CLAAS KGaA mbH Postfach 1163 33426 Harsewinkel Guideline – Quality Tel.+49 (0)5247 12-0 www.claas.com Supply Chain Management. CLAAS Fertigungstechnik GmbH, Beelen
BRÖTJE Automation GmbH, Wiefelstede
CLAAS U.K. Ltd., AGROCOM GmbH & Co. Saxham/Great Britain Agrarsystem KG, Bielefeld
The CLAAS Group – CLAAS Selbstfahrende Erntemaschinen GmbH, Harsewinkel CLAAS Service and Parts GmbH, CLAAS Vertriebsgesellschaft mbH, Hamm Harsewinkel Locations worldwide. CLAAS Global Sales GmbH, Harsewinkel
Usines CLAAS France S.A.S., Metz-Woippy/ France CLAAS Industrietechnik GmbH, Paderborn
CLAAS Automation GmbH, Nördlingen CLAAS Tractor SAS, Vélizy/France CLAAS Hungaria Kft., Törökszentmiklós/Hungary
CLAAS Saulgau GmbH, CLAAS Réseau Agricole S.A.S., Bad Saulgau Vélizy/ France
CLAAS Tractor SAS, Le Mans/ France CLAAS Omaha Inc., Omaha/Nebraska/USA CLAAS France S.A.S., 000 CLAAS, Vostok, Paris/France Moscou/Russia CLAAS Ibérica S.A., 000 CLAAS, Madrid/Spain CLAAS of America Inc., CLAAS Italia S.p.A., Omaha/Nebraska/USA CLAAS India Ltd., Vercelli/Italiy Chandigarh/India
BRÖTJE Automation USA CLAAS India Ltd., Inc., Faridabad/India Omaha/Nebraska/USA
CLAAS of America LLC., Columbus/Indiana/USA
CLAAS Argentinia S.A., Sunchales/Argentinia
Agricultural equipment Stand 28.08.2008 Agricultural equipment Stand 28.08.2008 Product companies Product companies Sales companies Sales companies Production technology Production technology
Industrial enginee - Industrial engineering
CLAAS Group
2 3 The system solutions, products and services of the The following quality guideline for the entire CLAAS group CLAAS group represent technical innovation, highest qua - explicitly documents the valid QM elements for the buying lity and absolute reliability. process to be applied. Effective adherence to the descri - bed procedures for identifying concerns early will make The image of the CLAAS products and the loyalty of our error elimination possible. customers provide evidence for extraordinary perfor - Quality as a Principle. mances of CLAAS products and are also spur to continue Collaboratively we will agree to the relevant elements for our effort for quality and our pursuit of progressive system the respective business with you and use this as the base solutions. In particular the high customer satisfaction con - for our common supply relationship. The rigid application tributed to the continuous growth of the CLAAS group of this agreement leads to a continuous improvement of Worldwide. CLAAS. worldwide. the quality of our products and services. The achieved customer satisfaction is a guarantee for both parties for a Continuous improvement of our quality standards over the long-term and positive business development. entire supply chain process is our declared objective. The competence and motivation of our suppliers influences Quality policy significantly the reliability and quality of our products and services. Hence fundamental elements of our quality We are determined to exceed the expectations of our cus - understanding (philosophy) regarding our suppliers are tomers. We are committed to maintain peak customer - robust processes and their permanent enhancement satisfaction with faultless products and services. Quality is - proactive, open and fast communication the guiding principle in the way we do business. - professional project management and - the willingness for assumption of responsibility
Dr. Theo Freye Dr. Cornelius Weiß Rüdiger Mohr Speaker of the Executive Board Head of Corporate Quality Management Head of Corporate Purchasing
Editorial
4 5 No Compromises. Worldwide.
Content
I. General description ...... 8 II. General criteria ...... 9 Overview QM elements in the procurement process...... 10 III. Selection and Qualification Process ...... 12 1. Self assessment/References ...... 12 2. Audit ...... 12 3. FMEA ...... 13 4. Process Control Plan ...... 14 5. First Samples ...... 14 6. Process Capability ...... 16 7. Product audit ...... 17 8. Reliability Testing ...... 18 Supplier qualification process Flow Chart ...... 20 • Flow chart Component supplier...... 20 • Flow chart System Supplier...... 22 IV. Series Monitoring ...... 24 1. Continuous Evaluation ...... 24 2. Processing of complaints ...... 24 V. Further Agreements ...... 26 1. Special Release ...... 26 2. Logistic Agreement ...... 26 3. Emergency Plan ...... 27 4. Quality Assurance Agreement (QAA) ...... 27 5. Agreement of confidentiality ...... 27 VI. Appendix ...... 28 1. Definitions ...... 28 2. Abbreviations...... 29 3. Sources ...... 29
Content
6 7 I. General description. II. General criteria.
Purpose Responsibility Supplier CLAAS
This guideline explains the CLAAS quality standards to The supplier is required to adhere to the demands as laid Documented and certified QM system conforming to: • Clear and complete information to the supplier suppliers. The individual elements between the contractual out in the agreement and described in this guideline. • Clear communication channels and responsibilities partners will be fixed individually in our negotiation pro - • ISO / TS 16949, DIN EN ISO 9001, VDA 6.1 or • Specific, clear and generally comprehensible cess. The purchasing organisations of the individual locations upon approval by CLAAS Audit System documentation according to product-specific ensure that the agreed standards are implemented and • Development of a “Zero-Defect-Strategy” within the requirements The quality management standards, which are adhered to. quality planning. Elaboration of measures to achieve • Precise definition of volumes and delivery schedules documented here, are designed to ensure that: the quality objective “Zero-Defect” including the expected deviations - The produced components meet the CLAAS Support documentation • Understanding and acceptance of CLAAS • Support and advice specifications in every aspect requirements - The process capability and control of the supplier are The processes and techniques referred to in the • Qualified QM personnel such that the specifications are adhered to consistently. guideline use defined standards as reference (VDA, QS • Carrying out of required planning and test procedures, 9000 regulations). analyses, first samples, process control plan, process Area of Application capability, etc. • Open communication and information in regard to These requirements enter into effect with the agreement of - Problems that arise the establishment of a business between CLAAS and the - Demands that cannot be met supplier. - Capacity bottlenecks • Qualification of sub-suppliers If a quality assurance agreement (QAA) is concluded bet - ween CLAAS and the supplier, the supplier commits him - self to provide a similar QAA with other CLAAS compa - nies.
Premises
8 9 Overview QM elements in the procurement process
I. Selection and qualification process II. Series monitoring
QM elements in the Documents Information for QM elements in the Documents Information for procurement process the supplier procurement process the supplier
Supplier performance is 1. Self assessment / 1. Continous evaluation CLAAS Supplier Questionnaire Information Filled out by constantly monitored by references Assessment provided by supplier supplier CLAAS
2. Audits CLAAS audit Carried out by CLAAS 8D-Report / To be done by supplier 2. Processing of com - - System catalogue auditor at supplier CLAAS Form "Problem with every complaint plaints - Process Basis VDA 6 analysis"
3. FMEA FMEA Analyses Risk analyses carried VDA 4.1 / 4.2 or out by supplier QS 9000 FMEA III. Additional agreements
To be produced by the Request for Process control plan 4. Process control plan supplier to ensure 1. Exceptional Approval Exceptional Approval approval at CLAAS (QM-Plan / Control plan) process reliability before delivery
Agreement between To be produced by CLAAS 5. Samples VDA Volume 2 2. Logistic Agreement CLAAS and supplier supplier prior series Logistic Agreement QS 9000 PPAP production launch
To be carried out by VDA 6.1 6. Process capability VDA Volume 4 supplier for all marked * or 3. Emergency plan Supplier responsibility VDA 6.4 QS 9000 SPC seperate aligned characteristics
Agreement between VDA Volume 6 (Part 5) / Certificate of effectiveness 4. QAA 7. Product audit CLAAS QAA CLAAS and supplier audit system of the supplier of the QM system
To be carried out by Agreement between 8. Reliability VDA Volume 3 supplier if requested by 5.Agreement of confiden - Agreement of confidentiality CLAAS and supplier CLAAS tiality
*Symbol 1: *Symbol 2: Safety Critical Characteristic Key Characteristic / Functional Size Premises
10 11 III. Selection and Qualification Process.
1. Self assessment/References 2. Audit 3. FMEA
Objective Self assessment System audit Process audit Early recognition of potential for error in Objective Objective Objective design and/or production. Information about the supplier to complete the company Evaluation of the QM system of the supplier in respect of Assessment of process quality capability. profile on following points. - Completeness Support of the continuous improvement process. - General company data - Implementation Implementation - Technical information Implementation The supplier is requested to carry out a systematic - QM-System Implementation Process audits can be carried out in agreement between analysis of potential errors within design and/or production Auditing of the QM system by CLAAS auditors the supplier and CLAAS. planning. (Basis VDA 4.1 / 4.2, QS 9000 FMEA) References Basis: Basis: Objective - VDA Volume 6.1, Material Products - VDA Volume 6, Part 3 After completion of the engineering- / process- and / or • General information about the customer base of a - VDA Volume 6.2, Service - CLAAS process audit questionary system-FMEA the documented risk priority numbers potential supplier (RPN) may not be higher than 125. Timing and scope of the audit will be mutually agreed A process audit is carried out either on individual compo - • Additional input based on information gleaned from between CLAAS and the supplier. nents or on component families, if they are manufactured existing customers. using the same process. Note: only when both parties agree.
Implementation The questionnaire about supplier self-assessment is to be filled out by the supplier and to be returned to the purcha - sing department.
Selection and Qualification Process
12 13 4. Process Control Plan 5. First Samples
Objective Objective Sample selection Assurance that CLAAS quality standards are complied The supplier provides proof that the products have been Samples must be produced and tested under serial condi - The supplier is responsible for compliance to the material with by describing the planned processes, methods and produced under series conditions and that they comply tions (machinery, equipment, machining conditions) specifications of the product (including labelling, physical checking procedures. with the CLAAS specification. Components for series pro - characteristics etc.) duction require a written approval for first samples. Testing of production samples (Dimensions, Material Implementation testing). All test results have to be recorded in the sample report. The supplier plans and documents the procedures for Implementation The supplier has to assure for himself that all characteri - parts and component groups (QM-plan / Control plan). The supplier provides the samples and documents to The supplier is responsible for checking all the parameters stics comply with CLAAS specifications. CLAAS quality organisation. (Based on VDA Volume 2) on five parts. CLAAS supports the supplier with the review of CLAAS Even in cases where the supplier is not able to carry out documents (e.g. drawings, instructions, standards). Complete filled and signed sample report and, if requested The test samples are to be tagged clearly so that they can dimensional or material checks, the responsibility stays by CLAAS, inclusive process control plan. be easily matched to the test results. with the supplier. Then the checks have to be carried out Preventive action by a suitably qualified, reputable organisation. Manufacturing procedures must be checked beforehand Clear matching of drawing parameters to test results by When components have been pre-assembled the highest for possible errors (e.g. by use of FMEA or similar markings in the drawings as well as clear matching of test level of completion has to be sent to CLAAS. If requested Any deviation from these specifications requires an weakness analysis). results to the proband. the documentation for the single components has to be approval by CLAAS. marked accordingly and attached. Supporting documentation for process capability for all marked * characteristics and reliability data, if specified in the drawings.
*Symbol 1: *Symbol 2: Safety Critical Characteristic Key Characteristic / Functional Size Selection and Qualification Process
14 15 6. Process Capability 7. Product audit
Objective Minimum requirement Documentation Objective Proof of process capability by use of statistical methods Machine Capability / Short term Capability – Cmk ≥1,67 During production, the documentation is provided by the Inspection of the level of effectiveness of the QM activities for the critical characteristics as defined * in the drawings Process Capability / Long term Capability – Cpk ≥ 1,33 methods of statistical process control (SPC). installed by the supplier in respect on components or or separately aligned characteristics. The shape of distribution has to be checked, e.g. families involved. Gaussian Distribution. Attributive critical characteristics • Reduction of checking effort for customers In cases of attributive characteristics, which are marked Implementation and suppliers Process capability analyses characteristics * in the drawings (“safety critical” or as • The supplier is requested to plan and carry out product • Early recognition of process changes (Trends) The supplier checks the capability on at least 125 produc - “important”), all of the samples selected for the capability audits. Basis: VDA Volume 6.5 tion parts produced in sequence. Preferably the sample tests have to meet the specifications. • The results are to be analysed and documented in a Implementation batch should be produced in 25 lots of five units each. comprehensible manner, which includes target At marked * or separately aligned parts, which have a The process capability calculation takes place with familiar definition major impact on function, safety, assembly and reliability statistical methods (VDA Volume 4, QS 9000 SPC). • Deviations have to be eliminated by fault analysis and of the product. corrective actions Variances Proof If the characteristic does not comply with the given crite - The supplier at least has to prove that all marked parts ria, a selection test has to be carried out until 100% com - have been produced under controlled process conditions pliance is reached. The planned and implemented correc - (controlled and stable). tive actions are to be documented in action plans with schedules and responsibilities and made available to CLAAS if requested.
*Symbol 1: *Symbol 2: Safety Critical Characteristic Key Characteristic / Functional Size Selection and Qualification Process
16 17 8. Reliability Testing
Objective Reliability test procedures Confirmation that the product involved meets the lifetime The supplier refers to the specifications and drawings from specified by CLAAS. the CLAAS R&D function for the test procedure. In the case that CLAAS R&D gives no clear specifications the Implementation missing information has to be requested by the supplier.
Reliability tests Reliability analysis methods The supplier carries out reliability tests on the products The analysis and interpretation of the results are analysed that have been attributed a specific lifetime in the CLAAS using the Weibull method. drawings and documentation. Basis: VDA Volume 3, reliability testing
Calibration of the reliability test equipment Documentation The test rigs must be calibrated in accordance with the Test conditions and test results have to be recorded and manufacturer’s instructions with reference to the relevant when required to be presented by CLAAS. national norms.
Minimum standards A minimum product conformance level of 0.95 (95%) has to be attained in order to carry out the reliability data ana - lysis. Products, which fail to meet the minimum specified lifetime would not be accepted under any circumstances.
Selection and Qualification Process
18 19 Supplier qualification process Responsible Flow chart component supplier 1 1) Supplier 2) Supplier qualification team 3) Purchasing 4) Purchasing 5) Purchasing 6) Supplier Checking of drawings and 7) Supplier qualification team preparation of a process control 10 plan 8) Supplier qualification team 9) Supplier Self assessment by supplier 1 10) Supplier 11) Supplier qualification team 12) Supplier 12 Checking of correction and Checking of process control 13) Supplier documentation plan and drawings 11 Not 14) Purchasing O.K. 15) Purchasing Supplier information, no Supplier self assesment is 3 further action checked 2 O.K. 16) Purchasing Not 17) Supplier O.K. 18) Supplier qualification team O.K. Finalisation of quotation and time 19) Supplier schedule 13 3 20) Supplier qualification team
Drawings are prepared for 4 quotation purposes Not O.K.
15 Negotiation with supplier Checking of quotation and time schedule 14 Not O.K.
O.K. Revision of the quotation C* 5 Quotation is checked 6 Not O.K. Order of first samples 16 O.K.
QM system and / 7 or product audit Samples are shipped 17
O.K.
Audit results checked Corrective action defined 8 and carried out 9 Release for Checking of first samples B* 19 series production 18 Not O.K. A* O.K.
Release for series production 20 1 * A, B, C – Supplier classification
Selection and Qualification Process
20 21 Supplier qualification process Responsible Flow chart system supplier 1 1) Supplier 2) Supplier qualifiation team Supplier self assessment 1 3) Purchasing 4) Supplier qualifiation team Checking of 5) Supplier qualifiation team Corrective action documents 16 17 Not and drawings 6) Supplier 7) Purchasing 3 Supplier information, Supplier self assessment 2 O.K. no further action is checked O.K. Not 8) Purchasing 9) R&D / Purchasing O.K. O.K. 10) R&D / Purchasing 4 11) Purchasing QM System and / or product audit 12) Supplier 17 Corrective action Checking of calculation 18 Not 13) R&D / Project Management O.K. 14) Supplier O.K. 15) R&D / Project Management 5 Definition and 16) R&D / Purchasing Review of audit results implementation of 6 C* B* corrective actions. 17) Supplier 18) R&D / Purchasing / Management A* Checking the test 19) R&D 17 Corrective action 19 results of the prototypes 20) Supplier qualifiation team Agreement of confidentiality 7 Not concluded O.K. 21) R&D O.K. 22) Supplier qualifiation team
Handing over of required specifications to supplier 8 First sample process 17 Corrective action (see flow chart 20 Not component supplier) Specifications are checked with O.K. the supplier in order to clarify open 9 O.K. points and make quotation
11 Supplier information, Feasibility evaluation 10 Evaluation of the results of no further action and costs 17 Corrective action the field tests / pre-series 21 Not Not O.K. O.K. O.K. O.K. Handing over of specification book including detailed project plan is 12 given to CLAAS Reworking of 14 specifications and / or the project plan Release for series production 22
Checking of specifications 13 Not of the project plan O.K. O.K.
Follow up of project plan including defined development steps 15
* A, B, C – Supplier classification 1
Selection and Qualification Process
22 23 IV. Series Monitoring.
1. Continuous Evaluation 2. Processing of complaints
Objective Objective Basis for intensive and steadily improving business relati - Rapid elimination of the fault at CLAAS. onship is the optimisation of the testing process at CLAAS Damage limitation by narrowing errors down. and the supplier. It is important to give feedback to the Resolution of the problem, no repetition. supplier on the level of quality supplied including improve - ment potential. Implementation • Rapid detailed information to the supplier by CLAAS Implementation • Joint agreement about immediate measure • Continuous monitoring of the relevant data • Analysis of the problem by supplier - Quality • Documentation by the supplier of at least - Logistics - Problem - Costs - Cause - Innovation - Immediate measure - Motivation - Elimination measure • Analysis of the data and continuous information • Or conform to the VDA 8D - systematic to supplier • In the event of unsatisfying evaluations the supplier is required to formulate a written statement about cause and corrective action including proof of efficiency
Series Monitoring
24 25 V. Further Agreements.
1. Special Release 2. Logistic Agreement 3. Emergency Plan 4. Quality Assurance Agreement (QAA)
Objective Objective Objective Objective Avoid that components, which are nonconforming, get, • Minimal carrying costs by bundling of supply transports Continuity of supply in case of crisis, as for example may Approval of direct delivery to the place of use in the factories. without a special release, into the production process. and intelligent carrying concept result from: Decreasing of CLAAS goods incoming inspection. • Improvement of inventory by coordinated supply - machine or tool breakdown • Securing the delivery capability frequency - breakdown of computer system Implementation • Improvement of the process by standardised container - power failure The QAA will be agreed as an addition of the basic supply Implementation concept and shipping documentation (according to - damage to buildings and equipment (natural disasters) agreement. The QAA relevant products will be specified and After detection of a deviation the supplier has to inform VDA recommendation 4902) - supply bottlenecks of material documented accordingly. CLAAS (purchasing / procurement) immediately in written form. CLAAS decides on further action and informs the Implementation Implementation 5. Agreement of confidentiality supplier in written form. CLAAS Logistics Agreement Joint agreement on components that are essential for an emergency programme. Objective Implementing of the decision With this agreement both parties ensure the confidential For the case of a delivery approval for a limited lot size • Development of an emergency plan handling of all information and data, which will be exchanged these lots have to be marked clearly and precisely in the • Joint checking and approval of the emergency plan between CLAAS and the supplier. shipping documents regarding to the exceptional appro - val. Basically the delivery only can be carried out after sub - Implementation mission of the approval. CLAAS Agreement of confidentiality.
Further Agreements
26 27 VI. Appendix
1. Definitions 2. Abbreviations 3. Sources Cp/Cpk value - Process capability value VDA Volume 2: Quality Assurance of Supplies R & D - Research and development VDA Volume 3: Reliability assurance of car manufacturers DIN EN ISO 9001 Capability of measurement FMEA - Failure potential and influence analysis and suppliers New certification norm for quality management systems, Measuring of the degree of inaccuracy in relation to the PCP - Process control plan VDA Volume 4: Quality assurance during product realisation QM - Quality Management VDA Volume 6 (Part 1): QM system audit Material Products which was edited by the German (DIN), European (EN) tolerance of the characteristics to be measured. QAA - Quality assurance agreement VDA Volume 6 (Part 2): QM system audit Service and International Organization for Standardization (ISO). RPV - Risk priority value VDA Volume 6 (Part 3): Process-audit System supplier SPC - Statistical Process Control VDA Volume 6 (Part 4): QM system audit Production Equipment Critical Characteristics Takes responsibility for development and production of an VDA - German Automotive Industry Association VDA Volume 6 (Part 5): Product audit Characteristics of a product or production process that assembly, which can be separated functionally, such as QS 9000 PPAP Guideline Production Part Approval Process have a considerable influence on safety, function, assem - cutter bars, brakes, steering, hydraulics QS 9000 APQP Guideline Advanced Product Quality bly, adherence to legal safety standards and customer Planning and Control Plan satisfaction. Component supplier QS 9000 FMEA Guideline Failure Mode and Effects Analysis Works on the basis of documents, drawings, specificati - QS 900 SPC Guideline Statistical Process Control Lifetime ons etc. provided to them with no development responsi - QS 9000 MSA Guideline Measurement System Analyses Period from initial use to the point of failure after which the bility. product cannot be returned to a functional state. Weibull media rank method Supply Reliability Statistical method used in calculating product and Adherence to the requirements regarding on date of component reliability. delivery and delivery quantity.
Appendix
28 29 Forward-looking. Worldwide. CLAAS.
Future
30 31