Chrysler

PSQAQP150

ADVANCE QUALITY PLANNING

2

INTRODUCTION

Tell us about yourself

Your name

Your job and how long youve been doing it

Your role in the AQP process

What you would like to know about AQP?

3

OBJECTIVES

1.What is AQP?

2.Why should we do it?

3.How do we do it?

4

FOUNDATION OF AQP: CPCP

Chrysler Product Creation Process

Process Design / AQP (SQ Lead) IRE (Approx. timing)

Product Design (Engineering Lead)

Sourcing (Purchasing Lead)

5


6


7

AQP

PSO

A process that will ensure parts that meet all requirements are delivered on

time to designated manufacturing

facilities. AQP/PSO Manual 7th Edition, page 1

AQP: WHAT IS IT?

8

AQP: WHAT IS IT?

AQP focuses on the design/development of the Suppliers manufacturing process to ensure that it is capable of producing parts that meet design requirements at the quoted

tooling capacity

Customer requirements / CPCP timing

AQP Meetings

VP Build

Trial Runs (SRE)

Process Sign-Off / PV Testing

PPAP

PVP Build

Corrective Actions

Lessons Learned

Depicting product quality planning as a cycle illustrates the never-ending pursuit of continual improvement that can only be achieved by taking the experience in one program and applying that acquired knowledge to the next program. APQP & Control Plan Manual, 2nd Edition, page 1

9

AQP: WHY DO IT?

Minimize / reduce late changes to the part and process

Reduce / eliminate quality spills at all stages of production

Reduce / eliminate warranty

Increase customer satisfaction

In short, to eliminate waste and save money!

10

WHAT IS NEEDED: INPUTS

What do we need before we can begin AQP?

Sourced part or module (Supplier must be known)

Source package

CPCP Program Timing

Design Model

Engineering specifications

Engineering Change Notices (CNs), if applicable

Lessons Learned from previous programs

11

AQP: HOW DO WE DO IT?

Milestone

Pre-Volume Production

(PVP)

Volume Readiness Phase

Job 1 Offline

Launch Phase

Commercial Launch

PSO On-Site Visit &Production

Demonstration Run

PSO Result

Submit final PSW/PPAP

Complete PPAP requirements & submit Dimensional

PSW/PPAP

Complete corrective actions; reschedule On-Site Visit / PDR

as necessary

5 (Z)1-4 (N)

End & Forever

Requirements

Lessons Learned

A B C

5 + PVT (A)

D

12

Source Evaluation

New Supplier (Also new management/

organization structure)

New Location

New Process,

Commodity or

Technology

New Product

or Project

Has Not Shipped

Product for More

Than 24 Months

Events

On-Site Source Evaluation

13

Source Evaluation

1. Review list of possible

suppliers.

2. Analyze Fiat and

Chrysler suppliers with

existing ratings or

evaluations.

3. Screen supplier pre-

evaluation data.

4. Determine strategic

suppliers needing

evaluations.

1. Clarify scope of tasks

related to product, site,

technology and supplier

performance data.

2. Prepare decision

making

recommendation and

obtain management

approval for task.

1. Form the cross

functional team.

2. Hold kickoff meeting

and assign roles and

responsibilities.

3. Preliminary

discussion of supplier

pre-evaluation

package.

4. Schedule on-site visit

and confirm trip

details.

1. Perform on-site

evaluation.

2. Inspect facility.

3. Collate and coordinate

analysis results and

scoring.

4. Conduct closing

meeting with supplier

with verbal feedback of

major observations.

5. Resolve/clarify

discrepancies.

1. Finalize summary

report and defined

criteria.

2. Calculate evaluation

pass/fail rating and

identify any risk

factors.

3. Report to approved

managers.

4. Upload information to

GPSIS.

1. Complete gap analysis

form if supplier can be

considered for

business.

2. Assign supplier target

dates on action items.

3. Track progress to gap

close and follow-up

meetings.

4. Notify approved

managers of completed

status.

5. Re-load updated SE

form in GPSIS.

Identification Task

Clarification

Visit

Preparation

On-Site

Visit

Results

and

Reporting

Closure

SOURCE EVALUATION

Check if Fiat has a PSA (Potential Supplier Assessment)

If so, use PSA result

Pre-Evaluation form sent to Supplier for completion

Buyer sends Request form to SQ Commodity Manager

SQ Commodity Manager determines the SQE to lead the

Source Evaluation

SQE assembles team SQE, Engineering are mandatory

Purchasing, Supply recommended but may delegate

14

General Navigation

The tabs on this tool are arranged by function.

Tan tabs are general information and Cover Sheet

Green tabs are for the area-specific questions and data input

Dark Blue tabs are for reporting

Light Blue tabs are reference material

Supplier Source Evaluation Toolkit

Instructions for using this tool appear below

Note: Macros must be enabled for this tool to work properly.

SOURCE EVALUATION

Team reviews Pre-Evaluation information

Team holds on-site review at the Supplier with the SE tool

Gap analysis completed with action items and target dates

for unacceptable items

SE result determines if Supplier can be sourced or not

15

Date:

Zip / Postal Code

DUNS Code

eMail/Nic:

eMail/Nic:

Commodity Code

N

N

N

Total Management

N Expiration Date: Name and Local #

Mailing Executive

Position

Supplier Profile

Small Business Y/N

Woman Owned Y/N

Sheltered Workshop Y/NForeign Ownership

Name

Main Contact

Minority Classification

E-mail Address

Country

Percentage

HR/Safety

Union Representation Y/N

Union Information

Number of Employees at facility?

Dedicated to the Product Line

Name

Country

Buyer Name

Plant Manager

Head of Sales

Quality Manager

Supplier Contacts

CEO / President

City, State

[email protected]

Country

Jim Buyer

City, ST 12345

Materials Management

Phone #

Account Rep

Address (Assessed Location) Address

Comm name DC4321Commodity Name

Author Name email

123456789

AddressAddress 2

Hourly

Supplier Source Evaluation ToolkitSnameCity, ST

SnameSupplier Name

After Hours Contact

Traffic Manager

SOURCE EVALUATION

16

Score each question (or N/A)

0, 15, or 30 pts possible

Click on question number to go directly to

applicable workbook

section

Summary tab shows results for each section, plus an

overall percentage score

Overall percentage score determines if Supplier can

be sourced

SEs for commodities with safety characteristics

require a higher score

Individual items that are RED still require corrective

actions!

17 17

SOURCE EVALUATION

18

SCORING

60-80% >80% 90%

19

INITIAL RISK EVALUATION (IRE)

What is the IRE?

An assessment of the inherent risks in a new or

modified part

Determines Chrysler involvement with the AQP

and PSO for the new or

modified part

Required to be completed within 14 business days of

the part appearing in CQMS

AQP: SupplierPSO: Supplier

Initial Risk Evaluation

AQP: SupplierPSO: Chrysler

AQP: ChryslerPSO: Chrysler

LOW MEDIUM HIGH

20

IRE RISK DRIVERS

Are there issues preventing Production Tools Complete by the required date?

Expectation: Review the planned Tooling Kickoff (TKO) and Production Tools Complete (PTC) dates. PTC is required by Verification of Process (VP).

Guidelines: Tooling completion affects numerous AQP deliverables, such as PV Testing, Process Sign-Off, PPAP, etc. Late tooling should equate to a higher risk level;

completion after Pre Volume Production (PVP) should be an automatic High risk.

Will PPAP be completed by the required date? Expectation: Review the planned PPAP date. PPAP completion is required by PVP.

Guidelines: Late PPAP may equate to a higher risk level. Late engineering changes that push PPAP beyond PVP or Job 1 should be re-evaluated to determine if the risk

level of the part should increase. As soon as it is known that PPAP will be after PVP,

follow the "PPAP Submission Delay - Escalation" process in the Book of Knowledge .

Is the design complete? Expectation: Part design / CAD should be complete and attached as part of the

original Source Package.

Guidelines: If the Supplier submitted an RFQ to an incomplete or non-existent design, there is increased risk to the program. TKO without a complete design also represents

a High risk to the program.

21

IRE RISK DRIVERS

Has historical design stability (e.g., high CN activity) been considered?

Expectation: Review Lessons Learned from previous programs (both from the Supplier and on similarly-designed parts) for CN activity. Were engineering changes minimal and minor in scope?

Guidelines: A high incidence of CNs on the part, or one or more major part redesigns, should reflect a higher risk level.

What is the customer impact if the part fails? (Safety, Appearance, functionality, etc.)

Expectation: Determine the potential customer impact if the part fails. Would it cause injury, result in vehicle breakdown, or negatively impact customer perception?

Guidelines: Parts with a high degree of customer interface should have correspondingly higher risk levels. Examples include Safety components, parts that could result in a "walk-home" condition, or parts in high-visibility areas with Appearance requirements.

What is the level of process technology (e.g., established, widespread, innovative)?

Expectation: Review the proposed manufacturing process.

Guidelines: Processes that are using technologies new to the Supplier, Chrysler, or the industry may require a higher risk level.

22

IRE RISK DRIVERS

Is this a new manufacturing location? Expectation: Manufacturing locations new to Chrysler require a Source Evaluation performed with

an acceptable score. Ensure open issues from Source Evaluation have been closed. If the Supplier received an unacceptable rating, were the proper overrides obtained?

Guidelines: New Suppliers to Chrysler represent a higher risk to the program. Lack of an acceptable Source Evaluation for a new Supplier should be an automatic High risk.

Have there been historical quality problems with similar parts? Expectation: Review the quality history (Nonconformance Tickets, yardholds/PRIs, warranty issues

and field actions) of the part in question (if applicable) or parts with a similar design. Review the Master PFMEA for this commodity to ensure these issues have been addressed. Have there been repeat issues?

Guidelines: A high incidence of NCTs, a high c's/1000 rating, or ANY PRIs or field actions on similar parts represents a higher risk. Repeat issues or lack of corrective actions in the Master PFMEA also indicate a higher program risk.

What is the Supplier's Supplier Quality Bid List score? Expectation: The Supplier should be "green" per the Supplier Quality Bid List (SQBL). Their overall

score includes AQP/NCT, 3CPR (Level 1 and Level 2 incidences; reference ), yardholds, Forever Requirement Violations (reference ), ISO/TS-16949 Certification, and New Business Hold (NBH; reference ). "Yellow" or "Red" scores on the SQBL require a written override from a SQ Director for the Supplier to receive business.

Guidelines: A Supplier with a "yellow" or "red" SQBL score indicates potential additional risk to the program.

23

IRE RISK DRIVERS

What is the Supplier's Warranty history? Expectation: Review the Supplier's warranty history with the Customer Satisfaction

Team (CST). Are they meeting their targets? Have they had any recent warranty spikes

or field actions?

Guidelines: If the Supplier's warranty has been increasing, or if they have had a field action recently, it may indicate additional risk.

What is the Supplier's ability to successfully conduct AQP activities?

Expectation: Assess the Tier 1 Supplier's ability to manage AQP / APQP activities. Review PSO Element 1, requirements 1.2 through 1.2.4 ("Supply Base Management");

the Tier 1 should have all requirements met. Review if the Supplier location has

required multiple PSO visits in the past before receiving approval.

Guidelines: A lack of sub-tier Supplier management processes indicates high program risk, as does a history of failing to meet deliverable due dates. Multiple PSO visits in the

past can also indicate poor AQP management.

24

IRE RISK LEVELS

High Risk (H) Chrysler SQE leads the AQP

Chrysler SQE leads the PSO

Medium Risk (M) Supplier leads the AQP

Chrysler SQE leads the PSO

Low Risk (L) Supplier leads the AQP

Supplier leads the PSO

25

DESIGNATING THE IRE IN CQMS

Use the Part Information tab in CQMS Select Part Risk

Review and acknowledge

the IRE risk drivers!

26

To Enter Initial Risk Evaluation for One or More Parts:

1. Click the Part Information tab. Then, click the Part Risk link.

2. Logon to CQMS with your TID and user password.

3. Enter valid Chrysler Supplier Quality Deck Code

Note: SQE Deck Code is populated by default, where applicable. Select Clear to enter a new value.

4. Check the box for Unassigned Risk

5. To limit the results, enter a value for one or more Optional filters.

6. Click Find.

7. Click the radio button(s) for the parts where you want to apply a single Initial Risk value.

8. Select a risk value from the Initial Risk drop down.

Note: Do not make a separate selection for Current risk. The initial risk value will automatically populate to Current risk when updated.

9. Check the box to Acknowledge Risk Drivers

10.Click Update.

To Enter Initial Risk Evaluation for a Single Part:

1.Logon to CQMS with your TID and user password.

2.Click Part Information tab. Then, click the Part Risk link.

3.Type the full Chrysler part number in the Part Number field.

4.Check the box for Unassigned Risk

5.Click Find.

6.Click the radio button for the Supplier Code where you want to apply Initial Risk.

7.Select a risk value from the Initial Risk drop down.

Note: Do not make a separate selection for Current risk. The initial risk value will automatically populate to Current risk when updated.

8.Check the box to Acknowledge Risk Drivers

9.Click Update.


27

To Change Current Part Risk for a Single Part:


2. Click Part Information tab. Then, click the Part Risk link.

3. Type the full Chrysler part number in the Part Number field.

4. De-select the check box for Unassigned Risk

5. Click Find.

6. Click the radio button for the Supplier Code where you want to change Current Risk.

Note: Current Risk can only be changed once the Initial Risk has been captured. Do not select rows where the Current risk value is the same as the new risk value.

7. Select a risk value from the Current Risk drop down.

Note: Do not make a separate selection for Initial risk. The initial risk value cannot be changed once it is captured. If you attempt to enter a value for Initial risk, you will receive an error message.

8. Click Update.

To Change Current Part Risk for One or More Parts:


2. Click the Part Information tab. Then, click the Part Risk link.

3. Enter valid Chrysler Supplier Quality Deck Code

Note: SQE Deck Code is populated by default, where applicable. Select Clear to enter a new value.

4. De-select the check box for Unassigned Risk

5. To limit the results, enter a value for one or more Optional filters.


28

QUALITY PLANNING / AQP MEETINGS

What are AQP Meetings?

Regular reviews of the program status

A way to ensure progress of CPCP milestone deliverables

Ensures communication between AQP team members

1. AQP Kick-off Meeting2. Hold regular AQP

Meetings and track status

with Executive Summary,Timing Chart

29

WHEN / WHERE ARE AQP MEETINGS HELD?

Required for all programs following the AQP process

All components with a High IRE

Recommended for Medium and Low IRE programs, although the Supplier may also

use the APQP process (see the AIAGs Advanced Product Quality Planning and

Control Plan Manual, 2nd Edition)

Regular, frequent schedule Recommended weekly

No mandatory location If possible, it is strongly recommend that

some meetings are held at the Tier 1

manufacturing location, critical Tier 2 or

lower Suppliers, and at the Chrysler

manufacturing facility

30

WHOS IN CHARGE?

The Chrysler SQE leads the AQP Meetings for High IRE programs

The Supplier leads their own AQP/APQP Meetings for Medium and Low IRE programs

The Chrysler SQE can require

AQP Meetings for any program

on an as needed basis

31

THE AQP KICK-OFF MEETING

Should occur as soon as the part is sourced and given an IRE in CQMS Early involvement by Supplier Quality and the Supplier is critical

Should include all AQP Team members

Chrysler Supplier Quality Engineer

Chrysler Product Engineer

Supplier Personnel

Core Team

Chrysler SQ Manager / Vehicle Lead

Chrysler Buyer Chrysler Supply Other Chrysler

Personnel as needed

Sub-Tier Suppliers as needed

Extended Team

32

Review the IRE Gain additional team input

Review issues/risk drivers that gave the highest risk

Establish team roles and responsibilities (including responsibilities between Tier 1 and Directed/Consigned

Suppliers)

THE AQP KICK-OFF MEETING AGENDA

Directed Tier II

Part PO Tier I

Tool PO Chrysler

AQP/PSO Resp. Chrysler

Release/Logistics Tier I

Receiving Location Tier I

NCT Issued to: Tier I

eCIMS Issued to: Tier II

Consigned Tier II

Part PO Chrysler

Tool PO Chrysler

AQP/PSO Resp. Chrysler

Release/Logistics Chrysler


NCT Issued to: Tier II

eCIMS Issued to: Tier II

Standard Tier II

Part PO Tier I

Tool PO Tier I

AQP/PSO Resp. Tier I

Release/Logistics Tier I


NCT Issued to: Tier I

eCIMS Issued to: Tier I

33


Determine AQP meeting frequency How often, at what location, attendance expectations, etc.

Confirm core AQP Team members Chrysler SQE

Chrysler Engineer

Supplier Personnel (Quality and Program Management, at a minimum)

Review the source package Ensure requirements are accurate

Engineering specifications

Prototype build requirements

Review volume assumptions (e.g., shift pattern agreement with P.O. volumes)

Get an early idea of SRE/PSO cycle time & line speed requirements

Identify potential capacity issues up-front

34

Establish and review program timing / major CPCP milestones Prototype (VP, PVP) and Launch (Job 1) build dates and Material

Required Dates (MRD)

Dates for deliverables (including, but not limited to):


PFMEA Acceptance

Production Tools Complete

Equipment, Fixtures, Facilities, and Gages Complete

Gage R&R

Supplier Readiness Evaluation (SRE)

Dimensional Capability

Part I/S Draft & Final Complete

Pre-PSO Meeting

PSO On-Site Visit

PSO Complete

IMDS Submitted

PV Testing Start / Complete

PPAP submission

When initial program timing is developed, deliverables for milestones that are

already past due shall be included for completion. These deliverables shall be

distributed into appropriate, future milestones as determined by the AQP Team.

35


Establish AQP/Process Sign-Off (PSO)

expectations Maintenance of AQP forms and

documents

SRE/PDR part run quantities

Extended Run PSO?

Etc.

Confirm manufacturing location

36

GENERAL AQP MEETINGS

Agenda should include:

Program timing and major milestones If timing slips, an appropriate Risk Mitigation Plan shall be developed and

implemented to manage the risk

CPCP timing and deliverables for the current and next milestone Late deliverables also require an appropriate Recovery Plan

Open issues Prototype quality issues (NCTs, eCIMS, etc.)

Current or proposed Engineering Changes, IAAs

Sub-tier Supplier status

Etc.

37

Sometimes broken up into two types: High-level AQP and Working-level AQP

High-level Agenda based on Milestones / Timing

Focus on process-readiness vs. product design

Team provides brief updates on status

Working-level Agenda targets specific deliverables

Team members do the work during these meetings (i.e., develop PFMEA, Part Inspection Standard, Control Plan, etc.)

GENERAL AQP MEETINGS

38

AQP MEETING FORMS AND DOCUMENTS

AQP Timing Chart

Supplier must maintain and update for each AQP meeting

Tracks progress towards completion of all PSO elements, plus key Supplier Quality deliverables and AQP tasks (IRE, PPAP, etc.)

Details item status and customer responsible lead

Required for all programs following AQP (and all Fiat parts managed by Chrysler)

SUPPLIER:

SUPPLIER CODE: MY/VEHICLE FAMILY:

PART NUMBER(S):

REVISION:

PART NAME(S): REVISION DATE:

AQP MEETING DATE:

PART RISK (H/M/L): AQP MEETING LOCATION:

VP

PVP

Job 1

BEGIN

P LAN ACT P LAN ACT

SQE -

SQE 1

SQE -

ENG -

SQE -

SQE -

SQE -

SQE -

Confirm composition and commitment of Core

AQP Team Members

CU

ST

OM

ER

LE

AD

PSO

Element

END

Build

NameMRDBuild Date

Month-DateMonth-DateMonth-Date Month-Date

SUPPLIER

RESPONSIBLE

# of

Veh

AQP ACTIVITIES

eCIMS / Lessons Learned Reviewed

If status is 1, 2, or 3 (Red

or Yellow), you must

provide a Risk Mitigation

PlanEnter 1-5

Advance Quality Planning

Month-Date Month-DateMonth-Date

ADVANCE QUALITY PLANNING (AQP)

TIMING CHART

Month-Date Month-DateMonth-DateMonth-Date STATUS

# of

Days

YEAR

Month-Date

#NUM!FIAT PROGRAM

REVIEW STATUS#NUM!

CHRYSLER AQP

STATUS

RISK MITIGTION PLAN

YEAR

Month-Date

Initial Risk Evaluation (IRE)

Source Package Review

KEY MATERIAL/BUILD DATES

Verify deliverables timing to CPCP timing

Prior PSO Review (similar products)

Volume, ramp-up curve, and product mix verified

and capable - CPV, P.O, SP

Program & Style

Approval

EF EFEF

Step 2 Style

Freeze

Step 3 Tooling

Kickoff

EF

Verification of Process

VP EF

Pre Volume Production

PVP EF

Job 1 Offline

EF

Commercial Launch

EF

Step 5 Prod. Designs

Complete

0

0

0

VP

PVP

Job 1

BEGIN

P LAN ACT P LAN ACT

SQE -

SQE 1

SQE -

ENG -

SQE -

SQE -

SQE -

SQE -

SQE -

PTS -

ENG -

ENG -

ENG -

SQE -

ENG -

ENG 3

ENG 4

SQE -

Review CNs and IAAs (including associated Risk)

TAG Review (Chrysler-purchased tooling only)


AQP Team Members

Part Development Plan Complete

Status of Open Issues from Technical Review Risk

Assessment (FIAT parts only)

Supplier Quality Risk Assessment (SQRA)

CU

ST

OM

ER

LE

AD

PSO

Element

END

Build

NameMRDBuild Date

Production Tooling Complete (PTC)

SUPPLIER

RESPONSIBLE

# of

Veh

AQP ACTIVITIES



Design FMEA

Test Sample Sizes and Frequencies

# of

Days

Design Review - Customer Perception targets


Source Package Review

Confirm Supplier PPAP Self-Certification status

KEY MATERIAL/BUILD DATES





39

AQP TIMING CHART

1. Item or activity title Key AQP tasks and SQ

deliverables (IRE, Production Tools Complete, IMDS, PPAP)

All PSO Elements

2. Tracks Supplier responsibility for each item, with begin/end dates

3. Key build/MRD dates

4. Details Chrysler lead for each item

1

2

3

4




PlanEnter 1-5

STATUS RISK MITIGTION PLAN

Commercial

40

AQP TIMING CHART

5 6

5. Indicate the status of the task.

6. Brief description of the risk mitigation plan (or reference to a more detailed action plan)

Score Chrysler Definition

1

Not present / not started and: Very late to required milestone and will cause other required deliverables to be late to their required milestone/vehicle launch Risk Mitigation Plan does not exist Extremely High Risk to milestone/vehicle launch (certain to cause delay in milestone/vehicle launch)

2

Incomplete and: Late to required milestone and may cause other deliverables to be late to their required milestone/vehicle launch Risk Mitigation Plan exists but is not acceptable or requires unrealistic timing to meet milestone High Risk to milestone/vehicle launch (may cause delay in milestone/vehicle launch)

3

Incomplete and: Late to required milestone Risk Mitigation Plan exists and is acceptable Low Risk to milestone/vehicle launch

4 Incomplete and: Progressing according to required milestone timing No Risk to milestone/vehicle launch

5 Complete and approved

41

AQP TIMING CHART

7. Use this section to track progress of each item towards completion Shows suggested AQP start and finish CPCP milestones (solid black line)

Shows current progress (gold dotted line; manually adjusted)

Use solid red line to show current date (manually adjusted)

Details required deliverable dates (black diamonds)

Month-Date Month-Date Month-DateMonth-DateMonth-Date

YEAR

Month-Date Month-DateMonth-Date Month-DateMonth-Date Month-DateMonth-Date

YEAR

Month-Date

High risk; PO + 8 wks

All Other

Program &

Style

Approval

EF EFEF

Step 2

Style

Freeze

Step 3

Tooling

Kickoff

EF

Verification of

Process

VP EF

Pre Volume

Production

PVP EF

Job 1

Offline

EF

Commercial

Launch

EF

Step 5 Prod.

Designs

Complete

7

10 AQP Activities [Specific] Follow the instructions listed below: Used in FIAT

Program Review?

Initial Risk Evaluation (IRE) The SQE performs the Initial Risk Evaluation and determines the part risk to be High, Medium, or Low. No

Advance Quality Planning PSO Element 1. Includes overall program timing, Supply Base Management, Problem Solving, and most

supporting processes. Verify timing for tooling, fixtures, gages, testing requirements, and sub-components.

Regularly review and update timing plans, as needed. Review risk assessments for sub-components. Ensure

the Tier 1 Supplier has a process for tracking Sub-Tier Supplier quality and delivery, and that poor-performing

suppliers have been replaced or are receiving commensurate additional attention during the development

phase. Review the Tier 1 Supplier's plan for PSO on sub-components, and verify back-up plans exist for Sub-

Tier Suppliers with a high risk for supply issues.

Yes

Confirm composition and commitment of Core AQP

Team Members

Verify the core AQP Team members: Supplier Quality, Engineering, Plant Quality Center (for Part I/S), and key

Suppler team members (Quality, Program Management/Engineering). Identify non-core AQP Team members

that may need to provide input, such as Purchasing, Logistics/Supply, Supplier Sales Representative, etc.

Complete, and keep up-to-date, a contact list with all AQP Team members, their phone numbers, and email

addresses.

Yes

Source Package Review At the AQP Kick-Off Meeting, review the completed Source Package, noting key information and program

deliverables. Ensure engineering specifications and Quality and Supply requirements are understood by the

Supplier.

No

Volume, ramp-up curve, and product mix verified and

capable - CPV, P.O, SP

Review program volume requirements, planned product mix, and planned launch ramp-up curve. Ensure the

Supplier understands the requirements. Support the Buyer in timely Purchase Order issuance, and ensure the

quoted Daily Tooling Capacity is sufficient to meet Chrysler's needs.

Yes

eCIMS / Lessons Learned Reviewed Review quality spills from previous and similar products/processes. Use the eCIMS system, NCT system, and

completed 8-steps. Ensure issues are accounted for when developing Design and Process FMEAs. Verify that

issues resulting in past yardholds, PRIs, or Field Actions are adequately error-proofed or completely designed

out of the part in the new process.

Yes

Prior PSO Review (similar products) Review Process Sign-Off (or PCPA, for Fiat parts) results from previous programs, both on similar product and

from the same Supplier. Account for issues that may have resulted in lack of PSO approval so that do not

reoccur, and make sure all open issues have been closed.

Yes

Verify deliverables timing to CPCP timing Ensure the AQP Team has the most current CPCP timing, including all milestones. Verify that Supplier

promise dates for all deliverables are consistent with CPCP timing and are not late. Reference the "Supplier

Quality Deliverables Timing" form on the AQP/PSO website.

Yes



Applicable for FIAT parts only. Review the status of open issues created from the Risk Assessment during the

Technical Review (part of the FIAT Sourcing process). Verify progress and ensure it is consistent with what

was planned.

Yes

Supplier Quality Risk Assessment (SQRA) Review the status and issues from the Supplier Quality Risk Assessment (SQRA) with the Product Team

SQE. Ensure the AQP Executive Summary form is kept updated after each AQP Meeting with potential launch

risks and Risk Mitigation plans.

No

Part Number, Description, and Change Level PSO Element 2. Verify that the Supplier has the latest Technical Documentation, including the design model,

GD&T, access to the latest Chrysler Engineering Standards, access to color/gloss/graining masters, etc.

Review GD&T to ensure datums are adequately defined and special characteristics are identified. Verify CNs

allow sufficient time for tool modifications, testing, etc.; propose V2 timing for CNs that may create a risk to

launch. Note: Planning to run the PSO at an unapproved revision level (i.e., a future CN) results in a maximum

score of "3" for this item.

Yes

AQP TIMING CHART

42

Sample of task directions:

AQP TIMING CHART

43

Scoring Examples:

Task

Production Tooling

Complete (PTC)

Process FMEA

Issue

Late design release means the Supplier will not have

production tools ready by VP. They plan to build parts with

prototype tooling, using production intent materials and

gages. Tools will be available in time to provide parts for

PSO and the Pre-series build. (Suggested score = 3)

In a review of the PFMEA, the SQE discovers that the

Supplier has not implemented error/mistake-proofing on

several safety-related items. In addition, an overall audit

using the Supplier PFMEA Audit form returns a red result. (Suggested score = 1 or 2, depending on when this

is discovered)

44

AQP MEETING FORMS AND DOCUMENTS

AQP Open Issues

Open Issues must be created and maintained throughout the program

SQE has responsibility to maintain, but can delegate to the Supplier

Key Points:

1. ONE Individual as responsible for an item

2. Dates: when the issue was opened, target for completion, and actual

completion or closed

3. Priority or risk level (recommended)

4. Updates and comments

AQP Open Issues are considered quality records

Kept for life of the program, plus one year

Who retains them? (SQE)

45

PART INSPECTION STANDARD (PART I/S)

Provides clear communication and agreement between the Chrysler Manufacturing Plant, Engineering, Supplier Quality and the Supplier in regards to: Characteristics on the design model

which the Chrysler Manufacturing Plant considers to be most important

The measurement method, sample size, and frequency with which the Supplier checks those characteristics

DRAWING/SKETCH

SUPPLIERCHRYSLERDATEREVISION / DESCRIPTION

FINALPART NO: PART NAME/DESC:

SUPPLIER NAME: MANUFACTURING LOCATION:SUPPLIER CODE:

PART INSPECTION STANDARD VEHICLE MY / FAMILY: DATE:

DRAFT

ENG QLTY MGR

REV.

# ENGPLANT QC SQE

INITIAL SIGN-OFF / APPROVALDATETITLE SIGNATURENAME

Engineer - Chrysler

Plant QC Eng. - Chrysler

SQE - Chrysler

DRAWING NO. / REVISION LEVEL:

Engineering - Supplier

Quality Mgr. - Supplier

46

PART I/S

SUPPLIER CODE: SUPPLIER NAME: MANUFACTURING LOCATION:

FINAL

PART INSPECTION STANDARD VEHICLE MY / FAMILY: DATE:

DRAFT

PART NO: PART NAME/DESC:

INITIAL SIGN-OFF / APPROVALTITLE DATENAME SIGNATURE

Plant QC Eng. - Chrysler

SQE - Chrysler

Engineer - Chrysler

Quality Mgr. - Supplier

Engineering - Supplier

ITEM

#REMARKS / INSPECTION METHODFREQ.

SAMPLE

SIZE

MEAS.

METHOD

SPECIFICATION /

TOLERANCE

CHARACTERISTIC /

INSPECTION POINT

DRAWING NO. / REVISION LEVEL:

Provides the Chrysler Manufacturing Plant a tool to more quickly identify a problem and responsibility when a quality issue occurs

Gives the AQP team an opportunity to identify potential problems/conflicts between individual part requirements and Chrysler Build Objectives before the prototype build phase.

47

PART I/S TEAM

Team Members (minimum):

Chrysler:

Supplier Quality Engineer

Engineer

Plant Quality Center Engineer

Supplier:

Quality Manager

Engineering / Program Manager

Additional team members may be added, as needed. Examples

include the Chrysler Dimensional Engineer, Design Office, TAG

representative, etc.

48

PART I/S RASIC

Sup

plier

Sup

plier Q

uality

Sys

tem

& C

ompo

nent

Eng

inee

ring

Man

ufac

turin

g Qua

lity (P

lant

)

Veh

icle E

nginee

ring

Des

ign

Office

Selection of Parts C CS C RA C

Confirm Assembly vs Part Datum Scheme Alignment1

R/S C C/R A

Selection of Critical Dimensions1

R/S C C/R A

Sample Size and Frequency determination R A C C

Measurement Method of Critical Dimensions R S A C

Selection of Appearance Specs/Characteristics1

R/S C C/R A C S

Boundary Sample Creation and Review/Sign-off R S C A S S

Selection of Functional Specs/Characteristics1

R/S C C/R A

Completion of Part I/S form R S CA

Retention of Completed Part I/S RA I I I I I

Responsible - Those who do the work to achieve the task. There is typically one role with a participation type of Responsible

Accountable - Final Approving Authority

Support - Resources allocated to Responsible

Informed - Those who are kept up-to-date on progress, often only on completion of the task or deliverable; and with whom there is just one way

Consulted -Those whose opinions are sought; and with whom there is two-way communication

NOTES

1: Dependant upon which party is design-responsible

49

HOW IS THE PART I/S DONE?

Chrysler Product Creation Process (CPCP)

FINAL DRAFT CREATION

PART INSPECTION STANDARD

IRE FPSC PSO & PPAP

50

Part I/S Creation Phase


Scope of the program is defined (parts identified, critical characteristics identified, etc.)

Document is created

Identify Parts

& Provide

Information

Team Review Revise &

Sign Create

Part I/S

51

Use of the Part I/S Draft to check parts for the VP and PVP pilot builds

Follows the same basic flow for each build:

Part I/S Draft Phase

Implement &

Collect Data Team Review

Revise &

Resubmit

Build

Event


52

Part I/S is finalized for Job 1 and continuing volume production

The Part I/S remains a living document and can be revised as needed

Part I/S Final Phase

The Part I/S does not replace either the Control Plan or FPSC

at any program stage.


53

PART I/S AND OTHER DOCUMENTS

The Part I/S should be developed alongside other quality documents, especially the PFMEA, Control Plan, and

FPSC plan The Part I/S does NOT replace or supersede any other quality

documents!

Characteristics included on the Part I/S should also be included on the Control Plan for the part

The Part I/S should be updated at the same time as other quality documents (e.g., for CNs, FRs, etc.)


54

FPSC: Safe Launch; checks/inspections over and above Control Plan

Control Plan: Controls (w/ frequency, sample size) for

entire process

Part I/S: Ties controls for the final product characteristics

with visual representation (GD&T) and allows for

measurement scheme agreement with the Chrysler

Manufacturing Plant


Question: If were instituting 100% inspection for VP (or other pilot build), with a gradual lessening of frequency as

we move into production, should the Part I/S reflect this? No. The Part I/S is a tool to communicate how the Supplier will check

parts in production. As such, it should reflect the production control

plan inspection frequencies and sample sizes. If the team is requiring

100% inspection for a pilot build, this should be reflected on the FPSC

plan, NOT Part I/S. Per the RASIC on slide 8, SQ has the final

approving authority on sample sizes and frequencies.

55

PART I/S FLAG IN CQMS

56

PFMEA ACCEPTANCE

57

Part Inspection

Standard (Part I/S)PFMEA Acceptance

What is significant PFMEA Acceptance?

An audit or assessment of the Suppliers Process FMEA

Applicable for any part that also requires a Part I/S All parts with a High IRE and those parts selected by the Assembly Plant

Required to be completed 14 weeks prior to VP

PFMEA ACCEPTANCE

58

Supplier Quality Engineer (SQE) Supplier 3rd Party

Audit Result?

Identify Significant PFMEA Acceptance parts (Notify

Supplier)

End

3rd Party Review required?

Review PFMEA using "Supplier PFMEA Audit Summary" form

Review PFMEA using "Supplier PFMEA Audit Summary" form

Forward PFMEA to SQE

Forward PFMEA to 3P (copy SQE)

YES

Audit Result?

Make corrections to PFMEA (work with Chrysler SQE)

Enter Actual Date in CQMSGREEN

NO

Make corrections to PFMEA (work with 3P)

REDRED

YELLOW

YELLOW

Dispute ProcessIf Supplier and/or SQE disagrees with 3P assessment:1. Submit PFMEA to Sr. Manager - SQ Operations2. Sr. Manager - SQ Operations reviews PFMEA3. If result matches 3P, 3P assessment stands and process is

followed as normal4. If result differs, Audit Result changes and process follows

the new result flow for 3P

Audit Result?

GREEN

RED

YELLOW

GREEN

SQE determines if audit will be done by

themselves or 3rd Party

Auditor uses the Supplier PFMEA Audit Summary form

If not green, Supplier makes corrections and

resubmits per the

flowchart

PFMEA ACCEPTANCE

Criteria for using a 3rd Party Auditor include (but is not

limited to):

Suppliers who are "Red" in the Quality Bid List system

Suppliers who are on New Business Hold

Suppliers on the Top Problem Supplier Locations list

Parts from Suppliers that have been involved with / responsible for recent yardholds, Product Related Issues (PRIs), or Field Actions

The SQE makes the final decision for whether or not a Supplier must

use a 3rd Party auditor for this process

59

PFMEA ACCEPTANCE

60

Dispute Process

If the Supplier and/or SQE disagrees with the 3rd Party assessment:

1. Submit the PFMEA to the Sr. Manager - SQ Operations

2. The Sr. Manager - SQ Operations reviews the PFMEA with Supplier PFMEA Audit Summary form

3. If the result matches the 3rd Party, the assessment stands and process

is followed as normal

4. If the result differs, the Audit Result is changed and the process

follows the process flow for the new result

PFMEA ACCEPTANCE

61

Supplier Process FMEA: Audit Summary (based on Fourth Edition FMEA Manual)

MY/Program

Name of Component(s), Sub-System(s) or System(s):

Part Number(s):

Responsible Supplier:

Responsible Chrysler Supplier Quality Engineer:

Name of Auditor:

Date Reviewed:

Date of PFMEA audited (Later of Original or Rev. Level):

Rating Detail Criteria

Header: "Yes" if all answers in section 1 are "Yes."

Non-Header sections (2 through 13): Count # of sections 2-13 "No" and # "E/I."

Header "Yes" overall and no more than

three sections "E/I" overall = "Green"

Neither "Green" nor "Red" criteria met =

"Yellow"

Six or more non-Header sections "No"

overall = "Red"

1 Header Yes E/I No N/A Auditor Comments

1a Name of Vehicle(s)/Program(s) included? - -

1b Model Year of Program(s) included? - -

1c Name of Supplier included? - -

1d Part Number and Description included? - -

1e Core Team includes (at a minimum): Chrysler: Supplier Quality Engineer and

design-responsible Engineer. Supplier: Quality Engineer and Plant Mfg.

Engineer? Names and titles or area of responsibility are included? Note: Phone

#'s recommended, but not mandatory for this audit.

- -

1f Key Date shown is PPDC date or P.O. issuance + 60 days, whichever is later (for

new vehicle programs), or does not exceed PPAP date (for programs already in

production )? Note: Contact Chrysler SQE, if required.

- -

1g FMEA Date (Orig.) is shown? - -

1h FMEA "(Rev.)" date within past 60 days? Note: "N/A" if "(Orig.)" date is within 60

days.- -

Additonal Comments (not to impact audit results): - - - -

If all answers "Yes," check "Yes." If one or more "No," check "No." - -

Result

"No"___ "E/I"___

Overall Rating (place an "X" in the appropriate box)

Note 1: "E/I" = only minor "E"xceptions or requirement "I"nconsistently applied (approx. 25% or less) and correction still required.

Note 2: Do not allow a "No" answer to one question (e.g., Detection ranking too low) result in a "No" answer to another related question (e.g.,

lack of "Recommended Actions" or "Action Results"). Evaluate each question based only on their own merits.

Note: If PFMEA is done by process vs. part, a separate header sheet listing the various programs, parts, etc. for each element in Section 1 is acceptable.

If you dont know if something has been done, answer , No then follow up later.

Ask how? and when? vs. yes/no questions when assessing certain questions, (i.e., Did the Design-responsible Engineer provide input on Effects?).

Be sure to read and understand the Notes to help ensure consistency.

Additional Comments on the PFMEA

PFMEAs shall incorporate lessons learned from past programs or similar parts, internal and external nonconformance data related to

the parts, and customer (Chrysler) inputs, as outlined in the Supplier

PFMEA Audit Summary.

For the parts requiring PFMEA Acceptance in the Chrysler Quality Management System (CQMS), the SQE and Supplier shall jointly

audit the PFMEA no later than (14) weeks prior to VP SOF. In

addition, the result of the PFMEA audit shall be "Green" before the

Actual Date is entered in CQMS.

All PFMEAs, regardless of the risk level, shall be rated "Green" per the "Supplier PFMEA Audit Summary" form as part of PSO

requirements.

Please refer the PFMEA Acceptance process standard in the Book of Knowledge for more details.

62

The responsible SQE is expected to provide following support:

Ensure the Supplier provides the PFMEA and supporting documents within 2 weeks of email notification. Do not rework the documents beforehand.

If the 3rd party audit obtains a "Red result, the Supplier is required to contract one of the 3rd Party Auditors and start coaching and audits within

(2) weeks. The Supplier works with the 3rd Party Auditor until a "Green"

result is achieved. The supplier may be issued a Forever Requirement Violation (FRV) as Failure to

follow/respond to Chrysler requirements or requests if they refuse to seek coaching within (2) weeks of receiving a Red audit result.

If the supplier needs to dispute the audit result, the Supplier and/or SQE shall submit the PFMEA audit form as originally completed by the auditor

and an explanation for the dispute to the PFMEA Auditor Facilitator, Stanley

Zhou ([email protected]).

Please refer to the PFMEA 3rd Party Audits and Coaching process

standard in the Book of Knowledge for more details.

3rd Party PFMEA Audits

64

FIRST PRODUCTION SHIPMENT CERTIFICATION

What is FPSC?

Safe Launch activities

Audit / inspection above and beyond standard

process controls

Records retained by the Supplier; may be

requested by Chrysler

personnel at any time

65

FPSC BASICS

FPSC includes all Special Characteristics Product characteristics or manufacturing process parameters which can

affect safety or compliance with regulations, fit, function, performance or

subsequent processing of a product

Also includes any additional characteristics selected by the AQP and/or PSO Team (Chrysler or Supplier)

Key characteristics

Safety characteristics

Emissions characteristics

Torque requirements

SPC points

Others deemed critical by the Supplier or Chrysler

S

66

FPSC BY PROGRAM

NEW PROGRAMS

Begins with first shipment for VP build

Duration is until Job 1 + 90 days has passed (minimum)

Plan, results for VP, and effectiveness of the FPSC

reviewed during the Pre-PSO

Meeting

MODIFIED PROGRAMS / FR

CHANGES / RESOURCING

Begins with first shipment to a Chrysler (or Chrysler-designated)

facility

Duration is until 1st shipment + 90 days has passed (minimum)

Plan reviewed during PSO

The Chrysler AQP Team is final approver of the FPSC duration. Deviations from the minimum are to be approved in writing by the Chrysler AQP Team.

67

OTHER FPSC INFORMATION

The Supplier is responsible for ensuring that FPSC (or

equivalent) activities are implemented through the Supply

Chain (Tier 2 and lower). The duration of FPSC (or

equivalent) at sub-tier suppliers shall match that of the Tier

1 Supplier's FPSC.

FPSC is not a replacement for the Part I/S or Control Plan,

nor is the Part I/S or Control Plan a replacement for FPSC.

FPSC is intended to be an additional level of inspections or

audits to protect the Chrysler (or Chrysler-designated)

manufacturing facility during the pilot and launch phases.

PART QUALIFICATION PROCESS

68

Plant validation of BIW/QAF (Interior & Exterior Quality

Assurance Fixtures)

components (internal and

external suppliers) to fulfill the

customer requirements,

Quality standards, Build

Objectives (EBO) and Design

intent. Validation includes

Dimensional control.

Plant Metrology Center lead; SQE supports the plant by

ensuring Supplier submits

parts and data when required

and corrective actions are

completed

75% of Tolerance

75%-100% of Tolerance

Over 100% of Tolerance


69

Supplier submits part data from 5 parts and

transfer to Plant

Mark up two parts with measured

data to bring to plant

Meet with Plant to review parts and data

Supplier Creates new

PDCA if required

Supplier incorporates Changes in

Manufacturing Process if req.

If part has Red data supplier should submit PDCA and sub-tier data

Supplier (Internal & External) Requirements for Part Submission (preferred two Weeks prior to MRD) for each build phase

Plan Do Check Act (PDCA)/Quick Kaizen required for any red points

More loops should be repeated as corrective action timing permits

Parts and Data need to be characterized :

Part made from Soft Tool / Hard Tool

Tools are on Home Line / Temp Line

Special Means were /were not

Gage R&R Roadmap of Part


70

Vehicle Development Phase Mass Production

Continuous Loops

Additional loops will be required within each build phase (S1A, S1B etc.) according to:

Part achievement of Dimensional Compliance Engineering changes Part availability (Pilot Build Phase) Measurement schedule Process changes (e.g. soft to hard tools)

Must have knowledge of part production process hard tools/soft tools , maturity of supplier process

Parts shall be dimensionally correct for S1 / VP Parts shall meet PP/PPK per Appendix B of the AQP/PSO

Manual at S2 / PVP (min 30 pc sample) Parts shall meet CP/CPK of 1.33 at V1 and later (min 30 pc

Sample)

NOTE: Supplier should build in small batches for each burst build in the pilot phase to accommodate continuous improvement plans

NOTE: Submission due date - preferred 2 weeks prior to MRD First submission for each Pilot Phase must be complete before A Phase framing

NOTE: Request 2 additional parts for each pilot phase to accommodate submission requirement NOTE: Supplier Must submit for each of the 3 Pilot Phase (if applicable)

S1/VP S2/PVP V1

S1A - Framing S2A - Framing Loop 1


71

PART AVG. WEIGHT SUBMISSION DATE:

SUBMISSION: BUILD: PHASE:

FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC) S1 / VP Phase A

PART QUALIFICATION S2 / PVP Phase B

PART INSPECTION STANDARD (PART I/S) V1 / Job 1 Other

INITIAL PROCESS STUDY Post-V1 / Post-Job 1

OTHER

PROCESS:

TOOLING ASSEMBLY SPECIAL MEANS

COMMENTS:

Chrysler SQE/ASME Phone ( )

Chrysler Plant QE Phone ( )

Chrysler Engineer Phone ( )

Plant Mgr. (Supplier) Phone ( )

Quality Mgr. (Supplier) Phone ( )

Data Prepared by: Phone ( )

Special Means Not Required Date: Home Line Complete Date: Production Tooling Complete Date:

Email

Email

Email

Email

Email

Email

CharacteristicChar #

PROTOTYPE PRODUCTION TEMP LINE HOME LINE

PART NUMBER

SUPPLIER CODE

SUPPLIER NAME

M eisterbock R/Y/GCP3 CPK

3 Gage R&R

Acc?ACC/REJ

Free

State FitQAF

Variable /

Attribute

Dim.

Correct?1P P

2 P PK2

YES NO

MEASUREMENT RESULTS SUMMARYSpecification /

To leranceClassif.

MFG. LOCATIONPART DESCRIPTION

MY/VEHICLE

3 Parts shall meet CP/CPK of 1.33 at V1 and later

2 Parts shall meet PP/PPK per Appendix B of the AQP/PSO Manual at S2 / PVP

NOTES:1 Parts shall be dimensionally correct for S1 / VP

Supplier Completes Part Data Submission form- Requirement of Submission prior to MRD

Metrology Center will notify supplier of Disposition Green = Dimensionally Correct (< 75% of Tolerance) Yellow Dimensionally Correct (>75% and < 100% of

Tolerance) Red = Dimensionally incorrect - Quick Kaizen/PDCA

needed with data submission Metrology Center will notify supplier of Part Validation

Meeting Green Part = Metrology Center will notify supplier of next

build phase submission and give approval for next batch build

Red Part = Suppliers corrective action will determine next submission (PDCA needed documenting plan)


72

Supplier Submits GD&T or PIS (Part Inspection Standard - if available) - Requirement of Submission

Part I/S is used only if the part is required to have one based on Part I/S criteria Part I/S is NOT automatically required for parts undergoing the Part Qualification

Process!


73


74

Dimensional Compliance Team: -Product Release Engineer

-Have the released model/GD&T up to date -Ensure CN is complete to document dimensional revisions

-Supplier Quality Engineer (SQE) External Suppliers -Assist Metrology Center Rep by communicating requirements to the supply base -Assist supplier with Quick Kaizen/PDCA

-Advance Stamping Manufacturing Engineer (ASME) Internal Suppliers -Assist Metrology Center Rep by communicating requirements to the supply base -Assist supplier with Quick Kaizen/PDCA

-Metrology Center Representative -Maintains Master Part Approval Schedule -Schedules part disposition Team Meetings -Schedules part submissions

-Supplier Representative (Internal & External) -Timely part submissions with appropriate forms -When part is red, develops Quick Kaizen/PDCA


75

After 1 Day late Escalates to SQ Manager/Metrology Manager

After 3 Days Escalates to Plant Manager , Director, and Plant

Metrology Center Manager Level

After 5 Days Escalates to VP level, Manufacturing , P & SQ,

Engineering

Escalation Process:

PART DATA SUBMISSION FORM

76

Data Sheet

77

PART DATA SUBMISSION FORM

PART AVG. WEIGHT SUBMISSION DATE:

SUBMISSION: BUILD: PHASE:

FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC) S1 / VP Phase A

PART QUALIFICATION S2 / PVP Phase B

PART INSPECTION STANDARD (PART I/S) V1 / Job 1 Other

INITIAL PROCESS STUDY Post-V1 / Post-Job 1

OTHER

PROCESS:

TOOLING ASSEMBLY SPECIAL MEANS

COMMENTS:

Chrysler SQE/ASME Phone ( )

Chrysler Plant QE Phone ( )

Chrysler Engineer Phone ( )

Plant Mgr. (Supplier) Phone ( )

Quality Mgr. (Supplier) Phone ( )

Data Prepared by: Phone ( )

Email

Email

Email

Email

Email

Email

3 Parts shall meet CP/CPK of 1.33 at V1 and later

2 Parts shall meet PP/PPK per Appendix B of the AQP/PSO Manual at S2 / PVP

NOTES:1 Parts shall be dimensionally correct for S1 / VP

PROTOTYPE PRODUCTION

Classif.

Home Line Complete Date: Production Tooling Complete Date:

Variable /

Attribute

Dim.

Correct?1P P

2Char # P PK2

YES NOTEMP LINE HOME LINE

M eisterbock R/Y/GCP3 CPK

3 Gage R&R

Acc?

Special Means Not Required Date:

Build Use?Free

State FitQAF

MEASUREMENT RESULTS SUMMARYSpecification /

To leranceCharacteristic

MFG. LOCATIONPART DESCRIPTION

MY/VEHICLE

PART NUMBER

SUPPLIER CODE

SUPPLIER NAME

Results sheet

Form used to

submit data for: FPSC Part Qualification Part I/S Initial Process

Study

Information

carried over from

data sheet

WHAT IS CRAFTSMANSHIP? INFLUENCES AND CONCEPTS

CRAFTSMANSHIP REVIEWS

8 CRAFTSMANSHIP INFLUENCES

Design: tolerance stackup, mating parts have different form (Eng)

AAR: colour, gloss, grain (PDO)

Appearance Standards: AS-10169, objective standard which must be met for conformance (Supplier)

Supplier Process: no spec, boundary samples required, flow lines, sink marks, squeezeout, etc. (Supplier, SQ)

HMI: human-machine interface, tactile feel of buttons and controls, sounds made while functioning, efforts to press buttons, etc. (All)

Chrysler Assembly Process: internal practices, mallet scuff marks, ISD, missing/loose/shy, etc. (Mfg)

Nonconforming Parts: (Supplier, SQ)

Cleanliness: smudge marks, dirt, dust, etc.(All)

What else?

Interior vs Exterior Craftsmanship Philosophies

within Chrysler

Both follow the same principles

Interior managed by dedicated Interior Quality and Craftsmanship department, interior SQE is part of team

Exterior historically managed by SQ and started later in product development phase, craftsmanship reviews

held during S2 timeframe

Exterior Craftsmanship Reviews Main areas of

Concentration

Appearance Standards: AS-10169, objective standard which must be met for conformance (Supplier)

Supplier Process: no spec, boundary samples required, flow lines, sink marks, squeezeout, etc. (Supplier, SQ)

Nonconforming Parts: dimensional issues, improper materials used, (Supplier, SQ)

CRAFTSMANSHIP FOLLOW UP

Document results of review on PIS

Schedule follow up visits

Maintain craftsmanship PDCA

Ask for boundary samples during supplier visits to gauge current production

Maintain good communication between advance and current SQ post-review

83

PROCESS SIGN-OFF

What is PSO?

Verification that the AQP activities have

been successfully

completed

A review of the Suppliers process, from beginning to end

Production Validation Phase

Verification of Process (VP)

Supplier Readiness Evaluation (SRE)

First Production Shipment Certification

(FPSC)

PV Testing

Pre-PSO Meeting

PSO On-Site Visit &

Production Demonstration Run

PSO Result

Complete PPAP requirements & submit Dimensional

PSW/PPAP

Complete corrective actions; reschedule On-Site Visit / PDR

as necessary

5 (Z)1-4 (N)

5 + PVT (A)

Supplier

Quality RiskAssessment

(SQRA)

PartQualification

Process

(Assembly Plant Lead)

84

PROCESS SIGN-OFF: BRIEF SUMMARY

FOUR BASIC ACTIVITIES TO PSO:

1.Trial Runs / Supplier Readiness Evaluation (SRE) Readiness for the PSO On-Site Visit

Yields parts for PV Testing

2.Pre-PSO Meeting Document review

Evaluate SRE results

Schedule PSO On-Site Visit

85

PROCESS SIGN-OFF: BRIEF SUMMARY

3. PSO On-Site Visit Review of Suppliers process and facilities


Initial Process Study

4. PV Testing Functional testing, et. al.

Select component & system PV (Production Validation) level testing required by VP: Only that testing required to ensure the components

function as intended, and which have been agreed

upon between the supplier and the Chrysler Product

Engineer at Production Design Clean-up (PDC), and

documented in the Design Verification Plan and

Report (DVP&R).

Concurrent with other PSO activities

86

MORE INFORMATION

For full information and training on the

Process Sign-Off, please sign up for

PSQPSO200 in TEDS

87

PPAP

PSO Z APPROVAL

Supplier can submit the dimensional PSW

SQE can enter the dimensional PPAP into CQMS

Receive partial tool payment (at the discretion of purchasing)

Still needs an IAA to ship parts

PSO A APPROVAL

Supplier can submit the full PSW

SQE can enter full PPAP into CQMS

Receive full tooling payment

Can ship parts normally

88

Supplier sends the PSW to the Chrysler SQE Must copy the Supplier Quality Group mailbox ([email protected])

SQE reviews the PSW for proper information

Verifies correct part number, CN, IMDS

number present, etc.

SQE enters PPAP dates & disposition into CQMS

Supplier enters PPAP dates & disposition into

CQMS

Medium & High risk parts Low risk parts

PPAP

89

CQMS - PPAP Submission

Enter a Chrysler part number, click Find. Check box indicates row(s) to update. Enter dates as

MM/DD/YYYY or use the calendar icon. The Disposition is required with Actual Dates.

90

CQMS - PPAP Mass Update

Select an Update Element: Blank Promise Dates, Promise Due Next 30 Days, Not

Approved or All. Enter a CN or enter a Supplier Code and CN Model Year. Click Find.

Optionally enter a Commodity Code or a Deck Code (with Supplier Code and CN Model

Year) for additional filters.

91

CQMS - PPAP Mass Update

Check box indicates row(s) to update. Enter dates as MM/DD/YYYY or use the calendar

icon. The Disposition is required with Actual Dates.

92

LESSONS LEARNED

Ensure lessons learned from the current program are carried

forward into new programs

Corrective actions for issues documented in FMEAs, Control

Plans, etc. and added to the quality

documents of other, similar products

Hold a Things Gone Right / Things Gone Wrong review meeting (30-60 days post launch)

Document TGR/TGW and retain in an accessible location

Review prior to beginning new programs

Review AQP meeting minutes and open issues from previous programs

Keep the Master PFMEA updated as issues occur

93

FOREVER REQUIREMENTS

1. Proactively communicate with Chrysler. Know when to raise the red flag.

2. Request approval from Chrysler prior to implementing any anticipated process changes.

3. Request approval from Chrysler prior to implementing any internal or Sub-Tier manufacturing location changes.

4. Watch for sub-tier Supplier issues and tell Chrysler about them.

5. Notify Chrysler of potential supply / capacity issues

AQP/PSO 7th Edition Manual, Appendix E

94

FOREVER REQUIREMENTS

Changes to the process post-PSO require submission to Chrysler via the

Forever Requirements system

The Tier 1 Supplier is responsible to ensure all of their sub-tier Suppliers

follow the Forever Requirements

Submissions to Chrysler always come from the Tier 1, regardless of what level of sub-

tier is making the change

Full information and training on the Forever Requirements can be found in

MQCFRR200, available through TEDS

AQP TIMING CHART

Group Activity AQP Timing Chart scoring

96

SQ DELIVERABLES & TIMING

Shaded deliverables require promise and actual date entries into, or are managed through, the Chrysler Quality

Management System (CQMS)

SQ Deliverable Chrysler Product Creation Process (CPCP) Milestone

Initial Risk Evaluation (IRE) Complete N/A (Source Identified in CQMS + 2 weeks)

Part I/S Parts Identified 22 weeks prior to VP Start of Frame

PFMEA Accepted [PFMEA] 14 weeks prior to VP Start of Frame

Part Inspection Standard (draft) [Part I/S (d)] 10 weeks prior to VP Start of Frame

Component-level Production Validation (PV) Testing Complete VP - Verification of Process Build

Equipment, Fixtures, Facilities, and Gages Complete VP - Verification of Process Build

First Production Shipment Certification (FPSC) Start VP - Verification of Process Build

Gage R&R Complete [Gage R&R] VP - Verification of Process Build

IMDS Submitted VP - Verification of Process Build

Production Tooling Complete [PTC] VP - Verification of Process Build

Station Cycle Time / FTC Compliant VP - Verification of Process Build

Supplier Quality Risk Assessment (SQRA) VP, PVP, & Job 1 Offline

Dimensional Capability Complete [Dim Cap] PVP - Pre-Volume Production (Pre-Series)

Error / Mistake Proofing Implemented PVP - Pre-Volume Production (Pre-Series)

Key Personnel Hiring/Training Complete PVP - Pre-Volume Production (Pre-Series)

Production Demonstration Run (PDR) Complete [PDR] PVP - Pre-Volume Production (Pre-Series)

Production Validation (PV) Testing Complete [PVT] PVP - Pre-Volume Production (Pre-Series)

PPAP Complete [PPAP] PVP - Pre-Volume Production (Pre-Series)

Part Inspection Standard (final) [Part I/S (f)] Job 1 Offline

97

ADDITIONAL TRAINING

Register through TEDS

Process Sign-Off PSQPSO200

Forever Requirements / Resourcing MQCFRR100

Chrysler Quality Management System MQCQMS100

Advanced PFMEA DQIFMA210

Nonconformance Tracking System MQCNCT100

eCIMS DQCZRO100

Warranty Management MQCSWM100

3 Legged 5 Why MQCTLW100

Part Inspection Standard PSQPIS100

98

ADDITIONAL TRAINING

Training CDs available

DQIFMA201 - PFMEA

DQISPC350 - Statistical Process Control

DQIPCA300 - Process Capability Analysis

DQIMPT300 - Error Mistake Proofing

DQICPD400 - Control Plan Development

DQIFMA275 - Design FMEA

Contacts:

Sheri De Hesselle [email protected] 722-1370

Paula Mack [email protected] 722-1370

99

QUESTIONS?

Please visit the AQP/PSO website for electronic versions of the following:

The AQP/PSO 7th Edition Manual

AQP Executive Summary and Open Issues forms (including the PTLR)

AQP Timing Chart

PSO forms

FPSC form

Part I/S form

Appearance Approval form and instructions

Supplier PFMEA Audit Summary

Supplier Quality Deliverables Timing Requirements

Part Data Submission form

https://gsp.extra.chrysler.com/qlty/pso/index.html

Suppliers can access through the Chrysler Portal Reference section of COVISINT

BACKUP

Special Notes for Chrysler SQEs

Managing parts for FIAT

100

Chrysler SQEs Managing Fiat Parts

101

Macro phases legend

Approach / Style / initiative Approval / Sourcing

Technical / Technological Development

Industrialization

Production Ramp Up

Production Tracking (6 months minimum) / Supplier Containment / Continuos Improvement

6 months 9 - 10 months 1 m

16 - 17 months

Card 0

CSE

Product

Card

Recommendation

IRE

AQP TC

1 m

DaP = OK to Ship

PSO = Process Sign-Off (w/ PDR)

IRE = Initial Risk Evaluation

PS = Pre Series

CSE = Chrysler Source Evaluation

TFU = Tooling Follow Up

VP = Process Verification

AQP TC = AQP Timing Chart Review

SRE = Supplier Readiness Eval.

FPSC = First Prod. Shipment Cert.

Main Deliverables

Main Milestones

SQ Tools

Supplier Tooling Sign Off

5 - 6 months

VP PS

2 m

SRE

DaP Commercial

Launch

2 m

Job1

PSO

TFU

- Start -

>

Final CAD Mathematics (Step 5) Article Card Final Drawings Availability Codep

.

Samples - Selfqualification

/PPAP (SQ)

- Integrative tests

(E&D)

- Plant Approval

(Plant)

Qualification

Informative System VDDP

AQP TC FPSC

Pre-PSO

Fiat Sourcing Process

The Chrysler SQE

is required to

support the Fiat

Sourcing Process

in the same

manner as Fiat

SQEs

102

Opening of the Sourcing Agenda

Extraction to the Roll Out

PACKAGES creation

Input Check

Key Stakeholders Meeting

PRE-RFQ

Input Check

RFQ dispatch

Quotation analysis

Technical review

Target setting

Negotiation

Recommendation

Process steps

requiring SQE

involvement

103

Used when the Input check finds a gap in the data needed to proceed in the sourcing process

The KSM is a meeting among all those with key responsibilities in the development of major items,

time and strategy management

Its goal is to ensure that all the quotations received after the RFQ are comparable and

compliant to the requirements

Key Stakeholders Meeting (KSM)

104

PRE RFQ - Supplier Preliminary Data

Profile

The SPDP is a survey where we ask a potential supplier to provide all the general information

regarding its organizational size and structure

Applies to new suppliers, not yet present in our data base

Equivalent to the Supplier Pre-Evaluation form in the Source Evaluation process

105

PRE RFQ - Quality Bid List

All the suppliers involved in the sourcing process shall be included in the Quality Bid List. If they

are not, the SQE must complete a Business Case

The suitable suppliers will receive the RFQ from the buyer

An approved Business Case is requested for every new supplier, containing data about its

Quality System, benchmarks for similar parts and

the PSA (Chrysler personnel will use the CSE)

Chrysler Source Evaluation

106

SCORING

Potential Supplier Assessment

Source Evaluation Tool

60-80% >80% 90% 80% 90%

107

PRE RFQ - Quality Bid List

80 + = green (ok to bid)

60-79 = yellow (need SQ Sr. Manager or Commodity Managers (Chrysler) approval to bid)

Below 60 = red (need SQ Directors approval to bid)

108

PRE RFQ - Quality Statement of

Requirements

Goals of the QSR:

Inform the supplier about Fiat quality requirements, including those special requirements linked to the part

construction technology and/or the specific supplier

Obtain from the supplier all the information related to its Quality system, its standards, its future behaviors

Have the supplier commitment to project feasibility, as required on the Product Card (Scheda Prodotto).

The supplier shall fulfill and submit the form together with the quotation, being ready for clarifications during

the Technical Review

109

Technical Review

Attendees

Purchasing: Lead Buyer, SQE, TAG,

E&D,

Logistics: SCD

Technologies: (mandatory only in case of Stampings)

Quality Risk Assessment for all potential suppliers strong and weak points, improvement recommendations to be agreed upon before

sourcing

110

Technical Review procedure regarding the

SQE

The SQE receives the Quality SOR from the supplier and prepares related questions prior to the meeting, then verifies the agreement

Any partial agreement from the supplier to our Quality SOR must be discussed and could result in the suppliers exclusion from the subsequent stages

Neither the buyer nor the SQE may accept any technical deviation from the requirements (e.g. Reliability targets, metrics like ICP and TOC, Customer profile) without the approval of the model Vehicle line Team/Platform

When the RASI chart is required, the SQE takes care that the document is properly shared.

Any deviation in the Technical documentation, with all the underlying risks, must be accepted under the approval of the MR only, with the updated documentation itself

Quality Risk Assessment

111

QUALITY RISK ASSESSMENT

Supplier Name: Supplier Code:

Part Number: Part Description:

Project:

Supplier Quality Engineer: Commodity (C;E;M;P):

Buyer: Co-design? (Y/N):

Design Engineer:

ASSESSMENT CATEGORY

ISSUE (OBLIGATORY FOR CONDITIONAL

RATING) RATING

ASSESSMENT

#

1. New Process, Technology and/or Capacity

A = Approved; C = Conditional;

NS = Not Sourceable.

2. Supplying Location


NS = Not Sourceable

3. Facilities/Equipment


NS = Not Sourceable

4. New Design Responsibility


NS = Not Sourceable

5. Quality History


NS = Not Sourceable

6.

Key Characteristics Mgt. (Important, Critical, Safety/Report & Legal)


NS = Not Sourceable.

7. Quality Targets (PPM, IPTV, Quality Tracking ICP/TOC)


NS = Not Sourceable

8. Timing Concerns


NS = Not Sourceable

9. Program Management


NS = Not Sourceable

10. Other (SQE)


NS = Not Sourceable

11. Other (TAG)


NS = Not Sourceable

ASSESSMENT PARTICIPANTS:

DATE: SQE (Surname & Signature) TAG (Surname & Signature)

DATE: Buyer (Surname & Signature) Design Engineer (Surname & Signature)

Supplier Project Responsible Name & Signature (Obligatory for Conditional Rating) NOTE: If one of more Assessment Categories are rated Not Sourceable, the whole Risk Assessment is

considered NOT SOURCEABLE.

New process, technology, tools, capacity: not present; new tools capacity increase/new tooling new process to the plant extremely fast production acceleration new technology to company new technology to the industry

Supplying location current supplier current supplier-new location new supplier to the division out of region supplier with more than 2 years new to region new to industry out of region supplier first year imported

Facilities/Equipment

existing facility new addition/rearrangement to existing building new building new plant

New Design Responsibilities

carryover design customer is design responsible source is design & production responsible contract house is design responsible

Quality History few past problems; good response minor problems; poor responses company requires multiple Qualificazioni submissions high PPM or Bills with weight 90 no data-new source high Warranty or bid list Field Major Disruptions Top Q supplier

Key Characteristics Mgt. (Important, Critical, Safety/Report & Legal)

used to manage key characteristics good for important characteristics, not used to S/R characteristics not used to manage key characteristics

Quality Targets (PPM, R/100, Quality Tracking ICP/TOC)

It means how are the Supplier performances with respect to the targets

Timing Concerns

no timing concerns late release/source to plan PPAP/Qualificazioni late but before Material Required Date Full approval after start of saleable vehicles

Program management

past successful launches Advanced IP new source; unknown APQP program mgt ability launch problems/Launch Major Disruptions or Launch IP limited program management team capacity issues with past programs


The IRE shall be completed within 1 month of the sourcing Recommendation Report the equivalent Monitoring Level to Fiat at this time, using the

following chart:

Document the part risk level from the IRE on the AQP Timing Chart; the IRE will NOT be added in CQMS

112

SUPPLIER:

SUPPLIER CODE:

PART NUMBER(S):

PART NAME(S):

PART RISK (H/M/L):

#NUM!FIAT PROGRAM

REVIEW STATUS#NUM!

CHRYSLER AQP

STATUS


TIMING CHART

IRE Result Monitoring Level

High Total

Medium

LowPartial

Advance Quality Planning (AQP)

The AQP Kick-Off Meeting shall be held within 1 month of the sourcing Recommendation. Complete the first revision of the AQP Timing Chart, including a status

for each applicable task.

Report the Fiat Program Review Status to Fiat for entry into the VDDP system

113

#NUM!FIAT PROGRAM

REVIEW STATUS#NUM!

CHRYSLER AQP

STATUS


TIMING CHART

Advance Quality Planning (AQP)

General Notes:

Update the AQP Timing Chart after each AQP Meeting is held.

The Fiat Program Review Status will need to be reported to Fiat once more following the Supplier Tooling Sign-Off milestone, approximately 6

months before VP

The First Production Shipment Certification (FPSC) process is followed as normal, beginning at VP

The Chrysler SQE shall support the Fiat Assembly Plant for the Benestare process

The Part Inspection Standard process is not applicable and not required for Fiat parts. Completion of a Part I/S is at the discretion of

the Chrysler SQE (Fiat Assembly Plants do not currently follow the

Part I/S process).

114

Using the AQP Timing Chart form

115 115

RISK MITIGTION PLAN




PlanEnter 1-5

STATUS

Commercial

Score Chrysler Definition FIAT Definition

1Incomplete/non-existant; no recovery plan in place and

High Risk to launch Job Stopper

2Incomplete w/ inadequate recovery plan in place or

High Risk to launch Job Stopper risk

3Incomplete w/ recovery plan in place or minor issues

and Low risk to launch 2nd Level Issue

4Incomplete but progressing according to plan w/ no or

very minor issues Planned Activity according to Project

5 Complete and approved Implemented Activity

116

#NUM!FIAT PROGRAM

REVIEW STATUS#NUM!

CHRYSLER AQP

STATUS


TIMING CHART

Includes only the 29 tasks shown below

Tasks used in calculating the FIAT Program Review status:

Review CNs and IAAs (including associated Risk)

TAG Review (Chrysler-purchased tooling only)


AQP Team Members

Design Model Status review




Part Number, Description, and Change Level

Production Tooling Complete (PTC)


Design FMEA

Design Review - Customer Perception targets





Error and Mistake Proofing

Production Validation Testing Complete

Control Plan and Process Monitoring

Operating Instructions

Special Characteristics Identified and FPSC

Gage and Test Equipment Evaluation

Incoming & Outgoing Material Certification Plan

Test Sample Sizes and Frequencies

Parts Packaging and Shipment Specifications

Process Flow Diagram & Mfg. Floor Plan


Process FMEA

Part Delivery Plan Review (for VP, PVP, V1, etc.)

Part Qualification Process (PQP)

Confirm Supplier PPAP Self-Certification status

Use this task to track Fiat Benestare and matchability

Non-Chrysler Suppliers will not have this; for Fiat parts, verify the Suppliers testing

facilities have been appropriately certified.

Use this task to track Fiat Self-Qualification and Integrative

testing


117

It is strongly recommended that Chrysler personnel tracking Fiat parts

monitor and track the status of all tasks, not just the tasks used in

calculating the Program Review result. A small number of tasks remain

N/A, however.

Tasks on the AQP Timing Chart that are Not Applicable when managing Fiat Parts:

Part Development Plan Complete

Supplier Quality Risk Assessment (SQRA)

Layered Process Audit

Part Inspection Standard

Please be aware: the Chrysler AQP Status and the Fiat

Program Review status may be different!

Only N/A for Fiat parts from Non-Chrysler

Suppliers!


Documents

Chrysler