APPROVED
General Director of OAO “ZMZ”
______A.A.Matushin
______2013
Specific requirements of ОАО «ZMZ»
ОАО «ZMZ»
Contents
1 General………………………………………………………………………..………………..4
2 Normative References………………………………………………………...... 4
3 Definitions……………………………………………………………………………………...4
4 Requirements…………………………………………………………… ……………………..5
4.1 Quality management system (ISO/TS 16949 - 4.1, 4.1.1)…………………………………... 5
4.2 Documentation management (ISO/TS 16949 - 4. 2, 4.2.1, 4.2.2, 4.2.3, 4.2.3.1)..………… 5
4.3 Records management (ISO/TS 16949 - 4.2.4, 4.2.4.1)…………………………………… .5
4.4 Objects in quality sphere(ISO/TS 16949 - 5.4.1)…...………………………………………..5
4.5 Responsibilities and authorities (ISO/TS 16949 - 5.5, 5.5.1, 5.5.1.1)………………………..6
4.6 Representative of the customer (ISO/TS 16949 - 5.5.2.1)…………………………………...6
4.7 Assessment from site of the management (ISO/TS 16949 - 5.6, 5.6.1, 5.6.1.1, 5.6.2,
5.6.2.1, 5.6.3, 5.1)…………………………………………………………………………………6
4.8 Human resources (ISO/TS 16949 - 6.2.1, 6.2.2, 6.2.2.1, 6.2.2.2, 6.2.2.3, 6.2.2.4)…… … ..6
4.9 Planning of production, equipment and tooling (ISO/TS 16949 - 6.3,
6.3.1, 5.1.1)…………………………………………………………………………………… ….6
4.10 Plans of contingency (ISO/TS 16949-6.3.2)…………………………………… … 6
4.11 Manufacturing area (ISO/TS 16949 - 6.4, 6.4.1)………………………………… ….. 7
4.12 Cleanness in working places (ISO/TS 16949 - 6.4.2). Cleanness of production………… 7
4.13 Planning of processes for development of production (ISO/TS 16949 - 7.1, 7.1.1, 7.3.1,
4.2.1d, 7.3.4.1, 5.4.1, 5.4.2)……………………………………………………………………… 7
4.14 Acceptance criteria (ISO/TS 16949 - 7.1.2)…………………………………………… …... 7
4.15 Management of changes (ISO/TS 16949 - 7.1.4)… …………….…… 7
4.16. Definition of production requirements (ISO/ 7.2.1,7.2.1.1)
4.17 Assessment of production requirements (ISO/TS 16949 - 7.2.2, 7.2.2.1)…….. 7
4.18 Manufacturing capability of organization (ISO/TS 16949 - 7.2.2, 7.2.2.2)………… 7
4.19 Communication with customers (ISO/TS 16949 -7.2.3, 7.2.3.1)……………………… 8
4.20 Complex approach (ISO/TS 16949 - 7.3.1.1,7.3.2, 7.3.2.1, 7.3.2.2)…………………… 8
4.21 Special characteristics (ISO/TS 16949 -7.3.2.3. 7.2.1.1)………………………… . 8
4.22 Assessment of design (ISO/TS 16949 -7.3.4, 7.3.3, 7.3.3.1, 7.3.3.2)………………… .. 8
4.23Verification and validation of design (ISO/TS 16949 -7.3.5, 7.3.6, 7.3.6.1)……. .. 8
4.24 Prototype program (ISO/TS 16949 -7.3.6.2)…………………… . 8
4.25 Production part approval process (ISO/TS 16949 -7.3.6.3)…… 8
4.26 Purchasing process (ISO/TS 16949 -.4.1)…………………………………………. .. 8
4.27 Performance of official directions (ISO/TS 16949 -7.4.1.1)………………… 9
4.28 Development of supplier quality management system (ISO/TS 16949 - 7.4.1.2)… 9
4.29 Purchasing sources approved by customer (ISO/TS 16949 - 7.4.1.3)…………… 9
4.30 Purchase data (ISO/TS 16949 -7.4.2)……………………………………………… 9
4.31 Supply quality (ISO/TS 16949 -7.4.3.1, 7.4.3)……………………………………….. 9
4.32 Supplier monitoring (ISO/TS 16949 -7.4.3.2)………………………………………. 9
4.33 Work instructions (ISO/TS 16949 -7.5.1.2)………………………………………… … 10
4.34 Verification of adjustments (ISO/TS 16949 -7.5.1.3)…………………………………… . 10
4.35 Preventive and diagnostic maintenance and repair (ISO/TS 16949 -7.5.1.4)……… … 10
4.36 Management of production tools (ISO/TS 16949 -7.5.1.5)…………… … 10
4.37 Identification and traceability (ISO/TS 16949 -7.5.3, 7.5.3.1)…………… ….. 10
4.38 Customer’s property (ISO/TS 16949 -7.5.4, 7.5.4.1)…………………… ……… 10
4.39 Product preservation (ISO/TS 16949 -7.5.5, 7.5.5.1)……………………… …………. 10
4.40 Measuring systems assessment (ISO/TS 16949 -7.6.1)………………………… ……… .10
4.41 Laboratory requirements (ISO/TS 16949 -7.6.3, 7.6.3.1, 7.6.3.2)…………………… 11
4.42 Definition of statistics methods (ISO/TS 16949 -8.1, 8.1.1, 8.1.2)………… …… 11
4.43 Customer satisfaction (ISO/TS 16949 -8.2.1, 8.2.1.1, 5.2)……………… … 11
4.44 Internal audit (ISO/TS 16949 -8.2.2, 8.2.2.1, 8.2.2.2, 8.2.2.3, 8.2.2.4, 8.2.2.5)…… .. 11
4.45 Monitoring and measurement of production processes (ISO/TS 16949 -8.2.3,
8.2.3.1, 7.5.2)…………………………………………………………………………………….11
4.46 Monitoring and measurement of production (ISO/TS 16949 -8.2.4)…… ……12
4.47 Requalifying checks (complete control and functional tests) (ISO/TS 16949 -8.2.4.1) ….12
4.48 Production with appearance requirements (ISO/TS 16949 - 8.2.4.2)… … …12
4.49 Management of non-correspondent production (ISO/TS 16949 - 8.3, 8.3.1, 8.3.2,
8.3.3)……………………………………………………………………………………… …..12
4.50 Special permission of the customer (ISO/TS 16949 - 8.3.4)……………………………….13
4.51 Improvement of production process (ISO/TS 16949 - 8.5.1.2, 8.5.1, 8.5.1.1)……… …...13
4.52 Corrective actions (ISO/TS 16949 - 8.5.2. 8.5.2.1, 8.5.2.2, 8.5.2.3, 8.5.3)…… ..13
4.53 Examination of claimed production (ISO/TS 16949 - 8.5.2.4)…………… …….13
Attachment 1 Matrix of approving by customer the changes in large-scale production
Attachment 2 Regulation of actions applied for the Supplier in case of repeated non-correspondences …………………………… …………………14
1. General provisions
1.1 Specific requirements of OAO «ZMZ» (further – specific requirements) are applied with standard ISO/TS 16949.
Specific requirements contain special requirements of OAO “ZMZ” supplementing technical requirements and requirements of ISO/TS 16949. These specific requirements must be included in criteria of all types of quality management system audits (QMS) of supplier.
1.2 Specific requirements are applied for all types of suppliers performing supplies to OAO «ZMZ».
1.3 In this document the terms «supplier» and «organization» are interchangeable.
1.4 Specific requirements are available on website of OAO «ZMZ»
2. Normative references
2.1 ISO/TS 16949:2009 «Quality system in automotive industry. Special requirements in use of ISO 9001:2008 for serial production and spare parts production in automotive industry»
2.2 ISO 9000:2008 «Quality management system. Main regulations and glossary»
2.3 AIAG guidelines on performing of FMEA (failure mode and effects analysis)
2.4 AIAG guidelines on performing of APQP (Advanced Product Quality Planning)
2.5 AIAG guidelines on performing PPAP (production part approval process)
2.6 AIAG guidelines on performing SPC (statistics process control)
2.7 AIAG guidelines on performing MSA (measuring system analysis)
2.8 ISO14001:2004 «Ecological management system. Requirements and application guide»
2.9 GOST R ISO 14001:2007 «Ecological management system. Requirements and application guide»
2.10 OHSAS 18001:2007 «Health protection systems and labor safety provision. Requirements»
2.11 GOST R 54934-2012/OHSAS 18001:2007 «Labor safety standards system. General requirements to labor safety management system in organization»
2.12 ISO 19011:2011 «Guidelines on audit of quality management system».
2.13 GOST R ISO 19011-2012 «Guidelines audit of management systems».
3. Definitions
Terms according to ISO9000, ISO/TS 16949 and following terms with correspondent definitions are applied in these specific requirements:
3.1 legislative requirement: Requirement set up in normative document of state and federal significance;
3.2 mandatory requirement: Requirement set up in normative document of regional and administrative or local significance;
3.3 8D problem solving method: Systematized order of actions directed on definition and elimination of problem initial cause. Systematized order of actions directed on definition and elimination of source concern, prevention of repeated problem occurrence, distribution of experience on study of given problem for another similar processes and production.
In case of incompatible terminology between ISO/TS 16949 and given document, given document prevails.
4. Requirements
4.1 Quality management system (ISO/TS 16949 - 4.1, 4.1.1)
All suppliers must have certified QMS on correspondence to requirements ISO/TS 16949 or ISO 9001 and must submit plan of QMS certification for correspondence to requirements of ISO/TS 16949 during three months since selection (signing of the contract) and certify QMS during one – three years (under agreement with ОАО «ZMZ») since start of supplies.
The supplier should send a copy of certificate of QMS conformance to the manager ZMZ DOP and manager of UAZ quality and supplier development .
The Supplier should inform OAO “ZMZ” about expiry date of the certificate not later than three months if the repeated QMS certification is not planned.
The suppliers must have certified ecological management system (hereinafter – EMS) on correspondence to requirements ISO14001, or GOST R ISO 14001, or submit plan of EMS certification for approval by ОАО «ZMZ», if such requirement of OAO “ZMZ” exists.
Preferably, if suppliers have certified health protection management system and labor safety management system on correspondence to requirements OHSAS 18001 or GOST R 54934/ OHSAS 18001.
ОАО «ZMZ» reserves the right for making of additional requirements to suppliers as it is necessary.
4.2 Documentation management (ISO/TS 16949 - 4. 2, 4.2.1, 4.2.2, 4.2.3, 4.2.3.1)
If an organization uses documents of ОАО «ZMZ», the organization must guarantee correspondent status of given documents.
Documents referred to stage of product and process development and also stage of serial production, for example: drawings, specifications, management plans, control instructions must be kept not less than one year after termination of product manufacturing.
4.3 Records management (ISO/TS 16949 - 4.2.4, 4.2.4.1)
Records and entries about approval of equipment, entries about equipment and tools, entries about purchase orders, and also changes to them must be kept not less than one year after termination of product production.
Entries about results of product inspection and production process inspection should be kept not less than three years.
Entries about results of internal audits of QMS and process and production should be kept not less than three years since its creation.
4.4 Objects in quality sphere (ISO/TS 16949 - 5.4.1)
Supplier should tend to decrease level of defects up to zero.
Quality level РРМ is approved mutually by Supplier and OAO «ZMZ» at start stage of APQP (AIAG manual on execution of APQP) and indicated in the contract.
The supplier is obliged to agree target parameters on production with OAO "ZMZ ". In case the supplier does not attain the established target parameters, the supplier should submit to OAO "ZMZ " the plan of corrective actions on achievement of target parameters.
4.5 Responsibility and authorities (ISO/TS 16949 - 5.5, 5.5.1, 5.5.1.1)
The organization must define and inform OAO «ZMZ» about responsible contact person. This contact person must be responsible for following actions:
-To introduce immediate responses on locking of non-correspondent production and to confirm, that non-correspondent production hasn't been supplied to OAO "ZMZ";
- To affirm a requirement of OAO ZMZ on finalization or sorting of production;
- To affirm and allocate resources for finalization or sorting of production;
- To give subassembly, the components necessary for finalization, in case of occurrence of questions relative to production quality;
- To give the information on the shipped inappropriate production which is in a way (how to identify it, how to recognize where it is located);
- To coordinate urgent delivery of corresponding production.
4.6 The representative of the customer (ISO/TS 16949 - 5.5.2.1)
The organization should coordinate assignment of the representative of the customer with OAO "ZMZ".
The organization should notify OAO "ZMZ" within 10 days about change in the management, change of responsible person for quality or management of the organization.
4.7 An estimation from site of a management (ISO/TS 16949 - 5.6, 5.6.1, 5.6.1.1, 5.6.2, 5.6.2.1, 5.6.3, 5.1)
The management of the organization monthly should carry out meetings on quality of production for OAO "ZMZ".
4.8 Resources of the personnel (ISO/TS 16949 - 6.2.1, 6.2.2, 6.2.2.1, 6.2.2.2, 6.2.2.3,
6.2.2.4)
The organization should guarantee that the qualified and trained personnel participate in designing of production and manufacturing process for OAO "ZMZ" only.
The organization should pay special attention on qualification of the personnel participating in manufacturing of the products, which have special characteristics.
The personnel should be trained to work according to new or changed documents of OAO "ZMZ", in case of use. Records about training should be kept not less than three years from date of training.
4.9 Production scheduling, the equipment and facilities (ISO/TS 16949-
6.3, 6.3.1, 5.1.1)
It is preferable, if the organization applies principles of lean manufacturing or has plans on introduction of principles of lean manufacturing.
4.10 Plans of contingencies (ISO/TS 16949-6.3.2)
The organization should develop plans of action in case of contingencies: failure in work of municipal services, transport, information systems, shortage of a labour, malfunction of the main equipment, mass discrepancies, return from operation.
The organization should notify within 24 hours OAO "ZMZ" about stop of manufacturing and the arisen problem. The organization should undertake immediate reciprocal actions on providing of corresponding deliveries of production to OAO "ZMZ".
4.11 Industrial area (ISO/TS 16949 - 6.4, 6.4.1)
The supplier is obliged to provide safety for all personnel on workplaces.
4.12 Cleanliness on workplaces (ISO/TS 16949 - 6.4.2).
Cleanliness of production.
Requirements to cleanliness of production and production process should be stipulated at applying of FMEA (AIAG manual on carrying out FMEA). Corresponding actions should be introduced at applying of APQP.
The organization should apply means (to have conditions), providing cleanliness of production for OAO "ZMZ " and its packing.
Requirements of OAO "ZMZ", regarding technical accuracy of design documentation drawingand standard document(at their presence) should be executed.
4.13 Planning of product development processes (ISO/TS 16949 - 7.1, 7.1.1, 7.3.1, 4.2.1d, 7.3.4.1, 5.4.1, 5.4.2)
The organization should apply methodology of perspective planning of production quality - APQP (AIAG manual on carrying out of APQP) if other is not stipulated by consumers of OAO "ZMZ".
4.14 Criteria of acceptance (ISO/TS 16949 - 7.1.2)
The organization should coordinate criteria of production acceptance with OAO"ZMZ".
4.15 Definition of the production requirements (ISO/TS 16949-
7.2.1, 7.2.1.1)
The organization should inform and approve with ZMZ changes in large-scale production which influent on ZMZ requirements, functional and operation characteristics of production. The organization should give to OAO "ZMZ" the matrix of approval of changes in large-scale production according attachment to the managers:
Alexey N.Lazarev, production manager ОАО «ZMZ» ;
- Igor V.Miroshnichenko, manager of quality and supplier development departmentОАО «UAZ» .
4.16 Definition of production requirements (ISO/TS 16949 -
7.2.1, 7.2.1.1)
Theorganizationmustdefinelegalandobligatoryrequirementsonsafetyoftheproductsandmaterials. The organization must provide ZMZ with report about materials compoundupon request.
The organization must define requirements on utilization of the products and approve it with ZMZ.
Appliance of characteristics of the process and production process parameters relative to ZMZ special characteristics is identified with symbol «SC» - special characteristics.
4.17 Assessment of the production requirements (ISO/TS 16949 - 7.2.1, 7.2.1.1)
The organization can receive approval of OAO"ZMZ" to refuse from the requirement to carry out the official analysis of the requirements referring to production.
4.18 Production capability of the organization (ISO/TS 16949 - 7.2.2,
7.2.2.2)
The organization should include the information about subsuppliers in the report about industrial capability to produce supposed production for OAO"ZMZ" . The given report should contain the information about an opportunity to increase volume of producible production in comparison with the volume determined in the contract with OAO "ZMZ" if other requirement on increase in production volume is not stipulated by customers of OAO"ZMZ".
4.19 Communication with customers (ISO/TS 16949 -7.2.3, 7.2.3.1)
All information of ОАО «ZMZ», required by the supplier for realization of the projects can be taken in department on strategy and business developmentОАО «ZMZ» and quality and supplier development department ОАО «UAZ».
Contact information:
lexey Lazarev, production managerОАО «ZMZ»;
Igor V.Miroshnichenko,quality and supplier development department ОАО «UAZ»;
Alexandr N.Plotnikov, chief of supplier assessment and development department, ОАО «UAZ».
OAO «ZMZ» tends to maximum interaction with suppliers by means of electronic documents changeover.
4.20 Complex approach (ISO/TS 16949 - 7.3.1.1,7.3.2, 7.3.2.1, 7.3.2.2)
The organization should give documents on Product FMEA and Process FMEA of manufacturing and the plans of management designated by symbols of special characteristics, before approval of OAO "ZMZ", non dependent on level of РРАР.
The organization should give to OAO "ZMZ" a copy of documents on FMEA by inquiry.
4.21 Special characteristics (ISO/TS 16949-7.3.2.3.7.2.1.1)
The organization should receive from OAO"ZMZ" the allowance to use symbol "SC" for a designation of special characteristics in the documents.
The organization should introduce a control system of production special characteristics.
4.22 Assessment of design (ISO/TS 16949-7.3.4, 7.3.3, 7.3.3.1, 7.3.3.2)
The organization should give the information about results of the analysis of product design stages to OAO "ZMZ".
4.23 Verification and validation ofdesign (ISO/TS 16949-7.3.5,
7.3.6, 7.3.6.1)
The organization should inspect production on conformity to prospective application in production of OAO "ZMZ ".
4.24Prototype program (ISO/TS 16949-7.3.6.2)
The organization should receive acknowledgement of necessity in OAO "ZMZ" to have the plan of the prototype management.
4.25Production part approval process (ISO/TS 16949-7.3.6.3)
The organization should apply methodology of Production part approval process - PPAP (AIAG manual on carrying out of PPAP) if other is not determined by customers of OAO "ZMZ ". РРАРlevels should be approved by OAO"ZMZ".
РРАР Requirements should be applied to all subsuppliers of piece production.
4.26 Process of purchases (ISO/TS 16949-7.4.1)
It is preferable, if the contract is signed by the supplier in edition of OAO "ZMZ".
4.27 Performance of official instructions (ISO/TS 16949-7.4.1.1)
The organization bears the responsibility for conformity to legislative and obligatory requirements on safety of purchased production and the materials used at manufacturing of products for OAO "ZMZ".
The organization should give to OAO"ZMZ" the report about contents of materials from sub-suppliers on request.
4.28Development of supplier quality management system (ISO/TS 16949-7.4.1.2)
If otherwise is not stipulated, subsuppliers should have certificated QMSon conformity to requirements ISO/TS 16949 or ISO 9001 and to give the plan on QMS certification within three months from the moment of a selection (signing of the contract) and to be certificated during one - three years from the moment of the beginning of deliveries.
The organization bears the responsibility for quality of production delivered by the subsupplier.
The organization should give to OAO "ZMZ"the list of subsuppliers by inquiry. The organization should update the list of subsuppliers not less than two times one year.
4.29Purchasing sources approved by customer (ISO/TS 16949-7.4.1.3)
If otherwise is not stipulated by the contract, the organization should get approval of subsuppliers from OAO "ZMZ". Organization should inform OAO "ZMZ" about changes in approved suppliers.
4.30Purchase data (ISO/TS 16949-7.4.2)
The organization is responsible for transfer of requirements of the present document concerning components with special characteristics to subsuppliers, and also for the control of performance of these requirements.
Levels of РРАРfor the subsupplier should be established on the basis of РРАРlevels approved by OAO"ZMZ" for the organization.
4.31Supply quality (ISO/TS 16949-7.4.3.1, 7.4.3)
The organization should have performance characteristics of production purchased at the subsupplier in order to manage quality of purchased production. If necessary, the organization can add other characteristics.
OAO "ZMZ" has the right to apply to the supplier the actions in case of repeated deliveries of inappropriate production according to « the Rules of the actions applied to the supplier in case of repeating discrepancies » according to the appendix 1.
4.32 Monitoring of the supplier (ISO/TS 16949-7.4.3.2)
The organization should demand duly delivery of purchased production from subsuppliers in order to perform requirements of OAO "ZMZ" about deliveries of production in the terms determined by the contract.
Specialists of OAO «ZMZ» have the right to carry out audits of manufacturing processes at the subsupplier site under the prior notification.
The organization should provide access to carry out audits of manufacturing processes at the subsupplier site for the person authorized by OAO "ZMZ ".
4.33 Working instructions (ISO/TS 16949-7.5.1.2)
The personnel of the organization should use corresponding working instructions. The instruction about performance of the works not determined in the given working instruction should be given in writing.
4.34 Verification of adjustments (ISO/TS 16949-7.5.1.3)
The organization should inspect production after replacement of the tool.
Records of check results should be kept not less than one year from the moment of their creation.
4.35 Preventive and diagnostic maintenance and repair (ISO/TS 16949-7.5.1.4)
The organization should have documentary made out system of preventive maintenance of the equipment.
Records of equipment preventive maintenance results should be kept not less than one year from the moment of their creation.
4.36 Management of the industrial tool (ISO/TS 16949-7.5.1.5)
The organization should control service life of tooling.
4.37 Identification and traceability(ISO/TS 16949-7.5.3, 7.5.3.1)
If the contract stipulates the requirement of traceability, the organization should apply corresponding identification of production at all stages of production life cycle . Records on identification and traceabilityshould be kept not less than one year from the moment of their creation.
4.38 Customer’s property (ISO/TS 16949-7.5.4, 7.5.4.1)
The organization should inform OAO"ZMZ" about oncoming of service life termination of tooling belonging to OAO "ZMZ" in due time. Thus the organization should budget the expenses for tooling replacement in calculating of the cost.
4.39 Product preservation (ISO/TS 16949-7.5.5, 7.5.5.1)
The organization should apply method FIFO at movement of purchased production to OAO"ZMZ" and production delivered to OAO"ZMZ". In case of delivery of production to OAO "ZMZ" it is necessary to specify the information about a lot number in shipping documents.