受控发运操作规范DMSGMWB新OK.docx

1、受控发运操作规范DMSGMWB新OK上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册SGMW Purchase. & Supply Chain Center management manual-2009版本号Version #:A受控发运操作规范 Controlled Shipment Operation Procedure2009-12-1发布 2010-1-1实施Issued on Dec 1st, 2009 Implemented on Jan 1st, 2010上汽通用五菱汽车股份有限公司采购及供应链管理中心发布Issued by SAIC GM Wuling Automobi

2、le Co. Ltd Pur. & Supply Chain Center.前 言Forward本文件是上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册支持性文件,目的在于防止不合格品流向公司和最终用户，并对供应商限时实施永久性的整改措施。 It is a supporting document for management manual of Pur. & Supply Chain Dept., it is purpose to stop unqualified products flowing into company and end user, and execute time-

3、limited permanent containment measure to supplier.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心提出。Suggested by SGMW WWP& Supply Chain Center.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心归口。Supervised by SGMW WWP& Supply Chain Center.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心负责组织起草。Drafted by SGMW WWP& Supply Chain Center.本程序主要起草人：汪杰强Main drafter:

4、 Wang Jieqiang本程序如出现文字理解歧义，以中文为准。If there is any different understanding to the words of this process, please refer to its Chinese version.审核Auditing： 会签Subscribe ：批准Approval：上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册SGMW Pur.& Supply Chain Center. management manual受控发运操作规范 1 编制与适用范围本文件由采购及供应链管理中心负责编制，规定了实施受控发运的条

5、件及退出准则；适用于批量生产时不合格品、PPM值较高或有重复PRR单的供应商。2 术语/缩写PPM：百万分之不合格品数。PRR：问题报告与处理。一级受控发运（CSL1）：由供应商在供应商现场独立于生产线以外的遏制区域对零件实施额外检查的一种遏制不合格品程序，以确保不合格品不送到SGMW。二级受控发运（CSL2）：由SGMW或SGMW认可的第三方对供应商零件实施额外检查的一种不合格品遏制程序，以确保不合格品不送到SGMW。3 一级受控发运规定3.1 一级受控发运进入条件1） SGMW发布PR&R后，供应商采取短期和长期措施实施后仍无法遏制问题的发生，重复发生相同的问题和类似的问题。2）发生重大质

6、量问题（涉及国家法规/安全/环保）。3）由于零件质量问题对SGMW造成重大影响或损失（如：SGMW停线60min或以上，出现须对库存整车进行返工50辆或以上，50分的GCA问题等）。4）供应商违反PPAP程序（如擅自更改设计、原材料、分供方、工艺、检验标准等）。5)零件实物抽检不合格（性能、材料）。6）供应商产品存在质量高风险时，SQE可发布CSL13.2 职责3.2.1 SQE职责1）确认供应商质量问题是否满足进入一级受控发运的条件，完成供应商进入一级受控发运审批（SQE提出，SQE经理审核，SQ总监批准）。2） SQE发布SGMW一级受控发运通知，同时通11 Develop and Sco

7、peThis Process initiated by Purchasing & Supply Chain Center regulates controlled shipment entry and exit criteria, for un-conforming parts, high PPM or repeated PRRs of mass production.2 Terms /AbbreviationsPPM: parts per millionPRR: problem reporting and resolutionControlled shipment level-1 (CSL1

8、): is a containment procedure to protect SGMW from non-confirmation that a supplier implements extra inspection in additional to normal production.Controlled shipment level-2 (CSL2): is a containment procedure to protect SGMW from non-confirmation that an SGMW-approved third party implements extra i

9、nspection in additional to normal production.3 CSL13.1 Entry criterion 1) Suppliers short/long term action cannot containment same or similar problems happening after a PRR has been issued.2) Major disruption (related to Nation regulation/ safety / environment protecting).3) Severe impact or loss to

10、 SGMW due to quality problem (i.e. over 60 mins downtime, more than 50 vehicles rework, upwards of 50 points GCA deduction).4) Supplier offending against PPAP procedure. (i.e. Changing product design, raw material, sub-suppliers, process or inspection criterion without SGMW approval )5) Non-conforma

11、nce of normal parts actual check (performance, material)6) High- quality-risk of the supplier products 3.2 Responsibility3.2.1 SQE responsibility1) Review supplier non-confirmation to confirm whether or not it complies with the entry criterion. If applicable, accomplish the approval for the CSL1(Pro

12、posed by SQE, confirmed by SQE manager, approved by SQ （0/A）知生产采购科、计划科、物流科及SQA。3） 通过会议方式，使供应商理解一级受控发运要求（包括退出标准）。4） 审核、批准供应商一级受控发运计划/流程。5） 审核供应商的根本原因分析及纠正措施。6） 监控供应商的遏制活动数据。7） 审核供应商过程控制改进成效。8） 对供应商进行控制计划审核（PCPA）。9） 审核供应商是否满足供应商进入一级受控发运确定的退出标准，完成供应商退出一级受控发运审批（供应商提出，SQE同意，SQE经理审核，SQ总监批准）。10）向供应商发布SGMW一

13、级受控发运退出通知，同时通知生产采购科、计划科、物流科及SQA。3.2.2 采购员职责1） 如果供应商不配合执行SGMW一级受控发运要求时，采购员必须介入并通知采购总监，同时支持SQE开展一级受控发运。2） 会同SQE就进入受控发运状态的供应商受控发运产品的具体问题及改进情况提出是否停止该供应商该类产品或全部产品的新业务开展的建议。3.2.3 供应商职责1) 立刻针对具体的质量问题，建立与现有生产、检查区域独立的遏制区域。2) 通知其他使用相同零件的顾客，告知该不合格情况，并且根据需要制定、采用遏制活动。3) 跟踪不合格品断点，并向SGMW通报断点信息。1） 4) 在产品最小单元的包装上或料架

14、上贴上经供应商主管质量的最高领导签字的绿色圆形一级受控发运标签。5) 提供执行一级受控发运所需的平面布局图、作业指导书、检验指导书，工装（含检验工具）。Director.)2) Send CSL1 notice to supplier and inform Purchasing Section, Planning section and SC, SQA.3 Communicate CSL1 requirements to suppliers (including exit criteria) via meeting.4) Verify and approve suppliers CSL1 pl

15、an/process.5) Verify supplier root cause analysis and corrective actions.6) Monitor supplier containment activity data7) Verify supplier process control improvement effectiveness.8) Conduct PCPA at suppliers plant9) Check if supplier meets all exit criteria of CSL1, if applicable, complete exit appr

16、oval, (proposed by supplier, admitted by SQE, verified by SQE Manager, approved by SQE Director.).10) Send exit notice to supplier and inform Purchasing section, Planning section, SC and SQA.3.2.2 Buyer responsibility1) If required, inform Purchasing Director and support SQE, when the supplier is no

17、t cooperative in conducting CSL1 per SGMW requirements. 2) Together with SQE to advise whether or not implement New Business Hold on the CSL1-product or all products of the supplier depending on the CSL1 problem and improvement status.3.2.3 Supplier responsibility1) Immediately establish a additiona

18、l containment activity area focusing this specific quality problem.2) Notify the nonconformance to other customers using the same part, and take containment activities if necessary.3) Track breakpoints of nonconforming material and inform breakpoint information to SGMW. 4) Mark CSL1 label, a green-r

19、ound tag with signature of the highest quality leader, on the smallest package unit or rack. 5) Provide layout, instruction sheet, inspection sheet, tooling (including checking tool) used in CSL1.（0/A）6) 发运前100%检验行动，并在遏制区域公布检验结果。7) 每日组织会议来评审相关质量数据和结果，确认纠正措施有效性。8）查找问题的根本原因,制定、实施长期纠正措施。9）更新相关的质量文件（例如但

20、不限于：过程流程图，PFMEA，控制计划，作业指导书，检验指导书等）。10）满足退出一级受控发运的标准时，提出退出申请，并提供相关的支持性文件/证据。3.3 一级受控发运退出准则SQE根据实际情况，在供应商进入一级受控发运的同时，与供应商确定适用的退出准则。原则上供应商应在两个月内退出一级受控发运。1） 对售后重大问题，受控发运开始后经市场验证有效且没有重复出现。2） 对违反PPAP流程，立即恢复PPAP原状态或新状态申请并获得批准。3）需进行控制计划审核的，控制计划审核结果在70分或以上，并制定有不合格项进一步的整改计划。4）对实物抽检不合格的，进行第二次抽检应合格。5）该问题从CSL1实施

21、开始20个工作日内在SGMW内部缺陷数量为0。SQE根据问题的实际情况，可以制定相应的其他退出标准，但需经SQ总监批准。4 二级受控发运规定4.1 二级受控发运进入条件1） 处于一级受控发运的供应商，仍无法遏制问题的发生。2） 由于零件质量问题对SGMW造成重大影响或损失（如：SGMW 停线120min或以上，出现须对库存整车进行返工100辆或以上等）。6) 100% check and display the results in CSL1 area.7) Conduct a daily meeting to review quality data and the results, ensu

22、re the corrective actions taken are effective.8) Find out root cause, develop, and implement the permanent corrective actions,9) Update all applicable documentation, (such as but not limited. Flow Diagram, PFMEA, Process Control Plan and SOS, inspection Instructions etc.)10) Request exit from CSL1 a

23、nd provide supporting documentation when exit criteria is met.3.3 Exit criteria for CSL1SQE discuss and confirm the applicable exit criteria with supplier when supplier entering CSL1.In principle, supplier shall exit CSL1 in the two months since entry.1) For market issue, no repeated issue happened

24、after implement as per market validation.2) For offending-PPAP procedure issue, immediate get back to initial status or new status requisition approved.3) PCPA result is more than 70 points with further improvement plan for non-conforming if applicable.4) The result of the second sample taken check

25、should be conformance when the actual sample taken is NOK.5) There should be no defect found in SGMW since the entry of CSL1.6) SQE can define other exiting criteria but SQ Director approval is essential.4.0 Controlled shipment level-24.1 Entering condition of CSL21) In CSL1, but the same problem or

26、 similar problem re-happen again.2) Severe impact or loss to SGMW due to parts quality (such as; more than 120 minutes downtime, more than 100 vehicles rework).（0/A）3） 导致产品召回或采取市场活动的重大质量问题；4） 供应商违反PPAP流程并对SGMW造成重大质量问题（如擅自更改设计、原材料、分供方、工艺、检验标准等）。5） 实施GP-12的零件在SGMW仍然发现不合格品。6）供应商产品存在质量高风险时，SQE经SQ总监批准可发布

27、CSL24.2 职责4.2.1 SQE职责1） 确认供应商质量问题是否满足进入二级受控发运的条件，完成供应商进入二级受控发运审批（SQE提出，SQE经理确认，SQ总监批准）。2） 向供应商发布SGMW二级受控发运通知，同时通知生产采购科、计划科、物流科及SQA。3） 审核并批准供应商对二级受控发运第三方的选择（SQE经理审核，SQ总监批准）。4） 主持与第三方及供应商的二级受控发运启动会议。5） 审核、批准供应商二级受控发运计划/流程。6） 审核供应商的根本原因分析及纠正措施。7） 监控供应商的遏制活动数据。8） 审核供应商过程控制改进成效。9） 对供应商进行控制计划审核（PCPA）。10)

28、审核供应商是否满足供应商进入二级受控发运确定的退出准则，完成供应商退出二级受控发运审批（二级受控发运第三方建议，SQE审核、SQE经理确认、SQ总监批）。11) 向供应商发布SGMW二级受控发运退出通知，同时通知生产采购科、计划科、物流科、SQA及第三方机构。4.2.2 采购员职责1） 如果供应商不配合执行SGMW二级受控发运要求时，采购员必须介入并支持SQE开展二级受控发运。3) Severe market quality issues such as recall or field action adopted.4) Supplier offend against PPAP procedu

29、re and give quality problem to SGMW (such as: change design, raw material, sub-supplier, engineering, check standard with notification to SGMW)5）Implement GP12 or parts still be NOK at SGMW after mass production delivery check.6) High- quality-risk of the supplier products 4.2 Responsibility4.2.1 SQ

30、E responsibility1) Confirm supplier to meet the entering condition or not, complete CSL2 entering approval.( SQE released, SQE manager confirmed, SQ Director approval).2) Issue SGMW CSL2 notice to supplier and inform SGMW PSC Purchasing section, planning section and SC, SQA.3) Audit and approve the

31、CSL2 provider selection of supplier( SQE manager confirmed, SQ Director approval).4) Hold a CSL2 kick off meeting with supplier and the provider.5) Audit, approve suppliers CSL2 planning process.6) Audit supplier root cause analysis and corrective action.7) Monitoring supplier containment activity data.8) Audit supplier process control improvement effect.9) Conduct PCPA at supplier plant.10) Audit exiting criteria of CSL2, complete exiting criteria approval,(The provider suggested SQE agreed, SQE manager audit, SQ Director approval).11) Issue exiting notice to supplier and inform