Agenda: Training on Tenneco Supplier Manual

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 TABLE OF CONTENT

SECTION 3: PURCHASING
SECTION 4: SUPPLIER PERFORMANCE & ENGINEERING RE-
QUIREMENTS

SECTION 5: TOOLING & EQUIPMENT

SECTION 6: LOGISTICS

SECTION 7: PACKAGING

SECTION 8: ENVIRONMENT HEALTH & SAFETY

SECTION 9: CORPORATE RESPONSIBILITY FOR AUTOMO-

BILE CHAIN

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3.1 & 3.2 – Organizational & Operational Philosophy

 Supplier shall be committed and strive for-
 Highest quality,
 Most competitive pricing,
 Consistent schedule delivery
 Variability reduction
 Continuous Improvement
3.3 – 3.09 – Ethics, Supplier Criteria, Initial Assessment, RFQ,
Scheduling agreements, Shipping Releases, Service orders
 It is Tenneco ethic policy that personnel and supplier must not engage in any
activities nor have any personal or financial interest outside Tenneco.
 As per supplier criteria- Supplier shall be globally competitive in quality, technology,
service and cost, be capable of validating products for Tenneco specific
applications.
 Supplier must submit RFQ with detailed cost breakdown
 Service Orders- Order is issued to cover special processing of material by the
supplier are referred as service order

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3.10 – Fabrication & Raw Material Authorization
 Supplier shall be authorized only to keep maximum inventory as listed below:
 FG – Two weeks
 WIP- Two weeks
 RM – Two weeks
 Supplier shall keep two weeks Safety stock of material at any point of time
 Buyer may return over shipment at supplier expense (packing, handling, sorting &
transportation)
 Supplier shall maintain minimum inventory level of FG to ensure no effect on
Tenneco production line, for Export suppliers having regional warehouse there
should be an internal (manufacturing site) escalation level as well for external
(Tenneco)
KEY FACTORS
3.10.1 – Contingency Plan Requirements
 Tenneco promotes standard
documented method for carrying out
risk assessment, mitigating risk in plant
continuously, with validation & External Natural
Equipment
sustenance Influences Disaster

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3.11- 3.15 – Business review meetings, Supply Agreements, Prices, Finance &
Payment/ Terms/ Conditions
 Tenneco will invite supplier to participate in Business Review Meetings
 Supply agreements for repetitive, higher volume requirements are normally
awarded for a minimum period of one year, long terms (3-5 years) are frequently
negotiated.
 Suppliers are expected to offer suggestion to avoid price increase/ decrease in
existing cost but must comply with the Tenneco process change notification.

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4.1– Quality Systems
 Tenneco requires original equipment supplier to be certified with the latest version
of IATF and their system shall comprises of all Tenneco customer specific
requirements and to ensure ongoing conformance, a yearly assessment will be
completed.
 Exemption right reserved with Tenneco Direction and Quality Head

4.1.1– Engineering Design Rules and CAD Requirements

 At the start of each project, supplier must comply with Tenneco design rules and
CAD standards

4.2– Advanced Product Quality Process (APQP)

 Supplier’s organization to provides support/ resources for Advanced Product
Quality Planning
 Tenneco APQP tracking template to be use for APQP
 During Kick off, Pass through characteristics is identified and discussed and should
be reflected in the control plan with additional control in place (Poka Yoke, gages
etc.)

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4.2.1– Feasibility
Suggestion for
Drawing Not Feasible Feasibility by
Supplier

Identified concern If Feasible,

should be uploaded
via C Folder Upload in TITAN

4.2.2– Packaging Planning

 Packaging should be appropriate to ensure
 Preservation & protection of part during transportation.
 Efficiently handling & storage in Tenneco plant
 Comply with Materials Group of the Tenneco receiving facility, as specified in
the packaging plan.

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4.2.3 &_.1&_.2 – Launch Containment Requirements, Process & Exit Criteria
 To ensure
 100% defect free product
 100% compliant to fit, form, and function and properly identifiable at Tenneco
facility.
 Containment must also confirm capability to Significant and/or Critical
characteristics as identified by the supplier’s control plan.
 Supplier must submit the containment plan with inspection criteria in the
designated c-folder in TITAN prior to PPAP submission, CP shall be used
to document containment plan.
 Supplier will document and maintain containment results in alignment with the
approved control plan in the form of I-Chart.
 The containment shall start from first part shipped and continues till 90 days of
after initial samples and no less than 10 shipments after SOP.
 Exit after complying the above requirement
 If NC occurs during containment phase, it will be extended to 30 more days
after corrective action implementation.

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4.2.4 – Capacity Verification (Run@Rate)
 Capacity verification shall be done after PPAP approval, Tenneco reserves the right to
present during verification.
 During Run@ Rate following documents shall be reviewed:
 Process documentation & Part Quality
Daily Machine Capacity
 Capacity Calculation should be based on below criteria: Requirement
 Daily working of 20 hours
 5 Working days/ week
 48 (240 Days) Weeks/ Year
 Supplier must demonstrate serial production of minimum 300 pieces to ensure process
capability
 Run@ Rate approval requirements
 If meeting requirement D_MCR 100% - Completely Approved
 Meeting requirement D_MCR and
bottleneck process utilization is 90% - Approved with Caution
 Output < D-MCR – Red & Unacceptable,
(Follow up Run@Rate required)

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4.3 & 4.3.1– Production Part Approval Process (PPAP) & Submission
 PPAP approval is mandatory before shipment of product to Tenneco as per PPAP
requirements from the AIAG to the latest revision.
 Upon completion, supplier must upload PPAP documents in the TITAN. Documents
must be placed in the individual assigned C-folder
 Document must be save with appropriate file & name, e.g. Control Plan_30.03.2020 T
 PPAP Level 3 is Tenneco requirement, any waiver must be in written form.
Collaborative
4.3.1.1 – PPAP submission –Sample Folder Part 4.3.2.1 – Design Records
A minimum of 6 samples or 1 samples/cavity Supplier shall perform on going capability
study for special characteristics
These samples are random pcs. Form serial production
A training program about measurement,
Specific min. 300 pcs in single production/1-8 hrs. evaluation, and failure effects of these
characteristics must be developed for all
Identification is as per Tenneco PPAP sample label)
employees
This label must be printed in color - PINK Characteristics must be notified on PFD,
PFMEA & CP

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4.3.2.2 & 4.3.2.3 - Engineering change documents & Approval
 Written approval from Tenneco engineering is required for changes yet not incorporated
into the design records.
 Any deviations from design record required Tenneco engineering approval.

4.3.2.4 – DFMEA 4.3.2.5 – Process Flow Diagram

Not applicable Define Manufacturing process/ sequences

Identify Critical, key, Special or significant characteristics

Pass through characteristics must be identified as PTC

4.3.2.6 – PFMEA
When design is of Tenneco or its customer, Severity values of PFMEA may required Tenneco engineering
approval
If severity rating > 8, Poka yoke is must unless waived off in writing given by Tenneco Engineering
PFMEA shall be reviewed minimum at least once in a year
Supplier must indicate review of high RPNs and note in the corrective action, otherwise mention none, PTC
severity must not be less than 5.

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4.3.2.7 -Dimensional Results 4.3.2.8- Material/ Performance Test Results
Dimensional results must comply design requirement Submission, evidence of compliance

Ballooning shall be done of all dimension and notes Compliance of Material

One Master sample must be kept for future reference Compliance of required test

Capability studies are one of the

key requirement for PPAP
4.3.2.9 – Capability Studies acceptance
Capability studies to be carry out for CC/SC’s and PTC
Select pcs from significant run by taking 5 pcs skip X pcs, then take 5 until 125 samples
Normality test must be carried out before any capability study, P Value > 0.05
Results Interpretation
Index >1.67 The process currently meets the acceptance criteria

1.33 ≤ Index ≤ 1.67 The process may be acceptable, contact the authorized customer representative for a
review of study results
Index<1.33 The process doesn’t currently meet the acceptance criteria

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**MSA studies are required for gauges, measuring and
4.3.2.10 –Measurement System Analysis test equipment
Variable Gauge R&R Attribute Gauge R&R
• Should utilize 10 parts, 2 operators and 3 trial • In case of SC/ CC – 50 samples else 30 samples
• Selected samples should cover all the • Parts selection for Attribute study
manufacturing variation range • 25% near to LSL & USL
Acceptance Criteria based on R &R Studies • 30% of the process variation
• 10% should be outside LSL & USL
< 10% of tolerance Accepted
• Gauge must reject parts that are outside of
10-30% of tolerance May be acceptable, specification limit
contact Tenneco • Kappa Value (b/w appraiser, within appraiser,
> 30% of tolerance Unacceptable appraiser to standard) > 0.75
• In case of Guard Banding, Kappa value < 0.75
NDC (No. of Distinct Categories) --5 acceptable in case of false alarm
Measurement System Gauge Correlation (MSC)
• Establishing a correlation b/w Tenneco and the supplier by comparing 2 or more measuring instruments
required by guidelines below:
• MSC requires 10 minimum parts to be numbered and measured on all instruments to be correlated
• Part selected must be from full tolerance range
• Measurement system must be calibrated with adequate resolution and also pass gauge R&Rs
• Randomizing the order of measurement of the parts during MSC is a best practice

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4.3.2.10 –Measurement System Analysis
Measurement System Correlation Acceptance Criteria
If [R]>0.80, then the association is practically significant
Coefficient of If [R]<0.20, then the association is not practically significant
Determination, R
R-squared, the association is practically significant is >.64

< 3% at USL & LSL Accept

Offset
3%<offset<5% Marginal Accept
Linearity to Master Pass the hypothesis testing that slope between the master & the reference value =1
%SV & %Tol: 10% Acceptable Gauge
%SV & %Tol: 10% May be acceptable based on the importance of the application i.e. non-critical product.
to 30% Characteristics, cost of gauge, cost of repair etc. The tenneco approval team shall determine

%SV & %Tol: Over The measurement systems need improvement. Identify the problem and have them
30% error corrected
4.3.2.11 –Qualified Laboratory Documentation
External laboratories shall be qualified to ISO/TS-17025 or equivalent

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4.3.2.12 –Control Plan Requirement Acceptable

CP should Annual Special

Annual Part Part family CP
comply AIAG Process/ Characteristics
re-validation acceptable
requirement Product Audit incorporation

4.3.2.13 –Part Submission Warrant 4.3.2.14 –Appearance Approval

No Blank spaces are acceptable in PSW, Based on Tenneco requirement, it will be notified
must be sign off with date and contact no. whenever required

4.3.2.15 –Sample Production part 4.3.2.16 –Master Sample

Requirement

Must be defined as Samples must reach Master samples

Min. 6 samples PPAP samples at Tenneco before must be retained-
during shipping PPAP due date 1 nos.

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4.3.2.17 –Checking Aids
Checking aids must comply requirement of products
Preventive maintenance plan of checking aids

4.3.2.18 –Customer Specific Requirements (Tenneco & End User)

Requirement
Product IInd Party Auditor Annual Audit for Control of Supplier
Safety Competency special characteristics Changes Selection Process
Management of production, tooling and manufacturing, Release of Product &
test, inspection tooling & equipment Services

4.3.2.19 – Process Audit Requirements

Requirement

Requires Special Process Audits to be attached in Supplier’s

AIAG template to be used
Audit once in a year TITAN Assessment C Folder

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4.3.3 –PPAP Approval
Fully Approved
Part comply to product Tooling vendor Supplier tooling
Capacity Self
characteristics and fit registration form invoice will be paid
Assessment completed
& function Ok submitted with PPAP after full approval

Interim Approved
As long as the part is in Be granted only when
Tenneco may permits
Fit, form and function organization has prepared an
interim approved, no shipment of material for
impact must be evaluated limited qty
action plan agreed by
Supplier tooling to be paid Tenneco

Returned
PPAP
Production part delivery
Re-submission date must
Tenneco cost fee may be upload in
be agreed by Tenneco
is not allowed
PPAP Coordinator
applied TITAN –C
folder

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4.4 –Certified Parts Process (Optional)
Phase 1- If 5 lots ok Phase2 – Certified parts, if any defective part reach at Tenneco facility
then parts will be back to phase 1 and the cost of inspection has to be borne by supplier.
4.4.1 –Ongoing Quality/ Annual Parts Validation Requirement
 Annual part validation shall be done, you may exclude dimension which are
measured frequently
 The supplier must have a robust extended downtime planning process that
includes a shutdown/ startup checklist.

4.5 –Change Requests Tenneco required parts with revised drawing

4.5.1 –Deviation Process In Situations

Non-conformance in a lot/ batch but
required to run Tenneco Production line
Authorization shall be in When deviation request raised must ensure
Approved deviation
writing obtained from below details to share with Tenneco:
copy shall be attached
Tenneco Engineering & RequirementCurrent SituationQty
with shipment Invoice
affected manufacturing site affected Duration of deviation

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4.5.2- Process Change Authorization
Tenneco reserves the rights to approve or deny a request made by the supplier to change a
process or product.
Any changes in Any changes in Non-authorization
PCN approval Re-PPAP
design/ process design or process change & material
process is of required for
without prior should be disposal cost has
minimum 90 PCN & in
information is performed only to be borne by
days TITAN
considered as MRR after authorization supplier

4.6 –Supplier Performance Requirements

 Supplier performance is monitored and reported monthly (both quality and delivery)
 Supplier may review their performance in TITAN – Tenneco Cognos Report
 If not meeting the Tenneco performance requirement their should be a drive to meet.
 Failure to meet Tenneco’s expectation may lead to business hold or further actions

4.6.1 –Quality Performance

 PPM (part per million) Target – Zero
 Number of eMRR/ MRR’s- Material Rejection Report PPM
 Corrective Action Report, 8D

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4.6.2- Delivery Performance
Tenneco required 100% on time delivery, NC w.r.t. to delivery will cause creation of
MRR/eMRR, corrective action to be submitted.
Shipping Premium Freight: Any
Labeling: Any Supplier Late/ Over
Documentation: shipment expedited
part container Packaging: Not Delivery &
Any shipment that into Tenneco due
non-comply complying Tenneco Damaged
doesn’t correct shipment delays/
Tenneco Spec. packing guidelines Packaging
documentation quality issues

4.6.3 –Service Parts Delivery Performance Any extraordinary

cost has to be borne
 Supplier must support up to 15 years of service part requirements by supplier
after serial production is completed
 Supplier must maintain equivalent serial production pricing for a
period of 5 years, minimum, after serial production is completed
4.6.4 –Quarterly Supplier Scorecard
Measures on
Quality Delivery Service Cost

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4.7- Continuous Improvement
 Continuous improvement shall extend to all product characteristics with the highest
priority on special characteristics.
 Characteristics identified as PTC are required to have error-proofing (Poka-Yoke)
 Suppliers are required to have a defined Business Operating Procedure (BOS) for key
metrics monitoring
4.8 –Material Rejection If NC identified
All validated NC will Wherever, similar parts Suppliers must ensure
Communication
be accounted in is being supplied, submission of NC
from Customer
Suppliers supplier’s responsibility closure report on
thru eMRR.
performance to communicate eMMR/ Manually

Disposition of Suspect or Material at Suppliers' Material in Transit or

Non-conforming material location Tenneco Location
 The supplier shall enter the disposition in eMRR  Sorted container must be  Preferred –RTV
 NC part cost shall be borne by supplier identified with CSI  Accepted at Tenneco facility und
 In case of sorting, if NOK part continuous to flow yellow label, placed near deviation
at customer end, supplier will be placed in part number and on  Sort at Tenneco by supplier/ 3rd
controlled shipment status each box party

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4.9.1 & 4.9.2- Corrective Action Reporting & Timing Timing
 Reference the MRR number in CAR form
Problem, title, leader, For Containment 24 hrs.
1. Team Member
contact number, CFT
What is the problem, stated in the terms of
2. Problem Description requirement (Specification, prints)..
Why it is a problem?
3. Containment How does it affect the customer?
What is the impact?
Where and when detected?
4. Root Cause How was the failure
How many were found?
created?
5. Corrective Action How did the non- How many defective parts were sorted?
conformance escape ? How many defects were found?
6. Validation What is the containment action?
Resolve the issue. How wasHow are parts being sorted?
it validated?- Data What is the method of identification 14 Days
7. Prevention
For Corrective Action
Provide evaluation evidence of “like and similar” processes/ products
8. Congratulations
How was team rewarded? For Step 8 completion 60 Days

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4.10- Supplier Improvement
 Suppliers fail to meet the quality and/ or delivery requirement may be brought in for
a Main offender Meeting or placed into Supplier Improvement Program (SIP)
4.10.1 – Main Offender Meeting
 Supplier shall be asked to share 3 weeks improvement plan, if fail to meet the
requirement then supplier will be placed in SIP)
4.10.2 – Supplier Improvement Process
 Criteria for selection PPM>escalation level, 3 consecutive months
 Review Frequency
Exit Criteria: 3 Months 4 MRR’s per rolling 3 months
– A Month
rolling PPM/MRR’s and Plant and Buyer recommendation- Production
onsite assessment will be disruptions, On going quality issue
scheduled

4.11 –Controlled Shipping

 This process requires in case for sorting of non conformance material and classified
into two categories, Level l (CSI) & Level II (CSII)

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4.11.1- Controlled Shipping Level 1
 The inspection process is required to be performed by the supplier’s employees at the
supplier location, the supplier will be notified via phone that they have been placed on
CS1, this conversation will be followed by a written notification including the need of:
 100% inspection
 A containment plan
 Effective corrective action
If exit criteria aren’t met in agreed
 And the exit criteria upon timing, supplier may be placed
on Controlled Shipping Level II
4.11.2- Controlled Shipping Level II
 It is similar like CS1 but except third party implementation for inspection
 Comply with all requirements of CS1
 Identify parts, material and/ or containers with the Tenneco provided CSII. These labels
must be printed in Color- CSII- Orange
 Labels must be attached near the shipping labels and the MRR number identifications
must be added as required.

Supplier who are in level CSI/ CSII won’t Supplier that fail to meet CS II
be awarded any new business until they requirements/ timelines may be subject
exit. to Tenneco Revocation Process

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4.11.3- Tenneco Revocation Process
 Supplier that do not adequately respond to Controlled Shipping requirements of Tenneco or fail to
meet the exit criteria defined may cause suppliers to be removed from the Tenneco approved
supplier list and product may be resourced.
4.11.4- Customer Directed Supplier Meditation
 If a supplier is a “Customer Directed Supplier” and improvement shall be cared by Tenneco.
4.12- Cost Recovery
 Charges associated with quality or delivery issues may be debited as per below table:
Supplier Charge Back Cost Table
Cost Type Fee (USD) Description/ Notes
Administrative Fee $ 300 Per Incident
Receiving Inspection Fee $ 50 Per shipment for the inspection of supplier product for re-certification/ it certified process is
interrupted due to NC material (min. 1 hr charge)

Line Down Fee $ 50 Per employee directly affected

Change Over Fee $ 75 Per hour per employee affected
Sorting Fee (including material) $ 50 Per Hour Per employee directly affected. If supplier or supplier paid contractor does the
sorting fee may be waived (Buyer approval must)

Investigation Fee $ 75 Per hour per employee directly affected

Re-PPAP Fee $ 1000.00 Per part number submission
Online Visit $ 1500.00 Per employee; not valid for international trips, actual cost
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4.13- Supplier Quality System Assessment
 Tenneco reserves right to perform supplier quality audits supplier regardless of
certification status of production material.
4.14- Record Retention
Purchase Order – Tenneco Site Drawings– PPAP Level 3 Documents–
Minimum 1 0 Years Minimum 1 0 Years Minimum 1 0 Years

4.15- Training
 The supplier must demonstrate a comprehensive training program for all levels of staff.
The program should be based on total quality management and include quality planning
tools, Lean manufacturing, six sigma tools, Team Problem solving tools.
4.15- Field Issues
 If buyer, buyer’s customer or any governmental or other regulatory determines the
potential design or other defects in the product may cause failure of the product in the
field, in this seller will immediately cooperate with buyer, it’s customer or any authority,
Contain the defect  determine root cause develop & validate corrective action
plan implement the corrective action plan

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 SECTION:5 TOOLING AND EQUIPMENT
5.1- Tooling and Equipment Policy
 Each article of tooling must be clearly marked (stamped, stencil or permanently tagged)
identifying the item as “Property of Tenneco”/ alternate identification can be color
coding.
 Supplier can’t move Tenneco to an alternative location with their written approval.
 Tenneco reserves right to carry out audit of tooling at supplier premises.
5.2- Changes/ Maintenance to Tenneco Owned Tooling
 Tooling must be fully covered by insurance against damage, loss, or theft and free from
all liens and encumbrances at all times without expense to Tenneco
 Tooling must be in working condition as per agreement in PPAP
5.3- Payment/ Terms/ Conditions to Tenneco Owned Tooling
 Payment shall be done only after completion and submission of Vendor Tooling
Registration form on TITAN in A6 Folder
 Payment terms shall be as per Purchase Order Agreement
 Supplier when requested must furnish complete photographs, tooling drawings,
including all details, inserts, consumables etc.

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 SECTION:6 LOGISTICS
6.1- Tenneco Logistics and Export Policy
 Supplier are required to fully comply with Tenneco policies and required purchasing
documents, such as for exports International Traffic in Arms and Regulation(ITAR) and
Export Administration Requirement (EAR).
 Movement of material shall be appropriate enough to deliver at Tenneco site in intact
and good condition.
 Documentation (Customs & Legal) for each shipment is the responsibility of supplier.
6.2- Logistics and Material Protocol
 Supplier must comply with Tenneco Inbound Material and Logistics Protocol
(available in C folder of TITAN, and it has to be signed off before shipment of any part.
 Suppliers delivering to multiple location, requirement shall be sign off distinctly for each
location
6.3- Basic Packing List Requirements Sold to address, Ship to address, Ship
from address, Ship Date
 Each shipment must be accompanied by a packing slip
Tenneco PO Number or Line number
6.3- Basic Bill of Lading Requirements Tenneco Part number and revision level
 Bill of lading must be included with each lading
 Bill to address, Ship to address letter
 Ship from address weight, Freight pcs, Description of Quantity/ Skids, No of Containers,
product carrier Weight of shipment, Heat no (if req.)

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 SECTION:7 PACKING
7.1- Supplier Responsibility
 To ensure damage free shipment
 Tenneco & Supplier shall mutually designed packaging standard, once sign off may not
be altered without approval.
 Packaging must be designed in order to prevent Slacking, corrosion, breakage, marring
and disarrangement.
7.2- Ergonomics
 To ensure worker safety and loss prevention, package shall consider all human
interaction
7.3- Expendable Packaging Consideration
 Priority 1: Returnable packaging is preferred
 Priority 2: All expendable packaging must be readily recyclable or economically and
legally disposed of in accordance with local legislation.
7.4- Pack Quantity
 It is supplier’s responsibility to determine the packaged quantities and communicate this
standard packing quantity to the respective plant personnel for verification. Mixing of
part number is prohibited.

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 SECTION:7 PACKING
7.5- Additional Protection Within Containers
 For some parts, interior dunnage or bagging may be required to prevent parts damage
resulting from contact or contamination.
 Tenneco will identify parts which require additional protection
 It is supplier’s responsibility to design necessary dunnage.
7.6- Labeling and Identification
Non Handwritten bar coded identification label

Regional shipping part requirements shall apply for all geographic areas

Provision shall be made on the package system for the container identification and its contents
Regional requirement for hazardous material shipment must be adhered to specific identification
requirements

7.7- Substrate Handling

 Pallets must be secured liberally, shrink wrapped and wrap with tamper proof tape.
 Skid of products must be in compliance with Tenneco Global Substrate Policy.

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 SECTION: 8 ENVIRONMENTAL HEALTH & SAFETY
8.1- EH & S Policy
 All supplier should be committed to health and safety as their primary focus.
 Demonstrate the compliance of ISO 14001:2015 requirements .
8.2- Supplier Visits
 Any supplier need to seek permission prior to visiting their manufacturing line.
 Visitors going beyond office has to wear PPE (Gloves, Safety Shoes, Ear Plug) and
must sign off visitor form

9.2.1- REACH Compliance

9.2.2 – ROHS 2
 Supplier shall comply the requirements of REACH and ROHS 2, and must available to
produce evidence whenever required by Tenneco or legislation or local governance.

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T E N N E C O G L O B A L S U P P L I E R H A N D B O O K