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To
clearly communicate Dana requirements to our suppliers.
The following links show the Dana specific processes
that apply to the TS-16949:2002 requirements as well as
other pertinent international standards, specifications
and processes. This section is intended to guide
suppliers on the application of the Dana specified
supplier requirements related to these international
standards, specifications, and processes. Dana’s
expectations for compliance with specific sections of
the standards, specifications, and processes are
identified. Where no information is given, Dana’s
expectation is that your organization will have
developed an internal process to demonstrate compliance
with the standards, specifications, and processes.
In addition to the requirements set forth in the Dana’s
Supplier Quality and Development Manual, requirements of
Dana's customer(s) may also be incorporated into
purchase agreements or purchase orders. In such your
organization, should seek clarification from their
Supplier Development representative or e-mail
SupplierDevelopment@dana.com
1
Scope
2
Normal Reference
3 Terms and Definitions
4 Quality Management System
5 Management Responsibility
6 Resource Management
7 Product Realization
8 Measurement, Analysis, and Improvement
1
Scope
Dana’s expectations are consistent with those stated in
the international standards, specifications and
processes.
1.1 General
1.2 Application
Dana reserves the right to permit exclusions for its
Suppliers beyond 7.3.
Waiver / Deviation / Exception from your
Supply Chain Management representative. (Click on the
link provided.)
2
Normative Reference
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Dana uses the ISO-9001:2000, Quality management
systems – fundamentals and vocabulary as a normative
reference for this manual with additional or changed
Terms and Definitions specific to Dana provided in
section 3 Terms and Conditions, immediately below.
3
Terms and Definitions
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Dana uses the following terms in its procedures, process
maps and communications to define its supply chain
relationships:
“Supplier” is defined as a provider of goods or services
to Dana.
“Organization” is defined as your organization, a
Supplier to Dana.
“Customer” is defined as Dana or Dana’s customers.
“Customer Representative” is defined as your
organization's Representative to Dana.
When referencing elements from the ISO-9000 series of
publications, the terms are defined as indicated in the
normative references provided with the standards.
3.1 Terms and Definitions for the Automotive Industry
Dana’s definitions for terms and definitions are
described by TS-16949:2002 and its Normative References.
4
Quality Management System
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4.1 General Requirements
4.1.1 General Requirements Supplemental
4.2 Documentation Requirements
4.2.1 General
4.2.2 Quality Manual
NOTE: Quality Manual(s) from your organization may be
requested for review by Dana at any reasonable time. In
such case, you are required to submit the manual to your
respective Supply Chain Management representative.
4.2.3 Control of Documents
4.2.3.1 Engineering Specifications
Information on
Engineering Specifications defined by Dana can be
obtained from your Supply Chain Management
Representative. (Click on the link provided.)
4.2.4 Control of Records
4.2.4.1 Record Retention
The requirements for retention times for records can be
found by clicking the link provided
Record Retention.
5
Management Responsibility
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5.1 Management Commitment
5.1.1 Process Efficiency
Ideas that your organization submits through your Supply
Chain Management representative or the
Supplier Ideas System that result in measurable cost
savings can be used to offset year over year value
improvement expectation from your organization, unless
specifically addressed otherwise in your supply
agreement, or purchase order (click on the link
provided.)
5.2 Customer Focus
5.3 Quality Policy
5.4 Planning
5.4.1 Quality Objectives
5.4.1.1 Quality Objectives – Supplemental
Your organization’s Quality Objectives shall support the
Dana expectations for Quality, Delivery, Cost and
Technology. These specific objectives are found at the
Dana / Supplier Website –
Supplier Performance Feedback. (Click on the link
provided.)
5.4.2 Quality Management System Planning
5.5 Responsibility, Authority and Communication
5.5.1 Responsibility and Authority
5.5.1.1 Responsibility for Quality
5.5.2 Management Representative
Your Management Representative is responsible for your
organization’s overall Quality Management System.
5.5.2.1 Customer Representative
Your Customer Representative(s) to Dana must be
identified on the Supplier Profile for each site within
your organization (i.e. unique DUNS numbers). The
Customer Representative is responsible for updating the
Supplier Profile. The Customer Representative is
responsible for registering his or her organization at
the
supplier.dana.com site The Customer Representative
is responsible for communicating changes within this
manual to the pertinent individuals within the
suppliers’ organization.
5.5.3 Internal Communication
5.6 Management Review
5.6.1 General
5.6.1.1 Quality Management System Performance
5.6.2 Review Input
As
a result of the information extracted from the
Supplier Performance Feedback. System The
supplier shall review all associated corrective actions
and continuous improvement actions during your
organization’s Management Review Process.
5.6.2.1 Review Input – Supplemental
5.6.3 Review Output
Improvement plans and progress established by the
supplier Management Review may be reviewed or inspected
at any time by Dana.
6
Resource Management
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6.1 Provision of Resources
As
a result of the information extracted from the Supplier
Performance Feedback System, your organization shall
provide the resources necessary to contain and correct
any deficiencies, including but not limited to the
resources required to inspect, contain, or rework your
organization's product at the location designated by
Dana. Your organization shall provide on-going
inspection for Dana at the location designated by Dana
until permanent corrective actions have been effectively
implemented. Reference the
Supplier Corrective Action and Improvement System
and the
Restricted Shipping Process.
6.2 Human Resources
6.2.1 General
6.2.2 Competence, Awareness and Training
6.2.2.1 Product Design Skills
This requirement may be waived for Suppliers who are not
Product Design Responsible using the
Waiver / Deviation / Exception form.
6.2.2.2 Training
Training
on the use of the processes on the Dana / Supplier
Website is mandatory for your organization's Customer
Representative(s). On-line training and support
documentation can be found at the
Supplier Development & Learning site. Additional
training may also be mandatory for Suppliers where the
expectations have not been met through the
Supplier Performance Feedback.
6.2.2.3 Training on the Job
6.2.2.4 Employee Motivation and Empowerment
6.3 Infrastructure
6.3.1 Plant, Facility and Equipment Planning
6.3.2 Contingency Plans
In
addition to any requirements established in your supply
agreement or purchase order, you shall submit a
Contingency and Capacity Plan as part of Production
Part Approval Process (PPAP) documentation, as
determined through
Supplier System Assessment and
Supplier Advance Product Quality Planning (APQP).
6.4 Work Environment
6.4.1 Personnel Safety to Achieve Product Quality
6.4.2 Cleanliness of Premises
NOTE:
Lean Manufacturing tools are available to help your
Supplier develop methods for maintaining a safe,
orderly, and effective work environment at the
Supplier Development & Learning
site.
7
Product Realization
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7.1 Planning of Product Realization
The
Supplier APQP Process is used to track your Product
Realization process. Your Customer Representative is
responsible for ensuring that this information is
updated and reported to Dana.
7.1.1 Planning of Product Realization – Supplemental
Your
Customer Representative is responsible for obtaining and
verifying all Engineering Specifications for the given
products that you are intending to provide to Dana.
Engineering Specifications are available through your
Supply Chain Management Representative.
7.1.2 Acceptance Criteria
7.1.3 Confidentiality
You
shall comply with all applicable confidentiality
requirements of Dana and Dana’s customers as set forth
in any Confidentiality agreement, Supply Agreement,
Purchase Order, Drawing, Engineering Specification, or
otherwise.
7.1.4 Change Control
You must use
Engineering Change Request. To request
changes to product or process design that varies from
those stated in the current PPAP Documentation, this
includes any and all sub-tier supplier changes to
product or process. All changes Must be approved by
Dana in writing prior to implementation.
The supplier shall notify the Dana receiving
facility prior to the shipment, of any product which has
experienced any change from written requirements and/or
existing practice to the material, design, specification
or handling. This requirement also applies to any
change resulting from any form of process or product
improvement activity or any previous quality
nonconformance’s.
Additional guidance is contained in the AIAG Production
Part Approval Process (PPAP) manual 4th edition Section
3.1 Customer Notification and Submission to Customer.
If any of the previously noted changes occur, You must
forward A copy of the approved Engineering Deviation
Notice, or Engineering Change Notice to receiving Dana
facilities contact person(s) Prior to Shipment of the
modified materials:
·
Materials department (Production Control / Scheduling)
·
Quality Assurance
·
Supplier Quality Development Engineer
The supplier representative responsible for Change
Management Control shall ensure the successful
transmittal of the electronic communication, and confirm
success via a phone call. The supplier representative
is also responsible for transmittal and updating of all
related PPAP documentation and re-approval from the
receiving Dana facility resulting from the Change.
The receiving Dana facility Quality Assurance contact is
responsible to assure that all Customer approvals are
received before authorizing the shipment or use of any
material under Change Management Control.
No shipments are to be made without the documented
approval of the receiving facilities Quality Assurance
contact.
The receiving facilities Quality assurance contact will
decide if containment such as quarantine is required at
the suppliers or Dana's site.
Lots under Change Management Control shall be identified
using labels detailing the reason for the Change
Management Control, document references like SCAR, NCMR,
PPAP references, and waiver/concession references as
appropriate. Any labeling shall be approved by the
receiving Dana facility. All labeling shall contain the
reference # of the approved Engineering Deviation Notice
or Engineering Change Notice.
7.2 Customer-Related Processes
7.2.1 Determination of Requirements Related to the
Product
Part
specific requirements shall be documented or referenced
on the Part
Engineering Drawing or Specifications. General
requirements shall be documented or referenced on the
Purchase Order and/or in the Supplier Quality and
Development Manual. Additional requirements identified
by your organization that are not stated by Dana but
necessary for the intended use, where known shall be
noted on your organization’s Design and/or Process FMEA
and related documentation. If your organization does not
have clear engineering designs and specifications, your
organization shall communicate this to your Supply Chain
Management representative.
7.2.1.1 Customer-designated special characteristics
The
Dana Special Characteristic and Control sets
forth details on the designation, documentation, and
control of these in your organization’s documentation
and processes.
7.2.2 Review of Requirements Related to the Product
You must produce evidence that statistical process
control is being continuously used when appropriate to
assure stable and capable processes. Process capability
initially reported for PPAP section 2.2.11 (Initial
Process Studies) shall be updated to report long-term
process capability and stability using study results
which consist of measurements which have been collected
over a significant period of production, in such a way
to include all potential sources of variation that may
not be evident in short-term studies.
7.2.2.1 Review of Requirements Related to the Product –
Supplemental
To waive any requirements determined through the review,
your organization shall initiate a
Waiver / Deviation / Exception
to your supply chain
management representative.
7.2.2.2 Organization Manufacturing Feasibility
The output of your organization’s Manufacturing
Feasibility shall be recorded during
Supplier APQP: Team Feasibility Commitment.
7.2.3 Customer Communication
a)
Product Information is provided by an engineering
drawing and/or
Engineering Specifications.
b)
Inquiries, contracts or order handling, including
amendments shall be made through your Supply Chain
Management representative.
c)
Dana
Supplier Performance Feedback System is
available on the Dana / Supplier Website.
7.2.3.1 Customer Communication – Supplemental
To
promote global business, and to include all suppliers in
global opportunities, Dana requires the use of English
as our standard business language for documents and
correspondence.
Translated reference
documents may be provided from Dana to
assist in understanding of requirements.
7.3 Design and Development
To
waive this requirement your organization shall initiate
a Waiver
/ Deviation / Exception as set forth in
7.2.2.1 Review of Requirements Related to the
Product – Supplemental
7.3.1 Design and Development Planning
7.3.1.1 Multidisciplinary approach
7.3.2 Design and Development Inputs
Engineering Specifications are available
through your Supply Chain Management Representative.
Any deviations from these specifications shall be
processed through Engineering
Change Requests as described in 7.1.4 Change Control
7.3.2.1
Product Design Input
Packaging Specifications and Labeling requirements can
be found in the same manner as other Engineering
Specifications.
7.3.2.2. Manufacturing Process Design Input
Requirements for productivity, capacity, process
capability, and cost are defined during Request for
Quotation process, and reviewed during
Supplier APQP, where applicable, using the
Tooling and Equipment Approval.
7.3.2.3 Special Characteristics
The process special characteristics defined by your
organization to ensure product conformity to
specifications shall conform to the
Dana Special Characteristic Control policy.
7.3.3 Design and Development Outputs
The design and development outputs shall be related to
the engineering drawing criteria, the
Engineering Specifications, and the
Tooling and Equipment Approval.
Supplier APQP shall indicate the status of
the design and development outputs meeting specified
criteria as indicated by the process.
7.3.3.1 Product Design Outputs – Supplemental
Supplier APQP shall
indicate the status of the product design outputs.
7.3.3.2 Manufacturing Process Design Output
Supplier APQP
shall indicate the status of the process design outputs.
7.3.4 Design and Development Review
Any issues related to a systematic review of design and
development, which may impact the program requirements,
shall be communicated by your organization to Dana
through the
Supplier APQP. The purpose of the
communication is to align resources to preserve timing
commitments and develop corrective actions with your
organization when necessary to prevent recurrence in the
Product Realization Process on future launches.
7.3.4.1 Monitoring
7.3.5 Design and Development Verification
Any issues related to a systematic review of design and
development, which may impact the program requirements,
shall be communicated by your organization to Dana
Corporation through the
Supplier APQP. The purpose of the
communication is to align resources to preserve timing
commitments and develop corrective actions with your
organization to prevent recurrence in the Product
Realization Process on future launches.
7.3.6 Design and Development Validation
Any issues related to a systematic review of design and
development, which may impact the program requirements,
shall be communicated by your organization to Dana
Corporation through the
Supplier APQP. The purpose of the
communication is to align resources to preserve timing
commitments and develop corrective actions with your
organization to prevent recurrence in the Product
Realization Process on future launches.
7.3.6.1 Design and Development Validation – Supplemental
For organizations with engineering testing
responsibilities, the Design Verification Plan and
Report (DVP&R) shall be submitted with the
Supplier APQP for periodic review and be
included with PPAP documentation.
7.3.6.2 Prototype Program
If
Dana does not require prototypes from your organization,
this requirement can be waived through a
Waiver / Deviation / Exception as set forth
in 7.2.2.1 Review of Requirements Related to the
Product – Supplemental.
7.3.6.3 Product Approval Process
Dana requires its suppliers to conform to the latest
edition of the AIAG Production Part Approval Process
Reference Manual, Potential Failure Mode and Effects
Analysis Reference Manual, Advanced Product Quality
Planning and Control Reference Manual, and The
Measurement Systems Analysis Manual. All suppliers must
submit PPAP documentation to level 3 unless other wise
specified in your supply agreement or purchase order (http://www.aiag.org/).
Contact your Supply Chain Management representative for
unique Product Approval Process requirements.
7.3.7 Control of Design and Development Changes
You must use
Engineering Change Request. to request changes to
product or process design that varies from those stated
in the current PPAP Documentation, this includes any and
all sub-tier supplier changes to product or process.
All changes Must be approved by Dana in writing
prior to implementation. (See section 7.1.4)
7.4 Purchasing
This element is applicable to your organization's
Purchasing System. Dana’s Purchasing System is
described in this Supplier Quality and Development
Manual.
7.4.1 Purchasing Process
7.4.1.1 Regulatory Conformity
Your organization shall abide by
Dana's Supplier Business Conduct Guide.
7.4.1.2 Supplier Quality Management System Development
All templates, documentation and Lean tools presented in
the
Supplier Document Center and the
Supplier Development & Learning website are
available for use, with approval from Supplier
Development, by your organization and your sub-tier
suppliers in efforts to eliminate waste from the
overall supply chain. Your organization may contact
their Supply Chain Management representative for
specific information.
7.4.1.3 Customer-Approved Sources
Dana-approved sources specified for use by your
organization are subject to the requirements of your
organization. Where the requirements of your
organization differ from those of Dana, the requirement
to be deployed shall be resolved with your Supply Chain
Management representative. The use of Dana or Dana’s
customer-designated sources, including tool/gauge
suppliers, does not relieve your organization of the
responsibility for ensuring the quality of the source’s
products or compliance with all other contract
requirements.
7.4.2 Purchasing Information
Dana-approved sources specified for use by your
organization are subject to the requirements of your
organization. Where the requirements of your
organization differ from those of Dana, the requirement
to be deployed shall be resolved with your Supply Chain
Management representative. The use of Dana or Dana’s
customer-designated sources, including tool/gauge
suppliers, does not relieve your organization of the
responsibility for ensuring the quality of the source’s
products or compliance with all other contract
requirements. 7.4.3 Verification of Purchased Product
Dana-approved sources specified for use by your
organization are subject to the requirements of your
organization. Where the requirements of your
organization differ from those of Dana Corporation, the
requirement to be deployed shall be resolved with your
Supply Chain Management representative. The use of
Dana or Dana’s customer-designated sources, including
tool/gauge suppliers, does not relieve your organization
of the responsibility for ensuring the quality of the
source’s products or compliance with all other contract
requirements.
7.4.3.1 Incoming Product Quality
Dana-approved sources specified for use by your
organization are subject to the requirements of your
organization. Where the requirements of your
organization differ from those of Dana, the requirement
to be deployed shall be resolved with your Supply Chain
Management representative. The use of Dana or Dana’s
customer-designated sources, including tool/gauge
suppliers, does not relieve your organization of the
responsibility for ensuring the quality of the source’s
products or compliance with all other contract
requirements.
7.4.3.2 Supplier Monitoring
Dana Suppliers shall provide evidence of sub-tier
performance monitoring at Dana's request.
7.5 Production and Service Provision
7.5.1 Control of Production and Service Provision
All templates, documentation and Lean tools presented in
the
Supplier Document Center and the
Supplier Development & Learning website are
available for use, with approval from Supplier
Development, by your organization and your sub-tier
suppliers in efforts to eliminate waste from the
overall supply chain. Your organization may contact
their Supply Chain Management representative for
specific information.
7.5.1.1 Control Plan
Control Plans shall be updated in response to
Supplier Performance Feedback and
Corrective Action and Improvement System, or
any other process change or improvement and must be
aligned with your organization's Process FMEA.
7.5.1.2 Work Instructions
7.5.1.3 Verification of Job Set-Ups
7.5.1.4 Preventive and Predictive Maintenance
7.5.1.5 Management of Production Tooling
7.5.1.6 Production Scheduling
7.5.1.7 Feedback of Information from Service
7.5.1.8 Service Agreement with Customer
7.5.2 Validation of Processes for Production and Service
Provision
All processes for production and service provisions
Shall be reviewed annually by the supplier,
including all pertinent documentation (eg. FMEA, Control
Plan, Process Flow, etc.) This review includes all AIAG
specified special processes including CQI-9 heat treat
assessment, CQI-11 plating assessment, CQI-12 coating
assessment, IMDS etc. Submission of updated parts
warrants to receiving facilities on an annual basis with
all pertinent supporting documentation is required
to demonstrate that the organization is in compliance
with this requirement
7.5.2.1 Validation of Processes for Production and
Service Provision – Supplemental
7.5.3 Identification and Traceability
The level of detail required by the traceability
system and specified requirements for supplied product
shall be identified during
Supplier APQP on the Purchase Order and/or
Engineering Specifications.
7.5.3.1 Identification and Traceability – Supplemental
7.5.4 Customer Property
Dana packaging requirements can be found by contacting
your Supply Chain Management representative. Dana owned
tooling and equipment shall be qualified through the
Tooling and Equipment Approval.
7.5.4.1 Customer-Owned Production Tooling
7.5.5 Preservation of Product
7.5.5.1 Storage and Inventory
7.6 Control of Monitoring and Measuring Devices
7.6.1 Measurement Systems Analysis
7.6.2 Calibration/ Verification Records
Where a measurement system is found to be out of
calibration and suspected non-conforming product has
been shipped to Dana your organization must
contact their Supply Chain Management representative and
their Dana receiving facility quality manager.
7.6.3 Laboratory Requirements
7.6.3.1 Internal Laboratory
7.6.3.2 External Laboratory
8
Measurement, Analysis and Improvement
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8.1 General
8.1.1
Identification of Statistical Tools
8.1.2
Knowledge of Basic Statistical Concepts
8.2 Monitoring and Measurement
8.2.1
Customer Satisfaction
The
Supplier Performance Feedback System is used
to measure and report on the satisfaction of Dana with
your organization. The expectations of performance are
shown in the Supplier
Performance Feedback System.
8.2.1.1 Customer Satisfaction – Supplemental
The
Supplier Performance Feedback System shall be
used as input for your organization’s internal audit
process for improvement of your organization’s Quality
Management System.
8.2.2 Internal Audit
8.2.2.1 Quality Management Systems Audit
8.2.2.2 Manufacturing Process Audit
8.2.2.3 Product Audit
8.2.2.4 Internal Audit Plans
Your organization’s internal audit plan shall include
Dana-specific processes and verification of the
effectiveness of corrective actions issued to Dana. A
list of processes can be found in the
Process Approach section of this on-line manual.
8.2.2.5 Internal Auditor Qualification
8.2.3 Monitoring and Measurement of Processes
8.2.3.1 Monitoring and Measurement of Manufacturing
Processes
Where determined necessary through the
Supplier Performance Feedback System,
Supplier APQP, or
Supplier System Assessment your organization
shall provide evidence of the capability and capacity of
its Manufacturing Processes to Dana.
8.2.4 Monitoring and Measurement of Product
8.2.4.1 Layout Inspection and Functional Testing
An
annual layout inspection and functional verification to
applicable customer engineering material and performance
standards shall be performed unless otherwise specified
in the approved control plan, your supply agreement, or
purchase order. The results shall be available for
customer review. Submission of updated parts warrants
to receiving facilities on an annual basis with all
pertinent supporting documentation is required to
demonstrate that the organization is in compliance with
this requirement
8.2.4.2 Appearance Items
8.3 Control of Nonconforming Product
Communication of suspected nonconforming product shipped
to Dana shall be made immediately upon your discovery of
the situation through the Supply Chain Management
representative and the consuming Dana facility or
facilities. All incidents of nonconforming product will
require a response in the
Corrective Action and Improvement System.
8.3.1 Control of Nonconforming Product – Supplemental
8.3.2 Control of Reworked Product
Any deviations from an approved process shall have prior
approval through a
Waiver / Deviation / Exception as set forth
in 7.2.2.1 Review of Requirements Related to the
Product – Supplemental.
8.3.3 Customer Information
Proactive Notification shall be used to communicate
that nonconforming product has been shipped to Dana as
identified in 8.3
Control of
Nonconforming Product
8.3.4 Customer Waiver
Any deviations from the policies within this manual
shall be made through a
Waiver / Deviation / Exception. Requests for
permanent changes to the product or process shall be
made through the
Engineering Change Request.
8.4 Analysis of Data
8.4.1 Analysis and Use of Data
8.5 Improvement
8.5.1 Continual Improvement
8.5.1.1 Continual Improvement of the Organization
8.5.1.2 Manufacturing Process Improvement
8.5.2 Corrective Action
Corrective Actions in response to the
Supplier Performance Feedback System shall be
completed in accordance with the
Corrective Action and Improvement System.
8.5.2.1 Problem Solving
Reference problem solving tools are available from the
Corrective Action and Improvement System, the
Supplier Document Center, and training on
problem solving is available through
Supplier Development & Learning.
8.5.2.2 Error-Proofing
8.5.2.3 Corrective Action Impact
Failure modes of products from a supplier are tracked
through the
Corrective Action and Improvement System.
Repeat failure modes may result in mandatory training on
quality management systems and problem solving at your
organization’s expense. Such training is in addition to
any and all warranty or other contract remedies
8.5.2.4 Rejected Product Test / Analysis
Results from rejected product analysis shall be reported
using the
Corrective Action and Improvement System.
8.5.3 Preventive Action
If
your organization is planning to implement Preventive
Action that requires PPAP approval, your organization
shall submit their request through an
Engineering Change Request.
Supplemental
Global Casting Requirements
Dana – Global Minimum Casting Specific Quality
Requirements
The Supplier shall provide Confirmation of their
agreement (sign-off) to be able to meet the following
Dana Specific Casting Quality Requirements in addition
to any Dana Engineering Casting Specifications and or
Dana Customer Specific Casting Quality Specifications
before receipt of a Dana SCMG Purchase Order.
Dana Specific Casting Quality Requirements:
These requirements are in addition to any requirements
identified in Dana Engineering Specifications identified
on the Dana Approved Product Drawing or included as a
part of the purchase agreement.
Casting Development Requirements:
a) The supplier shall utilize modeling software for
casting development where at all possible.
b) All casting development runs are to be sectioned,
analyzed and documented. Sectioning a sufficient number
(target is 10%) of the parts produced in any
developmental run to clearly establish the location and
level of any internal characteristic that may be evident
in ongoing production runs and ensuring the product is
within all functional and specification requirements.
c) The supplier shall utilize in-house
non-destructive test capability for the validation of
all casting integrity during the product development
stage. If the supplier does not have the in-house
capability they shall contract an ISO/IEC 17025
(or national equivalent) certified external
source, which shall need Dana SQD approval.
d) The supplier shall conduct on the 1st Production
Run a Process Series Review (PSR) with:
i) A minimum of 1 piece (3 samples total) from the
beginning, middle and end of the production run must be
sectioned, analyzed and documented to validate process
stability & consistency with the development runs and
within specification limits.
ii) Dana Casting SME and/or assigned Dana
SDE must be present for PSR.
iii) This shall be conducted and approved by Dana SME/SDE
prior to PPAP submission.
PPAP Submission:
e) One additional sample from the initial production
must be x-rayed and documented evidence supplied with
the PPAP Submission that shows the results correlate
with all Pre-PPAP sectioning and analysis or the PPAP
will be rejected.
f) The PPAP submission must be based on data taken
from the initial production run and must include –
i) Photos of the sectioning results conducted in the
developmental runs & initial production run,
ii) X-Ray report & films from the part evaluated in
the 1st production run.
g) No production parts from the initial production
shall be shipped to Dana prior to the supplier receiving
a signed PSW indicating PPAP approval has been issued by
the Dana using location.
Ongoing Production/Process Change:
a) The Suppliers Control Plan must include specific
on-going process integrity checks at a minimum from the
beginning, middle and end of each production run to
ensure the process is maintained under control to ensure
internal casting quality integrity as demonstrated in
the development stage and this plan shall be approved by
Dana.
b) Any process change at the supplier must be
re-verified starting with the 1st Production Run of the
change. A PSR is not required, however the PPAP must be
updated and approved before any product can be shipped
to a Dana facility or supplier.
Annex A (normative) Control Plan
A.1 Phases of the Control
Plan
A.2 Elements of the Control
Plan
V1.5
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