Académique Documents
Professionnel Documents
Culture Documents
Ver. 1
Effective: April 1st 2018
Content
Section 1 - Purpose
6.1 - Training
7.4 - MSDS
Section 10 - Annex
Section 1 - Purpose
- This Supplier Quality Manual is intended for those suppliers who directly supply
parts / Components to Kia Motors Mexico (KMM) and sets forth the quality,
purchasing, and logistic requirements under which the supplier will provide
prototype, production and service material. This manual enhances / provides
clarification as Customer Specific Requirements, but does not replace any other
Automotive Standards.
- As KMM continues its quality leadership, a total commitment with the principles
of continuous improvement and zero defects is needed from our suppliers of
purchased parts and components.
- KMM is committed to develop and maintain positive working relationships with all
supplier partners, through a cooperative mindset, proactive actions, and self-
responsibility.
The scope of this document includes all suppliers of parts, products, modules, and sub-
assemblies supplied directly to KMM considered Tier 1 (does not include General
Purchasing suppliers or MIP suppliers).
The Supplier Quality Manual is issued and managed by the Supplier Quality
Development section within Procurement division of KMM.
KMM requires that all tier 1 suppliers of parts, components and materials, that are
manufactured and ship to KMM are:
Suppliers shall forward copies of their current certifications to the KMM Part
Development Person in charge.
Quality Manual -The supplier shall have a manual that conforms to the IATF 16949
requirements.
Quality Core tools such as FMEA, SPC and MSA will follow AIAG standards unless
otherwise required by KMM.
Sales agreement and Confidentiality letter shall be maintained as long as the business
relationship with KMM continues; this will include mass production and service parts as
described on the sales agreement.
All part approval records, purchasing record orders and tooling record orders shall be
maintained by the supplier for the duration of the component production lifetime and
plus one year thereafter.
Production Inspection records (i.e. Control Plan Checks, Inspection Agreement Results)
shall be maintained in a legible format for the duration of one year after creation.
KMM under the representation of Supplier Quality Development section will audit all
suppliers with over 6 months of shipping for mass production. Result of this audit it is to
be taken into consideration for the Quality 5 Star Rating Score.
An official notification will be sent to the supplier with two weeks advance notice at the
time the audit is related to the Quality 5 Star Rating, result will be final and score will be
shared only through VAATZ system after the final grade is released.
The supplier will define the internal quality objectives needed to address, achieve and
exceed customer expectations within a specified time period.
The supplier shall ensure that a contact list is provided for their facilities.
- Normal Contact - A name or names with contact information shall be provided for
routine contact during KMM regular production hours.
- 24 hour contact - Supplier should also provide the cell phone number for the
person (s) who can be contacted during non-production hours in the case of
extraordinary situations or circumstances.
The supplier is responsible for ensuring that the contact list is updated when any
organization changes are made. Lacking any changes, the supplier is responsible to
review the contact information a minimum of every six months to ensure it is current.
The supplier is responsible for holding regularly scheduled reviews of their internal
management systems to ensure that the goals and objectives of KMM are being met.
The reviews should capture goals from design, manufacturing, logistics, customer
satisfaction, internal and external quality performance, sub-supplier performance and
new business development.
6.1 - Training
The supplier shall have documented procedures for the training of its employees from
instructors that are well versed in the area being taught. An emphasis should be placed
upon customer focus.
- Overall training, induction training (Company information, quality basics, safety basics,
etc.)
- Process Specifics where personnel will be focused (Injection, Stamping, Welding, etc.)
KMM strongly encourages the use of Lean Manufacturing Principles to support the
process efficiency. Progress towards this goal should be an input to the Supplier´s
Management Review.
Supplier shall identify and evaluate the internal and external risks that may compromise
the continuity of production and/or shipping; a contingency plan shall be created to
address and minimize the possible impact of events that may include but are not limited
to: key equipment failure, line stop caused by internal or external supplied services or
sub parts, natural disasters, political unrest, quality problems, sub-supplier, capacity
problems or other events
Once the supplier is aware of a possible interruption of KMM production, the supplier
shall contact Production Control / PM, and Part Development at a maximum of 24 hrs.
The supplier shall communicate the nature of the problem and the recovery plan to
ensure sufficient supply of product.
6.4.1 3C5S - The supplier shall implement and maintain a 3C5S Program for its
premises with the purpose of maintaining a state of order consistent with the product
and manufacturing process needs.
Supplier should strength the security in the supply chain using international security
standards, to avoid contamination related to drugs, weapons, money laundering,
dumping, and terrorism, among others.
7.2.1 - Suppliers shall remain globally competitive and are expected to work with KMM
Part Development Team towards implementing cost saving ideas. The suppliers are
also expected to have an internal cost reduction system to manage their costs.
In the case of suppliers located in Mexico it’s expected to share a monthly positive
opinion with the Parts Development Team.
Supplier shall make an internal analysis of their products regarding origin qualification
according to each FTA (Free Trade Agreement)
When required supplier will provide certificate of origin of their products (NAFTA, EUR1,
etc.) or in case, Declaration of Origin
7.4 - MSDS
Suppliers shall review details of the equipment needed to manufacture products under
KMM requirements, the costs involved to utilize equipment needed to sustain robust
quality levels while achieving KMM Production Capacity, and also reviewing best
practices from past programs to ensure that the proper fool proof systems are in place
to avoid the associated process / part risks.
Supplier shall plan in advance and secure Manufacturing process to achieve the desire
tooling part input condition:
The supplier shall ensure that KMM designated special characteristics are identified and
are being monitored by inclusion on the control plan and all associated product and
processing documentation including but not limited to inspection agreement/Standard,
process diagrams, FMEAs, Work Instructions, etc. If HKMC Drawing does not specify
special characteristics, the Supplier Quality Development Specialist can provide
assistance.
For production parts, the supplier shall perform process capability studies on Special
Characteristics deemed critical from KMM. The process capability study must comply
with the regular AIAG Requirements, contained into the SPC handbook.
The supplier shall perform design verifications and product validation to ensure
conformance to KMM requirements (ES/MS).
Design Verification Test: Supplier shall determine all necessary tests for DV Test to be
implemented during PSO. The test plan shall be agreed with HKMC Design Center.
Product Validation Test: Test items (ES) are in accordance with HKMC Design Center
requirements.
When reasonable PV test cycle shall be continued until the test sample is failed or its
function is completely lost, result is considered a reliability test.
Test Samples used at PV should be retained in the initial 6 months after mass
production and used as reference in the case of quality concerns.
Supplier should communicate effectively with HKMC R&D Center in order to understand
the full expectation and requirements (ES/MS) for DV and PV.
Mass produced parts shall be submitted for periodic test according to the Inspection
Agreement or in agreement with KMM material testing lab for special cases.
For detailed information contact Quality Assurance Specialist.
The supplier shall comply with the content presented in the ISIR check sheet.
The supplier shall submit Initial Sample Inspection Report (ISIR) to their respective
KMM Supplier Quality Control Specialist. The contents of the ISIR will be reviewed to
ensure all requirements have been successfully completed. Formal Approval of the ISIR
is a mandatory for all part suppliers.
Contact your assigned Supplier Quality Control Specialist for additional details if
necessary.
Definitions
Suppliers having a Red Score for a given month may be requested to submit corrective
actions to the respective KMM Group.
FMEA´s - supplier can use PFMEA form of the ISIR checklist or can utilize their
specific company-template as long as is IATF 16949 compliant. Development
and management of this document may be found into the FMEA handbook from
AIAG.
Control Plan - Suppliers shall use an IATF 16949 compliant control plan.
Work Instructions - Operators shall utilize the most recent Work Instruction /
Operation standard applicable to the respective work station that have an impact
to the product quality. Instruction / Standard should be accessible for use to the
work station.
Supplier shall have an established and documented system for addressing and
analyzing preventive and corrective maintenance. Techniques for improvements in
equipment efficiency and effectiveness should be used; MTTR, MTBF are
recommended.
Suppliers shall utilize a FIFO (First in -First out) system to minimize product
deterioration and inventory obsolesces. On case of EO changes, or for any reason
different part level are to be incorporated to production, supplier has the responsibility to
notify KMM PD and PM Groups in order to coordinate the incorporation to KMM
Production.
Non-EO change - some changes may not require an EO number change; such an
example could be shifting a dimensional location, already within specification, closer
towards the nominal value. The supplier´s 4M Procedure will indicate whether KMM
should be contacted under the following criteria.
For changes made from sub-suppliers to KMM (i.e. tier 2, tier 3, etc.) the tier 1 Supplier
to KMM will control the submission process from their respective suppliers, and then
submit an ISIR or 4M Change to KMM. This is the expectation apart from Directed tier 2
suppliers for which KMM has direct involvement for approvals.
For 4M Submissions, suppliers shall refer to the ISIR check sheet to determine which
level of ISIR to be submitted.
KMM Suppliers will receive electronic production scheduling and will be expected to
send ASN at the time of shipment.
Returnable containers and other tooling ownership of KMM shall be compliant with the
terms and conditions noted in the sales agreement. Detail can be reviewed with the
KMM Part Development Person in Charge.
8.3.1 - Packaging
KMM utilizes the Quality 5 Star evaluation process as a supplier evaluation tool of the
Quality Performance and robustness of their Quality Management System.
The organization shall notify its Certification Body in writing record within five (5)
Working days if Quality 5 Star rating is below “3 Star –“.
This notification to the Certification Body will constitute a "customer claim" as defined by
the IATF 16949 Rules. This step will suspend organization's IATF 16949 certification.
However, a suspended certification is still acceptable to KMM requirements.
Even though the Certification Body may request a status report from KMM on the
implementation of corrective actions to address the Quality 5 Star under achievement,
the Certification Body alone must determine whether to withdraw the IATF 16949
certification within 90 days of suspension.
Note 1: New Quality 5 Star Rating requires another cycle of yearly evaluation.
The Certification Body may remove suspension of the IATF16949 certificate if the
organization’s corrective actions have addressed the non-conformances leading to the
certificate suspension, as determined by the Certification Body. The Certification Body
may remove the suspension even though the site remains under “3 Star –" rating status,
by accumulating 6 months of acceptable performance data.
Note 2: At its option, KMM may file an OEM performance complaint with the
Certification Body when confronted with a specific organization quality performance
issue where a root cause may be a nonconformance in the organization’s quality
management system.
KMM will send the notification letter to both the organization and the Certification Body's
Oversight Office.
The supplier shall have a process and systems (including containment and disposition
procedure) in place to prevent the shipping of non-conforming material to KMM, or any
sequencing site on the KMM Supply chain.
9.2.1 - Containment
Supplier shall have a specific location within its premises to segregate non-conforming
material and avoid mingling with OK parts.
Should the supplier need to contain product within KMM, supplier will contact the
Supplier Quality Control Department Person in Charge for the proper guidance on
instructions BEFORE starting with any containment. Departments that need to be
notified about this activity by supplier are: SQC and PM KMM Departments.
Quality 5 Star penalties can be applied depending on the severity of the problem.
Should the production line become interrupted due to a supplier related problem
(component defect, misassemble or supplier production problems) the supplier will be
financially charged for the production downtime in which they resulted responsible.
Supplier must notify KMM PM in case of disputing the charge as soon as received the
notice and no later than 10 days.
Item refers to the Authorization from KMM to have any kind of deviation of the original
ISIR Part / Assembly approval.
Supplier shall contact KMM SQC or PM Department in order to coordinate the deviation,
depending if is related to a product quality or delivery/shipping condition.
PM and SQC will guide on completing the respecting KMM Deviation form and process
in order to follow the approval chain. The supplier shall NOT ship without completing
approval.
Part Problem Report will be issued when a part is noncompliant in terms of fit, function
or appearance by the judge of Supplier Quality Control department.
Warranty claims will be communicated to supplier through the KMM Quality Assurance
department
In the case of a delivery problem, the respective notification will be given to supplier by
the KMM PM Department.
The supplier shall complete the corrective action report on all scenarios with the related
documents and reports to SQC, QA, SQD and/or PM.
The supplier shall present the corrective action plan to KMM in the specified
forms; 8D’s for detail information and 2 panel for executive presentations.
Section 10 - Annex
Tool used to monitor quality improvements during Pilot stages from Proto to SOP + 100
Days; a printed version shall be available on the manufacturing floor to enhance the
quick response and continuous monitoring of quality issues.
Customer Quality Satisfaction Board for Development
Internal and external quality defects data Total
Issue No. Description Responsible Countermeasure
Proto SP1 T1 T2 LP2 M SOP Units
1 "Part NG" Production (PIC Name) Short Description 1 0 2 0 3 0 0 6
Detail Information
Issue No. Description Responsible Contaiment Root Cause Countermeasure
On Going Stage shall be expanded into the different lots of production for effective
monitoring.
Tool used to monitor quality improvements during mass production; a printed version
shall be available on the manufacturing floor to enhance the quick response and
continuous monitoring of quality issues.
Previous two months shall be grouped in one column and current month shall be
expanded per day.
Issues are considered closed after 3 months of monitoring without recurrence.
Detail Information
Issue No. Description Responsible Contaiment Root Cause Countermeasure
-End of document-