
QA4.SQM.01.02
QA4.SQM.01.03
Supplier Quality System Audit Worksheet
PGW Supplier Qualification Background Information Form
Tool Progress Report
3-Jun-15
13-May-11
7-Apr-09
QA4.SQM.01.04
QA4.SQM.01.05
QA4.SQM.01.06
Design FMEA Form
Design FMEA Checklist
Product Inspection Standard Form
7-Apr-09
7-Apr-09
7-Apr-09
QA4.SQM.01.07
QA4.SQM.01.08
QA4.SQM.01.09
Process FMEA Form
Process FMEA Checklist
Product Validation Test Plan for Suppliers Form
7-Apr-09
7-Apr-09
7-Apr-09
QA4.SQM.01.10
QA4.SQM.01.11
Defective Part Certification Control Letter
Engineering Change Log
7-Apr-09
7-Apr-09
QA4.SQM.01.12
Supplier Request for Change Form
7-Apr-09
QA4.SQM.01.13
QA4.SQM.01.14
QA4.SQM.01.15
QA4.SQM.01.16
Sample Submission Checklist
Measurement Result Sheet Form
Design Information Checklist
Product Validation Plan Checklist
7-Apr-09
7-Apr-09
7-Apr-09
7-Apr-09
QA4.SQM.01.17
Control Plan Form
7-Apr-09
QA4.SQM.01.18
QA4.SQM.01.19
Product/Process Quality Checklist
Production Process Audit Checklist
7-Apr-09
7-Apr-09
QA4.SQM.01.20
QA4.SQM.01.23
Process Flow Diagram
PGW Prototype/Pre-Production Part Certification Form
7-Apr-09
4-Jun-14
QA4.SQM.01.24
Run at Rate Verification Form
7-Apr-09
QA4.SQM.01.25
Regrind Certification Letter
7-Apr-09
QA4.SQM.01.26
QA4.SQM.01.27
PPAP Checklist
PGW Packaging Proposal
7-Apr-09
7-Apr-09
QA4.SQM.01.28
QA4.SQM.01.29
PGW Identification Label for Unique Materials
APQP Tracking Form
4-Jun-14
4-Jun-14
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7-Apr-09
7-Apr-09
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QA4.SQM.01.30
New Supplier Selection Form
2-Nov-15
Appendix B – Revision Record
REVISION RECORD
Date
Revision Comments
7-Mar-01
B. Loftus
C. LaRocque
B. Loftus
A. Eckstein
3-Mar-06
Added "including a Part Submission Warrant form"
to Engineering Change section; removed Approval
Request Form and Sample Submission Summary
Form.
Added Defective Parts Certification Process and
accompanying Defective Part Certification Control
(DPCC) letter.
Major Revision
C. Adsit
7-Apr-09
Major Revision
Jan 2011
Added Honda change requirements, added PGW
IMDS #, added annual assessment for noncertified critical suppliers, added contingency plan
requirements, added level 3 PPAP.
Complete rewrite and reorganized
C. Fusko,
E. Treat
J. Slanga
E. Treat
Steve Taylor
R. Corliss
A. Eckstein,
C.Siess
B. Miller, C.Siess
04-Jun-14
2.2 Removed “2% Net 10”
2.7 Added QA4.SQM.01.28
3.1 Updated targets and weights, added onsite
executive management presentation
3.2 Added supplier 14 day rule
3.4 Added VAVE
4.1 Added QA4.SQM.01.29, added English
language requirement
4.4 Added notification to PGW receiving plant prior
to delivery
4.8 Added QA4.SQM.01.23
Updated link and revision date for Supplier QMS
Audit
Addition of 4.10.1 to address PPAP requirements
for bulk material suppliers and their sub-suppliers
Minor revision and clarifications throughout
Addition of QA4.SQM.01.30 in supporting
document list
22-Sep-04
03-Jun-15
4-Nov-15
Prepared By
Approved By
R Corliss
H Hood
E Robak
T Wright
S Sutara
D. Slaman
H Hood
E Robak
H Hood
E Robak
PGW LLC | Headquarters • 30 Isabella Street, Suite 500, Pittsburgh, PA 15212 USA |
©2001 - 2009 PPG Industries • All Rights Reserved | Legal Notices & Privacy Policies
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