Ford Q1 vs. QOS vs. QS-9000's TE Supplement - Will Ford want anything else?

[Linda Jurasin]

The company I work for is preparing for QS9000 with Tooling & Equipment Supplement. From some of the classes I have attended, I was told that if our company is QS9000 with T/E then we are automatically Q1. Is this true? Also, please explain the difference between Ford's Q1 and QOS. Based on your answer/explanation, when my company becomes registered to QS9000 with T/E, will we need to do anything different for Ford? Thanks in advance for your help.

Hmmm, well, good questions, Linda. Having just been through the TE registration process, AND Q1 status with Ford, the campaign is still fresh in my mind. Let me see if I can shed some light here, (or maybe further muddy the waters..)

First of all, you are to be commended for doing QS and TE..these are daunting tasks, and require alot of time, effort and patience......

Becoming QS-9000 and TE does NOT automatically make you a Q1 supplier. Ford will initiate that themselves, if they want you to participate in the Q1 program. You have to be a long-term, preferred supplier to Ford, in order to be considered for the Q1 program. The company I work for, is considered a TE supplier by Ford, (non-production parts). Part of the Q1 requirements for TE suppliers is COMPLIANCE to certain elements of the TE Supplement..note I did not say "registration". Basically, the R&M elements have to be implemented for the products that you sell to Ford. There is a system of customer endorsements, and a "grading scale", that you must satisfy, based on your performance, to be considered for Q1. My company made an internal decision to do full registration to TE, not simply compliance.

Part of the Q1 criteria is the development of an ISO-9001 system, (this you MUST be third-party registered to for Ford, by the way). If you are implementing QS-9000, look in the back of the QS manual, to the Ford specific requirements. There, you will see a "shall" for implementing a QOS. QOS= Quality Operating System". BAsically, this is a system of internal and external business and performance measurements, i.e. PPM, OTD, and whatever else is important to your business. You need to set goals, and show progress towards them, etc. If you are doing QS, you will satisfy the intent of a QOS through your QS-9000 measurable systems. i.e. PPM analysis, COQ, OTD, etc.

My suggestion for you would be to read and understand the Ford-specific requirements that are spelled out in the QS-9000 manual. In addition for the requirement for a QOS, is the need to utilize Ford's version of the AIAG APQP manual. It is called" FAO Advanced Product Quality Planning Status Reporting Guideline". If you are not familiar with this document, let me know, and I will get you a phone number to get it from, along with lots of other Ford stuff....Q1 info, QOS info, etc.

Again, being QS-9000 and TE compliant does NOT automatically make you a Q1 supplier, but it will satisfy the vast majority of the requirements. If you are doing alot of work for Ford, contact your STA there, and ask him about Q1. Ford is "revitalizing" Q1, and you will see more and more about it in the months to come.

Let me know if you have more qestions.

Bryon

Good luck with your QS/TE efforts.

[Linda Jurasin]

Bryon,

Since we design manufacture & market automated systems that apply adhesives, sealants & coatings to consumer & industrial products, some of the Ford -Specific requirements do not apply. We have been selling equipment to Ford for a number of years but to the best of my knowledge have not received any type of Q1 rating in the past.

No, I am not familar with Ford's version of AIAG APQP manual. Please provide the phone number regarding FAO Advanced Product Quality Planning Status, Q1 and QOS.

Thanks for everything, I appreciate your help & information .

Linda

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Sorry about the delay in responding..I have been quite busy of late.

Ok, phone number for Ford APQP book

(248) 398-7900

For the QOS information..there is a book out there called the QOS primer.....very helpful. Itis available from

Ford Motor Quality Publications
c/o edcor Data Services
P.O. Box 9079
Farmington Hills, MI. 48333
Phone (248) 626-3077

THey should also have some information about Q1 criteria also.

Hope this helps.

Bryon

This is the NEW Ford Q1 process (as of 7/24/98).
1) Provide copy of ISO Scope (to be sent with petition)
2) Provide copy of recent ISO audit summary and recommendations (to be sent with petition)
3) Include Reliability & Maintainability Section in Quality Manual (to be sent with petition)
4) Include Equipment Prove Out Section in Quality Manual (to be sent with petition)
5) ISO auditor should comment on R&M and Equipment Proveout Procedures
6) Quality Manual should specify that it complies with the 7 Categories of Ford Q1 Quality Operating System (QOS) requirements below (Communication, Teamwork, Management
Review, Measureables, Qualifying Tools, Continual Improvement, Dynamic Process):
a) Communication
i) Employees at all levels are aware of the FORD Q1 (QOS) process. NOTE: "Constant" awareness is recommended).
ii) Senior management has communicated clear expectations of the FORD Q1 (QOS) process.
iii) On-going performance is communicated regularly.
iv) The FORD Q1 (QOS) methodology has been communicated to the supply base, if
applicable.
b) Teamwork
i) A champion is identified for each measurable and is actively involved with teams.
ii) Teams are allocated resources to function effectively. (NOTE: Monthly meetings are recommended).
iii) Cross-functional problem solving and quality improvement teams have been established to work on opportunities identified by the FORD Q1 (QOS) process.
c) Management Review
i) Regular scheduled reviews are held.
ii) Evidence exists to support the FORD Q1 (QOS) process.
iii) On-going performance is tracked.
iv) Status of action plans and problem solving activities are reviewed.
d) Measurables
i) Internal and external Customer expectations are identified.
ii) Selected measurables relate to key processes and predict internal and external Customer satisfaction.
iii) Measurables for quality and delivery to Ford are established. (Note: this is not part of the Ford Q1 QOS Assessment form, but is part of the Endorsee process).
e) Qualifying Tools
i) Performance analysis over time used.
ii) Performance targets identified.
iii) Problem prioritization used.
iv) Structured problem solving used.
f) Continual Improvement
i) The FORD Q1 (QOS) process provides examples of quantifiable improvements which are significant and sustainable.
ii) Improvement trends correlate to measurables of internal and external Customer satisfaction.
g) Dynamic Process
i) Senior management champions the FORD Q1 (QOS) process and ensures its on-going
effectiveness.
ii) Periodic contact is made with internal and external Customers to verify or update expectations.
iii) Periodic reviews of key processes and measurables are made to ensure their continued suitability and effectiveness.
7) ISO auditor should comment on the compliance to Ford Q1 QOS
8) Obtain 3-10 endorsements (Plant Engineering or Manufacturing Manager) from Key Ford Customers, with new business within the last 24 months, as determined by the Ford Buyer
9) Ford Endorsees must score Q1 applicant 10 or more points out 15 possible points on these 5 Critical Questions:
a) Timing - Was the product delivered according to schedule?
b) Quality - Does the product meet the performance criteria (uptime, Cpk, Ppk)?
c) Quality - Did applicant provide adequate R&M data and (evidence of) and ongoing improvement program?
d) Cost - Did the product cost meet Ford objectives?
e) Installation Performance - Did applicant provide adequate service or support?
10) Ford Endorsees must score applicant on these 6 categories of the Supplier Performance Rating
(Timing, Quality, Cost, Program Management, Installation Performance, Performance of
Sub-Contractors):
a) Timing
i) Were design approvals submitted on time?
ii) Was the product delivered according to the agreed schedule (Critical Question #1)
iii) Was the product commissioned or runoff in appropriate time?
b) Quality
i) Does the product comply with Engineering specifications or standards?
ii) Does the product meet the performance criteria (uptime, Cpk, Ppk)? (Critical Question #2)
iii) Did the Supplier provide adequate R&M data and (evidence of) and ongoing
improvement program? (Critical Question #3)
iv) Did the Supplier effectively participate in Advanced Quality Planning?
c) Cost
i) Did the Supplier willing participate in cost improvement programs (SE, VA/VE)?
ii) Did the product cost meet Ford objectives? (Critical Question #4)
iii) Do you believe Engineering and process changes were fairly priced?
iv) Did the Supplier effectively manage Engineering changes?
d) Program Management
i) Did the Supplier provide adequate open communication and competent program
management skills?
e) Installation Performance
i) Did the Supplier provide adequate service or support? (Critical Question #5)
ii) Did the Supplier's Field Supervision ensure specified equipment or product functionality in time?
iii) Was the appropriate documentation, manuals & drawings on time?
iv) Was a recommended spares list available after commissioning?
v) Did the Supplier provide adequate training?
f) Performance of Sub-contractors
i) Did the sub-contractors (under applicant direction) perform to an acceptable standard?
11) Additional requirement for TE Suppliers - Obtain GREEN R&M status by 12/31/99 per RED-YELLOW-GREEN Report created by Hal Raffa of Ford Machinery and Tooling.
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our company prepare for Ford APQP
i would like to have some information or refernce about CRAFTSMANSHIP.