1. Business Operating System
ZFLS – Germany Accountability
ZFLS – Germany Accountability
ZFHS – St. Thomas, Ontario, Canada Accountability
Order Acquisition Sales / Marketing / Design / Contract Review
Order Fulfillment
Warrantee Fulfillment
Modification Notice Received
Log Modification Notice within SAP
Quality
Plan
Ship
Produce
Note: ZFLS has Design Authority – ZFHS processes Modification Notices as per ZFLS notification
Input relevant Changes
Quality
EDI Release > > Dealer Delivery
Distribute Modification Checklist Signoff
Drawing Change
All effected areas to update Drawing in use
Quality
Yes
Quality / Logistics / Engineering / Production No
Parts list change
Logistics
Bill of Materials update
Yes
Production Related Rework No
Technical Data
Quality / Logistics / Engineering / Production
Update Bill of Materials and/ or Drawing prints in use
Yes
Finished goods
44 DO
Create production order for rework volume
Approved
Demand
Approval of purchase request according to signing authorities
Fill out Purchase request form
Set up P.O. in SAP
Issue P.O to supplier
Logistics / Purchasing
Materials Expensed
Employee
Unfinished goods
44 CO No
Op 90
Reservoir Only
Accept Delivery
Clarify volume / price no
Return to Supplier
Reservoir Production
Yes
Conforming
Scrap
Unfinished goods
44 CO
In Production 44PO
yes
Logistics / Purchasing
Op 300 No
Yes No
Correct P.O price / volume
Logistics / Purchasing
Pack completed assembly into shipping container
Remove raw materials needed for Rework from 44PO / 44SO
Yes no
Band Required
Process Rework
Successful?
Finished goods
44 DO
Shipment
volumes & prices Accurate
P.O. existing?
Logistics
yes
Receive shipment against P.O / Follow Product Acceptance criteria
Ship to GM?
Internal /Supplier Nonconforming Product 44 QO No
Logistics /Quality
Yes
Central Inventory Components 44SO No
Logistics
Remove Reservoir, and Band from Box
Assembly Band on Reservoir
Yes
Material
Expensed
MSDS Available
Acceptable
Clarify with purchasing
Receiving
Op 600
Yes
Partial Op 60
Ship Product to GM with Green dot as per GP-12 requirement and sign off from QA Manager
Yes
Bracket Required
Final Inspection NO
Environmentally controlled ? NO NO
Yes
Record labor cost and material for rework
Verify WHIMIS label
Hold until MSDS Available
Apply Shop Label
Yes
Install Reservoir, Band and Bracket in fixture
Remove Reservoir, Bracket and Band from Box
Install and tighten Bolt to specification
Add Label to Band
Material handler verifies correct location of truck.
Unloads truck.Obtains paperwork from driver.
Counts # of skids and checks load
If qty of skids doesn’t match or there is damage to
any skid, this is to be marked on freight bill and the
Driver is to initial/sign and supervisor is notified
Material handler puts labels on the skid
And moves parts to the assigned location NO
QA inspect?
Op 80
44SO Central Inventory
Op 50
Op 60
Op 70
After truck is unloaded, material handler signs
Paperwork and keeps a copy
Product is washed according to appropriate cycle for product type & rack used
Yes
Piston, Worm, Housing, Cylinder Cover, Sector Shaft and Drilled Torsion Bar placed in appropriate racks and moved to washer
The material handler compares the packing slips
To part # on the containers/skids. If necessary
Wooden crates are removed and skid is prepared
For put away – mixed parts are put on separate skid
QA32 Awaiting QA release
(44QO unrestricted)
Material handler gives all paperwork to the Logistics office or puts in the assigned slot
Op 110
Yes
Op 10 & Op 20
Op 105
Subassembly of Torsion Bar Valve Body (WI~015)
Is Training Required? NO
Steering Gear Assembly
Verify Torsion Bar/Valve Ass’y Setup & First Off
Op 100
release to
Accounting
Accounting
Wash
Logistics Procurement receives paperwork and
Enters the receipt for each part into SAP on the
MIGO screen
Parts are issued to sub-assembly Ops No
Yes
Accounting
sign
Op 270
Assess training need
Op 120
Op 125
100% Testing in-line at Cell 70
Op 550
Conforming
Op 130
Labels automatically print for each part with
warehouse location assigned
Subassembly Worm Group Bench Op
Hydraulic Drilling Setup & First Off Verification
Logistics
Drilling Hydraulic Centre~019
yes
Pitman Arm?
Op 280
Conduct Training
verify
Attach Serial Number Plate Cell 80
preformed
Invoice / Customs
correct
manual
Op 150 no
Op 135
Op 137
Op 140
Op 285
Subassembly piston and steering limiter valve WI~016
goods cleared No
Piston Screw Machine Setup & First Off Verification
Piston Worm Machine Setup & First Off Verification
Subassembly of Worm Gear and Piston WI~020
Op 140
Yes
Training Effective?
Assembly Pitman arm to steering gear WI~013 NO
Yes
Op 290
Torque locking nut & stake to sector shaft Cell 90 WI~014
Op 300
Op 160
Op 400
complete
shipment
in SAP
Subassembly Cylinder covers WI~018
Attach lock nut /Pack completed assemblies into shipping container
Process Suspect Product
Final Assembly of Steering Gear
Complete transfer in SAP system and place into designated inventory location
Final assembly Cells See WI~003 to WI~009 Op
Op 500
Op 525
Op 700
Return Authorized Goods received at ZFHS
Ship to sub-contractor for paint op
Receiving Inspection
goods
Received at Customer Location
Logistics
load truck
Ship
Logistics /
Accounting
Logistics
call transport
company
Logistics
RGA notification sent to ZFHS Accounting
RGA notification sent to Customer
RGA notification sent to ZFHS Receiving
order
o.k.
End
yes
verify SAP
with
transportation
I Shaft Assembly
Subassembly of Station 1 Capping of Spider Joint WI~025
Op 100
change
system
Address Concern:
Op 10 & Op 20
Subassembly of Station 2 Profile Shaft Sub Assembly WI~026
Op 110
Assign RGA Number no No
Discussion: Is the “Quality Concern” an issue to be corrected and rectified
Subassembly of Station 3 Friction Test Station WI~027
Op 120
Representation required at Customer Site
Customer Complaint (GM specific)
Op 600
Subassembly of Station 4 Crimping WO~028
Final QA Inspection As required
Yes
Op 130
Issue Return Authorization
Op 550
Pick / Pack / Label /Barcode No
Check angular play in I-Shaft
Op 140
Logistics
Label correct?
Replace label with conforming information (Part Number and date)
Yes
Generate Internal System NCR
Send certified replacement product to Customer
Comply with Customer corrective Action requirements No
Send Representation
Conforming?
Sort ZFHS Product
Return Product:
Yes
Yes
Meets test parameters?
Assess No
Certify Stock at customer site:
Conforming
Zero Defect Reoccurrence
Track Trends
Internal Product Nonconformance
Supplier Product Nonconformance
Yes
Quality
Yes
Ship to GM? No
Op 600
Generate Incident Report
Ship Product to GM with Green dot as per GP-12 requirement and sign off from QA Manager
Final Inspection Refer to Final Inspection Form ZFHS-1510-QA
Op 300
Accountable Party
Level
Environmental Nonconformance NO
Root Cause Analysis
Assign NCR / set target date
Quality
Yes No
Direct Scrap
Yes
Major Emergency NO
Implement Corrective Action
Effective?
QA Released NO
Yes
Suspect Product
Conforming
Yes
Return to 44PO / 44SO / 44CO / 44DO or Return to Customer
Yes
Tag
QA Assess
Follow Emergency Plan PR-036
Plan & Implement Preventive Action if appropriate No No
Internal Product Nonconformance
Issue NCR / Incident Report
Quality No
Quarantine 44QO
Quality
Effective?
Zero Defect Reoccurrence / Close NCR
Return to Supplier
Yes
Determine Accountability
Obtain Supplier RGA#
Return to Supplier at Supplier Expense
Certified replacement stock
Supplier Nonconforming product Disposition
Supplier Product Nonconformance
Issue NCR / Incident Report
Disposition
Obtain Supplier Rework Authorization
Rework at Supplier Expense
Conduct Rework
Conforming Stock
Scrap at Supplier Expense
Certified replacement stock
Obtain Supplier Scrap Authorization
Scrap