CONTROLLED SHIPPING – LEVEL 1 AND 2
What is Controlled Shipping 1?
CONTROLLED SHIPPING 1 is a demand by AAM to a supplier to place a redundant inspection process (over and above normal controls) to sort for defective material. This is done to isolate AAM and AAM’s customer from defective products. The data from the inspection is critical and must be used to drive process improvements. How would it work?
AAM will identify a supplier and part number that is having the problem. AAM Supplier Quality will place the supplier on Controlled Shipping 1 Containment. It is the supplier’s responsibility to provide additional inspection of the product and provide proof of that inspection process. A picture of the Data Tracking Board and defective parts display should be attached to the PRR. The inspection operation needs: Detailed instructions about the defect and how to sort for that defect High visibility, should be in a well traveled location Adequate lighting and space Proper tools to do the job Data Tracking Board - Highly Visible - Showing defect, job instructions, and containment data Suppler Corrective Action Plan showing plans to permanently correct the issue All checked characteristics must be identified using paint marking pens All measurement data must be sent to AAM Detroit Supplier Quality Assurance Department on a weekly basis. All product shipped to AAM under the terms of Controlled Shipping 1 must be clearly marked “100% Certified for (the issue).” CONTROLLED SHIPPING 1 EXIT CRITERIA
Action Plans and/or irreversible corrective actions must be in place and proven capable of preventing non-conforming material from reaching all AAM Facilities. Material received at AAM must be defect free for 60 days after corrective action is implemented. All inspection data must indicate no incidents during the same continuous period. If incidents are reported during that time, the Controlled Shipping 1 period will be extended. To be removed from Controlled Shipping Level 1, suppliers will provide a letter to the AAM contact person acknowledging that they have met the above controlled shipping exit criteria. If all the criteria has been met and the data shows that it is justified, a letter will be sent to the supplier indicating that they are removed from Controlled Shipping Level 1. The supplier will not terminate the Controlled Shipping Level 1 activity until the removal letter is received from AAM. CONTROLLED SHIPPING – LEVEL 1 AND 2
CSL REV 02.03 What is Controlled Shipping Level 2?
CONTROLLED SHIPPING – Level 2 is the same activity but the “person performing the sort” is an impartial third party (Contract Sorting House). This activity will be in addition to Controlled Shipping Level 1. This is needed in selective cases where the supplier’s personnel and/or process have proven to be incapable to isolate the problem. This will last until the situation is revolved and the company is released, in writing, from CS2.
How would it work?
AAM will identify a supplier and part number that is having the problem.
AAM Supplier Quality will place the supplier on Level 2 Containment.
It is the supplier’s responsibility to provide additional inspection of the product and provide proof of that inspection process. A picture of the Data Tracking Board and defective parts display should be attached to the PRR. In addition, it is the supplier’s responsibility to arrange with a “Contract Sorting House” to provide impartial inspection of the product. The name of that company must be told to AAM SQA.
The “Contract Sorting House” will send a person(s) to the supplier to do the inspection.
What would the “Contract Sorting House” people do?
Go to the supplier and set up the Controlled Shipping Operation.
The inspection operation needs: Detailed instructions about the defect and how to sort for that defect High visibility, should be in a well traveled location Adequate lighting and space Proper tools to do the job Data Tracking Board - Highly Visible - Showing defect, job instructions, and containment data Suppler Corrective Action Plan showing plans to permanently correct the issue All checked characteristics must be identified using paint marking pens All measurement data must be sent to AAM Detroit Supplier Quality Assurance Department on a daily or weekly basis. All product shipped to AAM under the terms of Controlled Shipping 2 must be clearly marked “100% Certified for (the issue).”
CONTROLLED SHIPPING – LEVEL 1 AND 2
CSL REV 02.03 What are the roles?
Function Responsibility
Supplier Provide space and tools for both level 1 and level 2 inspections Take corrective action Send Level 1 sort data to AAM Pay the entire cost of the sorting house Travel Room & Board Wages
Contract Sorting House Send people to the problem source Perform the inspection Record the Data Sent the Data to AAM Weekly
SQE Approve the standards and process Monitor data for compliance Issue the exit letter, when appropriate
LEVEL 2 CONTROLLED SHIPPING EXIT CRITERIA
Action Plans and/or irreversible corrective actions must be in place and proven capable of preventing non-conforming material from reaching all AAM Facilities.
Material received at AAM must be defect free for 60 days after corrective action is implemented. Also the third party inspection must indicate no incidents during the same continuous period. If incidents are reported during that time, the Controlled Shipping 2 period will be extended.
To be removed from Controlled Shipping Level 2, suppliers will provide a letter to the AAM contact person acknowledging that they have met the above controlled shipping exit criteria. If all the criteria has been met and the data shows that it is justified, a letter will be sent to the supplier indicating that they are removed from Controlled Shipping Level 2. The supplier will not terminate the Controlled Shipping Level 2 activity until the removal letter is received from AAM.
CSL REV 02.03