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Requalification
Here you will find the training courses organized thematically according to the 9 chapters of a requalification as per GS 90018 “Requalification of product and process at suppliers”:
1. Product Requirements
Contents of the chapter
Technical drawing, special features, specifications, sampling, standards, parts life cycles, change management.
Contents
Standards, specifications, technical drawings and parts life cycles define the exact requirements for the product. An understanding of BMW Group standards, correct document control, change management, but also the maintenance and safeguarding of special characteristics (SC) are necessary in order to achieve high delivery quality.
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2. Production Planning
Contents of the chapter
Production control plan incl. change management, E/E protection, ESD, documentation of production issues.
Contents
The production control plan (PLP) is of central importance for planning and controlling the production process. It ensures that all production steps and tests are precisely defined and adhered to. Changes must be handled stringently by change management to ensure that they are implemented correctly and in full. Where relevant for the component, E/E protection and ESD (electrostatic discharge) are key aspects to ensure the integrity of electronic components. The complete documentation of production faults is also checked.
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3. Test & Validation
Contents of the chapter
Safeguarding of special characteristics and reliability characteristics (process capability), test planning, measurement reports, fail safe.
Contents
Chapter 3 focuses on the methods for ensuring product quality using suitable test procedures. This includes the testing of special and reliability characteristics by means of process capability studies. Coordinated test planning, proper documentation of test results in measurement reports as well as the application of methods for "fail-safe" are essential here. This minimizes the risk of product failures and increases the reliability of the products.
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4. Requalification and Audits
Contents of the chapter
Planning of requalifications and audits, product and process requalifications, Q-organization.
Contents
The planning and implementation of requalifications and audits is essential for ensuring quality standards in the long term. This includes both product and process requalifications. A well thought-out quality organization supports the systematic monitoring of and compliance with defined quality objectives and requirements.
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5. Targets and Q-Loops
Contents of the chapter
Q-targets, sustainable actions, process-FMEA, 8D-reports, handling of rework / scrap, internal complaint process.
Contents
The setting and tracking of quality targets and the implementation of sustainable actions are discussed in chapter 5. The process FMEA (Failure Mode and Effects Analysis) identifies and evaluates potential failures and their consequences. Systematic problem solutions are documented and tracked using the 8D reports. Effective handling of rework and rejects as well as a stringent internal complaints process are also crucial for improving production quality.
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6. Sub-Supplier Management
Contents of the chapter
Q-evaluation of sub-suppliers, requalifications of sub-suppliers, delivery quality, change management for purchased parts, warehouse management (FIFO, …).
Contents
Chapter 6 is dedicated to quality assurance along the supply chain. The quality assessment of sub-suppliers, their requalification and the continuous assurance of delivery quality are of central importance. Equally important is change management for purchased parts and efficient warehouse management (e.g. FIFO principle) to ensure production continuity.
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7. Shopfloor
Contents of the chapter
Implementation of the production control plan, process control and process parameters, cycle times, work documents (work instructions (AA), process instructions (VA), test instructions (PA), …) incl. document steering & history, operational resources, work environment, assurance against faulty handling (Poka Yoke), testing of special characteristics, metrics (OEE, …), capacities, logistics, training of personnel.
Contents
The operational implementation of the production control plan is checked in production on the store floor. The focus is on process control, adherence to cycle times and checking work documents (AA, VA, PA, …). A safe working environment and error prevention (Poka Yoke) contribute to product quality, as does the continuous monitoring of key figures such as Overall Equipment Effectiveness (OEE). Educated and trained personnel form the basis for the successful implementation of these measures.
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8. Maintenance
Contents of the chapter
Management of spare parts, personnel (qualification, availability, …), maintenance plan.
Contents
Chapter 8 deals with the scheduled maintenance and servicing of production systems and machines. Effective spare parts management and well-qualified personnel are crucial to ensure the availability and functionality of the systems. This also includes maintenance plans that include regular inspections and preventive measures.
Links to Trainings
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9. Test Equipment
Contents of the chapter
Test equipment monitoring (calibration), measurement system analysis, limit samples/ reference damaged parts (red rabbits).
Contents
The monitoring and calibration of all test equipment is checked in chapter 9. Calibration is necessary to ensure the accuracy and reliability of the measurements. The measuring equipment capability guarantees, that the measuring equipment used is technically capable of safeguarding the properties to be tested. In addition, limit samples and reference damaged parts (red rabbits) are used to ensure an objective assessment of product quality.
Links to Trainings
If you would like to learn more about these topics and participate in the trainings, click here.