Presentation on theme: "1 Confidential PCR Process Change Request Mike Rizuto Supplier Development Technologist March 16, 2015 Rev 3."— Presentation transcript:
1 Confidential PCR Process Change Request Mike Rizuto Supplier Development Technologist March 16, 2015 Rev 3
2 Confidential Overview We are at a supplier and we notice that one of the operations does not match the Control Plan. When the supplier is asked they state, “Yeah we used to run that operation on a vertical machining center but due to capacity constraints we moved it to our horizontal machining center. We haven’t updated the Control Plan yet.” “Really? I noticed the features have KPCs attributed to them have you established related Cpk values? Have you updated the Work Instructions? When did this change take place and was the process change PPAP’d through our PQR system?” Unfortunately the scenario above is not so uncommon. Suppliers not fully in tune with Polaris requirements do not know that most changes require a PPAP submission as defined by our PQR or at least a form of Polaris acknowledgement and approval. Most suppliers are not aware that unapproved changes put liability squarely with them. Once they are shown the PCR and approval by the customer removes the consequences from them to the customer they are usually very willing to comply (CYA). SQEs want to know that all processes are controlled including those of Tier I and II suppliers. Engineers want to know their prints and specifications are adhered to, Buyers cost opportunities realized and will review suggestions from the supplier which will enable that. Schedulers want to know if scheduled deliveries are going to be affected and Service Parts wants to know the gasket kits they purchased will continue to work with implemented changes. What does Polaris have which will communicate the above, route it and document the results? The PCR (Process Change Request) described in this presentation achieves those goals. Typically few know the processing capability of our supply base better than the SQE. SQEs have received training and related publications associated with PPAP implementation and have audited the supplier’s processes. It is usually the SQE who assists the supplier in understanding PQR/PPAP requirements. Who better to control the PCR process and subsequent PQR/PPAP submission? Rev 3
3 Confidential Rev 3
4 Confidential 1st Tab of the PCR Workbook Polaris Industries, Inc. must control the products and services provided by our supply base based on approved and validated products and processes. Polaris requires notification and right of approval of any proposed changes BEFORE implementing such change including rework which is done outside of the previously approved process (Control Plan/Flow Chart). Notification is achieved by completing and submitting, to the assigned Polaris Supplier Quality Engineer (SQE), a completed Process Change Request (PCR) spreadsheet. Changes as defined in the two tabs (When PCR is Req. & When PCR is Not Req.) includes but not limited to: material (purchased parts only), location of production, new or modified non-perishable tools, method of manufacture, subcontractor, services, drawings (revisions - purchased parts only), testing, inspection, or processing should require approval by Polaris Industries, Inc. Changes are not to take place without prior PCR acceptance. A PCR is a process change not a substitute for a Deviation Request or a Design Change Request (DCR). All requests associated with the Design Record will continue to be channeled through Deviations or DCRs. PCR’s shall be submitted through the supplier’s assigned Polaris Supplier Quality Engineer (SQE) or Supplier Development Engineer (SDE). To avoid delays in reviewing and approving include all supporting documentation such as timelines, drawings, photos, etc. the PCR should be as complete as possible when submitted. Accepted PCRs may require a Production Part Approval Process (PPAP) submission subject to the requirements noted on the PCR/PQR. When submitting PPAP’s based on PCR acceptance please include the approved PCR in element 2: Engineering Change Documents within your PQR/PPAP submission. An accepted PCR only grants permission to proceed with the change under the control of the supplier. Polaris PQR approval is required before any affected product is allowed to ship to Polaris. In the event this procedure is not properly followed Polaris will take appropriate actions needed to recover any costs associated with complications caused by unapproved changes to the products and services provided by suppliers. This will include, but not limited to, scrap, rework, production downtime, warranty, etc. If you have any questions feel free to contact your Polaris SQE or SDE. We appreciate your attention to this important matter.
5 Confidential 2nd Tab of the PCR Workbook Supplier completes white fields, Polaris completes grayed area of the cover sheet
6 Confidential Tabs of the PCR Workbook Subsequent tabs are used to support the change request. The more complete the data the faster the request is reviewed. The last tab “Polaris Notes” is where Polaris responses will be noted including content from reviewers.
7 Confidential Routing If the supplier is requesting only a process related change the PCR can be evaluated by the SQE/SDE or plant QE for dispositioning If the requested change may influence Design Record requirements or technical information the PCR should be routed to Engineering for approval If cost or delivery will be impacted then the Buyer and/or Scheduler should be included for approval Sometimes it is a good idea to consult with SMEs prior to approval Some changes may be internal to the product where Service Parts should be advised, i.e. internal seal kits Polaris will list names of internal personnel PCR is routed to for approval
8 Confidential Accepted/Rejected and PPAP Requirements If the PCR is accepted submission requirements noted here will match the PQR Note: If we accept the supplier is responsible for compliance and Polaris is responsible for the consequences of the change