Supplier Request for Engineering Approval Process SREA

1. Supplier Request for Engineering Approval Process SREA

2. What Is and Is Not anSREA ? An SREA is a process to identify, PLAN, and communicate a request to implement a PERMANENT product and/or process change that falls underneath the scope of AIAG PPAP. The results of the planning process are identified on the SREA form along with a timing plan and validation plan (if validation testing applies) The SREA is not applicable to temporary changes The Supplier Deviation Process applies 

3. What is the Purpose? The SREA process is to demonstrate that you, as a supplier, proactively communicate the desire to make a change and that it shows the work plan to execute the expectations of the Production Part Approval Process (PPAP)*. The objective is to gain approval to proceed with the plan to change. Failure to follow this process has the potential of creating a recall event (worst case) and creates chaos for GHSP and our customers.

4. WHEN is SREA Started? • Aftera decision to change has been made by supplier • Beforea change has been started • Before a change has been implemented or completed

5. General Situations when a SREA is Required (not all inclusive) • Change in manufacturing location from one address to another. • Changing the manufacturing process sequence. • Changing the control plan, such as frequency, evaluation technique or reaction plan. • Change to design records, specifications OR materials. If in doubt, call a GHSP SDE or SQE

6. Continued General Situations when a SREA is Required (not all inclusive) SREA applicable changes include but are not limited to: • A tool change (correction) that is not part of the approved PM plan. • Replacement tooling (non-perishable). • Request to make any change that would need to be documented on the design record. Regardless of which party is design responsible. • Any permanent change to the manufacturing process that would be documented on any element of PPAP. This includes work instructions and job set ups that were referenced on the control plan at time of PPAP approval.

7. PREPARING & PLANNING Before preparing an SREA Form to GHSP, work thru: • How long will this change take to implement? • What resources are needed to implement the tasks on the work plan? • How will we validate the product performance continues to meet requirements? • How many parts do we need to make as a bank build if the tool or equipment has to go out for more corrections? • What if the change results are not right the first time, contingency plan? • How have we considered the impact to the whole system for this change? Gages, Training, Error Proofing, First time capability…. • Do my outside suppliers (tool shops, gage shops, metrology, test labs, raw material, sub-tier) have capacity to support the work inside the timeframe?

8. PREPARING & PLANNING, continued Before preparing an SREA Form to GHSP, create: • A detailed timeline of tasks including action/owner/due dates. • A summary of data that demonstrates the need. • Include tasks that need to be executed by GHSP team members. • A detailed validation plan for Reliability and/or durability tests.

9. Filling out the SREA Form All information is required, empty or incomplete SREA will be rejected 12 13 14

10. Master Good – SREA Form All fields correctly filled out. Description explains WHY the change is requested and mitigation strategy

11. SREA First Time Approval Strategies • Make an implementation timeline that is detailed enough for people to “see” obvious planning of work including all the elements of PPAP. • Prepare the data to demonstrate why the change is necessary. Every situation is different. • Prepare a validation plan such as a DVP&R to show us the plan to validate the applicable reliability/durability requirements will be evaluated. • Apply the FMEA, Process Flow and other elements of PPAP proactively as a self check where appropriate

12. Master Good – Validation Plan Validation Plan will show what and how many and how to assess conformance (acceptance criteria) What part(s) What test and test Sections & how many Ford Solenoids Part Numbers 1078363B 290137A 7796033

13. Master Good - Timing Timing Plan will show sequence of What, When and Who. Must include enough detail to follow APQP elements to PPAP Owner Program Mgr Tool Eng Tool Eng Quality Eng Jane (customer) Quality Eng Jane (customer) GHSP Quality Eng Joe (customer) Quality Eng Quality Eng Quality Eng Quality Eng Joe (customer) Obtain PPAP Approval Quality Eng Quality Eng Quality Eng Quality Eng Continue Matrl Planner

14. Rejected ……..Now What? • Seek to understand why. There may be situations that prevent us from proceeding with the request. • Reconsider what modifications you might be willing to make to overcome the rejections. We will consider new/revised SREA packages • Respect the decision; we will make every effort to be collaborative and work together.

15. Approved……..Now What? PLAN The change process follows APQP PDCA Cycle DO = Execute CHECK = PPAP Submission ACT = Follow the control plan

16. What Is and Is Not anSREA ? An SREA is a process to identify, PLAN, and communicate a request to implement a PERMANENT product and/or process change that falls underneath the scope of AIAG PPAP. The SREA is not applicable to temporary changes The Supplier Deviation Process applies 

17. Supplier Deviation Process

18. What a Supplier Deviation IS and IS NOT • A Supplier Deviation is a process to identify, understand and communicate a request for a TEMPORARY product and/or process change that meets the scope of AIAG PPAP. • The Supplier Deviation form requires an understanding of what the deviation is, the cause of the deviation, associated potential failure modes and a plan to return to the normal state. • A Supplier Deviation IS NOT a method to implement permanent change or release change documents. The SREA process applies

19. What is the Purpose? • The Supplier Deviation Process is for a supplier to proactively identify and communicate a temporary change to a production intent product or business process. • The Supplier Deviation Process exhibits that you understand the reason for change, the potential risk of the change and have a plan to return to the normal state.

20. Examples of when to use a Supplier Deviation (Not all inclusive) • When shipping production intent parts that do not meet drawing specifications where the drawing specification will not change • When shipping production intent parts that do not meet drawing specifications with an Engineering Change in process to change print to match part • When a business process is temporarily changed and does not affect form/fit/function of a production intent part

21. Examples of when not to use a Supplier Deviation (Not all inclusive) • When shipping a pre-production product that meets design specifications • When the requested change is permanent • When a design record is required to be updated • When shipping production intent product without PPAP approval and a pending design change

22. Preparing and Planning • Before sending GHSP a deviation request, work through: • What product is affected by the deviation? • Is the product in launch or production? • What GHSP facilities are affected by the deviation? • What specifically is the deviation? • What is the reason for deviating? • What is the risk, both internally and externally, of deviating? (Check the PFMEA) • What are the specific actions required to return to the normal state? Keep in mind the 3W’s (Who, What and When)

23. Master ‘Good’ Form Example All fields correctly filled out. Description is thorough, root cause is identified, failure mode is understood, action plan is complete.

24. Deviation First Time Approval Strategies • Understand and document the root cause of the deviation from the design record prior to submitting the request. Ensure the problem solving has been completed at least through identification of permanent corrective action. • Have a timing plan in place for permanent corrective actions prior to submitting the request. • Identify a closure date when you will report back to GHSP the permanent corrective actions have been completed and the deviation is closed.

25. Rejected… Now what? • Seek to understand why • Not feasible due to product risk (warranty, quality, safety, assembly) • Timing not feasible • Action plan not accepted • Consider the reason for rejection and resubmit if applicable • Develop an alternative plan that does not require deviation in order to fulfill GHSP requirements

26. Where can I find the Appropriate forms?

27. Where can I find the self training modules?