Supplier Quality Manual (26th Edition) [PDF]

Citation preview

Quality Manual for Suppliers 26th Edition



PURCHASING DIVISION 206-1, NUNOHIKIBARA, MAKINOHARA-CITY, SHIZUOKA-PREF, 421-0407 JAPAN



-1-



Quality Manual for Suppliers 26th Edition



Introduction Purpose This Quality Manual was compiled for the purpose of establishing mutual reliance between Yazaki and the Supplier, as well as conducting both of productive activities of quality assurance. This includes the concepts and approaches for the quality assurance and basic issues including procedures to be observed that should be comprehended by the Supplier. Basic Principle Pursue improvement of productivity with innovative ideas and endless endeavors in corporate activities. Ensure "Higher Quality Products" "Lower Price" "Quicker Delivery" establishing Yazaki prestige. Procurement Principle 《Ensure open and fair business with suppliers pursuing mutual benefit and prosperity》 ◆Attain "mutual benefit" "mutual prosperity" with mutual ingenuity and innovative ideas. ◆Ensure competitive advantage unifying with suppliers. ◆Ensure two-way communication based on mutual reliance. Aim of Publishing In order to keep and control stable quality, continuous improvement and close chain activities shall be performed by reviewing position and responsibility of each Yazaki and the Supplier, and achieving fulfillment results is the requisite to satisfy rapidly progressing and increasing customers' requirements. This Manual is compiled based on the principle as mentioned above. We focus on the basic rules clarifying mutual responsibilities and roles to achieve effective activities, while respecting your voluntary efforts. The Supplier is expected to comprehend this concept and contents well enough to achieve the goal of assuring quality and improve the processes in the activities. For usage of as a daily guideline, please keep this Manual in easily accessible place. Moreover, please keep it updated for revision without delay whenever it is required. Reference of Master Agreement This Manual is considered as a part of Master Agreement the Quality Control Procedure section is included as mentioned below. < Master Agreement Chapter 4 Quality Assurance >



A = Yazaki, B = Supplier



No. 15 (Quality) 1. The Supplier shall assure the quality of products which satisfies the items as mentioned on No.1 of the next chapter. 2.The Supplier shall establish effective Quality Assurance system including R&D, design, material procurement, production, inspection, storage, transportation, etc. in order to assure the quality of products. 3. The Supplier shall keep inspection records on products and submit them to Yazaki when required. 4. To maintain and enhance the quality of products, the Supplier shall control its processes in accordance with requirements documents, such as "Supplier's Quality Manual" provided by Yazaki. Others Yazaki's receipt of standards created by the Supplier in accordance with requirements set forth in this Manual does not alleviate the responsibility of the Supplier in any manner. -2-



Quality Manual for Suppliers 26th Edition



Revision Record No.



Date



Revision Details



-



1990/06/20



NEW



Masuda



Masui



1



1993/09/20



Revision: Process Change Procedure



Masuda



Toyoda



2



1995/05/18



Revision: Handling Flow of Initial Component Supply Notice



Inada



Toyoda



3



1996/09/27



Revision: ISO9001, QS9000, relative Quality Manual



Inada



Toyoda



4



1997/01/30



Addition: Hazardous Substance Management / the Scope of Process Change



Inada



Toyoda



5



1997/12/16



Addition: Control Procedure of 112W High Voltage Parts



Masuda Yamaguchi



6



1998/07/09



Addition: Containment Action Procedure



Masuda Yamaguchi



7



1998/11/09



Revision: Change of Organization



Masuda Yamaguchi



8



1999/02/22



Revision: Update of QS9000



9



1999/05/31



Revision: (13) Containment Procedure



10



2001/05/31



Renewal



Hasuike Yoshioka



11



2002/01/21



Revision: Change of Organization



Hasuike Yamagishi



12



2003/03/14



Renewal



Hasuike



Suzuki



13



2003/09/21



Revision: Update of ISO/TS16949



Hasuike



Suzuki



14



2003/12/20



Revision: Update of ISO/TS16949



Hasuike



Suzuki



15



2004/06/22



Revision: Initial Sample Evaluation Procedure / Submission Document



Hasuike



Suzuki



16



2004/09/21



Revision: 11) Process Change Procedure



Hasuike



Suzuki



17



2004/10/21



Addition: Hazardous Substance Management



Hasuike



Suzuki



18



2005/02/11



Addition: Hazardous Substance Management



Hasuike



Suzuki



Checked Approved



Yamaguchi Yamaguchi



-3-



Suzuki



Yamaguchi



Quality Manual for Suppliers 26th Edition



Revision Record No.



Date



Revision Details



19



2005/09/13



Revision: Initial Control Procedure / Change of Organization



Hasuike Sugiyama



20



2006/04/21



Revision: Process Change Procedure



Hasuike Sugiyama



21



2007/02/21



Renewal: Consolidation of Quality Manual



Narita



Sugiyama



22



2008/02/21



Revision: Organization Change, Error Correction, Addition



Narita



Sugiyama



23



2009/09/21



Revision: Organization Change, Error Correction, Addition



Narita



Murasawa



24



2011/06/08



Revision: Organization Change, Error Correction, Addition SOC evidence expiration date change



Narita



Sugiyama



25



2016/04/01



Revision: Organization Changes, Addition, Error Correction



Uekusa Murasawa Aoshima



25.1



2016/09/01



Revision: Organization Changes, Addition, Error Correction



Uekusa Aoshima Kawase



Iwahori



26



2018/11/22



Revision: Organization Changes, Addition, Error Correction



Uekusa



Iwahori



-4-



Checked Approved



Quality Manual for Suppliers 26th Edition



Table of contents 1. Overview 2. Scope of application 3. Definition and explanation of terms [Related appendixes]



4. Quality control requirements · Basic requirements



Appendix 4A Administrative Procedures for Quality Assurance



· Quality management related requirements 4-1-1



Notification of responsible person



4-1-2



N-tier supplier management



4-1-3



Document and record management



4-1-4



Implementation of employee training



4-1-5



Changing point management



4-1-6



Process change management



4-1-7



Initial component management



4-1-8



Implementation of PPAP



4-1-9



Mass-produced product concession application



4-1-10



Continual improvement



Appendix 4-1-1A Responsible Personnel Reporting Procedure Appendix 4-1-2A N-tier Supplier Management Procedure Appendix 4-1-3A Document and Record Management Procedure Appendix 4-1-4A Employee Training Management Procedure Appendix 4-1-5A Changing Point Management Procedure Appendix 4-1-6A Process Change Procedure Appendix 4-1-7A Initial Component Supply Notice Appendix 4-1-8A Production Parts Approval Process Implementation Procedure Appendix 4-1-9A Mass-produced Product Concession Application Appendix 4-1-10A Continual Improvement Implementation Procedure



· Manufacturing process management related requirements 4-2-1



Lot management



4-2-2



Management of raw materials



4-2-3



Process management



4-2-4



Precision control of measuring devices



4-2-5



Product shipment management



4-2-6



Mold management



4-2-7



Actions to be taken in case of occurrence of defects



Appendix 4-2-1A Lot Management Procedure, Appendix 4-2-1B Traceability Management Procedure Appendix 4-2-2A Raw Material Management Procedure Appendix 4-2-3A Process Control Procedure Appendix 4-2-4A Measuring Devices Precision Control Procedure Appendix 4-2-5A Product Shipment Management Procedure Appendix 4-2-6A Mold Management Procedure Appended Tables 4, 5, 6 and 7 Defect Handling Flow, Appendix 4-2-7A Defect Handling Procedure Appendix 4-2-7B Abnormality Handling Procedure Appendix 4-2-7C Past Trouble Utilization Procedure, Appendix 4-2-7D Improvement Proposal Procedure



4-2-8



Management of equipment and jigs



4-2-9



Management of identification marking for materials



Appendix 4-2-8A Equipment and Jig Management Procedure Appendix 4-2-9A Material Identification Mark Management Procedure



· SOC management related requirements 4-3-1



SOC management



Appendix 4-3-1A SOC Management Procedure



4-3-2



SOC analysis



4-3-3



Handling of environmentally nonconforming products



4-3-4



Preparation and submission of JAMA sheet



4-3-5



Management of chemical substances



Appendix 4-3-2A SOC Analysis Procedure Appendix 4-3-3A Procedure for Handling Environmentally Nonconforming Products



Appendix 4-3-4A JAMA Sheet Preparation and Submission Procedure Appendix 4-3-5A Chemical Substances Management Procedure



· Production preparation related requirements 4-4-1



Production preparation activity



Appendix 4-4-1A Production Preparation Implementation Procedure Appendix 4-4-1B Production Preparation Milestone Management Appended Tables 1, 2 and 3 Production Preparation Action Flow



4-4-2



Issuance of 3D data and drawings, issuance of mold and equipment order form



Appendix 4-4-2A Drawing Receipt and Mold and Equipment Arrangement Procedure



4-4-3



Mold management ledger (registration/change)



Appendix 4-4-3A Mold Registration/Change Form Preparation Procedure



-5-



4-4-4



Arrangement and acceptance inspection of prototype parts



4-4-5



Part rank



4-4-6



Management of important parts



4-4-7



Cross functional activities



Appendix 4-4-4A Prototype Parts Arrangement and Acceptance Inspection Procedure



Appendix 4-4-5A Production Preparation Procedure by Each Part Rank Appendix 4-4-6A "S"/"A" Rank Parts Management Procedure Appendix 4-4-7A Cross Functional Activity Implementation Procedure [Bulletin of Cross Functional Activity] Examples



4-4-8



Preparation of production preparation plan



4-4-9



Preparation of Mold and Equipment Plan Report



Appendix 4-4-9A Mold and Equipment Plan Report Preparation Procedure



4-4-10



Examination of process design/mold/equipment



Appendix 4-4-10A Process Design Procedure



Appendix 4-4-8A Production Preparation Plan Procedure



Appendix 4-4-10B Drawing DR Handling Procedure Appendix 4-4-10C Equipment Specification Examination Procedure



4-4-11



Checking/handling of past trouble database



Appendix 4-4-11A Production Preparation Past Trouble Database Check Procedure



Appendix 4-4-11B Mass Production Past Trouble Database Check Procedure



4-4-12



Standard document preparation



Appendix 4-4-12A Manufacturing Process Plan Sheet/QC Process Chart Preparation Procedure Appendix 4-4-12B QC Process Sheet Preparation Procedure Appendix 4-4-12C Parts Inspection Standard Preparation Procedure Appendix 4-4-12D Packing Specification Preparation Procedure Appendix 4-4-12E Work Standard Preparation Procedure



4-4-13



HVPT



4-4-14



Process capability verification



4-4-15



Manufacturing process audit



4-4-16



Crimping check



4-4-17



Sample evaluation and parts test request



4-4-18



Application for concession of startup products



Appendix 4-4-13A HVPT Implementation Procedure Appendix 4-4-14A Process Capability Verification Procedure Appendix 4-4-15A Manufacturing Process Audit Evaluation Procedure Appendix 4-4-16A Crimping Check Evaluation Procedure Appendix 4-4-17A Sample Evaluation and Part Evaluation Request Procedure Appendix 4-4-18A Quantity Concession and Term Concession Application Procedure Appendix 4-4-18B Mold Concession Application Procedure



4-4-19



Design change request



4-4-20



Preparation and management of boundary sample sheet



4-4-21



Application for shifting to mass production



4-4-22



Initial period production control



4-4-23



Application for Mold (additional/renewal/cost reduction/disposal) application



4-4-24



Exchange of Material Delivery Specification



Appendix 4-4-19A Design Change Request Application Procedure Appendix 4-4-20A Boundary Sample Sheet Procedure Appendix 4-4-21A Procedure for Application for Shifting to Mass Production Appendix 4-4-22A Initial Period Control and Release Procedure Appendix 4-4-23A Mold (Increase/Renewal/Cost Reduction/Disposal) Procedure



Appendix 4-4-24A Material Delivery Specification Exchange Procedure



5. Audit



Appendix 5A Supplier Audit



6. Requirements by each industry and product type Quality Control Standard for Suppliers [Detailed Regulations]



7. Forms



Issued separately Issued separately



-6-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms 1. General rules This Quality Manual specifies basic compliance matters and procedures on quality control etc. for parts purchased by the Purchasing Department and its overseas bases of YAZAKI Corporation (hereinafter called "Yazaki/we/our") from our suppliers based on the Master Agreement.



2. Scope of application This Manual is applied to parts purchased from our suppliers.



3. Definition and explanation of terms Definitions and explanations of terms used in this Manual are as follows. (1) ISO (International Organization for Standardization) More than 140 countries participate in the International Organization for Standardization and form international standards. The general name of the international standards established by ISO is called ISO standard. (2) IATF (International Automotive Task Force) IATF is a system where a third party organization reviews whether an organization has appropriately established and operated a quality management system which conforms to the IATF 16949 Standard and, if it has, registers it. Nine automobile manufacturers in Europe and America and five automobile industry institutions (AIAG in the United States, VDA in Germany, FIEV in France, ANFIA in Italy and SMMT in UK) manage the IATF 16949 certification system. They create drafts of IATF 16949, establish certification rules, certify certification organizations, and so on.



(3) JIS (Japanese Industrial Standards) JIS is a Japanese Industrial Standards established under the Industrial Standardization Act (1949) aiming to promote industrial standardization in Japan. JIS have specific numbers. In principle, the number consists of the combination of an alphabet letter showing the field and a four-digit number. (Example) JIS D XXXX: Alphabet "D" indicates the field "automobile". (4) ISO 9001 This Standard specifies requirements for quality management systems when an organization has to demonstrate that it has the ability to provide products that meet customer requirements and applicable regulatory requirements and when it aims to improve customer satisfaction. (5) IATF 16949 IATF 16949 is a standard for quality management systems in the automobile industry established based on ISO 9001. It specifies basic quality management system requirements for organizations concerning automobile industry’s production parts and related service parts. (6) ISO 14001 It specifies environmental management systems for establishing systems to continuously reduce and prevent burdens on the environment by the business activities of the organization. (7) ISO/IEC 17025 The official name is "General requirements for the competence of testing and calibration laboratories". It is a standard that covers inspection methods and technologies, not products and services to be provided. When validity of the testing method itself is questioned and nonconformity has been detected, possibility of grasping the cause, etc. shall be examined by investigating based on the supply chain. (8) ISO/IEC 17799 It is an international standard for establishing information security management systems (ISMS) and security culture. In order to realize ISMS, ISO/IEC 17799 (JIS X 5080 in Japan Industrial Standard) proposes effective measures (control measures) for 10 fields from four viewpoints: human management, physical management, technical management and business continuity management. This Standard is a guideline and is positioned as a reference material for considering security measures of an organization. -7-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms (9) OHSAS 18001 OHSAS means the Occupational Health and Safety Management Systems. This standard aims for the organization to reduce the occurrence of problems by identifying risks concerning occupational safety and health of employees on work, planning measures, and implementing them. It is compatible with ISO 14001, so many organizations work on quality and environment simultaneously. Work towards ISO is now on progress. (10) QMS (Quality Management System) A management system for directing and managing organizations on quality. ISO 9001 is a requirement standard for establishing the quality management system.



(11) EMS (Environment Management System) A management system for directing and managing organizations related to the environment. ISO 14001 is a requirement standard for establishing the environmental management system.



(12) ISMS (Information Security Management System) For confidentiality preservation and management, it refers to defining the security level required for own risk evaluation as organization management in addition to technical measures for individual problems, having plans, allocating resources and operating the system. (13) Core Tool(s) Core tools are as follows: PPAP (Production Part Approval Process), APQP (Advanced Product Quality Planning), FMEA (Failure Mode and Effects Analysis), MSA (Measurement System Analysis) and SPC (Statistical Process Control). IATF 16949 may also require the use of core tools as customer specific requirements.



(14) PPAP (Production Part Approval Process) Customer's approval procedure for mass-produced products. When all the PPAP requirements are completed, a PSW (Part Submission Warranty) is issued.



(15) APQP (Advanced Product Quality Planning) Steps from product design and development to mass production shall be promoted by the Concurrent Engineering. (16) FMEA (Failure Mode and Effects Analysis) It quantitatively evaluates various expected failures relating to design or manufacturing process by the risk evaluation index (RPN = S x O x D: “the significance of the effect of the occurred failure (S)", "failure occurrence frequency (O)" and "failure detection rate (D)") to be used as judging criteria for taking preventive actions and making improvement.



(17) MSA (Measurement Systems Analysis) Techniques used for evaluating process capability or process performance, setting acceptance criteria, evaluating errors of various measurement data, etc. It can evaluate the authenticity of the measured data on which the evaluation is based. (18) SPC (Statistical Process Control) It means to control processes statistically. It means monitoring processes, finding problems, determining process performance, etc. through data collection and analysis.



(19) Defect rate PPM (Parts Per Million) A method of showing the performance of the process in parts per million by actually occurred nonconforming products. It is used to decide the priority of corrective actions.



-8-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms (20) Cp, Cpk (Process Capability Index) It is an index representing the extent to which the characteristics (dimensions, functions, etc.) of the product produced in the subjected manufacturing process satisfy the product specification (tolerance, upper and lower limits, etc.). In particular, it uses the group of products produced in the stable state as a parent population. Cp represents the degree of stability (variation) of product characteristics (size, function, etc.), and Cpk represents the degree of satisfying the product specifications after considering the deviation from the median of standard based on Cp. The process capability index can be obtained by the following calculation formula. σ = Fluctuation standard deviation within the subgroup in the stable state (1 lot, n = 30 or more) Cp = (Upper limit of standard - Lower limit of standard)/6 σ Cpk = (1 - k) x Cp (K = [Average value - (Upper limit of standard + Lower limit of standard) / 2] / [Upper limit of standard + Lower limit of standard / 2])



(21) Pp, Ppk (Process Performance Index) It is an index representing the extent to which the characteristics (dimensions, functions, etc.) of the product produced in the subject manufacturing process satisfy the product specification (tolerance, upper and lower limits, etc.). In particular, it uses the group of products produced in the process containing unstable elements as a parent population. Pp represents the degree of stability (variation) of product characteristics (dimensions, functions, etc.), and Ppk represents the extent to which product specifications are satisfied after considering the deviation from the median of standard based on Cp. The process performance index can be obtained by the following calculation formula. s = Fluctuation standard deviation between groups including unstable elements (5 lots or more, total n = 30 or more) Pp = (Upper limit of standard - Lower limit of standard)/6 s Ppk = (1 - k) x Pp 　(K = [Average value - (Upper limit of standard + Lower limit of standard) / 2] / [Upper limit of standard + Lower limit of standard / 2])



(22) GRR (Gage R & R: Repeatability, Reproducibility) The most common way to test the validity of the measurement method in the manufacturing field. One measurement method is repeatedly executed in various environments and judgment is made in light of the four criteria of "accuracy", "repeatability", "reproducibility" and "stability". It is common to use it for analysis of continuous data, but it can also be used for checking the measurement method of discontinuous data if applied.



(23) CFR (Cross Functional Review) It is a review by cross-functional team (Production, Sales, Development and Quality) for sales management in each Business Unit to achieve the QCDE target value. Each sales management quantitatively confirms the QCDE target achievement status of the project and clarifies risks and problems.



(24) MPPS (Manufacturing Process Plan Sheet)/QC Process Chart It is prepared at each stage of estimation and production preparation (mass production trial, mass production). All processes from acceptance of raw materials to shipment of finished goods are identified, equipment, quality characteristics, assurance items, quality standards, working hours, etc. along with those processes are defined, and control items in each element work are determined. * Element work: It is a grouping work when repetition work done by workers is broken down.



Reference example



Cutting







Cutting tool mounting



To pick up the material



Sharpen the right end.



To check



Sharpen the left end.



To start



To advance the cutting tool -9-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms (25) 3D, 8D Report -3/8 Description Report- (Quality Defect Investigation Report) It is a report to be created by using a process to tackle problem solving by an ordered analysis method corresponding to the root causes. It consists of the following items: 1: Team, 2: Problems, 3: Containment Action, 4: Root Cause, 5: Corrective Action, 6: Permanent Corrective Action, 7: Prevent Reoccurrence Action, 8: Team Recognition It is obligatory to submit 3D report within 48 hours and 8D report within 10 working days. 3D report includes the results of sorting parts, arrange of replacement, etc. as interim actions.



(26) FP (Fool Proof: Pokayoke) It is to take measures to prevent simple human errors (Poka). Each step of each process is checked, "what kind of human error or malfunction can occur at each step" is considered and measures to prevent errors are taken.



(27) 4M [5M + 1E] It is an acronym for "Man", "Method", "Material" and "Machine" and is used as a category for setting the root cause hypothesis. By controlling these change points, problem solving and traceability can be secured. Add "Measurement" and "Environment" to 4M is called "5M + 1E".



(28) 5S activities "5S activities" is a general term derived from the initials "S" of "Seiri (sifting)", "Seiton (sorting)", "Seiketsu (standardizing)", "Seisou (cleaning)" and "Shitsuke (discipline)", expressing the behavior/state to be observed thoroughly in terms of workplace management by adding the level elements. It makes it possible to make problems visible, create environment for promoting improvement and improve the quality of products and services provided by the organization.



(29) 5W 2H It is the 5W which took the initials of Why, What, Who, Where and When plus 2H which took the initials of How and How much. It is used as a basic element for composing sentences. In a corrective action report, etc., root cases and corrective actions can be clarified by appropriately understanding the elements such as "Why", "What", "Who", "Where", "When", "How" and "How much the cost effect is".



(30) Past troubles Problems, defects, troubles, etc. that occurred in the past are collectively referred to as past troubles. (31) Why-why analysis (5 Why) An analysis method to find a solution by identifying the root cause of the problem through repeating "why five or more times". It is a very effective tool to concentrate on examining the solution rather than searching for an offender of the problem. (32) Supplier The supplier is defined as a company that directly or indirectly supplies materials for parts, mass-produced parts or service parts to Yazaki group or other bases. Providers of heat treatment, painting, plating, and other finishing processes are also included. (33) N-tier supplier N-tier supplier means a company which is consigned a part or all of processes from Yazaki primary supplier based on the supply chain. Providers of heat treatment, painting, plating, and other finishing processes are also included.



-10-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms (34) Traceability The manufacturing history can be traced. In order to secure traceability, it is required to identify each piece. That is considered to be particularly important for the narrowing down subjected products when a trouble or the like occurs. It is required to enable tracking lot numbers in both direction between materials and products. (35) Conforming product It means a product which conforms to all requirements on a drawing and others. (36) Nonconforming product It means a product which does not conform to any or all requirements on a drawing or others. (37) Abnormal product It is a product that was not produced under normal conditions. It does not mean the state of the product itself. For example, when products were produced with equipment which has abnormality, they are considered to be abnormal products. It is required to check and judge whether they are conforming or nonconforming products by inspection later. Abnormal products are not always nonconforming products. (38) Part concession When products or manufacturing processes do not comply with Yazaki requirements, the supplier may apply for deviation approval to Yazaki with evaluation results of part characteristics. (39) Initial sample inspection It is an inspection led by Purchasing Department to accept parts produced with off-tool in off-process, which meet all requirements in the drawing. Samples, data, standards, etc. are comprehensively verified and evaluated.



(40) RoHS Directive (Restriction of Hazardous Substances) (Directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment) Approved by the European Parliament, this Directive aims to establish laws on specific hazardous substances in electrical and electronic equipment and minimize the risks of environmental and human health at all stages from production to disposal. Since July 1, 2006, it has been is fully prohibited to use the following six substances: lead (Pb), mercury (Hg), cadmium (Cd), hexavalent chromium (Cr6+), polybrominated biphenyl (PBB) and polybrominated diphenyl ether (PBDE), excluding some exceptions. (41) ELV Directive (End of Life Vehicles) (EU directive on end-of-life vehicles) It was established in May 2000 before the RoHS Directive came into effect in order to reduce automobile waste and reduce environmental impacts, and it took effect in October of the same year. In order to facilitate the recycling process, it is prohibited to use Cd, Pb, Hg and Cr6+, excluding some exceptions. (42) SOC (Substance of Concern) Substances which use is prohibited or restricted by the European Directive and customer requirements. (43) Important part General name of "S" rank part and "A" rank part. Parts that may directly or indirectly cause harm to people or parts that may cause fire or have serious effects on environments when they are defective.



-11-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms (44) "S" rank part It is an important safety part. Important safety parts are parts related to safety parts, exhaust gas regulations, domestic and overseas laws and regulations, and important parts that are directly related to the life of drivers because failure or breakage of such parts significantly affects the safe driving function of the car. Important security parts shall be designated by Yazaki and instructed in the drawings. However, the Recycling Law is excluded. (45) "A" rank part It is a part designated by Yazaki. * Composite electric circuit parts (R/B, J/B, F/B, bush connectors, female terminals, etc.) (46) Inserted part It is a part that bolts, nuts, etc. are assembled in it. Since those components are inside of the part, the part cannot be or hardly reworked. * Assembled part such as inserted part, R/B, etc. (47) Special process Special process means a process using a product processing method of welding, soldering, or heat treatment (48) Localization Activities to promote optimum production and optimum procurement aiming at cost reduction, shortening of lead time and stabilization of quality by them. It is called locally procured parts that are manufactured in the optimum process from initial period or after transfer of process by local procurement. (This Manual is based on Japan, and localization refers to overseas production and procurement.) (49) Part produced by localized additional mold It is a part produced with an additional mold which is built by a local mold manufacture in the optimum process, aiming at further cost reduction than the current parts. (50) Patterns of logistics and commercial flow The patterns of logistics are defined as follows. (This Manual is based on Japan.) IN-IN



Those produced n Japan and delivered in Japan



IN-OUT



Those produced in Japan and exported abroad



OUT-IN



Those produced overseas and imported to Japan



OUT-IN-OUT



Those produced overseas and exported overseas via Japan



OUT-OUT



Domestic



Those produced overseas and delivered within the country



International



Those produced overseas and exported to other countries



* OUT-OUT transaction is categorized into "direct transaction" with overseas W/H factories and "transaction through Purchasing Department" in overseas bases.



(51) L/O It refers to the line off of a new vehicle to be carried out by a car maker. (52) Overseas base of the Purchasing Department YGP: Singapore YCIC: China YIC-AP: Thailand PASI: Indonesia (53) JAMA sheet A data sheet that describes the data (content, purpose of inclusion, etc.) of substances contained in the component and material.



-12-



Quality Manual for Suppliers 26th Edition



1. General rules 2. Application 3. Definition and explanation of terms (54) PBB Polybrominated biphenyls (PolyBrominated Biphenyls) (55) PBDE Polybrominated diphenyl ethers (PolyBrominated Diphenyl Ethers) (56) Deca BDE Decabromo diphenyl ether (DecaBromo Diphenyl Ether) (57) HBCD Hexabromocyclododecane (HexaBromoCyclo Dodecane) (58) PFOS Perfluorooctane sulfonate (PreFluoroOctane Sulfibates) (59) Asbestos Asbestos (60) DMF Dimethyl Fumarate (Dimethyl Fumarate) (61) Specific phthalate ester - DEHP (DOP)



Bis phthalate



- DBP



Dibutyl phthalate



- BBP



Bis (butylbenzyl) phthalate



- DIBP



Diisobutyl phthalate



(62) Prototype part Parts that are handled by Development/Design Department in Yazaki (63) Off-tool Molds for producing mass-produced parts. (64) Off-process It is a process for mass-produced parts under the good 4M conditions. (65) Mass-produced trial part Parts before the examination of shifting to mass production, produced along production preparation activities by Business promotion Department after release of the mass production drawing (66) Mass-produced part Parts to be produced under 4M (Materials, Methods, Machine, Man, etc.) which have been approved at the examination for shifting to mass production. (67) Initial flow period It is a period in three months after L/O (line off) of the new vehicle in a car maker and until the end of special control to ensure quality stability.



-13-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents 4. Quality control requirements [Basic requirements] => Appendix 4A "Administrative Procedures for Quality Assurance" (1) Before ordering parts, Yazaki shall present requirements to the supplier. The supplier is responsible for ensuring that the parts ordered by Yazaki meet our requirements and satisfy the quality required by Yazaki. For this reason, - Producing sufficient quality from trial production stage - Establishing the process control system appropriate for the parts - Collecting quality information aggressively and using them effectively - Establishing an overall quality control system corresponding to changes with the times suppliers shall strive to establish an autonomous assurance system. (2) Also, the supplier has a responsibility to ensure that products satisfy customer requirements. (3) The supplier shall develop a quality management system as the goal to comply with the IATF 16949. If not otherwise specified by the customer, the supplier shall be certified as QMS (ISO 9001 etc.) and EMS (ISO 14001 etc.) by the certified third party registration agency. (4) The supplier is responsible for responding to special requests that are not regulated by this Manual when working on the smooth product launch and quality assurance. (5) In case of using N-tier supplier, the supplier shall develop the management contents in writing in accordance with this Manual. In addition, the supplier shall instruct and train them in order to satisfy the requirements of this Manual. [Quality management related requirements] (IATF 16949 5.3.1)



4-1-1 Notification of responsible personnel



=> Appendix 4-1-1A "Responsible Personnel Reporting Procedure" The supplier shall appoint personnel who are responsible for quality assurance and environment with responsibilities and authorities in order to respond to Yazaki requirements and assure the quality of delivered parts. Upon appointment, the designated forms "Notification of Responsible Person and Person in Charge of Quality Assurance", "Notification of Responsible Person and Person in Charge of Environment" and "Notification of Production Preparation Managers, Personnel" shall be submitted to the Audit Department of the Control (All of 4.4.1.1, 7.2.4 and 8.4 of IATF 16949) 4-1-2 N-tier supplier management => Appendix 4-1-2A "N-tier Supplier Management Procedure" When the supplier purchases parts from the N-tier supplier, audit, education and training are carried out by the supplier in order to maintain and continue quality assurance system equivalent to the supplier. The supplier also shall implement management that can check the supply chain per part number. (IATF 16949 7.5.3.2.1, 7.5.3.2.2, 8.1.2)



4-1-3 Document and record management



=> Appendix 4-1-3A "Document and Record Management Procedure" (1) Document and record management The supplier shall manage internal documents and the information distributed from Yazaki in order to submit them promptly upon Yazaki's request. The supplier which has multiple bases shall promptly communicate internal quality information, and requirements and information from Yazaki, to each base and strive to ensure the same quality control. (2) Storage of quality records The supplier shall try to maintain and improve the quality and the quality assurance system by utilizing manufacturing records, inspection and test records, precision control records of measuring instruments, audit and guidance records of the N-tier supplier, countermeasures against defects, etc. If not otherwise specified by the customer, the records shall be stored at least 20 years after the drawing/part number has discontinued. (IATF 16949 7.2.1, 7.2.2)



4-1-4 Implementation of employee training



=> Appendix 4-1-4A "Employee Training Management Procedure", Appendix 4-4-1A "Production Preparation Implementation Procedure" (1) The supplier shall plan and implement internal education and external training sessions so that employees can acquire knowledge and skills. (2) The supplier shall understand the requirements of IATF 16949 and train employees thoroughly.



-14-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents (IATF 16949 8.5.6.1)



4-1-5 Changing point management



=> Appended Table 1 "Pre-Preparation Management Flowchart [Mass-Production/Design Change]" Appendix 4-1-5A "Changing Point Management Procedure" (1) Changing point management The supplier shall clarify the management method for the change points occurring in the process and prevent occurrence of quality problems due to in-process change by appropriate actions and evaluation. (IATF 16949 7.5.3.2.2, 8.5.6.1)



4-1-6 Change management



=> Appendix 4-1-6A "Process Change Procedure" (1) Design change management The supplier shall apply changes based on the "Pre-Production Management Flowchart" when any specification described in Yazaki drawings (including instructions according to the drawings) has been changed. (2) Process change management When the supplier changes processes, "Advanced Change Information" and "Application for Process Change" shall be submitted based on "Process Change Procedure". If the change is related to the process change or drawing change of new parts, actions shall be taken based on "Pre-Production Management Flowchart" according to instructions by Yazaki. (IATF 16949 8.3.4.4)



4-1-7 Initial component management



=> Appended Tables 1 and 2 "Pre-Production Management Flowchart [Mass-Production/Design Change/ Prototype/Localized Additional Mold]" Appendix 4-1-7A "Initial Component Supply Notice" The supplier shall carry out the examination of shifting to mass production based on "Pre-Production Flowchart" for new parts, design changed parts and process changed parts (when changed), and shall submit "Initial Component Supply Notice (Pre-Notice / Information)" before delivery of the parts. (IATF 16949 8.3.4.4)



4-1-8 Implementation of PPAP



=> Appendix 4-1-8A "Production Part Approval Process Implementation Procedure" Upon request from Yazaki for customer requirements, the supplier shall promptly submit necessary documents in accordance with "Production Part Approval Process Implementation Procedure". (IATF 16949 8.7.1.1)



4-1-9 Mass-produced product concession application



=> Appendix 4-1-9A "Mass-produced Product Concession Application" If mass-produced parts cannot meet specifications required by Yazaki, the supplier shall apply for concession in accordance with "Mass-produced Product Concession Application". (IATF 16949 10.3.1)



4-1-10 Continual improvement



=> Appendix 4-1-10A "Continual Improvement Implementation Procedure" The suppliers shall set the target for improvement and continuously improve quality. [Manufacturing process management related requirements] (IATF 16949 8.5.2.1)



4-2-1 Lot management



=> Appendix 4-2-1A "Lot Management Procedure", Appendix 4-2-1B "Traceability Management Procedure" The supplier shall ensure lot traceability from receiving material to shipping parts. Effective system shall be used in the first part and end part inspection for "lot control". (IATF 16949 8.4.2.2, 8.5.1.7, 8.5.4.1)



4-2-2 Management of raw materials



=> Appendix 4-2-2A "Raw Material Management Procedure" The supplier ensures with evidence that hazardous substances regulated by Yazaki and the customer are controlled not to contain in "raw material". When Yazaki requires the supplier to investigate the content of hazardous substances, report the investigation results immediately to Audit Department in Yazaki. The supplier shall control raw materials based on first-in first-out rule, and handle the remaining material properly without fail to prevent mixing up of different materials.



-15-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents (IATF 16949 8.4.2.2, 8.5.1, 8.5.1.1)



4-2-3 Process control



=> Appendix 4-2-3A "Process Control Procedure" The supplier shall build up quality and clearly specify control items, with a goal to provide 100% good products that meet Yazaki requirements in manufacturing processes. (IATF 16949 7.1.5.2, 7.1.5.2.1, 7.1.5.3.1, 7.1.5.3.2)



4-2-4 Precision control of measuring devices



=> Appendix 4-2-4A "Measuring Devices Precision Control Procedure" The supplier shall prepare control standards and conduct periodic maintenance and calibration to ensure precision of measurement and test devices, etc. In order to assure the precision of gauges, inspection instruments, etc., the supplier shall decide the maintenance frequency for each material and measurement position, and maintain and control them. Changes are reported to Yazaki, if any. (IATF 16949 8.5.4.1)



4-2-5 Product shipment management



=> Appendix 4-2-5A "Product Shipment Management Procedure" The supplier shall carry out "4 point check" when packing. Also, the supplier shall clarify contents to be controlled for work environment, returnable containers, handling, transportation and conveyance, until opening at the customer, and decide maintenance management and troubleshooting methods. (IATF 16949 8.5.1.5, 8.5.1.6)



4-2-6 Mold management



=> Appendix 4-2-6A "Mold Management Procedure" In order to assure the precision of the mold used in mass-production, the supplier shall decide the maintenance frequency for each mold piece, and maintain and control them. When changing a mold, the supplier shall report to Yazaki based on "Mold Management Procedure". 4-2-7 Actions to be taken in case of occurrence of defects (IATF 16949 8.7.1.2, 8.7.1.3, 8.7.1.6, 8.7.1.7) => Appended Tables 4, 5, 6 and 7 "Defect Handling Flowchart" Appendix 4-2-7A "Defect Handling Procedure" => Appendix 4-2-7B "Abnormality Handling Procedure" Appendix 4-2-7C "Past Trouble Utilization Procedure" Appendix 4-2-7D "Improvement Proposal Procedure" When a defect has occurred in the market, the customer or Yazaki in the parts delivered, or when a defect was found at the supplier and it may affect the parts delivered, the supplier shall take proper actions immediately, also, contact QA staff in Yazaki and follow his/her instructions. Upon request, the supplier receives actual parts, sort or rework the subjected parts, and so on. Based on "Quality Defect Report" issued by Yazaki, "Recurrence Prevention Report" shall be prepared and submitted by the designated due date, and report to Yazaki, if necessary. Also, in order to prevent the recurrence of defects and make improvement for the next car launch timing, "Past Trouble Database" shall be prepared and used at the stage of RFQ (= request of quotation), CFR (= cross functional review), etc. (IATF 16949 8.5.1.5, 8.5.1.6)



4-2-8 Management of equipment and jigs



=> Appendix 4-2-8A "Equipment and Jig Management Procedure" The supplier shall carry out appropriate maintenance for equipment and jigs to be used, and maintain equipment performance and product quality, in order to achieve stable supply to the customer. 4-2-9 Management of identification marking for materials



(IATF 16949 8.2.3.1.2, 8.3.3.3)



=> Appendix 4-2-9A "Material Identification Mark Management Procedure" For material marking regulations aimed at improving the recycle rate prescribed in each country, the supplier shall clarify how to respond to customers' requirements.



-16-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents [SOC related requirements] (IATF 16949 8.4.2.2)



4-3-1 SOC management



=> Appendix 4-3-1A "SOC Management Procedure" To ensure compliance with environmental regulations and European Directives (EURO DIRECTIVES) requirements of each country, the supplier shall conduct process control so that no SOC is contained or mixed in the processes. (IATF 16949 8.6.5)



4-3-2 SOC analysis



=> Appendix 4-3-2A "SOC Analysis Procedure" The supplier shall prepare analysis data (evidence) to prove that regulated substances are not contained or mixed in products delivered to Yazaki. The analysis data to be submitted to Yazaki shall be based on measurement of the products produced under the same conditions as the mass production process. In addition, parts that are designated by Yazaki as parts with a high risk of containing SOC or their raw materials shall be analyzed at least once a year. When requesting Yazaki to analyze and judge the inclusion of SOC, the supplier shall follow "SOC Test Evaluation Flowchart". 4-3-3 Procedure for handling environmentally nonconforming products



(IATF 16949 8.6.5, 8.7.1.6)



=> Appendix 4-3-3A "Procedure for Handling Environmentally Nonconforming Products" When environmentally nonconforming products have been found, they shall be handled according to "Procedure for Handling Environmentally Nonconforming Products" (IATF 16949 8.6.5)



4-3-4 Preparation and submission of JAMA sheet



=> Appendix 4-3-4A "JAMA Sheet Preparation and Submission Procedure" When the supplier is required to submit a JAMA sheet, it shall be submitted with the form designated by Yazaki before the deadline. (IATF 16949 8.4.2.2)



4-3-5 Management of chemical substances



=> Appendix 4-3-5A "Chemical Substances Management Procedure" (YGS-C21-010) Substances listed in the GADSL specified by YGS-C21-010 (Chemical Substances Control Standard) in Yazaki drawings and listed in "YAZAKI group voluntarily controlled substance list" shall be investigated, and the use of the target substances shall be prohibited or limited. Handling method is described here. [Production preparation related requirements] 4-4-1 Production preparation activities



(IATF 16949 4.4.1.2, 7.1.3.1, 8.1.1, 8.3.1.1, 8.3.3.2, 8.3.4.1, 8.3.5.2) => Appendix 4-4-1A "Production Preparation Implementation Procedure", Appendix 4-4-1B "Production Preparation Milestone Management" Appended Tables 1, 2 and 3 Production Preparation Flow



[Mass Production/Design Change/Prototype/Locally Procured Increase Mold] The supplier shall voluntarily and systematically prepare production activities, understand the contents of implementation at each milestone, and implement activities to build conditions to produce good parts. 4-4-2 Issuance of 3D data and drawings, issuance of mold and equipment order form



(IATF 16949 7.5.3.2.2, 8.1.2, 8.2.3.1.1, 8.3.3.1)



=> Appendix 4-4-2A "Drawing Receipt and Mold and Equipment Design Order Procedure" The supplier shall check the contents of 3D data and drawings, mold and equipment order forms, notice of new / design changed part (hereinafter referred to as drawings, order forms, etc.) issued by Yazaki, and shall design and/or prepare molds and equipment. 4-4-3 Mold management ledger (Registration/Change) => Appendix 4-4-3A "Mold Registration/Change Form Preparation Procedure" The supplier shall take actions according to ""Mold Registration/Change Form Preparation Procedure" with the aim of clarifying the number of cavities, specifications, holders and holding locations of molds ordered by Yazaki to use for mass-production. 4-4-4 Arrangement and acceptance inspection of prototype parts (IATF 16949 8.3.4.3) => Appendix 4-4-4A "Prototype Parts Arrangement and Acceptance Inspection Procedure" Based on "Prototype Parts Arrangement and Acceptance Inspection Procedure", the supplier shall control the production schedule and the delivery date of prototype parts and molds.



-17-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents 4-4-5 Part rank => Appendix 4-4-5A "Production Preparation Procedure by Each Part Rank" The supplier shall conduct production preparation activities responding to importance based on the rank set by Yazaki per each product, evaluate products, and submit evaluation results and an evidence to Yazaki. (IATF 16949 8.2.3.1.2, 8.3.3.3)



4-4-6 Management of important parts



=> Appendix 4-4-6A "S/A Rank Parts Management Procedure" The supplier shall control the products that require special control according to Yazaki instructions to assure the quality. (IATF 16949 8.2.3.1.3, 8.3.2.1)



4-4-7 Cross functional activities



Appendix 4-4-7A "Cross Functional Activity Implementation Procedure" [Bulletin of Cross Functional Activity - Examples] The supplier shall consist of a person in charge and members for cross functional activities, and carry out activities based on "Cross Functional Activity Implementation Procedure". (IATF 16949 8.1.1)



4-4-8 Preparation of production preparation plan sheet



=> Appendix 4-4-8A "Production Preparation Plan Procedure" In principle, the supplier shall prepare and submit "Production Preparation Plan" within two weeks after receiving instruction of the plan, based on an order of new / design changed parts. (IATF 16949 8.2.3.1.3, 8.3.2, 8.3.4)



4-4-9 Preparation of mold and equipment plan report[



=> Appendix 4-4-9A "Mold and Equipment Plan Report Preparation Procedure" The supplier shall prepare "Mold and Equipment Plan Report" in accordance with "Mold and Equipment Plan Report Preparation Procedure" and submit it to Production Preparation Department in Yazaki. (IATF 16949 8.2.3.1.3, 8.3.2.1, 8.3.4)



4-4-10 Examination of process design/mold/equipment



=> Appendix 4-4-10A "Process Design Procedure" Appendix 4-4-10B "Drawing DR Handling Procedure" Appendix 4-4-10C "Equipment Specification Examination Procedure" It specifies the verification procedure of the process design at the supplier so that the suppliers can carry out reliable quality building activities at the process design stage. Evidence of the equipment specification review results shall be notified to Production Preparation Department in Yazaki and smooth production preparation activities shall be implemented. (IATF 16949 6.1.2.2, 8.3.3.2)



4-4-11 Checking/handling of past trouble database



=> Appendix 4-4-11A "Production Preparation Past Trouble Database Check Procedure" Appendix 4-4-11B "Mass Production Past Trouble Database Check Procedure" The supplier shall look through the Past Trouble Database of both production preparation and mass-production stages provided by Yazaki, and reflect the contents to the production preparation activities for quality improvement. 4-4-12 Standard document preparation (IATF 16949 8.3.2.1, 8.3.3.2 8.3.5.2, 8.5.1.1, 8.5.1.2) => Appendix 4-4-12A "Manufacturing Process Plan Sheet/QC Process Sheet Preparation Procedure", Appendix 4-4-12B "QC Process Sheet Preparation Procedure" 　Appendix 4-4-12C "Parts Inspection Standard Preparation Procedure" Appendix 4-4-12D "Packing Specification Preparation Procedure" Appendix 4-4-12E "Work Standard Preparation Procedure" The supplier shall prepare the standard documents, "Parts Inspection Standard", "QC Process Sheet" and "Packing Specification", in accordance with "Standard Document Preparation Procedure" to continuously satisfy the required quality, and shall submit them to Production Preparation Department in Yazaki. Work Standard, Inspection Point List, etc. are not required to submit, but they must be prepared. In conducting production preparation and process design, the Manufacturing Process Plan Sheet and QC Process Chart shall be prepared to clarify quality characteristics, assurance items, quality standards, working hours, etc. of all processes from raw material acceptance to product shipment. Those contents are applied to QC Process Chart and controlled. This content is reflected in the QC Process Chart and then managed.



-18-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents (IATF 16949 8.2.3.1.3)



4-4-13 HVPT (High Volume Production Trial)



=> Appendix 4-4-13A "HVPT Implementation Procedure" The suppliers shall implement HVPT to verify the stable quality in mass-production. In HVPT, products are fed consecutive 200 pieces (shots) or two hours or more as a standard, discussing with Yazaki for details. * HVPT: High Volume Production Trial (IATF 16949 9.1.1.1, 9.1.1.2, 9.1.1.3)



4-4-14 Process capability verification



=> Appendix 4-4-14A "Process Capability Verification Procedure" The purpose is to check the product quality and process stability and judge the validity of daily inspection items and frequency by verifying process capability. (IATF 16949 8.5.1.5)



4-4-15 Manufacturing process audit



=> Appendix 4-4-15A "Manufacturing Process Audit Evaluation Procedure" It specifies the process verification procedure and evidence submission procedure for the supplier. It is applied to all new parts, design changed parts, and their components ordered by Yazaki. 4-4-16 Crimping check => Appendix 4-4-16A "Crimping Check Evaluation Procedure" "Crimping check" is conducted in advance responding to change for terminals in order to prevent defects during crimping terminals at W/H factories. It is mandatory to use a dedicated applicator for crimping.



4-4-17 Sample evaluation and parts test request (IATF 16949 8.3.4.4, 8.3.6.1) => Appendix 4-4-17A "Sample Evaluation and Part Test Request Procedure" The supplier shall submit the inspection results of the parts produced under the same conditions as the mass production process to Production Preparation Department or contact to overseas bases in Yazaki according to "Part Test Request Procedure".



4-4-18 Application for concession of startup products (IATF 16949 8.7.1.1) => Appendix 4-4-18A "Quantity Concession and Term Concession Application Procedure" Appendix 4-4-18B "Mold Concession Application Procedure" In case of requesting concession for the startup products that do not satisfy specifications required by Yazaki, the supplier shall apply for the concession in accordance with "Quantity Concession and Term Concession Application Procedure" and "Mold Concession Application Procedure". 4-4-19 Design change request => Appendix 4-4-19A "Design Change Request Application Procedure" When any revision is required on the mass-production drawing, the supplier shall prepare an application in accordance with "Internal Design Change Request Application Procedure" and submit it to Yazaki. 4-4-20 Preparation and management of boundary sample sheet



(IATF 16949 8.7.1.1)



=> Appendix 4-4-20A "Boundary Sample Sheet Procedure" If a boundary sample (a sheet attached the sample) is needed, the supplier shall create it in accordance with "Boundary Sample Sheet Procedure" and submit it to Yazaki. (IATF 16949 8.2.3.1.3)



4-4-21 Application for shifting to mass production



=> Appendix 4-4-21A "Procedure for Application for Shifting to Mass Production" When submitting an application for transition to mass production, the supplier shall evaluate the production preparation results and check the state of solving the problems according to "Procedure for Application for Shifting to Mass Production".



-19-



Quality Manual for Suppliers 26th Edition



4. Requirements 5. Audit 6. Requirements for each industry and product type 7. Documents 4-4-22 Initial period production control => Appendix 4-4-22A "Initial Period Control and Release Procedure" After the application for transition to mass production has been approved, the supplier shall clarify the implementation procedure from the start to the end of initial period control in accordance with "Initial Period Control and Release Procedure". 4-4-23 Mold (additional/renewal/cost reduction/disposal) application



(IATF 16949 8.1.1, 8.5.6.1, 8.3.6.1)



=> Appendix 4-4-23A "Mold (Additional/Renewal/Cost Reduction/Disposal) Application Procedure" When molds are added, renewed or disposed, or molds are added or renewed for cost reduction, the supplier shall prepare "Application for Die (Addition/Renewal/Cost Reduction/Disposal)" according to "Mold (Additional/Renewal/Cost Reduction/Disposal) Application Procedure" and then submit it to Yazaki. As for the application for an additional mold or renewal mold, the supplier shall attach documents which shows current order situation, mold maintenance status, etc. as appropriate. 4-4-24 Exchange of material delivery specification => Appendix 4-4-24A "Material Delivery Specification Exchange Procedure" When the material specifications are undefined, suppliers shall exchange the written specifications with our Design Department.



5. Audit



(IATF 16949 8.4.2.4, 8.4.2.4.1, 9.1.2.1)



=> Appendix 5A "Supplier Audit" In order to ensure reliable quality assurance to customers, audits are conducted by Yazaki to check quality assurance activities, in accordance with this Manual, regularly or from time to time. The supplier shall submit "Process Audit Result and Improvement Request" after writing response to concerns pointed by Yazaki in the audits, if any, and make improvements based on it.



6. Requirements by each industry and product type => Appendixes issued separately Yazaki basic requirements are based on this Manual, but detailed requirements for each product type are specified in the separate detailed regulations. The supplier is required to understand well the contents in this Manual, reflect to internal standards and regulations, and comply with them. If there is any unclear point or discrepancy between the control method at the supplier and Yazaki requirements, the supplier shall coordinate with Quality Department in Yazaki and clarify the control method.



7. Forms When using a form specified in this Manual (indicated as [YKQ-xxxxx] in this Manual), refer to the separately issued "List of Related Forms". * In case that forms are submitted by electronic media, electronic stamp is available as a signature



-20-



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Exchanging Master Agreement



-



◎



Supplier ledger



Submission of supplier ledger



-



◎



Notification, submission, application



Registration of responsible Decide responsible person and contact person of production person preparation activities and quality/environmental assurance, and submit it. [When a new person is decided, for update on June 21 in every year, and any person has been changed (within one month)]



Submission of Quality Assurance Organization Chart



Application for mold (Additional/Renewal/Cost Reduction/Disposal))



Process change application Submit douments seven months before request date of process change. * Since the details vary depending on the customer, comply with the customer requirements.



○ ◎ ○



△



4-1-1A Responsible Personnel Reporting Procedure [YKQ-001-**] Notification of Responsible Person and Person in Charge of Quality Assurance [YKQ-002-**] Notification of Responsible Person and Person in Charge of Environment



Submission of organization 4-1-1A Responsible Personnel Reporting Procedure chart [No designated form] Organization Chart [When a new person is decided and any person has been changed (within one month)] Apply for production start or disposal when needed.



Procurement Standard Department



Exchanging Master Agreement



Suppliers (including N-tier suppliers)



Related articles and documents



Audit Department



Agreement



Implementation content



Procurement and Supply Department



Each Vehicle Program Promotion Departments



Development design



Delivery destination



Classification



Item to be implemented



4-4-23A Application for Mold (Additional/Renewal/Cost Reduction/Disposal) [YKQ-046-**] Application for Die (Addition/Renewal/Cost Reduction/Disposal) [YKQ-097-**] Certificate of Disposal of Dies, Equipment, Jigs and Tools



△



4-1-6A Process Change [YKQ-007-**] Application for Process Change and Regular Rroduction [YKQ-008-**] Process Change Implementation Plan/Progress Control Sheet (for Transfer within Japan) [YKQ-094-**] Report on Chemical SubstanceRelated Regulations inTransfer Destination Country [YKQ-062-**] Check Sheet for Prior Confirmation for Process Change [YKQ-067-**] List of Process Change/Change Point △ Confirmed Result [YKQ-055-**] Confirmation Request for Production Site Change [YKQ-046-**] Application for Die (Addition/Renewal/Cost Reduction/Disposal) [YKQ-057-**] Prior Confirmation of Packing Specification Change/Addition [YKQ-092-**] Advanced Change Information -21-



△



○



◎



○



◎



○



◎



○ △ △



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Occurrence of defects at the supplier



CFR0



Product planning Improvement proposal



◎



○



◎



△



△ ◎



○



◎



○



○



○



Create and submit the 4-2-7A Defect Handling Recurrence Prevention Report. Recurrence Prevention Report (Or according to the customer's request) [YKQ-017-**] Recurrence Prevention Report (RankA) [YKQ-018-**] Recurrence Prevention Report (Rank- ○ △ ○ B) [YKQ-019-**] Report for Re-Occurrence Prevention [8D] [YKQ-100-**] Quick Report of Quality Problem/Same-Day Report If any defective parts might be 4-2-7A Defect Handling miixed in the parts delivered, Quality Advance Information check lot numbers, quantity, [YKQ-020-**] Quality Advance Information ○ △ ○ shipping destination, etc. subject to the defect and report to Yazaki. Confirm action plans from the current vehicle. Create improvement proposals from the next development concept. * Make proposals for easy-tomanufacture products by using past troubles, defects shipped out, in-process defects, improvement activities, etc.



Procurement Standard Department



Corrective action



Receive defect information and 4-2-7A Defect Handling properly handle the defect. Quality Defect Report



Suppliers (including N-tier suppliers)



Quality defect



Occurrence of defects



○ △



4-3-4A JAMA Sheet Preparation and Submission Procedure Basically, each Development & Design Department requests to create it Submit it to the requestor.



5A. Audit Submit the document when Yazaki requests improvement [YKQ-045-**] Process Audit Result and or points concerns in the audit. Improvement Request Periodic Process Audit Check Sheet



Audit Department



Other



Periodic audit



4-1-2A N-tier Supplier Management [YKQ-003-**] Notification of Secondary or Tertiary Supplier [YKQ-004-**] Tier N Supplier Business Survey △ [YKQ-005-**] List of Enrollment Tier N Suppliers [YKQ-006-**] Tier N Consignment Part Number List



Procurement and Supply Department



Submission



Investigate the substances Preparation and submission of JAMA sheet specified by GADSL and ensure that they are not contained more than Yazaki's control value.



Each Vehicle Program Promotion Departments



When using the N-tier supplier, it shall be applied each time. * When changing a process, the actions above shall also be taken.



Related articles and documents



Development design



N-tier supplier application



Implementation content



Delivery destination



Classification



Item to be implemented



◎



◎



4-2-7C Past Troubles Utilization 4-2-7D Improvement Proposal [YKQ-060-**] Suggestion List for Design Department [YKQ-059-**] Suggestions for New Design ○ ○



-22-



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Evaluate the packaging by transportation trials etc. and examine the packing specification by checking quality of parts at arrival mainly in consideration of efficiency, Propose conditions, check points, etc. for each element work in each process.



Preparation of work standard



4-4-1A Production Preparation Activities 4-4-12D Packing Specification [YKQ-031-**] Packing Specification



4-4-1A Production Preparation Activities [No designated form] Work Standard



Examination of educational Propose training plans for each 4-4-1A Production Preparation Activities 4-1-4A Employee Training Management process. plan [No designated form] Training Plan Kick-off Kick-off Production preparation plan Create a schedule for each item from receiving drawings to the transition to mass production and review each activities.



CFR3



Prototype drawing review



Check the reflection status of request items to prototype drawings. Conduct a drawing review to prevent recurrence of defects from the past troubles. Examine mold structures, precision of equipment, materials, etc. to match them with the specifications in the drawing.



4-4-1A Production Preparation Activities 4-4-9A Mold and Equipment Delivery Date Response [YKQ-027-**] Die/Equipment Plan Report 4-4-4A Production Preparation Plan [YKQ-028-**] Production Preparation Plan



Procurement Standard Department



Preparation of packing specification



Suppliers (including N-tier suppliers)



Propose important quality items 4-4-1A Production Preparation Activities and inspection items, methods 4-4-12C Parts Inspection Standard [YKQ-029-**] Parts Inspection Standards and frequency.



Audit Department



Preparation of inspection standard



Procurement and Supply Department



Create improvement proposals 4-2-7C Past Trouble Utilization from the next vehicle concept. 4-2-7D Improvement Proposal [YKQ-060-**] Suggestion List for Design (Change point from CFR0) Department [YKQ-059-**] Suggestions for New Design 4-4-1A Production Preparation Activities Propose manufacturing 4-4-12A Manufacturing Process Plan Sheet/QC process flows, inspection items, control items and control Process Sheet [YKQ-056-**] Manufacturing Process Plan method Sheet/QC Process Chart Check the shapes and 4-4-12B QC Process Sheet manufacturing methodology and create quality improvement [YKQ-030-**] QC Process Sheet proposals.



Each Vehicle Program Promotion Departments



CFR2



Manufacturing process examination Manufacturing methodology examination



Related articles and documents



Development design



CFR1



Concept Improvement proposal



Implementation content



Delivery destination



Classification



Item to be implemented



○ ○



◎



○ ○



◎



△ ○ ○



◎



△ ○ ○



△



◎



△ ○



◎



△ ○



◎



○ △



◎



○ △



◎



4-4-19A Design Change Request Design Change Request [YKQ-049-**] Design Change Request



-23-



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Examine manufacturing process flow, inspection items, control items and control methods



4-4-1A Production Preparation Activities 4-4-12A Manufacturing Process Plan Sheet/QC Process Chart [YKQ-056-**] Manufacturing Process Plan Sheet/QC Process Chart 4-4-12B QC Process Sheet [YKQ-030-**] QC Process Sheet



Examine important quality items, inspection items, methods and frequency



4-4-1A Production Preparation Activities 4-4-12C Parts Inspection Standard [YKQ-029-**] Parts Inspection Standard



Evaluate the packaging by transportation trials etc. and examine the packing specification by checking quality of parts at arrival mainly in consideration of efficiency, i ht tconditions, check Examine



4-4-1A Production Preparation Activities 4-4-7C Packing Specification [YKQ-031-**] Packing Specification



Preparation of inspection standard



Preparation of packing specification



Preparation of work standard



Examination of training plan



points, etc. for each element work in each process.



Procurement Standard Department



Manufacturing process examination



○



Suppliers (including N-tier suppliers)



Receive and check the prototype drawings.



Audit Department



CFR3



Release of prototype drawing



Procurement and Supply Department



Discuss the design department 4-4-24A Material Delivery Specification about newly adopted materials [No designated form] Material Delivery Specification (Designated by the subjected department) and exchange a written specification (supplier material).



Each Vehicle Program Promotion Departments



Related articles and documents



Development design



Material specification



Implementation content



Delivery destination



Classification



Item to be implemented



◎



◎ ○



4-4-1A Production Preparation Activities 4-4-12E Work Standard Preparation [No designated form] Work Standard [No designated form] Work Procedure



Examine training plans for each 4-4-1A Production Preparation Activities [No designated form] Educational Plan process



Process design evaluation Perform evaluation of process 4-4-1A Production Preparation Activities [No designated form] Process FMEA control items, evaluate FP (Pokayoke) and preventive action to defects, and examine the upgrading of the process design quality.



-24-



△



○



△ ○



◎



△ ○



◎



△ △ ○



◎



△ ○



◎



△ ○



◎



△ ○



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Perform inspections on all characteristics of drawing specifications, clarify provisional and permanent measures for defective parts, and take actions.



4-4-1A Production Preparation Activities 4-4-17A Sample Evaluation and Part Evaluation [YKQ-034-**] Inspection Report [YKQ-035-**] Samples Evaluation Report (submitted to the development department and the production preparation department) [No designated form] Material Certificate (obtained from a material manufacturer) [YKQ-037-**] Certificate of Non-Use of Controlled Substances [YKQ-038-**] Report of Analysis of Substances of Concern in Part [No designated form] Environmental Evidence Samples for Analysis of SOC (Parts required attention, designated in the SOC Analysis Procedure)



Examine manufacturing location (factory name and location) Examine internal and external manufacturing (supply chain) * Application is required for new N-tier suppliers



4-1-2A N-tier Supplier Management [YKQ-003-**] Notification of Secondary or Tertiary Supplier [YKQ-004-**] Tier N Supplier Business Survey [YKQ-005-**] List of Enrollement Tier N Supplier [YKQ-006-**] Tier N Consignment Part Number List



-25-



◎ ○



Procurement Standard Department



Manufacturing location decision



4-4-1A Production Preparation Activities 4-4-4A Prototype Parts Arrangement and Acceptance Inspection [YKQ-041-**] Response Sheet for Prototype Parts Plan [YKQ-044-**] Trial Component statusment [YKQ-042-**] Prototype Parts Shipping Notification [YKQ-043-**] Invoice



○



Suppliers (including N-tier suppliers)



CFR3



Prototype evaluation



Delivery control of prototype parts Acceptance/money transfer of prototype mold Ordering, receiving and shipment of prototype parts Acceptance/money transfer of prototype parts



Audit Department



Prototype Mold Order/acceptance inspection of parts



Procurement and Supply Department



Evaluate the assurance level of 4-4-1A Production Preparation Activities Manufacturing process [No designated form] QA Network assurance level evaluation the quality assurance items from both aspects of occurrence and outflow and check the process "from receiving materials to shipping products" to verify the assurance level.



Each Vehicle Program Promotion Departments



Related articles and documents



Development design



Implementation content



Delivery destination



Classification



Item to be implemented



◎



○



◎



○ ○



◎



○



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Procurement Standard Department



Production preparation activities for each rank of part



Suppliers (including N-tier suppliers)



CFR4



Mass production drawing



○ ○



◎



△ ○



◎



△ ○



◎



○ ○



◎



4-4-1A Production Preparation Activities [No designated form] Process FMEA



Evaluate the assurance level of 4-4-1A Production Preparation Activities Manufacturing process [No designated form] QA Network assurance level evaluation the quality assurance items from both aspects of occurrence and outflow and check the process "from receiving materials to shipping products" to verify the assurance level. Equipment/jig examination Check the specifications of equipment, tools, etc.



Audit Department



Process design evaluation Perform evaluation of process control items, evaluate FP (Pokayoke) and prevention of defects, and examine the upgrading of the process design quality.



Procurement and Supply Department



4-4-1A Production Preparation Activities Check the reflecting status of 4-4-19A Design Change Request request items to massproduction drawing and check [YKQ-049-**] Design Change Request of problems and improvement points for trial production Conduct a drawing review to prevent recurrence of defects from the past troubles. Examine mold structures, equipment accuracy, materials, etc. to match them with the specifications in the drawing.



Each Vehicle Program Promotion Departments



Related articles and documents



Development design



CFR4



Mass production drawing review



Implementation content



Delivery destination



Classification



Item to be implemented



4-4-10C Equipment Specification Examination Procedure [No designated form] Equipment and Fixture Use Examination Result



4-4-2A Drawing Receipt and Mold and Equipment Arrangement Releasing 3D data and drawings, issuance of mold and equipment order form Conduct production preparation 4-4-5A Production Preparation Procedure by Each activities for each rank of part. Part Rank 4-4-6A "S"/"A" Rank Parts Management Receive and check the mass production drawing.



-26-



◎ △



　△ ○



○



○



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



4-4-1A Production Preparation Activities 4-4-12A Manufacturing Process Plan Sheet/QC Process Chart [YKQ-056-**] Manufacturing Process Plan Sheet/QC Process Chart 4-4-12B QC Process Sheet Preparation [YKQ-030-**] QC Process Sheet



Check whether processes with 4-4-1A Production Preparation Activities appropriate process capability [No designated form] Process Capability Survey have been built. Examine and improve methodology of processes which process capability is inadequate.



Decide important quality items 4-4-1A Production Preparation Activities 4-4-12C Parts Inspection Standard and inspection items and [YKQ-029-**] Parts Inspection Standard methods Decide inspection frequency in consideration of the process capability and assurance level. 4-4-1A Production Preparation Activities Evaluate the packaging by 4-4-12D Packing Specification transportation trials etc. and determine packing specification [YKQ-031-**] Packing Specification by checking quality of parts at arrival in consideration of efficiency, weight, etc.



-27-



Procurement Standard Department



CFR4



Preparation of packing specification



Determine manufacturing process flow, inspection items, control items and control method



Suppliers (including N-tier suppliers)



Preparation of inspection standard



4-4-1A Production Preparation Activities 4-4-9A Mold and Equipment Plan Report [YKQ-027-**] Die/Equipment Plan Report 4-4-8A Production Preparation Plan [YKQ-028-**] Production Preparation Plan



Audit Department



Process capability



Clarify the implementation plan for each production preparation item and make a schedule that can handle defects when they occur.



Procurement and Supply Department



Building of manufacturing process



Examine organization for cross 4-4-7A Cross Functional Activity Implementation [YKQ-080-**] Notification for Parts with Cross functional team and its Functional Activities activities. [YKQ-081-**] Report of Implementation for Cross Functional Activities [YKQ-082-**] List of Problems for Cross Functional Actiity and Improvement Results



Each Vehicle Program Promotion Departments



Start of mold/equipment manufacturing



Related articles and documents



Development design



Cross functional activities



Implementation content



Delivery destination



Classification



Item to be implemented



△ ○



◎



○ ○



◎



△ ○



◎



○ ○



◎



○ ○



◎



○ ○



△



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



CFR4



Indication to initial part



4-4-16A Crimping Check Evaluation Procedure [YKQ-103-**] Crimp Check Application Form and Report [No control number] Crimping Check Evaluation Result 4-4-1A Production Preparation Activities Perform inspections on all 4-4-17A Sample Evaluation and Parts Evaluation characteristics of drawing specifications and, for defective [YKQ-033-**] Notice of Judgment Result [YKQ-034-**] Inspection Report points, clarify provisional [YKQ-035-**] Sample Evaluation Report (submitted measures and permanent to the development department and the production measures and take these preparation department) measures considering parts [YKQ-036-**] List of Judgments After Part delivery. Evaluation [No designated form] Material Certificate (obtained from a material manufacturer) [YKQ-037-**] Certificate of Non-Use of Controlled Substances [YKQ-038-**] Report of Analysis of Substances of Concern in Part [No designated form] Environmental Evidence Samples for Analysis of SOC (Parts required attention, designated in the SOC Analysis Procedure) Submission of samples for analysis of massAnalyze samples from massproduced products produced products with an 4-3-2 Parts required attention designated in the analyzer at Yazaki to confirm SOC Analysis Procedure that SOC is not contained.



Procurement Standard Department



Boundary sample



4-4-1A Production Preparation Activities 4-1-4A Employee Training Management [No designated form] Educational Plan



Suppliers (including N-tier suppliers)



SOC analysis of massproduced products Check of non-SOC



Train employees in each process.



Audit Department



Initial sample evaluation Product evaluation



4-4-1A Production Preparation Activities 4-4-12E Work Standard Preparation [No designated form] Work Standard [No designated form] Work Procedure



Procurement and Supply Department



Crimping check



Determine conditions, check points, etc. for each element work in each process.



Each Vehicle Program Promotion Departments



Implementation of training



Related articles and documents



Development design



Preparation of work standard



Implementation content



Delivery destination



Classification



Item to be implemented



△ ○



◎



○



◎



△ ○ ○



◎



○ ○



◎



Conduct crimping check evaluation.



As necessary, grasp the capabilities of the characteristics (mainly appearance characteristics) which are not clarified in the drawing, and create and exchange the boundary sample.



◎



◎



4-4-20A Boundary Sample Sheet [YKQ-012-**] Boundary Sample Sheet



Indicate as initial parts to boxes 4-1-7A Initial Component Supply and bags for two months from the first delivery -28-



△ ○ ○



◎



○



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Submit PPAP when the final customer is BIG3 or any designated customers.



4-1-8A Production Part Approval Process Implementation



Concession application



For the parts failed in initial sample evaluation, discuss design department and other related departments in Yazaki. (For mold deviation, clearify the control range of the position needed special approval.)



4-1-9A Concession Application [YKQ-010-**] Application of Concession [YKQ-011-**] Deviation Component Evaluation Result



For special processes, submit work conditions and results of validity evaluation and functional evaluation for the conditions. After mass production processes are built, HVPT shall be carried out under the 4M conditions assuming mass production and, for problems, the improvement plan shall be defined and implemented.



Validity Evaluation Result (optional) Function Evaluation Result (optional)



Match the Production Process Plan and the standard document with actual work, extract problems and make improvement. Check the quality of parts accordingly to process design Check the status of solving problems in trial production



4-4-1A Production Preparation Activities [YKQ-045-**] Process Audit Result and Improvement Request [YKQ-074-**] Manufacturing Process Audit Evaluation Sheet



HVPT



Process check



◎



○



◎



△ △



4-4-1A Production Preparation Activities 4-4-13A HVPT [YKQ-072-**] HVPT (High Volume Production Trial) Result Report [YKQ-073-**] HVPT Problem Follow-up Sheet



-29-



Procurement Standard Department



PPAP (Production Part Approval Process)



Suppliers (including N-tier suppliers)



4-1-7A Initial Component Supply [YKQ-009-**] Initial Component Supply Notice (PreNotice/Information) (Need Approval by Yazaki) △ [YKQ-009-**] Initial Component Supply



Special process [Welding, soldering, heat treatment and adhesion]



Audit Department



○



Issue the Initial Component Supply Notice (PreNotice/Information) to delivery destinations.



Initial Component Supply Notice



Procurement and Supply Department



Make a plan for mold transper, Mold Transfer Plan Sheet which has been built in Japan and is going to transfer after initial sample inspection.



Each Vehicle Program Promotion Departments



Related articles and documents



Development design



Mold transfer plan



Implementation content



Delivery destination



Classification



Item to be implemented



○ ◎



△ ○ ○



◎



○ ○



◎



△ ○



◎



○ ○



　



◎



Quality Manual for Suppliers 26th Edition



[Appendix 4A] Administrative Procedures for Quality Assurance Overview 　 Matters that require administrative handling with Yazaki for quality assurance are listed as follows. For the details of the contents, refer to each implementation procedure to follow.



◎: Preparing/applying/implementing department ○: Submit to △: Related/collaborative department,



evaluation/operation/check Submit to/Related departments



Preparation of applying for Summarize quality target achievement situation the end of initial period control



4-4-1A Production Preparation Activities 4-4-22A Initial Period Control [YKQ-083-***] Application for Initial Period Production Control Release [No designated form] Quality Status Report 4-4-22A Initial Period Control [YKQ-083-**] Application for Initial Period Production Control Release [No designated form] Initial Period Control Plan [No designated form] Quality Status Report



Review for the end of initial Check quality target achievement status period control Number of complaints about outflow and in-process defect rate (PPM) Check intentional/unintentional changes in mass production conditions



CFR6



Review (Process inspection)



Create an action plan for the next vehicle. Create quality improvement proposals such as shape change and manufacturing methodology change. Process check of outflow complaints and concerned products, etc.



4-4-1A Production Preparation Activities 4-2-7D Improvement Proposal [YKQ-060-**] Suggestion List For Design Development [YKQ-059-**] Suggestions for New Design



Procurement Standard Department



4-4-1A Production Preparation Activities 4-4-21A Application for transition to mass production [YKQ-084-**] Application for Shifting to Mass Production 4-4-22A Initial Period Control [No designated form] Initial Period Control Plan 4-4-5A Production Preparation by Each Part Rank



○ ○



◎



○ ◎



◎



◎



○ ◎



○ ○



◎



○



* As for the details of the items implemented between the supplier and its N-tier supplier, the supplier shall clarify the items and take actions. The supplier shall perform management in order to submit documents promptly when requested by Yazaki about the implementation status.



-30-



Suppliers (including N-tier suppliers)



CFR5



Review for shifting to mass Review meeting for shifting to mass production production Mass production conditions check Initial period transition instruction



Audit Department



4-4-1A Production Preparation Activities 4-4-21A Application for Shifting to Mass Production [YKQ-084-**] Application for Shifting to Mass Production Application for Shifting to Mass Production and related documents



Procurement and Supply Department



Summarize the production preparation status including the initial sample evaluation result, process check result, HVPT implementation result, inprocess defect rate and improvement status to concerns.



Each Vehicle Program Promotion Departments



Related articles and documents



Development design



CFR5



Application for shifting to mass production



Implementation content



Delivery destination



Classification



Item to be implemented



△



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-1A] Responsible Personnel Reporting Procedure 1．Overview This is the definition of the registration procedure of the supplier's Personnel Responsible of Quality / Environment Control based on Yazaki requirements on Quality / Environment.



2．Qualifications and Registration of Personnel Responsible of Quality Assurance/Environment The appointed personnel shall have the following qualifications. Also, it is required to choose personnel who can be contactable in any emergency case including night time and holidays. (1) The top management of quality assurance, environment and production preparation respectively shall either be the President of the supplier or a person who is delegated with responsibility and authority in the areas of quality assurance, environment and production preparation by the President. (The person shall, in principle, have a position of director or higher) (2) The personal responsible for quality assurance, environment and production preparation respectively shall be those who can substantially lead in the areas of quality assurance, environment and production preparation (director, department manager or a person at the equivalent position). The PERSONNEL RESPONSIBLE shall be completely capable, responsible, and familiar with the daily activities of Yazaki, as well as having the capacity to instruct/train other personnel. (3) The persons in charge of quality assurance, environment and production preparation shall be those capable of substantially taking action in the areas of quality assurance, environment and production preparation and are selected whenever necessary.



3．Forms "[YKQ-001-**]Notification of Responsible Person and Person in Charge of Quality Assurance" "[YKQ-002-**]Notification of Responsible Person and Person in Charge of Environment" "[YKQ-101-**]Notification of Production Preparation Managers, Personnel"



4．Notification The persons in charge of quality assurance, environment and production preparation shall be selected and report using the above forms to Yazaki Quality Department. While reporting, quality assurance organization chart which identifies the position of the person in charge should be attached. Also, in a case that any change of the organization chart, the updated information shall be reported.



5．Submission 5-1 Submission Period Every June 21 regardless of the start or change of business, and within one month from a date of change. (If June 21 falls on a holiday, the next operation day) 5-2 Submission Method and Attention Media



:



Attention :



Electronic data Audit Department or overseas bases in Yazaki



-31-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-2A] N-tier Supplier Management Procedure 1. Overview It specifies the procedure for appropriate management according to the importance of the product (part) to improve quality when the supplier consigns production processes to N-tier suppliers.



2. Definition of N-tier supplier The second and subsequent suppliers are called N-tier suppliers in case that the supplier consigns a part or all of production processes to external companies. The N-tier supplier includes heat treatment, painting, plating, and other finishing process providers. Application is needed for welding, soldering, heat treatment and adhesion as special processes.



3. Restriction on use of N-tier suppliers For parts subject to IATF 16949, "S" parts and "A" parts among parts which need to pay attention and important parts, consignment to N-tier suppliers is not permitted in principle. (It is permitted when the use of the N-tier supplier has been applied and approved by Yazaki in advance.) However, when suppliers cannot produce or process important control parts or important parts that need special processes, the parts can be consigned to the N-tier supplier by advance application to Yazaki. Except for the above, for newly ordered products (parts), the supplier shall clarify the N-tire supplier which is planned to consign and report to Yazaki, when preparing an estimate for the new product (part). * Approval procedure before order receipt In principle, for products which are restricted to use, consignment to N-tier suppliers is not permitted. When consigning them from necessity, the supplier shall conduct process audit of the N-tier suppliers based on [YKQ-064-**] Concern of Components - Process Inspection Check Sheet and apply for the consignment providing the audit results. (Application shall be carried out even if it is registered in the following procedure.)



4. Development of quality control standards to N-tier suppliers The supplier shall clarify the quality control standards required for the N-tier supplier and develop them in writing. The supplier shall take actions as necessary to ensure that Yazaki quality control standards (this Manual) are satisfied.



5. Application procedure for use of N-tier suppliers When consigning to a new N-tier supplier, the supplier shall confirm in advance that the N-tier supplier conforms to Yazaki quality control standards (this Manual). The supplier shall enter the designated items in the forms "Notification of Secondary or Tertiary Supplier", "TierN Supplier Business Survey" and "List of Enrollment Tier N Suppliers", and submit them together with "Process Check Result" and "Quality Control Standard Check Result" conducted by the supplier to Audit Department in Yazaki. When a special process is used, forms shall be identified with colors. Also, in order to clarify the consigned part number, the supplier’s main equipment and the consigned part number shall be listed in "Tier N Consignment Part Number List".



6. Examination of N-tier suppliers Yazaki will check the documents submitted by the supplier and conduct process audits as appropriate to examine them. Concerns pointed by Yazaki for improvement will be listed in "Process Audit Result and Improvement Request" and notified to the supplier. Also, "Tier N Consignment Part Number List" shall be updated each time its content is changed.



7. Implementation of evaluation and audit for N-tier suppliers Suppliers shall evaluate the N-tier suppliers periodically (one or more times per year). At least the following items shall be evaluated and the evaluation process shall be documented. 　(1) Compliance with the product requirements 　 (2) Number of cases defective parts were shipped out 　 (3) On-time delivery rate 　 (4) Number of cases special transportation cost occurred An annual plan shall be prepared for the audit of the N-tier supplier depending on evaluation results and the occurrence of defects, etc., and the on-site audit shall be carried out on a regular basis. => Refer to "[Appendix 5A] Supplier Audit".



-32-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-2A] N-tier Supplier Management Procedure 8. Implementation of receiving inspection of products manufactured by N-tier supplier The supplier shall conduct receiving inspection to confirm that the parts consigned to the N-tier suppliers have been manufactured with no quality problem. (Part/product No., quantity, order numbers, inspection report, appearance, etc.)



9. Management method when consigning new products When consigning new products to N-tier suppliers, the supplier shall carry out production preparation activities equivalent to those performed in the supplier, give guidance, and periodically follow-up the production preparation status of the N-tier supplier.



10. Submission 10-1 Submission timing The supplier shall control "TierN Supplier Business Survey", "List of Enrollment TierN Suppliers" and "TierN Consignment Part Number List" in order to submit them immediately upon request from Yazaki. Also, when starting a new transaction, the supplier shall submit "Notification of Secondary or Tertiary Supplier" together with necessary documents three months before the start of business and new order placement, or seven months before the process change. The procedure shall be completed before the process change is applied. 10-2 Submission method and attention Number of copies



:



1 set (Electronic data)



Attention



:



Audit Department or overseas bases in Yazaki



10-3 Document to be submitted "[YKQ-003 -**] Notification of Secondary or Tertiary Supplier" "[YKQ-004 -**] TierN Supplier Business Survey" "[YKQ 005-**] List of Enrollment TierN Suppliers" "[YKQ-006-**] TierN Consignment Part Number List" "[No designated form] Process Check Result" "[No designated form] Quality Control Standard Check Result" "[No designated form] Quality Control Standard Check Result" "[No designated form] System Audit Result"



-33-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-3A]　Document and Record Management Procedure 1．Overview This procedure defines the Document/Record Control at the supplier.



2．Purpose The supplier shall aim to have proper information control, retention of information released from Yazaki, and aim for the reliable communication with relevant departments. (including overseas locations).



3．Scope of application This is applicable to the necessary records to be used in the Quality Management System, the supplier internal Quality Management System documents, other internal documents as well as external documents such as technical specifications, etc. and quality records released from Yazaki.



4．Document Control 4-1 Internal Document Control (1) Create document/standard guideline. When document/standards are created, list up the names of required documentation. (2) To approve the appropriateness before issuing the documents. (3) To conduct review, renewal, re-approval of documents. In addition, when any changes made to the documents, distinction of the changes made and also the revised editions is to be made. Obsolete versions shall be kept by electronic media, etc. so that revisions can be seen. (4) The relevant edition of the documents shall be kept such that it can be used whenever and wherever necessary. They are to be submitted promptly upon request from Yazaki (5) Appropriate control is needed for obsolete documents not to be used by mistake. In case that those documents are kept, identify them properly. (6) When documents are issued or revised, deploy them to related departments in the supplier and control the distribution of the documents. (including overseas bases). (7) To clarify the external documents and control the distribution of the documents. (8) Documents, such as standards, certificates and documents relevant to production preparation, shall be kept for 20 years from their invalidation.



4-2 External Document Control (1) Content confirmation and distribution management: Prompt confirmation of content and spreading to internal relevant Depts. (including overseas offices) are to be carried out. (2) Revision of internal documents: In the event of changes to Yazaki technical specifications etc., the relevant internal documents are to be revised. (3) Internal documents approval: In the event that changes to the technical specifications affect the documents approved by Yazaki, they need to be approved again. (4) Records for production change date: The dates for changes related to production are to be recorded. (5) Secret document control: With regard to the secret documents released from Yazaki, secrecy shall be kept with identification.



5．Record Control 5-1 Record Control (1) The records shall be kept in the state of readable, easily identifiable and retrievable. They are to be submitted promptly upon request from Yazaki. Reporting system within 2 hours shall be established. (2) Necessary controls are to be carried out with regard to record distinction, retention period, protection, retrieval and disposal of records.



5-2 Retention of Quality Record The basic retention period of the quality records is at least 20 years. However, the requests from the customers are to be satisfied with regard to products with customer requirements. A set of documents concerning a serious accident involving injury, death or property damage in the market or the handling of recalls shall be kept permanently. Such data shall be kept in the form of paper or electronic data. In case of keeping them in the form of electronic data, a backup system shall be established to prevent any loss. -34-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-3A]　Document and Record Management Procedure 5-3 Specification as Quality Records This is applicable to necessary records to narrow down the subjected parts when any market claim or recall occurs. The quality records shall be all records that provide traceability and summarized into a list of quality records. In case of addition of a new process, the process shall be added promptly. Quality records: Mandatory:



Work record/Daily report (machine or equipment no./operators/material lots/molding conditions), equipment check sheet, abnormality handling, sorted/reworked part records, manufacturing conditions, production history (quantity, actual working hours), in-process defects (defect phenomenon, quantity, disposal check), inspection certificates, receiving inspection records, shipping records, process patrol records, die/mold history (maintenance, cleaning, repair), inspection records, change records, ledger of stock arrival and delivery, training records, barcode matching results, inprocess operator handover memos (notes), history of purchase of indirect materials (type, quantity), records on abnormality, changes or quality defects for each plant (quality defect notification, recurrence prevention report), records on control and calibration of measuring devices, regular inspection records on measuring devices (daily/monthly/annual), working standards



Recommended: Waveform data of molding machine, monitoring video or photos



6．Document Control Standard Compilation to QMS The control procedures shall be implemented in accordance with documented supplier internal standards.



-35-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-4A]　Employee Training Management Procedure 1．Overview The supplier shall provide employees, including persons responsible for processes and managers, with employee training so that they can acquire knowledge and technical skills required for their job duties and improve their personality and productivity.



2．Training Plan The supplier shall understand the current skill level per position of each personnel with a skill map and set up a goal for each. The training shall be implemented systematically to achieve the target.



3. Training Materials Customers' needs and regulation requirements should be included in the training materials. Defects or problem examples shall also be included in QA materials. The materials should be easily comprehended.



4． Training Implementation 4-1 Basic Training, Safety Training Training on the company rules and regulations, and safety for personnel, is to be implemented. * Personnel: Regular personnel, part-time, trainee and temporary personnel (including contracting personnel) employed in operations.



4-2 Training and Evaluation of Workers (1) To implement the training for the actual job procedure and confirmation based on work procedures and standards. (2) Please use visually appealed materials such as movies and images, which will help the trainees comprehend the process. (3) Clarify accreditation criteria, provide operators and inspectors with adequate training, and evaluate their skill before the start of their job duties. (4) The superior shall periodically check to see if operators and inspectors perform their jobs properly, provide re-training, if necessary, and evaluate or confirm that they have achieved a necessary skill level. (5) For operations that require external qualification, identify such operations and make a list to ensure that qualified persons are assigned to the operations. (6) For operators of "S" and "A" rank products, the supplier shall use an accreditation system to ensure that operators who have an accreditation card with them are engaged in particular operations. If several accredited operators are assigned to a particular operation, the supplier shall manage them so as to ensure a smooth production. * In case of personnel changes, an application for the process change is required. (7) Operations performed by a trainee during a training period shall be recorded as change points to ensure that the trainee can achieve the level of necessary skills. (8) In case of absence from a particular job for more than one month, re-training shall be provided as a change point and the skill shall be re-evaluated.



4-3 Quality Control Training (1) Conduct the required quality control training for each level of associates, including general personnel, supervisors, managers, and top managements. Ex: Provide quality control training (such as dispersion, the level of unevenness, and process capability) to the production site section/group leaders. (2) Conduct training on the IATF 16949 and ISO 9001 quality manual



4-4 Technical Skill Training To be acquired with the job-related specialty technical skills and obtain the national official recognition and approval.



5． Retention of Training Records The supplier shall retain the training records of its personnel and be fully aware of the completed training status of the personnel. -36-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-4A]　Employee Training Management Procedure 6． Implementation of QC Circle Activities The control supervisor shall devise the training plan for the whole year and systematically implement training guidance for the QC circle activities which involves the participation in the supplier internal training and external seminars etc. periodically and the promotion of proactive improvement activities.



7． Environment Control Training (1) Conduct the required environment control training for each level of associates, including general personnel, supervisors, managers, and top managements. (2) To conduct training to enable taking appropriate actions corresponding to requirements of the environment laws and regulations of each country and the EURO directives. (3) The supplier shall endeavor to collect information so as to be always aware of environmental requirements set forth in laws and regulations.



-37-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-5A]　Changing Point Management Procedure 1．Overview The supplier shall clarify the control methods of change points, which may occur in the production process by taking a proper action and evaluation in order to prevent a problem with quality caused by change points.



2．Change Point The conditions of 4M (Man/Machine, Toolings/Material/Method) to produce good products change occasionally, which is defined as Change Point. Some changes can be predictable, others occur unexpectedly. 2-1 Intentional 4M Changes (Change is applicable as planned)



(1) Change parts due to a design change (2) Equipment condition change based on instructions. (3) New operators team up with in a production process. (4) Worn-out machines/equipment are replaced. (5) Equipment is modified or newly installed. Machinery parts are replaced. 2-2 Unintentional 4M Changes (Changes occur gradually or unexpectedly. Change is temporarily handled and then resumed)



(1) An out-of-order equipment or jig is repaired and then used. (2) Machines halt due to power outage or any abnormality and then resumed. (3) When any abnormality is found in a quality chart or a product, the operation is restarted with new 4M. (4) Unusual operators are deployed in the production process to support.



3. Change Control In order to manufacture good products consistently, proper action should be taken before or during any changes, regardless of whether it is intentional or unintentional. Change control is defined as preventive actions and should be taken. (1) Reassure that conditions for manufacturing good products are satisfied. (2) Verify the product quality is the same or better than the one prior to the change. (3) Reassure the change has no impact on the defect flow-out functions in the later processes.



4． Change Control Implementation 4-1 Definition of Change Points (Advance Preparation Stage) (1) Control items, which may affect quality, are decided per process. * Action or measures taken at the time of a change shall be specified in a flowchart or procedure in accordance with the "Change Point Control List". (2) Determine the forms/documents that are required. (3) Determine who/when/how to control (Person/timing/details). (4) Determine who will verify the correctness of the action or measures (person to check/evaluate). (5) The change must not have any impact on the normal manufacturing conditions to produce good products, which should be verified. Check the availability of flow-out preventive functions. (6) Establish communication methods of the later processes.



4-2 Important Points to Remember (1) In the preparation stage, change control methods should be examined and determined with consideration of actual implementation. (2) When a quality improvement action is taken, make sure to check not only for improvement points, but also to check for other relevant or irrelevant problems that may occur.



-38-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-5A]　Changing Point Management Procedure 4-3 Implementation In the event a change occurs, proper actions and evaluation should be performed based on the basic rule of the change control procedure. Make sure the process maintains good conditions, the manufacturing conditions are satisfied, the product quality is equivalent or higher than that of before change occurrence, and the defect flow-out preventive functions are not affected. (1) When design change is applied, change point control is implemented, evaluated and recorded based on "[Appendix 4-4-1A] Production Preparation Implementation Procedure". (2) When process change is applied, change point control is implemented, evaluated, and recorded based on "[Appendix 4-1-6A] Process Changes Procedure". (3) When any abnormality occurs, change point control is implemented, evaluated, and recorded based on "[Appendix 4-2-7B] Abnormality Handling Procedure".



4-4 Communication Network Communication network and the person in charge, in the event of occurrence of a change, should be identified. Information of the change shall be conveyed from the process in which the change has occurred to the shipping or inspection process, using actual products.



4-5 Action Plan The responsible persons (line leader, group leader, team leader, etc.) should comprehend the details of change points. He/She should take action, evaluate, and verify the change points based on the change point list. Manufacturing conditions should be satisfied to produce conformed products, Process should not be disturbed by the change, and the quality should be confirmed to be equivalent for higher than that of before change occurrence. Products manufactured at the time of the change shall be handed over to the next process after obtaining approval of the process supervisor. Any change of operators engaged in manufacturing any "S" or "A" rank products shall be preliminarily applied to Yazaki in accordance with the Process Change Procedure. The supplier shall make necessary considerations to ensure a smooth production of "S" or "A" rank products.



4-6 Recording Change Point Log should be created in order to record actions, evaluations, and verification results. The person in charge should verify that there are no mistakes or errors in the recording.



4-7 Visualization Actual current production process should be visualized by using QA board and Change Point control board. The layout of a process, distribution of personnel, personnel skill map, Change Point Control List and the results of action (records/products) shall be posted at the process for visibility.



4-8 Archive A defect occurrence in the later processes should be recorded and archived in order to identify if the change point caused the defect or not. The record shall be handled as a quality record and kept for more than 20 years.



5．Documents "[YKQ-061-**] Change Point Control List" "[Any form] Results of Confirmation of Change Points"



-39-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-6A] Process Change Procedure 1. Overview This procedure defines reporting method to Yazaki and procedure in case of process change.



2. Timing and submission of process change Process change shall be implemented after obtaining customer approval. In emergency case, process change is applied after the schedule is determined between the supplier and relevant departments in Yazaki. Since the time required for approval is different depending on customers, the application shall be submitted based on the supply chain in accordance with customer rules. Prior coordination department: quality projects/issues=> Quality Department, Cost related matters => Cost Control Department, delivery related matters => Procurement & Supply Department, in Yazaki * Depending on the content of the process change, re-evaluation may be required.



3. Scope of change When the following change is applied to a mass-produced product, process change application is required to submit. * It is called mass-produced product that the product has passed initial sample inspection after release of the mass-production drawing, and applicable to the followings. A When changing the personnel in the process manufacturing "S" rank product · When changing a worker in an important process * Process is controlled not to affect production and quality, and education/training plan is devised and submitted.



B When changing materials · Material changes requiring changes in drawings and specifications (Prior approval shall be obtained from the design department ) · Changes that do not require changes in drawings and specifications Example: Changes related to SOC and chemical manufacturers (rubber mixing recipe change) etc. (Based on "Material Delivery Specification Exchange Procedure", approval of the design department shall be obtained in advance using the Internal Design Change Request.) · Adoption of new materials (to be considered as design changes in the Internal Design Change Request) * When any design will be changed on procedural grounds, it shall be changed based on the design change procedure. (It is not necessary to submit a process change application.) If it is considered as a process change, a process change application shall be submitted with an evidence approved by Yazaki Design Department. (Including rust preventive oil, and lubricating oil, etc.) C When changing a material manufacturer or a design category (internal or external Yazaki) · When changing a material manufacturer, "Design Change Request" shall be submitted to Yazaki and the change shall be dealt with by design change. (It is necessary to change the material number described in the drawings.) D When changing a quality control value · Change the items listed in the inspection standards (increase or decrease) · Change the control values of upper and lower limits, frequency, measurement positions and procedures in the inspection standards E When equipment, indirect materials, jigs or tools related to manufacturing the product is built, renewed, modified, added or changed · Newly building or upgrading of manufacturing equipment · Change of inspection jig or measuring equipment (measuring tools) · Change of materials directly used for parts (paint, sealing material, welding) · Change of automatic measuring instruments (automatic leak tester) · Change of indirect materials F When changing a manufacturing process of component parts · Process change of components (regardless designed by internal or external Yazaki)



-40-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-6A] Process Change Procedure G When changing a manufacturing methodology · Adoption of a new manufacturing methodology · Change from manual work to jig, machine or the like · Plating method (pretreatment / plating method), heat treatment method, press method, injection molding method, welding method Cutting method (processing criteria, allowance, etc.), press-fit, crimping method, automatic tightening (assembly sequence, assembly method) In-line measurement (change of measurement method), cleaning method, soldering method, seal application method (application pattern etc.) Processing and assembly check (detection of model detection, detection method), FP (detection method), Automatic assembly (assembly sequence, assembly method) Marking method (stamping method etc.), adhesion method etc. H When changing a processing condition · MPPS change (addition, integration, order change, abolition, etc. of processes) · Molding/press conditions of resin, metal or rubber parts · Heat treatment conditions (processing, temperature, time, etc.) · Manufacturing conditions such as welding, cutting, plating, coating and assembly · Soldering conditions (temperature, time, flux) · Change of the amount of materials directly used for products (paint, sealing material, welding material) · Change of the amount of indirect materials (rust preventive oil, cutting fluid, etc.) I When making a change regarding the environmental requirements J When changing a mold [addition, renewal, modification] · Modification of mold: mold piece rebuilding, mold piece structure change · Change of the number of cavities (including the change of acceptance from limited to all cavities, gate block) · Mold structure, gate method, number of gates, gate shape, extrusion method, polishing, etc. K When changing the work shift · Change of work shift in production (Single shift to double shift, etc.) L When changing a packing specification · Change of packing quantity per box, packaging materials, etc. · Addition of packing specification * When changing the packing quantity per box, make sure to get an approval from Procurement & Supply Department in Yazaki in advance. M When changing the production location Production transfer between companies or production locations · From the N-tier supplier to the supplier or to an another factory of the supplier, domestic factory from/to overseas factory of the supplier · From overseas factory to an another overseas factory of the supplier, the supplier from/to an another supplier, etc.



* When adopting a new N-tier supplier, actions shall be taken according to "[Appendix 4-1-2A] N-tier Supplier Management Procedure. * For overseas factories, only the ones that are completed a system audit by Yazaki can be applied for production transfer. · Change of production line (including inspection process) · Building of a new or a temporary production line (including inspection process) N When changing logistics · Change of transportation method, transition method, inter-process transition method and transportation route



-41-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-6A] Process Change Procedure O Others · For any changes except for the above, it is required to apply after deep consideration of standard reporting to the customer, effect level to quality and production performance in the past, etc. * Process change and drawing change of new parts shall be made according to our instructions according to "[Appended Table 1] Pre-Preparation Management Flowchart." * For the items subject to FTA (Free Trade Agreement), a signature is required in the certificate of origin in some cases.



4. Product/process classification A Important part B Special process [welding, soldering, heat treatment and adhesion] C General part (products other than A and B) Mark the applicable item with circle.



5. Process change procedure 5-1 Method In planning a process change, the supplier shall issue "Advanced Change Information (for process change)" and discuss with Yazaki related department in advance. After the coordination, evaluation shall be performed prior to the change by using "Check Sheet for Prior Confirmation for Process Change" and "List of Process Change Change Point Confirmed Result". When there is no problem in the evaluation results, a concrete schedule shall be clarified by using "Process Change Application", "Process Change Implementation Plan PC Sheet" and "Report on Chemical Substance-Related Regulations in Transfer Destination Country". Those documents are created after all items are determined with Yazaki. The contents shall be described so that change contents can be understood for each part number and mold. 5-2 Description procedure (1) "Advanced Change Information (for process change)" The supplier shall enter the order handling department, Yazaki part number, part name, drawing type (M/P), written specification, customer name, customer part number, purpose of change, change content, reason for change, scheduled date of change, scheduled date of changed part delivery, change details and delivery results in the past three years in this sheet. (2) "Check Sheet for Prior Confirmation for Process Change" Part number, part name and necessary items shall be entered and checked based on the concrete implementation items of the check sheet. Check results shall be described in "evaluation/examination result" field. Problems and implementation items responding to the change shall be described. (3) "Application for Process Change and Regular Production" Part number : Describe the part number and part name of the part subject to process change. and part name When there are many subjected parts, describe the representative parts and attach a separate list for remaining parts. Change item



: Mark the applicable change contents with circle.



Reason for change



: Explain the reason for the process change and attach supplementary explanation, data, sample, photo, etc. as appropriate.



Possible implementation date



: Describe the possible implementation date according to the process change schedule.



Delivery destination



: Check the delivery destination code and name on a part number basis and describe them.



(4) "Process Change Implementation Plan/Progress Control Sheet" Manufacturer



: Describe the car maker name.



Car model code : Describe the car model code.



Item



: When changing a process, make an implementation plan for necessary items and describe them. * Discuss with Yazaki in advance to determine the schedule, if necessary for some items.



Schedule control : Clarify input, lead time and output, and describe the department in charge. Department in charge



: Describe the department responsible for promotion within the supplier.



Master schedule : Describe the master schedule for the change.



Schedule (Plan) : Make an implementation plan for the supplier and describe it. Schedule (Actual) : Describe the actual date. (Document of process change approved)



(5) "List of Process Change Point Confirmed Result" Describe the vehicle model and the part number. This form shall be prepared for each part number. * Attach supplementary materials as appropriate. Check whether there is any change, and if there is a change, describe the contents before and after the change, actions to be taken and assurance methods.



-42-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-6A] Process Change Procedure (6) "Report on Chemical Substance-Related Regulations in Transfer Destination Country This form shall be also prepared when transferring materials and indirect materials when the process is transferred to an overseas factory. It is not required to prepare this form when only the mold is transferred, materials and indirect materials have been already used in the transfer destination and it is obvious that the chemical substances related laws and regulations of the country/region of the transfer destination have been observed. Transfer destination country : Enter the country to be transferred.



Production start time



: Enter the mass-production start date at the location transferred



Part name & Applicable part Nos.



: Enter the part name and part number subject to process change.



Material name



: Enter the material name used for the subjected part.



Delivery destination



: Enter the customer or Yazaki base where the subjected parts are delivered.



Regulations in transfer destination



: Check that the parts subjected to transfer does not contain any chemical substances which are banned in the country transferred to.



Result of confirmation related regulations in transfer destination



: Check the checkboxes corresponding to the investigation result whether it complies with regulations.



Confirmed items, if "No problem"



: Check the checkboxes of applicable country and regulation confirmed.



Regulation that may be violated, if "Problem found" * Items in



: Check the checkboxes of applicable country and regulation confirmed. Also, enter the concrete descriptions that conflict with the laws and regulations.



shall be filled by Yazaki.



6. Procedure for transfer between domestic and overseas bases Except for overseas transfer based on the conditions at the time of new estimate, when transferring molds or processes between the domestic and overseas bases, "Confirmation Request for Production Site Change" shall be submitted to Yazaki in advance to obtain prior approval. This document shall be submitted as an attached document at the time of submitting the Process Change Application. Submit to: Cost Control Department in Yazaki



7. Precautions when transferring mold and production equipment to domestic and overseas bases When starting a new mold and production equipment, or when transferring production after mass production, attention shall be paid to the following contents and conduct production preparation activities so that the quality and productivity do not deteriorate due to the 4M change. When designated by Yazaki, initial control activities shall be developed. In order to remove the wall and nuance of the words of the transfer destination and the transfer origin, technicians and workers shall visit the transfer origin before transfer, understand the forms intended by the transfer origin (Manufacturing Process Plan Sheet, Work Procedure, Molding Condition Setting, Inspection Point Sheet, Judgment Standard, etc.), do actual work, and prepare building related forms jointly. Two sets of the same forms (Japanese and local language) shall be prepared. For final confirmation, the transfer origin shall visit the transfer destination and confirm that things are equal to those before transfer.



8. Process change prohibition period In principle, process change application is not accepted within four months after the vehicle L/O. * Details shall be based on the customer requirements.



9. Submission 9-1 Submission timing When the change application period differs depending on the customer, the customer’s requests shall be prioritized for details and it shall be submitted in consideration of the period of application from Yazaki to the customer. 9-2 Submission method and attention Submission method:



One copy (original) or electronic data



Attention:



Quality Department or overseas base in Yazaki based on supply chain



9-3 Document to be submitted "[YKQ-007-**] Application for Process Change and Regular Production" "[YKQ-008-**] Process Change Implementation Plan Progress/Control Sheet" "[YKQ-094-**] Report on Chemical Substances- Related Regulations in Transfer Destination Country" "[YKQ-062-**] Check Sheet for Prior Confirmation for Process Change" "[YKQ-067-**] List of Process Change Point Confirmed Result" "[YKQ-092-**] Advanced Change Information" where the answer fields of the delivery destination are filled Overseas transfer due to circumstances of the supplier: approved "YKQ-055-**] Confirmation Request for Production Site Change" At the time of starting the mold (additional/renewal): approved "[YKQ-046-**] Application for Die When changing a packing specification: approved "[YKQ-031-**] Packing Specification" -43-



(Addition/Renewal/Cost Reduction/Disposal)"



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-6A] Process Change Procedure 10. Judgment Upon approval of the process change, Quality Audit Department in Yazaki shall accept the application after confirming the contents and instruct necessary items. When the process change is impossible, the supplier shall discuss with Quality staff in Yazaki separately to examine the best method.



11. Product shipment When application to the customer is required to ship the products, the supplier shall obtain customer approval in cooperation with Yazaki before shipment.



-44-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-7A] Initial Component Supply Notice 1. Overview It specifies the definition of initial part delivery and necessary procedures. It aims to ensure early process stabilization, appropriate quality and prevention of quality problems by conducting secure production preparation activities.



2. Definition of initial product and Subjected product Initial part mean initially produced part as follow; (1) Newly ordered part (2) Part subject to design change (3) Part subject to process change (4) Parts designated by quality management in Yazaki



3. Delivered first parts 　The supplier shall carry out the procedure as shown in the table below when delivering initial parts. Table 1 Documents to be submitted Document Initial Component Supply Notice [YKQ-009-**] Initial Component Supply Notice (Prenotice/Information) Initial Component Supply Notice [YKQ-009-**] Initial Component Supply Notice (Prenotice/Information))



* Evidence means the Process Change Application/Flow Permit, Change Notice, Packing Specification Change/Addition Prior Check, etc. approved by us.



Timing



Submit to



The pre-notice shall be submitted without the date of shipment and the number of parts to be delivered. * The change contents shall be written in both Japanese and English. * Attach the evidence.



Issued when new/changed parts are finalized



Audit Department in Yazaki and delivery destination (including overseas bases in Yazaki): One copy (original) or electronic data



Enter the date of shipment and the number of parts to be delivered in the pre-notice issued at the time of determining the delivery order and then issue it. * The change contents shall be written in both Japanese and English. * Attach the evidence.



First delivery for each delivery destination



Contents



Form



Number of copies



Designated by Electronic data Yazaki Audit Department in Yazaki and delivery destination (including overseas bases in Yazaki): One copy (original) or electronic data



Attach the Packing Specification (approved).



First delivery of new/changed part



Indication of new part



Indicate "new part" on outer boxes and slip sheets in which the designated items are listed.



From the first shipment to two months after the examination of transition to mass production



Indicate "new part" on delivery slip and outer box



Designated by Yazaki Refer to "5. Indication of initial part"



---



Design changed part



Indicate "design changed part" on outer boxes and slip sheets in which the designated items are listed.



Two months from the first delivery



Indicate "design changed part" on delivery slip and outer box



Designated by Yazaki Refer to "5. Indication of initial part"



---



Initial sample



Submit the same piece which is measured dimensions.



When requesting initial sample inspection



Production Preparation Department or overseas bases in Yazaki



---



---



Submit the Inspection Report for all initial parts. Conduct inspection based on the drawings provided by Yazaki in advance.



When requesting the initial sample inspection



Production Preparation Department Designated by or overseas bases in Yazaki Yazaki



[YKQ-034-**] Inspection Report



[YKQ-007-**] Application for Process Change and Regular Production



Process change indication



Seven months before process change



When changing a process, be sure to submit it in advance for checking.



Indicate "process changed part" on slip sheets and outer boxes.



[YKQ-029-**] Obtain approval for the inspection contents of newly Parts Inspection Standards ordered parts and design changed part.



Two months from the first delivery



When requesting the initial sample inspection, When changing the design



-45-



1 copy



Production Preparation Department Designated by Electronic data or overseas bases in Yazaki Yazaki



Indicate "process changed part" on delivery slip and outer box



Designated by Yazaki Refer to "5. Indication of initial part"



---



Production Preparation Department Designated by Electronic data or overseas bases in Yazaki Yazaki



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-7A] Initial Component Supply Notice 4. How to issue "Initial Component Supply Notice (Pre-notice/Information)" (1) New parts and products The forms shall be issued when new/changed parts are finalized and before those parts and products are shipped to the customer. (2) Parts and products subject to design change (including changes requested by the customer, Yazaki and the supplier) A. If the revision code "□" is changed, and "ALL" is ticked in "Initial Component Supply Notice" field in the New Revised Notice of Part Number and Component Drawing (hereinafter called "Design Change Notice"), the Prenotice and the Information of Initial Component Supply Notice shall be issued. Example:



A



1



B



2



B. If the revision code "△" is changed and "YAZAKI GROUP ONLY" is ticked in "Initial Component Supply Notice" field in the Design Change Notice, the Pre-notice of Initial Component Supply Notice shall be issued to only Yazaki factories. Example:



A



1



A



2



C. Even if the revision code is changed, but "NO" is ticked in "Initial Component Supply Notice" field in the Design Change Notice, the Initial Component Supply Notice is not submitted.



(3) Parts and products subject to process change 　　When it falls under the following cases, the Pre-notice and the Information of Initial Component Supply Notice 　　shall be issued. A. Change between bases B. Change of supplier C. Change of suppliers of materials and parts D. Change of construction method E. In addition, when Quality management in Yazaki judges that it is necessary to issue the forms.



5. Indication of initial part Indication is required to relevant parts and products. However, for the products directly delivered to car maker or designated destinations, the instructions shall be followed. (1) Indication method In case of 4 (2) B, any of "new part", "design changed part" or "process changed part" is indicated on packages of minimum unit and outer boxes. A. In principle, the indication on packages of minimum unit shall be made with a rubber stamp. B. In principle, the indication on outer boxes shall be made with the specified adhesive tape. However, due to the preliminary coordination with the delivery destination, indication of "new part" and "process changed part" may be omitted. Also, for 4 (2) B and C, indication is not necessary. C. In conjunction with the change of the revision code "□" and the design change code "△" in a drawing, change the notation on the SHIPS label. * As for the setting method on SHIPS, inquire appropriately to Procurement & Supply Department. (2) Indication period Indication is applied to parts and products produced during the first two months after the startup of massproduction or the change was applied to them. However, due to the preliminary coordination with the delivery destination, the indication period may be shortened.



-46-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-7A] Initial Component Supply Notice



Method



Outer box



Inner package



Put the specified tape on the box.



Indicate it on slip sheet by stamping, printing, etc.



Display method Display classification



Color Design changed part



Tape



Color



REVISED COMPONENT



Red



Size



Blue letters on white Process changed background



Stamp L



Red letters on yellow background



New part



Size



L = 105 mm x W = 30 mm



part



NEW COMPONENT



Blue



W



REVISED COMPONENT



L = 45 mm x W = 15 mm



NEW COMPONENT



PROCESS CHANGE



PROCESS CHANGE



L



Part number 品　番



REVISED COMPONENT



W



数　量 Quantit ロット Lot



Model number



Inspection 検　査



Remarks 備　考



型　番



△



[Code [CodeNo.] No.]



Indication period



After two months from the first shipment, the indication and issuance of the Initial Component Supply Notice are not needed, even if the parts are shipped to other bases in Yazaki.



The indication shall be provided by the supplier. Obtain the evidence of the SOC analysis and confirm that there is no problem while observing the instructions above. * Reference: Contact for purchase of the display tape Synthetic Resin Section, Chemical Product Sales Department, Suzuyo Shoji CO., LTD TEL: 054-663-9277 FAX: 054-663-9278 Suzuyo Shizuoka Building 7F, 1-3 Sakae-cho, Aoi-ku, Shizuoka city, Shizuoka 420-0859



6. Submission of "Initial Component Supply Notice (Pre-notice/Information)" 6-1 Submission method and attention Media:



Electronic data



Attention: Submit to IN-IN IN-OUT OUT-IN



Audit Department in YAZAKI



OUT-IN-OUT Purchasing in Yazaki and delivery destinations (including overseas bases in Yazaki) OUT-OUT * Issue directly from local suppliers to the local delivery destinations of YAZAKI



-47-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-8A] Production Part Approval Process Implementation Procedure 1．Overview If there is a requirement of the Production Part Approval Process based on IATF 16949 from Yazaki customers, the supplier shall implement action, retain or submit necessary documents/records based on the requirement. The action shall be properly taken and maintained. When any changes are made, the same action is required.



2．Scope The applicable part is specified by Yazaki based on the requirements of IATF 16949



3．Definition Production Part Approval Process (hereinafter referred as PPAP) is a process to confirm whether the required specifications and process capability of the processes of the supplier who manufactures the parts meet customer requirements.



4．Words Definition Master Sample: Samples to measure the dimension for PPAP approval.



5．PPAP Requirements When PPAP is required by Yazaki, the supplier shall implement PPAP based on the listed items below. (1) The PPAP parts shall be picked under the actual production (mass production base, prescribed production efficiency, mass production tools, mass production gauge, mass production process, mass production material, mass production responsible operators). (2) The PPAP parts shall be picked after production process is verified. Unless required by customer, they shall be sampled from more than 300pcs., continuous in production for 1 to 8 hours. In the event that necessary production volume can't be prepared, the supplier shall coordinate with Yazaki Quality Assurance PIC. (3) The level 3 PPAP shall be prepared unless Yazaki assign. (4) PPAP shall be implemented ,and retained or submitted items shall be continuously managed based on each P/N AND customer. The supplier should compile list etc. to manage Yearly Layout update and PPAP data. (5) Old and new PPAP document should be saved in the same file (electronic data is acceptable). (6) PPAP data shall be retained for 1year after the period that the products are necessary for production and service is terminated (retained for 1year after corresponding parts have been terminated) (7) In the event of change as follows, the supplier shall inform Yazaki at Initial Sample Inspection or before production kick-off. *Followings are the items that require PPAP update. 1) Correction of deviation for parts submitted previously. 2) In the event of Yazaki assignment due to design change period. 3) Production with new or modified tools (except expendable tools), molding die (added, renewed, modified), pattern etc. (including added tool or exchanged tools). 4) Production with tools or equipment that are transferred from/to other site in the factory. 5) Change of parts, nonequivalent material or service (heat treatment, plating, etc.) that affect customer specified assembly, visual, function, durability. 6) Products produced with tools that haven't been used for production for over 12 months (Re-operation of molding die, molding machine.) 7) Change of product or process relating element component of production parts that affect products assembly, appearance, function, characteristics or durability and are manufactured at supplier or subsupplier. 8) Change of test method, inspection method. 9) The Others; Specified by Yazaki that apply to process change. -48-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-8A] Production Part Approval Process Implementation Procedure (8) The supplier should keep master sample (sample after PSW approval) for the same period as PPAP data retention period. (9) In case customers are Big 3, PPAP should be prepared for new parts in advance even if not required. (10) Expiration date of PPAP data should be controlled. In case enough period is not left until expired, it's not



available even though it hasn't expired. ( Consult with Yazaki PIC)



6．Retention and Submission of Requirement based on PPAP The supplier shall implement and translate following items into English, retain the documents or records, and submit documents, upon request. In the event of changes to following items, the revised shall be submitted to Yazaki to re-apply PSW. 必要資料



№



対応部署



備　　考



Yazaki Development Yazaki Agreement with customer before approval of changes to drawings Development Yazaki Results of evaluation of customer's specification requirements Development Yazaki Development



1



Approved drawing (Design document)



2



Approval of design change (If applicable)



3



Approval of customer's engineering dept.



4



Design FMEA



5



Process flowchart



Supplier



6



(P)Process FMEA



Supplier



7



QC process flowchart (Control plan)



Supplier



8



MSA study



Supplier



9



Results of dimension measurement



Supplier



10



Material certification (Physical properties), Performance tes



Supplier



11



Process capability survey



12



Laboratory Manual



13



AAR (Appearance approval report on design portions)



Supplier



14



Product sample (for submission)



Supplier



15



Master sample (for keeping)



16



Checking aids



17



Record of compliance with customer specific requirements



18



Part Submission Warranty (PSW)



19



Bulk material check list



Supplier



20



Run at rate (Production capability)



Supplier



21



Other documents required by Yazaki



Supplier



Supplier Yazaki Purchasing



Analysis with measurement system (Application of gauge R&R of 4th edition, Cgmk)



Rules for controlling measuring devices



Samples for part evaluation



Supplier Yazaki Auxiliary apparatus for handling products set forth in specifications Development Supplier Yazaki Purchasing



ISO/TS16949 certificate (Record on customer's special requests)



-49-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-9A] Mass-produced Product Concession Application 1. Overview This Appendix defines a procedure for exceptionally delivering non-conforming products under prior agreement with Yazaki.



2. Conditions and Period for Deviation Permit Deviation Permit Conditions [1] The non-conformance in question meets performance (functional) requirements. [2] The non-conformance in question neither precludes assembly, fitting, processing or mounting nor reduces workability. [3] There is a high possibility of obtaining approval signature of the customer, Production and Developing Department. Deviation Permit Period The Deviation Permit period shall, in principle, end with the completion of permanent measures. The supplier shall clarify the period and quantity for Deviation Permit.



3. Procedure for Applying Deviation Permit (1) Fill in a "[YKQ-010-**]Application of Concession" with the content of application, reasons for the application, measures taken to parts after the Deviation Permit, and a schematic view of a portion applied for the Deviation Permit. (2) Prepare conforming parts and those to be accepted in application for Deviation Permit. (3) The supplier shall consult with Yazaki based on documents and samples (in a face-to-face interview). (4) Yazaki shall determine the acceptance or rejection in consultation with related departments and the customer. (5) Yazaki shall fill in and send a response form with the results. *



Deviation Permit Application is not approved for critical characteristics and important products (parts).



4. Submission 4-1 Submission timing Before shipping of applicable products * Take into account the schedule to examine with Yazaki



4-2



Submission method and attention



Number of copies: Electronic data before meeting Attention: Quality Department or overseas bases in Yazaki Sample: Comparative samples that enable comparison with conforming parts shall be also prepared. Method: Receive a decision in a face-to-face interview. Retention: Products approved for the Deviation Permit application shall be kept together with documents as reference samples.



-50-



Quality Manual for Suppliers 26th Edition



[Appendix 4-1-10A] Continual Improvement Implementation Procedure 1. Overview The supplier shall set up a quality goal in line with requirements for continuous improvements and continue to improve quality to achieve that goal.



2. Requirements (1) Chief Quality Officer, as the top management, shall implement continuous improvement by advocating it in policy or setting up goals. (2) The supplier shall make a plan to achieve the goals and perform improvement activities in accordance with the plan. (3) The management shall review the progress of the improvement plan regularly (monthly) and know how the goals are achieved. (4) The following items shall be set up as goals for improvement. • Enhancing the level of completeness of processes • Reducing variance in product characteristics, such as dimension, or manufacturing conditions in manufacturing processes. • Reinforcing the quality assurance system Corrective or preventive measures to enhance quality performance or meet quality requests Corrective or preventive measures taken in response to the results of audits Corrective or preventive measures taken in response to the results of deployment • Improving productivity (5) The improvement plan and its progress shall be submitted when requested by Yazaki.



3. Submission Submission method: Electronic data Attention: Quality Department or overseas bases in Yazaki Revision: To change a plan that has been already approved due to the occurrence of a defect, the supplier shall correct or add the corresponding portion and submit the plan to a person in charge of quality at YC for re-approval.



-51-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-1A] Lot Management Procedure 1. Overview It specifies concrete lot management methods in order to clarify the manufacturing history which is necessary to assure quality of parts ordered by Yazaki.



2. Definition of lot The size of the lot needs to be reduced to the extent that the supplier can control, but at the most, one lot shall be the production amount per day.



3. Definition of charge Charge refers to the size from the start of production to the end of production in continuous production.



Lot



Lot



Lot



Lot



Charge



4. Scope of application All products manufactured according to the drawings issued by Yazaki are applicable. Products designated as important parts, "S and "A" rank parts, etc. shall be managed according to separately specified standards.



5. Basics of lot management When any defect is found in products or parts, causes shall be pursued, the scope of measures shall be grasped and lot management (not charge management) shall be conducted in order to minimize losses. When conducting lot management, the following items shall be observed. (1) Material lot management: In the molding process, record the used material lot. (2) Molding lot management: For molded products, indicate the lot number in a slip sheet (3)



Assembly lot management:



For assembly products, indicate the lot number in a slip sheet Make it possible to trace the lot numbers of the used component parts from the lot number of the assembly part.



(4)



Inspection lot management:



Inspect parts per receiving as one lot and record the molding lot and assembly lot numbers.



(5)



Shipment lot management:



For each shipment and delivery destination, keep the lot number of the molded products and the assembled products in the shipping history.



6. Storage of reference sample In principle, the supplier shall keep first and final products of each lot per shot or mold as reference samples and store them for at least six months. However, if it is difficult to store them per lot depending on the size or production volume of the product, it is allowed to store them per charge per shot or mold as reference samples. In this case, however, it is required to discuss with Quality staff in Yazaki in advance. * For products manufactured in the construction methods such as progressive type, header type and cutting type, three first and final products per lot shall be stored as duplicate samples. * For male and female terminals, three pieces shall be sampled per reel and stored for at least three years. For each event during the production preparation period (for each customer event), one piece from shipped products shall be stored.



7. Implementation of trend management Suppliers shall inspect the first, middle and final pieces from the same lot to prevent defective products and parts. Trend management shall be conducted by using a statistical method such as Xbar-R control chart looking through the inspection records, for a functional position designated by Design Intention Report, etc., and the position is determined with Yazaki at the time of product launch. * Sampling frequency shall be stated for each lot and charge in "Parts Inspection Standard". -52-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-1A] Lot Management Procedure 8. Setting of lot number The supplier shall set lot numbers so that it will be easy to trace and search parts from manufacturing history. The lot number basically consists of the last two digits of the year, the month and the day of manufacturing, "-" (hyphen) after the date, and a serial number. Description examples 0 Christian era



6 Year



0



9



Month



1



1



Day



0



1



Addition number



9. Indication of lot number 9-1 Indication to part The supplier shall indicate lot numbers by a minimum packing unit so that the lot number of the parts can be identified. Necessary items shall be indicated in a slip sheet and it is attached on each inner package before shipment. 9-2 Indication on outer box The suppliers shall indicate lot numbers on a outer box in order to support first-in-first-out rule.



10. Shipping control The supplier shall strictly follow the first-in first-out rule for lot control when moving manufactured parts between processes and shipping them to the delivery destinations. Lot numbers and quantities shall be recorded per each shipping destination to enable lot traceability.



11. Control on delivery As a general rule, one box shall consist of products from the same lot number when products are packed. When it is unavoidable to pack products from different lots in one box, all the lot numbers shall be indicated on the box.



12. Control of incomplete number of products for one box Incomplete number of products for one box shall be stored separately by specifying the part number, quantity, lot number and design change level, with color-coded labels or using dedicated storage boxes, etc. When those products are shipped, they shall be re-inspected, packed with the first product manufactured in the next production, and shipped, indicating both lot numbers on the packing box. When a change such as a design change has occurred, it ensures that products less than one box do not remain in other warehouses or there is no product controlled separately such as a service product, etc., and a system to carry out the first-in first-out rule without fail shall be established. Incidentally, it is prohibited to pack the products which are before and after design change in the same box.



-53-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-1A] Lot Management Procedure 13. Description in slip sheet (label) It is essential to list the following items in a slip sheet (label). It shall be attached on an outer box. In case that parts are subdivided in the outer box, the slip sheet is attached on all of inner packages. For parts directly delivered to the finished car manufacturer, if there is an instruction to attach a slip sheet (label) designated by Yazaki, it shall be used. If there is no instruction, a slip sheet (label) stating the customer part number shall be used.



· Part name



· Quantity



· Inspection mark



· Part number



· Die/mold numbe · Remarks field



· Lot No.



· Supplier code



· Joint number (for reel products only) · Design change level (revision code) □ △



· Customer part number (directly delivered to the car manufacturer)



(Reference format)



Detailed Slip For general parts (resin and rubber)



For metal parts （品



名）



品



PART NAME



（品



□ △



番）



PART NUMBER



（数



数



量



QUANTITY



□ △



型番 DIE №



ロット



量）



LOT



QUANTITY



（型



番



PART NUMBER



検



番）



査



INSPECTION



備考 REMARK



DIE NUMBER



（ロット№） LOT’S №



For parts directly delivered to car manufacturer



（検査印） INSPECTION MARK



CUSTOMER NUMBER



（ジョイント数） JOINT’S №



（コード№） CORD’S №



（



）



Add a field that can describe the customer part number to the regular label.



14. Submission The slip sheet (label) shall be prepared and submitted when starting a new business or adding a new item to it. Media:



Electronic data



Attention:



Quality Department or overseas bases in Yazaki When items stated in the slip sheet (label) is changed, clarify the change and resubmit the following document.



Revision:



Documents to be submitted: "[YKQ-098-**] Label Report"



-54-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-1B] Traceability Management Procedure 1. Overview The supplier shall clarify the manufacturing history or other items for parts ordered by Yazaki which are necessary to assure quality for their traceability.



2. Requirements Traceability is defined as the capability to trace production history, such as raw material lot nos., processing lot nos., including those of subsequent processing, assembly lot nos. and inspection lot nos. from a key lot no. The supplier shall establish a system to respond to an inquiry about subjected shipment within two hours. To reveal how many parts were delivered to what destination and when from the key lot no., the system associates a P/O no. with a lot no. In other word, the system allows Yazaki to reveal who did what operation on how many parts when and what was the result.



3. Controlled Items In order to control the state of each process from the material receipt to the product shipping in a traceable manner, a key item to be associated with a lot no. shall be designated for each process so that the state of operation in each process can be traced from a lot no. marked on a slip sheet (label) after shipping. Type



Basic ASSY Outsourcing



Process



Control document



Manufacturing materials



Daily report



Order no.



Order no.



Material lot no.



Ordering materials



Order form



Order no.



Material manufacturer



Material name



Material no.



Quantity (Weight)



Receiving materials



Delivery slip



Order no.



Material lot no.



Material no.



Quantity (Weight)



Materiial certificate



Keeping materials Pulling materials from warehouse



Inventory ledger



Storage date



Material no.



Material lot no.



Quantity (Weight)



Operator



Inventory ledger



Pull-out date



Material no.



Material lot no.



Quantity (Weight)



Operator



Manufacturing



Daily report



Manufacturing Manufacturing Manufacturing Material lot no. Amount of feed Operator name date lot no. conditions



Inspection



Inspection record



Inspection date



Manufacturing lot no.



Inspected lot no.



Equipment



Total number Operator name of inspected



Packaging



Daily report



Packaging date



ASSY lot no.



Packing lot no.



Packing specifications



Manufacturing Operator name lot no.



Shipping



Shipping record



Order no.



Part no.



Packing lot no.



Quantity



Ordering assemblies



Order form



Order no.



Material manufacturer



Part no.



Quantity



Receiving assemblies



Delivery slip



Order no.



Assemblies lot no.



Part no.



Inventory ledger



Storage date



Part no.



Inventory ledger



Pull-out date



ASSY



Daily report



Pulling from warehouse Receiving



Keeping assemblies Pulling assemblies from



Surplus parts Abnormality Changes



Control item Manufacturing Manufacturing date site



Line name



Operator name



Quantity



Inspection report



Operator name



Assemblies lot no.



Quantity



Operator name



Part no.



Assemblies lot no.



Quantity



Operator name



ASSY lot no.



Inspected lot no.



Assemblies lot no.



ASSY equipment



ASSY conditions



Work instructions



Pull-out date



Part no.



Quantity



Due date



Work instructions



Receiving date



Part no.



Quantity



Number of red boxes



Additional lot no.



Quantity



Change record



Storage lot no. Pull-out lot no.



Common



Occurrence date and time



Isolation direction



Instruction of handling



Results



Occurrence date and time



Instruction of handling



Results



Handling record



Customer part no.



Label



Inspection report



Product lot no.



Sorting procedure



Reworking Product lot no. date and time



Rework procedure



Products directly delivered to



Check record Yazaki part no.



Sorting work



Sorting record



Rework



Rework record



Die/Mold



Maintenance record



Date mark



Monitoring camera



Electronic media



Time



Sorting date and time



Changing Repair history die/mold piece Pixel level



-55-



Material certificate



Operator name



Delivery destination



Surplus parts ledger Abnormality handling record



Equipment



Equipment Environment data



Environment data



Inspection with Operator name dummy sample



Environment data



Handling record



Restoration record



Indication of OK product



Quatity of OK product



Quatity of NG product



Indication of OK product



Quatity of OK product



Quatity of NG product



Maintenance history



Cleaning history



Reference samples



Application to Yazaki



Reference samples



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-1B] Traceability Management Procedure How to think



Control/Check method



When



Working hour



Break time



Number of pieces



Monitoring camera



Where



Manufacturing



Inspection



ASSY



Shipping



Outsourcing



Who



Operator name



Qualified personnel



Skill



Training record



Work ovservation



What



Equipment no.



Capability



Daily inspection



Periodic inspection



Calibration record



Why



Normal operation



Handling of abnormality



Work support



Rework



How



Working procedure



Working method



Work ovservation



Monitoring camera



How many



Accepted/rejec ted



Measuring devices



Measuring devices



First, middle and end samples per lot



Result



Work record



Inspection record



Judgement criteria



Reference samples



Image



Number of adjustments



Quantity of dropped part



4. Creation "Control document" shall be created for each process to clarify controlled items and verify their relevance when starting business with a new supplier or adding a process. In case of any changes to the process control, update the existing documents.



5. Submission The following document is created and submitted at the start of new business with Yazaki or a new item is added to a slip sheet (label). Method: Electronic data Attention: Quality Department or oversea bases in Yazaki Revision: When anything is changed, clarify the change and resubmit the following document. Document to be submitted: "[YKQ-099-**] Traceability System"



-56-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-2A] Raw Material Management Procedure 1．Overview The objective is to prevent problems arising from containment of restricted and dangerous materials, mixing of foreign materials, as well as to speed up actions to control the problems through clear definition of control standard and method of controlling the raw materials for implementation at supplier's end.



2．Scope of application It applies to suppliers who supply parts and products processed from raw materials to Yazaki.



3．Purchase of Raw Materials The purchase of raw materials is implemented as follows: (1) The supplier shall create the master lists integrating all information of the material number (which is designated in a drawing), material code (which is an order code of paid material designated by Yazaki) material specifications, and material suppliers. All raw materials should be designated on the drawing. (2) On arrival of the raw materials, the contents of the delivery invoice shall be compared with the delivered materials, and material name, grade number, dimension, lot number, quantity (weight) shall be checked. (3) "Material Certificate" shall be received together with the delivered materials. The measurement values are checked whether they are within the standard values, etc. with the certificate. (4) The supplier shall obtain and keep data which show that the material does not contain any dangerous material restricted by the customer. * SOC data for paid material designated by Yazaki shall be obtained from Raw Material Procurement Department. (5) The supplier shall obtain the purchase specifications (materials standards) from Development or Raw Material Procurement Department. to ensure that all the materials used are in conformance with Yazaki specifications.



4．Raw Materials Control The supplier shall control the raw materials according to the following points to control in-and-out history of raw materials as well as to prevent the mixing-in of foreign materials. * Control shall be performed to provide traceability. (1) Record of stock arrival and delivery (raw material name, Year/Month/Day, size, grade, weight, etc.) (2) Ensuring First-in-first-out rule (3) Lot Control (4) Identification, classification, prevention of mixing (of different material, foreign matter, dust etc.) (5) Does not contain restricted and dangerous materials (6) Storage and control of remaining raw materials which are once opened (7) Storage Environment and Conditions The supplier shall clarify storage condition such as temperature, humidity and storing in cool and dark place, and a storage period. * The supplier shall obtain specifications and operation manuals from material manufacturers to understand the characteristics of each material for control. (Specifications shall be obtained in line with the supply chain) (8) Conditions for receiving or delivering materials (exposure to rain, toppling or falling down) (9) Compliance with laws and regulations of each country



5．Forms Items 4(1) to (6) shall be recorded and kept as past records in the register (supplier's form).



6．Retention of Material Certificate The supplier shall keep the "Material Certificate" in 20 years. Upon request from Yazaki, it shall be submitted promptly. -57-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-2A] Raw Material Management Procedure 7. Precautions for Exporting Materials from Japan to Overseas Affiliates or Locally Procured Materials When exporting materials to an overseas affiliate to produce products or parts there, the supplier shall comply with the chemical-related laws and regulations of the country that receives materials. The same shall be applied to local procurement of materials by an overseas affiliate.



8. Procedure for Addressing Any Alleged or Actual Infringement or Chemical-related Laws and Regulations of Each Country [1] The supplier shall promptly isolate any materials, including indirect materials, or parts that allegedly or actually infringe chemical-related laws and regulations of each country, collect relevant information, fill in "[YKQ-093-**] Quick Quality Report: (Violation/Suspected Violation) of Chemical Substance-Related Regulation" with necessary information and submit it to Audit Department in Yazaki promptly for directions. [2] When directed by Environment Control Department in Yazaki to transfer the process, the supplier shall act in accordance with "[Appendix 4-1-6A] Process Change Procedure" to ensure that the process change does not affect the production activities at the customer and Yazaki.



-58-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-3A] Process Control Procedure 1. Overview It specifies the process control procedure for suppliers to build quality of parts which meet Yazaki requirements in manufacturing process.



2. Management of manufacturing process The supplier shall standardize the following items and maintain processes in order to properly control the manufacturing process. (1) Stable quality shall be ensured by deep understanding and consistent action for the Manufacturing Process Plan Sheet / QC Process Sheet, Work Standard, etc. (2) In order to assure manufacturing quality, the accuracy of the necessary equipment, jigs and tools shall be controlled by daily inspection, cleaning, etc. periodically. (3) Appropriate guidance and education shall be provided to workers and inspectors, and qualified personnel with skills shall be assigned to work so that stable quality is always obtained. (4) Quality fluctuation shall be monitored by using control charts, quality records, etc., and appropriate defect prevention actions shall be taken to maintain quality. (5) Actions for nonconforming products and handling of nonconforming and similar products shall be clarified, and measures to prevent mixing of nonconforming and wrong products shall be securely taken. (6) Appropriate conditions and work methods shall be set, and work shall be done according to the work standards to ensure stable quality. When changing an appropriate condition or work method, products shall be checked according to the actions for the change point. Improvement items shall be identified from the occurrence of unpredictable problems and applied to the standard documents, and shall be maintained and improved. (7) Product quality control shall be securely performed by following the specified inspection standards and frequency (first and final product inspections are essential). (8) For items instructed to use control charts by Yazaki, process control shall be performed using control charts. For processes and items that suppliers deemed necessary, control charts shall be used. (9) For major quality characteristics, periodically and when any change happen (in molding conditions, equipment, material, mold, jig, etc.), the process capability shall be re-evaluated, and the inspection contents and process control shall be improved (10) Management, supervisor, and responsible personnel shall observe the quality situation and resolve defects based on the Work Standards specified in the Manufacturing Process Plan Sheet / QC Process Chart, and quality records such as the work situation and in-process defect rate. Records of patrol in the processes shall be kept. (11) Processes shall be controlled not to contain or mix SOC. * Everything that may affect the product, such as molding machines, molds, and equipment shall be controlled. (12) In the manufacturing process of female terminals, pitch dimensions are inspected by an image inspection machine, etc. for all terminals to assure quality. For the setting method of pitch dimensions in the image inspection machine, refer to the Detailed Regulation in this Manual. (13) When recycled material is used for resin molded parts, the supplier shall obtain an approval by Cost Control Department and Development Department in Yazaki prior to use. Also, careful consideration shall be given to concentrations, contamination, etc. of SOC. In that case, strict control is needed for equipment and molding conditions to ensure the quality of molded products, and it is also confirmed that recycled material is blended properly. In principle, it is prohibited to recycle glass-containing materials.



3. 5S, location code, work environment control The supplier shall understand that the work environment such as 5S gives a serious influence to quality and develop that to all the workplaces (regardless of the name of the base, branch, etc.). * 5S means "seiri (sifting), seiton (sorting), seiso (cleaning), seiketsu (standardizing) and shitsuke (discipline)". (1) The supplier shall establish the 5S Committee, the Health and Safety Committee, etc. and promote adequate 5S activities etc. (2) In order to maintain 5S mainly at the production sites at all times, 5S audit shall be conducted using the ideal state check sheet etc. periodically. The sites are checked and 5S activity is promoted (3) Adequate illumination is provided to all processes and all inspection sites. (4) Storage place of work-in-process products, reworked products and nonconforming products are clearly defined. (5) Storage place of returned defective products and in-process defective products, and a place for analysis, are clearly defined.



-59-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-3A] Process Control Procedure (6) Activities to minimize the risks to employees and product related to safety shall be taken and maximum consideration to the safety of the working environment shall be considered. (7) In order to judge normality and abnormality at a glance, process control shall be visualized.



4. Utilization of FP (Fool Proof - Pokayoke) 　The supplier shall examine and implement FP to prevent defective products from being produced and shipped out.



4-1 Implementation procedure (1) At the stage of estimate (product design and process design), process FMEA, QA network, etc. shall be verified. (2) When a defect occurs, adoption of FP shall be examined for corrective actions. (3) The contents of the FP shall be clarified, registered in the FP list and controlled. (4) Validation of the FP function shall be checked periodically (using a dummy sample, etc., at the first and the end of production) and records shall be stored.



5. Warehouse management The supplier shall clarify items to be controlled for warehouse and maintain them under proper condition to prevent defects in raw materials, parts, and product storage and ensure traceability. (1) Receiving procedure of raw materials, components and products shall be determined, it shall be checked if the required items (material certificate, inspection record, lot no.) conform to the standards, and the records shall be kept. (2) Raw materials, parts, and products shall be arranged and stored so that labels and other indications are easy to see at the designated places. (3) Materials, parts and products shall be kept so as to prevent damage and deterioration. Natural disasters such as earthquake, fire, wind and flood damage, human disasters such as theft, and dust and wrong material mixing shall be also taken into consideration. Material bags are opened carefully and completely closed (with a portable sewing machine, etc.), not to mix wrong material, foreign matter, etc. in bags. (4) Receiving inspection of parts shall be conducted to confirm that there is no difference from the part number ordered, no problem to parts, no damage on the package caused by transportation etc. (5) Rules to comply with the first-in-first-out shall be established and observed. (6) For raw materials, parts, and products for which expiration date must be set, such date shall be defined and managed. (7) Materials which have been stored for a long period should be used after confirming that they are within the warranty period designated by the material manufacturer. (8) For shipment of raw materials, parts and products, the delivery destination, lot number, quantity, etc. shall be recorded for each product number. (9) The above items, 5S, location code, handling method, compliance status of the Work Standard, etc., shall be periodically audited and corrected, and their records shall be kept. (10) For products that require preservation treatment, the preservation procedure shall be established and documented. (11) Products that have been stored for a long time shall be re-inspected when shipped. Care shall be taken not to affect the product, because characteristics are different depending on the raw materials, products and parts. * For raw materials, parts and products, the effect of aged deterioration due to the storage method on products shall be verified for each item and the storage period shall be set. * The storage period shall be added to the Manufacturing Process Plan Sheet / QC Process Chart and controlled for each product number. (12) During transportation between suppliers' factories and processes, measures shall be taken not to give any damage to products. (13) When the design has been changed, how to handle old products shall be clarified, and such products shall be controlled properly not to mix new parts and old parts. Especially, special attention is needed for service parts and incomplete number of products for one package.



-60-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-4A] Measuring Devices Precision Control Procedure 1．Overview This procedure defines precision control of measuring devices conducted by the supplier.



2．Precision Control of Measuring Devices The supplier shall periodically examine the precision of the following measuring devices used for judgment in inprocess inspection, shipping inspection, and first and end parts inspection, or manufacturing of a die/mold, in order to guarantee the precision of those instruments, set the control standard, and voluntarily control them with documents, etc. [Reference] (1) Measuring devices Dial gauge, micrometer, caliper, cylinder gauge, small-hole gauge, height gauge, height master, block gauge, torque master, torque wrench, three-wire gauge for measuring screw thread, dial protractor, etc. (2) Gauges Snap gauge, plug gauge, width gauge, ring gauge, step gauge, screw gauge, angle gauge, nozzle for air micrometer, master gauge, test bar, supplier-developed gauges, etc. (3) Mechanical apparatus 3-dimensional coordinate measuring machine, tension and compression testers, roughness gauge, hardness gauge, spring tester, inspection jig, and surface plate [Examples of Measuring Device Control Report] (1) Measuring Devices Inspection Standard (2) Measuring Devices Precision Control Card



3．Forms The precision control card is to be defined and recorded by the supplier "[Any form] Precision Control Ledger" "[Any form] Calipers Precision Control List" "[Any form] Micrometer Precision Control List" "[Any form] Dial Gauge Precision Control List"



4．Inspection Standard for Measuring Devices The standard used for regular inspection shall be provided a clear description of the inspector, inspection checklist, measuring apparatus, frequency, inspection methods, etc. to standardize the inspection procedure.



5．Calibration of Measuring Devices The calibration of the measuring devices is implemented with the following provisions. (1) Scope of measuring devices for calibration (2) Frequency of calibration (recommended to be at least once every year) (3) Annual plan for calibration (4) Indication method for expiry date of the measuring devices (5) Measuring devices for "S" and "A" rank parts shall be calibrated every six months or less.



6．Calibration Institute The supplier shall confirm that the calibration institute conforms to ISO/IEC 17025 standard or to its equivalent standard.



7．Daily Inspection In case of calibration at the supplier, it shall be conducted in the environment which meets ISO/IEC 17025 standard or equivalent to it.



8．Actions to Calibration Errors Products measured with an uncalibrated measuring device may be erroneously accepted and shipped out. The supplier shall create measures against such an outflow. In case of any outflow, the supplier shall notify Quality Department in Yazaki immediately. -61-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-5A] Product Shipment Management Procedure 1. Overview The purpose of this Appendix is to clarify the control procedure from packaging, transportation to opening package at a customer.



2. Scope of Application This Appendix is applicable to processes from sealing of a packaging box and arrival at a designated delivery destination to opening the box by the customer.



3. Process Control The supplier shall match four items with the customer order sheet to confirm that right products are to be shipped and there is no packaging problem. The supplier shall also confirm the handling of the products after sealing (storage, preparation for shipping, shipping, loading and transportation) to prevent the occurrence of a problem. (Refer to No.4. Implementation of Four-item Matching) The four items to be matched are as follows: Product: Packaged product Drawing: Drawing, inspection standards, a list of key points or other documents that allow the receiving department to confirm that the received products match with the drawing. Label: Contents indicated in label on inner bag and outer box (Yazaki label or label for directly delivery products) Order form: SHIPS and other order forms



4. Implementation of Four-item Matching The supplier shall ensure the implementation of the four-item matching when shipping, also, check the assurance level when process change is applied, or work method and procedure (usage of a barcode reader) are determined, then, clearly specifies the process that assure the products. The following are typical control points. The supplier shall clarify control points when designing a process and determine them in accordance with each process. (1) Whole process Confirm that no goods such as clips, ball-point pens and magic markers, which are not necessary for work, are left behind before the start of operation. Such goods shall be kept at a predetermined position such that the entire shape is visible. At the end of work, the goods shall be returned to a predetermined position. Confirm that no other goods is mixed together. Operation shall be performed for each part no. Do not rely on memory for work. Operation shall be suspended at the end of one cycle, not in the middle. The definition of one cycle shall be clarified. Talking to an operator during work is prohibited (this is also applied to the manager). Clarify the numbers of labels issued and used. Surplus products shall be used first. In case of packing different lots in one package, each lot number shall be indicated. (2) Sealing Confirm that the prepared container is the same one designated by the packing specifications (box size, plastic container no., etc.) Before sealing a container, confirm that products, drawing, label, and quantity (the number of bags and steps in the container) correspond with those specified in the packing specifications. (3) Storage Confirm that products are placed in the right location corresponding to the indication on the label. (4) Preparation for Shipping and Loading Confirm that product no. , quantity and delivery destination indicated in the label correspond to the P/O form (or shipping instruction, etc.) and that the containers are palletized as specified.



(5) Traceability Confirm that the P/O form no. is linked with a lot no.



5. Control of Working Environment, Returnable Container, Transportation and Handling The supplier shall regularly check the sites at which manufacturing, storage (including temporary storage), sealing, preparation for shipping, palletization and loading are performed or trucks for any exposure to water due to the leakage of rain, overflow from rainwater pipes, water leakage from air conditioning drains or entering of rain or snow, to avoid products from get wet. -62-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-5A] Product Shipment Management Procedure (1) Building Confirm no leakage of rain. Confirm that packages are not conveyed between buildings or no package runs off the edge of the roof at a loading site on a rainy day.



Confirm that no rain or snow enters when a door is opened. Prevent the entry of small animals, such as birds or insects (spiders, moths, etc.), into containers. Confirm no leakage from air-conditioning drain or of cooling water.



(2) Transportation (Trucks) Regularly checks the sheet on the celling of a truck and seams on the celling for leakage of rain. (3) Returnable Container Check returnable containers (made of plastic or bamboo) for any products left, dirt (waste, dust, pollen dust or insects) or no water leakage before using them and clean them, if necessary. The labels or marking of previous products, if any, shall be removed before use.



(4) Storage or Work under the Sky If there is a possibility of temporarily storing products in a roofless place on a fine day, clarify the action taken when rain starts to fall. Have a necessary number of water-proof covers (blue sheets or pallet covers) in place and clarify how to use them in a procedure.



6. Abnormality Handling Clearly define abnormality relevant to storage and shipping processes (Ex: Damage of container, exposure to water, hole in a corrugate box, and collapse of cargo). In case of outsourcing shipping or transportation to a subcontractor, service provider, external courier or internal courier, the supplier shall conclude an agreement or memorandum with the service provider and clarify abnormality handling, such as a reporting route and action.



7. Education Management Training on abnormality handling shall be repeatedly once or more a year so that workers get accustomed to the abnormality handling. The supervisor shall observe how they work to know how well rules are observed and how they behave on rainy days and shall promote compliance with the shipping control procedure. * Requirements specific to workplaces, such as the height of the fork of a forklift, shall be clarified and checked.



-63-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-6A] Mold Management Procedure 1．Overview This procedure defines the control of tool.



2．Scope of application This applies to the tool used for mass-produced products ordered by Yazaki.



3．Registration of Tool The supplier shall create a tool Control Record to control the following items for each tool: part no. to be manufactured, tool control no., tool approved date, tool specifications, number of cavities, design change no., origin of order, reason for manufacturing, date of manufacturing, place of manufacturing, storage place, country name, etc.



4．Marking of Tool (1) To mark the tool number designated by Yazaki and instructions in the drawing. Tool Number



： Use the tool number specified by Yazaki In the case of the additional / renewal tool, even if the part number is the same, tool number is assigned for identification. e.g.: Designated tool No. is "Z" Alphabet is assigned next to Z. 1st 2nd 3rd 4th 5th ・・・・・・ Tool No, Cavity No.



Cavity Number



ZA



ZB



ZA1



ZB1



ZA2



ZB2



ZC



ZD



ZE



・・・・・・



Numerical number is only used for cavity no.



： The ID of each cavity shall be stamped except for the inability to stamp due to the shape or function of a product. Ex: Tool no. of Z with four cavities: ZA1 to ZA4



Arrow Mark



： Inquire to Yazaki.



Date Mark



： Stamp showing production Year and Month



* Dial or stamping



Instructions from ： Based on the instructions of the production drawing drawing Tool Number



： Inquire to Yazaki.



Stamping of material ： Stamp the material name shown in the drawing (2) The stamping position and size are to follow instructions in the drawing. In addition, in case of no instruction in the drawing, the stamping position is determined with Yazaki in advance.



5．Tool Labeling 　



(1) Yazaki part number and tool number shall be indicated on every tool using a method that ensures they can be permanently maintained. *Permanent indication means that it cannot be removed, it is recommended to use a metal plate or stamp. In the event that paint etc. is used for the indication due to inevitable reasons, the supplier shall check the indication periodically to keep it on the tool. (2) The tool used for manufacturing parts shipped for Ford, Chrysler and GM is required to indicate the following customer identification mark on the parts. Ford



FO



Chrysler



CR



GM



GM



FO 7○○○-○○○○ **



-64-



Indicate Yazaki Part No. Indicate Tool No.



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-6A] Mold Management Procedure (3) In the case of tool transfer to overseas, stamping (punch mark) is applied to the tool to identify. Stamping (Punch mark) position is to be close to the tool number. The details will be discussed and determined with Yazaki.



6．Maintenance of Tool (1) For every tool or its piece, maintenance shall be conducted regularly by shot counts or production running hours. (2) After molding, the tool is to be cleaned and inspected in preparation for the next production. (3) To examine over whether spare pieces of the tool are needed. If yes, to prepare spare pieces and control them according to the Tool Control Record, etc. (4) For details, refer to "[Detailed Regulation 2-1-1] Mold Maintenance and Management Procedure".



7．Storage and Handling of Tool (1) To prevent the damage, rust or deterioration during the storage of tools and their related equipment, the supplier shall keep them under proper condition. (2) Tools are handled carefully. Do not place them directly on the floor. Example: cover (dust prevention), drying agent / rust preventive agent (rust/moisture prevention), pallets/rubber (damage prevention)



-65-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7A] Defect Handling Procedure 1. Overview It specifies the actions to be taken in case that a defect (including environmentally nonconforming products) occurs in the products delivered in Yazaki (delivery destinations, or customers including markets), and a defect may occur in the delivered products because the defect was found in a production process at the supplier, as well.



2. Handling of defect The content of the defect shall be appropriately grasped and appropriate measures and recurrence prevention measures shall be taken promptly. SOC shall be deployed in accordance with "[Appended Table 8] SOC Test Evaluation Flowchart", and when the measured value is "accepted with conditions" or "rejected", actions shall be taken according to "[Appendix 4-3-3A] Procedure for Handling Environmentally Nonconforming Products". 2-1 When defects are found at Yazaki or a customer (1) Issuance of Quality Defect Report Regarding defects and abnormalities found by Yazaki and customers, Yazaki shall check the situation. When there is a possibility that the defect/abnormality is caused by the supplier and Yazaki judge that it is necessary to take measures and actions, the Quality Defect Report shall be issued in principle. (2) Response to the Quality Defect Report The supplier who received the Quality Defect Report shall promptly conduct investigation and take measures, and in principle, fill in the "[YKQ-017/018-**] Recurrence Prevention Report (A/B rank)" or "[YKQ-019-**] Report for Re-Occurrence Prevention [8D]", and submit them to Quality Department in Yazaki within the specified period. The supplier who received the quality defect information issued by the car manufacturer shall issue "[YKQ-100-**] Quick Report of Quality Problem/Same-Day Report" and submit it to Quality Department in Yazaki no later than the due date. When there is a reason that "[YKQ-017/018-**] Recurrence Prevention Report (A/B rank)" or "[YKQ-019-**] Report for ReOccurrence Prevention [8D]" cannot be submitted by the due date, the supplier shall notify that to Quality Department in Yazaki in advance and get his/her approval. (3D report shall be submitted within 24 hours and 8D report shall be submitted within 10 working days.) However, if designated by the customer, the customer-specified form shall be used. Causes and measures shall be described in the following procedure. Cause of occurrence



Cause of outflow



: Describe the direct cause of the occurrence of defect/trouble and the deeply investigated root cause concretely. : Describe the cause and deeply investigated root cause of why defective/abnormal products could not be detected (in product inspection, receiving inspection or shipping inspection, or by Fool-Proof (pokayoke), etc.) and shipped out.



Measures to prevent recurrence : In order to prevent recurrence permanently, make measures against the occurrence and outflow and describe their implementation contents concretely.



(3) Products produced by overseas factories For OUT-IN and OUT-IN-OUT products, the Japanese supplier shall be responsible for own overseas bases and manage by They shall be managed by "[YKQ-065-**] Report for Corrective Action Status", "[YKQ-017/018-**] Recurrence Prevention Report (A/B Rank)" or "[YKQ-019-**] Report for Re-Occurrence Prevention [8D]" or equivalent internal documents. Upon request from Yazaki, the supplier shall promptly submit them.



2-2 Issuance of Flash Report of Internal Quality When there is a risk that a defect found in the supplier may affect the parts to be delivered, the supplier shall report the situation, contents, etc. to Quality Department in Yazaki using "[YKQ-020-**] The Quality Advance Information" and receive instructions. The supplier shall do the same when a defect has been found at Yazaki or the customer and 2 pieces or more defective parts (the same defect) may have been shipped out to 2 bases or more, including the base (including overseas base) where the defect was found. Defective products shall be identified and separated, and appropriate actions and measures shall be taken. The form to be used differs depending on the customer. * In OUT-OUT case, the defect is reported to Quality Department in the base received parts and overseas bases in Yazaki.



-66-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7A] Defect Handling Procedure 2-3 Other (1) Keeping running production at Yazaki and customer The supplier who found a defective part or received defect information shall work in cooperation with Quality Department in Yazaki in order to keep running production at Yazaki and the customer and take appropriate measures such as sorting or reworking parts, or delivery of replacement. (2) Investigation of similar parts and similar processes (deployment) Similar parts: Parts having the same shape and function Similar process: Domestic and overseas processes with the same manufacturing methodology The supplier who found a defective part or received defect information shall immediately investigate if the same defect has occurred or there is a possibility to occur the same defect in similar parts and similar processes and report the results to Quality Department in Yazaki. In case that suspect parts may have been delivered to the supplier's other bases, Yazaki (including overseas bases), or the customer, the supplier shall work in cooperation with Quality Department in Yazaki and take appropriate actions narrowing down the subjected parts per each delivery destination. (3) Recurrence prevention action Recurrence prevention action shall be reflected onto standard documents such as "[YKQ-056-**] Manufacturing Process Plan Sheet / QC Process Chart", "[YKQ-029-**] Parts Inspection Standards" and "[YKQ-030-**] QC Process Sheet" for reoccurrence prevention, and internal audit to check how the preventive action works shall be conducted and process capabilities shall be grasped appropriately to secure stable quality. Effectiveness of the action (product evaluation and behavior evaluation) shall be verified and evaluated periodically. Standard documents shall be revised according to the contents of this Standard and promptly submitted to Quality Department in Yazaki. (4) Preparation of sorting and/or reworking procedure for defective parts When the parts subject to the defect are sorted or reworked by an outsourcing company, not by the supplier, sorting or rework procedure shall be created. Jigs shall be manufactured depending on the situation and used. (They shall be sent to the domestic and overseas bases of Yazaki.) (5) Indication on inventory parts to be investigated for defects The first shipment of the sorted or reworked parts in inventory shall be indicated according to Quality Department in Yazaki and/or the customer.



3. Compliance of Delivery The supplier shall perform management aiming at the delivery compliance rate of 100% described in "[YKQ-017/018-**] Recurrence Prevention Report (A/B Rank)" or "[YKQ-019-**] Report for Re-Occurrence Prevention [8D]". If not reached, the supplier shall state the corrective actions in the Supplier Evaluation List issued by Yazaki and submit it.



4. Storage of defective products The supplier shall store defective parts returned from customers for six months from the report completion date. Defective parts which occurred market claims shall be stored permanently, and care shall be taken to the storage method in order to re-check the past defective parts, as necessary. If there is an instruction on the storage period, follow it.



-67-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7B] Abnormality Handling Procedure 1．Overview This procedure defines the reporting process of abnormal condition occurred in the production process at the supplier and actions to be taken.



2．Definition of Abnormal Condition -AbnormalityAbnormality is defined as below. It applies to all abnormalities relating to part quality found in the production process at the supplier. The supplier is to refer to the following and make a set of rules for every process based on the Abnormal Condition definition and implement the necessary control. The supplier shall clarify the definition of abnormality and post it on the production processes, using "[YKQ066-**] Quality Points For Abnormality Countermeasure" and spread out. “Abnormal Condition” means [1] when operation or work process is different from usual 　 [2] when the occurrence situation of defects is different from usual [3] when the standard operation cannot be carried out, etc. Item



Abnormal Condition Sound, color and sense of touch is different from usual Volume, weight and hardness is different from usual



[1] When it is different from usual Operation not possible according to procedure Operation or work process is different from usual



Different phenomenon was found in equipment, jigs, etc. Excess/lack of component was found



[2] When it is strange



OK/NG cannot be judged



[3] When there is part dropped



When operator dropped part or noticed the dropped pa



[4] When abnormality is shown on the quality control chart Never happened before, first occurrence of defect Unusually high number of defects than usual The occurrence situation of defects is different from Sudden disappearance of defects that usually appear usual Similar type of defects those from past occurrences



3．Information Reporting Flow and Containment Action Provide the reporting method and the reporting contact in the event of abnormality happened at the supplier. Reporting system to Yazaki is clearly specified in the work flow.



4．Rework of nonconforming part It is prohibited to rework nonconforming parts, in principle. In case that rework is unavoidable, report to Quality Department in Yazaki with a clear reason in advance, and rework the parts according to Yazaki's instructions. Work that is not listed in "[YKQ-056-**] Manufacturing Process Plan Sheet_QC Process Sheet" is considered as abnormal work (including rework).



Abnormality handling section



Abnormality Detected



Operator



Instructions for actions Abnormality Notification



Results Report Abnormality Notification



Supervisor



Instructions for restart of operations



Production manager/



Results Report



In order to report the abnormality swiftly and promptly as the above, clearly define each role of the operator who found the abnormality and the higher position personnel who reported. Create the work flow in writing so as the higher position personnel gives instruction for the restart of the operation. Train and educate employees for quick reporting from operator to manager when any abnormality is found.



-68-



Abnormality Notification



Quality manager Results Report



Abnormality Notification



In case that defective parts might have been shipped out, report to Yazaki Quality Department immediately and follow his/her



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7C] Past Trouble Utilization Procedure 1． Overview This Appendix defines a procedure for utilizing problems (herein after referred to as the "Past Trouble") concerning outflow of defective products, in-process defects, a defective shape of a die/mold, inappropriate setting of conditions and defects that occurred in the production preparation stage.



2． Purpose Register daily problems (outflow of defective products/in-process defect, etc.) to prevent the occurrence of such problems.



3． Past Trouble Examples (1) Product problems, production problems and difficulties. Defective products, production method problems, equipment or machine failure, etc. (2) Problems in Production Preparation Stage Production Preparation process problems (ex; DR was not performed or the method was not satisfactory) Tool (mold/die) design problem (material, dimensions, configuration, structure, etc…) Component manufacturing problems (materials, molding, processing, assemble, etc…) handling problems, communication problems, insufficient preparation, insufficient study, mis-arrangement, technical issues



4． Past Trouble Utilization Procedure (1) If a problem is found, corrective actions should be taken based on the supplier's Nonconformity Handling Procedure or Abnormality Handling Procedure rules. (2) Record the problem on Past Trouble and Improvement Registration Sheet, etc. (discretionary form). (3) Study the necessity of deployment of the same corrective action to the similar processes/ manufacturing methodology/products, and implement it, if necessary. (4) Adequately verify the Past Trouble in the production preparation stage and include measures to prevent the Past Trouble. Also consider fool-proof (poka-yoke) to prevent operator's mistakes or reduce their work load.



5． Procedure for Utilizing Past Trouble at Production Preparation Stage A problem that has occurred in the production preparation stage shall be registered in "KAKOTORA And KAIZEN Registration Sheet" and the sheet is submitted.



5-1 Submission Timing At the time of requesting for submission



5-2 Submission Method and Attention Submission method: Specified by department of requestor Attention: Department of requestor Submitted document: "[YKQ-071-**] KAKOTORA And KAIZEN Registration Sheet" < Past Trouble Utilization Flow > Phase



Event



CFR0 Product Planning (Current Vehicle BOM)



* Activity outline based on CFR phase



CFR1 PM Vision CFR1 Internal Competition



CFR5



HVPT / Initial Sample Insp. / Shifting to MP



CFR5 Start of Initial Period Production Control CFR5 End of Initial Period Production Control CFR6 Product Usage Status / Review Improvement Activity (VA/VE/in-process defect



Routine reduction) Problem Correction/New Technology/New Method



-69-



Improvement Case Registration Ledger Past Trouble (Filling)



CFR4 Mass-Production Drawing release



Perform Improvement, Results



CFR3 Prototype Drawing release / Production



Improvement Study, Corrective Action



CFR2 Part Drawing Review



New Technology, New Method, Problem



CFR2 Receive Order/Production Preparation



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7C] Past Trouble Utilization Procedure INPUT



Process in Supplier



OUTPUT



Document



In-Process



Outflow of Defect



Corrective Acton Study



Corrective Action/ Countermeasure



[YKQ-017-**] Recurrence Prevention Report Rank-A [YKQ-018-**] Recurrence Prevention Report B [YKQ-019-**] Report for Re-Occurrence Prevention [8D] [YKQ-071-**] KAKOTORA And KAIZEN Registration Sheet



Improvement



Standardization Study



Standard Documents Manufacturing Process Plan Sheet, QC Process Sheet, Part Inspection Standard, Packing Specification, Work Standard



[YKQ-056-**]Manufacturing Process Plan Sheet_ QC Process Sheet [YKQ-029-**] Parts Inspection Standards [YKQ-031-**] Packing Specification



System Study



System



Process FMEA Process FMEA, Process Design, Tool (Mold/Die) Design, Equipment



Past Trouble Record



Improvement



Past Trouble D/B



QA Network



[YKQ-071-**] KAKOTORA And KAIZEN Registration Sheet



Deployment Study



Improvement Plan Sheet Improvement



Entire Improvement



Maintenance



-70-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7D] Improvement Proposal Procedure 1. Overview This Appendix defines a procedure for reflecting proposals, including those relevant to past trouble, on the drawings of a new part.



2. Purpose The purpose of improvement proposal procedure is to receive proposals that lead to reduction in in-process defects and the improvement of a yield rate at the time of quotation and provide feedback to the next car models.



3. Procedure for Utilizing Improvement Proposals Verifying the possibility of reflecting improvement proposals on the next models during DR and make proposals that facilitates the manufacturing of products. During the production preparation phase, in particular, reflect past troubles D/B on measures to prevent problems adequately. Also consider the use of poka-yoke (fool-proof) to prevent operator's mistakes and reduce their burden.



4. Submitting Improvement Proposals When asked by Yazaki to quote a new model, make improvement proposals that lead to the enhancement of quality and productivity and cost reduction with "[YKQ-059-**] Suggestions For New Design" and "[YKQ-060-**] Suggestion List For Design Development". "[YKQ-059-**] Suggestions For New Design": Created for each part no. (or for each manufacturing method/type of product, if the proposals are same across part nos.) Monetary effect (man-hours) achieved by such improvement proposals shall be calculated as much as possible and included. "[YKQ-060-**] Suggestion List For Design Development": The proposals for new design shall be summarized into a list.



5. Submission 5-1 Submission Period When asked by Yazaki to submit a quotation.



5-2 Method and Place of Submission Submission method: Specified by requesting department Place of submission: Requesting department Submitted document： "[YKQ-059-**] Suggestions For New Design"



"[YKQ-060-**] Suggestion List For Design Development" ≪Past trouble flow≫ Phase



Event



CFR0 Product Planning (Current Vehicle BOM)



Improvement proposals for next new model (easy to manufacture/cost reduction)



CFR1 PM Vision CFR1 Internal Competition



CFR5 HVPT/Initial Product Control Start CFR5 Initial Product Control Termination CFR6 Product Usage Status/Review Routine



Improvement Activity (VA/VE/in-process defect reduction) Problem Correction/New Technology/New Method



* Activity outline based on CFR phase



-71-



Create Improvement  Proposals



CFR5 Initial Product Inspection/MP Switchover



Improvement Case Registration Ledger Past Trouble (Filling)



CFR4 Mass Production Drawing Issuance



Perform Improvement, Results



CFR3 Prototype Drawing Issuance/Production



New Technology, New Method, Problem



CFR2 Part Drawing Review



Improvement Study, Corrective Action



CFR2 Receive Order/Production Preparation



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-7D] Improvement Proposal Procedure IN PUT



Process in Supplier



OUT PUT



Document



In-Process Defects



Outflow Defect



Customer Requests Corrective Acton Study



Corrective Action/



Development Concept Product Specification Method Yield Rate Packing Specification



Countermeasure



New Technology



New Method



YZK(CFR0～CFR2)



VA・VE Study



Feasibility



Improvement Implementation



VA・VE Proposals



New Design Proposals



[YKQ-059-**] Suggestions For New Design



Requests for next new model ・Large Engineering Change ・Technology/Cost ・Quotation etc...



[YKQ-060-**] Suggestion List For Design Development



Standardization Study



Supplier's Requirements New Design Proposals Standard Documents System Kakotora Production Engineering Manufacturing Techniques Management Techniques



Quotation



Standard Documents



Manufacturing Process Plan Sheet Part Inspection Standard Packing Specification Work Standard



[YKQ-056-**] Manufacturing Process Plan Sheet_QC Process Sheet [YKQ-029-**] Parts Inspection Standards [YKQ-031-**] Packing Specification



System Study



Product Planning Vision Sheet



System



Process FMEA QA Network



Process FMEA Process Design Tooling Die Design Equipment Design



Kakotora Record



Improvement Plan



Kakotora List



Horizontal Application Study



Improvement Plan Sheet Improvement Implementation



Entire Improvement



Maintenance Management



-72-



Improvement Proposals



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-8A] Equipment and Jig Management Procedure 1. Overview It specifies management standards for appropriate preventive maintenance of major equipment and jigs used. The purpose is to maintain equipment performance and product quality and achieve stable supply to customers.



2. Scope of application It is applied to equipment and jigs used that are expected to cause significant damage to production activities when they break down or that are used daily.



3. Implementation procedure 3-1 Ranking of equipment and jigs (Confirmation of importance) Production engineering departments or relevant departments shall rank each equipment and jig according to the internal standards and determine the maintenance method. 3-2 Preparation of Equipment and Jig Inspection Procedure Determine the preventive maintenance method of equipment and jigs for each rank, and prepare the Equipment and Jig Inspection Procedure. This shall be prepared and issued by the production engineering department or relevant department. 3-3 Creation of Equipment and Jig Inspection List (Maintenance calendar etc.) [1] The Equipment and Jig Inspection List (maintenance calendar etc.) shall be prepared by the department that uses the equipment/jig according to the Equipment and Jig Inspection Procedure. [2] The inspection timing shall be determined by the department that uses the equipment/jig based on the inspection frequency specified in the Equipment and Jig Inspection Procedure. [3] The department that uses the equipment/jig shall examine the appropriateness of the inspection items, frequency establishment standards, measuring equipment, etc. in the Equipment Inspection Procedure based on the machine repair records and the machine stop records, and review the Equipment and Jig Inspection Procedure appropriately with the production engineering department or the relevant department and reflect them to the Equipment and Jig Inspection List 3-4 Operation [1] The department that uses the equipment/jig shall formulate and implement an annual equipment inspection plan (form prescribed by the department that uses the equipment/jig). [2] The department that uses the equipment/jig shall conduct inspections based on the Equipment and Jig Inspection List (maintenance calendar etc.) and record the results in the Equipment Inspection List. [3] Equipment/jig inspectors and checkers shall be determined by the responsible personnel of the department that uses the equipment/jig. [4] The responsible personnel of the department that uses the equipment/jig shall check the Equipment and Jig Inspection List periodically to manage the compliance status. [5] The equipment and jig setting conditions must not be changed in the manufacturing process. If any trouble has occurred and adjustment is required, it shall be checked by the production engineering department or relevant department, and changes shall be made. At this time, the quality state of the product shall be checked as well. 3-5 Packaging and protection of equipment, jigs and gauges Procedures for rust prevention for sections that affect the product and breakage prevention for storage shall be prepared and operated.



3-6 Availability of replacement parts for major manufacturing equipment and jigs [1] For replacement parts (spare parts, expendable parts), a list shall be prepared. [2] The list shall be prepared by the production engineering department or the department that uses the equipment/jig and shall be preliminary checked so that it is promptly obtained. [3] The list shall be prepared so that management (order placement point management etc.) to avoid excess or deficiency will be performed considering the delivery schedule and cost of parts. 3-7 Preventive maintenance activities In order to continuously improve the effectiveness and efficiency of production equipment, the following preventive maintenance method shall be used. [1] Recommendations of equipment and machine manufacturers [2] Optimization of time for storage, wear, operation, etc. [3] Methods presumed from statistical data and preventive maintenance activities [4] Fluid analysis [5] Circuit monitoring [6] Vibration analysis -73-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-8A] Equipment and Jig Management Procedure 4. Equipment and jigs [1] The Condition List (manufacturing conditions, setting conditions, etc.) shall be developed for each equipment or jig. Condition changes shall be verified to know if there is a possibility of affecting others. Also, there shall be a system that the responsible personnel (authorized person) performs changes. [2] Each equipment and jig shall be checked on a daily basis to evaluate FP functions and check and inspect if there are bolt/nut loosening, wear of receiver, etc., and the inspection records shall be stored.



5. Storage of records The Equipment and Jig Inspection List shall be stored for 20 years after the equipment/jig number is disposed of by the department that used the equipment/jig.



6. Handling abnormal condition [1] When an abnormality occurs in the equipment or jig, actions shall be taken according to the "Procedure for Handling abnormality" predetermined by the supplier’s department that uses the equipment/jig. [2] If there is a concern that abnormality of equipment and jig will affect Yazaki product supply over the long term, it shall be reported to department in Yazaki that placed the order.



-74-



Quality Manual for Suppliers 26th Edition



[Appendix 4-2-9A] Material Identification Mark Management Procedure 1． Overview The material marking is enforced for the purpose of part recycle ratio improvement, and it is regulated by each country. The approaches to accommodate customers' requirements for the material marking rules are clarified in this section.



2． Scope of application Indicated by R on drawings (An objective part is made of plastic with 100 grams or more, or made of rubber with 200 grams or more. The definition is varied in each country) Drawing indication example: This is a regulatory part regulation)



R



(recycle



3． Marking on Product Stamp a material name designated in a drawing on a die/mold and confirm that the stamped name is visible on a part. The marking of the material name shall represent critical characteristics and be checked for with the initial and last lots.



4． Implementation Guideline In order to prevent missing ▽R indication/incorrect description/incorrect part number indication, the following procedures should be observed, and customer's requirement should be satisfied. [1] Do not stamp ▽R to the parts, but it should be indicated on standard documents. Let operators in worksite have considerable quality consciousness. [2] Level of importance/innovation list should be prepared, and should be presented immediately when requested. [3] Ensure the traceability of the production lot. [4] A rework should not interfere with a material marking indication, which should be thoroughly controlled. If a rework causes interference with a material marking, the lot number should be clearly identified and the record should be kept. The total number of parts should be assured as well. [5] Create an audit plan, and perform internal audit once every year or more frequently. The audit result should be kept and prepared for submission for the time Yazaki requests. [6] A supervisor should be assigned on the production site in order for the operation to be thoroughly controlled. A training should be provided for the operators to realize the significance of the work. [7] Evaluate the assurance level by using the "[YKQ-069-**] Confirmation Sheet for Defect Outflow Prevention". If the evaluation result is not A, an outflow prevention method should be prepared separately. [8] Parts directly delivered to customers should be controlled based on the customer's requirements, which should be included in the documents to be presented to customers such as Part Inspection Standard/Initial Product Inspection Report.



-75-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-1A] SOC Management Procedure 1. Overview The purpose is to clarify the management system to ensure appropriate quality with respect to substances of concern (hereinafter referred to as "SOC") for parts, materials and secondary materials used in the manufacturing processes for products to be delivered from suppliers to us and for products they manufacture.



2. Scope of application This standard shall be applied to materials, parts, secondary materials, etc. delivered to us. However, DMF shall be applied to packaging materials.



Target substances: lead, cadmium, mercury, hexavalent chromium, PBB, PBDE (including deca BDE), DEHP, DBP, BBP, DIBP, HBCD, PFOS asbestos, DMF



3. Definition of terms (1) Evidence Evidence refers to the one that was analyzed in the material unit that is considered to be homogeneous and proved by the measurement data. However, for the other eight substances, except lead, cadmium, mercury, hexavalent chromium, PBB and PBDE (including deca BDE), IMDS etc. is admitted as evidence. Materials which are difficult to be divided into the homogeneous materials of the inspection analysis data (XRF, ICP, etc.) shall be ground for measurement, and they shall be judged as they contain no SOC if the measurement result is no more than the detection limit. Evidence requires one or more unique data for each product number in principle. However, it is not applied when only the cut dimension (of a tube or the like) differs. (2) Indirect materials Materials which are attached to the products including stationery purchased by each supplier, those which are likely to adhere to the products, and those which come into contact with the products including the equipment and which may adhere to the products. (Rubber bands, packing materials, etc.) (3) Process change The following process change which is thought to affect the content of SOC 1) Establishment of new process (however, only when there is a possibility of affecting SOC) 2) Installation of equipment and machine (however, only when there is a possibility of affecting SOC) 3) Change of material manufacturer or parts manufacturer 4) Change of materials and components 5) Process change of a N-tier supplier or its subsequent suppliers (only when there is a possibility of affecting SOC) 6) Other process changes that may affect SOC (4) Non-current products Product that has not been ordered and flown for at least three years.



4. SOC management system 4-1 Clarification of supply chain (1) All purchased parts, materials, and indirect materials (hereinafter referred to as purchased products) shall be identified and specified so that they can be managed individually. Unique numbers etc. that can identify each purchased product shall be set in the list of purchased products etc., and the management department concerning SOC shall be clarified. (2) The supply chain of each product shall be clarified. Suppliers for all purchased products shall be grasped and the SOC-related inquiry window shall be identified. Also, purchased products with a high risk of SOC inclusion and their suppliers shall be recognized, and the risk factor shall be ranked. 4-2 Clarification of requests to N-tier suppliers (1) The management system on SOC of purchased products shall be defined. The system that does not allow inclusion of SOC shall be incorporated into the management system chart to establish internal regulations, standards, etc. (2) To the N-tier suppliers, non-SOC content shall be clearly instructed in "[YKQ-029-**] Parts Inspection Standard" etc. SOC related items shall be included in the "Mater Agreement" or similar agreements, and the scope of responsibility in case of trouble occurrence shall be defined. (3) Requirements for the SOC management system for N-tier suppliers shall be defined and requirements shall be presented. Briefing sessions etc. for N-tier suppliers shall be held and the requirements shall be presented and summarized in a check sheet or the like.



-76-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-1A] SOC Management Procedure 4-3 Management of products purchased from the N-tier supplier (1) Business rules for SOC when accepting products purchased from an N-tier supplier shall be defined. How to manage SOC shall be included in the Acceptance Inspection Standard. Products to be inspected, frequency, inspection equipment, etc. shall be defined. (2) The proof of non-SOC content submitted by the N-tier supplier shall be attached to all purchased products. The Certificate of Non-use of Regulated Substances for all purchased products shall be obtained and how to respond to troubles shall be defined. (3) The SOC management system of N-tier suppliers shall be checked. The SOC management system of the N-tier suppliers shall be checked using a check sheet or the like and process check standards shall be established. (4) To confirm that the purchased products do not contain SOC, the SOC measurement system shall be developed. Measurement implementation standards shall be defined (ranking etc.) to perform measurement. If the company does not own inspection equipment, inspection shall be outsourced to an external institute. 4-4 Establishment and maintenance of SOC management system (1) The SOC content and inclusion prevention system shall be established at own company. SOC content measurement shall be performed for first lot produced for new parts and each process change. Service products and long-time inventory products shall be checked to ensure that they do not contain SOC. In process design and maintenance, it shall be confirmed that SOC does not adhere from indirect materials etc. (including packing materials, rubber finger tips and indirect containers touching products), and it shall be reflected in the internal regulations, work standards, etc. (2) The process development status shall be periodically checked. The risk-taking process shall be defined, and the process improvement status shall be periodically checked with a check sheet or the like. In addition, products (processes) with high SOC content risk shall be ranked as "parts with risk" and data management performed so that non-SOC content is assured. 4-5 Proof of non-SOC of products delivered to Yazaki (1) SOC management shall be included in the Parts Inspection Standard with Yazaki. It shall be applied to "[YKQ-029-**] Parts Inspection Standard" and the inspection data according to it based on Yazaki request. (2) Evidence of purchased products shall be obtained. Inspection analysis data (XRF, ICP, etc.) and material data (IMDS etc.) for purchased products shall be obtained. When evidence cannot be obtained, conduct inspection or inspection shall be outsourced. (3) The handling method when SOC content is detected shall be defined. Inspection criteria shall be defined in the internal regulations, standards, flows, etc. The troubleshooting procedure shall be developed.



(4) When receiving an order of non-current products, evidence shall be submitted to the person in charge of our Audit Department before shipment. * Evidence of our paid supply parts shall be obtained by inquiring of the person in charge of the Audit Department or the overseas base of the purchasing department in Yazaki. Evidence of our paid supply materials (Excel data is OK) shall be obtained by inquiring of the person in charge of the Raw Material Purchasing Department in Yazaki or the overseas base of the procurement department.



SOC management system model Clarification of requests to the N-tier suppliers Basic trade agreements, information briefing for suppliers, check sheets, etc.



N-tier suppliers



Management of purchased products from the N-tier



Construction and maintenance of SOC management system



Proof of non-SOC of delivered goods



Inspection data of purchased products, declaration/proof of nonuse, importance rank, etc.



Process development, internal audit, process change management, high risk process control, etc.



Inspection standards, inspection data on delivered goods, procedure of measures against troubles, etc.



Purchased product



Suppliers Clarification of supply chain



-77-



LOT warranty



Our acceptance inspection



Low-RISK



Product Purchased item list, supplier list, management system chart, etc.



YAZAKI



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-1A] SOC Management Procedure 5. Judging SOC content 　For the method of determining the SOC content, refer to "[Appendix Table 8] SOC Inspection Result Judgment Flow". Substance name



ELV threshold



Lead Pb



1000 ppm (0.1%)



Yazaki measurement control value (less than * Excluding ELV ANNEX II (exception rule) this value) 100 ppm (0.01%)



Cadmium Cd



100 ppm (0.01%)



Mercury Hg



1000 ppm (0.1%)



100 ppm (0.01%)



* Specific brominated flame retardants: PBB, PBDE (including deca BDE)



1000 ppm (0.1%)



100 ppm (0.01%)



Specific bromine-based flame retardant



1000 ppm (0.1%)



100 ppm (0.01%)



* When the customer requirement is more severe than the Yazaki measurement management value, the customer's request shall be given priority. (Measurement method, standard value, etc.)



Substance name



EU RoHS threshold



Yazaki measurement control value (less than this value)



Specific phthalate ester



1000 ppm (0.1%)



1000 ppm (0.1%)



Hexavalent chromium Cr



6+



50 ppm (0.005%)



* For four ELV-regulated substances + specific bromine-based flame retardant substances, each threshold and control value shall be observed.



* Specific phthalate ester (DEHP, DBP, BBP, DIBP)



6. Handling method when SOC contamination is confirmed * [Appendix 4-3-3A] Procedure for Handling Environmentally Nonconforming Products 6-1 When the SOC content is outside the Yazaki measurement control range and within the regulation range (1) The cause of contamination shall be defined in order to promptly respond to inquiries. (It shall be proved that it is not intentional inclusion.) 6-2 When the SOC content is outside the regulation range (1) Purchased products, processes, and processing that caused SOC contamination shall be identified. (If it is caused by the materials supplied by Yazaki.) (2) Manufacturer/Consignor who shipped contaminated products shall inform its recipient promptly. (3) Consultation with relevant parties (including car manufacturer if there is outflow to the market) shall be conducted and promptly collect all shipped contaminated products.



7. Avoidance of SOC containing risk to current products Products and parts to be delivered to Yazaki shall be assured every 25,000 pieces by the following method in order to avoid SOC containing risks.



In principle, the assurance method is basically based on the measurement of products and parts, but it is also possible to measure materials and indirect materials to be used. It is applied only when the measurement data, the target products and parts are integrally managed and can be assured. * Long components are counted by meter, and one meter represents one piece. (Measured every 25,000 meters) 7-1 Setting of target part number and measurement frequency (1) An annual measurement plan shall be formulated by preliminarily coordinating with the person in charge of Yazaki Audit Department based on delivery records of the previous year, such as product numbers to be measured and number of measurements, this year’s production plan, etc. The measurement plan shall be submitted to the person in charge of Yazaki Audit Department by January 20 every year. When the production plan is changed (production increase or decrease) significantly from the initial schedule, contact the person in charge of Yazaki Audit Department and review the plan. (2) Parts and materials to be supplied by Yazaki and specified materials (numbers with M) are not subject to measurement because they are assured by Yazaki. Parts and materials procured by themselves are subject to measurement. 7-2 Measurement method (1) When the number of production is less than 25,000, products/parts shall be measured each time when the shipped qty reaches 25,000. (2) When one lot of production consists of more than 25,000 pieces and manufactured using same material lot, it is possible to measure products/parts per material lot even when the number is more than 25,000 pieces. (3) Plated products to be measured shall be from the same plating bath and be plated on the same day. It is permitted to measure randomly sampled parts. Measurement data and target part number shall be defined and management to ensure traceability shall be performed. (4) Measurement data received from the N-tier suppliers or outsourcer may be used other than the supplier’s self measurement data. However, they shall be managed so that it is confirmed that they are data of the products and parts delivered to Yazaki. (Example: Describe Yazaki product numbers in the measurement data) (5) When self measurement cannot be performed (including measurement by a consigned external measurement company) and measurement data cannot be obtained from the N-tier suppliers, measurement can be consigned to Yazaki designated measuring company for fee. However, ASSY products shall be measured before they are assembled (by component parts). -78-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-1A] SOC Management Procedure 7-3 Management and submission of measurement results (1) Measurement results shall be submitted to the person in charge of Yazaki Audit Department and checked according to the previous section 5. Judging of SOC content. Depending on the judgement, the result shall be promptly reported to Yazaki. Precise measurement shall be performed, and actions shall be taken according to the Procedure for Handling Environmentally Nonconforming Products and instructions. (2) Yazaki sends the results of the measurement consigned. They are stored and managed. Yazaki also shall check the same measurement result and give instructions to the supplier according to the detection result as in the case of (1) above.



[Measurement and measurement data sending route] Measurement data Self measurement by Company A



Note 1 Product



Measurement sample



Company B



Measurement data



Measuring company designated by YAZAKI



Measurement data



Purchasing Department, YAZAKI



Measurement data



Company C



Company A: They have an analyzer, so they can perform measurement by themselves. Company B: They outsourced measurement to the measuring company designated by YAZAKI. Note 1: Measurement sample label Company C: They outsourced measurement to an external measuring institution.



Measurement sample Product



External measuring institution Measurement data



-79-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-2A] SOC Analysis Procedure 1． Overview This analysis procedure is set to test and prove if the parts supplied to Yazaki are consistently SOC-Free.



2． SOC Analysis Implementation Perform SOC analysis for each product ordered by Yazaki (not for each delivered product, but for each component for a product composed of several components) at the time of Part Evaluation (including at the time of design or process changes) and leave evidence. If several parts are made of the same materials in the same processes, only a single part may be subject to SOC analysis, regardless of the number of cavities in a die/mold. In the case where several parts are produced from different materials, each material shall be measured (For a plated product, the base and plating materials should be measured separately. For adhesive tape, both base material and adhesive should be measured separately). The following products shall be analyzed once a year or more as products require attention. Products which are conditionally accepted in the [Appendix 4-3-1A] "SOC Management Procedure" shall be regarded as high risk products and subject to analysis for each lot. Other products or parts shall be handled in accordance with [Appendix 4-3-1A] "SOC Management Procedure". Products or parts that exceed Yazaki controlled value (See [Appended Table 8] "Flow for Determining Results of SOC Inspection") in qualitative analysis (XRF, etc.) shall be subject to quantitative analysis (ICP or AAS).



3． SOC Analysis - Procedure for high risk part 3-1 Application High SOC Contamination Risk Part or Material, which are assigned by YAZAKI.



3-2 Analysis Method （1） An examination is required once a year or more frequently by using XRF Testing equipment's. （2） Hexavalent chromium analysis on chromate conversion coating shall be performed in accordance with [Appendix 8] "Overview of Method for Analyzing Hexavalent Chromium (EN15205 and EPA3060A)", depending on the type of chromate conversion coating to be analyzed. （3） For a plated product, the plated portions and the base material before plating or after removing the plating shall be analyzed. （4） For a soldered product, the soldered portions or the soldering material shall be analyzed.



3-3 Definition of subjected part and analysis lot （1） Rubber Part Analysis lot: Per material production lot after compounding/kneading step. After curing material shall be used for analysis. （2） Plastic Part Production material lot: such as recycled pellet materials procured externally, and materials of polyvinyl chloride products, excluding those supplied by Yazaki at cost. （3） Press Part (Metal)　- Plating Finished Part Analysis Lot: Per plating bath (tank), 1 day maximum (in this case, 1 bath needs 1 data for 1day, if there is no change.) If there are more than 2 different plating process ( e.g.: Tin(Sn) and Solder(Pb), Cr6+ and Cr3+aaa, 1 Lot is defined 1 day production per every part number [No grouping lot]. （4） Printing, etc. SOC Lot: Per ink can （5） Soldered Products Soldered products or parts, including lead-free solders, shall be regarded as soldering lots. （6） Others Per Part Production Lot, if the same material and the same process are used. When needed, YC directs high SOC contamination risk part or material other than above mentioned parts. -80-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-2A] SOC Analysis Procedure 3-4 Controlling analytical data （1） SOC Lot data shall be controlled and synchronize to Production Lot data for traceability management and tendency control. （2） For high risk products, analysis data for each lot shall be kept perpetually. For parts requiring attention, the latest analysis data shall be kept perpetually. Such analysis data shall be controlled to be made available promptly when requested by Yazaki.



3-5 Analysis by Third Party/Consignment to Yazaki （1） If there is no testing equipment's and is not capable of self-testing, request testing to an outside organization. In case consigns the testing to Yazaki, contact Yazaki Environment Dept to consult and determine the testing methods, location, and the sample shipment method. This process should be requested through "[YKQ-032-**] SOC Analysis Request Form". （2） SOC Lot data shall be controlled by the same way as mentioned in 3-4.



-81-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-3A] Procedure for Handling Environmentally Nonconforming Products 1. Overview It specifies the procedure for handling products when SOC has been detected in the delivered parts at Yazaki (customers including delivery destinations It also specifies the procedure for handling products when there is a possibility that SOC-contaminating nonconforming parts found in the process may affect delivered parts.



2. Handling of Environmentally Nonconforming Products Actions shall be taken according to the SOC Inspection Result Judgment Flow. When the measured value is "conditionally accepted" or "failed", actions shall be taken according to the following procedure. 2-1 When discovered at Yazaki «When the measured value is "Conditionally accepted"» (1) When receiving the information issued from Yazaki regarding SOC-contamination, issue "[YKQ-020-**] The Quality Advance information" with analytical data after thoroughly checking the situation. Analysis data shall also be attached to the notice. (2) Measure target products on a lot-by-lot basis, measure them with a quantitative analysis equipment (ICP, AAS, etc.), and report the results to the person in charge of Audit Department in Yazaki. The person in charge of Yazaki Audit Department shall check the measurement result, and if the measured value is within the conditional acceptance range, give permission to the lot only. The permission is not given to the lots without measurement data. (3) Investigate the causes of the contamination of SOC and the outflow, formulate a recurrence prevention measure, and submit it to the person in charge of Yazaki Audit Department. (4) When the measured value is accepted in the quantitative analysis result of the product after the measures are taken, apply for lifting of "conditional acceptance" to the person in charge of Yazaki Audit Department, and only after rifting is approved, first normal shipment will be enabled. «When the measured value is "Fail"» (1) When receiving the information issued from Yazaki regarding SOC-contamination, issue "[YKQ-020-**] The Quality Advance information" with analytical data after thoroughly checking the situation. (2) Stop shipment of subjected products and isolate them. (3) Current products and inventory products stored are promptly measured and the results shall be reported to the person in charge of Yazaki Audit Department. (4) In order to identify the scope of environmentally nonconforming products, investigate the cause of occurrence and outflow, report the shipping destination and shipping quantity of the subjected products to the person in charge of Yazaki Audit Department to receive instructions. (5) In accordance with the instructions of the person in charge of Yazaki Audit Department, immediately collect the inventory of the delivery destination and the distribution stock, and immediately deliver corrected products so that the production lines of the delivery destination will not stop. In that case, shipping permission shall be received from the person in charge of Yazaki Audit Department in advance. (6) Summarize the causes of occurrence and outflow of environmentally nonconforming products and measures in the Recurrence Prevention Measure Report, incorporate the following contents to it and submit it to the person in charge of Yazaki Audit Department by the designated date. [1] Analytical data of nonconforming products ... Quantitative analysis data such as ICP [2] Scope of nonconforming products (shipping destination, shipment volume) … Narrowing subjected lot [3] Cause of occurrence of nonconforming product, cause of outflow, preventative action, standardization of preventive action, and confirmation of effect [4] Handling and scheduling of corrected products shipping (7) According to the instructions of the person in charge of Yazaki Audit Department, isolated inventory products and collected products shall be appropriately handled (disposal, etc.). At that time, the number of isolated products shall be checked against the number of handled products and the results shall be recorded and stored. 2-2 When discovered by a supplier «When the measured value is "Conditionally accepted"» (1) Checking the information regarding SOC-contamination, issue and send "[YKQ-020-**] The Quality Advance information" with analytical data to Yazaki after thoroughly checking the situation. (2) Measuring target products on a lot-by-lot basis with a quantitative analysis equipment (ICP, ASS, etc.) and report the results to the person in charge of Yazaki Audit Department. The person in charge of Yazaki Audit Department shall check the measurement result, and if the measured value is within the conditional acceptance range, give permission to the lot only. Shipment permission shall not be given to lots without measurement data. (3) Investigate the cause of the contamination of SOC and the cause of outflow, prepare recurrence prevention measures, and submit it to the person in charge of Yazaki Audit Department. (4) In the quantitative analysis result of the products after taking the measure, apply for lifting of "conditional acceptance" to the person in charge of Yazaki Audit Department if the measured value is acceptable. Only after its approval, normal shipment will be enabled for the first time.



-82-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-3A] Procedure for Handling Environmentally Nonconforming Products «When the measured value is "Fail"» (1) Checking the situation about the information of environmentally nonconforming products thoroughly and promptly issue and send "[YKQ-020**] The Quality Advance information" with analytical data of current and inventory products to Yazaki Audit Department. (2) Stop shipment of subjected products and isolate them. (3) In order to identify the scope of environmentally nonconforming products, investigate the cause of occurrence and outflow, report the shipping destination and shipping quantity of the subjected product to the person in charge of Yazaki Audit Department and ask for instructions. (4) In accordance with the instructions of the person in charge of Yazaki Audit Department, immediately collect the inventory of the delivery destination and the distribution stock, and immediately deliver corrected products so that the production lines of the delivery destination will not stop. In that case, shipping permission shall be received from the person in charge of Yazaki Audit Department in advance. (5) Summarize the causes of occurrence and outflow of environmentally nonconforming products and measures in the Recurrence Prevention Measure Report, incorporate the following contents to it and submit it to the person in charge of Yazaki Audit Department by the designated date. [1] Analytical data of nonconforming products ... Quantitative analysis data such as ICP [2] Scope of nonconforming products (shipping destination, shipment volume) … Narrowing subjected lot [3] Cause of occurrence of nonconforming product, cause of outflow, preventive action, standardization of preventive action, and confirmation of effect [4] Schedule for shipping corrected products (6) According to the instructions of the person in charge of Yazaki Audit Department, isolated inventory products and collected products shall be appropriately handled (disposal, etc.). At that time, the number of isolated products shall be checked against the number of handled products and the results shall be recorded and stored.



3. Other When a process is changed due to the preventive action, actions shall be taken according to "[Appendix 4-1-6A] Process Change Procedure".



-83-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-4A] JAMA Sheet Preparation/Submission Procedure 1． Overview The materials listed onto all of Yazaki drawings shall be measured for any substances identified by GADSL in order to assure non-usage of any substances in question or they are under the threshold level. Consequently, a JAMA sheet should be obtained. This Appendix defines the procedure for creation and submission procedure of JAMA sheet.



2． Scope The latest version of JAMA sheet shall be submitted when requested by Yazaki or engineering change occurred due to environment related matter.



3． Download Steps If JAMA sheet is updated, follow the steps as mentioned below to obtain the latest version. （1） Have access to JAPIA website (http://www.japia.or.jp) （2） Select　JAMA/JAPIA Standard Material Datasheet (JAMA JAPIA Unified datasheet) （3） Select No. "01" JAMA/JAPIA Standard Material Datasheet (Data entry form) Select Japanese Version and right click to open the window. （4） Select "Save as in file" （5） Save the file in a designated folder. (first, create a folder for the file to be saved) （6） Download No. "02" JAMA/JAPIA Standard Material Datasheet (External file) JAMA/JAPIA unified datasheet(External List) Download Japanese version as well, and save it in the same folder. （7） Unzip JAMA/JAPIA Standard Material Datasheet (Data entry form) file, JAMA/JAPIA unified datasheet file (Document) and JAMA/JAPIA Standard Material Datasheet (External file).



4． Creation Steps （1） Have access to JAMA/JAPIA Standard Material Datasheet (Data entry form) JAMA/JAPIA unified datasheet (Document ) Japanese version, and select "Enable macros" (Security level should not be "high") （2） Enter the password and click "OK". If the password is unknown, contact a person-in-charge in YAZAKI Audit Subdivision. （3） Complete the sheet by consulting simple entry manual and entry example on JAPIA website. （4） Use Yazaki Part Number for Delivery Part Number if it is available. If you need a correction, capture CSV file on JAMA sheet first. （5） Repeat to perform "Entry Error Check" on top left corner on JAMA sheet until "No Error" message appears. （6） Select "CSV file output" in the middle of JAMA sheet to output the data. File Name:Supplier Code_Yazaki Part No._Creation Date_Creation Version a 　　　　　　 　Example 000_750000100_20100823__v211a



5． Submission Send the sheet with CSV format file to YAZAKI department requested.



-84-



Quality Manual for Suppliers 26th Edition



[Appendix 4-3-5A] Chemical Substances Management Procedure (YGS-C21-010) 1. Overview It defines the management procedure of YGS-C21-010 (Chemical Substances Management Standard) described in Yazaki drawings.. The substances listed in the GADSL and Yazaki group voluntarily controlled substances shall be investigated and the use of the subjected substances shall be prohibited or restricted.



2. Scope of application It is applied to all parts manufactured in accordance with Yazaki drawings.



3. Acquisition of the latest version of GADSL The latest GADSL Reference List shall be obtained according to the following procedure. (1) Have access to the GADSL website. (http://www.gadsl.org/) (2) Download the Excel file "GADSL Reference List" on the right side on the website.



4. List of prohibited or restricted substances Prohibited or restricted substances listed are GADSL and Yazaki group voluntarily controlled substances. (1) Use of chemical substances is prohibited or limited according to the GADSL classification. GADSL is classified into three types of attributes as follows. [1] P (Prohibit substances) Prohibited for all applications [2] D/P (Declare or prohibit substances) Some are prohibited by the intended use, and others require the application for use. [3] D (Declare substances) The application is always required when using parts with value exceeding the threshold. (2) GADSL shall be discussed at a general meeting held once a year at the Global Automotive Stakeholders Group (GASG), and be revised the following year (around February in the year). The latest version shall be used as appropriate. * GASG (Global Automotive Stakeholders Group) is a group that mainly revises GADSL. The list shall be reviewed for each region and discussed at the general meeting held once a year, and its revision shall be issued next year. (3) Yazaki group voluntarily controlled substances In order to ensure that the products of the Yazaki Group satisfy the regulatory and customer requirements, it specifies the control standards such as prohibition and declaration for chemical substances contained in the products. This standard specifies that there may be cases where the substances is listed as Yazaki group voluntarily controlled substances, instead of use of substances to be declared according to the GADSL when they are going to be prohibited by law. Please obtain the latest form from the following URL (https://www.Yazaki-group.com/ecology/).



5. How to declare to Yazaki Proceed a declaration when its required according to the survey result of the previous section (1) The JAMA sheet shall be prepared and submitted to Yazaki Design and Development Department. The JAMA sheet shall be prepared and submitted in accordance with "[Appendix 4-3-4A] JAMA Sheet Preparation and Submission Procedure".



6. Yazaki designated materials Materials supplied or designated by Yazaki are compliant with the Chemical Substances Management Standard (YGS-C21-010) so declaration is not required.



-85-



Quality Manual for Suppliers 26th Edition



[Appendix 4-4-1A] Production Preparation Implementation Procedure 1. Overview It specifies items and contents to be implemented to parts ordered by Yazaki in order to achieve early detection of issues aiming at the achievement and maintenance of quality objectives at the production preparation stage, solve problems, establish good product conditions and conduct process design.



2. Scope of application It is applied to products (parts) that are delivered to Yazaki and require production preparation such as new products (trial products, mass-produced products) ordered by Yazaki, products subject to design change (trial products, mass-produced products), mold renewal and increase.



3. Contents of production preparation implementation 3-1 Clarification of production preparation manager Clarify personnel responsible for overall production preparation activities for products (parts) ordered by Yazaki. 3-2 Handling of prototype parts Production shall be conducted based on "[Appendix 4-4-4A] Prototype Parts Arrangement and Acceptance Inspection Procedure" on prototypes ordered by Yazaki. 3-3 Grasping the requirements of design and development and W/H factory and/or customers (1) Participating in the DR before release of the mass-production drawing, propose and coordinate the mold, production, and quality requirements to Yazaki development department. (2) Grasping Yazaki required quality items based on parts drawings, Important Point Design Intent Notice and the Packing Specification Notice. (3) Grasping the requirements such as how W/H factory and /or customers use the parts,, product functions, packing specification in the subsequent processes and reflect them in the mold and processes. (4) Participating in the DRBFM and the DR and promptly solve problems to be improved in manufacturing technology on request by Yazaki, etc. (DRBFM:Design Review Based on Failure Mode) * If there are unclear points, contact the design and development department, production preparation representative in Yazaki and check the requirements to grasp them. 3-4 Using N-tier suppliers For important controlled parts and important parts, it is not permitted to use N-tier suppliers for "IATF products, "A" products, bush products, new processing methods, new technologies, new material parts, Lexus vehicle type parts, parts need attention, EV parts, RB, ECU BOX, constant power supply, direct delivery parts, etc.". For important controlled parts and important parts that are subject to a special process, however, if there are unavoidable reasons, such as impossibility of handing them in their relevant process, prior approval shall be obtained from us. Special measures may be taken depending on our consideration. To use an N-tier supplier of other products (parts), advance application shall be made in accordance with "[Appendix 4-1-2A] Ntier Supplier Management Procedure". 3-5 Preparation of production preparation plan sheet Prepare a Production Preparation Plan Sheet based on "[Appendix 4-4-8A Production Preparation Plan Preparation Procedure"]. It is aimed to clarify items concerning production preparation and to deliver the products in due. Even when making design changes, "[YKQ-028-**] Production Preparation Plan" shall be prepared and the relevant items shall be implemented. 3-6 Creating Mold and Equipment Plan form Prepare the Mold and Equipment Plan form in accordance with "[Appendix 4-4-9A] Mold and Equipment Plan Report Preparation Procedure" and report it to Yazaki. When designing a mold/equipment, a process plan (process design) including the machines, equipment, molds, jigs and tools shall be formulated while ensuring requirements of Yazaki fully and considering product safety (especially for molds, parting lines, ejection pins, gate positions, draft angle, etc. shall be considered after grasping the development intent. Safety of workers in work etc. shall be considered, too.)



3-7 Implementation of process FMEA, QA network, FTA, QFD, etc. The degree of quality assurance shall be verified using an appropriate method according to the product to be produced, difficulty, etc. -86-



Quality Manual for Suppliers 26th Edition



[Appendix 4-4-1A] Production Preparation Implementation Procedure 3-8 Creating Manufacturing Process Plan Sheet and QC process sheet Prepare the Manufacturing Process Plan Sheet/QC Process Sheet according to "[Appendix 4-4-12A] Manufacturing Process Plan Sheet/QC Process Sheet Preparation Procedure". Assurance items such as manufacturing technology, equipment, personnel, construction method and environmental items shall be defined and the assurance method shall be included. When consigning processes to an N-tier supplier, the quality assurance system, technology, quality control level, etc. shall be considered and it shall be confirmed that stable mass production is possible. 3-9 Creating QC process sheet When requested by Yazaki, the QC Process Sheet shall be prepared based on "[Appendix 4-4-12B] QC Process Sheet Preparation Procedure". 3-10 Management of production conditions For each process of welding, soldering, heat treatment, adhesion, molding (resin, rubber, metal and composite) and assembly as setting of good product conditions, upper and lower limit evaluation and management method of processing conditions shall be clarified and standardization shall be carried out. 3-11 Creating Work Standard Work contents in each process shall be dissolved to element work, ingenuity for visualization such as photographing shall be devised so that everyone can understand each work. A standard document shall be prepared. 3-12 Creating inspection plan and Parts Inspection Standard (1) An inspection plan for the design and development requirement items in the drawings, Important Point Design Intention Report, etc. shall be formulated and inspection standards and a gauge and inspection equipment arrangement plan shall be formulated based on the results. Items to be investigated: examination of inspection layout, selection of inspection items, first product measurement planning, sampling method, measurement method selection, selection and procurement of measuring tools and gauges, arrangement of personnel etc. (2) The inspection standard shall be prepared based on "[Appendix 4-4-12C] Parts Inspection Standard Preparation Procedure" and submitted to us. (3) When there is a request for submission of various forms from Yazaki or customer, prepare them and submit them to the production preparation representative in Yazaki. 3-13 Creating Packing Specification Prepare the Packing Specification based on "[Appendix 4-4-12D] Packing Specification Preparation Procedure". From shipment to unloading, product quality (scratch, deformation, rust, deterioration, etc.), no sticking from the tray, etc. shall be assured. Transportation evaluation and drop evaluation shall be performed to prepare the evidence of the Packing Specification. When it is necessary to divide the packing specification for each delivery destination, each specification document shall be prepared. (Domestic specifications, export specifications, direct delivery specifications, etc.) 3-14 Verification of past troubles and examination of FP Past troubles shall be fully verified and measures to prevent recurrence of past defects shall be incorporated at the stage of production preparation planning. Also, FP measures (a mechanism to prevent errors of workers, a mechanism to warn workers of mistakes, a mechanism to detect product defects if any and prevent start of processing, etc.) shall be examined and measures to prevent mistakes by workers and burden mitigation measures shall be examined. The results shall be submitted to production preparation representative in Yazaki using the mass production past trouble database. 3-15 Implementation of education for employees Required skills, qualifications, process input conditions, etc. in each process shall be defined, and the preparation of an educational plan shall be completed by HVPT. A skill map etc. shall be prepared and managed for each process. Workers who handle "S" and "A" rank parts shall utilize the certification system. In addition, the management system shall be established so that it does not hinder production, such as certification of multiple workers. 3-16 Implementation of parts test Yazaki parts test shall be conducted based on "[Appendix 4-4-17A] Sample Evaluation and Part Test Request Procedure" by one week before the examination of transition to mass production.



-87-



Quality Manual for Suppliers 26th Edition



[Appendix 4-4-1A] Production Preparation Implementation Procedure 3-17 Implementation of process capability evaluation and process performance evaluation Process capability verification shall be conducted on important dimensions and dimensions specified by Yazaki based on "[Appendix 4-4-14A] Process Capability Verification Procedure". If a reference process performance index (Ppk >= 1.33) cannot be obtained, appropriate process improvement shall be implemented. If mass production is unavoidably started without achieving the target, the contents of daily inspection shall be examined and an application shall be made production preparation representative in Yazaki for approval. 3-18 Resolution of remaining problem After identifying problems so that there will be no remaining problem by the time of HVPT, an improvement plan shall be formulated and resolution of problem items shall be completed.



3-19 Implementation of HVPT (High Volume Production Trial) Assuming mass production, production shall be verified after the completion of the autonomous process inspection. HVPT shall be carried out under the mass production conditions (good product conditions, mass production mold, mass production process, regular jigs, gauges, work standards, quality check standards, and educated workers). The contents such as the fraction defective, process capability, estimate contrast shall be evaluated. HVPT shall be carried out in the cycle of mass production conditions, and the verification quantity shall be decided by suppliers based on the production conditions such as the material/mold workmanship and required accuracy. The same HVPT shall be carried out for the assembly and inspection processes. 3-20 Implementation of process inspection before transition to mass production and examination of transition to mass production After completing satisfied 4M, verify if the target value has been attained by HVPT etc. and then confirm that mass production transition is possible. The autonomous process inspection prior to application for transition to mass production shall be carried out by the quality representative or the top manager himself/herself based on the MPPS/QC Process Sheet. Submit the Mass Production Transition Application Form for the relevant product number and the evidence of target achievement to Yazaki. 3-21 Implementation and cancelation of initial flow control The period of the initial flow control shall be up to three months after the L/O of the final customer (vehicle manufacturer etc.) from the shift to mass production. Coordination shall be made with Yazaki about the products that have been produced in small lots, and the initial flow control period shall be determined. Monitor the target value maintenance state during the initial flow control period. For the initial flow control period, try to take actions towards lifting initial flow control period. When applying releasing from initial control period, check the flown out defects, in-process fraction defective and production capability and perform cost verification, etc. to confirm that the initial flow control target value (cancellation condition) is satisfied and submit the cancel application. For dedicated processes, the fact that the relevant process is in the initial flow control period shall be clearly displayed in the target process during the initial flow control period.



3-22 Review Reflect the production preparation activities (in the result report meeting), record technical suggestion cases and improvement cases in "[YKQ-071-**] KAKOTORA And KAIZEN Registration Sheet" and reflect them to the next production preparation activities. 3-23 Important parts Products (parts) shown below shall be regarded as important parts and we may request special attention to them. "S" rank parts and parts designated by Yazaki 　 3-24 Implementation of on-site process check On-site checks shall be carried out according to the part rank as necessary. Or, submission of evidence materials such as a check sheet shall be requested as necessary.



4. Submission and storage Control document etc. so that they can submit them to Yazaki promptly when requested. Also, related documents shall be kept for 20 years after the discontinuation of the subjected product number. -88-



Quality Manual for Suppliers 26th Edition



[Appendix 4-4-1B] Production Preparation Milestone Management Procedure 1. Overview It specifies the production preparation milestone management procedure for the products (parts) ordered by Yazaki.



2. Scope of application It is applied to products (parts) that are delivered to Yazaki and require production preparation such as new products (trial products, mass-produced products) ordered by Yazaki, products subject to design change (trial products, mass-produced products), mold renewal and additional mold.



3. Grand schedule There is a grand schedule of the finished car manufacturer at the highest level, and in association therewith, there is a production preparation schedule for the unit manufacturers, Yazaki WH factories, ASSY suppliers, suppliers (component manufacturers), and the second and third tier suppliers. The schedule of the delivery destination where the products (parts) are delivered to needs to be aware of and act responsibly. When in charge of ASSY, the required delivery date of the components needs to be announced.. Moreover, when consigning processes to the second and third-tier suppliers, they shall develop a major schedule and strive for schedule management. For the development and inquiries of the latest schedule, they shall contact development design representative in Yazaki during the prototype production and production preparation representative in Yazaki during and after mass production trial. Time axis January February March



April



May



June



Finished car manufacturer



August



Mass production



Mass production



Trial production



Mass production



Mass production



Mass production



Trial production



Suppliers (component manufacturer)



November December



Mass production



Mass production



Trial production



ASSY suppliers



October



Mass production



Trial production



Yazaki WH factory



September Mass production



Trial production



Unit manufacturer



Second and third-tier suppliers



July



Trial production



Mass production



Mass production



Mass production



Always be conscious of the post-process (delivery destination) and launch production ahead of schedule.



4. Vehicle events and required process levels Major examples of event which customers hold and the process level required for each event are as follows. Unless there are special circumstances such as delivery delay, additional design change, and additional parts, it is necessary to always deliver products in the process level that is appropriate for the vehicle event. For important parts such as those for EV, HV, PHV and FCV in particular, production may be launched ahead of the schedule and additional matters may be added in accordance with the customer's request separately. Mass production trial



Mass-production prototype classification Trial production



Yazaki



Milestone management phase name Production preparation promotion representative



Toyota Group Renault, Nissan Customer vehicle event



Honda Mazda SUBARU Mitsubishi Suzuki



Required process level



CFR3



CFR4-a



Development design Production preparation



Mass production



CFR4-b



CFR5



1 Go to numerical value judgment



Exclude



OK (SOC Compliant)



YES



Apply to ANNEX II?



YES



(ANNEX of the RoHS directive as well)



OK (SOC Compliant)



For Aluminum, copper alloy, steel for machining and galvanized steel, refer to other flows 5), 6), 7).



NO Is measurement value less than 100 ppm?



YES



OK (SOC Compliant)



Is measurement value less than 500 ppm?



Go to ICP/AAS analysis.



NO



NO



YES



Measurement value is over 500 and less than 1,000 ppm.



Measurement value is 1,000 ppm or more.



Note 1) S/B judgment: According to XRF test report, Concentration level (ppm) = S



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note 3)



3σ (ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC. Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products "(Appendix 4-3-3A).



160



2) Judgment Flow Chart for "Cadmium"



※



Is that a result of the fluorescent X-ray analysis?



NO



Exclude



ELV ANNEX II



Material



ELV SPEC



YZK Screening SPEC



Cd



100 ppm (0.01%)



50 ppm (0.005%)



*In case that Customer SPEC is more severe than that of YZK



YES S/B > 1 Go to numerical value judgment



Is measurement value less than 50 ppm?



NO



NO



Is the waveform S/B ≤ 1 Note1)?



YES



OK (SOC Compliant)



YES



OK (SOC Compliant)



Is measurement value less than 50 ppm?



Go to ICP/AAS analysis.



NO



YES



Measurement value is over 50 and less than 100 ppm.



Measurement value is 100 ppm or more.



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note 3)



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ (ppm) = B When you confirm the peak form as S/B >1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products "(Appendix 4-3-3A).



161



3) Judgment Flow Chart for ”Hexavalent Chromium” (Metal sample)



(2)



(4)



(1)



Measurement method XRF = (1) Others = (2)



Exclude



ELV ANNEX II



Material



ELV SPEC



YZK Screening SPEC



Cr6+



1000 ppm (0.1%)



100 ppm (0.01%)



*In case that Customer SPEC is more severe than that of YZK



Is the waveform S/B ≤ 1 Note1)?



Measurement method ICP/AAS = (3) PAC/UV = (4)



※



YES



OK (SOC Compliant)



NO



(3) Is measurement value less than 100ppm?



YES



OK (SOC Compliant) Note 3)



NO NO



Cr treatment for anti-rust?



OK (SOC Compliant) Note 4)



YES Diphenylcarbazide Absorptiometry (Qual: Colorimetry, Qty: Absorptiometry) Note 5) Note 6)



Colorimetry: is measurement 2 value less than 0.05 μg/cm ?



(5) Diphenylcarbazide Absorptiometry Qual: Colorimetry = (5) Note 5) Note 6) Qty: Absorptiometry, UV = (6) Note 5) Note 8)



YES



OK (SOC Compliant)



NO Colorimetry: Is measurement value 2 less than 0.08 μg/cm ?



YES



OK with conditions (Prior management is needed) Note 2)



NO



(6) Absorptiometry: Is measurement value less than 0.05 μg/cm2?



YES



OK (SOC Compliant)



NO Absorptiometry: Is measurement value less than 0.1 μg/cm2?



NO 162



YES



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note 7)



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ (ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



The measurement value of the fluorescent X-ray analysis is the total chromium and cannot measure only the hexavalent chromium. So if the total chromium value is under the standard value, the hexavalent chromium value can be judged within the standard value. So enable to judge with the total chromium value.



Note 4) ‐



Metal chromium is 0 value, so no problem.



Note 5) ‐



Inspection method and judgment standard are based on the EN15205 (hexavalent chromium analysis for anti-rust chromate film), the hexavalent chromium should be under 0.1 μg/cm2. Galvanizing layer is not included in the chromate film.



Note 6) ‐



Colorimetry method indicates PACK test, digital PACK test and chromatometer.



Note 7) ‐



Refer to of [Appendix 4-3-3A] Environmentally Non-Conforming Products Handling Procedure.



Note 8) ‐



For a plating line changed or newly installed on or after August 1, 2011, chromate conversion coated products shall be measured 14 days (±2) after the chromate treatment. The products shall be analyzed by the diphenylcarbazide method. If the measurement result of absorptiometry (UV) is less than 0.03 μg/cm2, the products are acceptable.



163



4) Judgment Flow Chart for ”Hexavalent Chromium” (Resin sample)



(2)



(4)



Measurement method XRF = (1) Others = (2)



(1)



Is the waveform S/B ≤ 1 Note1)?



Measurement method ICP/AAS = (3) UV = (4) Note 4)



YES



OK (SOC Compliant)



NO



(3)



Pretreatment Complete disolution method = (5) Iron coprecipitation method = (6) Note 5)



Is measurement value less than 100 ppm?



(5)



YES



OK (SOC Compliant) Note 3)



NO Precise analysis, ICP/AAS, UV etc.



(6)



Is total Cr less than 500 ppm?



YES



Total Cr is over 500 and less than 1,000 ppm.



NO Total Cr is 1,000 ppm or more.



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



Precise analysis, by UV. Note 4)



Is Cr6+ less than 100 ppm?



YES



OK (SOC Compliant)



NO



NG (Countermeasure is Needed) Note 6)



164



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ (ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



The measurement value of the fluorescent X-ray analysis is the total chromium and cannot measure only the hexavalent chromium. So if the total chromium value is under the standard value, the hexavalent chromium value can be judged within the standard value. So enable to judge with the total chromium value.



Note 4) ‐



Pretreatment should be alkali extract by EPA3060A. Apply frost shattering before extract, and grain diameter should be under 250 μm. Sample should be dried enough.



Note 5) ‐



Iron coprecipitation method (JISK0102: Iron coprecipitation－ICP-AES) should be implemented If the extract liquid is colored with ink after the alkali extract by EPA3060A.



Note 6) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products " (Appendix 4-3-3A).



165



5) Judgment Flow Chart for ”Lead” in Aluminum



Is that a result of the fluorescent X-ray analysis?



NO



YES S/B > 1 Go to numerical value judgment



NO



Is measurement value less than 1,000 ppm?



NO



Is the waveform S/B ≤ 1 Note1)?



YES



OK (SOC Compliant)



YES



OK (SOC Compliant)



is measurement value less than 3,000 ppm?



Go to ICP/AAS analysis.



NO



YES



Measurement value is over 3,000 and less than 4,000 ppm. Measurement value is 4,000 or more.



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note3)



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ (ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



Refer to of [Appendix 4-3-3A] " Procedure for Handling Environmentally Nonconforming Products ".



166



6) Judgment Flow Chart for ”Lead” in Copper Alloy (Less than 40,000 ppm)



Is that a result of the fluorescent X-ray analysis?



NO



YES S/B > 1 Go to numerical value judgment



NO



Measurement value is less than 10,000 ppm?



NO



Is the waveform S/B ≤ 1 Note1)?



OK



YES



(SOC Compliant)



OK



YES



(SOC Compliant)



Go to ICP/AAS analysis.



Is measurement value less than 37,000 ppm?



NO



YES



Measurement value is over 37,000 and less than 40,000 Measurement value is 40,000 ppm or more.



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note 3)



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ (ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products " (Appendix 4-3-3A). 167



7) Judgment Flow Chart for ”Lead” in Steel for Machining and Galvanized Steel (3,500 ppm or less)



Is that a result of the fluorescent X-ray analysis?



NO



YES S/B > 1 Go to numerical value judgment



NO



Is measurement value less than 1,000 ppm?



NO



Is the waveform S/B ≤ 1 Note1)?



OK



YES



(SOC Compliant)



YES



OK (SOC Compliant)



Go to ICP/AAS analysis.



Is measurement value less than 3,200 ppm?



NO



YES



Measurement value is over 3,200 and less than 3,500 ppm.



Measurement value is 3,500 ppm or more.



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note 3)



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ(ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



Note 3) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products " (Appendix 4-3-3A). 168



8) Judgment Flow Chart for ”Lead-Free Solder” (Solder in solder tank, materials for wire solder or soldering paste) NO Is that a result of the fluorescent X-ray analysis?



YES S/B > 1 Go to numerical value judgment



Is measurement value less than 600 ppm?



NO



NO



Is the waveform S/B ≤ 1 Note1)?



OK (SOC Compliant)



YES



YES



Go to ICP/AAS analysis.



OK (SOC Compliant)



Is measurement value less than 500 ppm?



NO



YES



Measurement value is over 500 and less than 1,000 ppm.



Measurement value is 1,000 ppm or more.



OK (SOC Compliant)



Change a lead-free solder Note 2) NG (Countermeasure is Needed) Note 3)



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ(ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



If the measurement value of lead increases by using a lead-free solder, you will conduct adjustment to decrease lead in solder to less than 500 ppm with ICP or AAS (600 ppm with XRF).



Note 3) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products " (Appendix 4-3-3A). 169



9) Judgment Flow Chart for Specified Bromine: PBB, PBDE



IC or ICP = (1) Note 3) Others = (2)



Is that a result of the fluorescent X-ray analysis?



NO



(2) (1)



S/B > 1 Go to numerical value judgement



Is measurement value less than 100 ppm?



Is the waveform S/B ≤ 1 Note1)?



Exclude



ELV



ANNEX



II



Material



ELV SPEC



YZK Screening SPEC



PBB,PBDE



1000 ppm (0.1%)



100 ppm (0.01%)



*In case that Customer SPEC is more severe than that of YZK



YES NO



※



YES



OK (SOC Compliant)



OK



YES



(SOC Compliant)



NO Is SOC-Free Warrant present?



YES



OK (SOC Compliant)



NO HPLC =(3) GC/MS = (4)



(3)



Is there Nonuse Declarations of Specific Brominated substances?



OK



NO



(SOC Compliant)



YES



(4) Go to GC-MS analysis.



Is measurement value less than 500 ppm?



NO



YES



Measurement value is from 500 to 1,000 ppm.



Measurement value is over 1,000 ppm.



OK (SOC Compliant)



OK with conditions (Prior management is needed) Note 2)



NG (Countermeasure is Needed) Note 4)



170



Note 1) S/B judgment: -



According to XRF test report, Concentration level (ppm) = S 3σ(ppm) = B When you confirm the peak form as S/B > 1, it can be judged that the sample contains SOC.



Note 2) ‐



The products with the same lot number as the OK product by measurement is judged as OK.



‐



Basically, the investigation of the cause of SOC incorporation must be implemented and then the countermeasure must be taken. However, until the countermeasure is completed, every lot that is produced by using the identical material and process must be measured. The lot number judged as OK is allowed to use for limited duration of use.



‐



You must report the presence of SOC to customers and obtain their approval.



Note 3) ‐



IC (Ion Chromatography) analysis is for measurement of total bromine. Pretreatment should be “silica tube combustion method” or “oxygen flask combustion method”.



Note 4) ‐



Refer to " Procedure for Handling Environmentally Nonconforming Products " (Appendix 4-3-3A).



171