QSR Georgia site earns Ford Q1 rating

JASPER, Ga.—Quality Synthetic Rubber Inc. is taking the next step with one of its biggest customers.

The firm's plant in Jasper was just certified Q1 by Ford Motor Co., making it a preferred supplier to the Detroit 3 original equipment manufacturer. The designation goes to those suppliers who meet rigorous quality standards and are in turn given the exclusive option to bid on new business.

Q1 is only awarded to specific Tier 1 manufacturing locations, not suppliers as a whole entity. QSR also produces automotive parts at its Twinsburg, Ohio, location, but the firm said Jasper is the only QSR site to supply as a Tier 1.

"It's something we worked on over the last couple of years," QSR President Mike Berry said. "We had the TS and ISO certification for a long period of time, but I think this Q1 does differentiate us somewhat. The standards are quite high in quality, delivery and service. It's a small group of people and we're pretty proud of the Jasper crew for pulling this off."

Jasper employs about 240 at its 110,000 sq.-ft. plant. About 85 percent of its business comes from spark plug boots and rubber products for ignition systems. The other 15 percent is electrical connecting cable seals, which Plant Manager Matt Ledford said is overwhelmingly the largest product line throughout the company with the Twinsburg site as the primary location for that product.

About 85 percent of Jasper's products are silicone molded, with some ignition components made from EPDM.

"Our engineering capability and customer support is unparalleled, no question," Ledford said. "You have decades and decades of experience within this organization. Our material science capabilities are very strong, and then from a factory standpoint, the factories use a very mature work-management system to promote engagement at all levels of the organization. Our teammates are so engaged in the business that you can't help but be laser-focused on a common goal. These things set us apart from the competition and have for many years."

To achieve Q1, companies must hit many targets across five critical areas—capable systems, continuous improvement, ongoing performance, supplier manufacturing process and customer satisfaction. Locations must simultaneously achieve the following:

• 100 percent on-time delivery and service;

• Zero customer quality complaints/notifications and no open corrective actions;

• Best in class price per million measures;

• Its Q1 score must exceed 800 points out of a maximum 1,750; and

• Written endorsements from each ship-to Ford Manufacturing location, Ford Customer Service Division, Ford Supplier Technical Assistance and Ford Material Planning & Logistics.

Quality Manager Freddy Walker said the firm didn't have to add many new processes, but it did work significantly on its contingency plans. Walker said historically the plans would take care of power outages and equipment malfunctions, but Q1 requires the plan to expand and involve natural disasters, disruptions in Internet service, telephone service and supply issues.

"We improved some of our electronics systems to make sure our advanced shipping notices were sent on time," Walker said. "There was a lot of improved documentation and work instructions for shop floor associates. You want your work instructions written so robust that if a new employee came in off the street they could basically read that work instruction, follow it and perform that job."

Suppliers can lose its Q1 status if its score dips below 800. Walker said Jasper has such a high score that it is not concerned about losing its status, currently at about 1,400 points and consistently about 1,300 for the last 12 months.

Ledford said about 80-85 percent of Ford's suppliers are certified Q1, but the big distinction is that Ford only awards new business to those with Q1 certification.

"Our current business does not change, but it does allow us to bid on new programs at Ford," Berry said. "We have not had that opportunity in the past years, but with this certification we should be able to branch out with business to different divisions of Ford now that we're on their preferred list."