K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa 1.0 SCOPE Ths document specfes the general requrements for mass producton supplers and/or tool bulders that work drectly wth Sumtomo Electrc Wrng Systems, Inc. 2.0 DEFINITION AND ACROYNMS SEWS HDD OCSC CEG DET Prototype (PT) Tool Mass Producton (MP) Tool Tool Bulder or Tool Maker DWG, Dwg SEWS SM PV Test Defectve Parts Inspecton Standard (IS) NG Sumtomo Electrc Wrng Systems, Inc., SEWS Wre Harness Plants, Component and Warehouse, Engneerng, and Procurement SEWS Honda Development Department located n OCSC Oho Customer Servce Center (Marysvlle, OH) SEWS Corporate Qualty Dvson Component Evaluaton Group SEWS Detrot Engneerng Offce (Farmngton Hlls, MI) Tool developed for customers prototype tral event, whch could be used for mass producton Tool developed for mass producton Company that bulds the tool Drawng (It could be referrng to customer approved drawng or Sumtomo techncal drawng) SEWS Manual (www.sewsus.com/supplers) Part Valdaton Test requred by OEM. PV test s a responsblty of SEWS supplers Parts produced by tool makers or mass producton supplers that were judged defectve The Inspecton Standard ssued by SEWS to dentfy part specfc qualty requrement No Good or Not Good TDRS Tool Desgn Revew Sheet (COMP FORM 05) Progress Chart MP Tool Development Progress Chart (CEG-FORM-37) Devaton Devaton Request Sheet (CEG-FORM-03) Request Sheet MPR Mnmum Process Requrement (Honda Applcaton) (CEG-FORM-19) PV Test & PPAP Requrement TTAS GP-12 COA SEWS Qualty Requrements for new component s kcked-off by SEWS Procurement. (CEG-KO-01) Tool Transfer Approval Sheet and Process (CEG-FORM-36) Early Producton Contanment. A term orgnated from General Motors Specfc Secton of the Producton Part Approval Process procedure. Certfcate of Analyss also known as Materal Certfcaton Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa 3.0 TOOL DEVELOPMENT REQUIREMENTS 3.1. PROTOTYPE TOOL Applcaton Ths apples when PROTOTYPE TOOL needs to be kcked off and SEWS has not chosen the mass producton suppler Quotng Process The tool bulder wll supply a quote (pece prce) based upon the SEWS tool forecast. Tool bulder shall quote wth 3D data, SEWS Dwg, and/or customer Dwg. If SEWS s not able to provde a hghly detaled drawng for prototype quotes, specal nstructon wll be gven to the tool bulder for quotng (quote from current MP shape or Dwg, extra detal gven for crtcal areas, etc). Communcaton SEWS wll communcate drectly wth the tool bulder. The tool bulder s responsble for updatng and reportng the tool buld status to SEWS on a weekly bass utlzng SEWS Progress Chart. If t s deemed necessary by SEWS, the tool bulder wll be responsble for daly updates. Tool Development After each Dwg or data ssuance, the tool bulder must communcate any NG toolng condtons, toolng concerns, Dwg concerns, etc utlzng TDRS to SEWS as quckly as possble. SEWS prefers the tool bulder to request possble 3D modfcatons based on NG toolng condtons to SEWS pror to kck-off. Tool bulder shall not modfy toolng data under any crcumstance wthout notfyng SEWS and ganng SEWS authorzaton. Tool bulder must provde suggestons and mprovement requests to SEWS when the tool cannot be bult to the specfed desgn due to the tool lmtatons. SEWS wll requre the followng data and nformaton for or after the Kck-off Meetng. Plastc Products a. Drafted tool model b. Gate desgn and locaton c. Ejector pn sze and locaton d. Mold flow analyss e. Slde nformaton f. Insert nformaton g. Partng lnes Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa h. Engravng specfed n the drawng. Tool desgn concerns and change request Rubber Products a. Gate desgn and locaton b. Mold flow analyss (f technology s avalable at Toolng Desgn) c. Partng lnes d. Engravng specfed n the drawng e. Tool desgn concerns and change request Steel (Stampng) Products a. 3D data of progressve strp OR 2D flat blank layout b. Trm clearance % c. Engravng specfed n the drawng d. Tool desgn concerns and change request Part Qualty The tool bulder must nspect 100 percent of the parts before all shpments to SEWS The tool bulder s responsble for the quantty and the qualty of parts shpped from ther faclty or from any 3 rd party facltes If the tool bulder dscovers defectve parts upon ther pre-shpment nspecton, the defects must be removed and not be shpped to SEWS. The only excepton s n a stuaton where defectve parts have been approved by both CEG and Engneerng departments pror to the shpment SEWS wll requre replacement part at the tool bulder's expense f parts were rejected due to qualty defect dscovered durng nspecton or manufacturng trals n SEWS SEWS wll nspect all shpments from the tool bulder and may provde a qualty report to the tool bulder. The tool bulder s responsble to acknowledge the recept of the report and to submt a countermeasure report f requested by SEWS. Shpment Delvery due date and quantty wll be gven when the P.O. s ssued. The tool bulder must meet the P.O. requrement. If there s an ssue wth quantty or due date, t s the tool bulder s responsblty to nform SEWS and obtan approval to adjust the requrement. Raw Materal Procurement SEWS Procurement Department wll support the coordnaton of the raw materal procurement. Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa 3.2. PROTOTYPE TOOL wth SEWS DIRECTED MP SUPPLIER Applcaton Ths apples when SEWS has chosen or targeted a Mass Producton Suppler durng PROTOTYPE TOOL development phase. Quotng Process The Mass Producton Suppler wll supply a quote (pece prce) based upon the SEWS tool forecast. The Mass Producton Suppler shall quote wth 3D data, SEWS Dwg, and/or customer Dwg. If SEWS s not able to provde a hghly detaled drawng for prototype quotes, specal nstructon wll be gven to the tool bulder for quotng (quote from current MP shape or Dwg, extra detal gven for crtcal areas, etc). Communcaton SEWS wll communcate wth Mass Producton Suppler. The suppler wll communcate wth the tool bulder The suppler s responsble for updatng and reportng the tool buld status to SEWS on a weekly bass. Detaled requrements for Progress Charts can be found n the SEWS PV and PPAP Requrement (CEG-KO-01). If t was deemed necessary by SEWS, the suppler wll be responsble for daly updates. Tool Development After each Dwg or data ssuance, the tool bulder must communcate any NG toolng condtons, toolng concerns, Dwg concerns, etc utlzng TDRS to SEWS as quckly as possble. SEWS prefers the tool bulder to request possble 3D modfcatons based on NG toolng condtons to SEWS pror to kck-off. Mass Producton Suppler shall not modfy toolng data under any crcumstance wthout notfyng SEWS and ganng SEWS authorzaton. Mass Producton Suppler must provde suggestons and mprovement requests to SEWS when the tool cannot be bult to the specfed desgn due to the tool lmtatons. SEWS wll requre the followng data and nformaton for or after the Kck-off Meetng. Plastc Products a. Drafted tool model b. Gate desgn and locaton c. Ejector pn sze and locaton d. Mold flow analyss e. Slde nformaton Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa f. Insert nformaton g. Partng lnes h. Engravng specfed n the drawng. Tool desgn concerns and change request Rubber Products a. Gate desgn and locaton b. Mold flow analyss (f technology s avalable at Toolng Desgn) c. Partng lnes d. Engravng specfed n the drawng e. Tool desgn concerns and change request Steel (Stampng) Products a. 3D data of progressve strp OR 2D flat blank layout b. Trm clearance % c. Engravng specfed n the drawng d. Tool desgn concerns and change request Part Qualty The suppler must nspect 100 percent of the parts before all shpments to SEWS The suppler s responsble for the quantty and the qualty of parts shpped from ther faclty or from any 3 rd party facltes If the suppler dscovers defectve parts upon ther pre-shpment nspecton, the defects must be removed and not be shpped to SEWS. The only excepton s n a stuaton where defectve parts have been approved by both CEG and Engneerng departments pror to the shpment SEWS wll requre replacement parts at the suppler's expense f parts were rejected due to qualty defect dscovered durng nspecton or manufacturng trals n SEWS SEWS wll nspect all shpments from the suppler and may provde a qualty report to the suppler. The suppler s responsble to acknowledge the recept of the report and to submt a countermeasure report f requested by SEWS. Shpment Delvery due date and quantty wll be gven when the P.O. s ssued. The suppler must meet the requrement. If there s an ssue wth quantty or due date, t s the suppler s responsblty to nform SEWS and obtan approval to adjust the requrement Raw Materal Procurement SEWS Procurement Department may be able to support the coordnaton of the raw materal procurement. Durng the quotng process, Raw Materal Procurement Process must be dscussed and agreed between SEWS and the suppler. Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa 3.3. MASS PRODUCTION TOOL wth SEWS DIRECTED MASS PRODUCTION SUPPLIER Applcaton Ths apples when prototype tool development phase s complete, and SEWS has chosen a mass producton suppler for a MASS PRODUCTION TOOL Communcaton SEWS wll communcate wth the Mass Producton Suppler It s the responsblty of the suppler to communcate all nstructons and gudelnes requred to produce a qualty part to ther tool shop or to ther contracted tool bulder For extreme emergency cases, SEWS may communcate drectly wth the tool bulder; however SEWS wll always nclude the suppler by copyng them n the communcaton. It s the suppler's responsblty to stay updated and to clarfy any questons or ssues. The suppler s responsble for updatng and reportng the tool buld status to SEWS on a weekly bass usng SEWS Progress Chart. Detaled requrement of Progress Chart can be found n a SEWS PV and PPAP Requrement (CEG-KO-01). If t s deemed necessary by SEWS, the suppler wll be responsble for daly updates. Tool Development After each Dwg or data ssuance, the tool bulder must communcate any NG toolng condtons, toolng concerns, Dwg concerns, etc utlzng TDRS to SEWS as quckly as possble. SEWS prefers the tool bulder to request possble 3D modfcatons based on NG toolng condtons to SEWS pror to kck-off. Mass Producton Suppler shall not modfy toolng data under any crcumstance wthout notfyng SEWS and ganng SEWS authorzaton. Mass Producton Suppler must provde suggestons and mprovement requests to SEWS when the tool cannot be bult to the specfed desgn due to the tool lmtatons. SEWS wll requre the followng data and nformaton for or after the Kck-off Meetng. Plastc Products a. Drafted tool model b. Gate desgn and locaton c. Ejector pn sze and locaton d. Mold flow analyss e. Slde nformaton f. Insert nformaton g. Partng lnes h. Engravng specfed n the drawng. Tool desgn concerns and change request Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa Rubber Products a. Gate desgn and locaton b. Mold flow analyss (f technology s avalable at Toolng Desgn) c. Partng lnes d. Engravng specfed n the drawng e. Tool desgn concerns and change request Steel (Stampng) Products a. 3D data of progressve strp OR 2D flat blank layout b. Trm clearance % c. Engravng specfed n the drawng d. Tool desgn concerns and change request Part Qualty The suppler s responsble for the qualty of all produced parts shpped by ther tool bulder. The suppler s responsble for on tme delvery as agreed upon the recept of an offcal request or Purchase Order (PO) The suppler s responsble to nvestgate and take necessary countermeasures f or when SEWS fnds qualty or process problems. The report must be submtted to SEWS for revew. The suppler s responsble for nspectng 100 percent of nventores shpped to SEWS untl PPAP s approved. Once PPAP s approved, the suppler s requred to mplement a GP-12 or Safe-Launch Program. The suppler s responsble to comply wth SEWS Suppler Manual, PV Test and PPAP Requrement, MPR (Honda Applcaton), SEWS Inspecton Standard, and SEWS Packagng Gudelnes for the duraton of the APQP process ncludng toolng buld, part samplng, and mass producton. Tool Transfer Approval Process The Tool Transfer Approval Process s requred f the tool bulder s located n a dfferent country as the Mass Producton faclty. The suppler can transfer the tool to the Mass Producton Suppler s locaton only after obtanng approval from SEWS. The suppler s requred to submt the Toolng Transfer Approval Sheet (TTAS) along wth the applcable drawng, dmenson data (ISIR), applcable functon data, and Materal Certfcaton (or COA, Certfcate of Analyss) The tool must be n-transt to the Mass Producton Suppler s locaton wthn 14 days of TTAS approval unless there s a wrtten agreement between the suppler and SEWS. Once the TTAS s approved by SEWS, changes to the tool at the tool bulder s prohbted unless there s a wrtten approval by SEWS. If the suppler judges that some of the qualty ssues cannot be resolved untl the tool s at the Mass Producton Suppler s ste, a Devaton Approval Request must be submtted to SEWS along wth TTAS. The suppler must note the root causes, proposed countermeasures once tool s at Mass Sumtomo Electrc Wrng Systems, Inc.
K. Endo M. Sampson D. Newcomb G. Perezchca I. Estorga K. Takgawa Producton Suppler s ste, and expected countermeasure completon date n the devaton request. It s suppler's responsblty to montor the movement of the tool from ther tool bulder to the suppler s ste. The movement of the tool must be clearly noted n the SEWS Progress Chart. Progress Chart must show the date of tool shpment. Tool Tral at Tool Bulder Due to the early tral events scheduled by SEWS customers, SEWS may ssue a P.O. for a large volume of parts that must be produced by the tool bulder's faclty. If n these cases, the suppler must confrm that ther tool bulder utlzes a machne that s smlar n tonnage as the planned suppler mass producton machne. Raw Materal Procurement and Supply to Tool Bulder Suppler s responsble for procurement of raw materal and supplyng enough amounts to the tool bulder for trals and requred quantty to SEWS. SEWS Procurement Department may be able to drect suppler to a rght contact for raw materal procurement. Sumtomo Electrc Wrng Systems, Inc.