Delco Remy Europe
SUPPLIER HANDBOOK
MANAGING OE SUPPLIERS IN EUROPE
Delco Remy Europe
SUPPLIER HANDBOOK
APPROVAL and RELEASE
Purchased materials/components constitute a major proportion of the products manufactured by Delco
Remy, and, consequently, the quality of these materials/components is very important for the overall
quality of our products.
Delco Remy is committed for supplying “0” defect products to the market. This will be the combined
result of good specifications, standardization, and supplier consolidation and supplier qualification.
The basic Purchasing & Supplier Quality Assurance objectives are to:
(a) Realize the combined purchasing opportunity of working through the entire Delco Remy
organization,
(b) Achieve the optimized reliable, qualified supplier base
The purpose of this document is to communicate to current and potential suppliers, the Delco Remy
Supplier Quality Requirements.
Delco Remy shall therefore be very careful in selecting suppliers, using only those that can demonstrate
the full commitment and ability to comply with the described requirements, and to support this through
the quality of products and services provided.
Signed
Dated
Jef Verelst
Director Purchasing Europe
Delco Remy
EPI 7.4-01-02-V3
Vincent De Rooj
Director Quality Europe
Delco Remy
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COMPANY PROFILE
The heritage of Delco Remy dates back to 1896 when that was founded by the Remy brothers.
In 1918 Delco Remy became part of Dayton Engineering Laboratories Co. (DELCO), a division of General Motors,
until 1994 when the Company broke away to become an independent organization once again.
Following a period of rapid expansion Delco Remy now has over 35 factories worldwide and employs over 6000
people. Delco Remy is the largest focused manufacturer of starters and alternators, supplying Original Equipment
(OE) and the Aftermarket, both passenger car and heavy duty.
In Europe, Delco Remy has production facilities in Hungary and Poland for brand new units and component parts
and remanufacturing factories in the U.K., Belgium, Tunisia, Denmark and Hungary.
Delco Remy's worldwide facilities manufacture an extensive range of premium quality heavy-duty products for OE
and aftermarket customers with the split of business is 57% for the OE and 43% for the aftermarket. Delco Remy in
Europe offers a full range of heavy duty brand new starter motors in 12 V and 24 V from 2,3 kW up to 9 kW and
heavy duty alternators range in 12 V and 24 V versions.
Delco Remy is proud to supply prestigious vehicle manufacturers like Caterpillar, Cummins, Detroit Diesel, Daewoo,
ERF Freightliners, GM, John Deere, AGCO-Massey Ferguson, Mack, Daimler Chrysler (ex-Mercedes), RVI,
TEREX, Volvo, and many East European HD machinery manufacturers.
Delco Remy's excellent range of HD products covers both American and European aftermarket applications for bus,
trucks, construction, agricultural equipment, marine, and other industrial machinery.
Our HD customers in Europe are supported by a European Distribution Center located in Belgium, stocking many
thousands of new and remanufactured units for American and European heavy-duty application as well as a
complete range of remanufactured units for passenger cars.
As a remanufacturing specialist, Delco Remy also offer a range of brake calipers, steering racks and ignition
distributors under the XL brand along with automatic transmissions under the AMT brand.
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QUALITY POLICY
We are committed to excel in everything we do. All our decisions and actions show our sincere effort to delight
DELCO REMY CUSTOMERS, SHAREHOLDERS, EMPLOYEES and SUPPLIERS and to continuously add more
value to them year after year.
We set up and implement Quality, Environment and Safety Management Systems and have them certified
according to the business needs and customer demands.
We organize our activities into business processes and set up Annual Business and Quality Objectives. We
measure our performance and continuously improve our effectiveness and efficiency to strengthen our long-term
competitive position.
We work together by empowering our employees and by having total communication throughout the organization.
We partner with our customers and suppliers in common developments.
We communicate and ensure an in-depth understanding of the Quality Policy at all levels of the company. We
review the Quality Policy at a regular basis to ensure its suitability for all aspects of our business.
01/10/01
Patrick Mobouck
Managing Director
On behalf of Delco Remy Europe Management
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Table of content
APPROVAL and RELEASE................................................................................................................................................ 1
COMPANY PROFILE .......................................................................................................................................................... 2
QUALITY POLICY ............................................................................................................................................................... 3
1.
OBJECTIVE, APPLICATION AND SCOPE ................................................................................................................... 5
2.
PURCHASING POLICY AND STRATEGY .................................................................................................................... 5
3.
DRE SPECIFIC CHARACTERISTICS............................................................................................................................. 7
REQUIREMENTS TOWARD THE QUALITY MANAGEMENT SYSTEM ................................................................................................ 7
DEPARTMENTAL RESPONSIBILITIES ............................................................................................................................................. 7
Purchasing and Supplier Quality Assurance ......................................................................................................................... 7
Engineering ............................................................................................................................................................................ 7
Manufacturing and Procurement ........................................................................................................................................... 8
CLASSIFICATION OF SUPPLIERS .................................................................................................................................................... 8
PRECONDITIONS FOR BUSINESS.................................................................................................................................................... 9
SUPPLER EVALUATION PROCESS ................................................................................................................................................. 9
Supplier Questionnaire .......................................................................................................................................................... 9
Quality Management System Evaluation................................................................................................................................ 9
Self Evaluation Survey ..................................................................................................................................................... 10
Quality Value Responsiveness Source Evaluation Survey ............................................................................................... 10
Process audit ..................................................................................................................................................................... 10
PPAP (PRODUCTION PART APPROVAL PROCESS) ..................................................................................................................... 11
SUPPLIER PERFORMANCE MONITORING .................................................................................................................................... 12
DELCO REMY CHARGE BACK SYSTEM ...................................................................................................................................... 13
CORRECTIVE ACTION REQUEST TOWARD SUPPLIERS ................................................................................................................ 14
PACKAGING REQUIREMENTS...................................................................................................................................................... 14
CHANGE APPROVAL .................................................................................................................................................................. 14
DR directed design changes ................................................................................................................................................. 14
Supplier requested changes .................................................................................................................................................. 14
Request for permit ................................................................................................................................................................ 15
DOCUMENTATION, RECORDS AND RETENTION PERIOD............................................................................................................... 15
PART DRAWING AND SPECIFICATION MAINTENANCE .................................................................................................................. 15
APPENDIX.................................................................................................................................................................................. 17
Appendix A
Supplier Questionnaire ........................................................................................................... 18
Appendix B
QVR Self Evaluation Survey ..................................................................................................... 20
Appendix C
DRE PPAP submission requirements .......................................................................................... 31
Appendix D
SPM letter ............................................................................................................................... 37
Appendix E
CAR request ........................................................................................................................... 38
Appendix F
Change request ...................................................................................................................... 39
Appendix G
Request for permit ................................................................................................................. 40
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1. Objective, Application and Scope
The objective of Delco Remy is to provide quality products and services that exceed the quality expectations of our
customers in the areas of Quality, Value and Responsiveness. Suppliers who support these objectives are
recognized as being strategically important to DR.
It is intent of DR to develop mutually beneficial, long-term strategic relationship with suppliers who show strong
dedication to continuous improvement philosophy.
This manual identifies and outlines our minimum quality system and quality performance requirements toward
current and potential suppliers to meet in order to supply DRE products and services. Additional product related
quality requirements might be specified on the Delco Remy Europe drawings, specifications and/or purchase orders.
This instruction is valid for all the Delco Remy Europe OE manufacturing plants.
2. Purchasing Policy and strategy
The Supplier – Customer relationship is based on
 Mutual trust / confidence
 Mutual satisfaction
What does Delco Remy offer?
 Correct and open way of doing business
 Interesting volume with high potential for future business growth
 Access to global subsidiaries and worldwide volume
 Long-term relationship
What does the above allow the supplier?
 Partner with a world-class customer
 Make the necessary investments
 Make profit
 Secure the future of the company
Selection and long term co-operation with suppliers is based upon 4 cornerstones which in their turn are
supported by financial stability.
1. Quality
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In products
In the production processes
In logistics (packing, marking)
In administration and communication
2. Delivery service
 Quick delivery of components for prototypes
 Reliability 99.75%
 High delivery frequency (daily or weekly)
 Short (cyclic) lead times
 Flexibility in mix and volume
 Guaranteed capacity
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3. Technical competence
 Technical know-how and experience
 Innovating ability
 Early supplier involvement & commitment
o
o
Work together, guarantee manufacturability in order to improve quality.
Think together in order to minimize costs and shorten development time
4. Minimum overall cost
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Competitive pricing
A yearly price decrease through a policy of continuous improvement
Minimum logistic costs (packing, stocks, transportation)
Minimum costs because of non-performance (shortages, poor quality)
Sharing of exchange rate risks
Payment conditions in line with our sales
Minimum costs of tooling, patterns, moulds
 Minimum costs of communication and administration
Supplier responsibility
Each supplier, or potential supplier, is responsible for the quality of the product they deliver. The ability to achieve
satisfactory product quality is a company-wide function that includes all the functional areas within the supplier’s
organization. It is required that each supplier establish and maintain, a quality management system, to achieve full
compliance with regard to design, development, manufacture and testing of products.
The supplier is responsible for ensuring that his sub-contractors also meet these requirements.
Right First Time and process capability and control
Instead of having to inspect, and possibly reject, goods upon receipt, it is much more profitable to make it "right first
time". Therefore, in achieving this objective, the emphasis is on defect prevention rather than on defect detection.
Suppliers will establish internal systems to improve process levels to a target of 100% "right first time".
Only by having "capable" processes, can a supplier continuously meet the "right first time" target all of the time.
Suppliers therefore have to prove capability continuously. This necessitates the use of Statistical Process Control
for those features that are deemed process critical.
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3. DRE specific characteristics
In order to confirm to the high customer expectations Delco Remy relies on the cooperation with their suppliers.
Requirements toward the Quality Management System
The Quality Management System of suppliers shall be based on the following requirements:
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The supplier shall establish and manage an effective quality management system which conforms at least to
the ISO9001:2000 standard requirements
Management shall be committed to the continuous improvement of quality and manufacturing
Active cooperation in the continuous improvement of the products and processes in order to reduce cost
Quality management activities shall be oriented towards reduction, elimination, and prevention rather than
detection of product defects
Supplier shall support the Delco Remy auditors during any audit or inspection
Supplier consider the product specifications and control requirements the part of the Purchase order
Departmental Responsibilities
Purchasing and Supplier Quality Assurance
Purchasing and SQA are authorized to make final determination on supplier approval status, additions or deletions
from the approved supplier list and award of business to any supplier for given commodity holding approved
supplier status.
Decision will be based on all relevant input from the appropriate cross-functional team.
Commodity managers are responsible for overseeing supplier relationships for the company. Along with the
principal purchasing responsibilities of ensuring most competitive supplier conditions for DRE this also includes
controlling supplier affected design changes issued by DRE engineering.
Supplier Quality Assurance Europe is responsible for setting up and announcing the European quality requirements
on purchased materials, parts and services, taking part in selecting new sources, approving the new suppliers and
subcontractors, compiling the approved suppliers’ list, and keeping this updated, following the suppliers quality
performances reported by the plants and initiate improvement actions in case of serious non-conformities and in
addition to that Supplier Quality Assurance Europe is also authorized to prevent awarding business to suppliers
which are not in compliance with the minimum quality requirements. The local SQA is responsible for controlling all
product quality submissions (PPAP) as well as the supplier performance results, issuing and following the corrective
actions to suppliers.
Engineering
Engineering represents an integral part of the Commodity team and is authorized to prevent business from being
awarded to suppliers incapable of complying with Purchase order and/or engineering specifications. Engineering
reviews all potential new sources for technological status, prototyping capabilities, and use of CAD systems.
Principal engineering responsibilities include product design, development of materials, processes, manufacturing
and design of measurement systems.
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Manufacturing and Procurement
Manufacturing, Procurement and the Local Quality are responsible for monitoring the supplier’s compliance with all
quality and specification requirements. If the supplier is found to be non-compliant they request documented
corrective action from the supplier and report the above requests and actions to the Quality manager.
The Quality manager is authorized to prevent the use of non-conforming material.
Classification of suppliers
For the mutual benefit for of the customer and supplier and the implementation of the global strategy, a strategic
classification is used for global suppliers who has the technical and administrative capability to develop a
relationship with DR on a European level.
1. Preferred supplier
This is the level that each supplier is expected eventually to achieve. Suppliers having QS9000, ISO/TS 16949,
VDA or any equal certification and committed to meet all customer expectations. Preferred suppliers are
characterized by financial stability, a leadership position in engineering, quality, cost and delivery. Suppliers
classified as preferred will be given first consideration on all new business.
2. Approved supplier
The minimum requirement for this level is the ISO9001:2000 certification and has the target of becoming a
preferred supplier. In addition to that the suppliers who successfully completed the management system
assessment process, the QVR >70%.
3. Compatible/ Historical supplier
Suppliers who are suppliers from the past, has no certified quality management system and has not completed
successfully the management system assessment process. For these suppliers new business cannot be awarded
till a detailed quality improvement plan is submitted to DRE and the development activities meeting the DRE defined
goals.
The objective is that all our suppliers reach the preferred level
The requirements to obtain the preferred status is the following:
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Minimum of 12 months as an Approved DRE supplier
PPM less than the target for 12 month (applicable where objectives were set)
ISO/TS16949, QS9000, VDA certified or QVR>95%
No interruption in the production during the previous 12 months (line stop due to quality failure)
PPAP submitted on time and approved at 1st time
Continuous competitive pricing
Short lead time and quick follow up of corrective actions
Purchasing and Supplier Quality Assurance basing on the performance indicators review the supplier status every
6-month.
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Preconditions for business
Means that these requirements shall be met to issue P/O or call material off from the suppliers.

Compliance to the QVR Quality System Survey requirements
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Approved PPAP (all production material must fully comply with all requirements such as dimensional, functional,
performance, process, material etc, specified on the DRE drawing)
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If DRE owned tooling is used, the supplier maintains a current tooling maintenance record, which includes
number of cycles and scheduled and unplanned maintenance.

For additional requirements, refer to the Purchasing agreement or Purchase order.
Suppler Evaluation Process
Supplier Questionnaire
(Appendix A)
The Supplier questionnaire is a document, which assists in the gathering of general business information about a
supplier.
Prior to doing business with any supplier, it is obviously desirable to obtain information about the supplier. This
allows the customer to evaluate whether the supplier is sound from a business point of view and could be involved
in business development with DRE. The Supplier Questionnaire has been designed to both obtain and record
necessary information from the supplier, to assist in making preliminary supplier selection decision. The document
intends to obtain general information both related to the overall company and also it’s specific manufacturing,
distribution locations from where DRE plants would be served. Fulfilled Supplier Questionnaires shall be returned to
the relevant DRE Purchasing Commodity Manager.
Quality Management System Evaluation
The process of the supplier selection and the management system evaluation is the following:
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The Purchasing Commodity Manager identifies potential suppliers that may be able to supply a component or
series of components.
The Purchasing Commodity Manager is responsible for the list of candidate suppliers to identify a "short list"
Purchasing Commodity Manager forwards the self-evaluation survey to the short list (sometimes this happens
in parallel with a RFQ).
Candidate suppliers return the self-evaluation survey within 3-4 days (the quote may take longer to submit).
Suppler Quality Europe and Purchasing Commodity Manager confer on self-survey results. This may eliminate
some potential suppliers that score very low. The Purchasing Commodity Manager and Suppler Quality Europe
decide on which suppliers shall be selected for on-site QVR Survey.
Suppler Quality Europe, Purchasing Commodity Manager and the Purchasing Commodity Manager or the
Product Design Responsible Engineer arranges to perform the survey as a team.
The team uses the QVR survey to assess the suppliers quality system in action. The first section of questions
concern management practices and records and is mostly performed in the office areas. The remainder of the
QVR sections concern plant floor operational issues and practices and is performed on the shop floor.
Suppliers scoring 70% and greater on the quality will be eligible for selection as a DRE supplier.
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Self Evaluation Survey
This document will be sent to all new, potential suppliers, which have not quoted DRE business before. The
document will be sent together with the relevant RFQ forms. Potential suppliers must review its content, complete
and return a copy of the Self Evaluation Survey (incl. Part I and II) to the DRE Purchasing Commodity Manager. If
the potential supplier is ISO/TS16949, QS9000, VDA certified a copy of the certificate should be submitted instead
of the survey.
Quality Value Responsiveness Source Evaluation Survey
(Appendix B)
The QVR survey is used for approving new suppliers. The QVR is a method to evaluate the suppliers in their
business process in Quality Management System.
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All new suppliers to Delco Remy European OE facilities must be in compliance with DRE quality requirements,
which are based on QS-9000 and the ISO/TS 16949 requirements. DRE Supplier Quality Manager conducts a
QVR audit at the manufacturing facilities and if required at the sub-contractor facilities. All suppliers must pass
the QVR audit prior to the sourcing decision if they do not have the automotive certification. This is an
extensive, one-day evaluation of suppliers’ quality & manufacturing methods.
The QVR assessment is a mandatory requirement for all manufacturing facilities to conduct business with
Delco Remy Europe.
Suppliers that do not meet Delco Remy minimum score requirements for QVR Audit must implement approved
corrective action plans prior to sourcing decision. Delco Remy supplier quality organization will perform a
follow-up audit to approve the implemented corrective actions.
Process audit
Process audit is performed at the current suppliers who has certified quality management system, in the following
cases:
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Introduction of a new parts/ processes or major changes in the process
Unsatisfactory performance (quality, delivery)
Verification of purchased product
Critical components
The process audits are executed by the Supplier Quality Manager Europe or the Local Supplier Quality Engineer
together with the Purchasing Commodity Manager or the Plant Buyer and if required by the representative of the
Technical department from the plant.
As a result of the process audit, an audit report is prepared and the supplier shall submit improvement action plan
related to the DR comments.
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PPAP (Production Part Approval Process)
The purpose of the production part approval process is it to determine if the supplier understands all customer
engineering design record and specification requirements and the manufacturing process at the supplier is capable
to produce products, which continuously meet the DRE requirements.
Production part approval from DRE will be required for new or modified and/ or changed parts and processes prior
to volume production.
It means that suppliers have to submit to DR parts and supporting documentation for approval to DR
before the series production. Without this approval no parts can be delivered to any of the DRE plants.
Submission to DR is to be made in accordance with the DRE Part Submission Requirements. (Appendix C.)
The samples have to be made according to the DR drawing with tools and equipments in series production.
Production part approval is always required prior to the first production shipment of product in the following
situations:
 Product modified by an engineering change to design records, specifications, or materials.
 Use of another optional construction or material than originally approved.
 Production from new or modified tools (except perishable tools), dies, molds, patterns, etc, including additional
or replacement tooling (Partial or complete).
 Production following refurbishment or rearrangement of existing tooling or equipment.
 Production following any change in process or method of manufacture.
 Production from tooling & equipment transferred to a different plant location or from an additional plant location.
 Change of source for subcontracted parts, material, or services (e.g. heat treating or plating).
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Supplier Performance Monitoring
Process description
SPM (Supplier Performance Monitoring) describes the supplier requirements that shall be in use for suppliers who
produce parts for DR.
Objectives:
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Achieve Consistency at Delco Remy Europe facilities
Continuous supplier Performance feedback
Identify areas for Continuous Improvement
Exceed Customer expectations
Communicate ZERO defect expectations
For the suppliers’ continuous performance monitoring DRE applies the SPM monitoring system. Which is:
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A process to identify and focus on areas for improvement that require immediate attention and effective
resolution
Common approach to record and report in-coming supplier issues at plant level
Monthly supplier report card based on weighted measures
METHOD:
Monthly calculation:
(PPM score + Delivery + Sort/Rework + CARs) * Response Rating = SPM
PPM (1 month data)
# of Defects
* 1, 000, 000 = PPM
# of units build
WEIGHTED ITEMS
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PPM (Use PPM Score Table)
Delivery (# of occurrence for late, over, under, early)
Sort/Rework (Labor minutes for sort/rework)
CARs (# of Corrective Action toward the suppliers)
Response Rating (Per respond rating table)
Classification of suppliers
Suppliers are classified basing on their monthly performance as:
A 0-1000
SPM
GOOD
B 1001-5000
SPM
ACCEPTABLE, IMPROVEMENT NEEDED
C above 5000 SPM
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PPM score TABLE
0-50
5
0.5
51-100 10
101-150 15
151-200 20
201-250 25
251-300 30
1.0
301-350 35
351-400 40
401-450 45
451-500 50
501-550 55
551-600 60
601-650 65
1.5
651-700 70
701-750 75
751-800 80
801-850 85
851-900 90
901-950 95
951-1000 100
(5 Points Per 50 PPM Beyond 1000)
SUPPLIER HANDBOOK
RESPONSE RATING
A) Pro-active in following DRE procedures
B) Communicates non-conformities prior shipping
C) Meets timing requirements on or before target
dates
D) Meets DRE procedures when requested
E) Initiates containment once discrepancy is
discovered at DRE facility
F) Meet timing commitments
G) Provides on-site support when required
H) Fails to meet DRE procedures
I) Slow to acknowledge non-conformities and
requires excessive communication to initiate
actions
J) Fails to meet timing commitments
DRE plants inform the suppliers in a standard letter monthly about their performance. (Appendix D.)
Delco Remy Charge Back System
DR will debit all associated costs to the appropriate supplier for non-conformances verified as a Supplier Quality
issue at any of the DRE manufacturing plant according to the specific contracts entered into between the supplier
and DRE. The associated costs could include sort / rework, downtime, premium freight, receiving inspection
activities, and other charges DRE may incur as a direct result of supplier originated quality problem.
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Corrective Action Request Toward suppliers
(Appendix F)
In case of non-conforming product is shipped to any DRE plants, agreement is settled with suppliers about the
handling of the non-conforming parts/material.
Possibilities:
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Delivery is turned back to supplier
Quarantine the delivery, sort and reworked by the supplier at the DRE plant
Quarantine the delivery, sort and reworked by DRE and the cost is charged to the supplier
If the supplier identifies non-conformities at his plant just before shipping, permits shall be asked in writing from
DRE according to this handbook. (Appendix G.)
When the defective material is identified at any DRE plants the following actions shall be taken:
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CAR request is raised by the plant SQA and immediately communicates the problem to the supplier. First
containment action response shall be sent in 24hours.
The CAR report shall fully be completed within 7 days or at the date referred on the report.
It is a responsibility of the supplier to notify any other DRE plant that regularly takes delivery of the same part
number or similar parts, which could also be affected.
Packaging requirements
DRE and the suppliers shall agree upon the packaging, including the following requirements:
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All the packaging unit shall be labeled and the label shall include:
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DRE part number with engineering level and part name.
Quantity
Supplier name and DRE supplier code.
Lot traceability number and date.
Change Approval
DR directed design changes
Any changes initiated by DRE in relation to product design, raw material specification, drawing details etc. will be
communicated to suppliers by DRE Purchasing in writing. Suppliers shall reconfirm content and if necessary shall
give notification on potential changes in cost, delivery, tooling, quality or any other items of importance. All
responses will be evaluated and after acceptance a new, valid product documentation will be issued and sent to
suppliers. After getting the new product documentation and revised purchase order from DRE, supplier will be
authorized to implement the change. Suppliers shall not implement changes into production until an authorization is
not given and a PPAP approval (if required) is not finished.
Supplier requested changes
(Appendix F)
It is a DRE requirement that suppliers are not to incorporate any changes into production without prior written
authorization from DRE Purchasing. Suppliers contemplating changes into design, manufacturing process, material,
subcontractor, control methods are required to notify DRE Purchasing or SQA prior to implementation so that a plan
can be created for re-qualification.
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Request for permit
(Appendix G)
Suppliers requesting temporary relief from DRE drawings, specifications, processes must submit to DRE
Purchasing a “Request for Permit” form found in the appendix. The supplier is responsible for completing the
document and attaching the supporting data and obtaining the approval from DRE.
The supplier will receive the approved “Request for Permit” form with DRE signatures as evidence of the approval
and authorization to proceed. The form must be attached to the delivery to avoid the rejection of the parts at the
receiving inspection.
Documentation, records and retention period
Documentation
The DRE Purchasing organization provides all the necessary documentation to the supplier, which are important for
meeting the requirements related to parts to be purchased in future.
This documentation can be:
 Drawings
 DR specifications, standards
 Control plans ( in case of outsourcing of own production)
 Critical parameters (kpc)
Record retention
The supplier shall retain for a minimum of 10 years the following documents, such as: Sales and Purchase
contracts, drawings, specifications, complete PPAP document package, FMEAs.
All the remaining documents shall be retained for minimum of 3 years.
Part drawing and specification maintenance
All suppliers are required to keep and maintain an accurate and current file of all the latest applicable drawings and
specifications received from DRE for each current production part or raw material. Applicable specifications are the
followings:
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Drawing
Control requirements
Material specifications
Technical specifications
DRE auditors will audit this requirement.
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CHANGE RECORDS
Version
Date
Description of Change
1
2
3
Original Release
11/26/2002
New measurable for process and define PPAP level 4
4
5
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Appendix
APPENDIX A
SUPPLIER QUESTIONNAIRE
APPENDIX B
QVR SOURCE EVALUATION SURVEY
APPENDIX C
DRE PPAP SUBMISSION REQUIREMENTS
APPENDIX D
SPM LETTER
APPENDIX E
CAR REQUEST
APPENDIX F
CHANGE REQUEST
APPENDIX G
REQUEST FOR PERMIT
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Appendix A
Supplier Questionnaire
EPP 7.4-02-F05
SUPPLIER QUESTIONNAIRE
1. Main data
Supplier Name:
Address
Phone:
Executive:
Year of foundation:
Stock capital:
Owners:
2. Personal data
Number of employees:
Administrative workers:
Physical workers:
Other:
Qualification:
Fax:
Internet:
University degree:
Secondary school:
3. Production data
Main profile:
Trading:
Manufacturer:
Main activity:
Secondary activities:
Production area:
Office area:
Warehouse area:
Possible co-operation:
Offered production capacity:
Main production and measuring equipments (type, age)
1.
3.
2.
4.
4. Commercial data
Turnover
1998
1999
3 main customer and your turnover
CustomerName
Turnover
1998
1999
1.
2.
3.
Average hourly wage of the typical activities:
1.
2.
Stock value:
Main supplier/turnover
1.
2.
3.
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4.
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5. Quality
Does your firm have Quality or Environmental System Certification?
If yes, please attach a copy the Certification.
Certification is valid till:
If not, does the company have plan for certification?
Does the company have defined quality objectives? (Short description)
Does the company register the final test data of the delivered lots?
Does the company certify the delivered lots by measurement data?
6. Contacts
Commercial manager
Logistic manager
Production manager
Quality manager
Financial manager
7. Other
Main investments during the last 2 years:
tel:
tel:
tel:
tel:
tel:
Planned investments in the near future:
Does the firm have an integrated logistic system? (Administration, follow-up, invoicing, capacity
Planning, delivery planning)
Other important information about the company:
Date:
EPI 7.4-01-02-V3
Completed by:
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Appendix B
QVR Self Evaluation Survey
SUPPLIER QVR SOURCE EVALUATION SURVEY
Supplier Name: ________________________________________________
Date: _________________________
Address: ______________________________________________________
______________________________________________________________
Phone No: ______________________
Fax No: ______________________
Supplier Personnel Contacted:
DRE Survey Representative(s):
___________________________
_______________________________
___________________________
_______________________________
___________________________
_______________________________
Survey Results:
Survey Score: ________
Follow-Up Survey required: 
Supplier Profile:
Commodity/Service Provided: _________________________________________
Date Established:___________
No. of Facilities at this Location: ___________
Total Square Feet:____________
Is the company Public or Private?
What are the annual Sales for this location?
___________________
___________________
No. of Employees at this Location:
Manufacturing
___________________
Engineering
___________________
Quality
___________________
Purchasing
___________________
Tool Makers
___________________
Management/Office
___________________
Total
____________
What is the current capacity utilization?
___________________
How may shifts per day?
___________________
Is this location ISO or QS-9000 certified?
___________________
Does the supplier offer any competitive advantages?
(Quality, Cost, Technology, Delivery)
___________________
Are there in house prototype capabilities?
___________________
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A. Management Responsibility
Pts.
Rating
1. Does the company have a written quality policy or statement identifying the company’s objectives
and commitment towards quality?
______
 The supplier must have a written vision, mission, or quality statement for the company.
2. Is the written statement oriented towards reduction, elimination, and prevention rather than
detection of product defects?
______
The statement or statements must specifically contain reference to defect reduction, elimination
and prevention ideals. A representative of top management must sign the statement.
3. Is the quality policy effectively communicated so that is understood and maintained throughout the
organization?
______
 Included in Quality training.
 Employee signed acknowledgment.
 Quality Policy Posted in Accessible Areas.
4. Is there documented evidence; supported by appropriate records that upper management is
proactively involved in developing, reviewing, and maintaining the quality system?
______
 Quality Operating System (QOS).
 Quality Awareness Training.
 Published Quality Goals.
 Quality Improvement Program.
 Customer Satisfaction (PPM report card, off hour phone numbers, problem response, customer
satisfaction survey).
 A documented management review process must be developed and implemented that
measures the effectiveness of the overall quality program. The management review process
needs to set internal measurement benchmarks which will measure the overall quality system.
This will also allow for a measurement of improvements. Documented corrective actions must
be assigned during the management review process in the form of precise statements of the
action items, who is responsible for accomplishing the action items, due dates for
implementation, etc. Each person or team member responsible for their assigned action items
must document what is being done in the form of a formal report for review to illustrate
progress on what is being made.
 Management reviews should also include a review of internal audits, training plan,
internal/external rejects, on-time delivery performance, etc.
5. Are quality responsibilities clearly defined and adequately staffed with qualified and experienced
personnel to assure effective implementation of quality policies as well as the achievement of quality
objectives?
______
 ASQC Certification (not required, but is further evidence to support this question).
 Job descriptions that describe responsibilities, work experience, and educational
requirements).
 Use overall survey information to summarize an answer - towards the end of survey.
6. Is there a clearly identified supplier representative whose function includes ensuring that the elements
of customer standards are implemented and maintained?
3 Pts. ______
 Program Manager, Sales Engineer or Quality Engineer (program specific routine preventative
activities).
 Documented evidence would include this activity identified in a job description or procedure.
 Position must be responsible for ensuring that all customer requirements are incorporated into
the suppliers quality system and properly maintained. Activities would include the review of
quotes, drawings, specifications, engineering change notices, and component drawing
changes to assure capability of meeting customer standards.
Section A Total 8 Pts.
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B. Quality System
Pts.
Rating
1. Is there a documented comprehensive quality system capable of meeting customer requirements?
5 Pts. ______

The supplier should have a quality manual (plan), or set of procedures documenting the quality
system, signed off and approved by the appropriate supplier representative(s).
Section B Total
C. Contract Review
5 Pts. _____
Pts.
Rating
1. Does the supplier conduct a documented contract review per internal procedure(s) to ensure that all
requirements are thoroughly understood and are within the supplier’s capability prior to order
acceptance?
2 Pts. ______




There must be a documented procedure identifying the responsible persons with sign-off
required for all receipts of customer RFQ's, drawings, and specifications to ensure that all
requirements are acknowledged and incorporated into the suppliers manufacturing and quality
systems.
Print review revision requests should be submitted to DRE for concurrence.
There must be written acknowledgment of DRE drawings, specifications, and/or purchase orders
returned to DRE.
The supplier should have documented evidence of feasibility studies and/or reviews (with signoff by appropriate personnel) that have been conducted on new and/or changed products to
assure design, manufacturing, and assembly feasibility. See AIAG checklist in APQP manual.
Section C Total
D. Design Control
2 Pts. ____
Pts. Rating
1. Are plans developed that identify the appropriate activities and responsibility for each design and
development activity?
______

Program schedule, work plan, Gantt chart. Activities to be scheduled may include Feasibility
analyses, tool design, process design, process documentation, production validation or PPAP
build, customer approval, etc.
2. Does the supplier have adequate resources and facilities available for use, i.e., computer aided
design, engineering analysis, etc.?
______

May include, but not be limited to; CAD systems, mold flow analysis, finite element analysis,
VSA, etc.
Section D Total
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E. Document Control
Pts. Rating
1. Has the supplier established and documented a procedure or procedures for controlling documents
and data?
______
 Procedures should be available for controlling supplier and customer documents, i.e., drawings,
specifications, process documentation, (job/inspection instructions, process flow diagrams,
PFMEA’s, Control Plans, etc.).
2. Are all changes (revisions) identified on each document and do these revision notes indicate the
purpose/reason for the change?
2 Pts. ______
 This includes control plans, process flow diagrams, and FMEA’s.
3. Are special characteristic symbols, where applicable, shown on process control plans and other
pertinent documents such as control charts, in-process instructions, etc.?
______
 Procedures or instructions should be available that define the use of customer and supplier
designated key/critical characteristics.
Section E. Total
F. Purchasing
4 Pts. ______
Pts.
Rating
1. Is there a documented procedure for the qualification of sub-suppliers, which includes an evaluation
of their business practices, policies, and procedures?
______
 There must be written sub-supplier requirements for their selection and approval.
2. Is an on-site survey or assessment conducted at the sub-supplier's manufacturing location prior to the
issuance of a purchase order and does it include a performance evaluation based on quality, delivery,
cost and technical support?
______
 The supplier’s plant, division, or corporate personnel should perform Audits/survey.
 Surveys of commercial raw material sub-suppliers, i.e., GE Plastics, may be exempt from this
requirement.
Section F. Total
H. Product Identification and Traceability
2 Pts. ______
Pts. Rating
1. Do records indicate that lot identity and disposition are maintained throughout the supplier’s
manufacturing and delivery process to assure lot integrity and traceability to materials used and
processes performed?
5 Pts. ______
 The supplier should have a procedure describing the controls to assure that lot and material
identification are used throughout the manufacturing process.
2. Does the supplier identify parts returned from the field for rework or sort with a unique lot number for
traceability?
______
 Return material authorization number, customer rejected material report numbers, etc.
 Reworked or sorted parts shipped back to the customer must be traceable to a unique number.
Section H. Total
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I. Process Control
Pts. Rating
1. Are individual operations specified by detailed work instructions on the traveler or posted at each
operation?
______
 The instructions must be readily available, i.e., posted in a conspicuous location so as to be
accessible to the operator for reference, and must be east to follow as well as sufficiently
detailed to prevent errors in the work being performed.
2. Does the supplier's procedures require approval of the operator, process and equipment after set-ups,
tool changes, etc., prior to actual use?
3 Pts. ______
 People should be properly trained to perform the operation through a documented certification
process. Personnel should be trained in the operational and functional aspects of their
assignments. This includes familiarity with quality assurance procedures, inspection techniques,
and non-conforming material control.
 There must be a documented procedure for approval of the process and equipment after setups tool changes, etc.
3. Are workmanship standards defined to accept/reject criteria by written specifications, photographs,
and/or labeled limit samples for operators?
______
 Boards containing pictures and/or limit samples to depict typical cosmetic anomalies which
have been agreed to by the customer as preferable, acceptable, or reject.
 Visual aids to determine if standards are being met or exceeded.
Section I. Total
J. Incoming Purchased Materials Control
5 Pts.
______
Pts.
Rating
1. Is there a procedure for the control and verification of purchased material prior to release to
production and is there evidence of adherence to the procedure?
______
 Minimum requirements include:
 Sample size per lot or reference to a specification table that rejects on 1 non-conformance.
 Parameters, dimensions, or features to check.
 Part number (including revision), description, supplier lot number, and supplier identification.
 Test procedure, or lab procedure.
 Inspection instruction, or blueprint.
 Measuring equipment and/or test equipment specified, available, and used.
2. Is the material storage area clean, well organized, and sufficiently maintained to prevent damage,
contamination, and/or loss of traceability on raw materials or components?
______
 Materials awaiting inspection must be properly identified and segregated from accepted
production materials.
 Rejected or suspect material must be adequately identified, segregated and controlled to
prevent its use.
Section J. Total 2 Pts. ______
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K. In-Process Inspection and Testing
Pts.
Rating
1. Is first piece inspection (set-up approval) required after each machine set-up, tool change, or process
change per a formal quality plan or documented procedure?
2 Pts. ______
 First piece inspection should be performed and documented to assure adherence and
compliance to set-up instructions and specifications prior to a production run.
2. Are set-up parts identified and segregated from production parts to prevent their inadvertent
shipment to the customer?
5 Pts. ______

Set-up parts/material can either be tagged, labeled, color coded or destroyed and must be
moved out of the process flow to prevent inadvertent mixing with acceptable production
material.
3. Does the supplier track in-process rejection trends and rejection rates in Parts Per Million (PPM) or by
any other acceptable means?
3 Pts. ______
 The supplier must track rejection rates in PPM or other acceptable means.
Section K. Total 10 Pts. ______
L . Final Inspection and Testing
Pts.
Rating
1. Is final inspection and testing performed in accordance with the quality plan or documented
procedures to verify conformance of the final product to the specified requirements?
______
 Operator and inspection instructions or control plans that identify test/inspection equipment
should be used. The sample size, frequency of inspections and/or tests to be performed must
also be identified including 100% testing if performed.
2. Do records indicate that the supplier tracks outgoing rejection trends and rejection rates in Parts Per
Million (PPM) or by any other acceptable means?
3 Pts. ______
 The supplier must track rejection rates in PPM or other acceptable means.
Section L . Total 4 Pts. ______
M. Inspection, Measuring and Test Equipment
Pts.
Rating
1. Does the supplier have a program or documented procedures to control, calibrate and maintain
inspection, measuring, and test equipment?
______
 The supplier’s procedure for gage control must be evaluated for its effectiveness.
 All calibration masters must be traceable to the National Institute of Standards and Technology
(NIST) or equivalent recognized organization.
 The procedure must detail the proper care and maintenance of inspection/test equipment when
not in use.
Section M. Total 1 Pts. ______
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O. Control of Non-Conforming Product
Pts.
Rating
1. Does the supplier have a documented procedure for immediate customer notification in the event
that non-conforming material is suspected of being shipped?
5 Pts. ______
 The supplier must have a documented plan or procedure delineating responsible personnel and
specific actions (customer notification, etc.) required if suspect or non-conforming material has
been shipped. The procedure must provide for the ability to identify and contain all suspect
material based on a sound traceability system.
2. Does the supplier track the rejection rate of returned goods from his customers in Parts Per Million (PPM)
or by any other acceptable means?
______
 The supplier must track rejection rates in PPM or other acceptable means.
Section O. Total 6 Pts. ______
Q. Handling, Storage, Packaging, Preservation and Delivery
Pts.
Rating
1. Does the supplier have a procedure for handling, storage, packaging, and delivery of product?
______
 Handling, packaging, storage, and delivery of the product methods must be adequate to
prevent non-conforming material from entering the shipping process.
2. If delivery performance is not 100% to schedule, are there appropriate analyses to determine root
causes and corrective actions to prevent recurrence?
5 Pts. ______
 Recognized procedures include the use of DRE 5 phase, Ford 8-D, Chrysler 7-D, etc.
3. Does the supplier have an inventory management system to optimize inventory turns and stock
rotations?
______
 May include, but not be limited to the use of Kanban, just in time shipping schedules, pull
manufacturing systems, QOS Goals, etc.
Section Q. Total 7 Pts. ______
S. Internal Quality Audits
Pts.
Rating
1. Is there a documented procedure for use in conducting internal audits or evaluations to determine the
effectiveness of his quality system in achieving stated quality objectives?
______
 The audit program should review the overall quality program to assure the adequacy of the
program.
Section S. Total 1 Pts. _____
T. Training
Pts.
Rating
1. Is there an established and documented procedure for identifying the on-going training needs of
employees and are the needs being met?
______
 All employees, including management, should be provided training. Training in statistical
techniques is recommended for all employees. Additional training in other areas such as total
quality management, mistake proofing, design of experiments, etc., is to be conducted on a
need to know basis.
Section T. Total 1 Pts. ______
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V. Statistical Techniques
Pts.
Rating
1. Are statistical techniques being used to control processes, minimize part-to-part variation, and verify
he capability of process parameters and product characteristics?
5 Pts. ______
 X bar R charts for variable data.
 P charts for percent non-conforming.
 PPM charts for PPM non-conforming.
 Moving average and range charts for batch control.
2. Are short-term capability studies conducted on all new or changed processes prior to running initial
sample parts?
______
 Process capability must be established on new or changed processes for DRE key product
characteristics.
 Process capability studies are required with a minimum CpK of 1.67 for DRE significant
characteristics. A CpK of between 1.33 and 1.67 will require a plan for improvement. A CpK of
less than 1.33 will not normally be a basis for rejecting material, however, 100% inspection will be
required on all DRE key product characteristics until the CpK is greater than 1.33.
3. Do production personnel possess adequate statistical skills and knowledge to understand Control Plan
requirements, analyze data, and make the necessary corrections (if required) to the processes, which
they are monitoring?
______
 Control charts, records, and procedures should indicate actions taken when out of control
conditions occur or non-conforming material is detected. These include:
 One or more points outside the control limits.
 Seven or more points outside the control limits.
 Eight points showing a consistently increasing or decreasing trend.
 More than four points above or below the process mean.
Section W. Total
W. Advanced Quality Planning
7 Pts.
Pts.
______
Rating
1. Is there a documented procedure and/or stated commitment to use advanced quality planning
techniques on all new or changed products/processes?
______
 The supplier should have a procedure or procedures documenting the use of advanced quality
planning techniques. The procedure or procedures should delineate the involvement and
responsibilities of each function in the organization involved in advance quality planning for new
or changed products/process.
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 Departments such as manufacturing, engineering, sales & marketing, and quality assurance are
expected to participate in advanced quality planning.
 The advanced quality planning process should include a review of quotes, drawings,
specifications, engineering change notices, component drawing changes, and sub-supplier
capabilities to assure capability of meeting specified customer requirements.
Section W. Total 1 Pts. ______
X. Production Part Approval Process
Pts.
Rating
1. Is there complete organized and supporting data for all production part submissions and
is the supporting data filed together for each part?
______
 The supplier must have on file a copy of the DRE approved PPAP submission to the latest DRE
engineering release level.
Section X. Total
Y. Continuous Improvement
1 Pts. _____
Pts.
Rating
1. Is the supplier involved in activities for the purpose of continuously improving the quality, cost, and
delivery of products and services provided?
______
 This should include the publishing of plant/department goals that are reviewed and approved by
upper management, a well-defined and implemented quality operating system (QOS), and/or
the implementation of a cost of quality system.
Section Y. Total
Z. Manufacturing Capabilities
1 Pts. ______
Pts.
Rating
1. Is the supplier's plant layout clean, efficient, organized, and well lighted with demonstrated evidence of
“good housekeeping” being practiced throughout the manufacturing process?
5 Pts. ______
 Lighting should be sufficient to carry out visual work and recording at or near the activity.
 Operations should be organized to facilitate good material flow and minimize the potential for
handling damage to occur.
 Unidentified or rejected materials/parts should not be lying around.
 Everything should be in its proper place.
2. Is the quantity of equipment, size and physical plant layout capable of handling increased production
volumes without serious detriment to overall operations and part quality?
5 Pts. ______
 Current capacity should be examined based on a 40-hour, 2 shift, 5 day work week.
3. Does the supplier have resources available for the support of tool and gage design and fabrication?
_____
 Computer Aided Design System.
 Tool Room, EDM capabilities.
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4. Does the supplier have resources available for tool and gage complete dimensional inspection?
______
 CMM.
 Gage crib, etc.
Section Z. Total
AA. Preventative Maintenance
12 Pts. ______
Pts.
Rating
1. Is there a schedule of planned regular maintenance on all machinery, tooling and equipment used to
produce products including parts cleaning equipment?
______
 There must be a documented timetable for the events which are to be performed on all
equipment and tooling used in the manufacture of product.
 There must be evidence of adherence to the documented schedule of events, i.e., records that
the maintenance is performed by the schedule.
2. Are records available for all maintenance conducted within the facility (both regularly scheduled and
any unscheduled emergencies) whether done by outside contractor or company employees?
______
 A log or database, which records all equipment repairs, lubes, inspections, and adjustments, is
required.
 Machine interventions and/or maintenance that is unscheduled must include root cause analysis
and documented corrective action.
3. Does the supplier monitor uptime/downtime on a real time basis as a measure of maintenance program
effectiveness?
______
 The supplier must have an uptime/downtime measurement system, either manual or preferably
computer controlled and monitored.
Section AA. Total
3 Pts. _____
Total Points Available ________
Actual Points Scored ______
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Reference
Question Number
EPI 7.4-01-02-V3
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Surveyor's Comments On Item Rating (*)
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Appendix C
DRE PPAP submission requirements
PPAP (Production Part Approval Process)
Delco Remy Europe Sample Submission Requirements
The purpose is it to determine if the supplier understands all customer engineering design record and specification
requirements and the manufacturing process at the supplier is capable to produce product, which continuously
meets the requirements.
Production part approval from Delco Remy Europe plants will be required for new or modified and/ or changed parts
and processes at production transfer prior to volume production.
It means that suppliers have to submit to Delco Remy parts and supporting documentation for approval to
the DR facility before the series production. Without this approval no parts can be delivered to any of the
DRE plants.
Submission to any DRE plant is to be made in accordance with the PPAP manual. All DRE production material
suppliers will be required to obtain a copy of the PPAP manual from the address below.
(Possible to order:
Carwin Continuous Ltd.
Publications Department, Unit 1, Trade link, Western Avenue
West Thurrock, Gras, Essex, RM20 3FJ United Kingdom
Tel.: 1708861333 ext.202
Fax.: 1708867941)
The samples have to be made according to the DRE drawing with tools and equipments in series production.
PPAP samples must be submitted to verify characteristics that could possibly be affected by the following:
1.
2.
3.
4.
5.
New or changed part
New or changed process
New or changed tooling, moulds or equipment
New or changed materials.
New or changed location of manufacture
Parts requiring PPAP
PPAP submission will be required for all parts tooled for DRE facilities or parts tooled by a DRE customer or
anybody for use by DR prior to the first production shipment of the product to any DRE facility. In case of minimum
production batch restrictions the PPAP can arrive with the first order and retained till all the inspections and reviews
are done and released for production after the decision. The supplier shall be notified that in case of rejection the
total qty will be returned.
PPAP submission is also being required for any commercial parts specifically modified to conform to a DRE part
number and any part, process, material or special requirement if specified by DRE facility.
Parts not requiring PPAP
-Non-manufacturing material
-Parts controlled by standards. Certificate of conformance shall be required for verification.
-Parts purchased from distributors.
-Chemicals and adhesives. Certificate of conformance shall be asked for verification
The certificate of the conformity shall be requested with the first production order.
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Submission levels
In general all new parts will be submitted to level 3 (PPAP guidelines). But depending on the commodity the level of
submission is differs:
Level1 not used
Level2 raw material, steel, Cu, packaging material
Level3 general requirement (machined parts, electrical parts, assembled parts)
Level4 for low volume and service part or Historical supplier
Level5 optional only in light duty
(in case of



Critical components
If customer requirement
If Plant Quality Manager request)
Level 5 submission (onsite verification and approval at supplier’s manufacturing location by DRE) shall be
requested well in advance of the required submission. Inspection, data analysis shall be completed by supplier prior
to the onsite visit.
DRE Commodity manager defines the date of the PPAP submission and communicates the required level to the
supplier. The originator defines the requested PPAP level after consultation with DR engineering, Supplier Quality
Assurance and DRE customer care. These dates are to be planned in accordance.
Documentation requirements
The necessary supporting documentation depends on the submission level requirement:
Level 2 –
At Customer Location - Warrant, Parts, Drawings, Inspections Results, Material, Laboratory and
Functional Results (which applicable)
Level 3 –
At Customer Location – Warrant, Parts, Drawings, Inspections Results, Material, Laboratory and
Functional Results (which applicable), Process Capability Study, Process Capability Results, Control Plan, MSA,
FMEA.
Level 4 –
Warrant, Parts, Drawing, Inspection Results, Material, Laboratory and Functional Results (which
applicable) and other requirements defined by customer.if needed
Level 5 –
At Supplier Location – Warrant, Parts, Drawings, Inspections Results, Laboratory and Functional
Results, Process Capability Study, Process Capability Results, Control Plan, MSA, FMEA.
Documents to be submit basing on the requested level:
A.
Warrant form (EPI7.4-05-01-F1)
This form shall be fulfilled, signed and returned with the parts.
B.
Material, laboratory and functional results
All laboratory results, performance tests, durability or functional test shall be included.
This shall be submitted with the parts. Data should be less than 1 year old and should be obtained from on
accredited laboratory.
C.
Inspection results (EPI 7.4-05-01-F02)
This shall be provided with all parts for all dimensions. If there is more than 1 cavity than a complete dimensional
layout is required for each cavity. In case of customer request only critical dimensions are to be checked. The
measurement reports shall be matched to the sample parts (numbering).
D.
FMEA (EPI 7.4-05-01-F03)
The FMEA to be used to determine and identify where potential failures in product and process can occur the effect
of those failures, the actions necessary to eliminate or reduce the probability of the potential failures from occurring
and to provide documentation of the failure elimination process.
E.
Control plan (EPI 7.4-05-01-F04)
The product control plan is developed using information obtained from the PFMEA, feasibility studies, drawings, and
specifications. It is a written description of the system and processes that have been developed and implemented to
prevent the production of non-conforming material. Suppliers are required to identify the methods and controls used
to monitor all DR designated key characteristics (◇) in their control plans.
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Key product characteristics:
The diamond symbol (◇) is used by DR on the drawings to indicate key product or process characteristics. KPC
are defined as attributes of a component, material, manufacturing and/or assembly operation, which have been
designated by DR engineering as being significant to part function relative to quality, reliability and durability
performance. The key characteristics indicate the safety, legal and special customer requirements.
Supplier has to prove that 100% of the product meets the DR requirements.
Possibilities:
1.
100% check at the supplier or at the subcontractor
The inspection results shall demonstrate that the continuous conformance to specification.
2.
Process capability results and SPC (Statistical Process Control)
The process capability index (Cpk) shall verify that the manufacturing process is continuously under control and the
Cpk > 1.67.
The method for monitoring these characteristics must be described and specified in the supplier’s control plan.
F.
Process capability study
Process capability studies shall be submitted for each DRE designated key product characteristics.
G.
MSA (Measurement system analysis)
Measurement system variation studies (Gauge R&R) must also be submitted for each DR designated key product
characteristics. (See QS9000 series MSA handbook)
Sample parts
Generally for the level 2 and 3 submission, each submission requires 5 parts unless otherwise specified by DR
Purchasing or SQA engineer.
If there is no other agreement with the customer the qty is the following:
Plastic parts:
5pcs min.
1 pcs/cavity
Castings, forged parts:
5 pcs of non machined casting or forged part
min. 1 part/cavity
Machined parts:
5pcs
Treated parts (heat treatment, covering, etc.)
5 pcs
Machine cutted material:
5 parts
Assembled parts:
5pcs
Samples shall be sent separately from production deliveries, and shall always be labeled "PPAP Sample parts" in a
very visible way. Together with the parts the required supporting documentation shall be sent to the attention of the
SQA engineer. The supplier/ customer part number, engineering change level and lot nr should be identified on the
label attached to the parts.
Decision about the samples
EPI 7.4-01-02-V3
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Delco Remy Europe
SUPPLIER HANDBOOK
DR engineering, quality assurance and manufacturing check the submitted parts and documentation according to
the requirements and decide about the conformance to specifications.
The result of the review can be the following:

Full approval:
The part or material meets the customer specifications and requirements. Therefore the supplier is authorized to
ship to the production.

Interim approval:
Permits shipment of material for requirements on a limited time or piece qty basis. After the deadline material can
be shipped to any DRE facility if the corrective actions are implemented, new permission is not given.

Reject:
The submission, the production parts did not meet the requirements
DR SQA informs the supplier about the result.
DR verification at supplier
DR reserves the right to verify purchased product at the supplier’s manufacturing location. When this occurs, DRE
will utilize the level 5 PPAP onsite approvals.
Customer Verification of subcontracted product
When required by DRE’s customer by contract DRE will permit its customers to participate in verification of product
from suppliers to DRE. When this occurs, DRE will utilize the level 5 PPAP onsite approvals.
Delco Remy Europe
EPI 7.4-01-02-V3
Part Submission Warrant
34
EPI 7.4-05-01-F01.
Delco Remy Europe
SUPPLIER HANDBOOK
Part Name ________________________________________________________________ Part Number ________________________
Safety and/or
Government Regulation
Yes
No
Engineering Drawing Change No ______________ Dated _____________
Additional Engineering Changes _______________________________________________________________ Dated _____________
Shown on Drawing No _____________________________ Purchase Order No ________________________ Weight (kg) ________
Checking Aid No _________________________________ Engineering Change No _____________________ Dated _____________
SUPPLIER MANUFACTURING INFORMATION
SUBMISSION INFORMATION
_____________________________________________________
Supplier Name & Supplier Code
Dimensional
Material/Functional
Appearance
Customer Name/Division ________________________________
_____________________________________________________
Street Address
_____________________________________________________
City
State
Zip
Buyer/Buyer Code _____________________________________
Application ___________________________________________
Note: Does this part contain any restricted or reportable
substances.
Are plastic parts identified with appropriate ISO marking codes.
REASON FOR SUBMISSION
Initial Submission
Engineering Change(s)
Tooling: Transfer, Replacement, Refurbishment, or additional
Correction of Discrepancy
Tooling Inactive > than 1 year
Yes
No
Yes
No
Change to Optional Construction or Material
Sub-Supplier or Material Source Change
Change in Part Processing
Parts Produced at Additional Location
Other – please specify
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 – Warrant, Appearance Approval (for designated appearance items only).
Level 2 – Warrant, Parts, Drawings, Inspections Results, Laboratory and Functional Results, Appearance Approval Report.
Level 3 – At Customer Location – Warrant, Parts, Drawings, Inspections Results, Laboratory and Functional Results, Appearance
Approval Report, Process Capability Results, Capability Study, Process Control Plan, Gage Study, FMEA.
Level 4 – Warrant, Parts, Drawing, Inspection Results, Material, Laboratory and Functional Results and other requirements defined by
customer if needed
Level 5 – At Supplier Location – Warrant, Parts, Drawings, Inspections Results, Laboratory and Functional Results, Appearance
Approval Report, Process Capability Results, Capability Study, Process Control Plan, Gage Study, FMEA.
SUBMISSION RESULTS
The results for
dimensional measurements
material and functional tests
appearance criteria
statistical process package
These results meet all drawing and specification requirements:
Yes
NO (If “NO” – Explanation Required)
Mold / Cavity / Production Process _____________________________
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable customer
drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular
production process. I have noted any deviations from this declaration below:
Explanation/Comments: _________________________________________________________________________________________
Print Name ________________________________________ Title ______________________________ Phone No. ______________
Supplier Authorized Signature ____________________________________________________________ Date __________________
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Part Warrant Disposition:
Approved
Other
Rejected
Part Functional Approval:
Approved
Waived
Customer Name _________________________________ Customer Signature ________________________Date ________________
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Delco Remy Europe
SUPPLIER HANDBOOK
Report #:
Delco Remy Europe
Initial Sample Report
Dimensions
EPI 7.4-05-01-F02.
Material
Supplier:
Page #:
Function
Part Number:
DWG Change #:
Part Name:
SUPPLIER
No.
Dimension,
Requirement
Test Method
DR
Test Results /
Test Report Number
Test Results /
Test Report Number
Supplier
Remark:
Title:
Date:
DR
Signature:
Remark:
EPI 7.4-01-02-V3
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OK NOK
Delco Remy Europe
SUPPLIER HANDBOOK
Appendix D
SPM letter
SPM Letter
Date:
Supplier code:
Attn:
As part of our continuous improvement activity, DRE will measure, track, & report monthly data to our
suppliers based on data collected for Supplier Performance Measurement. Listed below is your Supplier
Performance Measurement for each plant that you shipped to for the past month.
This report measures your company’s performance in the areas Quality (PPM), Downtime, Delivery, Sort /
Rework, Corrective Action Requests, & Responsiveness.
The Purpose of this report is to enable DRE & its suppliers to identify areas where performance does not
meet Quality Value Responsiveness (QVR) objectives. DRE has applied this common approach to monitor
supplier performance for DRE suppliers.
DRE will be analyzing this data for the purpose of assessing its suppliers’ dedication to achieving best in
class QVR. This information will be used to aid in the selection of suppliers during future business award
decisions.
Please contact myself if you require additional information or assistance.
Sincerely,
Supplier Quality Assurance
Supplier Performance Measurement
Month:
Defect Units
Del.
ppm
ppm
Score
Delivery
time
Sort
CAR
rework
Response SPM
DR Plant:
Equation:
/
=
refer to table (
+
+
+
)
*
=
Supplier Rating Categories
A 0-1000
SPM
GOOD
B 1001-5000
SPM
ACCEPTABLE, IMPROVEMENT NEEDED
C above 5000 SPM
EPI 7.4-01-02-V3
NOT ACCEPTABLE
37
Rating
month
Rating
YTD
Delco Remy Europe
SUPPLIER HANDBOOK
Appendix E
CAR request
Delco Remy Europe
Corrective Action Request
Supplier’s Name /
Order No.
Name:
Fax:
Consignment Note No.:
Date:
Lot No.:
Ref. No.:
-
Part No.:
Part Name:
Disposition of the nonconforming product
Quantity:
Description of Defect (please add a sketch if possible)
Rework
Cost:
Repair
Cost:
Accepted with devaluation
Cost:
Rejected, substitution
Cost:
You will be charged with the cost above.
Signature:
Contact person:
Tel:
Fax:
THE SUPPLIER MUST FILL THIS SECTION
If the column is too small to be fully entered, attach another sheet please!
Date of Return:
Temporary Corrective Action (e.g. segregation):
Cause of defect:
Introduced from:
Corrective Action in the manufacturing:
How passed the defect undetected:
Introduced from:
Signature:
Corrective Action in the inspection:
Introduced from: //________
Signature:
Please mark the first corrected shipment.
Delco Remy Europe Quality must fill the section below!
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SUPPLIER HANDBOOK
Appendix F
Change request
CHANGE REQUEST
Supplier Name:
Date:
Part Number:
Dwg No.:
Part Name:
Dwg Revision Number:
Detailed Change Request:
Reason For Changes:
Supplier Authorized Signature:
Date:
(Title/ Name)
Supporting data attached to this request: Yes:
No:
DRE PLANT APPROVAL
PDR engineer/ Date
SQA engineer/Date
Eng. Change Number:
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SUPPLIER HANDBOOK
Appendix G
Request for permit
REQUEST FOR PERMIT
PART
PROCESS
Supplier Name:
Date:
Part Number:
Dwg No.:
Part Name:
Dwg. Rev. No.:
Quantity:
Lot No.:
Method used to identify quantity:
Temporary Change Requested (Explain in detail; Provide sketches if needed):
Reason For Temporary Change:
Corrective Action Plan:
Supplier Authorized Signature:
(Title/Name)
Supporting Data Attached To This Request: Yes:
Date
No:
DRE PLANT APPROVAL
PDR engineer/ Date
SQA engineer/Date
Eng. Permit Number:
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