Engine Group Supplier Pass-Through Characteristics
What is a Pass-Through Characteristic? All products and processes have features described by characteristics that are important and need to be controlled. However, some characteristics (called Special Characteristics) require extra attention/efforts to minimize the risk of adverse consequences. Special Characteristics are those product or process characteristics that affect vehicle or process safety, compliance with government regulations, or customer satisfaction, and for which specific actions are required to ensure products will meet all engineering requirements. Special Characteristics are identif during the DFMEA/PFMEA process, and are include on the control plan. Special characteristics (Critical Characteristics (CC or Ford inverted delta) and Significant Characteristics (SC)) are either managed with special controls (see below), or, in the case of High-Impact Characteristics (HIC), receive special emphasis (and appear on process control documents). Pass-Through Characteristics do not meet the FMEA criteria to be Special Characteristics, but require special controls because of their impact on the customer. Your product characteristics are classif on your control plans as:
Class. column Blank CC What the designation indicates Not an identif Characteristic Critical Characteristic affects regulatory compliance or safe functioning Significant Characteristic, reduced variation will improve satisfaction High Impact, either a YC which does not require special control, or if out of specification would have a severe impact Potential Pass Through Characteristic Criteria (1 is OK, 10 is bad) Severity 1 Severity 5-8 and Occurrence 4-10 Severity 5-8 and Occurrence 4-10 Action required Control effectively with normal controls Use special controls and have proof Cpk >1.33 Use special controls and maintain Cpk >1.33 Special Emphasis, Cpk >1.0
Severity >4 and Occurrence 6 and is not controlled by subsequent processing
Communicate with your customer(s) to determine if it will have special controls
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Engine Group Supplier Pass-Through Characteristics
Class. column P What the designation indicates Pass Through Characteristic Criteria (1 is OK, 10 is bad) A YP and there is agreement with the customer to add special controls Action required Use special controls
How do you identify a Pass-Through Characteristic? It is a “Form, Fit or Function” characteristic, a part print feature, and meets ALL 4 of the following criteria: 1) FMEA identification: Severity of 5 or greater (“vehicle operable, comfort or convenience item operable at reduced level, custome 100 % reworked, or repair outside the repair department”) o Occurrence of less than 4 (note: if O >= 4, they would be an SC with a Severity of 5 or greater), o Detection of greater than 6 (i.e. the detection is not already using “Zero Defect Methods” (see below)) o Is not a Special Characteristic (these are already subject to special controls). 2) Is not controlled or functionally tested by International and is not controlled by subsequent processing of the using Ford plant (i.e. it will pass through to the final customer), 3) Is identif by International or the OEM customer that if defective it would have a significant impact on customer satisfaction and warranty (note: the customer may choose to identify any characteristic as a “Pass Through” characteristic), 4) Supplier, International and/or OEM Customer reach an agreement on the proper method of control. Pass-Through Characteristics include all characteristics or features of parts suppl to International which are not controlled by subsequent processing at the International plant and meet the criteria listed above. You have to accept the FMEA team ratings as correct, and that the management of identif Special Characteristics is adequate. Pass-Through identification is not an effort to re-do or second-guess the decisions of the APQP team. Issues with APQP adequacy, including FMEAs and Control Plans, are handled with a Supplier Quality System Review. o
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Engine Group Supplier Pass-Through Characteristics
What is my responsibility when for Pass-Through Characteristics? You use “Zero Defect Methods”, which are process control techniques which assure that all parts manufactured meet the design specification. Examples include: 1) Discrepant parts cannot be made because the item has been errorproofed by process/ 2) Error detection in-station (automatic gauging with automatic stop feature). Cannot
3) Error detection in-station or error detection in subsequent operation by multiple layers of acceptance: supply, select, install, verify. Cannot ac 4) Error detection in subsequent operations, OR gauging performed on setup and first piece check (for setup causes only); 5) 100% inspection in station or in s 6) Pre-control (qualif based on capability), SPC, or Sampling (qualif based on capability). The decision on the solution has to be shared between supplier and customer so that they reach consensus on the appropriate controls to be used. The Quality Management System documentation (FMEAs, Control Plans, Work Instructions, etc.) must be kept up to date. Once any system is implemented, measure the effectiveness until you have verif that it works. This is often a joint effort between supplier and customer. What is the process to identify Pass-Through Characteristics? Follow the steps below to develop candidate Pass-Through Characteristics (YP). You should also talk with your customer, review their concerns, and review their historical data and market research. All YP’s must meet the four (1) requirements for Pass-Through Characteristics, listed above. The Pass Through Characteristic Worksheet is designed to assist you with this process. Once you have identif the YP’s from your FMEA review, or customer input, record them on the format, below, for the next step, which is confirming your Pass-Through Characteristics in conjunction with your: o Determine if the YP is controlled or functionally tested in subsequent operations at the using Engine Assembly Plant(s). Your customer can then determine that each YP characteristic or failure mode is not controlled by subsequent processing of the using (Ford) plant. If the YP is not controlled in subsequent operations either in sub-Tier supplier operations or the International Engine Plant(s). then your customer has to decide whether a part with the defective YP characteristic would have significant impact on customer satisfaction or www.internationalsupplier.com /Engine Group – Page 3
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Engine Group Supplier Pass-Through Characteristics
warranty. They must decide whether the cost to prevent (mistakeproofing) is less than their cost of warranty and customer dissatisfaction. o You and your customer must then reach an agreement on the appropriate action (mistake-proofing or other controls) to ensure zero defects reach the customer. o You complete the action and establish verification (such as a rabbit) to ensue that it is effective, along with the appropriate work instructions. Update your FMEAs, Control plans, and Work Instructions using the symbol “P” to represent a Pass-Through Characteristic. Provide the information to your customer in the form below or other format with the same information:
Supplier # Supplier Name Customer Decisions: Supplier Contact
Process / Operation
Description
Characteristic / Failure Mode Enter the symbols for detection (see list below) Supplier Process Internal Supplier Process (identify) Pass Thru to (Y or N) Subsequent Process
Contact Tel. #
Communicate with International Please contact us if you have questions. It’s bad enough to have problems, but not communication your difficulty or concern until it is too late for effective action compounds your difficulty! See International Engine Group Supplier contacts Owner/Approver: Steve Branson Author: Tony Greene Revision Date: 11/21/05 New Work Instruction www.internationalsupplier.com /Engine Group – Page 4
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Ford process
Engine Group Supplier Pass-Through Characteristics
Revision Date: 10/16/2006 End of document. More defined method to develop candidate pass-through characteristics.
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This is an electronic document. If printed it is not controlled. DW000D05-Rev. Date 10/16/06
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