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MANAGEMENT56HOW MANY SHIFTS PER DAY DOES YOUR PLANT NORMALLY WORK?4LIST YOUR PRIMARY IN-HOUSE MANUFACTURING PROCESSES: ,Is the supplier familiar with the following:* Corrective Action System?(Are all interrelated processes in-house?CDoes the supplier currently deliver orders to the US, UK, and Asia?FINANCIAL STABILITYOHave you declared bankruptcy or changed majority ownership in the last 3 years? State DetailsList Examples and ExceptionsTRAINING)WHAT TYPE OF PRODUCTS DO YOU MANUFACTURE?@Design Reviews, FMEA's, Control Plans, Timing Charts, Checklists@Control Plans compared to product and process SPC Charts updated$SPC, Error Proofing, Visual controlsGList your current ratio, % revenue into R&D, and % growth in last 5 yrsEISO/IEC Guide 25 or ISO/TC 17025 or National Equivalent Accreditation- HEAT TREAT SYSTEM SURVEY REPORT 0Select business that best describes your companySection 2: Type of Business -PROVIDE CODE AND COMMENTS THAT BEST DESCRIBES$YOUR CURRENT SITUATION FOR EACH ITEM4.124.13PLATING SUPPLIER SURVEYSection 4: Physical SecuritySection 5: Access Controls5.45.55.6Section 6: Procedural Security6.46.56.66.76.86.96.10Section 7: Personnel Security-Are trucks / containers inspected on arrival?"Section 8: Documentation Security"Section 9: Education and Training8Are unused seals secured to prevent unauthorized access?[Is a dedicated person in charge of all access and use of seals to prevent unauthorized use?FDo you advise the consignee of the seal number used on each container?9After loading, does the container go direct to the port ?,Section 10: Conveyance and Manifest Security9.19.210.110.210.310.411.111.211.311.4Date Completed!C-TPAT SVI Number (if applicable))Telephone & fax number of contact person:=2) If yes, what is your certification & certification number:# C-TPAT SURVEY ACTION PLANCurrent statusRECOMMENDED IMPROVEMENTSTARGET COMPLETION DATE DATE COMPLETED)Are there procedures for drivers waiting.VDo you have procedures for reporting timely movement of incoming and outgoing freight. RIf no, will you be implementing any form of security training in the near future?City / CountryeSection 11: FOREIGN Container Security (if applicable)/_______________________________________________ Cadmium Plate" per AMS-QQ-P-416; BS EN 12330" with Phosphate Dip " over Copper Chrome Plate" Color  Metallic / Black3" Gloss  Bright / Glossy / Satin / Brushed / Matte" over Copper / Nickel2" per SAE AMS-QQ-C-320; MIL-F-14072 or BS EN 12540Copper" per SAE AMS 2418E-Coat$" Gloss  Glossy / Semi-gloss / Dull Fluorocarbon " Emralon" XylanGeomet plus SealerNickel" Bright / Black)" per MIL-F-14072; QQ-N-290; SAE AMS 2418 Phosphate " per GM4435M" Zinc PhosphatePolymer Coating/" per FED-STD-595; MIL-PRF-23377; MIL-PRF-22750." Phosphate plus Delta Protekt plus Delta Seal " Ultratec " Sermagard Powder Coat/" Gloss  Glossy / Semi-gloss / Textured / FlatTin" Bright per ASTM B545 Zinc Plate0" per ASTM B633; BS EN 12329; AS 1789; DIN 50961>" with Hexavalent Chromate  Bright, Yellow, Olive Drab, Black " with Phosphate Dip Zinc Plate " with Trivalent Black Chromate" Gloss  Bright / Semi-gloss" Sealed Zinc Cobalt)" with Chromate  Bright / Black / YellowZinc-Iron Alloy'" with Chromate  Metallic Grey / BlackZinc-Nickel Alloy" per ASTM B8410" with Chromate  Metallic Grey / Black / YellowManual AutomaticBarrel RackFinish Aluminum " per MIL-DTL-83488  F)Black Oxide per MIL-F-495; MIL-DTL-13924  F: Brass " Gloss  Bright / Dull / Brushed / Antique / Satin F9D" with Chromate Dip  Bright, Yellow, Olive Drab, BlackAdditional Processes:Additional Comments: Comments (For Southco Use Only):(Send copy of cert)YEARS IN BUSINESS?YEARS AT CO.=* PLEASE SEND AN UP-TO-DATE COPY OF YOUR ORGANIZATION CHART. List testing equipment: VDo you mix parts to optimize load size? If yes, how do you separate? _______________!Do you have available capacity: /Number of automatic and manual plating lines: How old is the equipment?: >What industry and automotive specs do you plate to and meet?: 9What process controls do you have in place (automatic?): 0Do you do SPC in process? (If so, what kind?): ?Do you have a Quality Manual? (If yes, please supply a copy): automotive?LWhat outside certifications do you have such as ISO 9001/2000, TS16949, and i** NOTE: - % = PERCENT OF TOTAL VOLUME PPM = RETURN + SCRAPPED + SORTS + REWORKS) X 1,000,000 / RECEIPTS(+"How long do you retain records?: 3Do you have gauges to check plating over threads? Will you if requested: XDo you provide plating thickness measurements with each batch?: _____________________0Do you have minimum lot sizes? (if so what?): $What are your typical load sizes?: (How do you manage your waste treatment: *Do you do both barrel and rack plating?: >Do you bake plated parts to relieve hydrogen embrittlement?: 4What is your capacity in pounds to plate and bake?: .Do you analyze your plating baths and tanks? In house? Frequency? 8What kind of test equipment do you use to analyze them? IPlease check all processes you do and add any additional processes below:RFollowing is a list of current processes we currently utilize or are considering. 9Does the supplier use statistical Process Control (SPC)? HDoes the supplier use Measurement Process Control System Analysis (MSA)?0Does supplier use Finite Element Analysis Tools?8Does supplier use Design for six sigma or similar tools?*Do you design and/or build your own tools?Are you EDI capable?COST REDUCTIONIS AN ON-SITE AUDIT REQUIRED?Supplier Quality Engineer3What is the geographical extent of your business: KAre you willing to participate in team meetings at your facility and ours: Do you pick up and deliver?: 1What are your leadtimes of processing materials: PARENT COMPANY AFFILIATESYEARS IN POSITION  ISO 14000TS 16949WHAT INDUSTRIES DO YOU SUPPLY?10,NAME YOUR TOP 5 CUSTOMERS % OF BUSINESS!DO YOU HAVE SCHEDULED SHUTDOWNS? WHAT ARE THEY?BDo you advise the port of the seal number placed on the contanier?CERTIFIED TO BY REVIEWED BY1) Is your Company a certified participant in a government-sponsored supply chain security program (eg. C-TPAT) YES  C-TPAT SURVEY - continued)Factory InlandCarrierSection 3: Certification?3) If no, do you plan to become certified within 12 months ?: (Check One)4 - NO - WILL NOT BE CONSIDERED'3 - NOT NOW - MAY CONDIER AT LATER DATE2 - PARTIALLY IN PLACE1 - YES#Section 4 TO 11: Security < CriteriaqIs there a record keeping system for machine calibrations? What information is contained on the record? (8.4 a-h)?Are there procedures that provide housekeeping practices? (7.6)% Heat Treat Service Provided By:nDoes the heat treater have a defined program to being about continual improvement in quality and productivity??Does the heat treater react appropriately to customer concerns?ZAre process monitoring and inspection/tests performed according to the instruction sheets?KAre reprocessed parts audited for conformance to all customer requirements?tAssess the heat treater's furnace loading system, in-process handling and shipping process for any cause of concern. C-TPAT SURVEY"Section 1: Facilities Information Company Name:Street Address:Mail Address ( P. O. Box )/Name and Title of person providing information:E-mail Address:SupplierNVOCCFrt Fwdr Air Consol.No.CodeCommentsmAre all buildings constructed of materials which resist unlawful entry and protect against outside intrusion?BIs there secure perimeter fencing around buildings and warehouses?NAre separate gates used for employees, visitors, and truck/commercial traffic?AForm 1178 - Supplier Confidentiality and Non-Disclosure Agreement.Form 1315a - Calibration Supplier RequirementsCertificate - ISO 17025Certificate - ISO 9001:2000Certificate - TS16949 REQUIRED? RECEIVED?DOCUMENT REVIEW 1234678910KReview with Supplier - Form 1058 Supplier Quality Statement of RequirementsXForm 1315b - Heat Treat System Survey Report (required from all Heat Treat suppliers)NForm 1315c - Plating Supplier Survey (required from all Plating suppliers)]Form 1315d - C-TPAT Survey (required from any supplier importing to a US Southco facility)nForm 1316 - Supplier Development Audit Worksheet (required from supplier's not certified to ISO 9001:2000)Buyer$Supplier Representative Name / Title!Supplier Representative SignatureKIf a manned gatehouse is used, is it equipped with a communications system?4Are there CCTV cameras and if so, who monitors them?7Does the CCTV system cover interior and exterior areas?5Are recorded tapes retained for a minimum of 30 days?7Are all interior/exterior areas adequately illuminated?-Are locks installed on all windows and doors?/Do you have an alarm system for theft and fire?OIs private vehicle parking separate from the shipping, loading and cargo areas?iAre there communication systems in place to contact internal security or local law enforcement personnel?YDo you employ an identification system for all employees? Describe method - badges, etc.0Do you record, identify and escort all visitors?IIs the packing area restricted to those employees assigned to work there?YAre there designated security personnel or devices in the packing area? Please describe.cWhat procedures are in place to challenge unauthorized or unidentified persons in controlled areas?4.1jIs there an employee and/or security officer designated to supervise the introduction or removal of cargo?4.2WDo you verify outgoing finished merchandise is marked, counted, weighed and documented?4.3*Is tamper-proof tape used to secure boxes?4.4}Do you have documented procedures for affixing, replacing, recording, tracking and verifying seals on containers or trailers?4.50Are shortages or overages detected and reported?4.64.7(Are storage areas secured and inspected?4.8NAre there procedures for reporting any abnormalities in the movement of cargo?4.96Do you have a transportation tracking system in place?4.104.11wAre procedures in place to notify law enforcement agencies in cases where illegal activities are detected or suspected?5.15.2VDo you conduct background checks and application verifications where permitted by law?5.36.1yDo you have controls in place to check the accuracy of all shipping documentation, to include invoices and packing lists?6.2RIs the documentation supplied to government officials for export control purposes?6.3kFor Suppliers holding Southco inventory, do you currently utilize FIFO for inventory handling and shipping?If your documents are prepared on a computer system, do you have systems to maintain the integrity of the data and to prevent unauthorized changes or access?7.17.2CDoes your company provide a security training program to employees?8.1yDo you maintain processes to protect against the introduction of unauthorized personnel and material in the supply chain?8.2XDo you physically search all readily accessible areas, securing panels and compartments?8.3qDo you have procedures for reporting cases in which unmanifested materials, or signs of tampering are discovered?uDo you ensure manifests are complete, legible, accurate and submitted in a timely manner to Customs, when applicable?GAre gates manned and or monitored, and locked during non-working hours?Preliminary Supplier EvaluationSupplier Name: Vendor No:Supplier Location:Evaluation Date: Conducted By:GENERAL EVALUATION INSTRUCTIONSPurpose0This Preliminary Supplier Evaluation (PSE) is to9assess the supplier's technology and ability to produce a'quality product to Southco's standards. Application6To evaluate a supplier prior to awarding a contract or!adding to approved supplier list.$Please complete this form and fax to at fax numberbyPRELIMINARY SUPPLIER EVALUATIONCOMPANY OVERVIEWSUPPLIER NAME:SUPPLIER ADDRESS:CITY, STATE, ZIP CODE:TITLE CEO/PRESIDENT QC MANAGER PLANT MANAGER PROD. CONTROL PROCESS ENGR. PRODUCT ENGRSALESOTHER!IF YES, SEND COPY OF CERTIFICATE.IF NO, PLANNED DATE? REGISTRAR?NUMBER OF EMPLOYEES?2.4.HOURLY5.UNION REPRESENTATION?!IF YES, NAME AND EXPIRATION DATE?6.YOUR CURRENT PLANT UTILIZATION?2% IMPACT OF SOUTHCO QUOTED BUSINESS ON YOUR PLANT?7.DAYS PER WEEK?8.9.!THEIR CERTIFICATE WITH THIS FORM.10.9DO YOU CURRENTLY MANUFACTURE PARTS FOR THE AUTO INDUSTRY?YESNO11.4WHAT ARE THE TYPICAL TOLERANCES WITH WHICH YOU WORK?12.NAME PHONE NO.PPM13.!STANDARD LEAD-TIME TO PPAP PARTS?WEEKSQUALITY SYSTEM1. * PPAP?* Containment?* Lab Accreditation?* Prototype?3.Y/NPPAP manual / packagesControl Plan / ProcedureISO 17025, A2LAInternal System Documentation 8D, five stepExamplesQuestionNotesPROCESS CONTROL#Work area chean and well organized? Flow DiagramAdequate lighting Process StepsReceiving Raw Material Material IdentificationsNonconforming Material In-ProcessFinal InspectionProduct Rework1Preventative Maintenance Tools & Equipment Calibration(State Control Plan / Inspection CriteriaVerification/EffectivenessDESIGN CONTROL$Capable of Electronic Data Transfer? CAD / CAM Transfer Data Prototype LabConverted ToolsIf yes, What percentage?)Do you perform your own tool maintenance? PURCHASING"How do you qualify your suppliers?How do you rate your suppliers?State Plan / Procedure(HANDLING, STORAGE, PACKAGING, & DELIVERY;What is the supplier's current inventory management system?6How many days of finishd product inventory is on hand?FWhat process assures that your production capacities are not oversold?=What type of packaging and labeling do you currently utilize?9Does the supplier have the capability to design products?9Does the supplier have a comprehensive prototype program?EIs the supplier capable of converting prototype tools for production?wAre control plans revised for product and process changes or when processes are found to be unstable or non-capable?6Does the supplier utilize defect prevention methods?#.;Does the supplier use a disciplined problem solving method?BIs there a planning process consistent with the elements of APQP? 2Does the supplier perform internal quality audits?,Frequency, Documentation, Corrective actions1What are the supplier's current shipping methods?< ,How does the supplier cover for absenteeism?2How does the supplier train replacement employees?;How does the supplier deal with internal language barriers?2How is the effectiveness of the training verified?QUESTIONIIIIIIIVVVI EFFECTIVE DEFICIENT PURCHASING DESIGN CONTROL PROCESS CONTROL QUALITY SYSTEM TRAINING* HANDLING, STORAGE, PACKAGING, & DELIVERYSOURCING RECOMMENDATION DO NOT SOURCEReason: SOURCE Comments:DATE:Southco Supply Chain Management!Calibration Supplier RequirementsMSouthco maintains control of all monitoring and measuring devices used in theSManufacture of our products. To ensure valid results, all equipment is verified atRSpecified internals against national or internationally recognized standards. AllJcalibration and gauge suppliers are required to show compliance to Southco-requirements via one of the following methods" OrFCompleted Southco Assessment (Form 1311), which is located below, withsatisfactory results.QThe following request will accompany all purchase orders for calibration servicesS Please perform calibration using standards traceable to the National Institute of OStandards and Technology, in accordance with procedures set forth in ANSI/NCSL LZ540-1 ISO10012 and Fed-std-H28, as applicable. Please provide Southco withOadequate Certification of Calibration containing before and after readings and Jother pertinent data. This certificate should also include a statement ofconformance after calibration." Lead Auditor Auditor 2 Auditor 3 Auditor 4 Audit Status:Date: Part Number:Part Description:Revision Level:IAR:%ISO / IEC Guide 25: 1990 E, Section 4Organization and ManagementCOMMENTS;Who is the Technical Manager for the Laboratory? (4.2 f, g),Who is the Deputy Technical Manager? (4.2 h)%ISO / IEC Guide 25: 1990 E, Section 5 Quality System, Audit and Review#Does the following exist? (5.2 a-s)a. Organizational charts"b. Procedures for document control)c. Job Descriptions for all Lab Personnel@d. Written procedures that describe the traceability of measurese. Work Order Review Procedures@f. Written calibration procedures for all calibrations and tests$g. Procedures for Corrective actions*h. Procedures for random audits of the labFi. Procedures that define the timing of a review of the quality system%ISO / IEC Guide 25: 1990 E, Section 6 Personnel6Is the training syllabus defined and documented? (6.3)%ISO / IEC Guide 25: 1990 E, Section 7Accomodation and Environment/Is the environment of the Laboratory Monitored?%If so to what extent? (7.1, 7.2, 7.3)DAre there procedures that define the access to the Laboratory? (7.5)%ISO / IEC Guide 25: 1990 E, Section 8!Equipment and Reference MaterialsCAre there maintenance procedures for the measuring equipment? (8.2)14.15.N/AJAre there up to date training records for all Laboratory Personnel? (6.2) bAre there procedures that define how the calibration status of equipment is identified? (8.2, 8.3)LAre there procedures for identifying items that have been calibrated? (8.3) [Is there Managerial Staff assigned to the Laboratory? (4.2a, f, g, h) iDo they have the authority and resources needed to direct the Laboratory? (4.2 a, d, f, g, h)Are the authorities and responsibilities defined for all personnel who perform work connected to the Laboratory? (4.2 a, d, f, g, h)16.%ISO / IEC Guide 25: 1990 E, Section 9&Measurement Traceability & Calibration17.>Are there procedures for placing equipment into service? (9.1)18.lAre there procedures for calibration schedules for measurement equipment and reference standards? (9.1, 9.6)19.^Is the calibration path to national and or International standards well documented? (9.2, 9.3)20.VAre there procedures that define the specific use for reference standards? (9.4 - 9.7)21.&ISO / IEC Guide 25: 1990 E, Section 10Calibration and Test MethodsTAre there procedures for all calibrations performed in the Laboratory? (10.1 - 10.4)22.PAre there procedures that define sampling plans when such plans are used? (10.5)23.~Are there checks in place for any manual calculations that are performed as a part of measurement results preparations? (10.6)24.qAre there procedures in place that regulate when computers can be used and what computers can be used? (10.7 a-e)&ISO / IEC Guide 25: 1990 E, Section 11&Handling of Calibration and Test Items25.]Are there procedures for segregating and identifying items that need to be calibrated? (11.1)26.Are there procedures that mandate an inspection of items when they are received to determine their readiness for measurement? (11.2)27.xAre there procedures that describe how calibration and test items shall be stored to protect them during storage? (11.3)&ISO / IEC Guide 25: 1990 E, Section 12Records28.=Is the following information retained for laboratory records?Original Data and CalculationsCalibration Records Copy of Calibration CertificatesPersonnel InvolvedProcedure Used29.[Is the record system set up to record all pertinent data from test and calibrations? (12.1)30.NAre there procedures that provide for adequate storage of test records? (12.2)Certificates And Reports31.Are there procedures for filling out measurement test reports and calibration test reports accurately, clearly, unambiguously and objectively? (13.1)32.RDo you conduct pre-employment screening and interviewing of prospective employees?Do you have procedures in place to inspect containers prior to loading at your facility to include the following inspectiion points: front wall, left and right side floors / doors, outside and undercarriage, and the locking mechanisms on the doors?gAfter loading, is the container stored in a secure area to prevent unauthorized access or manipulation? Name (Southco Reviewer) Title Print Name Signature Title3___________________________________________________sAre there procedures for notifying clients of possible errors in the test or calibration that was performed? (13.6)33.Are there procedures that define the proper use of electronic or electromagnetic means for transmitting test or calibration results? (13.7)34.jIs there evidence that the following information is being recorded on certificates and reports? (13.2 a-o)/A title "Calibration Certificate", Test Report"'Name and address of the test laboratory3Unique identification of the report "serial number"-Name and address of client, where appropriateDescription of item measuredCondition of item(Date of receipt and date of test of item&Identification of the test method used,Reference to sampling method, where relevant2Any deviation from identified standard test method.Measurements, examinations and derived results;A statement of the estimated uncertainty of the calibrationmA signature and the title of the person accepting responsibility for the content of the certificate or reportZWhere relevant, a statement that the results relate only to the items calibrated or testedHWhere relevant, any sub-contracting services shall be identified as such&ISO / IEC Guide 25: 1990 E, Section 13&ISO / IEC Guide 25: 1990 E, Section 14)Sub-contracting Of Calibration Or Testing35.VIs there a documented process for approving sub-contractors for the Laboratory? (14.1)36.dAre records kept on sub-contracting services and are measurements audited on a regular basis? (14.2)&ISO / IEC Guide 25: 1990 E, Section 15%Outside Support Services and Supplies37.tAre there documented records of the data gathered during the approval process of the outside suppliers? (15.1, 15.2)38.eIs there a listing of all outside service providers that have been approved by the Laboratory? (15.3)&ISO / IEC Guide 25: 1990 E, Section 16 Complaint< s39.[Are there documented polices and procedures for the handling of customer complaints? (16.1)40.Are there audit procedures that can be followed when a complaint is issued, questioning the quality of the Laboratory's measurements? (16.2)ADDITIONAL COMMENTS SPACE:Use Of Form Guidelines9Do you have a cost reduction program (internal/external)?[This form is a tool to use in calibration supplier audits. It may be used to assess levelsVof compliance to ISO Guide 25 and to develop corrective action plans where gaps exist.6It is not a requirement to use this form in any audit.Division&(If part is outsourced for heat treat)H.T. Supplier Name Supplier CodePlantAddressCityState/Country and Postal CodePhone No. (Area Code)Quality Manager Ford EngineerSupplier in conformance withFord Heat Treat System SurveyCorrective action requiredPurchasing assistance required"Supplier acknowledgement signature Survey No.:B./HEAT TREAT PROCESSES AVAILABLE AT THIS LOCATIONA. GENERAL INFORMATION AnnealingBrightFull Homegenize Isothermal Local (Flame, Induction) Spheroidize Hardening ConductiveFlameFurnace InductionInduction-Atmosphere Neutral Salts Precipitation TufftridingVacuum Carburizing Fluid BedGasIonPackSaltCarbon Restoration NitridingCarbonitridingFerritic NitroTool Steel TreatingHigh Speed SteelTreatingFurnanceAluminum/NonferrousT-5T-6 AustemperingCarbo AustemperingCryogenic Treating (Deep Freeze)DipTorch Marquenching/ MartemperingPress QuenchingSteam Treating SinteringTemper/Stress Relief NormalizeSolution RecrystallizeBrazingYesNo"Survey representative signature(s)State and Postal CodeC.+FORD PARTS, PROCESS AND SPECIFICATION LIST. Part Name Part NumberMaterialProcessHardness (Surf/Core)Case Depth (Effect/Total)D.&HEAT TREAT EQUIPMENT AND CONTROLS LISTFurnaces AtmosphereElectric Fluidized Bed Gas/Oil Fired Salt Bath Atmospheres Ammonia (NH3) Dissociated Generators Endothermic ExothermicNitrogenOtherTemperature Instrumentation Flow Meters Mixing Valves Controlling Indicating Recording ThermocoupleTest PyrometerTest Thermocouple (Standard)Primary StandardAtmospheres ControlsInfrared MonitoringResistance Wire TestOxygen (O2) Probe . *Flame Units (List)Induction UnitsE.!TYPE OF QUENCH SYSTEMS AVAILABLE:OilWater Caustic (%)Salt (%) Synthetic (%) Other (List)F.$INSPECTION/TEST EQUIPMENT AVAILABLE:Emission SpectrometerCarbon/Sulfur AnalyzerHardness TestersBrinnelRockwellRockwell SuperficialRegional Supply Chain ManagerMicrohardness (Tukon)Magnetic Penetrant InspectionLiquid Penetrant InspectionMechanical Test Equipment1Cut-off Equipment (abrasive wheel, bandsaw, etc.)!Metallographic Sample Preparation Metallograph"Scanning Electron Microscope (SEM) Eddy CurrentGas Chromatography Quenchometer Fluroscope Ultra SoundHeat Treating Facility's NameYAssign a rating for each element based on the Heat Treat System Survey Scoring GuidelinesA.PLANNING FOR QUALITY0Is the responsibility for quality planning of heat treat processes clearly defined? Assess the adequacy of the heat treater's quality planning effort. Identify the key contact personnel/department for quality planning and quality concern resolution. Include names, department names, and phone numbers.Are Failure Mode and Effects Analyses (FMEA) and Control Plans used as a basis for establishing quality programs for heat treat processes?iDoes the heat treater use analysis processes to determine special characteristics and process parameters?_Is the customer/end user of the heat treated product brought into the quality planning process?Does the heat treater have available and use a procedure for reviewing part design and heat treat process changes prior to implementation?JAre FMEAs and Control Plans reviewed and updated as part of the procedure?<Is customer approval obtained prior to implementing changes?hIs there a procedure for updating operator instructions and visual aids for process and product changes?TOTAL PLANNING FOR QUALITYRating (Total points available = 30) = STATISTICAL METHODSiIs Statistical Process Control (SPC) utilized for special product characteristics and process parameters?How are the special characteristics chosen? Describe the SPC methods used. Are they appropriate to the factors being controlled?Evaluate the heat treater's reaction to out-of-control conditions. Is the reaction as specified in the Control Plan? What is the role of the operator?Evaluate the heat treater's application of SPC, based on the evidence of the control charts, process logs and other appropriate documentation.xAre process verifications/capability studies conducted on new product characteristics and heat treat process parameters?MAre statistical control charts being used effectively to monitor the process?1WHAT IS THE GEOGRAPHICAL EXTENT OF YOUR BUSINESS?xDo control charts indicate that statistical control has been achieved and that process capability has been demonstrated?In all cases where process capability has not been demonstrated, is there a plan to improve the process? Is appropriate interim action being taken to prevent shipment of nonconforming parts?jDoes the heat treater have an effective system for ensuring the quality of incoming products and services?5How is SPC encouraged at Tier 1 and Tier 2 suppliers?]Assess the adequacy of the heat treater's control on the quality of the services it receives.TOTAL STATISTICAL METHODS (Total points available = 50) = GENERALZAre process/product monitoring and control functions and responsibilities clearly defined?DAre written procedures defining quality-related functions available?SAre these procedures appropriate to and adequate for the heat treater's operations?*Are the procedures implemented as written?3Is there a review process to verify implementation?aIs there an adequate procedure for reacting to ES, ES-M, product qualification and test failures?Are written process monitoring and control instructions available for incoming, in-process, laboratory, dimensional inspection and outgoing auditing?vAre all Special characteristics and Process Parameters included, particularly those affecting function and durability?>Are Special characteristics and related operations identified?*Are sample sizes and frequencies adequate?.Is appropriate statistical analysis specified?uAre appropriate process monitors, thermocouple and inspection/test equipment available to facilitate process control?Does the heat treater have an effective preventive maintenance program for heat treat process equipment, thermocouple and process monitoring equipment?Do records indicate that process monitors, thermocouples and inspection test equipment are periodically inspected and calibrated?XDoes the heat treater perform furnace temperature uniformity surveys (thermal profiles)?^Asses the adequacy of the heat treater's preventive maintenance program and its effectiveness.What controls does the heat treater use to indicate the processing and inspection status of products throughout the heat treating system.Are effective controls in place to provide accurate part processing information throughout processing storage, packaging and shipping?sAre controls adequate to prevent movement of nonconforming rejected in-process products into the production system?OIndicate which plant activities conduct process/product monitoring and control.:Assess the adequacy of the heat treater's control program.eDoes the heat treater have complete records supporting Production Part Approval (PPAP) certification?|When required, has product engineering approval of Product/Process Control Plan, samples and test equipment been documented.gAre in-house and customer quality concerns effectively communicated to all members of t<0 he organization?Are nonconforming parts returned by customer analyzed? Is the root cause of failure determined, verified and corrective action taken? XIs a disciplined method of problem solving, e.g., the Eight Discipline format, utilized? (Total points available = 80) = TOTAL GENERALIN-PROCESS AND OUTGOING4Are there adequate records of inspections and tests?MAre documented heat treat reject, reprocessing or scrap procedures available?&Assess the adequacy of the procedures?`Are heat treat processing, handling, storage and packaging adequate to preserve product quality?mAre plant cleanliness, housekeeping, environmental, and working conditions conducive to quality improvements?NAre there working conditions that could be detrimental to quality improvement?7Could product quality be affected by plant environment?TOTAL IN-PROCESS and OUTGOING (Total points available = 40) = Maximum = 200 points) =&TOTAL RATING POINTS FROM ELEMENTS 1-20#Conformance to QS-9000, Heat Treat System Survey Scoring Guidelines and W-HTX requires at least a "7" rating on each individual element and at least a "160" overall System Survey Rating. Suppliers should provide improvement action plans for all areas with a rating below "7" within 60 days. WarehouseE-MAIL ADDRESSSUPPLIER WEB ADDRESS: ARE YOU ISO-9001:2000 CERTIFIED?AVG. YRS SERVICE?FACILITY SIZE (SQ FT)?4WITH A COPY OF YOUR ISO/TS CERTIFICATION TO SOUTHCO.dISO/TS CERTIFIED SUPPLIERS STOP HERE. SIGN THE BOTTOM OF THIS DOCUMENT. RETURN THIS DOCUMENT ALONGJeCALIBRATION OR GAGE SUPPLIERS STOP HERE. THOSE WHO ARE NOT ISO 17025 ACCREDITED MUST COMPLETE SOUTHCOJ)iFORM 1315a AND RETURN WITH THIS SURVEY. SUPPLIERS ACCREDITED TO ISO 17025 MUST RETURN A CURRENT COPY OF A7J]NON-US COMPANY. IF YOU ARE A NON-US COMPANY AND WILL SHIP TO A US SOUTHCO FACILITY, YOU MUSTJDCOMPLETE AND SUBMIT THE C-TPAT SURVEY FORM 1315D OF THIS SPREADSHEET&L1ePLATING SUPPLIERS STOP. SIGN THE BOTTOM OF THIS DOCUMENT AND COMPLETE FORM 1315C OF THIS SPREADSHEETJGLQmHEAT TREAT SUPPLIERS STOP HERE. SIGN THE BOTTOM OF THIS DOCUMENT AND COMPLETE FORM 1315B OF THIS SPREADSHEETJOKZ\SUPPLIER HAS REVIEWED SOUTHCO FORM 1058 - SOUTHCO SUPPLIER QUALITY STATEMENT OF REQUIREMENTSb jbӸ/j:ͻ)*   h>MKjyt%ZL,-^~ V p D|s6nq9$@x)aQ7o&)=oYm6J_s Ma  Nb2 Q eb vSg p|l jZA1wgsq}m   R B GHHHHHHHHHHHHHHHHHHHHHHHHHIJefgggggg d< dddYYYYY =BBYYYYYYYZ @AAAAAAAA ]84 ^^^^^^^^^^^^^^^^^^^^^^^ _><``````````````````````````` ?K K?L?????????  ?@"?????????????? ?????????????  ?A"?????????????? ?????????????  ?B"??????????????>????????????????????????????>????????????????????????????? DC??????????  ?D"?????????????? ?????????????  ?E"??????????????>????????????????????????????>????????????????????????????>????????????????????????????? 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