SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL PROGRESS REPORT (TPR)
***** PRODUCTION PREPARATION *****
PURPOSE: To explain key points and submission procedure for the Quality Assurance Schedule and Tool Progress Report.
EXPLANATION:
The goal of a Quality Assurance Schedule (QAS) is to provide a schedule of the manufacturing and quality control activities necessary to assure the quality of parts for Mass Production. This schedule must show the relationship of the supplier’s production preparation activities to the REYES Supplier Parts Master Plan, and should be prepared by a cross-functional team.
Suppliers are required to prepare a QAS for each Tier 1 part, as well as direct supply sub-components. The schedule should span the time between the issuance of the Production Drawing or RDDP by REYES Design and three months after SOP at REYES. Similar parts, for example left hand and right hand, can be combined into one schedule.
The Tool Progress Report (TPR) is a detailed schedule of tooling milestones. This document allows REYES to track supplier tooling progress to schedule, as well as determine the potential effect of part changes on tooling.
SUPPPLIER RESPONSIBILITY:
1) Quality Assurance Schedule:
The supplier must create and submit a QAS per the date indicated on the REYES Supplier Parts Master Plan. The QAS should include, at a minimum, the following:
A. Master Schedule at the top of the first page of the QAS.
Note: Include timing for parts to be received at REYES.
B. Supplier Trial and Sample Schedule indicating supplier production trials and parts shipping schedule to meet trial requirements.
Note: The supplier’s assembly trials must simulate the mass production process and should include Mass Production level: (1) team member(s), (2) material, (3) process flow-layout and procedures, and (4) tool-dies, major equipment, fixtures and jigs. Integrity of the process must be maintained through each trial completion.
This section should also include:
1) Build out/start up plan (if applicable); include timing for previous model completion date, shut down period, inventory tracking, and start-up for new model
2) Ship dates to REYES
3) Hiring and training of personnel
4) Part/component assembly trial
C. Component Build and Ship Schedules should show all major components and indicate the location of the component build (i.e. on-line, at tool builder, Japan, etc.).
Note: Sub-supplier control should include dates sources will be selected, evaluated, and tried.
D. Production Level of the part’s components.
Note: The target for parts off production tooling and process is 1A, at latest.
This section should include:
1) RDDP or Mass Production Drawing Release date
2) Tooling – A general schedule
3) Equipment
4) Jigs
5) Checking fixtures
Note: The specifics for each new tool, jig, or checking fixture should be detailed on individual Tool Progress Reports.
E. Timing for Evaluations that will be performed on the part or component supplied to REYES. The detail of the required evaluations should be specified on the Part Evaluation Plan. This section should include:
1) Material
2) Dimension
3) Appearance
4) Performance
5) Function
F. Plan for the internal Quality System Development at the supplier. Examples of what to include are:
1) Standardized work
2) Maintenance logs
3) Receiving inspection checksheets
4) Daily check sheets
5) Procedures
6) Systems
G. SQM Requirements (Dates according to SQM / Supplier Parts Master Plan):
1) Supplier Quality Assurance Contacts
2) QAS – Quality Assurance Schedule
3) TPR – Tool Progress Report
4) Part Evaluation Plan
5) Sample Data Sheets
6) Inspection Standard
7) C/F – Checking Fixture (if applicable)
8) Process FMEA
9) MQC/CP – Manufacturing Quality Chart / Control Plan
10) Material Certification
11) Engineering Change Instruction (ECI) Implementation
12) Color Match (if applicable)
13) Grain Approval (if applicable)
14) Provisional Approval
15) Final Approval
Note: The supplier shall indicate submission timing for the above items on the QAS. If submission timing for any of the above requirements, as indicated on the QAS, is after the due date required by the Supplier Parts Master Plan, the supplier must inform REYES Quality and outline the reasons for the delays.
H. Management Status Reviews must be conducted to encompass each of the above listed items. These should show on the QAS as periodic milestones, which allow for adequate “target vs. actual” reviews of process, tooling, countermeasure activities, etc.
2. Tool Progress Report (TPR):
A. A Tool Progress Report must be prepared for each new die, jig/equipment, and checking fixture, as well as for tooling to be modified for model year changes.
Note: If additional tooling is added after Provisional Approval has been issued, see Process Change Request requirements.
B. List all major steps from design to trial on each Tool Progress Report.
C. Write in target date at the end of each bar on the Tool Progress Report.
Note: Dates should coincide with those found on the QAS.
D. Write in Tool Completion Date in the assigned space.
3. All related departments within the supplier, must approve the QAS and TPR before submission. In addition, the supplier’s top management is responsible for monitoring this plan to achieve milestones as scheduled.
4. The supplier must submit a QAS with the TPR attached to both REYES Quality and the appropriate REYES Purchasing contact per the date indicated on the Supplier Parts Master Plan.
5. REYES Quality and Purchasing will review and confirm the supplier’s activity to the Master Schedule. Request for any adjustments will be negotiated between the supplier and REYES Quality.
6. The supplier must review the QAS and TPR status periodically.
A. If all schedules meet the plan indicate “No change to schedule” on the QAS/TPR Status Report and submit a copy to both REYES Quality and Purchasing by the 5th of each month.
Note: These updates will discontinue at SOP.
B. If there are any changes to dates or content on the original QAS or TPR they must be listed on the QAS/TPR Status Report. A copy of both the status report and the revised QAS/TPR must be submitted to both REYES Quality and Purchasing by the 5th of each month.
Periodically, REYES may require the supplier to re-submit an update of the QAS and TPR. If requested, these updates must be submitted by the requested date.
QAS/TPR SUBMISSION PROCEDURE
SUPPLIER / REYES QUALITY / REYES PURCH.INITIAL DRAFT / / /
REVISIONS / / /
UPDATES / / /
Revision 1 / Reyes Automotive Group
San Antonio, TX / Section 2.3
March 2006 / Page 1 of 5