The purpose of this document is to communicate expectations to our sub-contractors.  These expectations may be specifically defined herein or in the form of a named reference that provides further detail.

• This manual applies to sub-contractors of assembly components, tooling, materials, and services (hereafter referred to as product) that are used in any process at AT&DC.
• Long term business relationships will be developed with sub-contractors who demonstrate ability and commitment to meeting AT&DC requirements, with competitive prices and ALWAYS 100% on time delivery.
• No portion of this manual is intended to imply that AT&DC will accept anything other than 100% defect free product.

2.0 CONTROL RESPONSIBILITY

3.0 PROPRIETARY INFORMATION SHARING

AT&DC recognizes our responsibility to provide sub-contractors with complete definitions of quality requirements.  To this end the sub-contractor will be provided with materials specifications, test, control requirements, or other pertinent information that defines a product's quality requirements.  In addition, your employee's may have visited our facilities or even traveled with us to our customers plant(s).  AT&DC and it's customers specifications, technical data, engineering drawings, customer names, plant layout(s), equipment lists or procedures are considered confidential. Sub-contractors are required to treat this information with strict business confidence.  Disclosure to third parties in any form, without written authorization is prohibited, with the exception of third party registrar access during registration audits.

4.0 GIFTS AND GRATUITIES

AT&DC prohibits it's employees from accepting any type of gift or gratuities.  Please do not attempt to ask our employees to "lunch" or offer "tickets" to sporting events, etc.

5.0 QUALITY SYSTEM

Sub-contractors are expected to adopt ISO 9001:2000 (minimum) as a fundamental quality system. 

6.0 ADVANCE QUALITY PLANNING (APQP)

Sub-contractors may be expected to participate in an AT&DC internal "APQP" team process.  This will better communicate needs and concerns.  These conferences may be held at AT&DC or one of it's customer sites.  AT&DC engineering or purchasing departments will make the necessary arrangements.  Typical topics can include, but are not limited to:

Identification of significant product/process characteristics

• Design/Tooling issues
• Preliminary control plans
• Packaging
• Gaging/Check fixture issues
• Enhancements or possible cost savings to the product using the  Value Added or Value Engineering (VA/VE) technique.
• Engineering changes to an existing product.

A complete and detailed PFMEA must be performed and maintained for all products.  Copies are to be available upon request.  The PFMEA is to be revised any time a process changes or when a new failure mode has been discovered.

A control plan may be necessary for products/services (as appropriate) supplied and shall be submitted to AT&DC Quality Assurance Department no later than four weeks prior to the initial sample submission.  The control plan format provided by the AIAG must be used.  Alternate formats require prior approval by the AT&DC Quality Assurance Department.

All significant characteristics (SC) must be included on the control plan.  Control plans must be re-approved prior to any process change.  Process change means any change in the processing concept, which could alter the fit, function or durability of the product.  This would include, but is not limited to:

New, different, or rehabilitated production machinery or equipment.

• A change in sub-suppliers of materials.
• A change in manufacturing methods.
• Optional construction notes/methods.
• A change in manufacturing locations.

7.0 GAGES and CHECKING FIXTURES

Design of Gages or Checking Fixtures must be approved by AT&DC Quality Assurance Department.

8.0 STATISTICAL PROCESS CONTROL (SPC)

Process potential studies (Pp/Ppk) are required on all dimensions identified as significant characteristics (SC), as shown on AT&DC drawings or it's customers drawings. Additional significant characteristics may also be identified during the APQP process.

The minimum capability analysis requirement is:

SC=Pp/Ppk.1.67

Sample size is a minimum of 125 pieces (25 groups of 5) per cavity taken from the 1000 piece run as specified in 9.0 below.  If greater than two cavities, AT&DC Quality Assurance must be contacted to allow any reduction in sampling.

The minimum requirements for ongoing control is:

SC=Cp/Cpk.1.33

Processes for SC's not meeting that capability require 100% inspection.  A quarterly report is to be maintained showing performance levels for SC's.  These reports shall be kept available for AT&DC review.  If process capability falls below the minimum requirements, a detailed action plan is to be submitted to the AT&DC Quality Assurance Department.  The action plan shall include short-term corrective action, in addition to plans for achieving the requirement.

9.0 PRODUCTION PART APPROVAL PROCESS (PPAP)

Suppliers to AT&DC of production intent product such as weld nuts, weld studs, etc will comply with the current edition of the AIAG PPAP manual. The level PPAP required by AT&DC will be communicated to the supplier by the purchasing department. Suppliers to AT&DC coil steel, stainless steel, aluminum, etc will submit material certifications for all shipments of incoming product. At the discretion of AT&DC, or if required by our customers, 3rd party testing of product maybe required.

10.0 PRODUCT IDENTIFICATION, PACKAGING, LABELING, and SHIPPING

Sub-contractors are required to maintain identification of individual lots (LOT CONTROL). A lot is defined as: "A quantity of product expected to be homogeneous in all significant attributes as produced by the same production process and from the same master lot of material, and produced during a specific operating period up to one (1) working shift." The LOT NUMBER must appear on the outside of each carton, container, bag, triple wall skid box, individual coil of steel, etc.

11.0 DELIVERY

AT&DC requires 100% on time delivery. 

• The ON TIME WINDOW is the day scheduled or up to four (4) days prior to the scheduled date.
• All costs incurred due to late delivery (e.g. plant down time or excess freight) is the responsibility of the sub-contractor.
• Delivery performance is tracked and corrective action may be required for less than 100% on time delivery performance.
• AT&DC reserves the right to refuse or return without prior authorization any product quantities which exceed the total release quantity for the current week.  Exceptions to this rule are standard package quantities, minimum purchase quantities or written approval from AT&DC purchasing.

12.0 CORRECTIVE ACTIONS REQUIRED OF THE SUB-CONTRACTOR

When AT&DC notifies the sub-contractor of non-conforming material, immediate action must be take to certify product at AT&DC, certify product in transit and isolate if necessary product in the sub-contractors facility.

• Prompt (within 3 hours same working day) reply to AT&DC's notification of defective product is mandatory.
• Notification of WHEN replacement production will arrive at AT&DC.
• Additional inspection for the non-conforming characteristics must be implemented pending corrective action and must remain in effect until adequate capability is re-established.
• Corrective action reports following the "8D" format (or other approved format) are required for all cases of non-conforming material.
• Initial written reports are required to be FAXED to AT&DC within 24 hours.  The initial report must contain the following information:
• a)Identification/acknowledgement of the problem
• b)Identification of the sub-contractor contact who will handle the problem.
• c)Containment actions taken to prevent any further non-conforming material from reaching AT&DC.  Containment includes material at AT&DC or in transit to AT&DC

A complete corrective action report will be required within seven (7) working days.  Additional responses to future due date may also be required.  A revised copy of the sub-contractors PFMEA and CONTROL PLAN is to be submitted to the AT&DC Quality Assurance Department within fourteen (14) working days.

• As requested, the sub-contractor will be expected to attend meetings on corrective action.

Handling charges may be assessed for all non-conforming product.

13.0 BLANKET PURCHASE ORDERS

Blanket purchase orders are the preferred method for repetitive purchase of production items or outside process services.  Blanket orders are given for the following reasons;

a)To convey routine order information/requirements.

b)To maintain price stability.

Blanket purchase orders DO NOT constitute or guarantee the following;

Product or services will be obtained solely from this sub-contractor nor quantity purchases beyond actual releases.

14.0 TERMS AND CONDITIONS OF A PURCHASE ORDER