MLA Supplier Quality Manual - Rev0 with Attachment (1).pdf

SQM - Supplier Quality Requirements & Procedures Approvals: Sr. Manager, Quality Control: RJ Patel Sr. Manager, Supply Chain Management: Girish Patankar Tommy Hoke Jill Castree Table of Contents 1 SCOPE.................................................................................................................................................................... 3 2 GENERAL REQUIREMENTS................................................................................................................................... 3 2.1 PRODUCTS QUALITY............................................................................................................................................... 3 2.2 QUALITY MANAGEMENT SYSTEM............................................................................................................................. 3 2.2.1 Quality Planning........................................................................................................................................... 3 2.2.2 Control of Process........................................................................................................................................ 3 2.2.3 Product Monitoring and Measurement....................................................................................................... 3 2.2.4 Control of Measuring Devices...................................................................................................................... 3 2.2.5 Lot Control.................................................................................................................................................... 4 3 SUPPLIER APPROVAL PROCESS............................................................................................................................ 4 3.1 GENERAL............................................................................................................................................................. 4 3.1.1 Conditional Approval.................................................................................................................................... 4 3.1.2 Sub-tier Suppliers......................................................................................................................................... 4 3.2 SPECIAL PROCESS AUDIT........................................................................................................................................ 5 4 PRODUCTION PART APPROVAL PROCESS (PPAP)............................................................................................... 5 4.1 GENERAL............................................................................................................................................................. 5 4.2 ELEMENT REQUIREMENTS...................................................................................................................................... 6 4.2.1 Level 2 PPAP (Class 1 and 2 Parts)................................................................................................................ 6 4.2.2 Level 4 PPAP (Class 3 Parts).......................................................................................................................... 8 4.3 TOOLING CONSIDERATION.................................................................................................................................... 10 4.4 PPAP REVIEW.................................................................................................................................................... 13 5 SUPPLIER QUALITY SCORE................................................................................................................................. 13 5.1 GENERAL........................................................................................................................................................... 13 5.2 SCORING........................................................................................................................................................... 13 6 REJECTED MATERIAL REPORT (RMR)................................................................................................................. 13 6.1 GENERAL........................................................................................................................................................... 13 6.2 RMR NOTIFICATION AND RESPONSE PROCESS........................................................................................................ 13 6.3 ALTERNATIVE RMR RESPONSE PROCESSES............................................................................................................. 14 6.3.1 Deviation.................................................................................................................................................... 14 6.3.2 Rework........................................................................................................................................................ 14 6.3.3 Sort at supplier expense............................................................................................................................. 14 6.4 APPEAL............................................................................................................................................................. 15 6.5 FAILURE TO RESPOND.......................................................................................................................................... 15 7 SUPPLIER CORRECTIVE ACTION REQUEST......................................................................................................... 15 7.1 GENERAL........................................................................................................................................................... 15 7.2 CONTAINMENT................................................................................................................................................... 15 7.3 ROOT CAUSE...................................................................................................................................................... 15 7.4 CORRECTIVE ACTION........................................................................................................................................... 15 8 RELIABILITY......................................................................................................................................................... 16 8.1 GENERAL........................................................................................................................................................... 16 8.2 WARRANTY REDUCTION ACTIVITIES....................................................................................................................... 16 9 PROCESS CHANGE REQUIREMENTS................................................................................................................... 16 10 SUPPLIER REQUEST FOR DESIGN CHANGE........................................................................................................ 17 SQM - Supplier Quality Requirements & Procedures 11 DEVIATION REQUEST......................................................................................................................................... 17 12 DRAWING CONTROL.......................................................................................................................................... 17 13 CONFIRMATION OF QUALITY ASSURANCE SYSTEM AND QUALITY CONTROL................................................. 18 13.1 QUALITY RECORDS.............................................................................................................................................. 18 13.2 QUALITY AUDIT.................................................................................................................................................. 18 14 QUALITY STANDARDS........................................................................................................................................ 18 14.1 WELDING......................................................................................................................................................... 18 14.2 COSMETICS........................................................................................................................................................ 18 14.3 SPECIAL STANDARD............................................................................................................................................. 18 SQM - Supplier Quality Requirements & Procedures 1 Scope This document defines the quality requirements for suppliers of parts and materials that are used in MLA products. This document describes the expected actions, documentation, and communication to be used by MLA and MLA’s suppliers. The required actions defined in this document are intended to ensure that the supplier’s products meet the expectations of MLA and our customers. 2 General Requirements 2.1 Products quality It is the expectation of MLA that each supplier will provide parts that meet all the functional, physical, and other requirements listed on the drawing and associated specifications. The use of subcontractors; independently selected, MLA-designated, or ML-approved, does not relieve the supplier of the responsibility to ensure the quality of subcontracted parts, materials, and services. 2.2 Quality management System 2.2.1 Quality Planning The supplier shall implement and maintain a quality system that has been well conceived through careful planning such as the current ISO 9001 or equivalent standard. The supplier’s quality system shall be documented in a quality manual. The quality manual shall detail the procedures that the supplier uses to ensure product quality including, but not limited to, process controls, training, and implementation of effective corrective actions, and have the approval and direction of executive management of the supplier's facility. 2.2.2 Control of Process Suppliers shall control product realization processes according to their quality system as approved by MLA. If the system should deviate including, but not limited to, relocation of equipment, facility, etc., it is the supplier's responsibility to take the necessary action to re-establish control. The supplier shall apply procedures and effective controls sufficient to maintain required specifications, reduce variation, document inspection and test results, and maintain identity of materials throughout the process. Written processing and inspection/test instructions should be readily available, understood, and followed by appropriate personnel. 2.2.3 Product Monitoring and Measurement MLA nonconforming material shall be identifiable as to process status and shall be reviewed for correction or rejection. The supplier shall ensure that nonconforming material is not shipped to MLA without written MLA deviation approval. If written deviation approval from MLA is granted, a copy of the deviation record must be submitted with the product shipment in accordance with the Product Inspection Report Submittal Requirements listed below. 2.2.4 Control of Measuring Devices The supplier shall establish and maintain documented procedures to control, calibrate, and maintain inspection, measuring, and test devices used to ensure conformance of the product to the specified requirements. 3|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Calibration and test sources must be accredited to ISO/IEC 17025 or equivalent. Inspection, measuring, and test equipment shall be used in a manner that ensures that the measurement uncertainty is known and is consistent with the required measurement capability. 2.2.5 Lot Control Suppliers shall have lot identification control procedures in effect when materials and/or processes require lot segregation for effective control and traceability. 3 Supplier Approval Process 3.1 General All new suppliers must be approved within the ML group of companies. This process will be initiated upon identification of the supplier as a potential candidate for MLA. The approval process will include completion of a self-assessment using the form contained in CAQ023. In cases where the supplier will provide class I or II parts as defined in MSJ1-2002, this will also include an on-site assessment by an ML company quality representative. The self-assessment and on-site assessment, if required, shall result in a minimum score as shown in table 1 below. Part Class Minimum Score I 90 II 80 III 60 Table 1 – Quality System Assessment Score Requirements Quality system approval can be revoked at any time at the discretion of MLA. 3.1.1 Conditional Approval MLA, at its discretion, may give temporary conditional approval. To gain full approval, the supplier will be required to complete improvements to their quality system as directed by the Auditor. These improvements must be made within the time frame established by the Supplier Quality Engineer (SQE), or the conditional approval will be revoked. 3.1.2 Sub-tier Suppliers Sub suppliers may be audited based on the complexity or criticality of part(s). Below is a flow chart showing how to decide the necessity of audit for sub suppliers. 4|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 3.2 Special Process Audit Special processes (e.g., forging, casting, and heat treating) audit may be required and will be determined by the part requirement and criticality on the drawing. The assessment forms (XAR201-XAR216) will be provided as needed by MLA Supplier Quality Engineer (SQE). 4 Production Part Approval Process (PPAP) 4.1 General PPAP elements address the planning and production activities for purchased parts to reduce the potential for receipt of defective components at MLA. The supplier will be required to submit/attach PPAP documentation as per the drawing requirements to Commodity Manager and/or Supplier Quality Engineer (SQE)upon their request. PPAPs will be required in each case where a supplier is making a new production part number for MLA. Unless otherwise specified, on new programs, PPAPs will be required in the pre-production phase. The documentation and parts submitted shall be representative of the intended production process, including tooling. If parts are not representative, notify the Commodity Manager. 5|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 4.2 Element Requirements Supplier Quality Engineer (SQE) will determine PPAP level based on part drawing and/or MSJ12002E. Part class level can be found on the drawing bottom right corner (See below image). o If this section does not have circle on class 1 or 2, it is deemed as class 3 part. o 4.2.1 Level 2 PPAP (Class 1 and 2 Parts) Bubble Print and Inspection Report ✓ Labeled or numbered in an orderly fashion and correspond to the Inspection Report. ✓ General form used by both MLA and the supplier for documenting the evaluation of dimensional inspection. Quality Control Plan ✓ A planning tool used to summarize and document product and process control characteristics, the capability of process/measuring systems and the plan to control the process (Appendix A). In terms of control plan, suppliers may use their standard format or may contact the MLA Supplier Quality Engineer (SQE) for an example form (Appendix A). Performance Test Report 6|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures ✓ General form used by both MLA and the supplier for documenting the evaluation of material, and performance specifications mentioned on MLA drawing. ✓ Related standards for each part are described in the top right column or note in blank area of drawings (refer following pictures). In case supplier needs any information about part standards, supplier shall reach out to commodity manager. 7|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Material Certificate ✓ The supplier shall perform tests for part(s) and product material(s) when chemical, physical, or metallurgical requirements are specified on MLA drawing. ✓ Materials requiring records, certifications and /or test results include but are not limited to: Structural steels including plate, sheet, tubing, bars, rounds, and shapes. Casting, forging and Welded products. Weld Penetration Test ✓ A welding penetration test will be required for all welded parts. All parts requiring welding shall follow P-M40UCA-01 welding standard and testing requirements. FMEA Analysis or Process Flow Diagram. ✓ The process FMEA is a document that describes the potential failure modes, potential causes of those failures, and calculated risk associated with each potential cause in processes. Suppliers may use their standard FMEA format or may contact the MLA Supplier Quality Engineer (SQE) for an example form (Appendix B). Process Capability Study plan & Results. ✓ CpK – The capability index for a stable process. The estimate of the standard deviation is based on variation within the subgroup. ✓ Capability study will be required for all tight tolerance machined class 1 parts. MLA Supplier Quality Engineer (SQE) will provide dimensions or specifications that are required capability study to suppliers. For process capability study submissions, products shall be manufactured at the production site using the tooling, gauging, process, materials, and operators from the production environment. This production run shall be a minimum of 30 consecutive parts, unless otherwise specified by the supplier quality representative. MLA SQE may request suppliers to improve measuring methods or frequency in their regular production process if there are dimensions or specification that are below Cpk 1.33. Suppliers may use their standard format for capability study, but MLA SQE will send a calculation sheet if requested. (Appendix C). Results Interpretation Index Value > 1.33 The process currently meets MLA requirements. The process is currently acceptable but may require 1.00 ≤ Index Value ≤ 1.33 some improvement. The process does not currently meet the acceptance Index Value < 1.00 criteria. 4.2.2 Level 4 PPAP (Class 3 Parts) Bubble Print and Inspection Report 8|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures ✓ Labeled or numbered in an orderly fashion and correspond to the Inspection Report. ✓ General form used by both MLA and the supplier for documenting the evaluation of dimensional data. Quality Control Plan ✓ A planning tool used to summarize and document product and process control characteristics, the capability of process/measuring systems and the plan to control the process. In terms of control plan, suppliers may use their standard format or may contact the MLA Supplier Quality Engineer (SQE) for an example form (Appendix A). Performance Test Report ✓ General form used by both MLA and the supplier for documenting the evaluation of material and performance specifications mentioned on MLA drawing. ✓ Related standards for each part are described in the top right column or note in blank area of drawings (refer following pictures). In case supplier needs any information about part standards, supplier shall reach out to commodity manager. 9|Page Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Material Certificate ✓ The supplier shall perform tests for part(s) and product material(s) when chemical, physical, or metallurgical requirements are specified on MLA drawing. ✓ Materials requiring records, certifications and /or test results include but are not limited to: Structural steels including plate, sheet, tubing, bars, rounds, and shapes. Casting, forging and Welded products. Weld Penetration Test: ✓ A welding penetration test will be required for all welded parts. All parts requiring welding shall follow P-M40UCA-01 welding standard and testing requirements. 4.3 Tooling Consideration All tooling to be paid by MLA must be ordered on a purchase order and unless otherwise agreed upon, final tooling invoices shall be paid only after MLA approves the initial samples produced with production tooling. An on-site inspection of the tooling utilized by the supplier to produce the MLA parts may be waived based upon the type of tools and volume requirements. However, MLA representatives upon demand may inspect all tooling owned by MLA and held at the supplier's location. The supplier shall identify all MLA tooling that is held at the supplier's location with an appropriate identification control system for easy identification. 10 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Additional Drawing Examples 11 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Additional Drawing Examples 12 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 4.4 PPAP Review After sample parts and documentation have been submitted to MLA by supplier, Supplier Quality Engineer (SQE) will review documentation. PPAP approval will be indicated on the part submission warrant (PSW). The PSW is generated automatically in our system; therefore, the supplier is not required to submit their warrant to MLA. If a PPAP component is deemed to be deficient by the MLA SQE, the supplier will be notified of the deficiency and will be requested to resubmit that PPAP component. 5 Supplier Quality Score 5.1 General MLA assigns a score to each supplier monthly to grade their quality performance for the month. The quality score is a component of the overall score used to evaluate supplier performance by our sourcing group. Scoring is based on PPM which is determined by dividing the quantity of pieces rejected by total pieces received in each month times one million. Suppliers with low scores are reviewed on a regular basis to determine if corrective action is needed. 5.2 Scoring There are twenty-five (25) points available for the quality section of the supplier score. Scores are established using receiving inspection results and line rejects. Full points are awarded for achieving a PPM equal to or less than 400 PPM. No points will be awarded for a supplier with a PPM of 5000 or greater. The following table lists PPM scores and its classification rating. PPM Scoring Range Classification 400 or less 25 Excellent A 401-585 24 Acceptable B 586-770 23 Needs Improvement C 2145 or more 16 or less Unacceptable D Table – Supplier Scores 6 Rejected Material Report (RMR) 6.1 General If a nonconformance is found, MLA communicates the problem using an RMR. It is MLA’s policy to return nonconforming parts or material to the supplier for replacement. There may be situations where MLA chooses to not enforce this policy and, in these instances, other actions may be taken based upon internal evaluations and discussions with the supplier. 6.2 RMR Notification and Response Process Upon generation of an RMR, the supplier will be notified by e-mail which may contain a hyperlink to the RMR. The supplier shall provide a returned goods authorization (RGA) and shipping instructions in the area provided on the 13 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures RMR. Supplier shall make first reply to RMR within 3 days in case local supplier and 5 days in case international supplier. Upon receipt of the RGA, MLA will return the defective material to supplier at the supplier’s expense. 6.3 Alternative RMR Response Processes In those cases where the material will not be returned to the supplier, the supplier shall initiate an alternative process to satisfy their obligations. Alternatives to our standard policy include deviation, rework, or sort. At the supplier’s request, parts may also be scrapped at MLA at supplier’s expense. 6.3.1 Deviation The commodity manager, in coordination with the supplier, may request that the parts be used as-is by using the deviation process. The deviation request will be filled in by the commodity manager and will be routed to the appropriate personnel at MLA. If approved, the parts may be used. 6.3.2 Rework Defective parts may be reworked by the supplier at MLA or by a third party. The supplier is expected to arrange all rework activities, including transportation to and from the rework location. MLA may be willing to rework defective parts at the supplier’s expense; however, we do not have the staff to accommodate rework. The supplier will be charged our fully burdened overtime rate for rework performed by MLA personnel. The supplier will be charged our fully burdened overtime rate of $100 per hour for reworking performed by MLA personnel. 6.3.3 Sort at supplier expense Defective parts may be sorted by the supplier at MLA or by a third party. The supplier is expected to arrange all sorting activities, including transportation to and from the sorting location. MLA may be willing to sort defective parts at the supplier’s expense; however, we do not have the staff to accommodate this additional work. The supplier will be charged our fully burdened overtime rate of $100 per hour for sorting performed by MLA personnel. Nonconforming parts will be managed per the requirements stated in section 6 as appropriate. 14 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 6.4 Appeal The supplier may appeal against a rejection by MLA by making a request with the quality department or commodity manager at MLA. The facts supporting the appeal will be considered by the MLA and the supplier will be notified of our decision. If the appeal is accepted, the RMR will be modified or voided as appropriate. 6.5 Failure to Respond If the supplier fails to respond to an RMR, MLA will send a reminder of the need to respond. If the supplier has not responded in 30 days, the commodity manager will be notified to help resolve the problem. If a response is not received at 45 days, MLA reserves the right to return the parts at the supplier’s expense or take other actions as necessary to support MLA’s needs. Failure to respond will be considered as implicit acceptance of MLA decisions and associated charges. It is the supplier’s responsibility to notify MLA Quality and Purchasing of any personnel changes. 7 Supplier Corrective Action Request 7.1 General The notification of supplier corrective action request is a process used by MLA to gain confidence in the supplier’s ability to provide consistent quality or perform at a higher level than has been demonstrated. Reasons for supplier corrective action request generation include grievous defects, recurring problems, serious production impact, or other reasons at the discretion of the Supplier Quality Engineer (SQE). The supplier should consider the supplier corrective action request to be an indication of MLA’s perception that a serious system deficiency exists and should treat the subject with urgency and thoroughness. 7.2 Containment It is our expectation that containment will be initiated immediately upon receipt of notification that a problem has been detected at MLA. Containment must be sufficient to prevent future shipment of additional defective products to MLA and require documentation. MLA will request 3D/6D/8D investigation depending on the impact of rejection. 7.3 Root Cause The supplier is responsible for investigation into the root cause of the problem and may be assisted by an MLA if such assistance is needed. Adequate root cause investigation is necessary to ensure that corrective action can be implemented in a manner that prevents future problems. The results of the root cause investigation shall be documented. MLA will request 3D/6D/8D investigation depending on the impact of rejection. 7.4 Corrective Action Corrective action must address the root cause and ensure that the defect will not reoccur. Corrective action will be reviewed for adequacy and approved after the effectiveness is verified by the Supplier Quality Engineer (SQE). 15 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 8 Reliability 8.1 General Our suppliers are a critical partner in providing forklifts to our customers that perform in the expected manner for their design life. To ensure adequate product life, MLA will define testing and analyses for selected components to validate acceptable performance in expected operating conditions. These tests and analyses may be defined at the component level or higher as deemed necessary by MLA. The supplier may perform additional tests and analyses at their discretion that supplement defined requirements. It is expected that the supplier will actively and independently review reliability performance and pursue solutions to reliability problems that may arise throughout the component life cycle. 8.2 Warranty Reduction Activities Warranty claims reflect the supplier’s contribution to the reliability of our forklifts. We expect the supplier to actively pursue reduction of warranty claims through process improvements and design changes. The MLA Supplier Quality Engineer (SQE) will assist the supplier in investigations and understanding of product application issues that may contribute to warranty as needed. 9 Process Change Requirements Any change that may affect quality or reliability of purchased components shall be reported to the MLA Supplier Quality Engineer (SQE) and Purchasing groups at least 90 days prior to implementation of the change via 3M Process Change Notice form found in Appendix D. Approval must be obtained from MLA prior to shipping parts produced under these changed conditions. The following table lists common changes and typical requirements associated with those changes. MLA Change Description Typical Requirement Facility Move Quality System Assessment, New PPAP Sub Supplier Change Quality System Assessment, New PPAP as required Production Line Move New PPAP Material Change New PPAP Manufacturing Process Change New PPAP Manufacturing Equipment Change New PPAP Table 3 – Typical Change Requirements Requirements associated with changes not listed in the table above will be defined by the MLA Supplier Quality Engineer (SQE). 16 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 10 Supplier Request for Design Change The supplier is encouraged to request changes to MLA designed components to improve quality, reliability, cost, or function. All design change requests should be initiated and routed through the appropriate Commodity Manager. The Commodity Manager will coordinate all activities associated with the proposed change with appropriate personnel at MLA and supplier. 11 Deviation Request MLA drawings and standards define the part or assembly requirements. A verbal agreement between the supplier and anyone at MLA does not relieve the supplier from the responsibility of meeting the requirements listed on the drawings and specified standards. An approved MLA deviation request is the only acceptable document relieving the supplier of their responsibility to meet all drawing and documented specifications. Prior to shipment of parts or assemblies that do not meet MLA requirements, the supplier shall submit a deviation request to the MLA commodity manager and buyer/planner in order to receive confirmation of approval. 12 Drawing Control All Suppliers shall maintain latest revision drawings of MLA parts, including all the standards. These drawings and engineering standards shall be kept at the supplier’s location as controlled documents. Related standards for each part are described in the top right column or note in blank area of drawings. Supplier also shall keep those standards. In case supplier needs any information about part standards as shown in below ML drawing example, supplier shall reach out to. 17 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures 13 Confirmation of quality assurance system and quality control 13.1 Quality records MLA may request the submission of documents or records related with quality of products such as inspection record etc. to confirm the quality assurance system and quality control of the supplier's products. 13.2 Quality Audit MLA may request to enter the supplier's factory or office, with the supplier's consent, to confirm the supplier's quality assurance system and quality control for the products for MLA. 14 Quality Standards 14.1 Welding The standard “P-M40UCA-01 apply to all welded components unless otherwise specified in print (Please refer to attached file). 14.2 Cosmetics Cosmetics of products shall follow standard “P-M10UCA-02” (Please refer to attached file). 14.3 Special Standard If there are any quality requirements that cannot be clearly expressed numerically in the specifications, MLA may establish quality standards which may have visual aids etc. with supplier's agreement. 18 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Appendix A – Example format of control plan 19 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Appendix B –Example format of process FMEA 20 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Appendix C - Example format of capability study 21 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Appendix D – 3M Process Change Notice 3 M Process C hange N otice V en d or en try f ield Su p p lier n ame: A p p lication d ate: 1. D o you p la n or h a v e ch a n ged th e p rocess f or a n y p a rts p rov id ed to M LA w ith in 9 0 d a ys? Yes ( mov e to section 2 ) No 2. D eta ils of 3 M p rocess ch a n ge 2.1 C h a n ge D escrip tion ： T yp e Facility Mov e Prod u ction Lin e Mov e Man u f actu rin g Process ch an ge Su b Su p p lier Ch an ge Material Ch an ge Man u f actu rin g Eq u ip men t Oth ers D et ail 2.2 D a te of p rocess ch a n ge： 2.3 Rea son f or ch a n ge： M LA S Q E en try f ield Reject A p p rov e Req u iremen ts In sp ection rep ort Material certif ication rep ort New PPA P Samp le p arts Oth ers Process au d it f rom MLA Date： 22 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Supplier Quality Manual Acknowledgement Form The contents of the Mitsubishi Logisnext Americas Supplier Quality Manual and its documents should be reviewed, understood, and utilized by all management personnel within the supplier organization that engage in the development, manufacture, verification, and delivery processes of product supplied to MLA. This issue of the Mitsubishi Logisnext Americas Supplier Quality Manual is a revision that supersedes all previous documents. Please destroy your previous issue and notify MLA of receipt, review and acceptance of the current manual and required Logisnext standard (Weld and cosmetic) by signing and returning a copy of this acknowledgement electronically to Supplier Management Representative. Your issue of the Supplier Quality Manual is a controlled document recorded in your company’s name. Future additions, deletions and/or corrections will be directed by MLA to suppliers. This manual is proprietary and should be maintained in a proprietary manner. If MLA and its supplier(s) cease to do business, this manual should be returned to MLA. This Supplier Quality Manual will help you, the supplier, to continue as a supplier to MLA. It will also help MLA to produce high quality lift trucks, which will allow it to continue as a viable customer to its suppliers. Supplier Name: ____________________________________ Date: _________________ Supplier Representative: _____________________________ Title: __________________ 23 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 SQM - Supplier Quality Requirements & Procedures Revision History: Revision Change Revision Date Synergize SQ Manual for Houston and Marengo Campus Unified PPAP levels (by part classification on drawing and if not on the drawing using MSJ12002E standard). Documentation requirements for each PPAP level, with examples showing drawing requirements. 0 Sorting charges and failure to respond on rejection greater 4/29/2024 than 45 days resulting in parts return to supplier. Welding and cosmetic requirements. Added supplier acknowledgement form to confirm Supplier’s agreement to our standards. 24 | P a g e Document Title Governing Department Approval Manager Revision Date Revision Number SQM Supplier Quality RJ Patel 4/29/2024 0 Engineering Manual Engineering Dept. Issue Number Subject Code CHG UCA N P-M40UCA-01 REF Issued Written By: Reviewed By: 4/24/2018 R. Gube R. Jasinski Title Manufacturing Tolerances for Welded Joints Summary General tolerance standard for visual inspection of welded joints. Scope This Unicarriers Engineering standard applies to all welded forklift components unless otherwise specified on prints. This standard supersedes P-M40NFC-01 Contents 1. Objective ········································································· 3 2. References ······································································ 3 3. Definitions ·································································· 3 - 4 4. Engineering Standard ·················································· 5 - 15 1) Fillet Weld Leg Size ················································ 5 - 6 2) Weld Length ······························································· 6 3) Excessive Convexity/Concavity of Fillet Welds ·················· 7 4) Excessive Reinforcement/Concavity of Square Groove (Butt) Welds ······························································ 8 5) Undercut/Wash ··························································· 9 6) Overlap/Cold Lap ·················································· 9 - 10 7) Blowholes, Pits, and Porosity ······································· 10 8) Crater······································································ 11 9) Stops and Starts ························································ 11 10) Spatter ···································································· 12 1/14 Contents (continued) 11) Stuck Wire ······························································· 12 12) Cracks····································································· 13 13) Slag ········································································ 14 14) Root Opening/Weld Gap ············································· 14 15) Intermittent Fillet (Stitch) Welds ···································· 14 16) Weld Studs and Weld Nuts ·········································· 14 17) Resistance Spot Welds ········································· 14 - 15 18) Plug and Slot Welds ··················································· 15 19) Rework ···································································· 15 20) Vital Characteristics ··················································· 15 2/14 1. Objective This Standard applies to all structural welds used in the manufacture of forklift equipment and should be used to establish standard acceptance criteria for the visual and dimensional inspection of welds. The purpose of this standard is to evaluate and maintain weld quality levels consistent with industry practice and maintain confidence that the product welds will perform as intended. Specific practices and weld parameters used for production welding are to be based on those used to qualify the process. This is accomplished through documented Welder Performance Qualifications (PQR) and a Welding Procedure Specification (WPS) program. Continuous weld process quality validation is accomplished through the implementation of OP 7.5.2.QE. Weld evaluation should be made prior to paint and/or assembly to ensure complete visual access and provide for a more professional rework, where required. 2. References OP 7.5.2.QE: Weld Process Validation Procedure P-M10UCA-02 : Functional and Cosmetic Standard ANSI/AWS A3.0 : Standard Welding Terms and Definitions ANSI/AWS B2.1:1998 Specification for Welding Procedure and Performance Qualification 3. Definitions Visual Inspection: Examination of welds by visual, nondestructive means. Specific gages and scales are used to validate weld specifications. Structural weld: Welds which carry the primary working loads during normal operations. Weld Bead: Weld material deposited from a welding process. May be accomplished in multiple passes. Weld Length: The length of uninterrupted weld. Root of Joint: The intersection point of the two base metals. Root of Weld: The point where the back of the weld intersects the base metal surfaces. 3/14 Leg: Distance from the root of the joint to the toe of the weld. If the leg length is not specified, the nominal size shall be the thickness of the thinnest base metal being joined. Toe: Junction between the face of a weld and the base metal. Face: Exposed surface of a weld. Throat: Actual - The shortest distance from the root of the weld to the face of the weld. Theoretical - The perpendicular distance from the root of the joint to the hypotenuse of the largest right triangle that can be inscribed within the fillet weld cross-section. Parent/Base Metal: Metal to be joined by welding. Throat (Actual) Base Metal Face Throat (Theoretical) Root of Joint Toe Root of Weld Leg 4/14 4. Engineering Standard 4.1.1 Fillet Weld Leg Size (a) Any continuous fillet weld shall be considered acceptable provided that any underrun of the nominal leg size specified does not exceed 1.5 mm and 10% of the weld length. (b) If actual leg size is less than permissible limits, the weld shall be reworked and re-inspected. A L: Leg Size (Weld Size) L A: Under run L 4.1.2 Clips and Brackets Unspecified fillet weld leg size for clips and brackets shall be no smaller than the material thickness of the clip or bracket being welded. Weld origin and termination shall be sufficiently spaced from the clip or bracket edge to prevent undercut and edge burn-through. 4.1.3 Excessive Leg Size (a) Excess leg size shall not exceed 1.3*L (130%) for all welds specified. (b) If leg size is greater than permissible, the weld shall be rejected and reworked only if there is interference with the next assembly, is cosmetically unappealing or will otherwise produce an adverse effect upon the weldment. The reworked weld is to be re-inspected. 4.1.4 Fillet Weld Limitations This section refers to the maximum allowable weld size in a single pass. This limitation is intended to minimize the risk of lamellar tearing in the base metal from shrinkage stresses developed during the welding process. 5/14 Weld Position Process and Corresponding Maximum Single Pass Fillet Leg Size SMAW GMAW FCAW SAW Flat 9.5 mm (3/8") 9.5 mm (3/8”) 12.7 mm (1/2") 12.7 mm (1F) (1/2") Horizontal (2F) 7.9 mm 7.9 mm 7.9 mm (5/16") 7.9 mm (5/16") (5/16”) (5/16") Vertical 12.7 mm 9.5 mm (3/8”) 12.7 mm (1/2") --------------- (3F) (1/2") Overhead 7.9 mm 6.4 mm (1/4”) 7.9 mm (5/16") --------------- (4F) (5/16") 4.2.1 Weld Length (a) Weld length, (l) :+20/-0 mm This does not apply if the weld interferes with areas marked “to be free of weld spatter or weld material” (b) All starts and stops are to be consistent and fully fused. 4.2.2 No Weld Zone Weld restricted areas identified on prints are considered as no weld zones. No weld zone dimensions shall not be any less than that specified on the prints but may be larger. To maintain the no weld zone dimensions, the adjacent weld may be shorter than that specified. Good welding practices should be employed to minimize the variations between the print specification and the measured dimension of both the weld zone and adjacent weld. l:= Length of uninterrupted weld 4.3.1 Excess Convexity / Concavity of Fillet Fillet weld profiles should be flat or have only slight reinforcement unless otherwise called for on the print. The following figures show examples of desirable, acceptable and unacceptable fillet weld profiles. 6/14 4.4.1 Excessive Reinforcement of Square Groove (Butt) (a) Reinforcement is the material on the face of the weld in excess of the specified weld thickness. (b) Butt welds shall be convex unless specified to be ground flush. The reinforcement shall be as specified in the table below. Reinforcement Height Base Metal Thickness (H) 0 thru 12.7mm Flush thru: 1.5mm Over 12.7 thru 25.4mm Flush thru: 3.0mm Over 25.4mm 4.5mm 7/14 (c) If a grind-flush weld is specified, convexity before grinding need only be enough to ensure that the groove is completely filled with weld materials. (d) Excessive reinforcement shall be removed by grinding. 4.4.2 Excessive Concavity of Square Groove (Butt) (a) Concavity shall be evaluated according to the following: Vital parts are to have concavity ≤ 0.2+(0.04*W.) General parts are to have concavity ≤ 0.2*W. (b) Concavity exceeding acceptable limits shall be reworked by the addition of weld metal and re-inspected. W: Width of non-welded joint D D: Concavity W 4.5.1 Undercut / Wash (a) Undercut is a sharp depression at the fusion line of the weld metal and the parent metal. (b) Wash is a shallow, rounded depression at the fusion line of the weld metal and the parent metal. (c) Undercut or Wash shall not exceed 10 percent of the weld length or 25 mm continuous, and shall not exceed the values specified below. t Undercut Vital Parts Not Allowed a General Parts a ≤.1t ≤ 1.5mm t: thickness of material a: depth of undercut or wash (d) Undercut not meeting permissible standards must be reworked. 8/14 4.6.1 Overlap (a) Overlap is the protrusion of weld metal beyond the bond at the fusion line, between the weld metal and base metal where the weld is not fused with the base metal. 5mm, then the weld must be reworked by adding weld material. (c) Longitudinal offset of A2 should be evaluated to the specific weld type criteria, (fillet or groove weld). (d) All starts should be fully fused. A1 A1: Remaining Crater A2 A2: Longitudinal offset Weld Joint 4.10.1 Spatter (a) Spatter is defined as metal particles expelled during welding which do not form part of the weld bead. (b) Care shall be taken to prevent weld spatter by maintaining specified weld settings and using anti-spatter solutions. (c) Weld spatter shall not be permitted in areas specified on the drawings to be free of weld material and weld spatter. (d) No weld spatter is permitted on Class 1 surfaces as defined in the Cosmetic Standard P-M10UCA-02. (e) Unacceptable weld spatter shall be removed. 11/14 4.11.1 Stuck Wire (a) A stuck wire is a visual defect referring to unfused weld wire stuck to the weldment. (b) Unfused welding wire must be removed. 4.12.1 Cracks (a) A crack is a fracture type discontinuity characterized by a sharp tip and a high ratio of length to width, see the figures below. (b) Cracks shall not be permitted. (c) Verification of suspect cracks shall be confirmed by the use of an appropriate NDT method. (d) Rework shall consist of removing the crack to sound metal, verifying complete removal by the appropriate NDT method, re-welding and re-inspecting. Longitudinal Transverse Star Toe Crack 12/14 4.13.1 Slag (a) Slag is a non-metallic inclusion entrapped in the weld metal or between the weld metal and base metal. (b) All slag must be removed from the weld bead surface and base metal surfaces. (c) Slag inclusions are not permitted. (d) Any slag inclusions must be removed and the weld must be reworked. 4.14.1 Root Opening / Weld Gap (a) Root opening is defined as the space between parts before welding. (b) If root openings greater than 3.0 mm (1/8") are continually encountered, special welding procedures are required to handle each individual case. Engineering and Quality Control shall be contacted for corrective action in this case. (c) Caulking of welds is prohibited. 4.15.1 Intermittent Fillet (Stitch) Welds (a) Intermittent fillet (stitch) welds shall have weld segments (anchor welds) at each end of the joint, unless otherwise specified on the drawing. (b) The length of any segment of an intermittent weld shall not be less than four (4) times the weld size. Welds less than 6.4mm (1/4”) size shall not be less than 25.4mm (1in.) in length. (c) Intermittent weld specifications that do not fit the designed joint shall be addressed by Engineering and Quality Control before production is approved. In the event that the part is current production, the issue is to be addressed promptly. 4.16.1 Weld Studs and Weld Nuts (a) Weld studs and weld nuts are welded components that are typically projection welded and may or may not be specified with a weld symbol on the drawing. (b) A standard nut or stud that is to be welded must have specific callouts with weld symbols on the drawing. 13/14 4.17.1 Resistance Spot Welds (a) A resistance spot weld is a weld produced from the resistance to the flow of electric current through the work piece. (b) The weld distortion of the spot weld must be within print specifications. (c) The maximum indentation on the sheet surfaces caused by the welding electrodes shall not be greater than 50% of the thickness of the thinnest sheet being joined. (d) Welds that are not at the location specified on the drawing or at a different location than specified shall be classified as substandard welds and are to be evaluated. (e) A peel or chisel test shall be performed no less than quarterly. 4.18.1 Plug and Slot Welds (a) A plug or slot weld is made through a circular hole or slot in one member of a joint fusing that member to another. (b) A plug or slot weld will be welded flush or to within +/-1mm of the top surface of the base material being welded. 4.19.1 Rework (a) Rework of welds must conform to the same requirements of the original weld and should be welded with the same process and parameters as the original weld. (b) All rework must be inspected to be in conformance with the original specifications. 4.20.1 Vital Characteristics Vital is designated on the Engineering drawing by the symbol below and indicates the number of Vital specifications. If there is no Vital designation, the part is a general part. 14/14 Engineering Manual Engineering Dept Issue Number Subject Code CHG UCA N P-M10UCA-02 Ref Issued Written By: Reviewed By: 4/27/2018 Ryan Gube R. Jasinski Functional and Cosmetic Acceptance Standards for Carbon Steel Bars, Plates, and Title Shapes Summary Standard to define the minimum acceptance criteria for the chemical, physical and mechanical properties of the common engineered materials. Visual conformity of this standard is based on internal Company cosmetic requirements. product form. Scope This specification covers rolled steel bars, plates, sheets, and tubing purchased for the manufacture of forklift components. This standard also covers supplementary requirements necessary for the material to comply with this standard. The standard will be in effect under the following circumstances: Any part change requiring PPAP New part sourced Change in supplier New part revision This standard supersedes P-M10NFC-02 Contents 1. References ····································································· 2 2. Definitions··································································· 2 - 3 3. General Requirements ······················································ 4 4. Unacceptable Material Conditions ······································· 4 5. Cosmetic Surface Classes ················································· 4 6. Cosmetic Surface Class Designations ·································· 5 7. Surface Classification Examples ····································· 6 - 8 (1) 1. REFERENCES: ASTM A36/A36M-00a: Standard Specification for Carbon Structural Steel ASTM A6/A6M-01: Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates and Shapes ASTM A500-01: Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes ASTM A1008-01: Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability ASTM A1011-01: Standard Specification for Steel, Sheet and Strip, Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy and High-Strength Low-Alloy with Improved Formability ASTM E709-95: Standard Guide for Magnetic Particle Examination P-M40UCA-01: Company Manufacturing Tolerances for Welded Joints 2. DEFINITIONS: Consistent Finish: A surface condition that is harmonious over the entire area. If the material is lightly textured, it must be lightly textured over the full surface. Localized surface variations will be cause for rejection. Customer Interface Surface: Typically a high gloss, smooth surface associated with the Class 1 specification. Class 1 surfaces are those that have high visibility to the fork truck operator. Discontinuity: Any local variation in material continuity, including change in geometry, holes, cavities, cracks, structure, composition, or properties. Injurious Defect: When any discontinuity, single or multiple, is of such size, shape, type, and location that it creates an elevated chance of material failure in service. Localized Imperfection: A surface feature that causes the visual perception of a discontinuity and is evident as an inconsistent surface finish. A localized imperfection can be light grinding marks resulting in a uniform finish but is unacceptable due to the inconsistency of the surface. Mill Finish: The finish produced in hot rolling that does not conform to any definite contour. Mill finish products may contain some discontinuities, the more common of which are checked surfaces and edges, thin edges (feather) or damaged surfaces and edges due to handling or processing. Workmanlike Finish: A finish that is in compliance with the requirements of this standard as specified on the purchase order. (2) Scratches: A linear defect over 5mm that can be repaired by polishing with a fine particle compound. Scratches are acceptable for all Class surfaces, provided they cannot be felt with the fingertip. Gouges: Hollowed out areas, either linear or rounded. Gouges are prohibited on Class 1 & 2 surfaces and acceptable on 3 & 4 surfaces if the depth and length of the gouge do not exceed the requirements of the applicable standard. Pits: The wasting of base material as a result of corrosion. Corrosion pitting is unacceptable on Class 1 & 2 surfaces. Isolated pitting less that 0.5mm in diameter is tolerable on Class 3 & 4 surfaces provided there is no loose rust or scale involved and the depth does not exceed the limits of the applicable standard. Grinder or Jitterbug swirl marks: Scratch like indications left as a result of power sanding. Swirl marks shall be evaluated using the scratch criteria. Rolled in scale impressions: Light indications pressed into the material as a result of a forming operation. Acceptable if the indications cannot be felt with the fingertip. Friction Digs: Light indications pressed into the material as a result of a forming operation. Acceptable if the indications cannot be felt with the fingertip. Roller Marks: Light indications pressed into the material as a result of a forming operation. Acceptable if the indications cannot be felt with the fingertip. Die Marks: Light indications pressed into the material as a result of a forming operation. Acceptable if the indications cannot be felt with the fingertip. Weld bead, defect etc: Refer to UCA’s Engineering Standard P-M40UCA-01. (3) 3. GENERAL REQUIREMENTS: The material furnished under this standard shall conform to the requirements of the current edition of the applicable ASTM standard. Additional supplementary requirements necessary to meet the quality requirements specified in the standard shall also be met. The material shall be free of injurious defects and shall have a workmanlike finish. Any discontinuity open to the surface shall be considered potentially injurious and shall be characterized by the wet magnetic particle (MT) inspection method to determine size, orientation and frequency. All suspected potentially injurious indications shall be referred to UCA for a determination based on component use and discontinuity location. It is the supplier’s responsibility to exercise their right of rejection (ASTM A 6/A 6M, paragraph 17.2) of all material with questionable discontinuities, ensuring compliance to this standard and the requirements of the intended application. Any indication that causes UCA or the end user to question the integrity of the part is unacceptable. There shall be no unauthorized weld repair on the material provided to UCA. 4. UNACCEPTABLE MATERIAL CONDITIONS: Seams: Longitudinal discontinuity on the surface of the material and caused by entrapped gas. Seams are elongated during the rolling process and, when viewed in the cross section, are perpendicular to the surface. Laps: Discontinuities that occur during the hot rolling of both semi-finished and finished material. Laps are the folding over of material and caused from gouging during the rolling process or misalignment of the rolls. Lamination: A subsurface, nonmetallic discontinuity flattened by the rolling process and aligned parallel to the rolling direction. Laminar tear: A subsurface, step-like crack in the base metal propagating from a lamination and with the basic orientation parallel to the rolled direction. Cracks / Linear indication: Any linear discontinuity with length 3 times greater than width and can be either surface or subsurface. 5. COSMETIC SURFACE CLASSES: Surface classification is determined by product use and customer visibility and can be referenced in the attached supplement. There are four designations of surface classes used to distinguish between the highly visible areas to the least visible locations. Material selection shall be based on the cosmetic as well as the functional requirements of this standard. Merchant Quality steel (e.g. A36M) is unacceptable for use in any UCA applications, unless specifically called out on the drawing. (4) 6. COSMETIC SURFACE CLASS DESIGNATIONS: Class 1: A consistent finish with no rust or scale. Class 1 surfaces are typically those provided by a cold rolled or cold reduced process. Visually, the class 1 surface is comparable to a 240 grit finish, at least a 16 Ra rating or confirmed by visual comparison with a micro finish comparator surface finish block. *Class 1 surfaces are considered a customer interface surface that requires a consistent finish. Trim panels and overhead guard pillars are examples of class 1 surfaces. Class 2: A consistent finish with no rust or loose scale. Class 2 surfaces are typically those provided by shot blasting, pickled and oiled product or a quality hot rolled mill finish. Visually, the class 2 surface is comparable to a 60 grit finish, at least a 125 Ra rating or confirmed by visual comparison with a micro finish comparator surface finish block. *Class 2 surfaces are highly visible locations without the requirement of the high gloss appearance due to the functional requirements of the parts. Masts and counterweights are examples of surfaces considered class 2. Classes 3 & 4: A typical mill finish with no rust or scale and not requiring a consistent finish. *Classes 3 & 4 finishes are typical of those areas least visible to the operator. (5) 7. SURFACE CLASSIFICATION EXAMPLES: CLASS 1 PILLARS INSTRUMENT FRAME (FRONT, TOP AND RADIATOR COVER SIDES) TOP PANEL TOP OF FENDER FRAME (UPPER PORTION) CLASS 2 OHG MAST RAILS: FRONT, COUNTERWEIGHT, SIDES, REAR UPPER PORTION, EXCLUDING ANY EXHAUST PORTS MAST CYLINDERS FLOOR FRAME (LOWER PORTION) (6) CLASS 3 INSIDE OF TOP OF FRAME INSTRUMENT FRAME UNDER THE TOP PANEL LBR – TOP, SIDES, REAR OF VERTICAL RIBS (EXCLUDES FRONT SURFACE) STEER WHEEL CARRIAGE BARS (EXCLUDES FRONT FRAME STEP AREA SURFACE) (EXCLUDES BOTTOM FRAME BELOW SURFACE) INSTRUMENT PANEL DRIVE WHEEL CLASS 4 MAST BEAMS NO CLASS FRONT SURFACE OF LBR COUNTERWEIGHT FRONT OF CARRIAGE LOWER PORTION FLOOR OF STEP WHEEL WELL (7) RPX WPX TGX SPX (8)

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