SECTION 3.4 – PROCESS CHANGE REQUEST (PCR)

*****MASS PRODUCTION*****

PURPOSE: To provide advance notification of any change that affects the REYES approved part design and quality requirements. This includes both the supply chain and/or “direct” manufacturing process.

TIMING: From achievement of QRC through the life of the part.

REQUIREMENTS:

  1. The supplier must establish a cross-organizational system that prevents any negative impact or results to the product design, quality requirements or production volume resulting from any changes to the supply chain or manufacturing process.
  1. Process changes are classified as Level I, II & III based on their potential impact. These classifications determine the requirements for submission and verification as shown in Table 3.4-1: PCR Submission Requirement Guidelines. After reviewing the guidelines, if the supplier is unable to determine the correct level they must contact REYES Quality for direction.

3. A two-step process is required for all Level I process changes.

Pre-Notification:

Pre-Notification with joint (REYES Quality, Supplier and Purchasing as needed) determination is made for go-and-see verification, quality planning, sample part submission, sample part testing, process capability studies, inspection plan verification and other quality requirements as determined necessary. Guideline for pre-notice timing completion should be 10 working days minimum prior to submission of a Process Change Request (PCR).

Process Change Submission:

Completion of PCR requirements, verification of quality requirements, revision of all related documents, (MQC, Inspection Standards, Standardized Work Instructions, etc..) and implementation and approval of the actual process change may take anywhere from several weeks to three months or more, depending on the scope and impact of the process change and related verification activities.

  1. Notification of PCR is through the designated REYES Quality representative.
  1. REYES Purchasing approval is required for sub-supplier changes (Tier I, Tier II, etc..) and plant location changes and sub-supplier classification change from “self procured” to “direct supply” (or reversed). An approved Sub-Supplier / Plant Location Change Request (SSCR) form must be submitted with the PCR.
  1. Mass production volume and quality requirements must be consistently maintained while gaining PCR approval and implementing the process change. The establishment of safety stock for the pre-change components / parts may be required.
  1. Notification and approval is not required for Level III process changes. However, if the supplier forecasts or discovers any impact to quality or productivity, REYES must be notified immediately upon discovery. This includes REYES Quality, Production Control and / or Purchasing based on the impact of the issue.
  1. Records of all process changes and related information must be maintained and available for REYES review upon request.
  1. The supplier should discuss with REYES Quality and / or REYES design to determine whether an Engineering Change Request (ECR) should be issued prior to implementing the PCR process.

FLOW CHART(s):

Table 3.4-1: PCR Submission Requirement Guidelines

LEVEL / CHANGE TYPE / IMPACT / REQUIREMENT
I /
  • Any change affecting Ñ, Ð and MVSS parts
  • Change of manufacturing location (new or existing facility)
  • Change of sub-supplier (new or location change)
  • REYES or Toyota ECIs that affect Ñ, Ð and MVSS parts
  • Change of material (supplier, specifications)
  • Change of manufacturing method (new technology, system, method)
  • Removal or addition of permanent inspection
  • Change of tool, die, mold, etc..(modification, repair, type)
  • Initial use of new machine
/
  • REYES Purchasing (approval as applicable)
  • REYES approval prior to change
  • Pre-Notification
  • Joint quality assurance planning including on-site verification (go & see)
  • PCR Submission
  • Achievement of REYES PCR & SQM requirements
  • Assure that parts meet standard before, during and after change
  • FIFO and traceability of change part
  • Notification & ID of first change part delivery

II /
  • Relocation of equipment or process within supplier facility
  • Modification change or repair of machine, equipment, tool, die, mold, etc..
  • Addition or elimination of shift
  • Removal of permanent inspection process
  • REYES or Toyota ECI affecting dimension or appearance
  • Change of sub-supplier classification (self-procured, direct supply)
/
  • REYES Purchasing (approval as applicable)
  • REYES approval prior to change
  • PCR Submission
  • Achievement of REYES PCR & SQM requirements
  • Assure that parts meet standard before, during and after change
  • Internal quality verification and tracking required

III /
  • Normal machine repair
  • Wear replacement of tool, die, mold, etc..(replace with expendable, not perishable tooling)
  • Change of cycle time, manpower, staff
  • Addition or removal of temporary inspection process (does not affect Ñ, Ð or MVSS parts)
  • Minor day-to-day kaizen activity
/
  • REYES notification not required
  • PCR submission and approval not required
  • Internal quality verification and tracking required
  • Assure that parts meet standard before, during and after change

Flow Chart 3.4-1: PCR Submission / Approval Process

SUPPLIER / REYES QUALITY
Pre-Notification / /
Planning Approval / /
First Off-Tool Sample Approval / /

Flow Chart 3.4-1: PCR Submission / Approval Process continued

SUPPLIER / REYES QUALITY
Mid-Size Trial Production Approval / /
Mid-Size Trial Production
(Supplier SQCS) / /
REYES SOP / /
Revision 1 / Reyes Automotive Group
San Antonio, TX / Section 3.4
March 2006 / Page 1 of 5