Skoda Specific Quality Requirement v3 [PDF]

Zitiervorschau

ŠKODA AUTO, a.s. specific quality requirements

These specific ŠKODA AUTO a.s. quality requirements specifies cooperation conditions between the supplier and the company ŠKODA AUTO in order to ensure quality of the parts and the processes within the purchasing and supplier chain.

LAH 5E0 011 FAHRZEUG

Petr Štický

Head of prod.tech.-E/E and supplier audit Tel.: +420-326-821139 E-Mail: [email protected]

Version 3.0 1.3.2016

Roman Mogalle-Kiebler

Frank Schreier

MGMT Quality Assurance ŠKODA AUTO a.s. Tel.: +420-326-811638 E-Mail: [email protected]

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Head of QS Product technique/purch.parts

Tel.: +420-326-821135 E-Mail: [email protected]

Introduction The ŠKODA AUTO specific quality requirements describe general conditions for the supplier of purchased parts in terms of the ŠKODA AUTO a.s. quality. The ŠKODA AUTO specific quality requirements specify and complete the requirements for quality defined in the documents of VW Concern Formel Q. The part specific requirements are available in the part technical requirements documentation of the technical development or in the technical specifications drawings.

During the demand phase, the supplier receives supported documents which represent the quality requirements for the part requested (series of the Formel Q documents and ŠKODA AUTO a.s. quality technical requirements). While processing the offer, the supplier is obliged to consider the requirements and by submitting the offer the supplier confirms that he is aware of the stated requirements in the ŠKODA AUTO a.s. technical requirements and that he accepts them and will respects and meets them without reservation. The supplier is responsible to implement the requirements in his supply chain including orders placement (e.g. relocated production processes, “outsourced” process operations, manufacture of parts in another production site, hired labour etc.).

In case of any deviations or situations when the ŠKODA AUTO a.s. specific quality requirements are not met, is the supplier obliged to specify them in the purchase order for the purchasing department and to discuss the issue with specialized divisions. If changes or non-observance of the requirements emerge while implementing the development, production and supply of parts, the quality department reserves the rights to transfer the related extra-costs arisen on behalf of the supplier.

The Czech version of the quality technical requirements of ŠKODA AUTO a . s . is the binding document. When contradictions arise, the Czech version will prevail. Copying, use and transfer of the technical requirements is only allowed to the suppliers within the ŠKODA AUTO a.s. supplier chain.

The use of the applications in the protected zone of the supplier KBP platform www.vwgroupsupply.com is needed for the supplier and ŠKODA AUTO quality department cooperation. A prerequisite is a particular registration of the supplier in the protected zone (login) and acceptance of individual applications, before placing an order.

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Contract documents in order to ensure quality of supplies to Co. ŠKODA AUTO a.s. Cooperation conditions between the supplier and the company AUTO a.s. are specified in the documents below. The supplier is obliged to familiarize with the documents and fulfil obligations defined there. The documents are being updated on a regular basis and the supplier is obliged to follow the changes. Valid are documents as currently amended. Information about updating of the ŠKODA AUTO .a.s quality requirements is available on the internet (http://www.vwgroupsupply.com) by the means of the application INBOX. All updated documents can be found at www.vwgroupsupply.com

Other related documents, for instance: Specific quality requirements for parts, related standards, drawings, etc. VDA publications and standards in the automobile industry, available at www.vda-qmc.de • TLD-BZD (Documentation of design status of cars from the point of view of mandatory documented parts) • Obligation of identification of fitment parts (BG) defined in TLD-BZD for the supplier (see document on KBP) • Legal regulations and requirements for supplied products – valid without restrictions • •

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Content Introduction Other related documents Content 1. Demand and offer processing 1.1. Offer conditions 1.2. Tender documents 1.3. Processing of supplier concept 1.4. Framework agreement on quality 2. Contract awards quality criteria 2.1. Elements of supplier assessment 2.2. Measures to ensure contract awards 2.3. Agreement on liability for concept (KVV) 3. Working with suppliers in the product design process 3.1. New parts Integral qualification programme/Maturity level assurance/ Purchased part management 3.2. Important milestones for QPNi maturity levels 3.3. Cubing/Meisterbock evaluation 3.4. Requirements for measuring and measuring performance 3.5. Graining of mould / part 3.6. Sampling 3.7. 2-day production (2DP) 3.8. Changes in capacities during current serial production 4. Quality actions during serial production 4.1. Continuous guarantee of process capability 4.2. Product safety, product liability 4.3. Identification and solving of issues 4.4. Continuous improvement programme 4.5. Change management 4.6. Requalification 4.7. Lessons learned 4.8. Solving of liability for defect issues and solving of special issues 4.9. Supplier technical review (TRL) 4.10. “Critical supplier” programme 4.11. Applications review (AR) 4.12. External service providers 4.13. Supplier qualification to rating “A” 5. Additional information/requirements 5.1. Reasons to charge the supplier, charge-back by customer quality department 5.2. Requirements for internal/external auditors at suppliers 5.3. Quality technical requirements (QTR) 5.4. Use of recycled material 5.5. Requirements for observance of the ESD rules at the suppliers Terms and abbreviations List of revision

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2 3 4 5 5 5 6 6 7 7 7 7 8 8 10 10 11 13 13 15 15 16 16 16 16 16 18 18 18 19 19 19 19 19 19 19 19 20 21 21 21 22

1.

Demand and offer processing

1.1. Offer conditions Chapter 1.1 Formel Q-Concrete valid without restrictions. Other mandatory requirements: • • • •

Access (registration) to the VW KBP platform of the Concern suppliers www.vwgroupsupply.com Installation of other IT connections to ensure cooperation with the ŠKODA AUTO A.S. quality department. Assurance of a German-speaking contact person. Correspondence with ŠKODA AUTO A.S. quality is carried out in Czech/German language.

1.2. Tender documents Chapter 1.2 Formel Q-Concrete valid without restrictions. Other mandatory requirements: Following documents and requirements need to be provided for the documents stated in the point 1.2: • • • • • • •

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Planning of defected parts flow from the quality point of view, see also VDA standard “Analysis of defected parts from field” (Schadteilanalyse Feld) Control devices for the certain project (e.g. gauges, models of devices) must be involved and specified clearly in an offer. Availability of general standard test devices (e.g. 3D gauge, colorimeter etc.) is required. Electrical components, units and function parts: filled-in checklist “Requirements for production and test technology of electric and electronic production groups”. Coolant hose: Requirements for production and test technology of coolant hoses Free of charge samples and documents necessary for release and sampling (samples to approve prototypes, initial samples etc.) Observance of valid environment legal regulations Observance of generally valid legal regulations: the supplier is obliged to ensure observance at the time of valid legal regulations in particular markets and to prove them to ŠKODA AUTO a.s. where appropriate. ŠKODA AUTO a.s. must be promptly informed about changes (e.g. loss of registrations or certificates) (see also related documents “List of COP contact persons at ŠKODA AUTO a.s.”). Obligation to register the production plant of the suppliers/sub-suppliers at the platform www.vwgroupsupply.com. The supplier is obliged to define a name of a product safety inspector (record to the LDB - VWGroupSupply.com), responsibility lies with the supplier (obligation to provide the information). Each production site must have an own DUNS number and must be registered at LDB. This applies both for the current and new supplier, the sub-suppliers (UL) as well as the potential suppliers.

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1.3. Processing of supplier concept Chapter 1.3 Formel Q-Concrete valid without restrictions. Addition to nomination of responsible persons: A qualified and well informed quality department representative involved in work of the SET and project must be nominated until the project SOP. His name, function and deputy are ranked to the production group SET and BTV/TV (responsible component engineer) via the system LION for each project separately. Persons responsible for quality control and product safety are written into the supplier database (www.vwgroupsupply.com) – see chapter 4.2. Production planning: Presentation of planned production processes, distribution of the production within a plant and supply chains is supposed to be done in an appropriate way, e.g. using a 3D representation, image documentation. 1.4. Framework agreement on quality Chapter 1.4 Formel Q-Concrete valid without restrictions. Notification of changes in production process and supply chain: Any production relocation (also within one production site) or essential changes1 in the production process must be announced to the customer (dept. Purchasing, Logistics, Quality, R&D) always in writing signed by authorized representatives of the supplier in advance and a range of changes, a concept of deliveries and a timing plan of the implementation specifying main milestones (implementation date, sampling, BMG if relevant, pre-stock of parts, internal release after relocation, customer release) must be provided. An approval by ŠKODA AUTO a.s. is required before the implementation. If the ŠKODA AUTO a.s. Purchasing department does not agree otherwise, the costs arisen will be transferred to the supplier. After the production relocation, changes to the process or to the product, new sampling of the parts and development release (BMG), if relevant for the part, are required. Samples necessary for the release must be provided to the particular department of ŠKODA AUTO a.s. Quality and R&D for free together with the current life history of the part. Changes to the deliveries are informed to appropriate ŠKODA AUTO a.s. plants through the LION system. The parts and supplies after the implemented change or the production relocation must be visibly identified as per the agreement with the quality operator of ŠKODA AUTO a.s. responsible for the specific purchased part. In case of the production relocation or significant changes to the production process is the supplier obliged to carry out internal two-day production in order to confirm the production capacities and quality of the supplied parts. The resulting report will be provided to the Purchasing, Logistics, Quality and R&D.

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Changes in supplies, e.g. design, material and its composition, production procedure, sub-supplier and/or production site

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The supplier/sub-supplier is obliged to announce in writing any changes to the address or the company’s name in LDB department GQD-3 Supplier audit and the Purchasing department of ŠKODA AUTO a.s.. Additions to module suppliers and selected parts: In case of several direct contracted suppliers, the supplier who supplies the final assembly to the customer or who carries out the assembly, undertakes the responsibility (system supplier). The system supplier (the supplier of assemblies covering assembly activities and responsible for individual components/assemblies) is also responsible to meet the requirements for assuring the quality at his sub-suppliers. In case of “selected parts” there are following points: • • • • • • • • • • •

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To ensure and prove quality capability and performance of the supply chain1. To define agreements on quality assurance considering the ŠKODA AUTO a.s. quality requirements. To ensure information flow between contract partners. Requirements for handling with D/TLD parts and for documents needed2. Requirements to assure the traceability of parts. To carry out initial sampling of all parts/assemblies from the sub-suppliers, unless agreed by the customer otherwise during the offer phase. To carry out 2-day production prior to serial SOP at the sub-supplier (fulfillment of quality programme QPNi according to the Formel Q New parts – Integral). To ensure quality and volume of supplied parts over the product life time. To implement the Formel Q requirements on the whole supply chain. To take over the responsibility for quality of purchased parts and “selected parts” regarding assembly and condition of supplies during shipping. Initial sampling is done by the supplier of the assembly/system/module. Deviations and exceptions of this statement agreed between the supplier, Purchasing- and Quality department ŠKODA AUTO A.S. must be confirmed in a written contract.

Contract awards quality criteria

Chapter 2 Formel Q-Concrete valid without restrictions. 2.1. Elements of supplier assessment Chapter 2.1 Formel Q-Concrete valid without restrictions. Consideration of rules and methods of QTR and UL. 2.2. Measures to ensure contract awards Chapter 2.2 Formel Q-Concrete valid without restrictions. A requirement to sustain the note of the audit is max. 1.1 (car audit). 2.3. Agreement on liability for concept (KVV) Chapter 2.3 Formel Q-Concrete valid without restrictions. ________________ 2

See also Formel Q Capability

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3.

Working with suppliers in the product design process

3.1. New parts Integral qualification programme / Maturity level assurance /Purchased part management Chapter 3.1 Formel Q-Concrete valid without restrictions. Application in system LION: Only online processing in the module LION QPNi via the supplier platform of the VW Concern KBP is acceptable in case of new contracts. All requirements in the documentation stated in the following chapters must be implemented online only in LION with particular modules: a. TTA (Parts-dates-contact persons) b. QPNi (Qualification programme for new parts Integral) c. CoRe (Commitment & Review) d. TGS (Part generation level) For given procedure there are requirements defined in the Formel Q new parts and rules of application according to the QPNi manual for suppliers, LION. All data and information must be available in the German language. Exceptions must be discussed with a responsible person for the part. Quality planning in design and pre-series phase: The supplier is obliged update the quality framework schedule in the QPNi in order to include all agreed milestones of the project defined by the customer (e.g. SOP, 0 series, PVS, quality assurance process, FMEA, test periods, BMG release, initial sampling, 2DP, release). The supplier is obliged to send electronically the data recorded in QPNi during the project monitoring to the particular responsible component engineer (BTV) of the ŠKODA AUTO a.s. Quality department (Prio A, B, C). The supplier is responsible for implementing suitable QFD analyses, feasibility studies, strategies of zero defect, FMEA design and process analyses (on request also in German/English) including concepts to ensure quality and measurement (e.g. statistical analyses of tolerances including assembly parts and assembly variability influences), process flow graphs, operational equipment and maintenance plans. The Design-FMEA is submitted to the technical development and the Process-FMEA to relevant ŠKODA AUTO a.s. departments. The supplier defines significant quality signs of the product and the process during the development, proved by relevant customer departments, e.g. within the SET activity. If the customer submits requirements, these must be considered primarily. The supplier is obliged to create test plans (including requalification ones) and to present them to a relevant department of ŠKODA AUTO a.s.. The checking signs of the product and the process resulting from the defined quality signs are included in these test plans. This rule is especially for the D/TLD parts. And all the signs together with the mandatory documentation must be defined in the test plan. Electrical parts, assemblies and functional parts must be 100% checked for the function of the supplied unit. The supplier must prepare a COP test plan for supplies

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significant for COP (worldwide valid legislations for production conformity). The supplier is supposed to define or provide suitable test equipment until the first serial tools (SWZ) or limited production tools (KSW) are made. Dimensioning of this test equipment needs to be agreed with a responsible component engineer (BTV). When procuring the test equipment, the possibility to carry out inspections of some relevant parameters must be considered (e.g. function, dimension, fitment, assembly). The capability of all test equipment is determined by analyses until the 0 series launch based on the general rules valid for the European automobile industry summarized in the manual “Determination of capabilities of measuring systems”. Within the responsibility of the supplier for the quality of related supplied parts (complete systems) used for assembly of final assemblies during the preparative or the final phase (e.g. cockpit, front end module), additional test equipment for independent assessment (e.g. Meisterbock of parts, fitment and assembly cubing) should be agreed at the supplier together with adequate measuring devices. The supplier is obliged to update the QPNi module in the system LION throughout the design phase and the process to ensure the possibility to monitor the activities during their planning and implementing. Assessment and corrective actions are done according to the QPNi classification. Parallel to the launch of the serial supplies, the ppm programme for complaints from the 0 km and the customer field is discussed and launched to ensure the continuous quality improvement of the serial production. The ŠKODA AUTO a.s. quality department expects supplies according to the time schedule, technical specifications and drawing requirements. The parts must meet all functional-technical, assembly-technical, dimensional, physical, chemical, kinematic and visual requirements as well as environment requirements, stated in the technical documentation. Furthermore, all the requirements defined in this technical requirement sheet must be met without restrictions. Part history, parts marking, quality proving for pre-series: The aim is to properly allocate the supplier and his manufacturing site as well as the production data to the specific ŠKODA part number. Part history: Recording of the part history in the LION system begins together with first production start of the pre-serial phase. All part changes, sampling notes, release and modification are recorded in there. Repeated supplies without changes of the status do not have to be recorded. During the pre-series, the part history must be attached to the quality certification for each modification. In case of a requirement from ŠKODA AUTO A.S. a.s. the supplier is obliged to feed data into the Lion TGS system Quality certification for pre-series: See document “Quality certificate for pre-series”. Changes during serial supplies: The supplier is responsible to announce all changes notifiable as stated in the chapter 1.4. (see also chapter 3.7 Initial sampling).

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3.2.

Important milestones for QPNi maturity levels

Chapter 2.1.1 Formel Q New part Integral is valid without restrictions. 3.3.

Cubing / Meisterbock evaluation:

Regarding the milestones VFF / VFA the supplier will introduce, after agreement with the responsible ŠKODA AUTO a.s. quality engineer (BTV), the current status of the parts including complete measuring reports in order to provide evaluation on the internal or external Cubing / Meisterbock. All the visual parts in the car interior and particular fixing points are evaluated at Cubing / Meisterbock. During this evaluation is also carried out correlation of the colour and gloss measuring, if needed also other specific properties of the part. The supplier is responsible for modification and approval of his supplies volume. The supplier bears responsibility concerning the function, matching, appearance, haptic, smell, throughput, fitment process capability, operator comfort (operating forces, noises) and flexibility. The supplier together with the sub-suppliers carries out the modification loops. For Cubing / Meisterbock are supplied current samples in two versions (colour and type agreed with the metrology of Cubing / Meisterbock). As circumstances may require, more than two parts can be demanded. Evaluation requirements for Cubing / Meisterbock: Significant requirements are: • Parts produced on serial tools or limited production tools / serial single tools • Parts with corresponding marking • Parts with particular measurement report together with: - given fixing and reference points - given sequential and functional contours - dimension stability verification while comparing the nominal and actual values - given settings Deviations are displayed in a coordinates overview according to mathematical rules about signs or using the overview perpendiculars (+ too much on part, - too little on part). When displaying sequential contours, e.g. according to cuts, it is needed to record the course of the contours and display comparison of the regulation and the reality of the data in the area in the rate of 1:1. In principle, the data are edited and displayed to fulfill the report from measuring (principle sketches), series numerical are not accepted. The method of representation is agreed in advance together with the ŠKODA AUTO a.s. quality engineer (BTV).

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3.4.

Requirements for measuring and measuring performance Positioning fixtures for 3D measuring

The measuring position of the part is primarily defined in the technical position (like the part in the car). Exceptions must be agreed with ŠKODA AUTO a.s.. The design of the positioning fixtures for the 3D measuring must be according to the standard 39D 690 - Werks-Norm für die Konstruktion von Bauteilaufnahmen / Messaufnahmen (ehemals Handbuch 20). The positioning fixture must enable scanning of RPS points in order to balance the part directly on the measuring part. Secondary RPS points must be able to be measured after single placing of the part into the fixed as well as free condition, i.e. without fixation using clams either supports. Support of such secondary RPS point must be designed as removable or shifting by 20mm. The design of the positioning fixture of the supplier must be the same as the fixture of Co. ŠKODA AUTO a.s., if ŠKODA AUTO a.s. has his own positioning fixture for the particular part. ŠKODA AUTO a.s. specifies a list with so called PRIO parts for the specific project, the supplier must send them for approval to the quality department of ŠKODA AUTO a.s., design proposal of the positioning fixture in the format 3D CAD compatible with Catia V5. The positioning fixture must be produced with accordance to the approved design proposal which can be checked on site at the suppler by ŠKODA AUTO a.s.. The positioning fixture must be at the supplier at the latest by the date o f TBT VFF ZP5/ZP7 based on the project plan. Holes in metal parts Holes in all the metal parts supplied to ŠKODA AUTO a.s. must be performed according to the standard 39V 875 – Erstellen von Presswerkzeugen. Measuring of parts Regarding the measuring of the parts the supplier must use only SW which meets all the requirements defined in the points below. The measuring programme for measuring of the parts must be according to the PMP points if they are available for the specific part and stored in KVS, measuring principles defined in the PMP based on the VW 10126 standard must be followed while measuring. The direction of the normal deviation during measuring must be the same as the direction defined in PMP. The supplier defines a fixing plan for each measured part. Fixing plans for PRIO parts to be provided in ŠKODA AUTO a.s. for approval.

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ŠKODA AUTO a.s. reserves the rights to add other points above the range of the ones defined in PMP. The ŠKODA AUTO a.s. quality department provides a list with parts for which the supplier will send measuring results to the SPL system. Measuring frequency and results sending to the SPL system is once a week. ŠKODA AUTO a.s. reserves the rights to change this frequency on the basis of the current needs. The positioning of the parts and RPS measuring must meet the standard VW 01055 – Classification of reference points (RPS). Format of results of the measured values in SPL The file of the measuring output must be a text format which is possible to read in the SPL system. The output of the measuring elements must always contain at least X, Y, Z, plus other items based on the type of the measured element, this does not apply for distances. Patterns for the acceptable formats of the measuring reports for the SPL system are available on request in the quality department of ŠKODA AUTO a.s.. Requirements for cubing For all parts must be cuing at the supplier including integration to the control plan, deviations must be agreed in writing by the quality department ŠKODA AUTO a.s.. The positioning of parts in cubing must simulate the positioning conditions in a car. Required tolerances: surfaces in area without relation to function outline and surfaces in area with relation to gaps basic surfaces and holes sizes of holes and cut-outs basic frame - base acceptable total tolerance in assy incl. basic frame

± 0,2 mm ± 0,1 mm ± 0,1 mm max. + 0,2 mm ± 0,05 mm ± 0,2 mm

Material for cubing inserts: Required stainless steel: ČSN 17024 or EN 1.4031, alloying: X39Cr13. VW design regulation for cubing: 39D20501. To perform reference elements for balancing of SMS as holes of ø20 with milled (or grinded) front surface so that all the reference coordinates are accessible to the measuring sensor from the measuring side of the part. Identification of the measuring points and coordinate positions is done according to the ŠKODA AUTO a.s. assignment and it is defined during the meeting about dimensioning of the test equipment. The measuring data are always recorded and processed electronically, manual data exchange is not accepted. Individual changes must be agreed with the responsible quality engineer (BTV). The way of measuring and fixing must simulate the actual conditions in a car (partial

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Cubing) and it is a part of the product audit at the supplier. 3.5.

Graining of mould / part:

The release for graining is done by the supplier in writing after approval with the responsible quality engineer (BTV) and it is a part of the supplier’s timing plan. 3.6.

Sampling Initial samples and conditions for their release:

Also the requirement from Formel Q New parts Integral are valid without restriction. Initial samples must be produced under the serial conditions by the use of the serial equipment and are delivered to the Quality department of ŠKODA AUTO a.s. and documented through the online system BeOn. The delivery dates for the initial samples are approved by the Purchasing department and documented in the LION system. The use of the BeOn system is mandatory for initial and follow-up sampling. More information is available at the B2B platform (www.vwgroupsupply.com). The supplier is charged for additional costs arisen when not meeting the ŠKODA AUTO a.s. requirements (e.g. not meeting the requirements for the serial production, incomplete supply of required initial samples, incomplete documents for sampling, sampling in another place than in the defined production site, delivery of samples to wrong production site/ wrong unloading place, …). The supplier is obliged to inform the company ŠKODA AUTO a.s. on time about any potential delay. Incomplete documents as well as non-fulfilment of the technical specification requirements leads to non-acceptance of the initial sampling report (total Note 6). For parts with a sampling result 3 and 6, the supplier must carry out repeated/new sampling. Regarding the 0-series, a sampling result “Note 1” must be submitted. For the initial sampling are submitted at least 5 parts (samples) including the initial sampling inspection report (ISIR). The exact quantity of parts is approved by the particular responsible component engineer (BTV) in advance. On request also semi-finished products or individual subcomponents of the part or a certain supply must be provided for the purpose of the sampling (valid throughout the whole product service life time). The initial sampling is required in case of: - new parts - each technical modification - new and/or modified production facilities, tools/spare tools - changed production processes/methods (internally or at the sub-suppliers) - production relocation (internally or at the sub-suppliers, new sub-suppliers)

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- longer production cut-off (> 1 year) - new customer place of Volkswagen Concern Sampling level according to VDA 2. Level 0: cover sheet, material data sheet, certificate, e.g. for granulates, glues, colours. Level 1, 2 and 3: see VDA 2. When unclear, the implementation and range of the repeated sampling has to be discussed with a particular responsible component engineer (BTV) in advance. Production conditions during the production of the parts intended for the sampling are recorded. These are the basis for evaluation during 2DP (see also 3.7 – 2-day production audit – 2DP). If ŠKODA AUTO a.s. sampling does not confirm the test results of the supplier stated in the ISIR and assessment is “Note 3” or “Note 6”, the supplier is charged for the costs associated with the tests implementation. If there is a need to carry out an inspection of the supplier process when “Note 3” or “Note 6”, the supplier may be charged (e.g. travel expenses). If the supplier declares and identifies all deviations from the technical specifications in advance, there is no financial charge (e.g. unfinished BMG tests, missing graining, incorrect function of SW, etc.). Initial sampling inspection report content: The documents for the initial sampling must be complete in the BeOn system. Among others, these include: - Completely filled-in cover sheet of the initial sampling report with appendix according to the VDA 2 and the drawing document/specific quality requirements - Production location with a number of the supplier (incl. index) and DUNS No. - Part history - Exact chemical composition of the used materials including all the substances of the individual parts via the IMDS. Regular data transfer into the BeOn system may occur in case of accepted records only. If the data about the material acceptance by ŠKODA AUTO a.s. is not available in the IMDS, the initial sample is automatically assessed with “Note 6”. In this case, a repeated sampling must be carried out. The recording into the IMDS for complete parts and assemblies must be carried out according to the rules about data feed for complete parts and assemblies - Material safety data sheet according to the EU regulation on hazardous substances for materials, fixtures and products, established under the European law on hazardous substances - The transfer of measured values for non-metal material interior parts is carried out according to the valid standards. The results must be from a certified lab. - The filled-in measuring report including drawing, or principal sketch with marked measured points – no numeric columns. All unobserved characteristics or out of tolerances dimensions or non-achievement of the defined values for the function tests need to be agreed in advance with a particular designer. Deviations from the technical specifications must be recorded in the ISIR documentation. If a deviation has been issued by the ŠKODA AUTO a.s. R&D, this must be attached.

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- Complete control report involving all the tests of single parts, function tests, surface quality tests etc. - Submission of the process capability for the defined significant features - When sampling the assemblies, it is necessary to define sub-suppliers. The supplier is obliged to provide results of individual parts/components sampling done at the sub-suppliers and attach to the sampling documentation for ŠKODA AUTO a.s.. Within the supply chain, the sub-supplier will provide results of sampling for the customer to the supplier and documents related to the sampling. On request of ŠKODA AUTO a.s., all the sampling documentation within the supply chain shall be provided to the appropriate Quality department of ŠKODA AUTO a.s.. - Weight data of parts/assemblies are always defined in grams per piece (g/pc). - In case of repeated sampling, the part number with a previous generation index level and particular number of the ŠKODA control report is recorded in the BeOn system in the field “Previous ISIR”. Delivery address of initial samples: The initial samples for sampling need to be delivered according to the time schedule and in the defined quantity to the particular customer plant, where the sampling will be carried out. It will be informed by the Purchasing department of ŠKODA AUTO a.s. a.s. while ordering. The packing units of the initial samples must be clearly identified “Initial sample”. 3.7.

2-day production (2DP)

Requirements from Formel Q New parts Integral are valid without restriction. Production release: obligation of the supplier to store the data about the stability of the machines and the devices, the production and the products (Cm, Cmk ,Cp, Cpk, SPC, …). Product audit: the supplier must carry it out for at least 5 pieces of the product. Destruction tests are required for 1 piece minimum. Visual inspections, function tests, dimensional tests etc. are carried out for 5 pieces, if the customer does not specify otherwise. Product weight: if the production weight of the parts does not correspond to the calculated weight defined in the drawing document, after analyzing it, is the supplier obliged to inform the particular operator of the R&D department of ŠKODA AUTO a.s.. The final product weight has maximum tolerance +-5%. 3.8.

Changes in capacities during current serial production

In case of significant rise or drop of the previously planned production capacities (based on a nomination letter +15%) there needs to be carried out repeated 2DP. The procedure needs to be discussed with the responsible quality engineer (BTV).

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4.

Quality actions during serial production

4.1.

Continuous guarantee of process capability

Chapter 4.1 standards of the Formel Q-Concrete valid without restrictions. Additional requirements for process capability: ŠKODA AUTO a.s. expects from the supplier and from the whole supply chain consistent assurance of robust production process as per VDA and Formel Q. Significant product signs are defined in the drawing documentation and the Specific quality requirements of R&D, if available for the particular part. The supplier must define production/process conditions in order to ensure the required process capability to reach zero defect regarding the product and to describe them in the production/process control plan. For continuous check and approval of the process capability focused on selected significant signs are valid the following boundary values: • preliminary process capability Ppk >= 1,67 • long-term process capability Cpk >= 1,33, with continuous improvement (goal: Cpk >= 1,67) Both short-term and long-term capability is checked. For SW relevant parts including assy supplies (JIT/JIS e.g. frontend, bumper, dashboard) there is SW management to ensure up-to-dateness based on the requirements of the Volkswagen Concern production plant – up-to-dateness of the supplied SW/HW incl. appropriate SW/HW updates. 4.2.

Product safety, product liability

Chapter 4.2 standards of the Formel Q-Concrete valid without restrictions. 4.3.

Identification and solving of issues

Chapter 4.3 standards of the Formel Q-Concrete valid without restrictions. 4.4.

Continuous improvement programme

Chapter 4.4 standards Formel Q-Concrete valid without restrictions. Complaints from 0 km: Only released sampled parts can be delivered to the series. Claimed parts must to be sent to the supplier to carry out a prompt failure analysis. Root causes, corrective actions and implementation dates are defined for failures. The effect of the actions implemented is then checked. The same procedure refers to the sub-supplier, too.

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The complain process is done online via the KPM Halle portal. Current actual ppm values for the 0 km are available in the SCQ system on the KBP portal “Process description to process insufficient supplies (claims from field) between ŠKODA AUTO a.s. and supplier” (www.vwgroupsupply.com). The agreed ppm values are obligatory and are taken into account when evaluating the supplier – here apply FORMEL Q agreements (Formel Q-Concrete valid without restrictions). Sorting and re-working: Only faultless parts (released parts) can be delivered to the series. After detecting a failure on purchased parts in the ŠKODA AUTO a.s. plants, the supplier must immediately and without delay, provide an expert assistance on site, sorting activities, spare supplies or rework activities. If the supplier cannot ensure this service by himself without delay, the purchased parts quality department of ŠKODA AUTO a.s. is competent to implement a 100% check of the parts by an external company at the production line by well-known Troubleshooting and additional cost is transferred on the supplier in case his fault is proved. When repeated issues occurred with the quality of supplies, the purchased parts quality department ŠKODA AUTO a.s. can initiate a 100% check of the supplies via WARENFILTER and the supplier is obliged to ensure the 100% check of the supplies via this filter. Other specifications of the warranty fulfillments remain the same. Field complaints: For claimed purchased parts from the field (complaints from contract services), the supplier must ensure a prompt analysis, implementation of necessary corrective actions and verification of the implemented measures efficiency, as well as required measurements at the sub-suppliers. To avoid failure repeating, reworking of the current process FMEA at the supplier is to be always ensured. It is subsequently submitted to the quality department ŠKODA AUTO a.s.. Besides these issues, which must be agreed with a responsible worker for parts, the supplier is also obliged to ensure the NTF process (NTF no trouble found) according to the VDA Analysis of defected part from the field for the NTF contribution bigger than 30%, based on minimal 15 defected parts per year. Other information related to this process can be found in a document “Rules for further charge resulting from field and 0-km complaints caused by supplier / Regelung zur Weiterbelastung von lieferantenverursachten Feld- und 0-km Beanstandungen“ in KBP.”. The complaints are processed via the online portal KPM Halle if available to both sides. Defect causes and accepted corrective actions are communicated through the 8D report.

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At the supplier is implemented an effective system of evidence/archiving of analysed parts. Early warning system Chapter 4.3.2 Formel Q-Concrete valid without restrictions. Obligation for own monitoring of the customer field Chapter 4.3.3 Formel Q-Concrete valid without restrictions. Customer field monitoring evidence: Each supplier must know how his products behave when being used. The supplier must be able to prove his activities which are running in order to be informed about the performance of his parts when being used. For this purpose serve parts analyses obtained from the field claims in the reference market. Moreover, the failure rate can be monitored through the list of spare parts on a monthly basis worldwide. Long-term quality: The supplier participates actively on removing failures led by ŠKODA AUTO a.s. when parts are being used (vehicle service life time), if the time of its usability (service life) has not been limited by contract (generally technical requirements of R&D e.g. for used parts such as brake lining or rubber wiper blades). The supplier is obliged to carry out his own specific tests for volumes of supplies important from the point of view of COP (internationally valid legislations) (see also 3.1). These tests are recorded and results sent to a contact person for COP in ŠKODA AUTO a.s.. 4.5.

Change management

Chapter 4.5 Formel Q-Concrete valid without restrictions. Immediate implementation of changes released by sampling by a responsible quality engineer (BTV) is expected. 4.6.

Requalification

Chapter 4.6 Formel Q-Concrete valid without restrictions. Documentation: Tests and their documentation according to the ISO TS 16949, chapter 8.2.4.1, need to be carried out at once in three years, unless otherwise defined. For parts with the D/TLD documentation must be followed an interval for requalification performance at least once a year (see Formel Q capability). 4.7.

Lessons Learned

Chapter 4.7 Formel Q-Concrete valid without restrictions.

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4.8.

Solving of liability for defect issues and solving of special issues

After being released by the customer, the supplier is still responsible for the product safety and function as well as for informing him in case of any deviations from legal requirements. Chapter 4.8 Formel Q Concrete s valid without restrictions. 4.9.

Supplier technical review (TRL)

Chapter 4.9 Formel Q-Concrete valid without restrictions. 4.10.

“Critical supplier” programme

Chapter 4.10 Formel Q-Concrete valid without restrictions. 4.11.

Applications review (AR)

Chapter 4.11 Formel Q Capability is valid without restriction. The application review is usually done at manufacturers of plastic parts for interior and exterior. 4.12.

External service providers

The supplier must have all equipment necessary for analyses. Also external service providers may be invited to the analyses in exceptional cases (universities, institutions, external laboratories). These external service providers must submit a valid certification for these specific activities. The supplier is responsible for documentation management towards ŠKODA AUTO a.s.. 4.13.

Supplier qualification to rating “A”

Formel Q Concrete valid without restriction.

5.

Additional information/requirements

5.1. Reasons to charge the supplier, charge-back by customer quality department -

Problem analysis (PA): confirmation of supplier’s fault Supplier self assessment (SL): repeated self assessment result < 90% or nonconfirmation of the self assessment result during the customer process audit. The applicant for the order is not charged for the first audit cost.

-

Supplier technical review (TRL): TRL result RED

-

Process / product audit (VA): 1, “C“ – supplier evaluation (quality not capable) 2, Repeated evaluation “B“ – see Nomination agreement

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-

Sub-supplier management (UL): result RED (transferring costs to the direct supplier)

-

Quality target agreement: the target agreement about decreasing the failure rate has not been fulfilled (HSF, ppm, SF, audit points)

-

Vorcheck: result RED

-

2-day production (2DP): result RED or repeated YELLOW

-

Production relocation: unplanned, unannounced or unapproved production relocation

-

Sampling of parts: re-sampling – comments to the documentation, incomplete documentation, differences between the test results, the deadline of the resampling was not met, none or very small improvement after re-sampling, the deadlines defined at the „Readiness meeting“ was not met.

-

Occurrence of defects C1, B, B1, A, A1 found by the customer at check points, during drive tests DKA (Dynamische Kurzaudit – extended drive test) and car audits.

-

Car audit: the audit notes not reached during the car audit

-

HSF– supplier responsibility, complaints from customer field: extra costs incurred at the customer plant, VW Concern

Transferring costs to the supplier - quality extra costs for actions done at the supplier -

Travel expenses incl. accommodation costs

-

Daily expenses: expenses for creating reports according to the tariff rate (occupational category of employees)

-

Output: the number of man-days for the auditors of the Volkswagen Concern who are on duty at the suppliers

-

Critical supplier programme: integration into level 2 or 3

5.2.

Requirements for internal/external auditors at suppliers

The lead auditor must be an iternal employee of the plant/company. Any differences must be agreed in writing with a particular auditor of the Volkswagen Concern.

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5.3.

Quality technical requirements (QTR)

Chapter 2 and 3 Formel Q Concrete and chapter 2.2 Formel Q New parts Integral valid without restriction. The ŠKODA AUTO a.s. Quality department reserves the right to carry out QTR including actual check of the status on site at the supplier. 5.4.

Use of recycled material

The use of recycled material is allowed only with a writing approval of the ŠKODA AUTO a.s. R&D. The information about the recycled material ratio must be specified in the drawing document of the product, sampling, IMDS. Repeated use of the recycled material is prohibited. 5.5.

Requirements for observance of the ESD rules at the suppliers

Requirements for fulfilment of the ESD rules at the suppliers of Assembly units (bumpers, Frontend, Cockpit, assy headliners and sunroofs, seats, door modules, powertrain) It is highly necessary to follow the below stated rules while assembling ESD relevant parts to assembly units based on the Specific quality requirements and standard VW 80132 (ESD-Richtlinie für Automobilhersteller): Logistics:

- check of ESD packing regarding damage at receipt from suppliers - handling with parts in the designated area (EPA-zone) - when repacking into internal packing units to follow basic rules for ESD protection: earthed work area, ESD shoes and coats for operators, if defined to use gloves as well - to use ESD packing material for internal handling

Production: - to assemble ESD relevant parts only in designated areas which are protected against unauthorized use (EPA) - before entering the zone where ESD relevant parts are assembled, to ensure testing of operators, at least once a shift, incl. records - to provide ESD shoes and clothes, maybe also gloves, for operators handling with the parts or who are in the EPA-zone - in case of for final electric testing of parts, to ensure appropriate inspection and maintenance for the devices Before entering the zone where are ESD relevant parts assembled, to ensure testing of operators, at least once a shift, including records. To ensure training in all levels of the operators at all the work places. For more details see the standard VW 80132 available to all suppliers at KBP.

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In case of further inquiries please contact: Denis Mach, GQD-3, [email protected]

Terms and abbreviations

3D AE

Three dimension

Supplied products/parts BeOn BMG BTV/TV CAD Cpk COP ČSN EMPB HSF HW / SW OK Supply chain

Parts/products to be provided by ŠKODA/Volkswagen to the supplier for further treatment/processing at the defined cost or free of charge. System for online sampling of parts (Bemusterung Online) Release, approval of design sample Responsible component engineer/technical responsibility ŠKODA AUTO a.s. Computer Aided Design (design with computer support) Index of process capability Conformity Of Production

EN KBP KPM KVS LDB NTF PMP Ppk ppm QDX QFD QPNi QS QTR SCQ RPS SET

European standards KonzernBusinessPlatform (Concern portal for suppliers) KonzernProblemManagement (VW Concern system) System for design data management of VW Concern Lieferantendatabank – database of supplier at vwgroupsupply.com No Trouble Found

SMS SPL

Coordinate measuring device System for evaluation, presentation and work with measuring results on 3D SMS machines press shop and weld shop

SW

Software

Abweicherlaubnis (Deviation permit)

České státní normy (Czech national standards) Erstmusterprüfbericht – ISIR (Initial sampling inspection report) Hallenstörfälle (Defects on part at 0km) Hardware / Software All correct Also sub-supply chain, Supply Chain: The supply chain include all planned and implemented • Sub-suppliers of purchased parts, • Defined creators of values (dislocated work place, dislocated production site, production partner, sub-supplier, defined third side within production site) • Development services, • Test services and laboratories, • Defined supporting function e.g. logistics, maintenance or • Other services which may have a direct influence on the product quality or production process.

Plan of measuring and checking points Preliminary Capability. Preliminary process capability Parts per Million. Defines a rate of defected parts to 1 million of supplied parts within a given period Quality Data Exchange (standard VDA to the data exchange for the 0 km / service network – field online Quality Function Deployment Qualification programme for new parts / Formel-Q New parts Integral Quality assurance Quality Technical Requirements Quality assurance and parts monitoring system (Quality status) Reference Points system Simultaneous Engineering Team (cross functional team, a group of representatives from various departments of the company which are involved in the process of the product creation)

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Selected parts (setzteile)

Parts being defined in written by ŠKODA/Volkswagen as individual parts or assemblies including a year volume of purchase and prices in the framework agreement contracted with a third supplier which are; however, purchased or being available via the system /module supplier. These “selected parts” are sampled and released by workers of the system/module suppliers responsible for assemblies. Volumes of the selected parts refer to parts and volumes which are submitted to the supplier by the purchasing regarding the place of origin.

TBT VFF

Teilebereitstellungstermin Vorserien-Freigabe-Fahrzeuge (delivery date of parts pre-series, release, car)

TL TLD UL VDA VFF Zákazník ZP5 ZP7 ZSB

Technical delivery conditions Technical guideline for documentation Management of sub-suppliers Association of AUTO A.S.motive industry Cars released to pre-series: with parts from serial tools before PVS ŠKODA AUTO, a.s. Zielpunkt 5 Zielpunkt 7 Assembly of parts

Further definitions of terms see Formel Q-Concrete.

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Overview of versions Version

Date

1.0.

18.10.2010

Description Initial version, lastenheft proposal based on Audi AG Work group - changing to Škoda Auto requirements

2.0, 2.1.

22.9.2011

New Škoda logo Changing wording to Škoda requirements Removing non-valid documents which were referred to Removing references to documents which are already in FQ concrete Adjusting single font type Approving by head of Škoda Auto quality department, signed by Dr. Bort - publication, 3 language versions

2.2.

10.5.2012

Changing texts: p. 7 - specifying requirements for DUNS numbers p. 9

- Audit note (vehicle audit)

p. 15 - adding text Note 3, individual notes, overall note p. 17 - process audit - removing scoring system Saving LAH into KVS and employee portal Reviewing text format 2.3.

16.11.2012

Changeover to KBP - p. 3 - removing reference to quality documents valid on B2B Changing texts:

p. 3 - LAH.893.909.A changing index to C p. 16 - adding text to tests results according to TL1010

Removing logo "Qualitätssicherung" from all headings of all pages 2.4.

5.3.2013

Changing texts: p.4 - instead "News" is "INBOX" p.19 - Sorting and re-working - Correction of text

2.5.

27.6.2013

Changing texts: p. 1 - Updating names of Škoda's managers p. 2 - Replacing "costs" by "extra costs" p. 3 - Purchasing conditions for production material - "for Škoda Auto" deleted p. 11 - Completing sentence - requirement for Lion TGS p. 12 - Quality certificate for pre-series - correcting document's title p. 14 - Deleting sentence: The VDA volume 4.1 and the Škoda regulation… p. 17 - Deleting sentence: Checklist “Requirements for production and test technology… p. 19 - Deleting title of VDA volume p. 21 - Replacing "anytime" by "by mutual agreement"

2.6.

18.2.2014

Changing texts:  p.  1 - Updating names of Škoda's managers                          p.  6 - Content                          p.  15 - Initial sampling inspection report content – correction of the text                          p.  21 - Point 4.14. – new subject                          p.  22 - Updating the contact persons

3.0.

1.3.2016

Complete changes acc. to the new versions of the Formel Q documents: Formel Q Concrete, Formel Q Capability, Formel Q New parts Integral Changes mainly include: Changes to the text in the whole document acc. to Formel Q Removal of invalid references/chapters New chapters or new titles of chapters, different numbering, etc..