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Visteon Corporation Customer Specific Requirements For Use With ISO/TS 16949: 2002 Visteon Corporation Customer Specific Requirements to ISO/TS 16949:2002 1. Introduction Quality professionals from Visteon collaboratively developed this document. The content of the document was developed using the Customer Specific Documents of several automotive OEMs and with the consultation of the Joint Task Force for Supplier Quality, Automotive Industry Action Group (AIAG). Key contact for interpretation of this requirements document is: Visteon Corporation: Supplier Development / Performance Manager Visteon Technical Center 16630 Southfield Road Allen Park, MI 48101 Fax: 313-755-9644 Email: supplierperformance@visteon.com 2. Customer Requirements Document Structure This document is structured as a companion document to ISO/TS 16949:2002. The paragraphs to this document mirror the paragraphs to ISO/TS 16949:2002. Where guidance by the customer is referenced, a requirement will be stated to clarify Visteon interpretation. For suppliers of semiconductor components, the Customer Specific Requirements (ISO/TS 16949:2002) Semiconductor Commodity uses this same structure and should be used as a companion requirements document to this document and ISO/TS 16949:2002. The requirements of all three documents must be met where applicable. Some additional requirements are contained in the Annex B, which is not auditable by registrars. The contents of this entire document are considered requirements for doing business with Visteon and should be implemented even if the organization is not registered to ISO/TS 16949:2002. In second party audits, the expectation of Visteon is that all these requirements (where applicable) are implemented. 3. Reference Documents The following reference documents are available through AIAG (248-358-3003) or Carwin Continuous (UK) in Europe (44-1-708-861333) and shall be used to develop the quality system. The AIAG reference manuals to the latest edition shall also be used. Production Part Approval Process, PPAP Statistical Process Control, SPC Potential Failure Mode and Effects Analysis, FMEA Advanced Product Quality Planning and Control Plan, APQP Measurement Systems Analysis, MSA Materials Management Operations Guideline, MMOG The Customer Specific Requirements (ISO/TS 16949:2002) Semiconductor Commodity is available from the Automotive Electronics Council website www.aecouncil.com. Semiconductor Assembly Council (SAC) documents are available through www.sacouncil.org. 1. Scope ISO/TS 16949:2002 and this document define the fundamental quality system requirements for the Visteon Corporation supply chain. This document contains the company specific requirements supplemental to Technical Specification, ISO/TS 16949:2002. These supplemental requirements may also apply to QS-9000, ISO9001: 2000 and other similar registrations as applicable and developed within this document. These supplemental requirements shall be in the scope of the registration/certification audit in order to be recognized as satisfying the Visteon supplier criteria for third-party certification by an IATF recognized and contracted certification body. All ISO/TS 16949:2002 requirements and the requirements of this document shall be documented in the organizations quality system. See 7.4.1.2 for further clarification of other applicable standards and the requirements. The English language version of this document shall be the official version for purposes of third party registration. Any translations of this document shall be for reference only. Copies of this document are available at: Visteon Corporation: http://www.visteonsupplier.com 2. Normative references See 3 above for a listing of references. 3. Terms and Definitions ASDE (Supplier Performance Engineer, SPE, in Europe) Advance Supplier Development Engineering is the group of engineers within Visteon that are responsible for assisting suppliers on a new program to launch products. Capacity verification A verification methodology to demonstrate that an organization can meet the capacity planning volume requirements as defined in the purchasing Request For Quote (RFQ). Customer References within this document to “customer” shall be interpreted as Visteon. This pertains to the corporation receiving and purchasing product from the organization. DVPR This is the Design Validation Plan and Report. It contains the validation plan and subsequent report of the results. Family Parts These are groups of parts processed on the same production line, using the same control plan, PFMEA and process equipment. The parts differ only in end item value. PPAP for the “family” is approved for using the extreme values to the “family” specification to bound the “family”. MMOG The Materials Management Operations Guidelines (MMOG) is a document jointly created by the Automotive Industry Action Group (AIAG), OEM representatives, and automotive suppliers. MTBF Mean Time Between Failure is a metric to measure the reliability of equipment. OEE Overall Equipment Effectiveness is a metric to determine the utilization of equipment in a manufacturing process. OEM Original Equipment Manufacturer (OEM) is intended to be the end item producer of the vehicle. Organization Providers of production or service parts, or heat treating or other finishing services directly Visteon. Within Visteon, the organization is commonly referred to as the “supplier”. Paynter Chart A Paynter Chart tracks specific defects or issues over time to verify effectiveness of containments and corrective actions. Quality Roadmap A quality roadmap is a communication tool to provide the customer a plan to reduce quality defects. This tool includes the use of trend lines, performance goals, Pareto charts, Paynter charts and 8Ds. Report Card An on-line information system that provides Quality and Delivery rating information to organizations that supply Visteon. The external website to access is Report Card (http://www.visteon-tpnet.com/) RMA A returned material authorization is a tracking number supplied from an organization authorizing the return of material. SDE Supplier Development Engineering (SDE) is the group of engineers within Visteon responsible for assisting suppliers with current model quality issues. Supplier, or organization, manufacturing sites are assigned to specific SDEs. SPE Supplier Performance Engineering is the group responsible for APQP in Europe. They are equivalent to the ASDE group. Shall A mandatory requirement. Should Indicates a mandatory requirement with some flexibility allowed in compliance methodology. Subcontractor Provider of production or service materials or services directly to the organization. VPDS This is the Visteon Product Development System. It includes a series of performance gates to validate readiness to move to the next gate in the product development process. These gates include evaluation of supply chain readiness. 4. Quality Management System 4.1 General requirements 4.1S All ISO/TS 16949:2002 requirements and the requirements of this document shall be documented in the organizations quality system. See 7.4.1.2 for further clarification of other applicable standards and the requirements. The entire facility (producing automotive products for Visteon) must be registered to the applicable standard. Where the entire facility does not produce automotive products, a clear definition of what product lines are registered shall be included in the registration scope. 4.2 Documentation requirements 4.2.2S Quality manual All ISO/TS 16949:2002 requirements and the requirements of this document will be included in the organizations quality system. 4.2.4.S Control of Records Production part approvals, tooling records, purchase orders and amendments shall be maintained for the length of time that the part (or family of parts) is active for production and service requirements plus ten calendar years unless otherwise specified by Visteon for their respective products. This includes any customer owned tooling. Production inspection and test records (e.g., control charts, inspection and test results) shall be retained for one calendar year after the year in which they were created. Records of inspection shall be maintained for each inspection or test performed. Where practical, the actual test result (variables or attributes) should be recorded. Simple pass/fail records of inspection are not acceptable for variables measurements. Records for internal quality audits and management review shall be retained for three years. Some programs may require longer retention periods than specified above. An organization may specify the retention period in its procedures or specifications. The above does not supersede any regulatory requirements. 5. Management Responsibility 5.2S Customer focus The organization shall demonstrate customer satisfaction through meeting continuous improvement objectives consistent with a well-developed QOS/BOS. See 5.6 for additional information on content and frequency. A self- assessment of QOS/BOS effectiveness shall be done yearly. Annex A contains a suggested outline of BOS/QOS metrics. 5.5 Responsibility, authority and communication 5.5.2.1S Customer representative The organization customer representative is the primary interface to the customer. When the customer representative changes, the organization shall notify Visteon Supplier Performance, Commodity Purchasing and shall update the Report Card contacts as appropriate. If the organization changes senior management responsible for quality or company ownership, Visteon Commodity Purchasing shall be notified within 10 business days. This notification may be completed through an email and copied to the SDE of record on Report Card. 5.6 Management review 5.6S The organization management shall hold monthly QOS/BOS performance meetings. These meetings shall review all facets of the business including design, manufacturing, logistics, customer satisfaction, subcontractor performance and new business development. The meetings need not be held as one meeting, but may be a series of meetings covering each of the metrics each month. The QOS/BOS process shall be documented as part of the organization documentation. 6.2 Human Resources 6.2.2.2S Training The organization shall ensure that only trained and qualified personnel are involved in all aspects of the design and manufacture Visteon products. This training will include the appropriate Visteon systems. Records of training will be traceable to the revision of the source training material (e.g., policy, procedure, work instruction). These records are to be maintained for 3 years from the date of the training. 6.3 Infrastructure 6.3.1S Plant, Facility and Equipment Planning The organization shall have lean manufacturing implementation plans. 6.3.2S Contingency Plans The organization shall prepare a contingency plan following guidelines available at visteonsupplier.com. Upon request, the organization shall provide a copy of their contingency plans to Visteon. The organization shall notify Visteon receiving plants, the buyer and the SDE of record on Report Card within 24 hours of organization production interruption. The nature of the interruption shall be communicated with the immediate actions taken to assure supply of product. Production interruptions may include (but are not limited to) natural disasters, political unrest, war, capacity issues, quality issues, labor strikes or other events that prevent the organization from meeting the specified capacity volumes 6.4 Work Environment 6.4.2S Cleanliness of Premises This requirement includes the dunnage used to transport the product including returnable dunnage. 7. Product Realization 7.1S Planning of Product Realization The AIAG Advanced Product Quality Planning and Control Plan reference manual shall be used as a guide to develop and report progress on new programs. Reporting of APQP status shall utilize the forms and process flows provided by the responsible ASDE (SPE in Europe) and available at visteonsupplier.com. 7.2 Customer-related Processes Registration to ISO 14001 is required by December 31, 2004. End of life vehicle (ELV) reporting requirements are required as follows: Report prior to PPAP of the product and confirm completion for PPAP. Please contact the World Wide Visteon IMDS Manager (313-755-7384) for specific reporting requirements and see visteonsupplier.com. 7.2.1.1S Customer-designated Special Characteristics OEMs develop symbols for the definition of critical characteristics (safety sensitive) and significant characteristics (performance sensitive). Visteon has defined specific symbols for use on control plans, drawings or FMEAs and are documented in the Visteon Special Characteristics Identification Process at visteonsupplier.com. Some OEM programs may dictate the use of the OEM symbols. If so, the ASDE/SPE will notify the supplier of those requirements. 7.2.2.1S Review of Requirements Related to Product- Supplemental Waiving of the requirement to review product requirements shall be obtained from the Commodity Buyer. 7.2.2.2S Organization Manufacturing Feasibility Manufacturing feasibility reviews (AIAG, Advanced Product Quality Planning and Control Plan, Appendix E) shall include supplier and customer organizations as appropriate. Suppliers shall manage short-term product volume changes of less than 20%. The organization shall notify Visteon for volume changes of a more permanent nature, identify any capacity constraints and provide an evaluation of any risks to the customer. 7.2.3.1S Customer Communication-Supplemental During the request for quote response, the organization shall verify the data exchange formats with Visteon. The Buyer will assist in the coordination of the definition of these requirements. 7.3 Design and Development 7.3.1.1S Multidisciplinary Approach New Model Program Requirements Personnel The organization shall ensure that new Visteon programs are properly managed and resourced within the organization. A supplier Program Manager shall be appointed for each Visteon Program and an Organization Chart of their support team provided. Advanced Product Quality Planning The supplier shall carry out APQP on all new Visteon components. The Program Manager or their designee will lead the APQP Process for any new Visteon component and shall provide monthly updates of the APQP Status Report (and any supporting notes) to the Visteon Program Buyer. If a component has been designated as High Impact, the supplier shall also provide monthly updates to the Visteon Supplier Program Engineer (in Europe), Advance Supplier Development Engineer (at all other Visteon locations) or other designated person. All members of the organization’s support team shall be suitably trained in the particular APQP Process as defined by Visteon. An alternative quality planning process may be specified when required by Visteons Customer Input Requirements. Launch Readiness/Safe Launch Reviews The Program Manager or their designate shall ensure that the Visteon designated LRR/Safe Launch Process is carried out on any new Visteon component that has been identified as high impact. All data integral to this process such as Overall Equipment Effectiveness (OEE) and compliance to MMOG shall be made available to Visteon for confidential review. Visteon shall specify the type of Review Process to be followed and the reporting frequency. PSW Submission PSW submissions shall follow the AIAG PPAP manual, but the warrant shall be the Visteon form available at visteonsupplier.com. The organization’s PPAP Submission Level will be defined by Visteon in the APQP Process. This is normally set at the level identified in Report card, but may differ according to program or other requirements. An alternative approval process may be specified when required by Visteons Customer Input Requirements. Launch Support As agreed in the suppliers Safe Launch Plan, appropriate supplier personnel will either be on-site at Visteon or on 24 hr call to support a Visteon plants needs during a Launch Phase. Visteon will define the duration of this Phase. Launch Concerns The Supplier shall respond to Launch concerns in accordance with the Visteon Safe and Flawless Launch Expectations available at visteonsupplier.com FMEA and Control Plan Approvals Design engineering and SDE/ASDE/SPE approval is required for FMEAs and control plans for designated safety or regulatory items regardless of the sites PPAP level. Approval may take the form of PSW approval by SDE/ASDE/SPE and the responsible design engineer, but the preferred method is to sign the documents. Approval of changes to these documents after initial acceptance is also required. Visteon reserves the right to require approval of FMEA and/or control plans for any Visteon purchased part from any supplier organization. FMEAs The organization shall prepare documented process FMEAs for all part numbers supplied to Visteon. Where the organization is responsible for design, the organization shall prepare a documented design FMEAs for all parts it designs for Visteon. A formally documented design FMEA may be waived by the SDE/ASDE/SPE manager for parts that are commercial off the shelf items or which use computer aided design checks to check design integrity (e.g., design rule and manufacturability checks). FMEAs may be written for families of parts where batch processes and common tooling are used. Families shall be clearly defined and have a full part number listing of the family. Visteon engineering shall approve the family designations. Upon request by Visteon, the organization shall provide a copy of the FMEA documents for review. If the document is considered proprietary, the organization will provide qualified technical support and bring the FMEA to the requestor for review without retention of copies. FMEAs shall be prepared using the AIAG Potential Failure Mode and Effects Analysis reference manual as a guide. Control Plans All Visteon parts shall have Control Plans. Family control plans may be used for parts with common processes. The family shall be clearly defined on the control plan so that applicability is defined. The AIAG Advanced Product Quality Planning and Control Plan reference manual shall be used as a guide for the development and format of Control Plans. Design and process controls shall focus on prevention rather than detection and correction. Special attention shall be placed on the identification of input control characteristics rather than on post-processing inspection and containment. Repaired and/or reworked product shall be re-inspected to all control plan requirements and documented procedures. Control Plans for Control Items (Critical Characteristics) Fasteners Heat-treated parts will conform to the reference standard in the drawing notes. Traceability shall be maintained for lot control to the chemical composition and/or quenched hardness testing. External laboratories used to test material shall conform to the Laboratory Requirements of 7.6.3.2S. Changes to control plans for control items require the approval of the ASDE/SDE/SPE as appropriate and Engineering. Before implementation, the organization shall modify the control plans and submit them to ASDE/SDE/SPE and Engineering for signatures. 7.3.2.3S Special Characteristics Many of the OEMs