International PSO

8/9/2019 International PSO

1/92

Welcome to.Planning forPlanning for

ProcessProcessSignSign--OffOff


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Slide 3

Rules for

Lego ActivityFor your Table (Team):

Build one racing car model

Every team member must be involvedin assembling the racing car

Plan your build

Picture & documentation is in envelope

Your team has 10 minutes.


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Slide 4

What is PSO?A systematic and sequential review of the

Suppliers planned and actual manufacturing

process at the quoted peak daily line rate,

including:Manpower Methods

Facilities Procedures

Equipment Software Level

Material Tooling


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Slide 5

Todays Agenda

1. PSO Strategy

2. Pre-PSO

Documentation Review

3. Pre-PSO Supplier

Readiness Evaluation

4. PSO on-site Visit

5. Post PSO visit


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Slide 6

LogisticsLogistics

Breaks & Lunch

Location of Restrooms Turn off Cell Phones

Ground Rules


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Slide 7

Process Sign-Off Strategy

PrePre PSOPSO Review Requirements


Supplier Readiness Evaluation

PSO OnPSO On--Site VisitSite Visit Witness Production DemonstrationRun

PV & Packaging Shipping Testing

Complete Sign-off

PostPost PSOPSO PPAP Warrant

Continuous ConformanceRequirements


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Slide 8

Scope of Process Sign Off

Why: Verify supplier quality planningprocess & production processesare capable of producing qualityparts in sufficient quantity

Who: Product Team Members &

SupplierWhen: Starts early in CDS process, PSO

sign-off shall occur prior to S1,CC throughout the life ofprogram

How: Pre-PSO Documentation Review,PSO on-site visit and Post PSOrequirements


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Slide 9

Risk Drivers

Part RiskAQP Activity

LevelPAP PSO

Low Self Directed SupplierLed

SupplierLed

Medium Collaborative Supplier DCX

High Directed DCX DCX


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Slide 10

Where do PSO elements fit into CDS timeline?

PPDC

D2EFG1 G2

FinalSpecs

(Lastenheft

)

S0 Start S1 St artS1 End

S2 Start

D1 C

S2 End

& V1H

(165) Wks (143) Wks (121) Wks (104) Wks (78) Wks

Theme

Selection

(35) Wks

SO EndPre Specs

(Rahmenheft)

A

(22) Wks (10 ) Wks

#1 Part Number, Description

PostV1

#6 Control Plan

#2 Design FMEA

#3 Test Sample Sizes and Frequencies (DVP&R Plan & DV Testing)

#4 Process FMEA

#1.4 Engineering Standards(CATIA Comments Page)

#5 Process Flow Diagram/Floor Plan

#9 Parts Handling Plan

#10 Operating Instructions

#11 Tooling/Gages Identified

#14 Error/Mistake Proofing Plan

#19 Parts Packaging/Shipping Plan

#16 Evidence of Product Specification

(SRE Run Results)

#20 Gage & Test Equip. Evaluation

#17 Line Speed Demonstration

#15 LPA Plan

#22 Initial Process Study

#24 PV Testing Complete

Initial Risk Evaluation (IRE)

PPAP

CP25 Disclose Parts in EBOM

OD210 Production Release Design

OD50 Complete DFMEA

OD100 Complete PFMEA

OD160 Define Material Handling Plan

VF30 Complete DV & PV Testing

OD160 Define Material Handling Plan

OD220 Tooling/Equipment Design CompleteOD140 Complete Gage, Fixture, Test Equipment & Mistake Proofing Requirements & Test Plan

VF116 Complete Production Control Plan

VD150 Verify Work Station Designs & Operation Descriptions

OD140 Mistake Proofing Requirements & Test Plan

OD90 Complete Process Design

VF30 Complete DV & PVTesting

VF130 Complete PSO

CP50 Conduct Supplier Initial Risk Evaluation

(0) Wks

LEGEND

Yellow = PSO Element

Requirement

Red = Non-PSOactivity

Note: PSO ElementRequirement isfollowed bycorresponding PAPTask.

B Z


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Slide 11

Process Sign-Off Strategy

PrePre PSOPSO Review Requirements



PSO OnPSO On--Site VisitSite Visit Witness Production Demonstration

Run


Complete Sign-off




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Slide 12

Module 2: Pre-PSO



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Slide 14

Some Changes from PSO 4

Summary Report is now 3 pages

PSO elements are in logical order

Each element has checkbox to indicateaccept or re ect

Each sub-element has its own yes orno checkbox

Documents with * review during AQP &again in Pre-PSO Document Review


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Slide 15

PSO Plan Activity

Ah, Grasshopper..At your table, drawing from your PSO experience:

What are some of the things you have foundthat have served you well?

What has caused you problems?

One piece of advice to a new SQS?

Flip chart your responses.


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Slide 16

PSO Process Elements Verified During On-Site Visit

Documentation

1. PART N MBER, Accept RejectDESCRIPTION &

CHANGE LEVELYes No

* Cross-reference sheet

[if applicable]

1.4 Engineering Standards

Identified

* CATIA Comments Page

with list of applicable

standards

(e.g. DCC. Environmental, etc.)

Process

Accept Reject

Yes No

Acceptable supplier

change notice

procedure

Evidence of customer

change notice

Process for obtaining

the latest revisions of

standards


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Slide 17

Element 1 Differences

Procedure to ensure Supplier has latest

Engineering Standard revision level

A system in place to notify all applicable

departments of specification changes as they

occur

erify change notice procedure is cascaded

down through Extended Enterprise 2 downthrough Extended Enterprise 2nd & 3rd Tier

Suppliers


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Slide 18


Documentation

2. DESIGN FMEA Accept Reject

Yes No

* Design FMEA

complete &

acceptable

Process

Accept Reject

Yes No

DFMEA updated

to include

applicable DV

failures


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Slide 19

FMEA Driven Reaction Plan

RPN = Severityx Occurrencex Detection

DCXGuidelinesUse a Rolling Top 20 Paretomethodology, give specialattention to:Severity =8, 9, 10

Severity =>5 withOccurrence =>2

Detection = 10


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Slide 20


MEA done with latest A AG guidelines

MEA best practice document and

communication process shall bereviewed periodically

Re-verify Design MEA after any D &

P failures Reaction Plan


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Slide 21


Documentation

3. TEST SAMPLE Accept RejectSI ES &FREQ ENCIES

Yes No

* Signed DV & PV plans

* Signed DVP&R

[DV complete]

* Signed Waivers

[if applicable]

Process


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Slide 22


oth D & P and D P&R have to be signed

by DaimlerChrysler engineering

Must have signed waiver if D has any

deviations

ailures must be addressed with Daimler

Chrysler 8-Step Corrective Action form

Supplier must have Test to ailure plan


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Slide 23


Documentation

4. PROCESS Accept RejectFMEA

Yes No

* Process FMEA

completed

& acceptable

Process

Accept Reject

Yes No

Process correlates

with occurrence

and detection

numbers on PFMEA


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Slide 24


MEA done with latest A AG guidelines

MEA best practice document and

communication process shall bereviewed periodically

Re-verify Process MEA after any D &

P failures Reaction Plan


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Slide 25

Common FMEA Mistakes:

Some Rules to Follow

Common Mistakes

No clearly defined MEA scope

Process Causes or Controls Used

Root Cause not dentified

orget to use Error MistakeProofing

Setting Arbitrary Thresholds

Too ague Not Detailed

Too Late

Not Updated

Some Rules State the failure effects in termsof what the customer(mightnotice or experience.

Potential cause is how the failure

couldoccur. Elimination of specified potential

causes should result in areduction in RPN it is a checktoensure you found theengineering root cause. The

severityw

ill remain the same.


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Slide 26

asic MEA Evaluation Questions

To prepare for Quality Gates ask these questions Are all of ma or functions represented?

Have you used historical data to identify all potential failure modes? Are they

detailed and specific?

Are the effects to the customer described in detail? s the severity rate

correctly evaluated?

Are the potential causes detailed enough? Do they include how, when, whereand what failed?

Does the current controls detect the cause?

When was the MEA last updated? s it up to the latest design date?

Are high RPNs being addressed?

What tests were used to validate corrective action?

Are responsibilities and completion dates listed for recommended actions?

s there evidence of error mistake proofing?


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Slide 27


Documentation

5. PROCESS FLOW Accept RejectDIAGRAM &MFG FLOOR PLAN

Yes No

* Flow Diagram

* Manufacturing Floor Plan

* Work Station Layout

Process

Accept Reject

Yes No

SPC operations

identified on flow

diagram

nique equipment

numbers identified

on mfg floor plan,

flow diagram, or

workstation layout


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Slide 28


dentification of stations that measure

key characteristics shall be clearly

identified on flow diagram Unique identification machine numbers

shall be identified on the manufacturing

floor plan, flow diagram or work station

layout


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Slide 29


Documentation

6. CONTROL PLAN Accept Reject

Yes No

* Process characteristics

identified on the Control

Plan

* Verification ofMistake

Proofing on

Control Plan

Process

Accept Reject

Yes No

Proper adherence to

Control Plan

Rework / Repair

stations have

acceptable controls

[if applicable]


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Slide 30

Control Plan Evaluation Criteria Does it align with the process flow diagram?

Does it reference DFMEA or PFMEA?

Does it have Mistake Proofing or Error Proofingmethods?

Does the reaction plan procedure have more than tonotify the supervisor?

Does what they are controlling make sense for theprocess? How was it determined?

Will the sample size and frequency be sufficient to

identify problems early enough?

What continuous improvement plan do they have inplace?


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Slide 31


nclude Mistake Proofing verification

More attention on rework repair operations

they shall have controls equivalent to the

primary line

A mechanism which links the Suppliers

D MEA & P MEA to the Control Plan

Supplier shall look at the High Severity Zone &Potential High Warranty Zone to ensure that they

are addressed


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Slide 32


Documentation7. Q ALITY Accept Reject

PLANNING

Yes No

* Completed PAP/APQP

PSO Summary Matrix

7.2 Supply Base Management* Easy Map, etc.

Risk sub-components

Level 3 PPAP data

7.3 Problem Solving Methods* Example of a DOE, etc.

2 SIDs for DCC systems

* Example of a problem solving

technique

Process


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Slide 33


Quality Planning now includes Supply ase

Management & Problem Solving Methods

Supplier shall risk all components listed on

the ill of Material

PSO activities to be done for medium & high risk

sub-components

Sub-tiers to submit level 3 PPAP documentation

along with line speed demonstration results


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Slide 34

Element 7 Differences, cont

Communication Plan for lessons learnedacross production lines within Suppliersfacility and other Supplier facilities which ship

product to DaimlerChrysler DOEs or other acceptable methods of

process optimization

Problem solving methods should be verified

by specialist A minimum of two S Ds shall be obtained for the

DaimlerChrysler problem solving systems e-C MS


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Slide 35


Documentation

8. INCOMING MATERIAL Accept Reject

Q ALIF / CERT

PLANYes No

Certificates of Analysis

Copies of sub-tier PSWs

* Plan for lot control

* Plan for traceability

Process

Accept Reject

Yes No

Evidence of sub-tier

monitoring

Proof of lot control

Proof of traceability


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Slide 36


DaimlerChrysler requires use of the Lot

Sampling Table or Supplier can use 2 or

more inspection requirements in TS-16949

section 7 4 3

Dock to Stock no incoming inspection is

dependent on receiving 3 shipments without

defects or external complaints Supplier shall

have documentation to support requirement


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Slide 37


Documentation

9. PARTS HANDLING Accept RejectPLAN

Yes No

* Routing/Traveler Cards

* Parts Handling Plan

* ContainerMaintenance

Plan

Process

Accept Reject

Yes No

Evidence of acceptable

parts handling

Acceptable method of

inventory control


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Slide 38


Documented plan on how parts are managed& tracked throughout entire manufacturingprocess

Should address segregation & identification ofscrap, rework repair and W P

f Suppliers traceability system depends ontheir O system, then all sub-tiers shall use

O as well

Document how containers are inspected &repaired


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Slide 39


Acceptable method of inventory control

for Work n Process

Acceptable method of inventory controlfor returnable dunnage


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Slide 40


Documentation

10. OPERATING Accept RejectINSTR CTIONS

Yes No

* Work Instructions

* Inspection Instructions

* Rework/Repair Instructions

Process

Accept Reject

Yes No

Visual displays clearly

present at each station

Operators follow

work instructions

Evidence of proper

operator training


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Slide 41


Operating nstructions shall be approved bySuppliers cross functional team, includingoperators

A robust process of training and qualifyingoperators prior to operators performingproduction processes shall exist List of Training requirements for each unique

workstation

isual inspection stations shall have methodsestablished to verify operators ability to finddefects i e periodic testing, re-certification


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Slide 42


Documentation

Accept Reject

11. TOOLING EQ IPMENT

& GAGES IDENTIFIED

Yes No

* Tooling & Equipment List

* Supplier Tool Record

Process

Accept Reject

Yes No

STR in agreement with

Suppliers manufacturing

facility

DCC ownership tags

present


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Slide 43


During on-site PSO visit, SQS verify all gagesfixtures listed on STR Supplier Tool Recordare present on Suppliers manufacturing floor

When tooling is purchased for Tier 2s Tier 3s,verify the STR states the appropriate location

All tooling, gages, fixtures and capitalequipment required to produce a productshall be identified and appear on a tooling list

All DaimlerChrysler owned tooling, gages andfixtures shall be permanently tagged per AME84-206-0021 GR GR&R Tag


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Slide 44


Documentation

12. SPECIAL PROD CT Accept Reject& PROCESSCHARACTERISTICS

IDENTIFIEDYes No

* First Production ShipmentCertification (FPSC ) planacceptable &

contains special

process & product

characteristics

Process

Accept Reject

Yes No

SPC performed for

identified

Special Characteristics


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Slide 45


All DaimlerChrysler directed sub-tiers

shall abide by the same PSC quantity

requirements as DaimlerChrysler Tier 1

Tier 1-> 2 DCC Assembly plant = 2000

pieces; directed Tier 2 = 2000 pieces

Completed PSC shall be reviewed with

the DaimlerChrysler PSO team PostPSO activity


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Slide 46


Documentation

13. PROCESS Accept RejectMONITORING

Yes No

* Control charts

* 1st piece approval

procedure

Process

Accept Reject

Yes No

Acceptable 1st piece

approval process

1st piece approval records

Control &

Performance Charts

maintained appropriately


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Slide 47


Targets for TC, Scrap and Rework to beidentified and documented Plans to improve TC, scrap and rework shall be

documented PSO Team shall approve all Rework Repair

operations, procedures and work instructions

Must have acceptable irst Piece Approvalprocess irst piece retained until end of production run

Documented evidence of its execution maintained


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Slide 48


Documentation

14. ERROR & Accept RejectMISTAKEPROOFING

Yes No* Error & Mistake

Proofing Plan

* List of Error &Mistake Proofing

Process

Accept Reject

Yes No

Boundary samples

created & utilized

Mistake proofing

contingency plan

with visual/audiblealarm


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Slide 49


More detailed Element description

MEA Severity >8 & all Special Product ProcessCharacteristics have Error Mistake Proofing

Error Mistake Proofing with Line Station Lock-out toensure defects dont reach next operation

Audible and isual indicators shall notify operator ofthe failed operation

Supplier create oundary Samples for processverification and agreed upon by PSO Team oundary samples to include known conforming and

non-conforming; Appearance Master Samples, etc


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Slide 50


Documentation

15. LAYERED Accept Reject

PROCESS

A DIT PLANYes No

* Acceptable LPA plan

* Frequency & structure

chart

Process

Accept Reject

Yes No

Acceptable LPA

performed


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Slide 51

Layered Process Audit LPA

LPA is an ongoing system of process checks, that verify

proper methods, settings, operator craftsmanship, error

proofing devices and other inputs are in place to ensure

a defect free product.

How does LPA work?

Process Audits are conduct bylooking at:

1) Build Technique2) Error Proofing

3) Machining Attributes

Encourages ManagementInvolvement:

Production Supervisor [1x shift] Area Management [2 x week]

Plant Manager [1 x week]


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Slide 52

LPA enefits

Reduces

Build variation based on work

standardization

End-of-line inspection

Part defectsImproves First time through capability

Morale

Facilitates Operator training

Management operator interface

Reinforces Safety regulations


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Slide 53

LPA Compliance erification

Documentation Review:

LPA Roll-out Timing Plan

LPA Procedures

LPA Work Instructions LPA Structure & Frequency Chart

LPA Process Control Audit Checklist

LPA Error Proofing Verifications Checklist

LPA Compliance Form: To be submittedmonthlyto SQ Specialist


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Slide 54


Documentation

16. EVIDENCE OF Accept Reject

PROD CT

SPECIFICATIONSYes No

* Supplier Readiness

Evaluation Completed

and Acceptable

Process

Accept Reject

Yes No

Completed & acceptable

Measurement System

Verification Report


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Slide 55


Supplier Readiness Evaluation form Supplier is required to perform Readiness

Evaluation run SRE at the production line speed

RecordF

irst Time Capability, Gage R&R, etc Recommendation for Suppliers to submit

PSO Summary Matrix required forBody &White with SRE form for PSO review

Compliance Report revised to MeasurementSystem erification Report Approve Suppliers process for measuring

product process characteristics


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Slide 56


Documentation

17. LINE SPEED Accept Reject

DEMONSTRATION

Process

Accept Reject

Yes No

Contingency plan

forBottlenecks

[if applicable]

Line Speed Observed:_______ FTC:_____


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Slide 57


PSO team to compare Quoted Tooling

Capacity to the Daily Capacity Planning

olume

f there is a discrepancy between the two

numbers, the PSO team shall meet with

the DaimlerChryslerBuyer and the

Supplier to determine the required PSOline speed


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Slide 58


Documentation

18. O TGOING Accept RejectQ ALIFICATIONPLAN

Yes No

* Outgoing inspection

plan

* Part inspectionstandard

Process

Accept Reject

Yes No

Evidence of

non-conformance

containment

Evidence of outgoing

audits [using part

inspection standard]


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Slide 59


Part nspection Standards are required for allKey parts as identified by Engineering Standard list all Product Characteristics inspected

by Supplier on finished product prior to shipment Outgoing Qualification Plan include Forever

Requirements Supplier Notification of Potential Non-

Conformance Process

Documented evidence of outgoing auditsusing the Part nspection Standard and

Containment Records


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Slide 60


Documentation

19. PARTS PACKAGING Accept Reject& SHIPPINGSPECIFICATIONS

Yes No

* Dunnage design

sign-off from MHE

[if applicable]

* Packaging & shipping

plan

Process

Accept Reject

Yes No

Acceptable container

management

plan


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Slide 61


Material Handling requirement shall

include a Unit Load Data ULD sheet

for Supplier designed dunnage approval

DaimlerChrysler directed 3rd party

dunnage suppliers do not need MHE

design approval


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Slide 62


Documentation

20. GAGE & Accept RejectTEST EQ IPMENTEVAL ATION

Yes No* Gage R&R studies

* Calibration plan &

schedule

Process

Accept Reject

Yes No

Appropriate gages

used in the

process

Calibration performed

according to schedule

NOTE: The gage plan must explain howthe

gage was determined.


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Slide 63


More detailed Element description

Effective system to ensure calibration ofequipment done per schedule

Reaction Plan for containment ofequipment that is out of calibration

A Gage Plan that explains how

appropriate gage for process isdetermined


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Slide 64


All gages used in the process shall be

identified on Control Plan

RPNs reduced by measuring gaugingshall have an acceptable gage

evaluation and calibration frequency


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Slide 65

Measurement System erification Report

CHANGELEVEL(S)P

PRE-PSO MEETING DATE

PSO ON-SITE VISIT DATE / NUMBER

Q

Q

Q

Q

Q

Q

R

S

Joe SchmoeMary Smith

John Doe

Bushing- Sw age Toe Link Bush

1/5/05

LX

99999AF

11/19/04

T. Automotive

Somewhere, MI

04885735AA

Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual ) for Ppk requirements.

DATA

SUMMARY EXAMPLE

1.6/1.7

2.2/2.3

P P / P PKP

Length

Hole Size

(3.6 - 7.5 mm)

(2.0 0.02 mm)

CALIPER

CMM MACHINE

30

30

100%

93%

QUANTI TY

ACCE P TE D

30

28

FT C

P E RCE NTAGE

(without repair)

CH AR AC TER IST IC SP EC IF IC AT IONM E THOD OF

M E AS URE M E NT

QUANTI TY

A T T E M P T E D

COMMENTS:

End of Inner to End of Outer 4.5 +/- 0.8 caliper 2.94/2.93

4.89/3.65

4.63/2.95Outer Metal O.D. 40.30 +/- 0.1 caliper 30

Inner Metal I.D. 12.20 +/- 0.10 caliper 30

PQUANTI TY

A T T E M P T E D

Number of parts witnessed: Witnessed By:

CH AR AC TER IST IC SP EC IF IC AT IONM E THOD OF

M E AS URE M E NTP P / P PK

FT C

P E RCE NTAGE

(without repair)

QUANTI TY

ACCE P TE D

the number of characteristics selected depends upon the complexity.

Variable data is preferred but attribute data is acceptable.

MEASUREMENT SYSTEM VERIFICATION REPORT

As part of the PSO, the actual measurem ent process must be w itnessed by the PSO Team.

A minimum of 3 characteristics are to be checked. For any given part, assembly, or process,

A minimum of 30 randomly selected samples s hall be checked during the PSO on-site visit.

SUPPLIER PROGRAMMFG. LOCATION SUPPLIER CODE

PART NUMBER(S) PART NAME(S)

For attribute data, a 30 piece sample with one or more non-conformances is unacceptable.

All deviations shall be listed in the COMMENTS section of this document.

30

93%

100%

97%

28

30

29

PSO

DaimlerChrysl

5th Edition


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Slide 66

Repeatability & Reproducibility:

Some Rulesf repeatability is large compared to reproducibility thereasons may be:

nstrument needs maintenance

Gage may need to be redesigned to be more rigid

Clamping or location for gaging needs to be improved Excessive within part variation

f reproducibility is large compared to repeatability, thereasons may be:

Appraiser needs further training on how to use & read gage

Calibrations on gage dial are not clear

A fixture may be needed to help appraiser use the gagemore consistently


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Slide 67


Documentation

21. PREVENTIVE Accept RejectMAINTENANCEPLANS

Yes No* PM Plan

* PM Schedule

* PM Procedures/Work

Instructions

Process

Accept Reject

Yes No

PM performed

according to schedule

Robust PM Process

All tooling/equipmenton PM schedule


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Slide 68


PM plan to incorporate lessons learned from

prior production lines or Tooling Equipment

related Quality concerns

Addresses 3rd party outsourced PMrequirements

Activities shall be identified on the schedule

PM process equal to or better than that of the

Supplier


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Slide 69


Documentation

22. INITIAL Accept RejectPROCESSST DY

Yes No Deviations [if applicable]

Sample size:_______ PpK requirement:_____

Process

Accept Reject

Yes No

Acceptable First

Time Capability

Acceptable Process

Capability


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Slide 70


Modified form Expanded to incorporate more information from

Production Demonstration Run e g USL, LSL,UCL, LCL

FTC requirement of 90% or greater < 90% needs approval of SQA Quality Manager

Capability Matrix shall be used for those whodeviate from nitial Process Study samplesize requirements Ppk is based on sample size agreed upon by the

PSO team


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Slide 72

PSO Process Elements Required ForFull Approval

Documentation

23. PACKAGING Accept RejectSHIPPINGTEST APPROVAL

Yes No Signed shipping /

simulation test

approval

[MHE LD sheet]

Process

Accept Reject

Yes No

Shipping/simulation

testing completed


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Slide 73

New Element

Packaging shipping test results require

Corporate and Assembly Plant Material

Handling Engineering approval

Simulation test results require CorporateMaterial Handling Engineering approval

DaimlerChrysler directed 3rd party dunnage

shall have shipping simulation testing

performed


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Slide 74


Documentation

24. PROD CTION Accept RejectVALIDATIONTESTING COMPLETE

Yes No

Signed DVP&R

[PV complete]

Signed Waivers

[if applicable]

Process

Accept Reject

Yes No

BSR/NVH testing

complete

PV test completed

Repair/rework process

validation completed

[if applicable]


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Slide 75


ncludes BSR N H

Requires Engineering signatureapproval of P test plans

Requires Engineering signatureapproval of P test results D P&R

P testing must include parts from

rework repair process whereapplicable


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Slide 76


Documentation

25. CONTIN O S Accept RejectCONFORMANCE (CC)

Yes No

Continuous

Conformance Team

identified & Trained

Warranty process

flow diagram Forever Requirements

submission procedure

Process

Accept Reject

Yes No CC team is sufficient

to support Post-PSO

activities

Acceptable process

for warranty analysis

Family PV testing

agreed to by the

PSO team

Vehicle Families included in familyPV:______________________


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Slide 77


Service Requirements now identified forDesign & Serviceability

Suppliers required to identify resources for

Life of Program ncludes:

Layered Process Audit uploads required quarterlyfor life of program

3CPR 3rd Party erification Audit requirements Warranty requirements

Forever Requirements


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Slide 79

Module 3: Pre- PSO Supplier

Readiness Evaluation

Supplier Readiness


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Slide 80

Supplier Readiness

Evaluation purpose First documented build attempt

Provide pre-production datausually minimum of 30 pieces

Confirm process is:

Set-up

Debugged

Ready for ProductionDemonstration Run

Supplier Readiness


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Slide 81

Supplier Readiness

Evaluation Data

Confirms proper setup, operation and

performance of installed production line

This data is used to estimate: Production rates

FTC

ields Pp and Ppk for special characteristics


82/92


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Slide 83

Process Sign-Off StrategyPrePre PSOPSO

Review Requirements




Run


Complete Sign-off




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Slide 84

Module 4: PSO on-site isit


85/92

Slide 85

PSO on-site Visit purpose Witness build using production tools

Run must meet quality & production rate

requirements

PSO Team observes first 22 elementsof the PSO Summary Report

Success will result in parts for

Production alidation testing

PSO on-site Visit is


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Slide 86

PSO on site Visit is

conducted

Kick-off Meeting with appropriate plantmanagement to discuss:

Purpose

Agenda for Day

Observing Production DemonstrationRun

Closing Meeting to review results ofassessment


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Slide 87

DaimlerChrysler Process Sign-Off Summary

Report

4

ES N O

ES OP T ION

1 PARTNUM

ER DESCRIPTIONAND

ccep

ejec

ccep

ejec

C

ANGELEVEL

*Cross reference sheet Yes

o A ccepta

le Supplier change Yes

o

(IF

LI

BL

)

notice proce

ure

14 Engineering Stan

ar

s Identified Ev idence of custo mer change

Yes

o notice procedure

*C A TI A comments page

Process for o taining the Yes

o

ith list of applica

le standards latest standard re v ision

(e.g

VI

M

L e

c)

ccep

ejec

ccep

ejec

2 DESIGNFMEA

*Design F M E A complete Yes

o D F M E A updat ed to include Yes

o

accepta

le

applica

le D V failures

ccep

ejec

3 TEST SAMPLE SIZES AND FREQUENCIES

Yes

o

*Signed D V an d P V plans

*Signed D VP

R (D V complete)

*Signed

ai ver s

/

PARTNUM

ER(S)

MFGLOCATION SUPPLIER CODE

PART NAME(S)

Some

hereMI

04885735

99999

F

Bushing- S

age

oe Link Bush

C

ANGELEVEL(S) PRE-PSO MEETING DATE

PSO PROCESS ELEMENTS

* Documents

ith asterisk should

e re vie

edduring AQP meetings and again during the Pre-PSO Documentation Revie

PROGRAM _L

_______________________

B

PSO ON-SITEVISIT DATENUM

ER__01/05/2005____

11/19/04

DAIMLERC R SLER PROCESS SIGN-OFF SUMMAR REPORTALL PROCESS SIGN-OFF ELEMENTS APPROVED:

SUPPLIER

PSO EXTENDED RUN:

N O

.

u

omo

i

e

DOCUM E N T A T ION P R OC ESS


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Module 5:


89/92

Slide 89

Module 5:

Post-PSOPrePre PSOPSO Review Requirements




Run


Complete Sign-off




90/92

Slide 90

Continuous Conformance

Support

La ere Proce Audit

Proble Solving Methods Warranty

Annual Validation

Forever Require ents


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Slide 91

PSO 5th Edition Layout

ntroduction & Strategy

PSO Element Description

PSO Element Requirements

PSO Forms Commodity Specific Requirements

Guidelines for New SpecialistSuppliers

PSO Worksheets

Appendix


92/92

Slid 92

Workshop Ob ectives1 Explain and apply the PSO Strategy; including purpose, requirements and

procedure for each step

2 dentify the required tasks and uses for each of the 25 Checklist Elements onthe PSO Sign-off Summary Report for both the Documentation and Processside

3 Demonstrate how to evaluate some of the ma or forms used to ensure aquality product

4 Describe the new guidelines for design and process FMEA

5 Describe the requirements involved in a Layered Process Audit

6 Develop a plan on how to accomplish all the elements on the PSO SummaryReport

7 Determine if a supplier is ready for the PSO on-site visit based on evaluationof the SRE documentation

8 dentify observations that could be made during a Demonstration of aProduction Run

9 Evaluate certain documentation requirements during the demonstration of thesuppliers production run

10 Plan how to ensure quality products throughout the life of the program