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SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 2 of 43
Sumitomo Electric Wiring Systems, Inc.
Supplier Quality Manual Contents
Page
Introduction / Sumitomo Business Principles 3
Approval / Revision Record 6
1.0 Supplier Documentation and Quality Audits 8
1.1 Quality and Environmental Requirements 8
1.2 Notice of Responsible Person of Quality Assurance 9
1.3 Quality Audits 10
1.3.1 Potential Supplier Audit 10
1.3.2 Pre-Production Audit 10
1.3.3 Mass Production Audit 10
1.3.4 PK Audit 11
2.0 Part / Production Documentation 11
2.1 PPAP 11
2.2 Prototype Tools and Components 13
2.3 Tool Transfer Approvals / Localizations 13
2.4 Initial Production Parts of a Change Point 13
2.5 Mass Production 13
2.6 Deviations for Non-Conforming Parts 14
3.0 Defect Notification Report 15
4.0 Problem Resolution 15
4.1 Problem Improvement Request 15
4.1.1 Problem Improvement Request (PIR) / Quality Concern Report (QCR) /
Abnormality Report (ABR – Japan)
15
4.1.2 Initial Response 15
4.1.2.1 Sort and Rework Requirements 16
4.1.3 Countermeasure Response 16
4.2 Controlled Shipping 17
4.3 Fees 17
5.0 Supplier Rating 18
5.1 Focus Suppliers 18
6.0 Relation to Purchase Order 19
DNR-PIR (SEWS WIRE HARNESS DIVISION) 20
SUPPLIER COMMITMENT FORM
7.0 SEWS Components Division Specific Packaging Requirements
21
22
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CORP-QA-7.4.3.2-01 Page 3 of 43
Sumitomo Business Principles
Sumitomo Electric Wiring Systems, Inc. (SEWS) and other companies of the Sumitomo Group share
the Sumitomo “Business Principles”, which have supported Sumitomo business ethics for over four
hundred years. The principles of placing “prime importance on integrity and sound management”
and “not pursuing easy gains or acting imprudently” remain valid at all times, and we should
adhere to them always. As for “respecting humanity and attaching importance to technical
expertise”, it is no exaggeration to say that these values constitute the permanent corporate
philosophy of our company. Sumitomo Business Principles have been defined below:
Sumitomo shall:
• Offer the very best goods and services to satisfy customer needs.
• Build technical expertise, realize changes and strive for consistent growth.
• Contribute to creating a better society and environment, with a firm awareness for our social
responsibility.
• Maintain high corporate ethics and strive to become a company worthy of society’s trust.
• Nurture a lively corporate culture that enables employee self-improvement.
Our Quality Pledge
“Quality for a Better Tomorrow” a commitment made by Sumitomo Electric Wiring Systems to our
customers our worldwide markets and to us. Working as a team, we support this pledge by
combining excellence in day-to-day communications with a world-class work ethic and state-of-the-
art processes to produce products which consistently meet and exceed our customer’s
expectations of quality, delivery and cost.
Quality
Sumitomo Electric Wiring Systems is a leading supplier of wiring harnesses, functional components,
electronic control units and connecting components to the automobile industry. We pride
ourselves in showing the utmost quality and professionalism to achieve the desired end result. The
automotive industry is a dynamic world filled with constant changes as new technology emerges
and consumer tastes evolve with the growing number of choices available.
Some of the biggest advances have been made in the field of automotive electronics distribution
systems technology. Consequently, the automotive wiring harness has become the lifeblood of the
modern automobile. Wiring harnesses produced by Sumitomo Electric Wiring Systems not only act
as a power conductor for basic functions, but also for a whole range of new and exciting safety and
convenience features. Wiring harnesses, functional components and electronic control units are
composed of many component parts; therefore, quality control of components is essential to
assuring superior quality.
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CORP-QA-7.4.3.2-01 Page 4 of 43
Performance Standard
The basic standard of performance SEWS expects of our suppliers is the same as we demand of
ourselves – that is to strive toward zero defects. This must be the goal of each of us to effectively
compete in the world market.
Sumitomo suppliers are selected based on their ability to provide superior performing products,
superior value, superior technologies and processes, and superior customer service. Suppliers
awarded with Sumitomo business are expected to meet or exceed the expectations defined in the
SEWS Supplier Quality Manual.
SEWS objective is to define the quality requirements to develop long term relationships with
suppliers who are committed to never ending improvement in quality, delivery, and productivity
which will mutually benefit the relationship.
This manual outlines the general requirements for SEWS’ suppliers concerning the basic quality
system used to assure the quality of products supplied to SEWS.
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CORP-QA-7.4.3.2-01 Page 5 of 43
QUALITY SYSTEM
SEWS requires our suppliers to join us in becoming prevention oriented, using the necessary quality
control / quality assurance activities to produce acceptable quality on a continuing basis. SEWS will
audit our suppliers for compliance to SEWS’ Quality system requirements.
This manual outlines the general requirements for SEWS’ suppliers concerning the basic quality
system used to assure the quality of products supplied to SEWS. SEWS’ requires that the supplier
meet the requirements of this SQA Manual as well as any additional requirements as specified by
SEWS Customers.
DELIVERY SYSTEM
SEWS requires that the supplier obtain 100% on-time delivery performance. In the event that
100% on-time delivery cannot be achieved, the supplier shall communicate to SEWS Material
Control / Production Control to resolve all issues, in a manner consistent with each purchase order
and SEWS’ Global Terms and Conditions. On-time Delivery will be monitored as part of the Supplier
Scorecard Rating Program.
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Approval / Revision Record
Title Name Signature / Date
Vice President Rich Whitaker Rich Whitaker / 6/19/2014Rich Whitaker / 6/19/2014Rich Whitaker / 6/19/2014Rich Whitaker / 6/19/2014
Assistant General Manager Corporate
QA
Tom Minton ToToToTom Minton / 6/19/2104m Minton / 6/19/2104m Minton / 6/19/2104m Minton / 6/19/2104
General Manager Components QA Deborah Gillenwater Deborah Gillenwater / 6/19/2104Deborah Gillenwater / 6/19/2104Deborah Gillenwater / 6/19/2104Deborah Gillenwater / 6/19/2104
General Manager Electronics QA Hironao Ishii Hironao Ishii / 7/8/2014Hironao Ishii / 7/8/2014Hironao Ishii / 7/8/2014Hironao Ishii / 7/8/2014
General Manager Midwest Wire
Harness Division QA
Gil Albee Gil Albee / 7/11/2Gil Albee / 7/11/2Gil Albee / 7/11/2Gil Albee / 7/11/2014014014014
General Manager Central Wire Harness
Division QA
Ken Woosley Ken Woosley / 7/11/2014Ken Woosley / 7/11/2014Ken Woosley / 7/11/2014Ken Woosley / 7/11/2014
General Manager Detroit Wire Harness
Division QA
Mark Comeau Mark Comeau / 7/16/2014Mark Comeau / 7/16/2014Mark Comeau / 7/16/2014Mark Comeau / 7/16/2014
Manager QA – NCSC / MCSC Chris Jennings Chris Jennings / 7/21/2014Chris Jennings / 7/21/2014Chris Jennings / 7/21/2014Chris Jennings / 7/21/2014
Manager SQA – ECSC Alvaro Mendoza Alvaro Mendoza / 7/21/2014Alvaro Mendoza / 7/21/2014Alvaro Mendoza / 7/21/2014Alvaro Mendoza / 7/21/2014
Manager Purchasing - Corporate Barry Brown Barry Brown / 7/21/2014Barry Brown / 7/21/2014Barry Brown / 7/21/2014Barry Brown / 7/21/2014
Manager Electronics Purchasing –
Detroit
Yoshio Pierce Yoshio Pierce / 7/28/14Yoshio Pierce / 7/28/14Yoshio Pierce / 7/28/14Yoshio Pierce / 7/28/14
Manager Purchasing – ECSC Gabriel Perezchica Gabriel PerGabriel PerGabriel PerGabriel Perezchica / 7/29/2014ezchica / 7/29/2014ezchica / 7/29/2014ezchica / 7/29/2014
Manager SQA – Midwest Wire Harness
Division
Marcus Sampson Marcus Sampson / Marcus Sampson / Marcus Sampson / Marcus Sampson / 8/12/148/12/148/12/148/12/14
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Revision
Level
Date Revision History
0-3 8/21/1995 Previous Revisions
4 4/28/1997 Re-issue of complete manual. Suppliers to destroy old version. Addition of delivery standard. Addition of System
Audit. Addition of Pre-Production Audit. Revised Supplier Rating System to include delivery rating. Addition of
revision record.
5 7/1/2000 Revision of PIR Procedure
6 7/31/2002 Re-issue of manual
7 1/10/2003 Addition of requirements (per end customer) for IMDS
8 10/30/2003 Format and Grammar. Revised PIR procedure. Revised Sort and Rework requirements. Revised PPAP expectations.
Revised General Procedures. Revised Registration Requirements. Added organizational chart. Added SEWS
Business Principles. Revised audit guidelines and procedures
9 12/15/2005 Revised monetary values. Revised organization chart. Added requirements for IPP Tag. Updated PPAP
requirements. Updated Mass Production requirements. Updated IMDS requirements. Added bar code
requirements. Added tool transfer requirements. Updated PPAP requirements. Added confirmation audit.
Updated supplier rating for quality.
10 3/5/2007 Revised Supplier Rating and monthly scoring.
11 9/29/2008 Addition of MP Audit check sheet. Addition of N+3 audit check sheet, addition of MPR requirements. Addition of
W/H PIR process flow, revised Quality and Environmental requirements. Revised PPAP requirements. Deleted Org
Chart. Deleted general tooling guidelines.
12 03/14/2012
REMOVED: “Quality Systems Audit”, “Countermeasure Audit”, “Quality Assurance Confirmation Audit”, “N+3 Audit”
UPDATED: Quality and Environmental Requirements, Notice of Responsible Person of Quality Assurance, PPAP
Requirements, Tool Transfer Approvals / Localizations, Mass Product Parts, Deviations for Non-conforming Parts,
Lifetime Deviations, Defect Notification Report, Problem Improvement Request (PIR) / Quality Concern Report
(QCR) / Abnormality Report (ABR), Sort and Rework Requirements, Countermeasure Response, Supplier Rating,
Relation to Purchase Order
ADDED: Conflict Materials Requirements, Potential Supplier Audit, PK Audit, Defect Notification Report, Initial
Response, Focus Suppliers
13 6/19/14 Revisions are in RED Font
Added requirements for TS16949 compliance (Sub-Tier Requirements)
Added new requirements for IMDS/SoC/Conflict Minerals reporting
Added revised requirement for annual layout
Added section for Components Division specific requirements
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1.0 Supplier Documentation and Quality Audits
1.1 Quality and Environmental Requirements
1.1.1 Quality Requirements
Suppliers shall be third party registered to the latest revisions of ISO 9001 or ISO/TS 16949,
by an accredited third-party certification body, unless an approved waiver has been
provided by SEWS. Suppliers must notify SEWS immediately upon loss of certification.
SEWS expectation is for our suppliers to strive for TS16949 certification. Suppliers that are
not TS16949 certified must meet following minimum system requirements:
1. Control Plans – TS16949: 7.5.1.1, 7.5.1.2, 7.5.1.3, 7.5.1.4. ISO9001: 7.5.3
Note: Control plans shall comply with TS16949 Annex A (normative), unless the
supplier has prior approval from the responsible SEWS SQA representative.
2. Process Approach – ISO9001: 0.2
3. Performance – TS16949: 8.2.1.1, 7.4.3.1, 7.4.3.2, 8.5.2.1
4. Internal Auditing – The supplier shall audit it’s quality management system to verify
compliance with ISO9001, SEWS SQA Manual, TS16949: 8.2.2.2, 8.2.2.3, 8.2.2.4. The
supplier shall have internal auditors who are qualified to audit the requirements of
ISO9001 and SEWS SQA Manual
5. Control of Non-Conforming Product – TS16949: 8.3.1, 8.3.2, 8.3.4
6. Part Approval – TS16949: 7.3.6.3, 4.2.3.1, 8.2.3.1, 7.6.1, 7.6.2, 7.1.4. SEWS shall be
notified of any changes that could impact product realization as described in
TS16949 7.1.4
7. Management Responsibility: TS16949: 5.1.1, 5.4.1.1, 5.5.1.1, 5.5.2.1, 5.6.1.1, 5.6.2.1,
6.3.2
In addition to ISO and TS standards, suppliers shall conform to the requirements of the
International Material Data Systems (IMDS) and submit information about their raw
material usage. Suppliers must also monitor and control their processes to assure that
there are no sources of contamination that would cause the product sold to SEWS to exceed
any of the SoC/ELV elements as indicated in the GADSL regulations, this includes all sub
materials that pertain to the product such as inks, markers, additives, etc. SEWS
environmental guidelines can be accessed at:
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http://www.sewsus.com/SupplierInformation/SEWS%20North%20America%20EU%20Chem
ical%20Standard.pdf.
Suppliers shall have a standard in place to control, monitor and report GADSL/SoC items to
SEWS including as a minimum the following points:
• Responsible department/person for SoC is defined
• There is a list of purchased items, including sub-materials with specific names or
internal part numbers controlled and verified by the Supplier, for compliance to
GADSL/SoC guidelines
• GADSL/SoC requirements are verified at the feasibility stage of product realization
activities
• Control of materials used for maintenance operations to assure SoC substances are
not introduced into the process, i.e. Lead Solder, etc.
• Supplier shall have the capability, either internally or externally, to test product
supplied to SEWS for the 6 SoC substances. SEWS requires verification of SoC with
PPAP submissions
• Control of materials to assure as changes are made to GADSL/SoC requirements, the
inventories are exhausted or disposed of to comply with “Sunset Dates” or
agreements with SEWS
SEWS will comply with the Automotive OEM directive for the reporting requirements for
“Conflict Minerals”. SEWS requires our supply base to comply with the “Conflict Minerals”
directive, that stem from the Dodd-Frank Act, intended to curb violence and other human
rights violations in the Democratic Republic of Congo (DRC). SEWS suppliers must identify
whether they use any of the minerals identified as “Conflict Minerals” and comply with the
reporting guidelines and requests that stem from the OEM activities for compliance to the
regulation.
For more information on environmental procedures and requirements go to
www.sewsus.com, then click Supplier Information where you will find the link for IMDS-ELV
Requirements. As part of the material reporting requirements suppliers will capture a
screen shot of accepted IMDS submittal and include with PPAP.
Information about raw material usage shall be submitted to:
• SEWSUS – 56679
• K&S WIRING – 17259 (NISSAN PRODUCTS ONLY)
1.2 Notice of Responsible Person of Quality Assurance
It is the responsibility of the Supplier to report to SEWS the names of key individuals who
are responsible for delivering a quality product to SEWS. Suppliers shall use the Supplier
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Commitment form to register the persons with responsibility for SEWS products. There
must be someone available with authority to make necessary decisions and shall include
both on and off shifts. The responsible person(s) shall review SEWS Supplier Quality
Assurance Manual and sign the Supplier Commitment Form acknowledging compliance with
these documents. Any change in this responsibility shall be reported to SEWS immediately.
Failure to register to the SEWS Supplier Quality Manual does not relieve the supplier of
obligations to fulfill SEWS Requirements.
1.3 Quality Audits
SEWS’ Supplier Quality and SEWS Customers may complete various audits during the life of
the contract. SEWS encourages our suppliers to strive for continuous improvements in their
quality systems through the use of quality audits, with thorough follow-up in areas of
concern. When any non-conformance is found during an audit, an improvement plan and
implementation status must be submitted along with countermeasures to the auditor.
Suppliers should fully understand the audit purpose and contents beforehand, and be
prepared for the audit. It is the responsibility of the supplier to perform a pre-audit to
confirm compliance to SEWS procedures. The supplier shall make their facilities available to
SEWS and SEWS customers as needed for auditing purposes. Audit forms will be provided
by SEWS as needed.
1.3.1 Potential Supplier Audit
Upon consideration of a potential new supplier, SEWS may perform a systems
quality audit at the supplier’s facility prior to acceptance. Suppliers will be provided
a copy of the assessment prior to the visit.
1.3.2 Pre-production Audit
Once a supplier is ready for production, a Pre-Production Audit may be performed to
validate the processes and quality systems. The Pre-Production Audit is designed to
assure all requirements for the start up of new and/or changed processes are met.
This audit should be performed by SQA/QA and Purchasing from SEWS. The “Pre-
Production Audit” may be performed by the supplier and results submitted to
Supplier Quality at the discretion of SQA/QA and Purchasing.
Criteria for conducting a Pre-production audit include, but not limited to
• Start-up of a new component, include localization
• Significant process changes, material changes or
• SEWS customer requests
• Tool repair, location change
• Ongoing problems with quality, delivery, etc.
1.3.3 Mass Production Audit
SEWS SQA/QA may audit the supplier’s quality systems, verifying the control plans
and standards for a part that the supplier has in current mass production. The
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supplier must obtain the minimum score required. If the supplier does not meet the
minimum score required or there are any areas of concern, the supplier will be
required to submit corrective actions with evidence of the improvements. SEWS
SQA/QA will decide whether to accept the improvement documentation to close the
audit or to schedule a follow-up audit for verification.
1.3.4 PK Audit
Periodic or quality assurance confirmation audits may be performed as a proactive
measure in assuring realization of quality, delivery, and program growth
expectations. This audit will focus on change points and technical / process
improvements.
2.0 Part / Production Documentation
2.1 PPAP
SEWS requires that all suppliers submit a Level 3 PPAP for new components and/or any
changes in product or process for current mass production parts. If SEWS customer does
not require Level 3 PPAP, SEWS may waive requirement to supplier for the Level 3 PPAP
Submission.
Initial notification must be submitted via an Advanced Notification of Initial Production
Parts (AIPP – CORP-QA-7.4.3.2-06) to all ship-to locations. Each SEWS division will notify the
supplier of any additional documentation requirements.
Level 3 PPAPs should be submitted using the AIAG or SEWS Customer guidelines and format
(example: Phased PPAP). SEWS reserves the right to waive AIAG PPAP requirements in lieu
of specified documentation to meet SEWS and SEWS customers’ requirements. PPAP
documentation must be submitted in a timely manner based upon project timing. PPAP
approval must be given prior to shipment. SEWS may provide a waiver to ship prior to PPAP
at the discretion of SEWS QA. Annual layouts of components may be required to meet
SEWS Customer Requirements.
Any changes made after initial PPAP Approval will require resubmission of the PPAP. SEWS
shall be notified of any internal process changes that could affect product quality using the
AIPP form. SEWS will determine which level of the PPAP has to be submitted based on the
change made. Changes could include but are not limited to prior approved raw material,
mass production equipment, assembly equipment, and/or location changes. PPAP approval
must be given by SEWS prior to shipment.
SEWS SQA / QA will notify supplier when annual PPAP’s are required.
Level 3 PPAP includes the following (please refer to current version of AIAG Manual to
assure full compliance):
• Part Submission (CFG-1001 or NAOP 4.5-1 F-PSW)
• Minimum 5 Sample Parts (per cavity if applicable)
• Engineering Drawings numbered for inspection results
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• Process Flow Chart
• Failure Mode Effect Analysis (Design and Process FMEA)
• Process Control Plans (Control Plans, MQC, PQCT)
• Inspection results – dimensional (ISIR form)
• Single / Multiple Cavity Tool
A 100% dimensional layout on all dimensions called out in the Sumitomo and
Customer Drawing. Parts must be clearly identified as the measurement samples.
• Inspection results – functional (Evaluation form)
• Material Certification
• Appearance Approval Report (if applicable)
• Inspection Equipment List / Lab Scope (As per control plan)
• Gage R&R (All gages used in dimensional checks of the component)
• Customer material requirements per Annex II of 2000/53/EC
• Packaging Specifications
• IMDS – International Material Data System (Reporting System)
• Lab Accreditation
• Bulk Material (Please refer to the AIAG PPAP manual for applicable requirements)
When identified, suppliers will be required to complete dimensional studies to the SEWS
internal issued drawing and / or the customer issue drawing. Requirements for the
customer issued drawings include but are not limited to:
• 100% dimensional analysis
• Process Capability (PPK / CPK) on specified dimensions
• Capability Study for functional testing on all areas identified on the drawing
• Capability Study for functional testing identified as critical by SEWS.
Dimensional studies completed to the customer drawing must meet all requirements,
functionally and dimensionally. Tool correction will be required if the supplier cannot meet
the above dimensional and functional requirements. Failure to correct the tool will result in
the supplier monitoring the areas which do not meet customer requirements 100%
throughout the life of the component or until the tool is corrected to meet the customer
drawing and / or requirements.
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2.2 Prototype Tools and Components
To ensure that a certain level of quality is maintained for prototype tools and components,
suppliers must adhere to the general prototype requirements contained in this manual or
any requirements provided by SEWS.
2.3 Tool Transfer Approvals / Localizations
Before new tools are transferred to the permanent production facility a Tool Transfer
Approval Sheet (TTAS – CORP-QA-7.4.3.2-03) must be submitted to SEWS Purchasing
(contact for program) along with mass production supplier’s functional and dimensional
analysis of the parts molded at the tool builder which was evaluated by the mass
production supplier. This part analysis will be submitted to SEWS using the form contained
in this manual or forms provided by SEWS during the kick off meeting prior to submitting
TTAS. If any failures are identified, a deviation request must be submitted to SEWS for
approval. Failure to complete the TTAS form may delay production and PPAP approval
resulting in a claim against the supplier for failure to meet timing. During the tool build if
there are any discrepancies between the 2D and the 3D drawing, the supplier will reference
the 2D as the master and will contact SEWS purchasing immediately. Purchasing will then
distribute the information about the conflict accordingly. SEWS will work with the supplier
to resolve any issues.
SEWS encourages feedback and suggestions from its suppliers during tool builds and prior
to production.
2.4 Initial Production Parts of a Change Point
For a PPAP that is submitted for components that are already in mass production (i.e.
replacement tooling, supplier change, additional tooling) upon approval of the PPAP the
first shipment of new components will be identified with an Initial Production Parts tag.
This IPP tag will reference a SEWS internally issued number that will be assigned to that
particular component PPAP. Failure to do so will result in a rejection of the first shipment of
new components and a PIR issued against the supplier.
2.5 Mass Production Parts
� Lot retention samples will be established on a part by part basis. When not
specified, lot retention samples shall consist of a period of a minimum of six
months to include first and last shots / pieces of each run.
� Control plans shall identify SEWS designated CPK dimensions and functional
requirements to be verified at the start and end of each run.
� For Packaging and Bar Code Requirements SEWS suppliers shall comply with the
bar coding requirements as defined in SEWS Part Identification and Labeling
Requirements. To see the specification, go to http://www.sewsus.com.
� The practice of First In First Out (FIFO) will be implemented and followed for all
necessary components used in production of SEWS components. The supplier
will be responsible for controlling an internal system to ensure that the practice
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of FIFO is efficient to meet this standard. This will include, but not limited to,
raw material, assembly components, production parts requiring secondary
operations, assembly operations, and finished goods.
� For changes to a mass production component, either initiated by SEWS or the
supplier, the Advance Notification of Initial Production Parts will be utilized. This
form will be used as the means of communication between SEWS and the
supplier whenever there is a proposed change to the mass production
component or the mass production operation.
• The changes include but are not limited to:
• Design Changes
• Raw Material Changes (Supplier / Grade)
• Assembly Changes including Location Changes
• Process Changes including Location Changes
• Packaging Changes to include box type or quantity
• Additional Tools
2.6 Deviations for Non-Conforming Parts
In principle, suppliers are fully responsible to ensure that all products shipped to SEWS
conform to all applicable specifications and drawings. When a specification or drawing
cannot be met, the supplier must apply for a deviation using the Deviation Request Sheet
(CORP-QA-7.4.3.2-07), however the supplier must be able to provide evidence that one or
more of the following criteria apply:
• Part must comply with all finished goods PPAP requirements of SEWS’ customers
• Non-conformity cannot be corrected even if the material, mold or die is changed or
reworked.
• Rework or change to mold/die would result in an interruption to SEWS’ assembly
process or delivery process
• The deviation does not affect fit or function. Anything that is deemed functional will not
be considered.
Under no circumstance will it be acceptable to ship nonconforming parts to SEWS without
prior written approval from SEWS Quality Assurance.
Types of Deviation
A. Limited Quantity
A Limited Quantity deviation limits the quantity of non-conforming parts to be used and
will be applied when a certain amount of non-conforming parts are needed urgently to
support SEWS production.
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B. Limited Period
A Limited Period Deviation limits the period during which non-conforming parts may be
used.
C. Lifetime
Lifetime deviation is a permanent deviation for specific mold or dies and is approved
only under special circumstances.
To request a deviation for characteristics designated on Sumitomo drawing or
specification, the Supplier shall submit a deviation request sheet, applicable supporting
data and samples. In the case of multiple production tooling, samples will be required
from each mold or cavity affected. Quantity for samples and test requirements should
be negotiated with SEWS QA.
SEWS will provide disposition of each deviation request and will notify the supplier. The
supplier shall not deliver the non-conforming parts without written approval from SEWS.
SEWS will notify supplier of any special identification requirements for shipment of
deviated parts.
3.0 Defect Notification Report
The Defect Notification Report (DNR) is issued by SEWS SQA/QA to notify the supplier that a
potential quality issue exists. A formal countermeasure is not required from the supplier at
this point; however SEWS would request the supplier to begin an investigation and provide
feedback as requested. If the DNR is deemed a supplier defect, a PIR will be issued.
NOTE: Defect Notification Report (Form may differ by plant)
4.0 Problem Resolution
4.1 Problem Improvement Request
Whenever SEWS finds a problem or defect with mass production parts from any supplier,
SEWS’ SQA/QA will evaluate the severity of actual defect samples, DNR, and/or other reject
documents to make a determination of the actions the supplier will be required to take.
4.1.1 Problem Improvement Request (PIR) / Quality Concern Report (QCR) /
Abnormality Report (ABR) (Japan)
A PIR, QCR or ABR will be issued to the supplier by SEWS SQA/QA. The supplier shall
examine the facts to determine the suspect range and the cause(s) for the defect
occurrence and flow-out. The supplier shall implement an appropriate
countermeasure for each.
4.1.2 Initial Response
Supplier is required to provide an initial response to SEWS within 24 hours. Initial
response shall include containment activities, details for certification of good
product, sort and rework plans, and the investigation proceedings.
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Containment Reporting shall include quantity of suspect parts in inventory and in
transit, sorting / rework authorization number (if required), return material
authorization number (RMA), picture of certification tag.
Failure to provide sort / rework authorization number does not absolve the supplier
of the responsibility for containment / sort cost.
4.1.2.1 Sort and Rework Requirements
If sort and rework activities are required, the supplier is responsible to
designate a representative to be on site within 24 hours of notification for
supervision and administration activities. It is recommended by SEWS that
the supplier coordinate all sort activities.
In the event SEWS coordinates sort activities, suppliers will be responsible for
any and all costs incurred. SEWS will hold final approval of all sort and
rework plans.
4.1.3 Countermeasure Response
The Supplier shall submit a Countermeasure Response and evidence of the
implemented action to SEWS within 14 days of date of issue, unless otherwise
specified by SEWS. It is the responsibility of the supplier to request an extension if
timing cannot be met.
The Countermeasure Response shall include a root cause analysis, evaluation and
analysis and a final corrective action and plan.
The Root Cause Analysis shall provide details on how the defect occurred and why
the flow-out of the defect was not detected.
The Final Corrective Action and Plan shall provide detailed information to ensure the
nonconformity does not recur.
If PFMEA / Control Plan are updated due to actions taken, updated PFMEA / Control
Plan must be submitted with Countermeasure Response.
Identification of countermeasure parts
• The supplier is required to identify each container of temporary countermeasure
parts stating parts certified on what date and for what non-conformance. These
tags should appear on all containers until the permanent countermeasure is
implemented.
• The supplier shall place a PIR C/M label on the first 3 shipments of permanent
countermeasure parts. This will notify SEWS’ Receiving Inspection to take
appropriate actions to verify the countermeasure.
NOTE: Please see the DNR – PIR process flow for the SEWS Wire Harness Division
for specific reporting requirements and information flows.
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 17 of 43
4.2 Controlled Shipping
When necessary or designated by the OEM or SEWS customer, SEWS suppliers will adhere
to SEWS Customers specific levels of Controlled Shipments.
4.3 Fees
Suppliers are responsible for all costs incurred while the defect situation is contained and
remedied. Expenses such as, but not limited to the following, will be charged to the
supplier.
There shall be a minimum administrative cost of $100 per shipment of non-conforming
product. Non-conforming product is defined as a deviation from the SEWS engineering
specification or engineering drawing. Fees may be waived at the discretion of SEWS.
Replacement of defective / suspect raw material with validated stock.
Warehousing / storage fees accumulated through the disposition of defective / suspect raw
materials and / or finished goods.
All necessary travel expenses required to disposition defective / suspect raw materials and /
or finished good.
Rework or repair models, tolling, gauges, testing equipment or third party testing.
Labor for sorting or reworking defective / suspect raw material will be a $50 / hourly rate
per employee if conducted by SEWS.
Production overtime at Sumitomo facilities
Administrative, corporate and management support fees.
Shipping fees related to the return of suspect / defective materials.
Duties, taxes and fees related to scrapping materials outside the U.S.
Labor for sorting or reworking finished goods will be a $50 / hourly rate per employee if
conducted by SEWS.
Scrapping or reworking of finished goods due to defective supplier materials.
Excess and additional freight charges and air shipments
Production downtime at customer locations, to include all costs incurred by SEWS from the
customer.
Recovery costs due to a vehicle recall.
Follow up actions and assessments, as appropriate.
All other fees associated with a defective condition.
SEWS will hold approval on finalization of all sort and rework to ensure that all
requirements are met and satisfied. The supplier will not be released from the sort and
rework requirements until such approval is released and issued to the supplier.
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 18 of 43
All costs are calculated based on US currency. Debits are issued to the supplier through the
Accounting Department in cooperation with your responsible buyer.
Suppliers are responsible for any and all costs incurred due to rework or defective material.
SEWS will track incidents of premium freight from the supplier, however this will be tracked
internally and only reported to supplier if SEWS deems necessary.
5.0 Supplier Rating
Suppliers will receive a monthly rating report in the areas of Quality, Delivery and
Purchasing performance. It is the expectation of SEWS that our suppliers maintain the best
score possible on their supplier rating.
The monthly scoring is as follows:
90-100
Supplier meets or exceeds expectations of SEWS.
80-89
Supplier meets expectations of SEWS; however improvements may be required. Should the
scoring remain at this level for a consistent time period, SEWS may visit the supplier to
conduct a general process audit and investigate the root cause of problems attributing to
the reduced rating.
70-79
Supplier does not meet expectations of SEWS. SEWS may arrange a process audit with the
supplier. Any findings from the process audit will require immediate corrective actions.
Below 70
Supplier does not meet expectations of SEWS and is in jeopardy of being de-sourced. The
supplier may be placed on New Business Hold at the discretion of SEWS.
SEWS will convene to collectively determine whether the supplier has opportunity for
improvement or whether it is the best interest of Sumitomo to begin preparations for
future termination of any or all transactions between SEWS and the supplier.
Suppliers who have scores in any individual section (Quality, Cost, or Delivery) which have
been deemed by SEWS to be below satisfactory standards may be subject to additional
corrective action requests, audits, and de-sourcing discussions in addition to those outlined
above.
5.1 Focus Suppliers (Zero Defect Activity “ZD”)
Suppliers with recurring problems or suppliers that fail to respond to Problem
Improvement Requests may be selected as a “Focus Supplier”. Suppliers in this
category may be required to participate in meetings with SEWS. The frequency
(weekly, Bi-weekly, monthly, etc.) and means (telephone, face-to-face, etc.) will be
decided by SEWS and informed to the supplier. Suppliers will be placed on “Special
Containment” which will require 30 days of defect free shipments. Inspection results
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 19 of 43
must be provided to SEWS during this time. Focus suppliers will be required to attend
meetings at a SEWS’ facility to review and present Quality Improvement Plans.
6.0 Relation to Purchase Order
Supplier acknowledges and agrees that the requirements of this Supplier Quality Manual, as
it may be amended, shall become part of, and shall be incorporated by reference in any
purchase order issued by SEWS to the Supplier. The Supplier Quality Manual supplements
each purchase order and does not relieve the Supplier of any obligations that arise from a
purchase order or from SEWS’ Global Terms and Conditions for Suppliers that is an integral
part of each purchase order. By signing the Supplier Commitment Form (CORP-QA-7.4.3.2-
02), Supplier acknowledges that it has read the Supplier Quality Manual and reconfirms the
applicability of the terms of accepted purchase orders from SEWS.
*Notice: Any forms contained within or referenced by this manual may differ from issuing
plant.*
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CORP-QA-7.4.3.2-01 Page 20 of 43
DNR – PIR (SEWS WIRE HARNESS DIVISION)
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 21 of 43
SUPPLIER COMMITMENT FORM
SENIOR /
EXECUTIVE
MANAGER
SALES QUALITY ENGINEERING MANUFACTURING
管理職管理職管理職管理職 営業営業営業営業 品質品質品質品質 技術技術技術技術 製造製造製造製造
NAME
TITLE
PHONE
FAX
CELL
RECEIPT AND ACKNOWLEDGEMENT OF SUPPLIER
The undersigned supplier acknowledges receipt of the Supplier Quality Manual of Sumitomo Electric Wiring Systems,
Inc. (“SEWS”) and agrees that, for good and valuable consideration, they will comply with all the terms, conditions, and
requirements of the SEWS Supplier Quality Manual.
________________________________________________________________
Print Name of Supplier
_______________________________________________________________________
Print Name of Authorized Representative
_______________________________________________________________________
Signature of Authorized Representative
_______________________________________________________________________
Date Signed
Failure to sign form and return it to SEWS does not relieve you from your responsibilities of meeting the requirements of the SEWS Supplier Quality
Manual. Please forward all questions to your customer representative.
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 22 of 43
SEWS Components Division ~ Specific Requirements
Packaging Specification for Sumitomo Scottsville Components Division Building#5
All packaging must comply with the requirements set forth.
No alternative packaging will be accepted without prior written approval.
Any requests for alternative packaging should be submitted using the Sumitomo Packaging
Specification Data Sheet
See attachment for Sumitomo Packaging Specification Data Sheet:
Page 28 of 42 Page 29 of 42
1) Specification of bags
Structure:
1) All product must be bagged inside of external container.
2) Bag size shall be product variable except where specified (example: seal
production)
3) Bags to be clear in color
4) Bag Mil thickness must comply with the following (unless otherwise
specified):
* Bag Pack = 1.5mil minimum
* Bulk Pack = 2.0mil minimum
2) Specification of Boxes:
Structure:
1) Boxes must comply with either the B-Carton or J-Carton Specifications
unless otherwise specified.
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CORP-QA-7.4.3.2-01 Page 23 of 43
2) Box identification marking:
a) Pass through product - Box exterior must display Sumitomo
name/emblem per B/J-carton drawing
b) Consumable parts - Box exterior must display Supplier Name/Markings
2) Box construction must comply with a minimum of 44 ECT requirements
(or equivalent)
See attachments for box specifications:
Page 30 of 42 Page 31 of 42
3) Box Packing
Unit Weight:
Maximum allowable shipping weight of each box & product must not exceed
22lbs (unless otherwise specified)
Packing Method
1) Product shall be packed in the box in a manner to prevent damage to
product while in transit and warehousing.
Quantity of product per unit shall take into consideration sufficient space
to prevent compression of parts due to overfilling the box.
4) Specification of Pallets:
Structure:
Pallets must comply with the pallet specifications included here:
1) Pallets must be ISPM 15 certified and be visibly marked to show
compliance.
2) Pallets must utilize spiral nails.
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CORP-QA-7.4.3.2-01 Page 24 of 43
3) Pallet style and dimensions must comply with the attached pallet
drawing. :
Page 32 of 42
5) Palletized box configuration
Packaging:
1) Maximum packaged skid height is 65" - measured from floor to top of load
2) All box labels must be visible from the exterior of pallet to allow scanning
without removing boxes.
3) All pallets must be packaged in a manner to prevent damage to product
and container while in transit and/or storage.
4) Double stacking of pallets is acceptable if sufficient protection (sturdy
divider) is secured in place between top of bottom load and bottom of
top pallet.
Securing of boxes/loads to pallet:
Boxes/loads must be secured to pallets by one of two methods:
1) Stretch wrap
* 70 gage wrap minimum
* Number of wraps: 3 wraps on bottom / 2 wraps on top (minimum)
* Wrap must be secured to the pallet with minimum of 3 wraps
2) Banding
* Plastic banding required
Note: Corner protectors should be used in the case that any box
deformation occurs due to the application of the wrap or banding.
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CORP-QA-7.4.3.2-01 Page 25 of 43
6) Specification of Raw Material Resin Container:
All resin shall be received in one of two methods:
1) Silo
2) Gaylord
Silo Transfers:
Silo transfer requires in-line magnets (with screen) from truck to silo
Supplier must establish controls to prevent the creation of "strings" due to
material transfer at excessive speed. Dense phase offloading is required.
Gaylord specification:
1) Size:
* 48"x45"x40"tall
2) Strength:
* 350lbs bursting test No. 2317
3) Stacking:
* Stacking method must be identified on Gaylord
Example: 3 high max stacking
2 high max stacking if over 1800lbs
7) Specification for Seal packaging:
All seal packaging must comply with the enclosed Seal Packaging Specification.
Page 33 of 42
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8) Specification for Terminal Reel Packaging:
Any terminal product packaged on terminal reels must comply with the pecifications
included here.
Non-returnable packaging
1) Terminal reels must comply with the enclosed terminal reel specification
unless otherwise specified.
2) Reel construction must comply with a minimum of 44 ECT requirements
(or equivalent).
See attachment for terminal reel specifications
Page 34 of 42
3) Terminal reel splicing:
a) Maximum of three (3) spliced joints allowed per reel
1) Splice qty per reel must be indicated on reel label
b) Splices must be made using copper wire
c) Splice length should not exceed 50mm in length
4) Terminal reel packaging
a) Terminal reels must be shipped in boxes that comply with the Terminal
Reel Box specification below:
b) Box construction must comply with a minimum of 44 ECT requirements (or
equivalent).
1) Bursting Test: 200lbs/sq inch
2) Min Comb WT Plies: 84 lbs/M sq ft
3) Size limit: 75 inches
4) Gross WT LT: 65 lbs
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CORP-QA-7.4.3.2-01 Page 27 of 43
c) Terminal reel qty/box will vary depending on reel specification
d) Labeling is required on each boxes and reel to ensure traceability.
Page 35 of 42
Returnable Packaging.
Returnable packaging specifications are currently being developed.
At this time any supplier seeking to provide returnable shipping containers
for terminal products must submit packaging proposals to SV5 for approval. Proposals should be
submitted per the Packaging Specification Data Sheet included in the header of this document.
Any/all packaging proposals must receive SV5 mgmt approval prior to shipment.
9) Specification for Metal Raw Material:
All metals (Raw Material) must comply with the enclosed Raw Material Specification.
Page 36, 37, 38, 39, 40 of 42
10) Specification for Resin Raw Material:
All pelletized resin material must comply with the enclosed Resin Specification.
1) Pellet size specification
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CORP-QA-7.4.3.2-01 Page 28 of 43
Page 41 of 42
2) Chemical composition
a) Must comply with design requirements established during product development.
3) Mil cert requirements
a) Material certs are required to be submitted as follows:
1) Each raw material shipment
2) Each raw material lot
b) Material cert minimum required information::
1) Supplier Information 11) Pellet Appearance
2) Material Grade 12) Melt Flow
3) Material Part Number 13) Tensile Strength
4) Lot Number 14) Tensile Elongation
5) Production/Cert Print Date 15) Tensile Strain
6) Order date 16) Notched Charpy
7) Ship Date 17) Izod Impact V-Notched
8) Qty Shipped 18) Flexural Strength
9) PO Number 19) Flexural Modulas
10) Material Color
4) Sample requirements
a) Silo shipments require material samples to be submitted with material certs:
5) Additional requirements
a) Meets FMVSS 302 (Supplier maintains records)
b) Meets SOCELV (IMDS registration required by supplier)
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CORP-QA-7.4.3.2-01 Page 29 of 43
11) Box label layout:
1) Molding subcontractors labels must follow the enclosed Box Label Layout specification
Page 42 of 42
PART INFORMATION PHOTO (or Sketch) BOX W/PARTS PHOTO (or Sketch) SUMITOMO P/N: OEM PROGRAM: SUPPLIER P/N:.
DESTINATION PLANT(s): Total
Weight(kg)
QTY QTY/BOX NAME L W H WT
DIMENSIONS (cm) WEIGHT PER
L W H PIECE (G)
BOX PHOTO (or Sketch)
PREVENTATIVE DEGRADATION
METHOD (IF APPLIED)
Oiling
Silica-Gel (Desiccant)
Sealed bags
Sealed bags w/water
SUMITOMO PART NUMBERS WITH SIMILAR PACKAGING: APPROVED / NOT APPROVED WITH THE
1.) 6.) FOLLOWING REQUESTED CHANGES AND
2.) 7.) COMMENTS:
BOX TYPE 3.) 8.)
Carton Box 4.) 9.)
Carton Box with dividers 5.) 10.)
Returnable Plastic Container
SKID PHOTO (or Sketch) PART NAME: SUMITOMO USE ONLY
SUPPLIER NAME: MATERIAL FLOW ENGINEERING PLANT
Sumitomo Electric Wiring systems
SUMITOMO SUPPLIER CODE: Approved as is Approved as is
SUPPLIER ADDRESS: Approved with changes Approved with changes
2687 Old Gallatin Road
Scottsville KY 42164 Not Approved Not Approved
PHONE:
DIMENSIONS (cm) HEAT TREAT
L W H PER ISPM FAX: SIGNATURE: SIGNATURE:
132 81.2 11.4 REQUIREMENTS CONTACT:
TITLE:
EMAIL: DATE: DATE:
DIMENSIONS (cm) DATE:
L W H Wrapped Strapped Pallet Stackable
132 81.2 165.1 Yes No No
MIN: 6 Boxes MAX: 30 Boxes
REMARK 1: REMEMBER, THE RESPONSIBILITY FOR ENSURING COMPONENT QUALITY FROM YOUR PLANT TO THE POINT OF USE REMAINS WITH YOU - THE SUPPLIER OF THE PRODUCT.
PACKAGING SPECIFICATION DATA SHEET
CONCEPT PKG APPROVAL FINAL PKG APPROVAL
DIMENSIONS (cm)
MATERIALS
Deviation details from SV standard pack specifications:
Boxes secured to pallet with shrink wrap.
Additional Details:
PALLET DIMENSIONS
CONTAINERS PER PALLET
FULL PALLET DIMENSIONS
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 30 of 43
PART INFORMATION PHOTO (or Sketch) BOX W/PARTS PHOTO (or Sketch) FINISHED P/N: OEM PROGRAM: Supplier P/N:
DESTINATION PLANT(s): Total
Weight(kg)
Qty/Bag Qty/Box NAME L W H WT
3000 3000 B-Carton Cardboard 44 41 31
DIMENSIONS (cm) WEIGHT PER
L W H PIECE (G)
7 9.9 10.4 0.17
BOX PHOTO (or Sketch)
PREVENTATIVE DEGRADATION
METHOD (IF APPLIED)
Oiling
Silica-Gel (Desiccant)
Sealed bags
Sealed bags w/water
SUMITOMO PART NUMBERS WITH SIMILAR PACKAGING: APPROVED / NOT APPROVED WITH THE
1.) 6.) FOLLOWING REQUESTED CHANGES AND
2.) 7.) COMMENTS:
BOX TYPE 3.) 8.)
Carton Box 4.) 9.)
Carton Box with dividers 5.) 10.)
Returnable Plastic Container
SKID PHOTO (or Sketch) PART NAME: SUMITOMO USE ONLY
SUPPLIER NAME: MATERIAL FLOW ENGINEERING PLANT
1 Molding Corporation
SUMITOMO SUPPLIER CODE: Approved as is Approved as is
123456
SUPPLIER ADDRESS: Approved with changes Approved with changes
1 Molding Rd
Google, Ky 12345 Not Approved Not Approved
PHONE: 555-555-9955
DIMENSIONS (cm) HEAT TREAT
L W H PER ISPM FAX: 555-555-2755 SIGNATURE: SIGNATURE:
132 81.2 11.4 REQUIREMENTS CONTACT: John Doe
TITLE: Quality Engineer
EMAIL: [email protected] DATE: DATE:
DIMENSIONS (cm) DATE: 6/5/2014
L W H Wrapped Strapped Pallet Stackable
132 81.2 189.2 Yes No No
MIN: 6 Boxes MAX: 36 Boxes
REMARK 1: REMEMBER, THE RESPONSIBILITY FOR ENSURING COMPONENT QUALITY FROM YOUR PLANT TO THE POINT OF USE REMAINS WITH YOU - THE SUPPLIER OF THE PRODUCT.
69181000
PACKAGING SPECIFICATION DATA SHEET
CONCEPT PKG APPROVAL FINAL PKG APPROVAL
DIMENSIONS (cm)
MATERIALS
69181000
Additional Details:
1 bag/box
Deviation details from SV standard pack specifications:
Request deviated box size
Requested size: 10x12x14
Dimensions in inches
11245W9SO3F-NA
CONTAINERS PER PALLET
FULL PALLET DIMENSIONS
Boxes secured to pallet with shrink wrap.
PALLET DIMENSIONS
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TITLE:
Purpose:
This instruction details seal box and seal bag labels and packaging requirements. This document provides additional
information to be used in conjunction with the SEWS Part Identification and Labeling Requirements document.
SealsMaximum seal box weight: 22 lbs.
Maximum seal box size: L -17.5", W - 16", H - 11"
Maximum seal bag volume: .134 cubic foot (One US Gallon)
Bag Quantity (increments of 500) must not exceed size of bag specified above
*Every seal bag label must contain part number and quantity (See example of format below)
No Seal Bulk Pack Allowed
Seal Box label Format Example: SEWS Part Identification and Labeling Requirements (section 4.7, 5.0, 5.1, 5.3)
*Critical parts of the label
Barcode Reads (example)
P71350273
Q00020000
S4XCNS0021006
In addition to section 5.1 no
dash (-) allowed in barcode
Barcode Reads (example)
A123456
Order number to be designated
by SEWS and informed to
supplier
Seal Bag Label Format Example: SEWS Part Identification and Labeling Requirements (section 5.0, 5.1, 5.3)
*Critical parts of the label
Barcode Reads (example)
P71350273
Q02500
S206068
In addition to section 5.1 no
dash (-) allowed in barcode
Addendum:
Sumitomo Electric Wiring Systems, Inc.
Part Identification and Labeling Requirements
Section 4.6 Serial Number Area: Each shipping container and bag must bear a label with a unique
serial number. In this way each container, regardless of content or destination,
can be differentiated from others.
WORK INSTRUCTIONAREA: Supplier Quality Assurance
Seal Box / Bag Packaging Specifications
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 35 of 43
Reel Type Item
1.125" Reel Frame
(28.58 mm) Reel Core
1.400"
(35.56 mm)
0.763"
(19.38 mm)
WORK INSTRUCTIONAREA: TERMINAL MANUFACTURING GROUP
A1, A2, and A3 Reel Dimension SpecificationsTITLE:
Purpose: This Work Instruction covers the scope of A1, A2, and A3 reel dimension specifications for
purchasing and production requirements.
Reel Frame
A1
Material
Corrugated Paper (Cardboard)
Styrofoam
Reel Construction
"A" Dimension
Reel Width
ϖ0.0625" (+1.59 mm)
ω0.0000" (-0.00 mm)
ϖ0.0800" ( +2.03 mm)
ω0.0000" (-0.00 mm)
ϖ0.0800" ( +2.03 mm)
ω0.0000" (-0.00 mm)
A2
A3
Dimensions are in inches
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CORP-QA-7.4.3.2-01 Page 36 of 43
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TITLE:
PURPOSE:
THIS SPECIFICATION IS APPLIED TO THE METAL STRIP THAT IS SUPPLIED FOR SUMITOMO ELECTRIC WIRING SYSTEMS, INC SV#5
1. QUALITY:
1 CHEMICAL COMPOSITION:
SEE TABLE 1A
2 SURFACE CONDITION:
THE SURFACE MUST BE SMOOTH AND SHALL BE FREE FROM SCRATCHES, MARKS,
MECHANICAL DAMAGE, DISCOLORATION, FOREIGN MATERIAL AND OTHER INJURIOUS DEFECTS.
GRAIN SIZE WILL BE .010 NOMINAL AT RF (READY FINISH).
3 SURFACE ROUGHNESS:
0.50 um MAXIMUM.
4 SURFACE EDGE:
TO BE FREE FROM BURRS.
2. DIMENSIONAL TOLERANCES:
TABLE - 2
Alloy THICKNESS INCH (MM) WIDTH INCH (MM)
260 / 268 +.0004, -.0004 (+.010, -.010) +0.0, -.006 (+0.0, -.15)
C194
KLF-5
MSP1 / MAX251
3. PLATING THICKNESS:
TABLE - 3
PLATING THICKNESS INCH (MM)
COPPER/BRASS SUBSTRATE .000020 MIN. (.0005 MIN.)
T.I.N. .00004 TO .00008 (.0010 TO .0020)
1 PEELING TEST:
AFTER 180 DEGREE BENDING (INSIDE RADIUS 0.5 t), THERE IS NO FLAKING ON TIN PLATE
(BOTH PARALLEL AND TRANSVERSE).
2 ANTI - HEAT TEST: ( RE-FLOW ONLY )
AFTER HEAT TREATMENT (356 DEGREE F X 2 HOURS), THERE ARE NO DISCOLORATION
AND BLISTER ON THE TIN PLATE.
+.0004,-.0004 (+.010,-.010) +.002,-.002(+.05,-.05)
+.0004,-.0004 (+.010,-.010) +0.0, -.004 (+0.0, -0.10)
WORK INSTRUCTIONAREA: TERMINAL MANUFACTURING GROUP
Raw Material Specifications
+.0003,-.0003 (+.008,-.008) +.002,-.002(+.05,-.05)
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4. METHOD OF TESTS:
1 OUTSIDE APPEARANCE TEST:
VISUAL CHECK , SEWS AND VENDOR WILL AGREE UPON REFERENCE
SAMPLES FOR BURR, SINK AND BRIGHTNESS.
2 DIMENSIONS TEST:
MEASURE THICKNESS AND WIDTH INCH OR (MM).
3 CHEMICAL COMPOSITION:
ASTM DESIGNATION E36, E53, E54, E62 AND E75
4 PLATING:
THICKNESS AND PEELING TEST.
5 MECHANICAL PROPERTIES AND GRAIN SIZE:
TENSILE STRENGTH : ASTM DESIGNATION E8
VICKERS HARDNESS :ASTM DESIGNATION E18
GRAIN SIZE :ASTM DESIGNATION E112
6 ELECTRICAL RESISTIVITY (OF TIN) :ASTM DESIGNATION E193
m (mV / mA)
5. REPORT OF DATA. (EVERY LOT):
1 CHEMICAL COMPOSITION:
Cu, Pb, Fe, Zn, Sn, Ti, Mg. (WHERE APPLICABLE)
2 MECHANICAL PROPERTIES AND GRAIN SIZE:
TENSILE STRENGTH, GRAIN SIZE, ELONGATION, AND VICKERS HARDNESS WILL BE
TESTED ON ROLLED STRIP BEFORE PLATING. THIS DATA WILL BE FOR REFERENCE ONLY.
3 DIMENSIONAL DATA:
(IN INCHES TO FOUR DECIMAL PLACES, IN MM TO THREE DECIMAL PLACES).
THICKNESS, WIDTH AND PLATING THICKNESS.
4 TEST DATA:
PEELING TEST (SUBMIT RESULTS IN BOTH PARALLEL AND TRANSVERSE).
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CORP-QA-7.4.3.2-01 Page 39 of 43
6. STATISTICALLY CONTROLLED ITEMS:
1) TIN PLATING THICKNESS 2) COPPER SUBSTRATE THICKNESS
7. CONTROLLED ITEMS:
1) OVERALL DIMENSIONS 2) BATH TEMPERATURE
3) BATH CHEMISTRY 4) PLATING CURRENT (amps)
SURFACE ROUGHNESS SHALL BE MEASURED AND GUARANTEED BY THE VENDOR.
8. PACKING:
1. SPECIFICATION OF COIL SIZE:
A) COIL DIRECTION COUNTER CLOCKWISE
B) OUTSIDE DIAMETER 36.0" MINIMUM AND 46.0" MAX.
C) INSIDE DIAMETER 16.0" MINIMUM AND 18.0" MAX.
D) INTERNAL PAPER NONE
E) COIL END TAPE NO TAPING
F) BANDING PRE APPROVED BANDING ONLY
G) LAPPING NONE
H) LABEL ID AND OD EACH COIL
2. SPECIFICATION OF TRANSPORTATION SKID:
3. SPECIFICATION OF MATERIAL SPACERS:
A QUANTITY OF (6) APPROVED RADIAL SPACERS, SPACED 60 DEGREES APART ARE TO
SEPARATE EACH RAW MATERIAL PANCAKE. THE LENGTH IS TO EXTEND INTO THE INSIDE
DIAMETER, AND BEYOND THE OUTSIDE DIAMETER A MINIMUM OF 1" AND A MAXIMUM OF 3".
SPACER THICKNESS NOT TO EXCEED 3/4".
MATERIAL TO BE PACKED ON A WOODEN PALLET, USING A VAPOR BARRIER. DO NOT MIX ROUND NUMBERS ON THE SAME PALLET, THEN
USE STRAPPING 4 TIMES EQUALLY SPACED FROM THE INSIDE DIAMETER TO THE OUTSIDE DIAMETER OF THE SKID. STRETCH WRAP
MATERIAL ADD TOP AND STRAP
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4. SPECIFICATION OF PALLETT PACKAGE:
A) UPPER PROTECTOR 48" MAX. DIAGONALLY
B) COVERING VINYL STRETCH WRAP
C) WINDING DIRECTION COUNTER CLOCKWISE
D) NUMBER OF COILS NO REGULATION
E) PALLET O.D. 48" MAX. ON THE DIAGONAL
F) PALLET I.D. 12" MAX.
G) BANDING STEEL W/ EDGE PROTECTION
H) GROSS HEIGHT MAX. 23" INCLUDING SKID
J) GROSS WEIGHT 2000 LBS.
8A. PACKING: (FOR IMPORTED MATERIAL ONLY)
1. EACH MATERIAL COIL TO BE INDIVIDUALLY PACKED IN VAPOR BARRIER PAPER. THEN COILS TO BE PACKED
IN WOODEN CRATE. AND (4) DESICCANT BAGS ADDED TO EACH CRATE.
A) COIL DIRECTION COUNTER CLOCKWISE
B) INTERNAL PAPER NONE
C) COIL END TAPE FILAMENT TAPE
D) BANDING PLASTIC BAND
E) LAPPING LAMINATED PAPER
Note: Packing can be altered form the above specif ication, but a w ritten formal request from the supplier must be approved prior to material
shipment.
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 41 of 43
2. SPECIFICATION OF WOODEN CRATE:
THE CONTENSE OF THE SHIPPING MARK SHOULD BE PRINTED ON THE OUTSIDE
A) UPPER PALLET WOODEN CASE
B) NUMBER OF COILS NO REGULATION
C) SPACER BETWEEN COILS NOT USED
D) SPACER UNDER COILS NOT USED
E) DESICCANT OZ. 15g X 2pcs.
F) BOTTOM PALLET 850 X 850mm MAX
G) GROSS WEIGHT 500 KG. MAX.
H) GROSS HEIGHT NO REGULATION
9. LABEL MARKING:
THIS LABEL DISCRIPTION IS FOR BOTH , MATERIAL AND SKID LABELS
1. ALLOY DESCRIPTION 6. LOT / TRACE NUMBER
2. TEMPER. (Ksi or n/mm2) 7. MANUFACTURER'S DATE.
3. DIMENSIONS, STANDARD AND METRIC. 8. MANUFACTURER'S NAME.
4. COIL NUMBER 9. SEWS RM NUMBER.
5. COIL WEIGHT.
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 42 of 43
PURPOSE:
THIS SPECIFICATION IS FOR PELLETIZED PLASTIC RESIN SUPPLIED BY AN OUTSIDE VENDOR/SUPPLIER.
1. QUALITY:
1. MATERIAL PROPERTIES REQUIREMENTS:
MUST MEET PHYSICAL PROPERTIES REQUIRED PER MATERIAL SPECIFICATION.
2. PELLET CUT AND QUALITY
PELLET CUT MUST BE IN SPECIFICATION WITH NO LONGS OR FINES AS DESCRIBED BELOW.
2. MATERIAL SIZE SPECIFICATIONS:
TEST METHOD TEST NAME UNITS
CALIPER PELLET SIZE mm
3. OTHER SPECIFICATIONS:
1. SHALL BE FREE OF METAL OR OTHER NON-PLASTIC CONTAMINATION
2. SHALL NOT HAVE EXCESS DUST OR FINES AFTER EXTRUSION
3. SHALL NOT HAVE MISCUTS, STRINGS, LONGS OR OTHER ABNORMAL DEFECTS
4. NO ADDITIVES (COLORANTS, LUBRICANTS, PLASTICIZERS, ETC.) SHALL BE ADDED DURING EXTRUSION.
4. FREQUENCY OF CHECKS:
1. PHYSICAL PROPERTIES
PROPERTIES SHOWN IN ITEM 2 ABOVE WILL BE CONFIRMED AND REPORTED ONCE PER PRODUCTION RUN.
2. VISUAL AND OTHER SPECIFICATIONS
EACH GAYLORD SHALL BE VISUALLY INSPECTED FOR POSSIBLE CONTAMINATION AND MISCUTS
3. A DOCUMENT SHOWING THE RESULTS SHALL BE INCLUDED WITH SHIPMENT
5. RECORDS RETENTION
1. RECORDS OF TEST RESULTS SHALL BE MAINTAINED FOR A MINIMUM OF 1 YEAR.
2. RECORDS OF PROCESS SETPOINTS SHALL BE MAINTAINED FOR A MINIMUM OF 1 YEAR.
6. CONTROLLED ITEMS:
1. DATA POINTS OF THE FOLLOWING ITEMS SHOULD BE MAINTAINED TO TRACK THE STABILITY OF THE PROCESS.
1) PELLET DIMENSIONS 4) FLEXURAL MODULUS 7) IZOD IMPACT STRENGTH
2) PELLET COLOR 5) TENSILE STRENGTH
3) MELT FLOW 6) TENSILE ELOGATION
WORK INSTRUCTIONAREA: Supplier Quality Assurance
Ø3.5 MAX, 6mm MAX LENGTH
TITLE:
SPECIFICATION
Specification of Pelletized Alloy Resins
SEWS “CONNECT WITH THE BEST”
CORP-QA-7.4.3.2-01 Page 43 of 43
Label Size: error serial number add add city st zip date part desc qty certified coo
4" H x 6" W 0 1012485533 SEWS 2687 OLD GALLATIN RD SCOTTSVILLE KY 42164 20140401 RP69000202 X-B PA6T FE18502 BKB116 1000 C MADE IN/C.O.O USA
MAX CHARACTERS 1 10 4 20 11 2 5 8 35 50 11,3 1 17
QUALIFIER S P Q
1) Serial numbers can not be duplicated or re-used
A, AD
BB, BC
CP, CT
DA, DT, DTR
E
FC
I
L
M, MI
P, PL, PS
Q
R
S, SE, SW
T, TP
Y
Field: Qualifier:
Part Number P
Quantity Q
Serial number S
Possible room for each field
Code and field name Qualifier
Location ^FO700,785^A0R60,60^FD%prim_loc%^FS
Part Name ^FO690,50^A0R40,40^FD%description%^FS
Part Number ^FO560,100^A0R60,60^FD%part%^FS
Part Number Bar code ^FO480,180^B3R,N,80,N^FDP%part%^FS P
Quantity ^FO375,100^A0R60,60^FD%boxqty%^FS
Quantity Bar code ^FO300,180^B3R,N,80,N^FDQ%boxqty%^FS Q
Lot # ^FO265,930^A0R30,30^FDLOT # %trav%^FS
line 1 ^FO670,50^GB0,1225,1.5^FS
line 2 ^FO265,50^GB0,1225,1.5^FS
serial number ^FO170,100^A0R50,50^FD%container%^FS
Serial number Bar code ^FO90,150^B3R,N,80,N^FDS%container%^FS S
tool number ^FO60,780^A0R25,25^FD%mold%^FS
Made in/C.O. USA ^FO20,50^A0R20,20^FD%coo%,^FS
Location,address,city,st,zip ^FO20,393^A0R20,20^FD%location% %address% %city% %state% %zip%^FS
PO ^FO225,930^A0R30,30^FD%source_type%:%source%^FS
PO Bar code ^FO140,930^B3R,N,80,N^FD%source%^FS
Date ^FO20,1030^A0R40,40^FD%date%^FS
User ^FO20,1210^A0R25,25^FD%user%^FS
HEIGHT in mm
BOLD PARTNAME 3
BOLD BOX 5
BOLD PART NUMBER 3
BOLD (P) 3
BOLD QUANTITY 3
BOLD (Q) 3
BOLD LOT # 3
BOLD SERIAL # 3
BOLD (S) 3
BOLD TOOL NUMBER: 3
BOLD PRINT DATE 3
BOLD All Barcodes 10
barcode type
3 of 9
Barcode qualifier requirement:
1) Barcodes for the fields listed below are required to start with a qualifying letter, also identified below.
Subcontractor/supplier serial number requirement:
2) Subcontractor/supplier serial numbers must start with a supplier identification letter/number.
2a) The supplier identification letter/number should be confirmed through SEWS SV PC.
2b) The following identification letter/numbers are currently in use:
7mm
3mm
- 7mm from top 7 mm indented
- line 15 mm down , 7mm indented , stops 5mm from end
- 3mm down and 138 mm indented
- 18 mm from top and 7mm indented
- 21 mm down 13 mm indented
- 23 mm down 23 mm indented
- 7mm indented 42 mm down
- 7mm indent and 47 mm down
- 13mm indented 45 mm down.
- 13mm indented 45 mm down.
- 23mm down 7mm indent
- line 65 mm down , 7mm indented , stops 5mm from end
- 62mm down 116 mm indent
- 62mm down 127mm indent
- 7mm indent 67 mm down
- 71 mm down 13 mm indent
- 7mm indent and 71 mm down- 19 mm indent 77 mm down
- 72mm down 117mm indent
- 67mm down 122mm indent
- 67mm down 116 mm indent
- 27mm indent 94 mm down
- 50mm indent 94 mm down
- 112mm indent 94 mm down
- 128mm indent 94mm down
- 152mm indent 94 mm down- 76mm indent 88 mm down
- 97mm indent 88 mm down