pso 6.0.pdf

AQP PSO

Advance Quality Planning &

Process Sign-Off 6th Edition


6th Edition

January 2009

ADVANCE QUALITY PLANNING &

PROCESS SIGN-OFF (PSO)


INTENTIONALLY LEFT BLANK


Advance Quality Planning & Process Sign-Off (PSO)

FOREWARD TO THE 6th EDITION

This manual defines the requirements for Advance Quality Planning (AQP) and Process Sign-Off (PSO), required to verify conformance to Chryslers Quality System Standards. AQP, PSO, ISO/TS-16949 and the Chrysler Development System (CDS) form the foundation for Supplier readiness to ensure a successful program launch. A Suppliers certification to ISO/TS-16949 alone is not sufficient for PSO approval; all PSO requirements must be met to assure conformance to dimensional, material, functional and, where applicable, appearance requirements. In addition, every external Supplier of production parts to Chrysler shall be ISO/TS-16949:2002 third party registered. Effective January 5th, 2009, the requirements stated in this document apply to all Chrysler Production Suppliers, including sub-tier Suppliers. In order to achieve part quality improvements, this manual has been modified to reflect Chryslers current AQP and PSO philosophy. Emphasis was placed upon adherence to the Chrysler Development System (CDS). In addition, the Supplier Quality Assurance Process (SQAP) 3rd Edition Manual, formerly used within the NEA market, has been incorporated into the PSO process. Review this manual carefully and in its entirety to assure that all PSO requirements are known and understood. The name Chrysler, as used in this manual, refers to Chrysler LLC and its subsidiaries which manufacture Chrysler, Dodge and Jeep brand vehicles. The word Supplier is intended to indicate both external and internal Tier 1 Suppliers. The term sub-tier Suppliers refers to all Tier 2 and lower organizations, both internal and external. Chrysler PSO Team denotes Chrysler Employee involvement only, while PSO team indicates all individuals involved in the PSO process (i.e., Chrysler and Suppliers). The term Chrysler Supplier Quality Engineer or SQE, as used in this manual, refers to the Chrysler LLC Supplier Quality Engineer. The term shall, as used in this manual, indicates mandatory requirements. The word should indicates a suggestion or recommendation. Suppliers choosing other approaches shall be able to show that their approach meets the intent of this manual. For questions or comments concerning the Process Sign-Off manual, please contact your Chrysler Supplier Quality Engineer (SQE).


ACKNOWLEDGMENTS


PROCESS SIGN-OFF (PSO) 6th Edition

AQP & PSO 6th Ed. Team Members

David Eller Manager Supplier Quality Processes & Training

Bryan Book Supplier Quality Processes & Training

Vic Randolph Supplier Quality Processes & Training

Rich Merna Supplier Quality Processes & Training

Inbo Kim Sr. Manager CoC International Supplier Quality

Jim Gajda Manager International Quality

Jinghua Rong Manager Supplier Quality (NEA)

Chris Hegele Supplier Quality - Exterior

John Che Supplier Quality - Electrical

Rick Lewis Supplier Quality Body-In-White

Larry DAgostino Supplier Quality Chassis

Mike Carr Supplier Quality Chassis

Greg Masel Supplier Quality - Interior

Mariana Luna Supplier Quality Powertrain

Lisa Sacino Corporate Quality

Jose Velez Powertrain Manufacturing Quality

Lynn Yang Powertrain Quality

Ed Myzienski FMEA CoC

Requests for revisions or changes to the manual should be directed to the Supplier Quality

Operations group



PROCESS SIGN-OFF (PSO)

Table of Contents

Page Advance Quality Planning......................................................................................... 1 Process Sign-Off ...................................................................................................... 4 Process Sign-Off Element Requirements.................................................................. 11 Appendix A Forms and Instructions ......................................................................... 49 Appendix B Tables and Examples ........................................................................... 69 Appendix C FTC Calculations .................................................................................. 75 Appendix D PSO Extended Run ............................................................................... 81 Appendix E Forever Requirements ........................................................................... 83 Appendix F Internal PSO Requirements .................................................................... 89 Frequently Asked Questions .................................................................................... 95 Reference Manuals............................................................................................... 100 Glossary .............................................................................................................. 101 Index................................................................................................................... 113

COPYRIGHT 2009 CHRYSLER LLC 1

Advance Quality Planning (AQP)

PURPOSE: Advance Quality Planning (AQP) details the tasks performed by the Supplier and Chrysler that ensure parts which meet all requirements are delivered on time to designated manufacturing facilities.

PROCESS INPUTS: Those items necessary in order to begin the AQP process include:

New or modified component or module with the Supplier identified Source package Engineering specifications and design model Chrysler Development System (CDS) timing and gate requirements Engineering Change Notices (CNs), if applicable Lessons Learned from previous programs

PROCESS OUTPUTS: Completion of the AQP process results in: Process Sign-Off (PSO) A Approval Appearance Approval Production Part Approval Process (PPAP) A disposition and Part Submission

Warrant (PSW) completion DESCRIPTION: The AQP process begins when the Supplier is identified for a new or modified part and the part is assigned to the appropriate Chrysler Supplier Quality Engineer (SQE). The SQE leads the AQP Team, which also includes the Chrysler Engineer and Supplier personnel (including the Program Manager, Engineering, and Quality functions at a minimum). Other supporting Chrysler personnel are included as needed (e.g. the Buyer, Product Team SQE (PTSQE), Logistics, Material Handling Engineering (MHE), and Advance Manufacturing Engineering (AME)). The SQE and Supplier are responsible for ensuring that required quality gate deliverables are complete and acceptable by their due dates. Reference the Chrysler Quality Management System (CQMS) Part Information screen, the "CDS Quality Gate Timing" report in the Advanced Quality Information System (AQIS), and the CDS website for timing for all deliverables. Deliverables that are considered Risk to Launch (see below), or are late for their quality gate, should have a Recovery Plan documented in the Executive Summary form and implemented by the AQP team, as necessary. Key Components The Product Team SQE (PTSQE) is responsible for designating Key components by quality gate G1 Theme Selection. Reference the Chrysler process Key and Risk to Launch Component Designation for Supplier Quality in the Global Sourcing Book of Knowledge (BoK) for full details.

NOTE: Suppliers do not have access to the Chrysler BoK and should contact their SQE for information on any process in that system.

Initial Risk Evaluation (IRE) An IRE is required on all new or modified parts or modules within 14 days of Supplier selection. SQEs can reference the process Completing an Initial Risk Evaluation (IRE) in the BoK for details on submitting an IRE into the appropriate Chrysler system.


Chrysler involvement in AQP and PSO is based upon the IRE, as follows: For parts assigned a High Risk Level, the SQE leads both the AQP and PSO. For parts assigned a Medium Risk Level, the Supplier leads the AQP and the SQE

leads the PSO. For parts assigned a Low Risk Level, the Supplier leads both the AQP and PSO.

NOTE: For programs with Supplier-led AQP, the Supplier may use either the AQP process or the AIAG Advanced Product Quality Planning (APQP) and Control Plan manual. See Chryslers Customer-Specific Requirements for ISO/TS-16949, cl. 4.2.2.

The following Risk Drivers should be reviewed in order to determine the risk level of the component or module when performing the IRE:

Are there issues preventing Primary Production Tools Complete by S1 Start? Will PPAP be completed by S2 Start Readiness? Is the design complete? Has Historical Design Stability (e.g., high CN activity) been considered? What is the Customer impact if the part fails (Safety, appearance, function, etc.)? What is the level of process technology (e.g., established, widespread, innovative)? Is this a new manufacturing location? Have there been historical quality problems with similar parts? Is the Supplier ISO/TS-16949 certified? Is the Supplier PPAP Self-Certified? What is the Suppliers EBSC measure for quality? Has the Supplier historically required multiple PSO visits to obtain PSO approval? Has the Supplier recently been placed on 3CPR? What is the Suppliers ability to successfully conduct AQP/APQP activities?

AQP Meetings AQP Meetings are required for all High-risk components and modules, and should be held on a regular schedule as determined by the AQP Team (suggested weekly). Meetings for Medium-risk components and modules can be held on an as needed basis, as determined by the SQE and/or Engineer. The SQE schedules the meetings, acts as chair, and is responsible for their proper documentation (but can delegate this task as necessary). Some meetings should be held at the Supplier and Chrysler (or Chrysler-designated) manufacturing facilities, if possible. The initial kick-off AQP meeting should be held at the beginning of the program, after completion of the IRE. Kick-off AQP meeting suggested activities include:

Review the IRE Establish team roles and responsibilities Determine AQP meeting frequency Confirm core AQP Team members Review the source package Review volume assumptions (e.g., shift pattern agreement with P.O. volumes) Establish and review program timing/major milestones/CDS gate timing Establish AQP/Process Sign-Off (PSO) expectations Confirm manufacturing location


When initial program timing is developed, deliverables for quality gates that are already past due shall be included for completion. These deliverables shall be distributed into appropriate, future quality gates as determined by the AQP Team.

AQP meetings should include review of the following activities:

Program timing and major milestones CDS timing and gate deliverables for the current and next quality gate Open issues

NOTE: The SQE is responsible for open issues tracking, but may delegate this task as necessary.

To assist with planning, tracking, and reporting deliverables and issues during AQP, the following documents and forms are available: the Executive Summary form, AQP Open Issues form, and AQP Timing chart. The Executive Summary and AQP Open Issues forms are required for all High-risk parts and strongly recommended for all other parts. See the PSO website https://gsp.extra.chrysler.com/qlty/pso/index.html and Appendix A for electronic and hard copy versions. Risk to Launch parts The PTSQE may designate any part to be a Risk to Launch at any stage of the program. Reference the Chrysler process Key and Risk to Launch Component Designation for Supplier Quality in the Global Sourcing Book of Knowledge (BoK) for full details. First Production Shipment Certification (FPSC) The First Production Shipment Certification (FPSC) process must be initiated by the Supplier prior to Gate C - S1 Start. See "First Production Shipment Certification" in the BoK and PSO website (https://gsp.extra.chrysler.com/qlty/pso/index.html). Process Sign-Off (PSO) PSO is the verification that AQP has been successfully completed. PSO is detailed more fully in the following section. Production Part Approval Process (PPAP) Upon receipt of PSO A Approval, the Supplier can proceed with their PPAP submission in the Chrysler Quality Management System (CQMS). PSO A Approval and PPAP submission is required prior to supplying parts for Gate S2 Start Readiness. An Interim Approval Authorization (IAA) may be required for parts that have not completed PPAP before they can be shipped to the Chrysler (or Chrysler-designated) facility. Suppliers should contact their Chrysler SQE or Product Engineer for additional information regarding IAAs. For full PPAP details, refer to the Production Part Approval Process (PPAP) manual from the AIAG and the Chrysler Customer-Specific Requirements for PPAP at http://qmsi.extra.chrysler.com/wi/clients/QMSI_e.

NOTE: PSO Z Approval, along with a dimensional PPAP submission, is insufficient to allow a Supplier to ship parts to Chrysler; an IAA is required.

Forever Requirements Proposed changes to the manufacturing process after PPAP must be requested through the WebCN/FR system prior to implementation. See Appendix E in this manual.


Process Sign-Off (PSO) PURPOSE: PSO is a formal review of the Supplier's production manufacturing process. It is the culmination of Advance Quality Planning (AQP) and verifies a Suppliers ability to manufacture production material that meets all Chrysler requirements at the Daily Tool Capacity as noted on the Production Purchase Order (P.O.). Process Sign-Off (PSO) shall be performed on all new or modified components with PPAP requirements or components that have been out of production for 12 months or longer. Additional conditions that may require a PSO include, but are not limited to:

Carry-over parts with historical quality problems and/or high warranty Carry-over parts which have experienced a Supplier-responsible yard hold within

the past calendar year New and/or additional production lines (e.g. capacity increases) Production line moves Any product or process change occurring during the lifecycle of a part or system Any other component that the SQE determines requires one

Full compliance with all PSO requirements ensures that the Suppliers manufacturing process is stable, in control, and capable of producing parts that meet all requirements.

PROCESS INPUTS: The following deliverables must be completed prior to beginning the PSO process:

Primary production tooling (prior to Gate C S1 Start) Equipment, fixtures, and gages (prior to Gate C S1 Start) Initial station cycle time and First Time Capability (FTC) compliant (prior to Gate C

S1 Start; may be combined with the Supplier Readiness Evaluation; see below) PSO documentation (completed during the previous AQP stages)

PROCESS OUTPUTS: PSO A Approval, which allows the Supplier to complete the PPAP. DESCRIPTION: PSO is a formal review of the Supplier's production manufacturing process. It includes evaluation of associated production facilities, related manpower, equipment, material, methods, procedures, software level(s), and tooling. The PSO examines the Suppliers entire production process, including in-house and secondary systems that support primary production line(s). It may include visits and/or reviews of sub-tier Suppliers processes, at the discretion of the Chrysler PSO Team. The PSO Team consists of, at a minimum, the Chrysler SQE, Chrysler Product Engineer and Supplier(s) Representatives. Other Chrysler PSO team members may include, but are not limited to: the Buyer, Center of Competence (COC) Engineer, and PTSQE. The Supplier shall identify Supplier PSO team members for both Chrysler-led PSOs and Supplier-led PSOs. For Supplier-led PSOs, Chrysler team members are not required to participate, but shall if deemed necessary.

The Chrysler SQE leads the PSO for components with Medium and High risk levels. The Supplier leads the PSO for components with a Low risk level.

The PSO process is comprised of four activities: the Supplier Readiness Evaluation (SRE), the Pre-PSO Meeting, the PSO On-Site Visit, and Production Validation (PV) Testing.


Supplier Readiness Evaluation (SRE) The Supplier performs the SRE prior to the Pre-PSO Meeting. The SRE consists of at least one trial run to evaluate the Suppliers readiness for the PSO On-Site Visit. In order to run the SRE, the following must be complete:

Primary production tooling All equipment, fixtures, and gages used in the production process The quantity of parts to be run (determined by the Supplier, with Chrysler PSO

Team concurrence).

NOTE: Station cycle time and FTC compliance activities may be combined with the SRE if performed prior to Gate C S1 Start. If the SRE cannot be run prior to Gate C S1 Start, station cycle time and FTC are done separately.

Results from the SRE are recorded on the Supplier Readiness Evaluation/Trial Run Results form (located in Appendix A and on the PSO website). For full SRE requirements, see Element 15 in this manual. Pre-PSO Meeting The Chrysler SQE will schedule and coordinate the Pre-PSO Meeting with the Supplier and Chrysler Engineer after the SRE has been completed. The following activities should take place during the Pre-PSO Meeting:

Review of all documentation required for the PSO Review of SRE results Review of expectations and agenda of the PSO On-Site Visit, including PSO

Extended Run requirements, if applicable (see Appendix D) Scheduling of the PSO On-Site Visit (if all previous items are acceptable)

The PSO Team should only schedule the PSO On-Site Visit when they agree that:

All required Supplier documentation has been reviewed and is acceptable The SRE is complete and the results have been documented and are acceptable to

the team, including station cycle time and FTC Production operators are trained and capable of running at the required line speed

PSO On-Site Visit The PSO On-Site Visit consists of the formal review of the Suppliers facility and processes, including the Production Demonstration Run (PDR). The purpose of the PDR is to demonstrate Supplier process capability and production capacity. The PDR shall produce dimensionally correct parts on the production line with production tooling. The PSO team shall witness at least one PDR during the PSO On-Site Visit using completed production tools. Production process review and measurements will provide the production line rate, the final evaluation of FTC, and other statistics that validate the Suppliers ability to effectively produce a part which meets all customer requirements. The PSO Team shall complete the first 20 elements of the PSO Summary Report at the Suppliers manufacturing facility during the PSO On-Site Visit. All portions of the Suppliers process shall be reviewed, including those outside of the PDR (e.g. Shipping & Receiving, Preventive Maintenance, Testing Facilities, etc.).


Production Validation (PV) Testing Production Validation (PV) Testing validates the Suppliers process and provides evidence that the parts meet engineering, quality, durability, and reliability requirements contained in the Performance, Process, and Material Specifications. Component-level PV testing shall be completed by Gate C S1 Start. PV Testing shall be conducted on parts from the SRE or equivalent trial run that meet the following requirements:

All process performance index (PP and PPK) requirements are met, or 100% dimensionally inspected.

The SRE/trial run met the required station cycle time and FTC. All sub-components and materials used in the SRE/trial run had an approved PPAP

(or equivalent). Production processes and tooling were used. All gages and testing equipment have acceptable R&R results.

Packaging and shipping or simulation test approvals are required by Material Handling Engineering, if applicable. However, PSO approval shall not be delayed due to a lack of approval(s) for Chrysler-provided and/or designed packaging (see element 17). PSO Approvals The Chrysler SQE is responsible for assigning the PSO approval level for Medium and High risk parts. The Supplier is responsible for Low risk parts. PSO N Approval: N Approval indicates that one or more PSO Elements is unapproved and corrective action is required by the Supplier. A new PSO On-Site Visit (including PDR) may be required, as determined by the Chrysler PSO Team. PV Testing may be delayed or repeated at the discretion of the Chrysler PSO Team. PSO Z Approval: Z Approval indicates that the first 20 PSO elements have been completed and approved. It authorizes the Supplier to submit a dimensional PPAP in CQMS, making them eligible for partial tooling payment (contact the Chrysler Buyer for details). PSO A Approval: PSO A Approval confirms that all PSO requirements have been met by the Supplier. The Supplier may submit both dimensional and material PPAP in CQMS, and is eligible for full tooling payment. Deviations from the PSO requirements in this manual (including Mandatory English document requirements, changes, omissions, and/or additions) shall be requested and approved in writing by the Chrysler SQE and Product Engineer, regardless of risk level. Approval(s) shall be obtained from Chrysler before completion of the PSO process. Requested deviations shall be detailed within the PSO Comments Sheet.


LowNew/Modified part Risk Level

4b) Supplier leads theAQP and Chrysler

leads the PSO.4a) Supplier leads theAQP and PSO

4c) Chrysler leadsboth the AQP and

PSO.

HighMedium

5a) Quality planning phasebegins. Use Chrysler AQP

forms and process or APQPprocess, as applicable.

5b) AQP begins. Conductregular AQP Meetings. UseExecutive Summary, AQP

Timing, and AQP Open Issuesforms to track deliverables and

open issues.

3) Review IRE "RiskDrivers" and assignRisk Level (H/M/L)

2) Determine New/Modified Parts.

6) Identify "Risk toLaunch" parts (may bedone at any program

stage). DevelopRecovery Plans, as

necessary

7) Begin FPSCprocess prior to Gate C

- S1 Start.

A

1) Identify "Key"components

Advance Quality Planning Flowchart


11) Conduct PSO On-Site Visit (including

PDR).

8) Schedule, determinequantity, and perform

Trial runs / SRE.

10) Schedule andperform Pre-PSO

Meeting. Review SREdata and other required

information.

12b) Submit full PSW/PPAP

12c) Submitdimensional PSW/

PPAP

12a) Resolve PSOOpen Issues.

Reschedule On-SiteVist, if required.

End AQP Process

14) Changes to thepart or process after

PPAP approval requiresubmission via the

WebCN/FR system.Repeat AQP process.

A

13) Complete PSOElement 21

PSO On-Site Visit Result

"N" Approval "Z" Approval"A" Approval

9) PV Testing


ADVANCE QUALITY PLANNING FLOWCHART RESPONSIBILITIES

RESPONSIBILITY LEGEND STEP

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SLE

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PR

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SU

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REMARK L = LEAD RESPONSIBILITY

1 Identify Key Components S L

S = SUPPORT 2 Determine New/Modified Parts

L S S

L/S = DEPENDS ON PART RISK LEVEL

3 IRE & resultant risk level

L S S S

4a Supplier-led AQP & PSO S S L Low risk

4b

Supplier-led AQP, Chrysler-led PSO L S L

Medium risk

4c Chrysler-led AQP & PSO L S S High risk

5a Quality Planning phase (APQP)

S S L Low & Medium risk

5b AQP phase L S S High risk

6 Identify Risk to Launch Parts

S L At any program stage

7 FPSC S S L Prior to Gate C S1 Start

8 Trial Runs/SRE S S L

9 PV Testing S S S L

10 Pre-PSO Meeting L/S S L/S

11 PSO On-Site Visit L/S S L/S

PSO Visit Result L/S S L/S Low: Supplier Med/High: SQE

12a Corrective Actions, reschedule PSO On-Site

S S L N Approval

12b Submit full PPAP L A Approval

12c Submit dimensional PPAP L

Z Approval

13 Complete Element 21 S S L

14 Forever Requirements submissions

S S S L Via WebCN/FR


PSO ELEMENT REQUIREMENTS


ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP) Element Requirements Documentation

1.1 All new or modified components or modules must have an Initial Risk Evaluation (IRE) performed by the Chrysler SQE. Those components assigned a High risk are required to follow the AQP process detailed in this manual. NOTE: The Chrysler AQP process is also recommended for all components or modules given a Medium or Low risk. Suppliers may use an equivalent Advance Product Quality Plan (APQP) process, if desired. All plans shall coordinate with the Chrysler Development System (CDS) timing for each applicable program and identify major milestones, required product or process deliverables, responsible organizations, and promised and actual timing dates. Reference the Advanced Product Quality Planning (APQP) and Control Plan manual and CDS at http://roadmap.tcc.chrysler.com/cds/.

1.1.1 The Supplier shall prepare and update after each AQP meeting an AQP Timing chart and, if directed by the SQE, an Executive Summary and AQP Open Issues form for each component or module following the Chrysler AQP process. The forms shall be prepared and updated for all other components upon request of the SQE. 1.1.2 Supplier contact information on the Executive Summary form must include, at a minimum, the primary contacts for the following (at a minimum): program management, quality issues, launch support, and warranty issues. The same name may be the contact for more than one of the preceding; however, there must be at least two different contacts listed. Other contact names shall be provided by the Supplier upon request.

1.1.2.1 The Supplier shall provide both a Plant and Warranty Quality Representative, as required, to assist Chrysler personnel throughout the life of the program. 1.1.2.2 When the Supplier is a Chrysler directed sub-tier, the Supplier Representative(s) shall support the Tier 1 in the same manner as they would Chrysler. Support is to begin at Gate G1 Theme Selection and continue through the life of the program.

Supply Base Management 1.2 The Supplier shall cascade AQP/APQP requirements throughout all sub-tier Suppliers (see ISO/TS-16949 cl.7.4.3). The Tier 1 Supplier is responsible for the quality of their sub-tier Suppliers.

1.2.1 The Supplier shall prepare a Supply Chain diagram. This diagram shall outline the entire Supply Chain, beginning with raw materials and ending with the Chrysler or the Chrysler-designated manufacturing facility. All secondary processes and/or services (e.g. plating, heat treating, etc.) shall be shown, including off-site storage or shipping locations.

AQP forms, as required (Process Schedule, Timing chart, Gate Requirements and Tasks, Executive Summary)

Supply Chain diagram Listed risk of all sub-

components and sub-tier Supplier processes.

PSO/PPAP documentation for all sub-components and sub-tier processes risked medium or high.

Sub-tier Supplier quality performance process

Sub-tier Supplier Forever Requirements conformance verification

Corrective Action procedure

DOE (Design of Experiments) process or equivalent

eCIMS or 8-Step Corrective Actions for issues encountered to-date

Lessons Learned Communication procedure


ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP), CONT. Element Requirements

1.2.2 Each sub-component listed on the Bill of Material (BOM) corresponding to the Chrysler part number shall have an IRE (or equivalent) performed by the Supplier. The criteria for risking components shall take into consideration the Chrysler risk drivers.

1.2.2.1 Each sub-component determined to be medium or high risk (or equivalent) shall be accompanied by a PSO (or equivalent process) conducted by the Tier 1 Supplier. Level 3 PPAP documentation is also required for sub-components. Additional documentation may be requested by the Chrysler SQE. See the AIAG Production Part Approval Process (PPAP) manual for details.

1.2.3 The Supplier shall have a process which monitors and documents the quality of all sub-tier Suppliers. This process shall include a list of sub-tier Suppliers rated acceptable by the Supplier and the criteria used to determine acceptability.

1.2.4 The Supplier shall have a process to cascade Chryslers Forever Requirements to all sub-tier Suppliers. This process shall include a method of verifying sub-tier Supplier knowledge and conformance to the Forever Requirements. See Appendix E for additional information.

NOTE: Suppliers with consigned Tier 2 Suppliers, and some directed Tier 2 Suppliers, may be exempt from the requirements listed above in 1.2 through 1.2.4, for those Tier 2 Suppliers only. Contact your Chrysler Buyer and SQE for information.

Problem Solving 1.3 The Supplier shall have a procedure to convey lessons learned and corrective actions throughout their facility and all other facilities within the same company. Reference ISO/TS-16949, cl. 8.5.2.1.

1.3.1 Corrective action shall be implemented across the entire manufacturing plant for every applicable Chrysler production line. 1.3.2 The procedure shall ensure the communication of lessons learned, best practices, and known systemic weaknesses across all facilities, and track the progress of implementation.

1.4 The acceptable methods for documenting root cause analyses and corrective actions are through the Chrysler e-CIMS system and/or the 8-Step Corrective Action form. 1.5 The PSO team shall review corrective actions for any non-conformances or test failures encountered prior to the PSO visit (e.g. during pilot builds, DV testing, etc.). The team shall ensure that all corrective actions have been completed and implemented.


ELEMENT 1 - ADVANCE QUALITY PLANNING (AQP), CONT. Element Requirements

1.6 The Supplier shall have a procedure for conducting Design of Experiments (DOE) or equivalent activities. DOE shall be conducted to identify and establish the optimal process parameters for all new and modified parts prior to the PSO On-Site Visit. 1.7 The Supplier shall support all Chrysler systems (e.g. eCIMS, Non-Conformance Tracking (NCT) system, CQMS, PRAS, COVISINT, etc.).

1.7.1 The Supplier shall have at least 2 individuals with valid SIDs and passwords for each applicable Chrysler system (e.g. Non-Conformance Tracking, eCIMS, COVISINT, PRAS, etc.). All individuals shall be fully trained in the use of each system for which they access, and at least one of the trained individuals shall reside at the Suppliers manufacturing facility. Contact information shall be kept current and updated regularly.

1.8 Design responsible Suppliers are shall consider Design for Serviceability, which ensures ease of disassembly of product with minimal cost and time.


ELEMENT 2 - PART NUMBER, DESCRIPTION AND CHANGE LEVEL Element Requirements Documentation

2.1 The PSO team shall review all PSO related documents to ensure correct part number, description and change level present, or are cross-referenced (see ISO/TS-16949 cl. 4.2.3). 2.2 A procedure shall be in place to ensure correct part number and revision level as changes occur. This procedure shall also ensure affected documents (e.g. Control Plan, PFMEA, etc.) are updated and applicable testing is performed for each change.

2.2.1 This procedure shall include communication and notification of changes throughout the Supply Chain. The Tier 1 Supplier is responsible to ensure product shipped to Chrysler (or other designated manufacturing facility) is the latest revision level. 2.2.2 This procedure shall include the receipt of an approved Chrysler Change Notice. The Supplier shall not make any changes without DOCUMENTED approval from the customer (i.e. voicemail, e-mail, etc. are UNACCEPTABLE).

2.3 Where the product identity is not inherently obvious, the Supplier shall employ an internal numbering system and provide a cross reference which enables users to identify the Chrysler part number and revision level which corresponds to the Suppliers numbering and revision system. 2.4 The Supplier shall have a process which prevents uncontrolled or out of date documents from existing on the manufacturing floor (e.g. Document audit). Refer to ISO/TS-16949, cl. 4.2.3. Engineering Standards Identified 2.5 A process shall be in place to obtain revisions to all Chrysler, governmental, Safety , and other product related standards and specifications. Chrysler standards are available to Suppliers via Engineering Standards Supplier Distribution (ESSD) https://essd.extra.chrysler.com/ESSD/Login.jsp.

2.5.1 This process shall address notification to applicable departments of standard changes as they occur. This process shall also include the frequency and responsibility for reviewing the standards (not to exceed two working weeks; reference ISO/TS-16949, cl. 4.2.3.1 Engineering Specifications).

2.6 The PSO Team shall verify that the CATIA Comment page or Part Information Page (PIP) lists all applicable standards, including, but not limited to, those shown on the source package and signed DVP&R (see 3.2 through 3.4).

2.6.1 Chrysler approval for deviations from required standards shall be documented on the CATIA Comment page/PIP and DVP&R.

CATIA files, drawings, Comment page, Part Information Pages (PIP) (including list of applicable engineering standards, software level and hardware level) (MANDATORY ENGLISH)

Geometric Dimensioning & Tolerancing (GD&T) sheets (MANDATORY ENGLISH)

Part number cross reference sheet (if applicable)

Engineering Change procedure

Document Control procedure


ELEMENT 2 - PART NUMBER, DESCRIPTION AND CHANGE LEVEL, CONT. Element Requirements

2.6.2 The PSO Team shall verify that the CATIA Comment page/PIP lists all sub-components of the end-item assembly. This listing shall include the Chrysler part number (if applicable), Supplier part number, quantity, and revision level.

2.6.3 The PSO Team shall verify that all dimensional requirements are defined on the GD&T sheets and attached to the design model. The Supplier shall consistently apply a mutually agreed upon (with the Chrysler SQE and Product Engineer) datum scheme throughout the part development process.


ELEMENT 3 - DESIGN FMEA Element Requirements Documentation

3.1 Design FMEAs (DFMEAs) shall be created using the latest AIAG and Chrysler guidelines. If AIAG and Chrysler guidelines conflict, Chrysler guidelines take precedence. See the AIAG Failure Mode Effects Analysis (FMEA) manual and Appendix B of this manual. 3.2 The Supplier shall have an internal best practice procedure used in the development of DFMEAs. It shall include documentation and data which explains how the DFMEA severity, occurrence, and detection numbers were developed.

3.2.1 This procedure shall be reviewed periodically for effectiveness and include lessons learned with inputs from past issues (e.g. eCIMS, NCT, warranty, CSA, yard holds, etc.).

3.2.2 The procedure shall include a process for continuous evaluation and improvement of failure modes listed in the DFMEA. This process shall have a method to determine which failure modes are the highest risk, and address those first.

3.3 Error proofing and controls shall be identified in the DFMEA.

3.4 The DFMEA shall be a living document traceable to all design changes. It shall contain all special characteristics (see Element 12). 3.5 A DFMEA shall be completed for each unique Supplier-designed product. The Chrysler Product Engineer shall have lead responsibility for reviewing and ensuring that the DFMEA is acceptable. The Supplier shall have lead responsibility for ensuring that the DFMEA meets all requirements. All DFMEA activities shall be completed on or before required quality gate timing. 3.6 The DFMEA shall include all sub-components of the end-item assembly. 3.7 The Supplier shall ensure all failures observed during Engineering Development (ED) and Design Verification (DV) testing are captured within the DFMEA. 3.8 The Supplier shall ensure the occurrence and detection ability of failures observed during DV testing correlate with the occurrence and detection values documented on the DFMEA. 3.9 Buzz-Squeak-Rattle (BSR) and Noise-Vibration-Harshness (NVH) issues shall be addressed, as applicable. NOTE: Special attention (as defined by Chrysler Engineering) should be given to failure modes with:

A Severity 8, regardless of Occurrence or Detection values. A Severity 5 and Occurrence 4, regardless of Detection (this

equates to high customer dissatisfaction). A Detection of 10.

DFMEA (MANDATORY ENGLISH)

Best Practice procedure


ELEMENT 4 - TEST SAMPLE SIZES AND FREQUENCIES Element Requirements Documentation

4.1 Products covered under a Performance Standards (PF) that specify test sample sizes, test frequencies, and acceptance criteria shall have testing requirements included in a Design Verification Plan and Report (DVP&R) and a Test to Failure verification plan, if applicable. Reference the Chrysler Product Assurance Testing manual. 4.2 Design Verification (DV) and Production Validation (PV) test plans shall be signed by the Chrysler Product Engineer prior to testing.

4.2.1 PV Testing shall be preceded by successful DV Testing, unless waived in writing by the Chrysler Engineer.

4.3 Completed DV and PV test results shall be accepted and signed by the Chrysler Product Engineer. 4.4 All functional requirements shall be defined in the DVP&R and verified against applicable Performance Standards for accuracy.

4.4.1 Deviations from the Performance Standards shall be documented on the CATIA Comment page/PIP and DVP&R (e.g. changes to test sample sizes, test waivers, etc.). See 2.6.1.

4.4.2 Continuous Conformance testing shall be documented on the DVP&R when applicable.

4.4.3 A "circle grid analysis", or other formability analysis, is necessary for PSO approval on stamped components if required by the Chrysler SQE and/or Engineer.

4.4.4 Chrysler internal stamped components shall meet the requirements in MQAS 90-6710 Dimensional Buy-Off Procedure for Upgrading Stamped Parts During Die/Tool Development.

4.5 All testing failures shall be documented on the DVP&R and addressed with a Chrysler 8-Step Corrective Action plan (available on the Forever Requirements webpage through COVISINT and internally through the electronic Book of Knowledge). 4.6 Annual validation testing shall be completed each year as specified in the Chrysler Product Assurance Testing manual and applicable Performance Standards, unless waived in writing by the Chrysler Product Engineer and SQE. Reference ISO/TS-16949, cl. 7.5.2. NOTE: A written waiver is required for each year that annual validation will not be performed.

4.6.1 The Supplier shall have a procedure to ensure on-time Annual Validation and prevent scheduling conflicts and fixture/testing shortages in the event of multiple Annual Validations.

Chrysler Engineering signed DVP&R (MANDATORY ENGLISH)

Applicable Engineering Standards (MANDATORY ENGLISH)

Chrysler Engineering signed DV and PV test plans (MANDATORY ENGLISH)

Annual Validation procedure


ELEMENT 5 - PROCESS FMEA Element Requirements Documentation

5.1 Process FMEAs (PFMEAs) shall be created using the latest AIAG and Chrysler guidelines. If AIAG and Chrysler guidelines conflict, Chrysler guidelines take precedence. See the AIAG Failure Mode Effects Analysis (FMEA) manual and Appendix B of this manual. 5.2 The Supplier shall have an internal best practice procedure used in the development of PFMEAs. It shall include documentation and data which explains how the PFMEA severity, occurrence, and detection numbers were developed.

5.2.1 This procedure shall be reviewed periodically for effectiveness and include lessons learned with inputs from past issues (e.g. eCIMS, NCT, warranty, CSA, yard holds, etc.).

5.2.2 The procedure shall include a process for continuous evaluation and improvement of failure modes listed in the PFMEA. This process shall have a method to determine which failure modes are the highest risk, and address those first.

5.3 Error/mistake proofing and controls shall be identified in the PFMEA. 5.4 The PFMEA shall be a living document, reviewed and updated for all process and/or product changes, as necessary. It shall contain all special characteristics (see Element 12).

5.5 The Chrysler SQE shall have lead responsibility for reviewing and ensuring that the PFMEA is acceptable. The Supplier shall have lead responsibility for ensuring that the PFMEA meets all requirements. All PFMEA activities shall be completed on or before required quality gate timing. 5.6 The PFMEA shall reflect the entire manufacturing process. 5.7 The Supplier shall ensure that all failure modes observed during pre-production runs are captured on the PFMEA.

5.7.1 The Supplier shall ensure the rate of occurrence and ability to detect failures observed during pre-production runs correlate with occurrence and detection values documented on the FMEA.

5.8 BSR and NVH issues shall be addressed, as applicable. NOTE: Special attention should be given to failure modes with:

A Severity 8, regardless of Occurrence or Detection values. A Severity 5 and Occurrence 4, regardless of Detection (this

equates to high customer dissatisfaction). A Detection of 10.

PFMEA (MANDATORY ENGLISH)

Best Practice procedure


ELEMENT 6 - PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN Element Requirements Documentation

6.1 The process flow diagram shall represent the entire manufacturing process from receiving through shipping operations, including main-line assembly processes and off-line supply processes.

6.1.1 The process flow diagram shall include the processing sequence, method, and equipment used at each station (including inspection and repair/rework stations). 6.1.2 Stations which measure special characteristics and/or contribute to significant nonconformances shall be identified.

6.2 The manufacturing floor plan shall document the layout of the facility and the station-by-station flow of the manufacturing process.

6.2.1 The manufacturing floor plan shall highlight all production equipment used. 6.2.2 The manufacturing floor plan shall show Work in Process (WIP), raw material, and scrap/non-conforming material storage locations. 6.2.3 The work station layout shall identify all work stations used in the process.

6.3 The flow diagram, manufacturing floor plan, and/or work station layout shall include each unique machine number. 6.4 The flow diagram, manufacturing floor plan, and/or work station layout shall include the number of operators (including float operators) required per station (including repair/rework stations). The PSO team shall verify the number of operators during the PDR. 6.5 The flow diagram, manufacturing floor plan, and/or work station layout shall identify bottleneck operations or stations. 6.6 All production equipment appearing on the manufacturing floor plan, flow diagram, and work station layout shall be verified by the PSO team during the PSO On-Site Visit.

Process Flow Diagram (or equivalent) (MANDATORY ENGLISH)

Manufacturing Floor Plan

Work Station Layout


ELEMENT 7 - CONTROL PLAN & PROCESS MONITORING Element Requirements Documentation

7.1 The Control Plan shall describe each step of the manufacturing process including, but not limited to: receiving, material handling and storage, in-process operations, testing, inspections, rework/repair, shipping, temporary or interim operations (e.g. back-up operations), and continuous conformance. Refer to the AIAG Advanced Product Quality Planning (APQP) and Control Plan manual.

7.1.1 Measurement and inspection frequencies detailed in the Control Plan, including all inspections for appearance requirements, shall be verified by the PSO Team during the PDR. 7.1.2 Repair/rework stations shall have controls equal to or exceeding those of the primary production line.

7.1.3 The Control Plan shall include verification of Mistake Proofing (e.g. number of pieces, frequency, etc.). 7.1.4 The Supplier shall have a process which links their FMEAs to the Control Plan. This process shall ensure that controls, lessons learned, etc. detailed in the FMEAs are carried forward into the Control Plan. 7.1.5 Controls implemented on similar products due to non-conformances (e.g., e-CIMS, warranty, NCTs, yard holds) shall be included in the Control Plan. See 1.3 and 1.3.1. 7.1.6 All product and process control parameters and tolerances shall be documented in the Control Plan.

7.1.7 All special characteristics identified in the GD&T documentation and DVP&R which describe material, process, performance, reliability, quality, and/or design requirements identified in the PFMEA shall be included in the Control Plan.

7.1.8 Sample sizes shall be based on industry-standard statistical sampling plan tables or shall use Statistical Process Control (SPC).

Process Monitoring 7.2 The Supplier is responsible for maintaining manufacturing process performance/capability and shall have a procedure requiring documented corrective actions for all out-of-control measurements. Reaction plans shall include containment of suspected nonconforming product and 100% inspection (approved by the PSO Team).

7.2.1 The Supplier shall maintain a minimum CP and CPK of 1.33 for on-going process capability. See 20.2.

7.3 The Supplier shall have a documented First Piece Approval procedure which verifies proper set-up at each station and that parts made meet applicable specifications.

Control Plan (MANDATORY ENGLISH)

1st piece approval procedure & records

Control Charts Process Performance/

Capability results Log Sheets Defect Tracking Sheets Craftsmanship Quality

Initiative procedure (if applicable)

Appearance Manual (if applicable)


ELEMENT 7 - CONTROL PLAN & PROCESS MONITORING, CONT. Element Requirements

7.3.1 The procedure shall require First Piece Approval at the beginning of each shift or production run and after any changes are made to the production process (e.g. tooling modifications, process adjustments, etc.). 7.3.2 The process shall include the retention of the first piece until the end of the shift or production run, identification of the first piece sample(s), and analysis of special characteristics.

7.3.3 The process shall include verification of the last piece produced at the end of the shift or production run against the approved First Piece sample.

7.3.4 Documented evidence of First Piece Approval process execution shall be maintained. The Supplier shall record the part number, manufacturing date, and any additional information as required by the PSO Team.

7.4 All inspection stations shall have a method of defect tracking (e.g. tally sheets, scrap sheets, etc.). 7.5 Visual displays of process performance (e.g. FTC, scrap, rework) and total production maintenance (e.g. downtime) shall be present and up-to-date on the manufacturing floor.

7.5.1 Targets shall be identified for each metric with documented plans for achieving those targets. Progress toward achieving targets shall be documented and tracked.

7.6 Where SPC methods are used, the Supplier is required to maintain a history of component production sequence, production line, production tool, and characteristics values. See the Chrysler Customer-Specific Requirements for ISO/TS-16949, cl. 4.1.1. 7.7 Suppliers shall have a Craftsmanship Quality Initiative Procedure for all components with appearance requirements. This procedure shall include team members, regular scheduled Craftsmanship reviews and audits, an issue resolution tracking matrix, creation and approval of Boundary Samples, and the retention of an Appearance Manual for each part. See 10.4-10.4.4 for Boundary Sample requirements.

7.7.1 Suppliers shall have an Appearance Manual for all components with appearance requirements. This manual shall include appropriate documentation (sign-off sheet, table of contents, revision history, general appearance characteristics acceptance specification), studio quality photos of product shown in appropriate views, studio quality photos for any deviation from design intent, and Craftsmanship worksheets (e.g., photos of conditions, containment and permanent correction actions, along with supporting documentation).


ELEMENT 8 - INCOMING & OUTGOING MATERIAL CERTIFICATION PLAN Element Requirements Documentation

Incoming Material Certification Plan 8.1 The Incoming Material Certification Plan shall include procedures used to certify incoming material prior to releasing into production. 8.2 The plan shall derive inspection frequency on component and sub-tier history.

8.2.1 The plan shall include an escalation process which increases the inspection frequency when a defect is found.

8.2.2 When the plan includes dock to stock (i.e. parts shipped directly from the receiving area without inspection) the process shall require at least three previous, consecutive, defect-free shipments without subsequent nonconformances.

8.3 The plan shall include incoming acceptance sampling plans, for both attribute and variable data. Two or more of the methods described in cl. 7.4.3.1 of ISO/TS-16949 shall be used; otherwise, the minimum requirements found in the Lot Acceptance Sampling Table (Appendix B) apply. Inspection frequencies and sampling plans shall be documented in the Control Plan. Lot size shall not exceed one shift or one production run, whichever is smaller. NOTE: The requirements in the Lot Acceptance Sampling Table are only for attribute sampling. SPC is superior and if used, the sampling quantities in the Lot Acceptance Sampling Table need not be followed.

8.3.1 The incoming acceptance sampling plan frequencies shall be based upon the assigned risk level of the purchased material or component (see 1.2.2).

8.4 The plan shall identify all processes performed by sub-tier Suppliers (e.g. plating, heat-treating, etc.) and include records of inspection/test results that relate to the appropriate lot code. 8.5 The incoming lot acceptance date (or date the lot was inspected) shall include the year, month, day and numeric sequence. 8.6 Sub-components or production materials used in the end-item assembly shall have full PPAP (or equivalent). The PSW for each sub-component shall be easily accessible.

8.6.1 Incoming materials or components shall meet all Chrysler appearance requirements of the final assembly, if applicable.

8.7 Certificates of Analysis shall comply with all standards/ specifications identified on the CATIA Comment page or PIP. 8.8 The Supplier shall have copies of their sub-tier Suppliers ISO-9001 certification on file.

Incoming Material Certification plan

Sampling plans Receiving Reports Inspection/test reports Copies of sub-tier

Supplier Certificates of Analysis for each specific sub-component

Copies of sub-tier Supplier PSWs (Part Submission Warrant)

Copies of sub-tier Supplier ISO-9001 certifications

Outgoing Material Certification Plan

Audit Work Instructions

Shipping reports Audit Records IMDS process


ELEMENT 8 - INCOMING & OUTGOING MATERIAL CERTIFICATION PLAN, CONT. Element Requirements

Outgoing Material Certification Plan 8.9 The Outgoing Material Certification Plan shall include procedures to qualify product prior to shipment to the customer. 8.10 The plan shall include outgoing acceptance sampling plans for both attribute and variable data. Inspection frequencies and sampling plans shall be documented in the Control Plan and consider the severity, occurrence, and detection values of a potential defect (per the PFMEA). 8.11 The outgoing lot acceptance date (or date the lot was inspected) shall be identified by the year, month, day, and production sequence. 8.12 Certificates of Analysis, if required by Chrysler for the finished product, shall comply with all standards/specifications identified on the CATIA comments page or PIP. 8.13 Shipping, Audit, and Containment Records shall be documented and maintained. 8.14 The Supplier shall have a process for Material/Substance Composition reporting via the International Materials Data System (IMDS). IMDS is available at http://www.mdsystem.com/index.jsp.

8.14.1 Components shipped to Chrysler (or Chrysler-designated) facilities shall have an IMDS number listed on the PSW.


ELEMENT 9 - PARTS HANDLING PLAN Element Requirements Documentation

9.1 The Parts Handling Plan shall include procedures that detail all internal material handling operations. 9.2 The plan shall describe the types of containers used throughout the internal manufacturing process (including all external processing such as heat treating, plating, etc.). Each container type shall be clearly defined with material dimensions, quantity per container, part numbers, stack height limits (static & mobile), weight, ergonomic requirements, maintenance requirements, etc. NOTE: Container information and maintenance may be included as a part of the Packaging Instructions and/or Preventive Maintenance. See Elements 10 and 19.

9.3 A method shall exist to clearly identify and differentiate rework/ repair, scrap, WIP bins, etc. NOTE: Chrysler does not procure returnable containers for Suppliers WIP (Work in Process) or for sub-tier Suppliers. Containers for WIP are the responsibility of the Supplier and/or sub-tier Supplier. Use of Chrysler containers for this purpose is unacceptable and considered misappropriation of Chrysler corporate assets. Z and/or A PSO approval cannot be given until appropriate corrective actions are implemented. 9.4 The plan shall include the procedures for in-process raw material re-stock (e.g. Kan-Ban) and inventory control (e.g. FIFO).

9.4.1 Material storage locations shall be clearly identified.

9.4.2 When FIFO is used as a method of inventory control, the Supplier shall have an effective method of ensuring FIFO stock rotation throughout the manufacturing facility.

9.5 The plan shall have a procedure by which material is tracked and moved from one process to another (e.g. travelers, routing cards, etc.).

9.5.1 Information shall include lot number, date, number of pieces entering/exiting the operation, number of pieces reworked/ repaired, number of pieces scrapped, operation number and shift.

9.6 All parts shall have lot control and traceability through all stages of production (including all sub-tier Suppliers and shipping, if applicable), and be documented and verified (cl. 7.5.3 & 7.5.3.1 of ISO/TS-16949). Lot size shall not exceed one shift or one production run, whichever is smaller.

9.6.1 Sorted, reworked or repaired material shall be traceable back to the sort, rework or repair process. 9.6.2 Part traceability shall be independent of inventory control processes (i.e., shall not be FIFO-dependent).

Parts Handling Plan Electro-static

Discharge (ESD) procedures (if applicable)


ELEMENT 9 - PARTS HANDLING PLAN, CONT. Element Requirements

9.7 The plan shall include containment of nonconforming material and use of the Chrysler Supplier Notification of Potential Nonconformance process. See the Forever Requirements website available through COVISINT.

9.7.1 The plan shall include handling and identification of non-conforming product, from receiving of returned material from the customer to final disposition.

9.7.2 The plan shall include the maximum amount of time allowed for disposition of quarantined product. Reviews of quarantined product shall occur daily, at a minimum. 9.7.3 The plan shall include proper coordination with Chrysler regarding purging suspect material, part and container identification for replacement material, and logistics and scheduling of replacement material.

9.7.4 The Supplier shall have a locked and/or controlled area for holding nonconforming, quarantined, or non-production product (e.g. engineering samples). Product in the holding area shall be clearly identified with part number, number of pieces, date quarantined, reason for quarantine, and expected disposition date.

Electro-Static Discharge (ESD) Requirements 9.8 Manufacturing facilities handling components that must be protected from ESD shall have the following:

ESD mats and/or floors Heel and/or wrist straps (ESD certified shoes are acceptable) ESD testers for operators to verify heel and wrist straps, and/or

shoe effectiveness. All ESD testers shall have up-to-date operator instructions and be included in the calibration procedures and schedule, as well as in the Preventive Maintenance plan

Clearly-identified ESD containers (e.g. bags, totes, etc.) for transporting ESD-sensitive product

ESD workbenches that are grounded with plugs for wrist straps, if applicable

ESD gloves and/or finger cots for handling of PCB's (e.g. rejects)

9.8.1 All ESD operators shall be properly trained and identified (e.g. badges, buttons, etc.).

9.8.2 Work instructions for ESD testers shall require ESD testing of all personnel before they enter the ESD production location.

9.8.3 The Supplier shall have an ESD certification schedule which mandates recertification of all ESD equipment, tools, testers, containers, and personnel on an annual basis (minimum). Records of the certification and the recorded measurements shall be kept.

9.8.4 The ESD manufacturing process shall be included in the Suppliers Layered Process Audit (LPA) plan.


ELEMENT 10 - OPERATING INSTRUCTIONS Element Requirements Documentation

10.1 All instructions, including but not limited to: operator, set-up, changeover, First Piece Approval, Mistake proofing, rework/repair, gage operation, inspection, and packaging, shall be approved and signed by the appropriate Supplier departments (e.g. Quality, Engineering, Manufacturing, etc.). They shall be dated and traceable to the level of parts being produced, and shall include sample sizes and frequencies.

10.1.1 Special characteristics shall be identified in Operating and any other appropriate instructions.

10.1.2 All instructions shall enable any adequately trained person to perform the described operation.

10.2 The Supplier shall have a process for training and qualifying key personnel prior to performing production operations (e.g. classes, mentorship, temporary supervision, etc.). Key personnel training records shall be documented and maintained.

10.2.1 A list of training requirements for each unique workstation shall be maintained.

10.2.2 Visual inspection stations shall have methods established to verify the operators ability to identify defects (e.g. periodic testing, recertification, etc.).

10.2.3 Operations requiring special certification (e.g. rework/ repair, gauging), and operators certified to perform them, shall be identified. 10.2.4 All key personnel needed to ensure that the Suppliers process(es) can meet the required volume at launch shall be hired and fully trained, and a plan shall be in place to support full production volume.

10.3 All instructions, control charts, defect tracking sheets, log sheets, and reaction plans shall be located adjacent to the process, visible to the operator and legible (reference ISO/TS-16949, cl. 7.5.1.2). Visual management techniques (e.g. displays, pictures, diagrams, etc.) shall be used whenever possible.

10.4 Process Boundary Samples used for pilot production shall be reviewed and approved by the Chrysler PSO Team. Boundary Samples for the start of regular production shall be obtained during the PDR and reviewed and approved by the Chrysler PSO Team.

10.4.1 The Supplier shall have a procedure which periodically (every 3 months, at a minimum) verifies the condition of designated Boundary Samples to ensure they are still acceptable. NOTE: The Boundary Sample verification procedure may be included in the Suppliers Preventive Maintenance Plan, if desired. See Element 19.

Operator instructions Set-up instructions Changeover

instructions First Piece Approval

instructions Mistake proofing

instructions Rework/repair

procedures and instructions

Gage operation instructions

Inspection instructions Key Personnel training

& qualification process Boundary Sample

verification procedure


ELEMENT 10 - OPERATING INSTRUCTIONS, CONT. Element Requirements

10.4.2 The Supplier must attach a Boundary Sample tag to each Boundary Sample with the following information: part name, part number, date that the Boundary Sample is valid until, description of the Boundary Samples purpose, and appropriate Supplier management signature (and Chrysler signature, if required). 10.4.3 The Supplier shall maintain Boundary Samples in a secure place. Three (or more) sets of Boundary Samples shall be provided to Chrysler, if required. 10.4.4 Boundary samples used to determine acceptance criteria for design characteristics (regardless of process capability) shall be approved by the Chrysler Engineer.

10.5 The Supplier shall have a process to ensure workstation organization and cleanliness (e.g. 5-S) which is implemented daily (at a minimum). Evidence of completion shall be maintained.

10.5.1 Necessary items on or near workstations (e.g. tools, sub-component stock) shall be stored in designated areas. Small tools or similar items should be secured to the workstation.

10.5.2 During the PSO On-site Visit, the PSO Team shall verify that work areas are free of trash and unnecessary items and all other items are in their designated areas (except when in use).

Rework and Repair Instructions and Procedures 10.6 The Chrysler PSO team shall approve all permanent rework and repair operations, procedures, and work instructions.

10.6.1 All reworked or repaired products shall be clearly and uniquely identified. See 9.6.1. 10.6.2 The rework/repair procedure and instructions shall state that when a sub-component is replaced which has Safety characteristics, the lot from which the replacement sub-component came shall be identified and it shall be linked with the final assembly on which it was used.

10.6.3 The rework/repair procedure and instructions shall state that when a sub-component is removed from an assembly which has been returned from a Chrysler facility and re-used in another assembly, the lot code of all sub-components with Safety characteristics shall be identified and traceable to the new assembly in which the component was used.

10.6.4 The rework/repair procedure and instructions shall require traceability in the event that any part returned from a Chrysler assembly plant is to be re-sent without rework or repair performed (e.g. parts sorted as good from a returned, quarantined lot).


ELEMENT 10 - OPERATING INSTRUCTIONS, CONT. Element Requirements

10.6.5 The Supplier shall have a procedure describing how temporary rework/repair operations are created and controlled. This procedure shall include:

Identification of all personnel responsible for creating temporary rework operations, instructions, and controls.

Notification and approval from Chrysler through the Forever Requirements prior to initiating temporary rework (and issuance of an IAA or CN, if necessary).

Requirements that rework/repair parts go through controls (including Error and Mistake proofing) equivalent or superior to the primary production line (see 13.4).


ELEMENT 11 - TOOLING, EQUIPMENT, AND GAGES IDENTIFIED Element Requirements Documentation

11.1 The Supplier shall establish a tooling list which includes all production and interim tooling, fixtures, gages, and equipment used in the production process.

11.1.1 The list shall indicate ownership (e.g. Supplier owned, Chrysler owned, other OEM, etc.) for each item listed.

11.2 All Chrysler owned tooling, fixtures, and gages shall be clearly and permanently marked with the same tool number as identified on the Supplier Tool Record (STR) and the Tool Purchase Order, and be identified Property of Chrysler. The method used to mark the tools shall be non-degradable and fireproof (paint, ink, paper tags, etc. are unacceptable methods of marking). All tooling, equipment, gages and fixtures shall possess unique identification numbers. See ISO/TS-16949 cl. 7.5.4 and the Chrysler Purchase Order. The STR can be obtained through the Supplier Quality Portal (under the Summaries header and Part Summary sub-header).

11.2.1 Chrysler-owned gages shall be manufactured and approved per the Chrysler gage standards on the Advance Manufacturing Engineering (AME) website http://ame.ctc.chrysler.com/gages.

11.2.2 The PSO Team shall verify the STR against the Suppliers production process during the PSO On-Site Visit. If tooling, gages, and/or fixtures reside at a sub-tier Supplier, the sub-tier location shall be indicated on the STR.

11.2.3 Chrysler-owned tooling shall only be used for the production of Chrysler product(s).

11.3 All tooling, fixtures, equipment, and gages used in the production process (e.g., from the laboratory, production, tool room, maintenance, quality, etc.) shall be identified in the Suppliers maintenance, storage, and calibration procedures.

Tooling list Supplier Tool Record

(STR)


ELEMENT 12 - SPECIAL CHARACTERISTICS IDENTIFIED AND FPSC Element Requirements Documentation

12.1 The Supplier shall develop a list of special characteristics using Chrysler input and their own knowledge of the product. Special characteristics are product characteristics or manufacturing process parameters which affect safety, fit, function, performance, compliance with regulations, or subsequent processing of product. They include all governmental, Key (diamond) , and Shield (safety and emissions ) characteristics. Torque requirements and characteristics identified as SPC points on the design model shall also be considered special characteristics. Other characteristics deemed critical to the process or component may also be designated as special characteristics by the Supplier and/or PSO Team. See the AIAG Production Part Approval Process manual and the Chrysler Customer-Specific Requirements for ISO/TS-16949.

12.1.1 Special characteristics shall be noted on applicable quality documents (e.g. Control Plan, DFMEA, PFMEA, DVP&R, set-up and operator instruction sheets, etc.).

12.1.2 The Supplier shall have documented definitions of internal special characteristics and the requirements for their selection, control, and monitoring.

12.2 All special characteristics shall be included in the Measurement System Report and the Initial Process Study. See 15.4 and 20.1.2. Safety Characteristics 12.3 A process shall be established and maintained to track Safety () related activities including a listing of all Safety () characteristics (also referred to as a Master Tracking List). This list shall provide overall Safety related coordination and assist in developing primary and secondary measurements. Engineering Standards shall be shown or referenced on affected procedures and work instructions for processing and verification during production.

12.3.1 The Supplier shall use SPC on all Safety () characteristics that shall be made available to Chrysler representatives upon request. See PF-SAFETY for additional requirements and information regarding Safety () characteristics. NOTE: For special characteristics not identified as Safety () characteristics or SPC points on the design model, SPC is not required unless specified by the PSO team.

12.3.1.1 Each Safety () designation shall have both a (100%) primary measurement process and a secondary QC Audit measurement process designed to maintain lot control.

12.3.1.1.1 The primary measurement shall be performed by production operators or skilled trades / Manufacturing Engineering (ME) personnel for robotics, equipment, dies, fixtures, tools, gages, etc. as determined locally.

List of special characteristics

Prototype build part layouts

FPSC Plan & Results (MANDATORY ENGLISH DOC)

Master Tracking List (if applicable)


ELEMENT 12 - SPECIAL CHARACTERISTICS IDENTIFIED AND FPSC, CONT. Element Requirements

12.3.1.1.2 The secondary measurements (QC Audit) shall have Quality Auditors performing visual and/or physical checks at specific sample sizes and frequencies and recording results on statistical charts.

12.3.1.1.3 The acceptable checking method, sample size and sample frequency for establishing lot control within the Suppliers facility shall be determined by the Suppliers Control Plan and/or as directed by the Chrysler PSO Team.

12.3.2 A process shall be in place and maintained which tracks any nonconformances related to Safety () characteristics, including proper corrective action notification, verification of implementation, and carrying forward lessons learned.

12.3.2.1 Detection of any nonconformance during sample verifications shall result in the immediate quarantine of all product, with disposition determined by the PSO Team.

12.3.3 Regular process audits on Safety () characteristics shall be performed as a part of the overall control plan OR as specified by the Chrysler PSO Team. In addition, Chrysler may perform audits and/or elect to have a third party audit completed.

First Production Shipment Certification (FPSC) 12.4 FPSC shall be performed on all new or modified components, including those undergoing a Forever Requirements (FR) change, regardless of risk level. It shall include parts from all production lines and tool cavities. FPSC begins at Gate C S1 Start for new parts, or at the first production shipment for modified parts and FR changes.

12.4.1 The duration of FPSC shall be determined by the AQP Team. It shall be for a minimum of the first 2000 inspected, defect-free parts shipped to each Chrysler or Chrysler-designated facility, or for a time period that lasts until V1 + 90 days. NOTE: Modified components, components undergoing a Forever Requirements change, and Low risk programs all default to a duration of 2000 inspected, defect-free parts, unless otherwise required by the Chrysler AQP and/or PSO Team.

12.4.2 The Supplier shall provide the FPSC plan and results from previous shipments for PSO team review at the Pre-PSO meeting. Corrective actions for non-conformances found during FPSC shall be approved by the Chrysler AQP and/or PSO Team and implemented before the PSO On-site Visit occurs. 12.4.3 If a defect is found during FPSC, the entire quantity or duration shall be repeated (i.e., 2000 additional pieces or duration extended, as appropriate). 12.4.4 FPSC-designated areas or stations shall have work and/or inspection instructions, visual displays, and be included in the Suppliers LPA process, as appropriate.


ELEMENT 13 - ERROR AND MISTAKE PROOFING Element Requirements Documentation

13.1 The Supplier shall have an Error and Mistake Proofing Plan which describes the development, implementation, use, and maintenance of error and mistake proofing within the organization. NOTE: Error proofing eliminates, by design, the possibility of producing a specific defect. Mistake proofing identifies errors in production and prevents them from becoming non-conformances.

13.1.1 The plan shall include the creation of Verification Samples for checking mistake proofing. These shall include all failure modes identified in the FMEAs.

13.1.2 Verification Samples shall be tested on the production line to ensure mistake proofing is operational. Frequency of verification shall take into account start of shift, production changeover, major disruptions, tooling maintenance, etc. Verification shall occur once per shift or per production changeover (whichever is more frequent) at a minimum. It shall also occur following any unplanned disruption or down time. See 14.4.2 and the Chrysler Customer-Specific Requirements for ISO/TS-16949 cl. 4.2.9.1.

13.1.3 Verification Samples shall be clearly marked, labeled, and controlled to prevent mixing with production materials. They shall be stored separate from WIP or finished product in a clearly marked container or designated area.

13.1.4 Error and mistake proofing software shall be tested for all known failures and bypass scenarios.

13.2 Line or station lock out shall be implemented at all process steps to prevent failed operations from proceeding to a subsequent station or into finished product. Audible and visual indicators shall notify of the failed operation. Corrective actions shall be implemented prior to restarting the line or station.

13.2.1 The Supplier shall have a contingency plan in the event the production mistake proofing is not operable. A visual and/or audible alert shall signify the mistake proofing is inoperable. The plan shall include notification of the Chrysler SQE via the Forever Requirements.

13.3 All failure modes identified in the FMEAs with a severity of 8 or higher shall have error proofing, if possible. Those failure modes that cannot have error proofing in place shall have mistake proofing. 13.4 Error and/or mistake proofing shall be used on all special characteristics. 13.5 All reworked or repaired product shall pass through error and mistake proofing equal or superior to the primary production line. 13.6 Error and mistake proofing verification shall be included in the Preventive Maintenance Plan.

Error and Mistake Proofing Plan

Mistake Proofing Contingency Plan


ELEMENT 13 - ERROR AND MISTAKE PROOFING, CONT. Element Requirements

13.7 Sequential sensing shall be used when the process includes physically independent cells making up one process flow. 13.8 Stations used as final verification (e.g. end-of-line (EOL) tester, vision station, etc.) shall leave unique identification proving that the part has successfully passed through the entire process. Error and/or mistake proofing shall ensure that parts cannot skip this operation.

13.8.1 Mistake proofing shall verify that the end-item assembly is correct and complete.

NOTE: Verifying that the component is in the machine prior to assembly, and then assuming it is on the finished product after the machine cycle is not acceptable.

13.9 All functions, efforts and travel shall be exercised and measured to their full extent 100% on line. 13.10 All sub-components shall have 100% verification of proper part selection through error and/or mistake proofing.

13.11 All cylinders applying components or performing staking shall be verified for full stroke. 13.12 Manufacturing processes (e.g. Injection Molding, Welding, Heat staking, etc.) shall have controllers (e.g. RJG, MACO etc.) with closed loop feedback systems maintaining established process limits.

13.13 All critical lubrication, adhesive points, liquids and gases shall be automated and have error and mistake proofing for proper flow, amount, and location.

13.13.1 Leak testing for liquids and gas shall be automated and measured 100% on line.

13.14 Assembly machines that accommodate right and left parts in the same process shall have error and/or mistake proofing to ensure proper assembly and packing. NOTE: The PSO Team may require separate paths for right- and left-handed parts, if necessary. 13.15 The Supplier shall have error and/or mistake proofing to prevent loose foreign objects in assembly. Requirements for Electrical Components 13.16 Electrical connections shall have a positive detent that can be identified through audio, tactile or visual feedback.

13.17 Electrical components and connections shall have continuity and functional check with automated line stop/lockout if continuity is not achieved.


ELEMENT 13 - ERROR AND MISTAKE PROOFING, CONT. Element Requirements

13.18 Terminal contact for in-process manufacturing (harness assembly, engine testing, device testing, etc.) shall meet the following:

Pogo pins shall not violate the contact area of the terminal(s) being tested

Pogo pins shall be maintained and inspected regularly The test fixture shall align the connector to the test fixture prior

to engagement of the pogo pins When pogo pin access is not provided and spring member

contact is the only option, the probe used to contact the terminal spring member shall be smaller in thickness than the minimum blade thickness (including tolerances) of the terminal being tested. If round pin terminals are being tested, the male pin probe shall be smaller than the minimum diameter (including tolerances) of the pin.

The depth of insertion of the probe shall be the minimum necessary for electrical contact testing.

Requirements for Modules/Sequenced Part Delivery (SPD) 13.19 Barcodes and/or pick lights with break beams (or equivalent) shall be used to ensure correct part selection and assembly per the broadcast. 13.20 Vision systems and/or color sensing shall ensure correct components and color match (where applicable). 13.21 Push-click-pull methods shall be used for electrical and other applicable connections.

13.22 SPD part sequence shall be maintained throughout the entire process, including rework and repair. 13.23 The Supplier shall have backup systems to ensure uninterrupted receipt of broadcast. 13.24 Components with Safety characteristics shall be traceable to the VIN sequence. 13.25 Rebroadcasts due to non-repairable conditions shall have additional tracking to maintain sequence and timely delivery.


ELEMENT 14 - LAYERED PROCESS AUDIT Element Requirements Documentation

14.1 Layered Process Audit (LPA) is a system of audits performed by multiple levels of the Suppliers management. Special characteristics (and other characteristics designated by the Supplier and/or PSO Team) and error/mistake-proofing are audited for process conformance. Reference the Chrysler Customer-Specific Requirements for ISO/TS-16949 cl. 4.2.9.1 and the LPA Fundamentals course (available through TEDS) for additional LPA requirements. 14.2 The LPA plan shall have procedures and work instructions for each level of management detailing roles and responsibilities. The plan shall include handling of nonconformances discovered during the audit as well as a schedule frequency and structure chart. 14.3 The LPA plan shall require top management reviews of LPA results. It shall state the frequency of management reviews and require documented meeting minutes and/or open issues. 14.4 The Supplier shall complete a Process Control Audit Checklist and an Error and Mistake Proofing Verification Audit Checklist. Examples of each can be found in the LPA course training manual.

14.4.1 The Process Control Audit shall be done once per shift (or as agreed to by the PSO Team) by a group leader or supervisor. Management audits shall be done weekly. Manufacturing areas shall be divided and auditors rotated so that all areas are included.

14.4.2 The Error and Mistake Proofing Verification Audit shall be completed once per shift or product change-over (whichever comes first) and whenever an unscheduled disruption occurs in the production line. The audit shall be performed by qualified, trained personnel only. See 13.1.3.

14.4.3 After PSO approval, no item shall be removed from the LPA checklists without the Chrysler SQEs approval regardless of risk. 14.4.4 All nonconformances discovered at Chrysler manufacturing facilities (at any program stage) shall be included in the LPA.

14.5 The Supplier shall demonstrate at least one level of an LPA during the PSO On-Site Visit. The LPA shall be on all processes undergoing PSO (not necessarily every part).

14.6 The Supplier shall maintain a list of trained individuals who are responsible for developing, implementing, and updating the LPA plan. 14.7 Suppliers without an existing LPA process (e.g., new Suppliers to Chrysler) shall have an LPA Implementation Plan which includes an action plan and timing for incorporating LPA across their facility. Processes of highest risk shall be the first to implement LPA. NOTE: The Supplier should consider customer quality issues, process capability, FTC, items identified as high risk on the PFMEA, operator-dependant operations, and amount of available error/mistake-proofing when determining which processes are the highest risks.

LPA procedures LPA work instructions LPA Structure and

Frequency Chart LPA Process Control

Audit Checklist LPA Error Proofing

Verification Audit Checklist

List of individuals responsible for updating LPA

LPA Implementation Plan (for new Suppliers)


ELEMENT 15 - SUPPLIER READINESS EVALUATION & MEASUREMENT SYSTEM REPORT Element Requirements Documentation

Supplier Readiness Evaluation (SRE) 15.1 Prior to the Pre-PSO Meeting, the Supplier, with concurrence from the Chrysler PSO team, shall determine part quantity for the SRE run. The PSO team shall determine (and agree upon) the required Line Speed (see 16.1.1), as well as the number of components and characteristics to be inspected. SRE results shall be recorded on the Supplier Readiness Evaluation/Trial Run Results form and reviewed by the Chrysler PSO Team before or during the Pre-PSO Meeting. The Chrysler PSO Team shall determine SRE results to be acceptable before scheduling the PSO On-Site Visit. 15.1.1 The Supplier shall present SRE results for each production line and/or tool used in the process. 15.2 The Supplier shall conduct the SRE on the latest released Production Part Number(s) with an approved Purchase Order (P.O.). The stated part number shall have a corresponding Production Tool P.O., with related tooling capable of meeting the required capacity and line speed(s).

15.2.1 All tooling and equipment shall be at production level, unless otherwise approved in writing by the Chrysler PSO team and Chrysler SQE Manager before the SRE is run.

15.3 During the SRE run, the Supplier shall measure and document all characteristics on all parts per the Control Plan, regardless of stated Control Plan frequency.

15.3.1 Process performance calculations (PP and PPK) are required for all special characteristics.

15.3.2 In the case of multiple production lines and tools, process performance calculations are required for each line and/or tool.

15.4 Prior to Gate C S1 Start, actual station cycle times and FTC shall be determined and recorded on the Supplier Readiness Evaluation form. The PSO Team shall review the data during the Pre-PSO meeting.

15.4.1 The AQP and/or PSO Team shall meet prior to Gate C - S1 Start and determine requirements for station cycle time, based on the overall line speed requirement.

15.5 The Supplier shall demonstrate a First Time Capability (FTC) of 90% or greater prior to Gate C S1 Start. Deviation from this requirement shall have signed approval from the Chrysler PSO Team and the SQE Manager. NOTE: The FTC requirement applies only to the primary production line. Secondary, off-line, and/or support processes do not require 90% FTC, unless specified by the PSO Team.

Supplier Readiness Evaluation (SRE) Run results

Measurement System Report


ELEMENT 15 - SUPPLIER READINESS EVAL. & MEASUREMENT SYSTEM REPORT, CONT. Element Requirements

15.5.1 For multiple production lines, tools, and/or cavities, FTC shall each be calculated separately.

NOTE 1: FTC is equal to the number of acceptable parts produced divided by the total number of parts run. See Appendix C FTC Calculations.

NOTE 2: Rework and repair are NOT counted in the number of acceptable parts, nor are parts initially rejected by the process but found to be acceptable after re-testing.

15.6 PV test parts shall be selected from a trial run/SRE that meets the requirements listed in 21.1.

Measurement System Report 15.7 During the PSO On-Site Visit, PSO Team members are required to randomly select and witness the measurement of product and/or process characteristics (including sub-component characteristics). Results shall be documented on the Measurement System Report form. This audit is typically completed before or during the PDR. Examples:

Stock thickness for a stamped part Moisture content, mold pressure or temperature for a

molded part Solder-ability, dimensional checks or reflow oven profile

for an electronic printed circuit board assembly 15.7.1 The PSO team shall decide the characteristics and quantity of parts to be witnessed for measurement verification prior to the PSO On-Site. All special characteristics shall be included (see 12.2). 15.7.2 A minimum of 3 characteristics

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