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QS-9000 TE Supplement
QS-9000 TE Supplement


Purpose

TE Supplement defines the fundamental quality system expectations of Chrysler, Ford, General Motors, Truck Manufacturers and other subscribing companies for internal and external suppliers of production, service parts and materials. These companies are committed to working together to ensure customer satisfaction, beginning with conformance to quality requirements and continuing with reduction of variation & waste to benefit the customer, the supply base and themselves.

Applicability

TE Supplement applies to all internal and external suppliers of:

  • Production materials
  • Production or service parts
  • Heat treating, painting ,plating and other finishing services directly to Chrysler, Ford, General Motors or other OEM customers subscribing to this document.
  • 'Shall', 'will', 'must' are mandatory requirements. 'Should' is preferred approach

This document supersedes all editions of Chrysler's Supplier Quality Assurance Manual, Ford's Q-101 Quality System Standard, General Motors' Europe General Quality Standard for Purchased Materials and the Truck Manufacturers Quality System manuals.

QS/TE 9000 Supplement

  • QS 9000, in conjunction with ISO9001/9002, is applicable only to suppliers of production parts/materials/production services to the automotive supply chain.
  • QS 9000 is not applicable to Tooling manufacturers/Equipment manufacturers, catering to the automotive industry.
  • Chrysler, GM, Ford have come out with a TE supplement to QS 9000 for interpreting the basic principles of QS 9000 requirements to manufacturers of Tooling and Equipment
  • Presently we have the second edition of TE supplement (June 98)
  • A Tooling/Equipment manufacturer can get 3rd party registration to QS/TE supplement, but this has not been mandated by the big three.
  • TE supplement supersedes Chrysler's 'TESQA Manual' and Ford's 'F & T QSS'.
  • A major aspect of focus in the TE supplement is the effective use of 'Reliability and Maintainability' concepts using 'Total Life Cycle Costing' for Tooling and Equipment.

History

  • American Society for Quality Control- automotive division 1988 summer conference
  • OEM VP's/ASQC sanction an OEM task force
  • Harmonize supplier quality manuals & formats
  • Concentrate on tactical projects vs strategic

Evolution of TE Supplement

  • Interpretation of QS 9000 for TE manufacturers
  • Commonizing OEM requirements
  • Move suppliers from job shop to processed focused

Goal

The goal of TE Supplement in conjunction with QS 9000 is the development of fundamental quality systems which provide for continuous improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain.

Purpose

The TE Supplement defines the fundamental quality system expectations of Ford, GM, Chrysler and other subscribing companies for suppliers of tooling and equipment. These companies are committed to working with suppliers to ensure customer satisfaction, beginning with conformance to quality requirements, and continuing with reduction of variation and waste to benefit the final customer, the supply base and themselves.

Approach

The TE Supplement fully embraces the current release of QS 9000. It is recognized by Chrysler, Ford and General Motors that QS 9000 requires consistent interpretation and application as it relates to Tooling and Equipment related industries.

The TE Supplement shall be used with QS 9000 as one document for the Tooling and Equipment industry.

The word 'shall' indicates mandatory requirements. The word 'should' indicates a preferred approach. Suppliers choosing other approaches shall be able to show that their approach meets the intent of QS 9000 and the TE Supplement. Where the words 'typical' and 'example are used, the appropriate alternative for the particular commodity or product should be chosen.

Applicability

The following replaces the QS 9000 'site' interpretation/definition found in the Applicability section. Site is defined as a supplier or subcontractor location at which value added manufacturing processes occur. The contents of QS 9000 as interpreted by the TE Supplement are to be applied to all manufacturers of machinery or any component thereof (e.g. replacement parts). Machinery consists of tooling and equipment to perform processes such as:

  • Assembly
  • Balancing
  • Casting
  • Deburring
  • Forging
  • Forming
  • Gaging
  • Heat Treating
  • Machining
  • Material handling
  • Measuring
  • Molding
  • Packaging
  • Painting
  • Plating
  • Robotics
  • Stamping
  • Washing
  • Welding
  • And other emerging manufacturing techniques

Implementation

QS 9000 in conjunction with TE Supplement is the quality system standard for all Tooling and Equipment suppliers. It is intended that QS 9000 and the TE Supplement be implemented in their present form, however it is recognized that not all of these requirements are applicable to every organization (e.g., Element 4.4 Design Control at a company which does not have design capability). The techniques in the Advanced Product Quality Planning and Control Plan Manual (APQP) required are for reference purposes only. Essential for understanding this document, the user shall understand the terms found in the glossary of this document, and how they apply to the Tooling and Equipment industry.

Tooling and Equipment suppliers are to delete the following reference documents from the related QS 9000 manuals listing:

  • Quality System Assessment
  • Production Part Approval Process
  • Semiconductor Supplement
  • AEC-A 100: QSA Semiconductor Edition

TE Supplement Rollout

  • Third party registration is not required
  • No date established for compliance
  • New requirements for TE Suppliers
    • QS 9000
    • TE Supplement
    • Reference Manuals

Reliability & Maintainability Concepts in Manufacturing Machinery/Equipment

R&M is a discipline. It is steeped in well documented techniques which are meant to direct both machine suppliers and users beyond the question of 'will it work?', to a quantifiable analysis of how long it will work without failure. The requirements for R&M encourage a partnership between the supplier and user of manufacturing machinery and equipment. Both members of this partnership must understand what equipment performance data is needed to ensure continued improvement in equipment operation and design, and must exchange this information on a regular basis. The successful implementation of an R&M program requires a strong commitment from both the user and supplier management teams. The R&M process developed for manufacturing machinery and equipment, has been organized into a five-phase program management process that includes Concept, Development/Design, Build and Install, Operation and Support, and Decommissioning/Conversion, with accompanying implications for suppliers and users. Application specific R&M techniques can be prescribed for each unique equipment acquisition by employing standardized worksheets which are keyed to an appropriate R&M matrix. The process is further supported by appendices for enhancing the understanding of the underlying technical aspects of R&M. In the longer run, this guideline will contribute to higher levels of productivity and competitiveness, and will be subject to change and modification as dictated by the industry's aspiration to be at the leading edge. Reliability and Maintainability are key ingredients to preserving production efficiency and lead to lower total life cycle costs necessary to assert a competitive edge.

Reliability is the probability that machinery/equipment can perform continuously, without failure for a specified interval of time, when operating under stated conditions. Increased reliability implies less failure of the machinery and consequently, less downtime and loss of production.

Maintainability is a characteristic of design, installation and operation, usually expressed as the probability that a machine can be retained in, or resorted to specified operable condition within a specified interval of time when a maintenance is performed in accordance with prescribed procedures.

Reliability and Maintainability (R&M) are vital characteristics of manufacturing machinery and equipment that enable U.S. manufacturers to be world class competitors. Efficient production planning depends on a process that yields high quality parts at a specific rate without interruption. Predictable R&M of the manufacturing machinery and equipment is a key ingredient in maintaining production efficiency and the effective deployment of 'Just in Time' principles. Improved R&M leads to lower total life cycle costs necessary to maintain the competitive edge. Improved R&M results in improved availability. Highly available production machinery offers the means for producing consistently high quality products at lower costs and at higher output levels. Successful application of R&M techniques has a very positive effect on employee morale because reducing downtime also significantly reduces employee stress.

R&M User/Supplier Benefits

User Benefits

  • Higher machinery and equipment availability
  • Unscheduled downtime reduced/eliminated
  • Reduced maintenance costs
  • Stabilized work schedule
  • Improved J-I-T performance capability
  • Improved profitability
  • Increased employee satisfaction
  • Lower overall cost of production
  • More consistent part/product quality
  • Less need for in-process inventory to cover downtime
  • Lower equipment LCC

Supplier Benefits

  • Reduced warranty costs
  • Reduced build costs
  • Reduced design costs
  • Improved user relations
  • Higher user satisfaction
  • Improved status in the marketplace
  • A competitive edge in the marketplace
  • Increased employee satisfaction
  • Increased understanding of product applications
  • Increased sales volume

Safety

Throughout any R&M program, consideration must always be given to safety. The benefits of an improved design must not be allowed to compromise the ability of the manufacturing machinery and equipment to be operated safely, and to be maintained without risk to personnel. Passive safety features should always be a criteria for good design.

Reduced Life Cycle Cost

Life Cycle Cost refers to the total cost of a system during its lifecycle. LCC is the sum of non-recurring costs plus operation and support costs. The total LCC can be lowered by emphasizing R&M during the conception and design stages. By using R&M to minimize stress (electrical, mechanical, thermal, etc), the equipment will be less prone to failure during operation. Consequently, the operation support costs which account for the bulk of total LCC will decrease.

Implementing R&M Through Life Cycle

Seven Key Practices:

  • R&M Planning
  • R&M Improvement Activities
  • Quantitative Requirements
  • R&M Testing Activities
  • Design Assurance Activities
  • R&M Analytical Techniques
  • User Feedback

The five Life Cycle Phases

  • Concept
  • Development design
  • Build & Install
  • Operation/Support
  • Conversion and/or Decommission

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