Supplier Day 2011 – Quality Expectations Randy Keough Quality Manager, Newaygo Division; Magna Mirrors NA Ed Enns Director of Supplier Quality & Development, Magna International
Supplier Day 2011 – Quality ExpectationsRandy KeoughQuality Manager, Newaygo Division; Magna Mirrors NA
Ed EnnsDirector of Supplier Quality & Development, Magna International
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Agenda
• Current State of Quality Performance• Systemic Concerns• Migration to Magna Supplier Manual• Supplier Performance Rating System Overview
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Current State of Quality Performance
• What is important to the OEM’s and how are we doing?
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Current State of Quality Performance
• Customer focus– Incidents and PPM reduction, launch performance
• 2010 vs 2011 Magna Mirrors OEM Performance– Improving but much more is needed to sustain our market
share
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Current State of Quality Performance
• Supplier Performance to Magna Mirrors Divisions
• Slight year-over-year improvement since 2009• Supplier PPM > 10x Magna Mirrors OEM PPM• Over 100 Incidents per month• Tremendous burden on our manufacturing divisions
933 Incidents
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Supplier Performance Rating System Overview
• How do you know if you are meeting expectations?
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Supplier Performance Rating System Overview
• SPRS – Quality, Delivery, Commercial & Service• Quality Criteria – PPM, DCAR, PPAP, QMS certification
– Actual PPM vs 10 PPM target– Actual PPM vs Stat code (commodity) average– DCAR – timeliness, pass-through to customer, repeats
• Web-based system – PPAP – rejected or limited
• New on-line distribution – Quality Management System certification
• TS16949/ISO9001 - MDSC upload by supplier• AIAG CQI-xx, Government Regulation certs (CCC, EEC, etc.)
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Current State of Quality Performance
• What are some common themes seen across the supply base?
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Systemic Concerns
• Root cause analysis and countermeasure development.– Systemic & engineering analysis lacking, 3x5 why – Timing not met
• may vary by issue type or OEM – Breaking clean points
• Core quality tools are not understood and used – PFMEA not robust, missing detailed attention to significant
characteristics– Control plans missing the proper detail– PPAP requirements not understood
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Systemic Concerns
• Missing annual validation of product and process– Get joint agreement with your MM QE during APQP– Activity and cost is the supplier’s responsibility.– Annual validation is a requirement for service also at some
OEMs – Chrysler, Ford, BMW
• Product and process verification methods are not robust– Testing does not flush out real world issues
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Systemic Concerns
• Gauges & Calibration– Measurement and inspection processes not reviewed for
impact to data ( measurement uncertainty )
– Calibration sources not approved or capable
– Management review of calibration reports• Missing or incomplete - out of tolerance conditions not
addressed.
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Magna Supplier Manual
• Where can you find the Magna Mirror requirements?
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Migration to Magna Supplier Manual
• Magna Mirrors Supplier Quality Requirements– Current Condition
• Magna Mirrors SQR Manual & Addendums• Location: https://dsc.magnadon.com
– New Condition January 1, 2012• Magna NA Supplier Requirements Manual• Magna Mirrors Addendum – Magna Mirrors clarification to the
Magna requirements• Location: Magna International Website (Supplier Resources
page) http://www.magna.com/magna/en/about/suppliers/na/default.aspx
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Migration to Magna Supplier Manual
• Magna NA Supplier Quality Requirements– No fundamental changes from the MM SQR– Standardizes requirements across Magna N.A.
• Introduction – general expectations regarding Magna/Supplier relationship, changes and social responsibility
• Basic requirements – qualification, Quality Systems, assessments
• Product/Process Development – APQP• Serial Production – process control, nonconforming material,
engineering changes, warranty• Materials and Logistics – packaging, labeling, lot control,
planning and forecasting, transportation, MMOG• Supplier Performance – reporting and continuous improvement