PSO

PSO
Process Sign-Off

Edition 5.5

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION


Edit ion 5 . 5

December 2 0 0 6

PROCESS SIGN-OFF
(PSO)


INTENTIONALLY LEFT BLANK

Proc e s s Sign-Off (PSO)

FOREWARD TO THE 5.5 EDITION

Th is ma n u a l s ha ll define t he requ iremen t s for Proces s Sign-Off (PSO) a n d det a il t he
docu men t a t ion requ ired t o ver ify con for ma n ce to Da imlerCh r ys ler 's (DCC) Qu a lit y Sys tem
St a n da rds . Th e PSO, ISO/ TS-16949 a nd Ch r ys ler Developmen t Sys tem (CDS) will for m
t h e fou n da t ion for Su pplier readines s t o a s s u re proa ct ive Adva n ced Pr odu ct Qu a lit y
Pla n n in g. A Su ppliers cert ifica t ion t o ISO/ TS-16949 a lone is n ot s u fficien t for PSO
a pprova l; a ll PSO requ iremen t s mu s t be met in order t o a s s u re con for ma n ce t o
dimens iona l, ma teria l, fu n ct ion a l a n d (where neces s a r y) a ppea r a n ce requ iremen t s . In
a ddit ion , it s h ou ld be noted t h a t ever y exter n a l Su pplier of produ ct ion pa r t s t o
Da imlerCh r ys ler Corpor a t ion s h a ll be ISO/ TS-16949:2002 t h ir d pa r t y r egis tered. Effect ive
01/ 01/ 2007, a ll requ iremen t s s t a t ed in t h is docu men t a pply to a ll Da imlerCh r ys ler
Pr odu ct ion Su pplier s , in clu ding s u b-t ier Su pplier s .

In or der t o a ch ieve a n appreciable impr ovemen t in pa r t qu a lity, t h is ma n u a l h a s been
modified t o reflect Da imlerCh rys ler Corpora t ion s cu rren t PSO ph ilos oph y. Emph a s is is
pla ced on t h e impor t a n ce of adh er in g t o ou r Pr odu ct Crea t ion Pr oces s , i.e. t h e Ch r ys ler
Developmen t Sys t em (CDS). Th is ma n u a l s h ou ld be reviewed ca r efu lly a n d in it s en t iret y
t o a s s u re t h a t a ll PSO requ iremen t s a re known a n d u n ders t ood. Th e 25 PSO Proces s
Elemen t s iden t ified in t he 5
t h
Edit ion PSO Ma n u a l were re-evalu a ted a n d, in s ome cas es ,
modified or r emoved.

Th e n a me Da imlerCh r ys ler an d DCC, a s u s ed in t h is ma nu a l, r efer t o Da imlerCh r ys ler
Corpor a t ion (i.e., DCC for mer ly kn own a s Ch r ys ler Cor por a t ion ) a n d it s s u bs idia r ies ,
wh ich ma n u fact u re Ch r ys ler , Dodge a nd J eep br a nd veh icles . Th is ma n u a l does n ot
a pply t o ot her Da imlerCh r ys ler AG s u bs idia r ies or opera t ion s , wh ich ma n u fa ctu re
Mercedes -Ben z, Freigh t liner or ot h er br a nd veh icles or pr odu ct s . Wh ere t h e wor d
Su pplier is u s ed in t h is ma nu a l, it is in t en ded to in dica te bot h exter n a l a nd in t er n a l Tier
1 Su ppliers . Wh ere t he ter m DCC PSO Tea m is u t ilized, it denotes Da imlerCh r ys ler
Employee in volvemen t on ly. Th e term PSO team indica tes all in dividu a ls in volved in t h e
PSO pr oces s (i.e., DCC a nd Su pplier ).

For qu es t ions or commen t s con cern in g t h e Proces s Sign -Off ma n u a l, pleas e con t a ct you r
Da imlerCh rys ler Adva n ce Su pplier Qu a lit y Pla n n in g Specia lis t (ASQP Specia lis t ).


ACKNOWLEDGMENTS

PROCESS SIGN-OFF (PSO)
Edit ion 5. 5

Proce s s Sign-Off 5 . 5 Re vis ion Te am Me mbers

David Elle r Mgr - AQP St ra t egy & Proces s es
Bryan Book AQP St ra t egy & Proces s es
Nanc e Taylor AQP St ra t egy & Proces s es
Vic Randolph AQP St ra t egy & Proces s es
Eric He lge s on ASQP - BIW/ Ext erior
Larry D'Agos t ino ASQP - Cha s s is
Simon Kis s one rgis ASQP - Elect rica l/ Elect ron ics
Cris Mille r ASQP - In terior
Ne il Murphy ASQP - Powert ra in
Ida Goodwill CDS
De nnis Fet t Corpor a te Qu a lit y
Chris Cot t am Ma nu fa ct u rin g Qu a lit y
Lynn Yang Power t r a in Qu a lit y
Mary Clor Pr oces s Qu a lit y En gin eer in g
Arno Re it e r Su pplier Qu a lit y - Gra z
Dave Kos ki ASQP - AQP/ PSO Un iver s it y
He c t or Magaa Su pplier Qu a lit y - Mexico

Re ques t s for re vis ions or changes t o t he manual
s hould be direc t ed t o t he PSO 5 . 5 Re vis ion Te am


PROCESS SIGN-OFF (PSO)

Ta ble of Con ten t s

Pa ge
In t r odu ct ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Pr oces s Sign -Off Flow Ch ar t & Res pon s ibilit ies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pr oces s Sign -Off Elemen t Requ ir emen t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Appen dix A Forms and Ins tructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Appen dix B Tables and Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Appen dix C FTC Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Appen dix D PSO Extended Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Appen dix E Forever Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Appen dix F Internal PSO Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Frequently As k ed Ques tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Referen ce Man u als . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Glos s ar y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

In dex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111


1
Proc e s s Sign-Off (PSO)

INTRODUCTION

SCOPE: Proces s Sign -Off (PSO) s h a ll be per for med on a ll new or modified pa r t s wit h
PPAP r equ iremen t s or pa r t s t h a t h a ve been ou t of pr odu ct ion for 12 mon t h s
or lon ger . Addit ion a l condit ions t h a t ma y r es u lt in a PSO bein g r equ ired a re:
Ca r r y-over pa r t s wit h h is t or ically h igh wa r r a n t y a n d/ or qu a lity
pr oblems ;
Ca r r y-over pa r t s wh ich h ave exper ien ced a Su pplier res pons ible ya rd
h old wit h in t h e pa s t calenda r yea r ;
New a nd/ or addit ion a l produ ct ion lines (e.g. ca pa cit y in creas es );
Pr odu ct ion line moves , wit h in a yea r of PSO appr ova l;
An y pr odu ct or pr oces s ch a n ge t h a t occu r s du r in g t h e lifecycle of a pa r t
or s ys tem.

PROCESS SIGN-OFF DEFINITION

WHAT IS A PSO?
Proces s Sign -Off is a for ma l review of t h e Su pplier 's pr odu ct ion
ma n u fact u r in g pr oces s . Th is pr oces s ver ifies a Su pplier s a bilit y t o
ma n u fact u re produ ct ion ma teria l a t t h e da ily tool ca pa cit y (a s n ot ed on t he
Produ ct ion Pu rch as e Order or a s pr ovided in wr it in g by t h e DCC Pr odu ct ion
Bu yer).

Ea ch PSO in clu des eva lu a t ion of a s s ocia ted produ ct ion fa cilit ies , r ela ted
ma n power , equ ipmen t , ma ter ial, met h ods , procedu res , s oft wa r e level(s ) a nd
t oolin g. Th e PSO is u t ilized t o s cr u t in ize t he Su ppliers en t ire pr odu ct ion
proces s , in clu din g a ll in-h ou s e a n d s econda r y s ys tems t h a t s u ppor t pr ima r y
pr odu ct ion line(s ).

Th e Da imlerCh r ys ler PSO is compos ed of t h ree pr ima r y act ivit ies :
1. Pre-PSO Meet in g
Th e DCC PSO Tea m s h all r eview PSO docu men t a t ion du r in g AQP meet in gs
a n d a ga in du rin g t he Pre-PSO Meet in g for complia n ce to PSO
r equ iremen t s .

2. PSO On -s ite Vis it
Th e DCC PSO t ea m s ha ll wit n es s a t lea s t one Pr odu ct ion Demon s t r a t ion
Ru n (PDR) u t ilizin g completed pr odu ct ion t ools a s pa r t of t h e PSO pr oces s
for a ll Collabor a t ive a nd Direct ed AQP Act ivit y Level pa r t s . PSO a ct ivit ies
s h a ll be condu cted by t h e Su pplier for a ll Self-Directed AQP Act ivit y Level
pa r t s . Da t a collect ion , a n a lys is , a n d s u mma r iza t ion a re t he t r u e meas u res
of pa r t qu a lit y a nd pr odu ct ion ca pa bilit ies . Obs er vin g t he PDR s h ou ld
r evea l is s u es s u ch a s bot t lenecks a nd inefficien cies . Pr odu ct ion Pr oces s
r eview a n d mea s u remen t s will pr ovide t he produ ct ion r a t e, Fir s t Time
Capabilit y (FTC) a n d ot her s t a t is t ics t h a t va lida te ea ch Su pplier s a bilit y t o
effect ively pr odu ce bot h t he requ ired qu a lit y a nd pr odu ct qu an t it ies .

2
Fu ll complia n ce wit h a ll PSO requ iremen t s a nd pr ocedu res en s u res t h a t
t h e Su ppliers ma n u fact u rin g proces s is s t a ble, in con t rol a nd ca pa ble of
pr odu cin g pa r t s t h a t meet a ll r equ iremen t s .

3. Va lida t ion Tes t in g
Pr odu ct ion Va lida t ion (PV) Tes tin g, of t h e Pr odu ct ion Demon s tr a t ion pa r t s ,
will va lida te t he Su pplier s s ys tem a n d pr ovide eviden ce t h a t t h e pa r t s
meet en gineerin g, qu a lit y, du rabilit y, a n d r elia bilit y r equ iremen t s
con t a ined in t h e Per for ma nce, Pr oces s , a nd Ma ter ia l Specificat ion s .
Pa cka gin g a nd s h ippin g or s imu la t ion tes t approva ls a re requ ir ed by
Ma ter ia l Ha n dlin g En gin eer in g if a pplica ble.

WHY IS A PSO NECESSARY?
Proces s Sign -Off is a n effect ive met h od of ver ifyin g a Su ppliers qu a lit y
pla n n in g proces s es . It con fir ms t h a t t h e pr oces s es ca n a nd will (wh en
pr oper ly a n d s u cces s fu lly execu ted) pr odu ce qu a lit y pa r t s in s u fficien t
qu a n t it ies for produ ct ion .

WHO CONDUCTS THE PSO?
Th e PSO Tea m con s is t s of, a t a min imu m, t he DCC ASQP Specia lis t , DCC
Pr odu ct En gin eer a n d Su pplier(s ) Repres en t a t ives .
Ot her PSO team members ma y in clu de bu t a r e not limited t o; t h e DCC
Bu yer , Cen ter of Competen ce (COC) En gin eer , a n d Veh icle Specia lis t .
Th e DCC ASQP Specia lis t h a s lea d res pon s ibilit y for t h e PSO for pa r t s or
modu les wit h Collabor a t ive a nd Directed AQP Act ivit y Levels .
Th e Su pplier h as lead r es pon s ibilit y for pa r t s wit h Self-Directed AQP
Act ivit y Levels .
Th e Su pplier s h a ll iden t ify Su pplier PSO t ea m members for bot h t h e
Da imlerCh r ys ler led PSOs , a s well as for Su pplier led Self-Dir ected PSOs .

WHEN IS THE PSO PERFORMED?
Th e Proces s Sign -Off, On -Site Vis it s h a ll be s chedu led by t he PSO Team
followin g t he Pre-PSO Docu men t a t ion Review, when t he PSO Team a grees
t h a t :
All r equ ired Su pplier docu ment a t ion h a s been r eviewed a nd is a ccept able;
Produ ct ion t oolin g is complete, on -s ite a t t h e Su pplier 's Pla n t , s etu p,
debu gged a nd t he Su pplier Readines s Eva lu a t ion (SRE) per for med;
SRE is complete a nd t h e res u lts h a ve been docu men ted a nd ar e
a ccept able t o t he t ea m; a nd
Th e produ ct ion oper a t or s a re tr a in ed a nd capable of r u n n in g a t t h e
r equ ired line s peed.

Th e pu r pos e of t h e PSO is to demons t r a t e Su pplier proces s ca pabilit y a n d pr odu ct ion
ca pa cit y. Th e PSO demon s t ra t ion s h a ll produ ce dimen s ion a lly correct pa rt s on t he h ome-
lin e wit h pr odu ct ion toolin g. Th e requ iremen t is t o complete a ll PSOs a nd PPAP
s u bmis s ions pr ior t o s u pplyin g pa r t s for S1 St a r t . If PPAP is n ot complete pr ior t o S1

3
St a r t , a n In t er im Appr ova l Au th or iza t ion (IAA) is requ ired. For s pecific requ iremen ts
r ega rdin g IAA s u bmis s ion , refer t o P&S pr ocedu re PSSP0108 a s well a s a n y s pecia l
r equ iremen t s of t h e s pecific DCC Pr odu ct Team. Su ppliers do n ot h a ve acces s t o t h is
procedu re a nd s h ou ld con t act t h eir DCC ASQP Specia lis t or En gin eer for a ddit ion a l
in for ma t ion rega r din g IAAs .

HOW IS THE PSO PERFORMED?
Refer t o Figu re 1 for t he PSO s t r a t egy a nd Figu res 2.1 a nd 2.2 for a s t ep-by-
s t ep flowcha rt a n d res pon s ibilit y ma t rix for t h e PSO pr oces s .

- Pre -PSO Mee t ing:
Th e DCC ASQP Specia lis t will in it ia t e PSO dia logu e wit h t he DCC Produ ct
En gin eer a n d t he Su pplier (i.e., for Dir ected a nd Collabor a t ive PSOs ).
Toget her, t h ey will s chedu le a nd coordina te t h e Pre-PSO Meet in g a s well as
t h e PSO On-Site Vis it . Th e ASQP Specia lis t will a dvis e t he Su pplier of t he
docu men t a t ion t he tea m will wa n t t o r eview a nd whet her t he pa r t h a s been
s elected for a PSO Ext ended Ru n .

- Proce s s Sign-Off On-Sit e Vis it :
Th e PSO Tea m s ha ll complete t h e fir s t 20 elemen t s of t h e PSO SUMMARY
REPORT a t t h e Su pplier s ma nu fa ct u r in g fa cilit y. Th e PSO Tea m s h a ll a ls o
ver ify t h e Su ppliers complia nce t o a ll 21 elemen t s of PSO Edit ion 5.5
before fu ll appr ova l is given . An y devia t ion s s h a ll be recor ded on t h e PSO
COMMENTS SHEET. A s u cces s fu l PDR s h a ll yield pa r t s for Pr odu ct ion
Va lida t ion (PV) Tes t in g.

Wh en appea r a nce approva ls a r e requ ired, t h e Su pplier s h a ll obt a in a s igned Appea r a n ce
Appr ova l Repor t (AAR) pr ior t o PPAP s u bmis s ion . Refer t o t he AIAG PPAP ma nu a l a nd
DCC En gin eerin g St a n da rds CS-9022 a nd PS-4559 for fu r t h er gu ida n ce.

PSO Z Ap pr ova l : Z Appr ova l is a n in t er n a l code wit h in t h e Power wa y.com s ys tem.
Th is code, in con ju nct ion wit h t h e s u bmis s ion of a dimens iona l Pa r t Su bmis s ion Wa r r a n t
(PSW), in dica tes t h a t t h e fir s t 20 PSO elemen t s h a ve been completed a n d appr oved. At
t h is poin t , t h e Su pplier ma y be eligible for pa r t ia l t oolin g pa ymen t (for fu r t h er t ool
pa ymen t in for ma t ion , r eferen ce t he s ou r ce packa ge a nd t h e DCC Pu r ch as in g con t act
n oted t here in ). Th e ASQP Specia lis t is r es pon s ible for en ter in g t h e Z appr ova l in t o
Power wa y.com for Directed a nd Collabor a t ive AQP Act ivit y Level pa r t s . Th e Su pplier is
r es pon s ible for en ter in g t h e Z a pprova l in t o Power wa y.com for Self-Directed AQP Act ivit y
Level pa r t s . Z a ppr ova l au t h or izes t he Su pplier t o s u bmit t h e Dimens iona l Pa r t
Su bmis s ion Wa rra n t (PSW) in t o Power wa y.com.

PSO A Ap pr ova l : Th e A Approva l is a n in ter n a l code wit h in Power wa y.com. Th is
code, in con ju n ct ion wit h t he s u bmis s ion of a ma ter ial a n d/ or fu n ct ion a l PSW (a nd a n
AAR, if r equ ired) con fir ms t h a t a ll PSO a nd PPAP requ iremen t s h a ve been met . Th e
Su pplier is t hen eligible for fu ll t oolin g pa ymen t . Th e ASQP Specia lis t is r es pon s ible for
en terin g t he A a pprova l in t o Powerwa y.com for Directed a nd Collabor a t ive AQP Act ivit y
Level pa r t s . Th e Su pplier is r es pons ible for en ter in g t he A appr ova l in t o Power wa y.com
for Self-Directed AQP Act ivit y Level pa r t s .

4
Th e PSO da te a n d a n A dis pos it ion a re requ ired t o be en tered in t o Powerwa y.com prior
t o t h e Su pplier s u bmit t in g t he Wa r r a n t (PSW) a n d en ter in g t h e PPAP da te a nd PPAP A
dis pos it ion . Th is r equ iremen t is t r u e for a ll pa r t s , r ega rdles s of AQP Act ivit y Level.

PSO N Ap pr ova l : The N dis pos it ion is a n in ter n a l code with in Power wa y.com. Th is
code in dica tes t h a t t h e PSO On-Sit e Vis it wa s u n s u cces s fu l a nd cor rect ive a ct ion is
r equ ired by t he Su pplier . A new PSO pla n ned vis it da te (or cor r ect ive act ion complet ion
da te) is requ ired t o be en tered in t o Power wa y.com.

Int er i m Ap pr ova l Aut hor i z a t i on
All pa rt s requ ire fu ll PSO a nd PPAP a pprova l. PSO A approva l is a prerequ is ite for PPAP
a ppr ova l. PPAP a ppr ova ls a re s u bmit t ed t h r ou gh Power wa y.com by t h e Su pplier . Fa ilu re
t o s u bmit PPAP before S1 St a rt will requ ire a n In terim Approva l Au t hor iza t ion (IAA).
Reference t he in t er n a l DCC pr ocedu re PSSP0108. Su ppliers do n ot h a ve acces s t o t h is
pr ocedu re a nd s h ou ld con t act t h eir DCC ASQP Specia lis t or En gin eer for a ddit ion a l
in for ma t ion rega r din g IAAs .

NOTE 1 : Even wit h Z Approva l, a n IAA is s t ill requ ired.

NOTE 2 : An y devia t ions t o t he PSO requ iremen t s ou t lined in th is ma n u a l mu s t be
r equ es ted a nd approved in wr it in g by t h e DCC ASQP Specia lis t a n d Pr odu ct En gin eer ,
REGARDLESS OF AQP ACTIVITY LEVEL. Appr ova l(s ) mu s t be obt a ined fr om DCC
be fore complet ion of t h e PSO pr oces s . Requ es ted devia t ion (s ) s h a ll be for ma lly ou t lined
in det a il wit h in t h e COMMENT SHEET of t h e completed PSO.

5

CONDUCT PRE-PSO
MEETING (REVIEW
SUPPLIERS
DOCUMENTATION & SRE)
PSO TEAM CONDUCTS
PSO ON-SITE VISIT or
SUPPLIER PERFORMS
PRODUCTION
DEMONSTRATION RUN
(Self Directed AQP)
SUPPLIER CONDUCTS
PV TESTING
PSO TEAM
COMPLETES
PROCESS SIGN-OFF
SUPPLIER SUBMITS PPAP
PART SUBMISSION
WARRANT
PROCESS SIGN OFF STRATEGY
REVIEW PSO
REQUIREMENTS WITH
PSO TEAM
& SUPPLIER
SUPPLIER PERFORMS
READINESS EVALUATION
RUN
SUPPLIER COMPLIES WITH
CONTINUOUS
CONFORMANCE
REQUIREMENTS

6

1
PART ENTERS
POWERWAY.COM
2
INITIAL RISK
EVALUATION
& AQP LEVEL
PROCESS SIGN-OFF FLOWCHART
3
SUPPLIER LED PSO
4
DAIMLERCHRYSLER
LED PSO
3A
SUPPLIER
UPLOADS DOCUMENTS
INTO POWERWAY.COM

5
PSO REQUIREMENTS
REVIEW WITH
PSO TEAM AND
SUPPLIER
Self Directed AQP
Collaborative/Directed AQP
6
SUPPLIER PREPARES
DOCUMENTATION AND
CONDUCTS READINESS
EVALUATION RUN
7
PRE-PSO MEETING:
DOCUMENTATION/SRE
ACCEPTABLE?
9
SCHEDULE
PSO ON SITE VISIT
10
SUPPLIER FINALIZES
LINE AND APPROVES
EVIDENCE OF PRO-
DUCTION READINESS
a c
YES
NO
d
Figure 2.1
8
SUPPLIER MODIFIES
AND SUBMITS
DOCUMENTATION
AND/OR CONDUCTS
READINESS
EVALUATION RUN

b

7
PROCESS SIGN-OFF

FLOWCHART RESPONSIBILITIES

RESPONSIBILITY
LEGEND PROCESS NAME
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U
P
P
L
I
E
R

REMARK
L = LEAD
RESPONSIBILITY
1
Par t en ter s
Power way. com
L P
S = SUPPORT TO 2 In it ial Ris k P S L S
P = PROVIDES
INFORMATION
3&
3(A)
Su pplier led PSO P S P S L
P/ S = DEPENDS ON
COMPOSITION OF
4
Daimler Ch r ys ler led
PSO
P S P L S
PSO TEAM
5
PSO Requ ir emen t s
Review
P S P L S
6
Su pplier prepares
docu men t at ion an d
r eadines s evalu at ion
P S P S L
7
Pr e-PSO
Docu men t at ion
Reviews
P/
S
S
P/
S
L S
8
Su pplier modifies an d
s u bmit s
docu men t at ion
P S P S L
9
Sch edu le PSO On -
Sit e Vis it
P S P L S
10
Su pplier fin alizes lin e
an d appr oves
eviden ce pr odu ct ion
P S P S L

8
11
PSO ON-SITE VISIT or
SUPPLIER CONDUCTS
PRODUCTION
DEMONSTRATION RUN
12
ELEMENTS 1-20
ACCEPTABLE?
A
YES
NO
c
NO
19
PSO APPROVED,
A DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
YES
d
NO
Figure 2.2
b
17
INVESTIGATE REASON
FOR FAILURE AND ROOT
CAUSE ELIMINATION
15
SUPPLIER CONDUCTS
ELEMENT 21
16
ELEMENT 21
ACCEPTABLE?
20
SUPPLIER SUBMITS
PPAP WARRANT & ENTERS
PPAP DATE IN
POWERWAY.COM
12A
PSO ON-SITE REVISIT
NECESSARY?
13
SUPPLIER CONDUCTS
CORRECTIVE ACTION
AND SUBMITS
DOCUMENTATION
NO
18
REPETITION
OF ELEMENT 21
SUFFICIENT?
YES
YES
14
Z DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
19A
SUPPLIER CONDUCTS
PSO IN ACCORDANCE
WITH PSO MANUAL
AND ENTERS PSO
DATE & DISPOSITION
INTO POWERWAY.COM

9
PROCESS SIGN-OFF
FLOWCHART RESPONSIBILITIES

RESPONSIBILITY
LEGEND PROCESS NAME
D
C
C

P
R
O
C
U
R
E
M
E
N
T

D
C
C

E
N
G
I
N
E
E
R
I
N
G

D
C
C

M
A
N
U
F
A
C
T
U
R
I
N
G

D
C
C

A
S
Q
P

S
U
P
P
L
I
E
R

REMARK
11 PSO On -Sit e Vis it
P/
S
S P/ S L S
L = LEAD
RESPONSIBILITY
S = SUPPORT TO
12
&12(A)
Accept an ce of Elemen t s
1-20
P/
S
S P/ S L P
P = PROVIDES
INFORMATION
P/ S = DEPENDS
ON
COMPOSITION OF
PSO TEAM
13
Su pplier con du ct s
cor r ect ive act ion an d
s u bmit s docu men t at ion .
ASQP pr ovides appr oval
P S P L L

14
"Z" code en tered in t o
Power way. com. Su pplier
en ter s Dimen s ion al PPAP
& dat e
S L P

15
Su pplier con du ct s
Elemen t 21
P S P S L

16
Accept an ce of Elemen t
21
P/
S
S P/ S L P

17
In ves t igat e reas on for
failu r e an d r oot cau s e
elimin at ion
P S P S L

18 Repet it ion of Elemen t 21
P/
S
S P/ S S L

19
PSO "A" dis pos it ion &
dat e en tered in t o
Power way. com. Su pplier
en ter s Mat er ial/
Fu n ct ion a l PPAP & dat e
P/
S
S P/ S L P

19A
Su pplier con du ct s PSO
an d en ter s A
dis pos it ion & dat e in t o
Power way. com
P/
S
S P/ S S L

20
Su pplier s u bmit s PPAP
war r an t an d dat e in t o
Power way. com
P S P S L
Refer t o
PPAP
Ma n u a l for
fu r t h er
det a ils

10


11

PSO ELEMENT REQUIREMENTS

12
PART NUMBER, DESCRIPTION AND CHANGE LEVEL
Element Requirement s Document at ion
1 . 1 Th e PSO team s h all r eview all PSO relat ed docu men t s t o ens u r e
all docu men t s h ave t he cor rect par t n u mber , des cr ipt ion an d ch an ge
level pres en t or cr os s -referen ced (s ee ISO/ TS-16949 cl. 4. 2. 3 Con t rol
of Docu men t s ).

1 . 2 A pr ocedu re s h all be in place t o as s u r e cor rect par t n u mber an d
r evis ion level as ch an ges occu r . Th is pr ocedu r e s h all als o en s u re
affected docu men t s (e. g. Con t r ol Plan , PFMEA, et c. ) are u pdat ed an d
applicable t es t in g is perfor med for each ch an ge.

1 . 2 . 1 Th is pr ocedu r e s h all in clu de commu n icat ion an d n ot ificat ion
of ch an ges t h r ou gh ou t t h e Su pply Ch ain . Th e Tier 1 Su pplier is
u lt imat ely r es pon s ible t o ens u r e pr odu ct s h ipped t o DCC (or ot h er
des ign at ed man u fact u r in g facilit y) is t he lat es t revis ion level.

1 . 2 . 2 Th is pr ocedu r e s h all in clu de t h e receipt of an appr oved DCC
Ch an ge Not ice. The Supplier s hall not make any changes
wit hout DOCUMENT approval from t he cus t omer (voicemail, e-
mail, et c. are UNACCEPTABLE).

1 . 3 Wh ere t he pr odu ct iden t it y is n ot in h er en t ly obviou s , t he Su pplier
s h all employ an in t er n al n u mber in g s ys tem an d pr ovide a cr os s
r eferen ce wh ich en ables u s er s t o iden t ify t he DCC par t n u mber an d
r evis ion level wh ich cor res pon ds t o t h e Su pplier s n u mber in g an d
r evis ion s ys tem.

1 . 4 Th e Su pplier s h all h ave a pr ocedu r e wh ich preven t s n on -
s t an dar dized or ou t of dat e docu men t s an d in s t r u ct ion s fr om exis tin g
on t h e man u fact u r in g floor (e. g. Docu men t au dit ). Refer t o ISO/ TS-
16949, cl. 4. 2.3 Con t r ol of Docu men t s .

Engi nee ring St andards Ide nt ifie d
1 . 5 A pr oces s s h all be in place t o obt ain r evis ion s t o all DCC,
gover n men t al, Safet y <S>, an d ot h er pr odu ct relat ed s t an dar ds an d
s pecificat ion s . DCC s t an dar ds ar e available via En gin eer in g St an da r ds
Su pplier Dis t r ibu t ion (ESSD) at
h t t ps :/ / es s d.ext r a. daimler ch r ys ler . com/ ESSD/ Login . js p.

1 . 5 . 1 Th is pr oces s s h all addr es s n ot ificat ion t o a ll applicable
depar t men t s of s t an dar d ch an ges as t h ey occu r . Th is pr oces s s h all
als o in clu de t he frequ en cy an d res pon s ibilit y for r eviewin g t h e
s t an dar ds (n ot t o exceed two wor kin g weeks ; referen ce ISO/ TS-
16949, cl. 4. 2.3. 1 En gin eer in g Specificat ion s . )

1 . 6 Th e PSO Team s h all ver ify t h at t h e CATIA Commen t page or Par t
In for mat ion Page (PIP) lis t s all applicable s t an dar ds , in clu din g, bu t n ot
limit ed t o, t h os e s h own on t he s ou r ce package an d s ign ed DVP&R (s ee
Elemen t 3 Tes t Sample Sizes an d Frequ en cies . )

1 . 6 . 1 DCC appr oval for all deviat ion s fr om lis t ed s t an dar ds s h all
be docu men ted on t he CATIA Commen t page/ PIP an d DVP&R.
- CATIA files , dr awin gs ,
Commen t page, Par t
In for mat ion Pages (PIP)
(in clu din g lis t of
applicable en gin eer in g
s t an dar ds , s oft ware
level an d h ar dware
level) (MANDATORY
ENGLISH)
- Gage Dimen s ion in g &
Toler an cin g (GD&T)
s h eet s (MANDATORY
ENGLISH)
- Par t n u mber cr os s
r eferen ce s heet (if
applicable)
- En gin eer in g Ch an ge
pr ocedu r e
- Docu men t Con t r ol
pr ocedu r e

13

PART NUMBER, DESCRIPTION AND CHANGE LEVEL, CONT.
Element Requirement s
1 . 6 . 2 Th e PSO Team s h all ver ify th at t h e CATIA Commen t page or
PIP lis t s all s u b-compon en t s of t h e en d-it em as s embly. Th is lis t in g
s h all in clu de DCC par t n u mber (if applicable), Su pplier par t
n u mber , qu an t it y, an d r evis ion level.

1 . 6 . 3 Th e PSO Team s h all ver ify th at all dimen s ion al r equ ir emen t s
ar e defined on t he GD&T s h eet s an d at t ach ed t o t h e des ign model.
Th e Su pplier s h all con s is t en t ly apply a mu t u ally agr eed u pon (wit h
t h e DCC PSO Team) dat u m s ch eme t h r ou gh ou t t h e par t
developmen t pr oces s .

14

DESIGN FMEA
2 . 1 Des ign FMEAs (DFMEAs ) s h all be created u s in g t h e lates t AIAG
an d DCC gu idelin es . If AIAG an d DCC gu idelin es dis agree, DCC
gu idelin es t ake preceden ce.

2 . 2 Th e Su pplier s h all h ave an in t er n al bes t pr act ice pr ocedu re t h at
is u t ilized in t he developmen t of DFMEAs . Th e pr ocedu re s h all in clu de
docu men t at ion an d dat a wh ich explain s h ow t h e DFMEA s ever it y,
occu r r en ce, an d detect ion n u mber s were developed.

2 . 2 . 1 Th is pr ocedu r e s h all be reviewed per iodically for effect ivenes s
an d s h all in clu de les s on s lear ned wit h in pu t s fr om pas t is s u es (e. g.
eCIMS, NCT, war r an t y, CSA, yar d h olds , et c. )

2 . 2 . 2 Th e pr ocedu re s h all in clu de u s e of t h e Rollin g Top 20 r u le
for con t in u ou s impr ovemen t . Th is requ ir es t h e Su pplier t o Paret o
failu r e modes an d addres s t h e t op 20% u s in g RPN valu es
(r egar dles s of act u al RPN valu e. )

2 . 3 Er r or pr oofin g an d con t r ols s h all be iden t ified in t h e DFMEA.

2 . 4 Th e DFMEA is a livin g docu men t an d s h all be t r aceable t o all
des ign ch an ges . It s h all con t a in all s pecial ch ar act er is t ics fr om
Elemen t 12 Special Pr odu ct / Pr oces s Ch ar act er is t ics Iden t ified.

2 . 5 A DFMEA s h a ll be completed for each u n iqu e Su pplier -des ign ed
pr odu ct . Th e DCC Pr odu ct En gin eer h as t h e lead res pon s ibilit y for
en s u r in g t h at t h e DFMEA meets all r equ ir emen t s . Addit ion ally, t imely
complet ion an d appr oval of all DFMEA act ivit ies s h all be completed on
or before requ ir ed qu alit y gat e t imin g. Referen ce t he CDS Qu alit y Gat e
Book at h t t p:/ / r oadmap. t cc. ch r ys ler .com/ cds / for s pecific t imin g.

2 . 6 Th e DFMEA s h all in clu de all s u b-compon en t s of t h e en d-it em
as s embly.

2 . 7 Th e Su pplier s h all en s u re all failu r es obs er ved du r in g En gin eer in g
Developmen t (ED) an d Des ign Verificat ion (DV) t es t in g ar e capt u r ed
wit h in t h e DFMEA.

2 . 8 Th e Su pplier s h all en s u re t h e occu r ren ce an d detect ion abilit y of
failu r es obs erved du r in g DV tes t in g cor relat e wit h t h e occu r ren ce an d
detect ion n u mber s docu men ted on t h e DFMEA.

2 . 9 Bu zz-Squ eak-Rat t le (BSR) an d Nois e-Vibr at ion -Har s h n es s (NVH)
is s u es s h all be addres s ed, if applicable.

NOTE: Special at t en t ion (as defined by DCC En gin eer in g) s h all be
given t o failu r e modes wit h :
- A Sever it y 8, regar dles s of Occu r r en ce or Detect ion valu es .
- A Sever it y 5 and Occu r r en ce 2, regar dles s of Detect ion (t h is
equ at es t o cu s t omer dis s at is fact ion an d cs / 1000 > 1. )
- A Detect ion of 10.
See Appen dix B FMEA Gu idelin es .
- DFMEA (MANDATORY
ENGLISH)
- Bes t Pr act ice
pr ocedu r e

15

TEST SAMPLE SIZES AND FREQUENCIES
3 . 1 Pr odu ct s covered u n der a Perfor man ce St an dar d (PF) t h at
s pecifies tes t s ample s izes , tes t frequ en cies , an d accept an ce cr it er ia
s h all h ave tes t in g requ ir emen t s in clu ded in a Des ign Ver ificat ion Plan
an d Repor t (DVP&R), in clu din g a Tes t t o Failu r e ver ificat ion plan .
Referen ce t he Pr odu ct As s u r an ce Tes t in g man u al.

3 . 2 Des ign Ver ificat ion (DV) an d Pr odu ct ion Validat ion (PV) t es t plan s
s h all be s igned by t he DCC Pr odu ct En gin eer PRIOR t o tes t in g.

3 . 3 Complet ed DV an d PV tes t res u lt s s h all be s ign ed by t h e DCC
Pr odu ct En gin eer .

3 . 4 All fu n ct ion a l r equ ir emen t s s h all be defin ed in t h e DVP&R an d
ver ified again s t applicable Per forman ce St an dar ds for accu r acy.

3 . 4 . 1 Deviat ion s fr om t h e Perfor man ce St an dar ds s h all be
iden t ified an d vis ible on t he CATIA Commen t page or PIP an d
DVP&R (e. g. ch an ges t o tes t s ample s izes , tes t waiver s , et c. ) See
Elemen t 1 Par t Nu mber , Des cr ipt ion , an d Ch an ge Level.

3 . 4 . 2 Con t in u ou s Con for man ce tes t in g s h all be docu men ted on
t h e DVP&R wh en applicable.

3 . 4 . 3 A "cir cle gr id an alys is ", or ot h er for mabilit y a n alys is , is
r equ ir ed for PSO appr oval on s t amped compon en t s if requ ir ed by
t h e DCC ASQP Specialis t an d/ or En gin eer .

3 . 4 . 4 DCC in t er n al s t amped compon en t s s h all follow t h e
r equ ir emen t s in MQAS 90-6710 Dimen s ion al Bu y-Off Pr ocedu re
for Upgr adin g St amped Par t s Du r in g Die/ Tool Developmen t .

3 . 5 All t es t in g failu r es s h all be docu men t ed on t h e DVP&R an d
addr es s ed wit h a DCC 8-St ep Corr ect ive Act ion plan (available on th e
For ever Requ ir emen t s webpage an d t h r ou gh COVISINT).

3 . 6 An n u a l valida t ion t es t in g s h all be completed each model year as
s pecified in t he Pr odu ct As s u r an ce Tes t in g man u a l an d applicable
Perfor man ce St an dar ds , u n les s waived in wr it in g by t h e DCC Pr odu ct
En gin eer an d ASQP Specialis t . Referen ce ISO/ TS-16949, cl. 7. 5. 2.

NOTE: A wr it ten waiver is requ ir ed each model year t h at an n u al
validat ion will n ot be per for med.

3 . 6 . 1 Th e Su pplier s h all h ave a pr ocedu re t o en s u re on -t ime
An n u a l Valida t ion , pr even t s chedu lin g con flict s an d fixt u r e/ tes t in g
s h or t ages in t he even t of mu lt iple An n u a l Valida t ion s .

- DCC En gin eer in g
s ign ed DVP&R
(MANDATORY
ENGLISH)
- Applicable En gin eer in g
St an dar ds
(MANDATORY
ENGLISH)
- DCC En gin eer in g
s ign ed DV an d PV tes t
plan s (MANDATORY
ENGLISH)
- An n u a l Valida t ion
pr ocedu r e

16
PROCESS FMEA
4 . 1 Pr oces s FMEAs (PFMEAs ) s h all be created u s in g t h e lat es t AIAG
an d DCC gu idelin es . If AIAG an d DCC gu idelin es dis agree, DCC
gu idelin es t ake preceden ce.

4 . 2 Th e Su pplier s h all h ave an in t er n al bes t pr act ice pr ocedu re t h at
is u t ilized in t he developmen t of PFMEAs . Th e pr oces s s h all in clu de
docu men t at ion an d dat a wh ich explain s h ow t h e PFMEA s ever it y,
occu r r en ce, an d detect ion n u mber s were developed.

4 . 2 . 1 Th is pr ocedu re s h all be reviewed per iodically for effect ivenes s
an d s h all in clu de les s on s lear ned wit h in pu t s fr om pas t is s u es (e. g.
eCIMS, NCT, war r an t y, CSA, yar d h olds , et c. ).

4 . 2 . 2 Th e pr ocedu re s h all in clu de u s e of t h e Rollin g Top 20 r u le
for con t in u ou s impr ovemen t . Th is requ ir es t h e Su pplier t o Paret o
failu r e modes an d addres s t h e t op 20% u s in g RPN valu es
(r egar dles s of act u al RPN valu e. )

4 . 3 Mis t ake pr oofin g an d con t r ols s h all be iden t ified in t h e PFMEA.

4 . 4 Th e PFMEA is a livin g docu men t an d s h all be t r aceable t o all
pr oces s ch an ges . It s h all con t a in all s pecial ch ar act er is t ics fr om
Elemen t 12 Special Pr odu ct / Pr oces s Ch ar act er is t ics Iden t ified.

4 . 5 Th e DCC ASQP Specialis t h as t h e lead res pon s ibilit y for en s u r in g
t h at t h e PFMEA meet s all r equ ir emen t s (green ) per t he Su pplier
PFMEA Au dit Su mmar y s h eet . Als o, t imely complet ion an d appr oval
of all PFMEA act ivit ies s h all be completed on or before requ ir ed qu a lit y
gat e t imin g. Referen ce t h e CDS Qu alit y Gat e Book at
h t t p:/ / r oadmap. t cc. ch r ys ler . com/ cds / for s pecific gate deliver ables .

4 . 6 Th e PFMEA s h all r eflect t h e en t ir e man u fact u r in g pr oces s fr om
r eceivin g t h r ou gh s h ippin g.

4 . 7 Th e Su pplier s h all en s u re t h at all failu r e modes obs er ved du r in g
all pr e-pr odu ct ion r u n s ar e capt u r ed on t h e PFMEA.

4 . 7 . 1 Th e Su pplier s h all en s u re th e r ate of occu r ren ce an d abilit y
t o detect failu r es obs er ved du r in g pr e-pr odu ct ion r u n s cor relat e
wit h occu r r en ce an d detect ion n u mber s docu men ted on t he FMEA.

4 . 8 BSR an d NVH is s u es s h all be addr es s ed if applicable.

NOTE: Special at t en t ion s h all be given t o failu r e modes wit h :
- A Sever it y 8, regar dles s of Occu r r en ce or Detect ion valu es .
- A Sever it y 5 and Occu r r en ce 2, regar dles s of Detect ion valu e
(t h is equ at es t o cu s t omer dis s at is fact ion an d cs / 1000 > 1. )
- A Detect ion of 10.
See Appen dix B an d t he Su pplier PFMEA Au dit Su mmar y s h eet
(in t er n al DCC wor k in s t r u ct ion PSWI-1047; Su pplier s do n ot h ave
acces s an d s h ou ld obt ain a copy fr om t h eir ASQP Specialis t . )
- PFMEA (MANDATORY
ENGLISH)
- PFMEA Au dit
Su mmar y
(MANDATORY
ENGLISH)
- Bes t Pr act ice
pr ocedu r e

17

PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN
5 . 1 Th e pr oces s flow diagr am s h a ll r epres en t t he en t ire
man u fact u r in g pr oces s fr om receivin g t h r ou gh s h ippin g
oper at ion s , in clu din g ma in -lin e as s embly pr oces s es as well as all off-
lin e s u pply pr oces s es .

5 . 1 . 1 Th e pr oces s flow diagr am s h all in clu de t h e pr oces s in g
s equ en ce, met h od an d equ ipmen t u s ed at each s t at ion (in clu din g
in s pect ion an d repair / rewor k s t at ion s ).

5 . 1 . 2 St at ion s wh ich meas u r e s pecial ch ar act er is t ics an d/ or
con t r ibu t e t o s ign ifican t cu s t omer is s u es s h all be iden t ified.

5 . 2 Th e man u fact u r in g floor pla n s h all s h ow t h e layou t of t h e facilit y
an d t h e s t at ion -by-s t at ion flow of t h e man u fact u r in g pr oces s .

5 . 2 . 1 Th e man u fact u r in g floor pla n s h all h igh ligh t all pr odu ct ion
equ ipmen t u s ed.

5 . 2 . 2 Th e man u fact u r in g floor pla n s h all s h ow Wor k in Pr oces s
(WIP), r aw mater ial, an d s cr ap mat er ial s t or age locat ion s .

5 . 2 . 3 A wor k s t at ion layou t s h a ll exis t wh ich iden t ifies all wor k
s t at ion s .

5 . 3 Th e flow diagr am, man u fact u r in g floor plan an d/ or t h e wor k
s t at ion layou t s h all in clu de each u n iqu e mach in e n u mber .

s t at ion layou t s h all in clu de t h e n u mber of oper at or s , in clu din g floa t
oper at or s , requ ir ed per s t at ion (in clu din g r epair / rewor k s t at ion s ). Th e
PSO t eam s h all ver ify t he n u mber of oper at or s du r in g t h e On -Sit e
Vis it .

s t at ion layou t s h all iden t ify bot t len eck oper at ion s or s t at ion s .

5 . 6 All pr odu ct ion equ ipmen t appear in g on t h e man u fact u r in g floor
plan , flow diagr am, an d wor k s t at ion layou t s h a ll be ver ified by t he
PSO t eam.
- Pr oces s flow diagr am
(or equ ivalen t )
(MANDATORY
ENGLISH)
- Man u fact u r in g floor
plan
- Wor k St at ion Layou t

18
CONTROL PLAN & PROCESS MONITORING
6 . 1 Th e Con t r ol Pla n s h all des cr ibe each s tep of t he man u fact u r in g
pr oces s in clu din g: receivin g, mater ial h a n dlin g a n d s t or age, in -
pr oces s oper at ion s , t es t in g, in s pect ion s , rewor k/ repair , s h ippin g,
t empor ar y or in t er im off-s t an dar d oper at ion s (e. g. back-u p
oper at ion s ), an d con t in u ou s con for man ce. Refer t o t he AIAG
Advan ced Pr odu ct Qu alit y Plan n in g man u al.

6 . 1 . 1 Meas u remen t an d in s pect ion frequ en cies det ailed in t he
Con t r ol Plan , in clu din g all in s pection s for appear an ce
r equ ir emen t s , s h all be ver ified by t h e PSO Team du r in g t h e
Pr odu ct ion Demon s t r at ion Ru n .

6 . 1 . 2 Repair / rewor k s t at ion s s h all h ave con t r ols equ ivalen t t o
t h os e of t he pr imar y pr odu ct ion lin e.

6 . 1 . 3 Th e Con t r ol Pla n s h all addr es s ver ificat ion of Mis t ake
Pr oofin g (e. g. n u mber of pieces , frequ en cy, et c. ).

6 . 1 . 4 Th e Su pplier s h all h ave a pr oces s wh ich lin ks t h e Su pplier s
DFMEA an d PFMEA t o t h e Con t r ol Plan . Th is pr oces s s h all en s u r e
t h at con t r ols , les s on s lear n ed, etc. det ailed in t h e DFMEA an d
PFMEA, ar e car r ied forwar d in t o t h e Con t r ol Plan .

6 . 1 . 5 Th e Su pplier s h all r eferen ce kn own is s u es fr om s imilar
pr odu ct s (e. g., e-CIMS, war r an t y, NCTs , yar d h olds ) an d in clu de
an y applicable preven t ive act ion s in t h e Con t r ol Plan .

6 . 1 . 6 All pr oces s an d pr odu ct con t r ol par amet er s an d t oler an ces
s h all be docu men ted in t h e Con t r ol Plan .

6 . 1 . 7 All s pecial ch ar act er is t ics iden t ified in t he GD&T s h eet s
an d t h e DVP&R an d an y s pecial ch ar act er is t ics t h at des cr ibe
mat er ials , pr oces s es , perfor man ce, reliabilit y, qu a lit y, an d/ or
des ign requ ir emen t s iden t ified in t h e DFMEA an d PFMEA s h all be
in clu ded in t h e Con t r ol Plan .

6 . 1 . 8 Sa mple s izes s h all be bas ed on in du s t r y-s t a n dar d s t at is t ical
s amplin g plan t ables or s h all u s e St at is t ical Pr oces s Con t r ol (SPC).

Proces s Moni t oring
6 . 2 Th e Su pplier is res pon s ible for main t ain in g ma n u fact u r in g
pr oces s capabilit y a n d s h all h ave a pr ocedu r e requ ir in g docu men t ed
cor r ect ive act ion s for all ou t of con t r ol meas u r emen t s . All r eact ion
plan s s h all in clu de con t ain men t of s u s pected n on -con for min g pr odu ct
an d 100% in s pect ion as appr oved by t he PSO Team.

6 . 3 A docu men t ed Fir s t Piece Appr oval pr ocedu re s h all exis t wh ich
ver ifies pr odu ct at each s t at ion is bein g made accor din g t o
s pecificat ion , pr oper mach in e s et -u p, an d cor rect par ameter s et t in g.
- Con t r ol Plan
(MANDATORY
ENGLISH)
- 1
s t
piece appr oval
pr ocedu r e & recor ds
- Con t r ol Ch ar t s
- Pr oces s Per for man ce
- Log Sh eet s
- Defect Tr ackin g Sh eet s

19
CONTROL PLAN & PROCESS MONITORING, CONT.
6 . 3 . 1 Th e pr ocedu re s h all requ ir e Fir s t Piece Appr oval at t h e
begin n in g of each s h ift or pr odu ct ion r u n a n d aft er an y ch an ges
ar e made t o t he pr odu ct ion pr oces s (e. g. t oolin g modificat ion s , SPC
adju s t men t s , et c. )

6 . 3 . 2 Th e pr oces s s h all in clu de t h e reten t ion of t he fir s t piece u n t il
t h e en d of t he pr odu ct ion r u n or s h ift an d iden t ificat ion of t h e fir s t
piece s ample(s ) an d an alys is of s pecial ch ar act er is t ics iden t ified by
t h e PSO Team an d t h e Su pplier du r in g t h e AQP pr oces s .

6 . 3 . 3 Docu men t ed eviden ce of Firs t Piece Appr oval pr oces s
execu t ion s h all be main t ain ed. Th e Su pplier s h all recor d t he par t
n u mber , man u fact u r in g dat e, an d an y addit ion al in for mat ion as
r equ ir ed by t h e PSO Team.

6 . 4 All in s pect ion s t at ion s s h all h ave a met h od of defect t r ackin g (e.g.,
t ally s h eet s , s cr ap s heet s , etc. )

6 . 5 Vis u al dis plays of pr oces s perfor man ce (e. g. FTC, s cr ap an d
r ewor k) an d t ot al pr odu ct ion main t en an ce (e. g. down t ime, et c) s h all be
pr es en t on t h e man u fact u r in g floor an d reflect cu r ren t qu alit y dat a.

6 . 5 . 1 Tar get s s h all be iden t ified for each meas u r able wit h
docu men t ed plan s for ach ievin g t h os e t ar get s .

6 . 6 Wh ere SPC met h ods are u s ed, t he Su pplier is requ ir ed t o main t ain
a h is t or y of compon en t pr odu ct ion s equ en ce, pr odu ct ion lin e,
pr odu ct ion t ool an d ch ar act er is t ics valu es t o as s is t in as s embly plan t ,
war r an t y an d field ret u r n r oot cau s e in ves t igat ion s . See t he
Daimler Ch r ys ler Cu s t omer -Specific Requ ir emen t s for ISO/ TS-16949,
cl. 4.1. 1.

6 . 7 Su pplier s s h all h ave a Cr aft s man s h ip Qu alit y In it iat ive Pr ocedu r e
for all compon en t s wit h appear an ce requ ir emen t s . Th is pr ocedu re
s h all in clu de: team member s , regu lar s ch edu led Cr aft s man s h ip
r eviews an d au dit s , con dit ion r es olu t ion t r ackin g mat r ix, r eten t ion of
an Appear an ce Man u al, an d con t ain men t pr ocedu res an d gu idelin es .

6 . 7 . 1 Su pplier s s h all h ave an Appear an ce Man u al for all
compon en t s wit h appear an ce requ ir emen t s . Th is man u a l s h all
in clu de: appr opr iat e docu men t at ion (s ign -off s h eet , t able of
con t en t s , revis ion h is t or y, gener al appear an ce ch ar acter is t ics
accept an ce s pecificat ion ), s t u dio qu alit y ph ot os of pr odu ct s h own
in appr opr iat e views , s t u dio qu alit y ph ot os for an y con dit ion s
deviat in g fr om des ign in ten t , an d all Cr aft s man s h ip wor ks h eet s
(ph ot os of con dit ion s , con t a in men t an d per manen t cor rect ion
act ion s , alon g wit h s u ppor t in g docu men t at ion . )

20
QUALITY PLANNING
7 . 1 All Adva n ce Pr odu ct Qu alit y Plan s (APQPs ) s h all coor din a t e with
DCC Ch r ys ler Developmen t Sys t em (CDS) t imin g for each applicable
pr ogr am. Th e plan s h all iden t ify major miles t on e even t s , requ ir ed
pr odu ct or pr oces s deliver ables , res pon s ible or gan izat ion s , as well as
s ch edu led an d act u al t imin g dat es . Referen ce t he AIAG Advan ced
Pr odu ct Qu alit y Plan n in g a n d Con t r ol Plan (APQP) ma n u al an d CDS at
h t t p:/ / r oadmap. t cc. ch r ys ler . com/ cds / .

Supply Bas e Manageme nt
7 . 2 Th e Su pplier s h all cas cade qu alit y pla n n in g t h r ou gh ou t all s u b-
t ier s (s ee cl. 7. 4. 3 of ISO/ TS-16949, Qu alit y Man agemen t Sys tems ).

7 . 2 . 1 Th e plan s h all in clu de an Eas y Map diagr a m. Th is diagr am
s h ou ld ou t lin e t he en t ire Su pply Ch ain , begin n in g wit h r aw
mat er ials an d en din g wit h t h e DCC or t h e DCC-des ign at ed
man u fact u r in g facilit y. All s econ dar y pr oces s es an d/ or s er vices
(e. g. plat in g, heat t reat in g, et c. ) s h all be s h own , in clu din g off-s it e
s t or age or s h ippin g locat ion s . Eas y Map can be fou n d on t h e
COVISINT webs it e.

7 . 2 . 2 Each compon en t lis t ed on th e Bill of Mater ial cor res pon din g
t o t h e DCC par t n u mber s h all h ave an In it ial Ris k Evalu at ion (or
equ ivalen t ) per for med. Th e cr it er ia for r is kin g compon en t s s h all
t ake in t o con s ider at ion t h e DCC ris k dr iver s . DCC r is k dr ivers are
fou n d on t h e In it ial Ris k Evalu a t ion docu men t in Power way. com.

7 . 2 . 2 . 1 Each s u b-compon en t det er min ed t o be mediu m or
h igh r is k (or equ ivalen t ) s h all be accompan ied by a PSO (or
equ ivalen t pr oces s ) con du ct ed by t h e Su pplier. Level 3 PPAP
docu men t at ion is als o r equ ir ed. Addit ion al docu men t at ion may
be requ es ted by t h e DCC ASQP Specialis t .

7 . 2 . 3 Th e Su pplier s h all h ave a pr oces s wh ich mon it or s an d
docu men t s t h e qu alit y of all s u b-t ier s .

Problem Solving
7 . 3 Th e Su pplier s h all h ave a pr ocedu r e t o con vey les s on s lear n ed an d
cor r ect ive act ion s back t h r ou gh t h eir facilit y, an d all ot h er facilit ies
wit h in t h e s ame compan y. (Referen ce ISO/ TS-16949, cl. 8. 5. 2. 1
Pr oblem Solvin g. )

7 . 3 . 1 Cor r ect ive act ion s h all be implemen ted acr os s
t h e en t ire man u fact u r in g plan t for ever y applicable DCC
pr odu ct ion lin e.

7 . 4 Th e accept able met h ods for docu men t in g r oot cau s e an alys es an d
cor r ect ive act ion s (for all n on -con for man ces , tes t failu r es , et c. ) are
t h r ou gh t h e DCC eCIMS s ys tem an d/ or t h e 8-St ep Cor rect ive Act ion
for m.
- AQP or APQP
t imelin e/ plan
- Lis t wit h PPAP s t at u s
of all s u b-compon en t s .
- Eas y Map Su pply
Ch ain diagr a m
- Lis t ed r is k of all s u b-
compon en t s an d s u b-
t ier pr oces s es .
- Level 3 PPAP
docu men t at ion for all
s u b-compon en t s an d
s u b-t ier pr oces s es
r is ked mediu m or
h igh .
- DOE (Des ign of
Exper imen t s )
- Copies of eCIMS or 8-
St ep Cor rect ive Act ion s
for is s u es en cou n t ered
in pr eviou s pilot
bu ilds .
- Les s on s Lear ned
Commu n icat ion
pr ocedu r e

21
QUALITY PLANNING, CONT.
7 . 5 Th e PSO team s h all r eview cor r ect ive act ion s for an y n on -
con for man ces or tes t failu r es en cou n t er ed pr ior t o t he PSO vis it (e.g.
du r in g pilot bu ilds , DV tes t in g, etc. ) Th e t eam s h all en s u re t h at all
cor r ect ive act ion s h ave been completed an d implemen ted (e. g. t h r ou gh
er r or an d/ or mis t ake pr oofin g, proces s or des ign ch an ges , etc. )

7 . 6 Th e Su pplier s h all h ave a pr ocedu r e for con du ct in g Des ign of
Exper imen t s (DOE). DOE (or s imilar act ivit ies ) s h all be con du ct ed to
iden t ify an d es t ablis h t h e opt imal pr oces s par ameter s for all n ew an d
modified par t s pr ior t o t h e PSO On -Sit e Vis it .

7 . 7 Th e Su pplier s h all s u ppor t all DCC s ys tems (e. g. eCIMS, Non -
Con for ma n ce Ticket (NCT) s ys t em, Power way. com, PRAS, COVISINT,
et c. )

NOTE: For s ou r ce packages t h at reflect pr opr iet ar y docu men t
exclu s ion s , t h os e docu men t s s it ed for exclu s ion ar e n ot requ ir ed t o be
u ploaded in t o Powerway. com. However, t hes e docu men t s s h all be
available for review at t h e requ es t of t he DCC ASQP Specialis t . A cover
page wit h t h e docu men t s t it le block, revis ion level an d dat e is requ ir ed
t o be u ploaded in place of t he actu al docu men t .

7 . 7 . 1 Th e Su pplier s h all h ave at leas t 2 in dividu als wit h valid
SIDs an d pas s wor ds for each applicable DCC eSys tem (e. g.
Power way. com, Non -Con for man ce Ticket s ys tem, eCIMS,
COVISINT, PRAS, et c. ) All in dividu als s h a ll be fu lly t r ain ed in
t h e u s e of each s ys tem for wh ich t h ey acces s .

7 . 8 Th e Su pplier s h all pr ovide both a Plan t an d War r an t y Qu alit y
Repres en t at ive, as requ ired, t o as s is t DCC per s on nel t h r ou gh ou t t h e
life of t he pr ogr am.

7 . 8 . 1 Con t act n ames s h all be pr ovided by t he Su pplier u pon
r equ es t . Addit ion a l con t act in for mat ion may be obt ain ed by DCC
pers on n el (on ly) t h r ou gh t h e ODIMS s ys t em via t h e p12 s creen .

7 . 8 . 2 Wh en t he Su pplier is a DCC dir ected s u b-t ier, t he Su pplier
Repres en t at ive(s ) s h all s u ppor t t h e Tier 1 in t h e s ame man n er as
t h ey wou ld DCC. Su ppor t is t o begin at Gat e G1

Th eme Select ion
an d con t in u e t h ou gh t h e life of t h e pr ogr am.

7 . 9 Des ign res pon s ible Su pplier s ar e res pon s ible for Des ign for
Ser viceabilit y, wh ich en s u res eas e of dis as s embly of pr odu ct wit h
min ima l cos t an d t ime.

22
INCOMING & OUTGOING MATERIAL QUALIFACTION/ CERTIFICATION PLAN
Incomi ng Mat erial Cert ific at ion Plan
8 . 1 Th e In comin g Mat er ial Cer t ificat ion Pla n s h all in clu de pr ocedu r es
u s ed t o qu alify an d cer t ify in comin g mat er ial pr ior t o r eleas in g in t o
pr odu ct ion .

8 . 2 Th e plan s h all h ave a pr odu ct validat ion pr ocedu re wh ich
deter mines t he frequ en cy of in s pect ion bas ed on componen t an d s u b-
t ier h is t or y.

8 . 2 . 1 Th e plan s h all in clu de an es calat ion pr oces s wh ich
in cr eas es t h e in s pect ion frequ en cy when a defect is fou n d.

8 . 2 . 2 Wh en t he plan in clu des dock t o s t ock (i.e. s h ips par t s
dir ect ly ou t of t he receivin g area wit h ou t in s pect ion ) t h e pr oces s , at
a min imu m, s h all r equ ir e t h ree previou s con s ecu t ive s h ipmen t s t o
h ave been defect -free an d wit h ou t s u bs equ en t in t er n al or exter n al
n on -con for ma n ces .

8 . 3 Th e plan s h all in clu de in comin g accept an ce s amplin g pla n s , for
bot h at t r ibu t e an d var iable dat a. Two or mor e of t he met h ods
des cr ibed in cl. 7. 4. 3. 1 of ISO/ TS-16949 s h all be u s ed; ot h er wis e, t h e
min imu m r equ ir emen t s fou n d in t h e Lot Accept an ce Samplin g Table
(s ee Appen dix B) apply. In s pect ion frequ en cies an d s amplin g pla n s
s h all be docu men ted in t h e Con t r ol Plan . Lot s ize s h all n ot exceed on e
s h ift or on e pr odu ct ion r u n , wh ich ever is s maller .

NOTE: Th e requ ir emen t s in t he Lot Accept an ce Samplin g Table are for
at t r ibu t e s amplin g on ly. SPC is s u per ior an d if u s ed, t he s amplin g
qu a n t it ies in t he Lot Accept an ce Samplin g Table need n ot be followed.

8 . 4 Th e plan s h all iden t ify all pr oces s es perfor med by s u b-t ier s (e. g.
plat in g, h eat -t r eat in g, et c. ) an d in clu de recor ds in dicat in g
in s pect ion / t es t res u lt s t h at relat e t o t h e appr opr iat e lot code.

8 . 5 Th e lot accept an ce date (or dat e t he lot was in s pected) s h all
in clu de t h e year , mon t h , day an d n u mer ic s equ en ce.

8 . 6 Compon en t s or pr odu ct ion mat er ials u s ed in t h e as s embly of par t s
for DCC s h all h ave fu ll PPAP (or equ ivalen t ). Th e PSW for each s u b-
compon en t in t h e en d-it em as s embly s h all be eas ily acces s ible.

8 . 7 Cer t ificat es of An alys is s h all comply wit h DCC En gin eer in g
St an dar ds iden t ified on t he CATIA Commen t page or PIP.

8 . 8 Th e Su pplier s h all h ave copies of t heir s u b-t ier s ISO 9001
cer t ificat ion on file.
- In comin g in s pect ion
plan
- Samplin g pla n s
- Receivin g Repor t s
- In s pect ion / t es t repor t s
- Copies of s u b-t ier
Su pplier Cer t ificat es of
An a lys is for each
s pecific s u b-
compon en t
Su pplier PSWs (Par t
Su bmis s ion War r an t )
Su pplier ISO-9001
cer t ificat ion s
- Ou t goin g In s pect ion
Plan
- Par t In s pect ion
St an dar d
- Au dit Wor k
In s t r u ct ion s
- Sh ippin g r epor t s
- Au dit Recor ds

23

INCOMING & OUTGOING MATERIAL QUALIFACTION/ CERTIFICATION PLAN, CONT.
Out going Mat erial Ins pe ct ion Plan
8 . 9 Th e Ou t goin g Mat er ial In s pect ion Pla n s h all in clu de pr ocedu res
u s ed by ou t goin g in s pect ion t o qu alify ou t goin g pr odu ct pr ior t o
s h ipmen t t o t h e cu s t omer .

8 . 1 0 Th e plan s h all in clu de ou t goin g accept an ce s amplin g plan s , for
bot h at t r ibu t e an d var iable dat a. In s pect ion frequ en cies an d s amplin g
plan s s h all be docu men ted in t he Con t r ol Plan .

8 . 1 1 Compon en t s or modu les t h at h ave been des ign at ed as key s h all
h ave a Par t In s pect ion St an dar d complet ed. Reference DCC in ter n al
pr ocedu r es PSSP0301 Par t In s pect ion St a n dar d for s pecific
in s t r u ct ion s on complet in g t h e Par t In s pect ion St an dar d an d
PSSP0600 Key Compon en t Des ign at ion for Su pplier Qu alit y.
Su pplier s do n ot h ave acces s t o th es e pr ocedu res an d s h ou ld con t act
t h eir ASQP Specialis t for fu r t her in for mat ion . Th e Par t In s pect ion
St an dar d for m is available on -lin e t h r ou gh COVISINT.

8 . 1 2 Th e lot accept an ce date (or dat e t he lot was in s pected) s h all be
iden t ified by t h e year , mon t h , day an d n u mer ic s equ en ce.

8 . 1 3 Cer t ificat es of An alys is , if requ ir ed by DCC for t he fin is h ed
pr odu ct , s h all comply wit h DCC En gin eer in g St an dar ds iden t ified on
t h e CATIA commen t s page or PIP.

8 . 1 4 Sh ippin g, Au dit , an d Con t ain men t Recor ds s h all be docu men t ed
an d main t a in ed.

24

PARTS HANDLING PLAN
9 . 1 Th e Par t s Han dlin g Plan s h a ll in clu de pr ocedu r es t h at det ail all
in t er n al mat er ial h a n dlin g oper at ion s .

9 . 2 Th e plan s h all des cr ibe t h e t ypes of con t ain er s u s ed t h r ou gh ou t
t h e in t er n al man u fact u r in g pr oces s (in clu din g a n y exter n al pr oces s in g
s u ch as h eat t reat in g, plat in g, et c. ) Each con t ain er t ype s h all be
clear ly defin ed wit h mat er ial dimen s ion s , qu a n t it y per con t ain er , par t
n u mber s , s t ack heigh t limit s (s t at ic & mobile), weigh t , er gon omic
r equ ir emen t s , et c.

NOTE: Con t ain er in for mat ion ma y be in clu ded as a par t of t he
Packagin g In s t r u ct ion s . See Elemen t 10 Oper at in g In s t r u ct ion s .

9 . 3 A met h od s h all exis t t o clear ly iden t ify an d differen t iat e
r ewor k/ repair , s cr ap, WIP bin s , etc.

NOTE: Daimler Ch r ys ler does n ot pr ocu r e ret u r n able con t ain er s for
Su pplier s WIP (Wor k in Pr oces s ) or s u b-t ier Su pplier s . Con t ain er s for
t h es e compon en t s are t he res pons ibilit y of t h e Su pplier. Us e of DCC
con t ain er s for t h is pu r pos e is cons idered mis appr opr iat ion of DCC
cor por at e as s et s and is unac cept able. If t h e PSO Team detect s a
con t ain er violat ion du r in g t h e PSO On -Sit e Vis it , Elemen t 9 Par t s
Han dlin g Plan on t h e PSO SUMMARY REPORT s h a ll be mar ked
REJ ECT in t h e Pr oces s colu mn a n d an explan at ion added t o t he
COMMENTS SHEET.

9 . 4 Th e plan s h all in clu de t h e pr ocedu r es for in -pr oces s r aw mat er ial
r e-s t ock (e. g. Kan - Ban ) a n d in ven t or y con t r ol (e. g. FIFO).

9 . 4 . 1 Mat er ial s t or age locat ion s s h all be clear ly iden t ified.

9 . 4 . 2 Wh en FIFO is u s ed as a met h od of in ven t or y con t r ol, t he
Su pplier s h all h ave an effect ive met h od of en s u r in g FIFO s t ock
r ot at ion t h r ou gh ou t t h e man u fact u r in g facilit y

9 . 4 . 2 . 1 Wh en t he t r aceabilit y pr oces s is FIFO-depen den t , t he
Su pplier s s h ippin g pr oces s an d all s u b-t ier s s h all con for m t o
FIFO.

9 . 5 Th e plan s h all h ave a pr ocedu r e by wh ich mat er ial is t r acked an d
t r an s fer red fr om on e pr oces s t o an ot h er (e. g. t r aveler s , r ou t in g car ds ,
et c. )

9 . 5 . 1 In for mat ion s h all in clu de lot n u mber , date, n u mber of pieces
en ter in g/ exit in g t h e oper at ion , n u mber of pieces
r ewor ked/ repair ed, n u mber of pieces s cr apped, oper at ion n u mber
an d s h ift .

9 . 6 All par t s s h a ll h ave lot con t r ol an d t r aceabilit y, t h r ou gh ou t all
s t ages of pr odu ct ion (an d s h ippin g, if applicable), an d be docu men t ed
an d ver ified (cl. 7. 5. 3 & 7. 5. 3.1 of ISO/ TS-16949. ) Lot s ize s h all n ot
exceed one s h ift or one pr odu ct ion r u n , wh ich ever is s maller .
- Par t s Han dlin g Pla n
- Mat er ial h an dlin g
pr ocedu r es
- Con t a in men t Recor ds

25

PARTS HANDLING PLAN, CONT.
9 . 6 . 1 Sor t ed, rewor ked or repair ed mat er ial s h all be t r aceable back
t o t h e s or t, rewor k or repair pr oces s .

9 . 7 Th e plan s h all addr es s con t ain men t of n on -con for min g mat er ial.
Th is s h all als o in clu de t h e u s e of t h e Daimler Ch r ys ler Su pplier
Not ificat ion of Pot en t ial Non con for man ce pr oces s ou t lin ed in t h e
For ever Requ ir emen t s locat ed on t h e COVISINT webs it e.

9 . 7 . 1 Th e plan s h all addr es s par t h an dlin g an d par t iden t ificat ion
for n on con for min g pr odu ct , fr om r eceivin g of ret u r ned mat er ial
back fr om t he cu s t omer t o fin al dis pos it ion .

9 . 7 . 2 Th e plan s h all det ail t h e maximu m amou n t of t ime allowed
for dis pos it ion of qu ar an t in ed pr odu ct .

9 . 7 . 3 Th e Su pplier s h all h ave a locked an d/ or con t r olled area for
h oldin g n on -con for min g, qu ar a n t in ed, or n on -pr odu ct ion pr odu ct
(e. g. en gineer in g s amples . ) Pr odu ct in t h e h oldin g ar ea s h all be
clear ly iden t ified wit h par t n u mber , n u mber of pieces , date
qu ar an t in ed, reas on for qu ar an t in e, an d expected dis pos it ion dat e.

Elect ro-St at ic Dis charge (ESD) Guidelines
9 . 8 An y man u fact u r in g facilit y h a n dlin g compon en t s t h at mu s t be
pr ot ected fr om ESD s h all h ave t h e followin g:
- ESD mat s an d/ or floor s ;
- Heel an d/ or wr is t s t r aps (ESD cert ified s h oes are als o
accept able;)
- ESD t es ter s for oper at or s t o ver ify h eel an d wr is t s t r aps , an d/ or
s h oe effect ivenes s . All ESD t es ters s h all h ave u p-t o-dat e oper at or
in s t r u ct ion s an d be in clu ded in t h e calibr at ion pr ocedu r es an d
s ch edu le, as well as t h e Preven t ive Main t en an ce plan ;
- Clear ly-iden t ified ESD con t ain er s (e. g. bags , t otes , et c. ) for ESD
s en s it ive pr odu ct t o be t r an s por ted t o an d fr om t h e lin e, an d in -
pr oces s ;
- ESD wor kben ches t h at are gr ou n ded wit h plu gs for wr is t s t r aps
(if applicable);
- ESD gloves an d/ or fin ger cot s for h an dlin g of PCB's (e. g. reject s . )

9 . 8 . 1 All ESD oper at or s s h all be pr oper ly t r ain ed an d be iden t ified
in s ome way (e. g. badges , bu t t on s , et c. )

9 . 8 . 2 Wor k in s t r u ct ion s for ESD t es ter s s h all man dat e t es t in g of
ever yon e as t hey en ter t h e ESD produ ct ion floor .

9 . 8 . 3 An ESD cer t ificat ion s ch edu le s h all exis t wh ich man dat es
r ecer t ificat ion of all ESD equ ipmen t , t ools , tes ter s , con t ain er s , an d
pers on n el on an an n u a l bas is (min imu m. ) Recor ds of t he
cer t ificat ion an d t h e recor ded meas u r emen t s s h all be kept .

9 . 8 . 4 Th e ESD man u fact u r in g pr oces s s h all be in clu ded in t h e
Su pplier s Layered Pr oces s Au dit plan .

26
OPERATING INSTRUCTIONS
1 0 . 1 Oper at or , s et -u p, ch an geover , 1
s t
piece appr oval, mis t ake
pr oofin g, rewor k/ repair , gage oper at in g, in s pect ion an d packagin g
in s t r u ct ion s s h all be appr oved and s ign ed by t h e appr opr iat e Su pplier
depar t men t s (e. g. Qu alit y, En gin eer in g, Man u fact u r in g, et c. ) Th ey
s h all be dated an d t r aceable t o t he level of par t s bein g pr odu ced, an d
s h all in clu de s ample s izes an d frequ en cies .

1 0 . 1 . 1 Special ch ar act er is t ics s h all be iden t ified in t h e appr opr iat e
in s t r u ct ion s .

1 0 . 1 . 2 All in s t r u ct ion s s h all en able an y adequ at ely t r ain ed per s on
t o perfor m t h e des cr ibed oper at ion .

1 0 . 2 Th e Su pplier s h all h ave a proces s for t r ain in g an d qu alifyin g
oper at or s pr ior t o oper at or s perfor min g pr odu ct ion pr oces s es (e. g.
clas s es , men t or s h ip, tempor ar y s u per vis ion , et c. ). Oper at or t r ain in g
s h all be docu men ted an d main t ain ed.

1 0 . 2 . 1 A lis t of t r ain in g r equ ir emen t s for each u n iqu e wor ks t at ion
s h all be main t ain ed.

1 0 . 2 . 2 Vis u a l in s pect ion s t at ion s s h all h ave met h ods es t ablis h ed
t o ver ify t he oper at or s abilit y t o fin d defect s (e. g. per iodic tes t in g,
r ecer t ificat ion , et c. )

1 0 . 2 . 3 Oper at ion s requ ir in g s pecial cer t ificat ion s h all be iden t ified
an d oper at or s cer t ified t o perfor m t h at oper at ion s h all be iden t ified
(e. g. rewor k/ repair . )

1 0 . 3 All in s t r u ct ion s , con t r ol ch ar t s , defect t r ackin g s heet s , log
s h eet s , an d react ion s s h all be locat ed adjacen t t o t he pr oces s , vis ible
t o t h e oper at or an d legible (referen ce TS-16949, cl. 7. 5. 1. 2 Wor k
In s t r u ct ion s . ) Vis u al ma n agemen t t ech n iqu es (e. g. dis plays , pict u r es ,
diagr ams , et c. ) s h all be u s ed when ever pos s ible.

1 0 . 3 . 1 Sa mple par t s u s ed as vis u al dis plays s h all be iden t ified an d
main t a in ed t o t he cor rect revis ion level. Th e Su pplier s h all als o
h ave a pr ocedu r e wh ich per iodically ver ifies t he con dit ion of
des ign at ed con for min g Bou n dar y s amples t o en s u re t he s amples
ar e s t ill accept able.

Rework and Repair Ins t ruct ions and Proc edures
1 0 . 4 Th e DCC PSO team s h all appr ove all rewor k an d repair
oper at ion s , pr ocedu res an d wor k in s t r u ct ion s .

1 0 . 4 . 1 All r ewor ked/ repair ed pr odu ct s s h all be clear ly an d
u n iqu ely iden t ified. See Elemen t 9 Par t s Han dlin g Pla n .
- Oper at or in s t r u ct ion s
- Set u p s heets
- In s pect ion in s t r u ct ion s
- 1
s t
piece appr oval
in s t r u ct ion s
- Mis t ake pr oofin g
in s t r u ct ion s
- Rewor k/ repair
in s t r u ct ion s
- Oper at or Qu alifica t ion
pr oces s
- Gage in s t r u ct ion s

27
OPERATING INSTRUCTIONS, CONT.
1 0 . 4 . 2 Th e rewor k/ repair pr ocedu r e an d in s t r u ct ion s s h all s t a t e
t h at wh en a s u b-compon en t is replaced wh ich h as Safet y <S>
ch ar act er is t ics an d a n ew s u b-compon en t is in s t alled, t he lot fr om
wh ich t h e replacemen t s u b-compon en t came s h all be iden t ified
an d it s h all be lin ked on e-t o-on e wit h t h e fin al as s embly or lot on
wh ich t h e s u b-compon en t was u s ed.

1 0 . 4 . 3 Th e rewor k/ repair pr ocedu r e an d in s t r u ct ion s s h all s t a t e
t h at wh en a s u b-compon en t is removed fr om an as s embly wh ich
h as been ret u r n ed fr om a DCC facilit y wh ich is t o be re-u s ed in
an ot h er as s embly, t h e lot code of all s u b-compon en t s wit h Safet y
<S> ch ar act er is t ics s h all be iden t ified an d lin ked on e-t o-on e wit h
t h e new as s embly or lot in wh ich t h e compon en t will be u s ed.

1 0 . 4 . 4 Th e rewor k/ repair pr ocedu r e an d in s t r u ct ion s s h all r equ ir e
t r aceabilit y an d/ or par t iden t ificat ion in t h e even t t h at an y par t
r et u r ned fr om a DCC as s embly plan t is t o be re-s en t wit h ou t
r ewor k or per for med (e. g. par t s s or t ed as good fr om a ret u r n ed,
qu ar an t in ed lot . )

28

TOOLING, EQUIPMENT, AND GAGES IDENTIFIED
1 1 . 1 Th e Su pplier s h all es t ablis h a t oolin g lis t wh ich in clu des all
pr odu ct ion , in t er im, an d/ or t empor ar y t oolin g an d equ ipmen t u s ed in
t h e pr odu ct ion pr oces s .

1 1 . 1 . 1 Th e lis t s h all in dicat e own ers h ip (e. g. Su pplier owned, ot her
OEM, et c. ) for each it em lis ted.

1 1 . 2 All DCC own ed t oolin g, fixt u r es , an d gages s h all be clear ly an d
per man en t ly mar ked wit h t h e s ame t ool n u mber as iden t ified on t h e
Su pplier Tool Recor d (STR) an d t h e Tool Pu r ch as e Or der, an d be
iden t ified Pr oper t y of Daimler Ch rys ler . Th e met h od u s ed t o mar k th e
t ools s h all be n on -degr adable an d firepr oof (pain t , in k, paper t ags , et c.
ar e u n accept able met h ods of mar kin g. ) All t oolin g, equ ipmen t , gages
an d fixt u r es s h all pos s es s u n iqu e iden t ificat ion n u mber s . Referen ce
ISO/ TS-16949 cl. 7. 5. 4 Cu s t omer Pr oper t y an d t he DCC Pu r ch as e
Or der . Th e STR can be obt ain ed fr om t h e DCC Bu yer .

1 1 . 2 . 1 Gages s h all be man u fact u r ed an d appr oved per t he
DCC gage s t an dar ds iden t ified on t h e Advan ce Man u fact u r in g
En gin eer in g (AME) webs ite h t t p:/ / ame. ct c. ch r ys ler. com/ gages .

1 1 . 2 . 2 Ver ificat ion of t h e STR aga in s t t h e Su pplier s
man u fact u r in g facilit y s h a ll be per for med by t he PSO team du r in g
t h e PSO On -Sit e Vis it . In t h e event t oolin g, gages an d/ or fixt u res
r es ide at t he Su pplier s s u b-t ier, th e s u b-t ier locat ion s h all be
in dicat ed on t h e STR.

NOTE: Daimler Ch r ys ler owned t oolin g s h a ll be u s ed for t h e
pr odu ct ion of Daimler Ch r ys ler produ ct (s ) on ly.

1 1 . 3 All t oolin g, fixt u r es , equ ipmen t an d gages u s ed in t h e
man u fact u r in g pr oces s (e. g. fr om t h e labor at or y, pr odu ct ion , t ool
r oom, main t en an ce, qu alit y, et c. ) s h all be iden t ified in t he Su pplier s
main t en an ce, s t or age, an d calibr at ion pr ocedu res .
- Toolin g lis t
- Su pplier Tool Recor d
(STR)

29
SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC
1 2 . 1 A lis t of s pecial ch ar act er is t ics s h all be developed u s in g DCC
in pu t as well as Su pplier kn owledge of t he pr odu ct . Special
ch ar act er is t ics are pr odu ct ch ar act er is t ics or man u fact u r in g pr oces s
par amet er s wh ich can affect s afety or complian ce wit h regu lat ion s , fit ,
fu n ct ion , perfor man ce or s u bs equ en t pr oces s in g of pr odu ct . Th ey
in clu de all gover n men t al, Key (diamon d) <D>, an d Sh ield (s afet y <S>
an d emis s ion s <E>) ch ar act er is t ics . Tor qu e requ ir emen t s an d
ch ar act er is t ics iden t ified as SPC poin t s on t h e des ign model s h all als o
be con s idered s pecial ch ar act er is tics . Ot her ch ar act er is t ics deemed
cr it ical t o t h e pr oces s or en d-item as s embly may als o be des ign at ed as
s pecial ch ar act er is t ics by t h e Su pplier an d/ or PSO Team. Referen ce
t h e AIAG PPAP (4
t h
ed. ) man u a l a n d cl. 4. 2. 1. 3, 4. 2. 1.4, an d 4. 2.1.5 of
t h e DCC Cu s t omer -Specific Requ ir emen t s for ISO/ TS-16949.

1 2 . 1 . 1 All s pecial ch ar act er is t ics s h all be n oted on all applicable
qu a lit y docu men t s (e. g. Con t r ol Plan , DFMEA, PFMEA, DVP&R,
an d s et -u p an d oper at or in s t r u ct ion s h eet s ).

1 2 . 1 . 2 Th e Su pplier s h all h ave docu men t ed defin it ion s of in t er n al
s pecial ch ar act er is t ics an d t h e requ ir emen t s for s elect ion , con t r ol
an d mon it or in g of t h em.

1 2 . 2 . All s pecial ch ar act er is t ics s h all be in clu ded in t he
MEASUREMENT SYSTEM REPORT an d t h e INITIAL PROCESS STUDY.
See Elemen t 15 Eviden ce of Pr odu ct Specificat ion s an d Elemen t 20
In it ial Pr oces s St u dy.

1 2 . 3 For s pecial ch ar act er is t ics not iden t ified as Safet y (<S>)
ch ar act er is t ics or SPC poin t s on th e des ign model, SPC is n ot requ ir ed
u n les s s pecified by t he PSO team.

Safe t y Charact eris t ics
1 2 . 4 A s ys t em s h all be es t ablis h ed an d main t ain ed t o t r ack Safet y
(<S>) r elated act ivit ies in clu din g a lis t in g of all Safet y (<S>)
ch ar act er is t ics (als o r efer red t o as a Mas t er Tr ackin g Lis t ). Th is lis t is
u s ed t o pr ovide over all Safet y relat ed coor din at ion an d t o as s is t in
developin g pr imar y an d s econ dar y meas u remen t s . En gin eer in g
St an dar ds s h all be s h own or referen ced on affected pr ocedu res an d
wor k in s t r u ct ion s for pr oces s in g an d ver ificat ion du r in g pr odu ct ion .

1 2 . 4 . 1 Th e Su pplier s h all u s e SPC repor t in g for all Safet y (<S>)
ch ar act er is t ics t h at s h all be made available t o DCC repres en t at ives
u pon r equ es t . Refer t o PF-SAFETY for addit ion al r equ ir emen t s an d
in for mat ion r egar din g Safet y (<S>) ch ar act er is t ics .

1 2 . 4 . 1 . 1 Each Safet y (<S>) des ignat ion s h all h ave bot h a
(100%) pr imar y meas u r emen t pr oces s an d a s econ dar y QC
Au dit meas u r emen t pr oces s des ign ed t o main t ain lot con t r ol.

1 2 . 4 . 1 . 1 . 1 Th e pr imar y meas u remen t is per for med by
pr odu ct ion oper at or s or s killed t rades / Man u fact u r in g
En gin eer in g (ME) pers on n el for r obot ics , equ ipmen t , dies ,
fixt u r es , t ools , gages , et c. as determin ed locally.
- Lis t of s pecial
ch ar act er is t ics
- PPSR (Pr e-Pr odu ct ion
Sample Repor t )
(MANDATORY
ENGLISH DOC)
- FPSC (Fir s t
Pr odu ct ion Sh ipmen t
Cer t ificat ion )
(MANDATORY
ENGLISH DOC)

30

SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC, CONT.
1 2 . 4 . 1 . 1 . 2 Th e s econ dar y meas u r emen t s (QC Au dit ) s h all
h ave Qu alit y Au dit or s perfor min g vis u al a n d/ or ph ys ical
ch ecks at s pecific s ample s izes an d frequ en cies an d
r ecor din g res u lt s on s t at is t ical ch ar t s .

1 2 . 4 . 1 . 1 . 3 Th e accept able checkin g met h od, s ample s ize
an d s ample frequ en cy for es t ablis h in g lot con t r ol wit h in t h e
Su pplier s facilit y s h all be deter min ed by t he Su pplier s
Con t r ol Plan an d/ or as dir ected by DCC.

1 2 . 4 . 2 A pr oces s s h all be in place an d main t ain ed wh ich t r acks
an y n on -con for ma n ces related t o a Safet y (<S>) ch ar act er is t ic
in clu din g pr oper cor rect ive act ion n ot ificat ion , implemen t at ion
ver ificat ion , an d car r yin g for war d les s on s lear ned (t o be in clu ded in
FMEAs , con t r ol plan s , exis t in g an d fu t u r e DCC pr ogr ams , et c. )

1 2 . 4 . 2 . 1 Detect ion of an y n on -con for man ce du r in g s ample
ver ificat ion s s h all r es u lt in t h e immediat e qu ar an t in e of all
pr odu ct , wit h dis pos it ion deter min ed by t he PSO Team.

1 2 . 4 . 3 Per iodic s ys tem au dit s relat ed t o Safet y ch ar act er is t ics
s h all be per for med as a par t of t he over all con t r ol plan OR as
s pecified by DCC. In addit ion , DCC may perfor m au dit s an d/ or
elect t o h ave a t h ir d par t y au dit complet ed.

Firs t Product ion Shipme nt Ce rt ificat ion (FPSC) Plan
1 2 . 5 Th e FPSC plan requ ir es t h e Su pplier t o pr ovide s t at is t ical
eviden ce of con for man ce t o s pecial ch ar act er is t ics . Cer t ificat ion is for
a min imu m of t h e fir s t 2000 par t s s h ipped t o each DCC or ot h er
des ign at ed plan t , or a s pecified t ime per iod as iden t ified by t h e DCC
PSO t eam, fr om each Su pplier pr odu ct ion lin e an d cavit y. 100% of t h e
FPSC par t s ar e t o be in s pected for con for man ce t o s pecial
ch ar act er is t ic requ ir emen t s . Th e FPSC qu an t it y may be adju s t ed by
t h e DCC PSO team bas ed on s u ch fact or s as low pr odu ct ion volu mes ,
et c. Referen ce t he in t er n al DCC pr ocedu re PSSP0106 Fir s t
Pr odu ct ion Sh ipmen t Cer t ificat ion (FPSC). Su pplier s do n ot h ave
acces s t o t h is pr ocedu r e an d s h ou ld con t act t h eir DCC ASQP
Specialis t for addit ion al in for mat ion .

1 2 . 5 . 1 Th e Su pplier s h all pr ovide t h e FPSC plan for PSO team
appr oval at t h e Pre-PSO meet in g.

1 2 . 5 . 2 All par t s an d compon en t s , regar dles s of r is k or AQP act ivit y
level, s h all meet FPSC requ ir emen t s .

1 2 . 5 . 3 All complet ed FPSCs for Collabor at ive an d Directed AQP
act ivit y level pr ogr ams s h all be reviewed wit h t h e DCC PSO team.

31
ERROR AND MISTAKE PROOFING
1 3 . 1 Th e Er r or an d Mis t ake Pr oofin g Plan s h a ll des cr ibe h ow t he
Su pplier addres s es er r or pr oofin g an d mis t ake pr oofin g fr om an
or gan izat ion a l level.

NOTE: Er r or pr oofin g elimin at es , by des ign , t he pos s ibilit y of
pr odu cin g a s pecific defect . Mis t ake pr oofin g iden t ifies err or s in
pr odu ct ion a n d pr even t s t hem fr om becomin g n on -con for ma n ces .

1 3 . 1 . 1 Th e plan s h all in clu de t he creat ion of Ver ificat ion Samples
for ver ificat ion of mis t ake pr oofin g. Th es e s h all in clu de all failu r e
modes iden t ified in t he DFMEA an d PFMEA.

1 3 . 1 . 2 Ver ificat ion Samples s h all be ver ified on t he pr odu ct ion lin e
as frequ en t ly as needed t o en s u re mis t ake pr oofin g is oper at ion a l.
Fr equ en cy of ver ificat ion s h all t ake in t o accou n t s t ar t of s h ift ,
pr odu ct ion ch a n geover , major dis r u pt ion s , t oolin g ma in t en an ce,
et c. Ver ificat ion s h all occu r on ce per s h ift or per pr odu ct ion
ch an geover (wh ichever is more frequ en t ) at min imu m. See Elemen t
14 Layered Pr oces s Au dit Plan , cl. 14. 7. 2 an d t h e DCC Cu s t omer -
Specific Requ ir emen t s for ISO/ TS-16949 cl. 4. 2. 9. 1.

NOTE: It is s t r on gly recommen ded t h at er r or an d mis t ake pr oofin g
ver ificat ion als o occu r wh enever t h e pr odu ct ion lin e exper ien ces an
u n plan n ed dis r u pt ion an d/ or down -t ime.

1 3 . 1 . 3 All Ver ificat ion Sa mples s h all be clear ly mar ked, labeled
an d con t r olled t o preven t mixin g wit h pr odu ct ion mat er ials . Th ey
s h all be s t ored s epar ate fr om WIP or fin is h ed pr odu ct in a clear ly
mar ked con t ain er or des ign at ed ar ea.

1 3 . 1 . 4 Er r or an d Mis t ake Pr oofin g s oft ware s h all be tes ted for all
pos s ible failu r es an d bypas s s cenar ios .

1 3 . 2 Lin e or s t at ion lock ou t s h a ll be implemen ted in t h e
man u fact u r in g pr oces s at all s t eps t o preven t failed oper at ion s fr om
pr oceedin g t o a s u bs equ en t s t at ion or in t o fin is h ed pr odu ct . Au dible
an d vis u al in dicat or s s h a ll n ot ify of t h e failed oper at ion .

1 3 . 2 . 1 A con t in gen cy plan s h all be docu men ted in t he even t t h e
pr odu ct ion mis t ake pr oofin g is n ot oper able. A vis u al an d/ or
au dible aler t s h all s ign ify t h e mis t ake pr oofin g is in oper able. Th e
plan s h all in clu de n ot ificat ion of t h e DCC ASQP Specialis t per t h e
For ever Requ ir emen t s .

1 3 . 3 Er r or an d/ or mis t ake pr oofin g s h all exis t for all failu r e modes
wit h s ever it y of 8 an d h igh er in t h e PFMEA an d DFMEA.

1 3 . 4 Er r or an d/ or mis t ake pr oofin g s h all be u s ed on all s pecial
ch ar act er is t ics .

1 3 . 5 All r ewor ked or repaired pr odu ct s h all pas s t h r ou gh er r or an d
mis t ake pr oofin g equ ivalen t t o t h a t on t h e pr imar y pr odu ct ion lin e.
- Er r or an d Mis t ake
Pr oofin g Plan
- Lis t of er r or an d
mis t ake pr oofin g
implemen ted by
oper at ion n u mber
- Er r or an d Mis t ake
Pr oofin g s t u dies
- Mis t ake Pr oofin g
Con t in gen cy Plan

32
ERROR AND MISTAKE PROOFING, CONT.
1 3 . 6 Er r or an d mis t ake pr oofin g ver ificat ion s h all be addres s ed in t h e
Pr even t ive Main t en an ce Plan .

1 3 . 7 Sequ en t ial s en s in g s h all be u s ed when t he pr oces s u t ilizes
ph ys ically in depen den t cells makin g u p on e pr oces s flow.

1 3 . 8 An y s t a t ion u s ed as a fin al ver ificat ion (e. g. en d-of-lin e (EOL)
t es ter, vis ion s t at ion , et c. ) s h all leave a u n iqu e, iden t ifiable mar k
in dicat in g t h a t t h e par t h as s u cces s fu lly pas s ed t h r ou gh t h e en t ire
pr oces s . Er r or an d/ or mis t ake proofin g s h all en s u r e t h at par t s can n ot
s kip t h is oper at ion .

1 3 . 8 . 1 Mis t ake pr oofin g s h all ver ify t h at t h e en d-item as s embly is
complete wit h cor rect con ten t .

NOTE: Ver ifyin g t h at t h e compon en t is in t h e mach in e pr ior t o
as s embly, an d t h en as s u min g it is on t h e fin is h ed pr odu ct after t h e
mach in e cycle is n ot accept able.

1 3 . 9 All fu n ct ion s , effor t s an d t r avel s h all be exer cis ed an d meas u r ed
100% on lin e t o t heir fu ll exten t .

1 3 . 1 0 All s u b-compon en t s , wh ich ar e s or ted for s pecific applicat ion
(con t en t or fu n ct ion ), s h all h ave 100% ver ificat ion of pr oper par t
s elect ion t h r ou gh er r or an d/ or mis t ake pr oofin g.

1 3 . 1 1 All cylin der s applyin g compon en t s or per for min g s t akin g s h all
be ver ified for fu ll s t r oke.

1 3 . 1 2 Ma n u fact u r in g pr oces s es (e. g. In ject ion Moldin g, Weldin g, Heat
s t akin g, et c. ) s h all h ave con t r ollers (e. g. RJ G, MACO et c. ) wit h clos ed
loop feedback s ys tems an d pr oces s limit s es t ablis h ed.

1 3 . 1 3 All cr it ica l lu br ica t ion , adh es ive poin t s , liqu ids an d gas es s h all
be au t omat ed an d h ave er r or an d mis t ake pr oofin g for pr oper flow,
amou n t , an d locat ion .

1 3 . 1 3 . 1 Leak tes t in g for liqu ids a n d gas s h all be au t omat ed
an d meas u r ed 100% on line.

1 3 . 1 4 As s embly mach in es t h at accommoda t e r igh t an d left par t s in
t h e s ame pr oces s s h all h ave er r or an d/ or mis t ake pr oofin g t o preven t
as s embly an d packin g er r or s .

NOTE: Th e pr oces s flow s h all accommodat e s epar ate pat h s of r igh t
an d left par t s if deemed neces s ar y by t he PSO team.

1 3 . 1 5 Th e Su pplier s h all h ave er ror an d/ or mis t ake pr oofin g t o
pr even t loos e foreign object s in as s embly.

33

ERROR AND MISTAKE PROOFING, CONT.
Requireme nt s for Elect ri cal Compone nt s
1 3 . 1 6 All elect r ical con n ect ion s s h all h ave a pos it ive deten t t h at can
be iden t ified t h r ou gh au dio, t act ile or vis u al feedback.

1 3 . 1 7 All elect r ical compon en t s an d con n ect ion s s h all h ave con t in u it y
an d fu n ct ion al ch eck wit h au t omat ed lin e s t op/ lockou t if con t in u it y is
n ot ach ieved t o ver ify in tegr it y of th e con n ect ion .

1 3 . 1 8 When makin g ter min al cont act for in -proces s man u fact u r in g
(har nes s as s embly, en gine tes t ing, device tes tin g, etc.) t he following
requ irements s h all be followed:
- Pogo pins s h all n ot violate the con t act area of t he terminal(s )
bein g tes ted;
- Pogo pins s h all be main t ained and ins pected regu larly;
- The tes t fixt u re s h all provide feat u res to align t he con nect or t o
the tes t fixt u re prior t o engagement of the pogo pins ;
- When pogo pin acces s is not pr ovided and s prin g member
cont act is the on ly opt ion, t he probe u s ed t o con t act t he termin al
s pr in g member s h all be s maller in th icknes s t han t he min imu m
blade t h icknes s (inclu ding t oler an ces ) of the ter min al being
tes ted. If rou n d pin termin als are bein g tes ted, t he male pin
probe s h all be s maller t h an the min imu m diameter (inclu ding
toler an ces ) of t he pin;
- The dept h of ins ert ion of the pr obe s h all be the min imu m dept h
requ ired to make electr ical con t act for tes tin g.

Requireme nt s for Modules / Sequenced Part Delivery (SPD)
1 3 . 1 9 Bar codes an d/ or pick ligh t s wit h break beams (or equ ivalen t )
s h all be u s ed t o en s u r e t he cor rect par t is picked an d as s embled per
t h e br oadcas t .

1 3 . 2 0 Vis ion s ys t ems or color s ens in g s h all en s u r e cor rect color
mat ch of compon en t s , an d cor rect compon en t s (where applicable).

1 3 . 2 1 Pu s h click pu ll met h od s h all be u t ilized for all elect r ical an d
ot h er applicable con n ect ion s .

1 3 . 2 2 SPD par t s equ en ce s h all be main t ain ed t h r ou gh ou t t h e en t ir e
pr oces s , in clu din g r ewor k an d repair .

1 3 . 2 3 Th e Su pplier s h all h ave redu n da n t s ys t ems t o ens u r e receipt of
br oadcas t .

1 3 . 2 4 Compon en t s wit h Safet y <S> ch ar act er is t ics s h all be t r aceable
t o t h e VIN s equ en ce.

1 3 . 2 5 An as s embly requ ir in g r ebroadcas t du e t o a n on -r epair able
con dit ion s h all h ave addit ion al t r ackin g t o main t a in s equ en ce an d
t imely deliver y.

34
LAYERED PROCESS AUDIT PLAN
1 4 . 1 Layered Pr oces s Au dit (LPA) is a s ys tem of au dit s perfor med by
mu lt iple levels of man agemen t per t h e Su pplier s or gan izat ion ch ar t .
Special ch ar act er is t ics (an d ot h er ch ar act er is t ics des ign at ed by t he
Su pplier an d/ or PSO Team) ar e au dit ed t o ver ify pr oces s con for man ce.
Th e pu r pos e of LPA is t o en s u re con t in u ou s con for man ce t h ereby
impr ovin g pr oces s s t abilit y an d fir s t -t ime capabilit y. Referen ce t he
DCC Cu s t omer -Specific Requ iremen t s for ISO/ TS-16949 cl. 4. 2. 9.1
an d t h e LPA Fundamentals cou r s e (available t h r ou gh TEDS) for
addit ion al LPA r equ ir emen t s .

1 4 . 2 Th e LPA plan s h all h ave pr ocedu r es an d wor k in s t r u ct ion s for
each level of man agemen t wh ich det ails t h eir r oles an d
r es pon s ibilit ies . Th e plan s h all a ls o addr es s h an dlin g of n on -
con for man ces dis covered du r in g th e au dit an d in clu de a det ailed
s ch edu le frequ en cy an d s t r u ct u r e ch ar t .

1 4 . 3 Th e LPA plan s h all r equ ir e top man agemen t reviews of LPA
r es u lt s . It s h all s t at e t he frequ ency of man agemen t reviews an d
r equ ir e docu men ted meet in g min u t es an d/ or open is s u es .

1 4 . 4 Th e Su pplier s h all complete a Pr oces s Con t r ol Au dit Ch ecklis t
an d an Er r or an d Mis t ake Pr oofin g Ver ificat ion Au dit Ch ecklis t .
Examples of each can be fou n d in t h e LPA cou r s e t r ain in g man u a l.

1 4 . 4 . 1 Th e Pr oces s Con t r ol Au dit s h all be done on ce per s h ift (or
as agr eed t o by t h e PSO Team) by a gr ou p leader , s u per vis or , et c.
Man agemen t au dit s s h all be done weekly. Man u fact u r in g ar eas
s h all be divided an d au dit or s r ot a t ed s o t h at all ar eas are in clu ded.

1 4 . 4 . 2 Th e Er r or an d Mis t ake Pr oofin g Ver ificat ion Au dit s h all be
don e on ce per s h ift or pr odu ct chan ge-over (wh ich ever comes fir s t )
an d wh enever an u n s ch edu led dis r u pt ion occu r s in t h e pr odu ct ion
lin e. Th e au dit mu s t be perfor med by qu alified, t r ain ed pers on n el
on ly. Referen ce Elemen t 13 Er r or an d Mis t ake Pr oofin g cl. 13. 1. 3.

1 4 . 4 . 3 Aft er PSO appr oval, n o item s h all be removed fr om t he LPA
ch ecklis t s wit h ou t t h e DCC ASQP Specialis t s appr oval r egar dles s
of in it ia l AQP Act ivit y Level.

1 4 . 4 . 4 All n on -con for man ces dis covered at DCC man u fact u r in g
facilit ies (at an y pr ogr am s t age) s h all be in clu ded in t he LPA.

1 4 . 5 Th e Su pplier s h all demon s t r at e at leas t on e level of an LPA
du r in g t h e PSO On -Sit e Vis it . Th e au dit s h all be on t h e pr oces s
u n der goin g t h e PSO; for PSO vis it s on mu lt iple par t s , t he LPA review
s h all in clu de ever y pr oces s , n ot n eces s ar ily ever y par t .

1 4 . 6 Th e Su pplier s h all ma in t ain a lis t of t r ain ed LPA Team
member s wh o s h all be res pon s ible for developin g, implemen t in g an d
u pdat in g t h e LPA plan . Th e Team s h all als o be res pon s ible for
u ploadin g on -goin g LPA r es u lt s in t o Power way. com qu ar t er ly.

NOTE: On -goin g LPA r es u lt s are NOT a requ ir emen t for PSO appr oval.
- LPA pr ocedu res
- LPA wor k in s t r u ct ion s
- LPA St r u ct u r e an d
Fr equ en cy Ch ar t
- LPA Pr oces s Con t r ol
Au dit Ch ecklis t
- LPA Er r or Pr oofin g
Ver ificat ion Au dit
Ch ecklis t

35

SUPPLIER READINESS EVALUATION AND EVIDENCE OF PRODUCT SPECIFICATIONS
Supplier Readines s Evaluat ion (SRE)
1 5 . 1 Pr ior t o t h e Pre-PSO Meet in g, t he Su pplier, wit h con cu r ren ce
fr om t h e DCC PSO team, s h all deter min e par t qu an t it y for t h e
Su pplier Readin es s Evalu at ion (SRE) r u n . Addit ion a lly, t h e PSO team
s h all deter min e (an d agree u pon ) t h e requ ired Line Speed (s ee 16. 1.1),
as well as t he n u mber of compon en t s an d ch ar act er is t ics t o be
in s pected. SRE res u lt s s h all be recor ded on t he DCC SUPPLIER
READINESS EVALUATION for m, u ploaded in t o Powerway. com, an d
r eviewed by t he DCC PSO Team before or du r in g t h e Pre-PSO Meet in g.
Th e DCC PSO Team s h all deter min e SRE res u lt s t o be accept able
before s chedu lin g t h e PSO On -Sit e Vis it .

NOTE: Th e Su pplier s h all pres en t SRE res u lt s for each pr odu ct ion
lin e an d/ or t ool.

1 5 . 2 Th e Su pplier s h all con du ct SRE act ivit ies on t h e lat es t releas ed
Pr odu ct ion Par t Nu mber (s ) wit h an appr oved Pu r ch as e Or der (P. O. )
Th e s t at ed par t n u mber level(s ) s h all h ave a cor res pon din g Pr odu ct ion
Tool P. O. , wit h relat ed t oolin g capable of meet in g t h e requ ir ed capacit y
an d as s ociat ed lin e s peed(s ).

1 5 . 2 . 1 All t oolin g an d equ ipmen t s h all be at pr odu ct ion level,
u n les s ot h erwis e appr oved, in wr it in g, by t h e DCC PSO team and
DCC ASQP Man ager before t h e SRE is r u n .

1 5 . 3 Du r in g t h e SRE r u n , t he Supplier s hall meas ure and
docume nt all c haract e ris t ics on all part s per t he Cont rol Plan,
regardles s of s t at ed Cont rol Plan frequency (e. g. meas u red on ce per
s h ift et c. )

1 5 . 3 . 1 Pr oces s perfor man ce calcu lat ion s (P
P
an d P
PK
) ar e requ ired
for all s pecial ch ar act er is t ics . Refer en ce Elemen t 12 Special
Pr odu ct an d Pr oces s Ch ar act er is t ics .

1 5 . 3 . 2 In t he cas e of mu lt iple pr odu ct ion lin es an d t ools , pr oces s
perfor man ce calcu lat ion s ar e requ ir ed for each lin e an d/ or t ool.
Th es e perfor man ce valu es will be u s ed as an in dicat ion of t h e
begin n in g per for man ce.

Meas urement Sys t em Report
1 5 . 4 Du r in g t h e PSO On -Sit e Vis it , PSO Team member s are requ ir ed
t o r an domly s elect an d wit n es s t he meas u remen t of pr odu ct an d/ or
pr oces s ch ar act er is t ics (ot h er t h an t h os e on t he en d-item
as s embly)u t ilizin g t h e MEASUREMENT SYSTEM VERIFICATION
REPORT for m. Th is au dit is t ypically complet ed before t he Pr odu ct
Demon s t r at ion Ru n .
Examples :
- St ock t h ickn es s for a s t amped par t
- Mois t u r e con t en t , mold pres s u re or t emper at u re for a
molded par t
- Solder -abilit y, dimen s ion a l ch ecks or reflow oven pr ofile
for an elect r on ic pr in t ed cir cu it boar d as s embly
- Su pplier Readin es s
Evalu at ion (SRE) Ru n
r es u lt s
- Meas u remen t Sys tem
Repor t

36
SUPPLIER READINESS EVALUATION & EVIDENCE OF PRODUCT SPECIFICATIONS, CONT.
1 5 . 4 . 1 Th e PSO team s h all decide t h e ch ar act er is t ics an d qu an t it y
of par t s t o be wit n es s ed for meas u r emen t ver ificat ion pr ior t o t h e
PSO On -Sit e Vis it (s ee below for min imu ms . ) All s pecial
ch ar act er is t ics s h all be in clu ded. Elemen t 12 Special Pr odu ct an d
Pr oces s Ch ar act er is t ics , cl. 12. 2.

1 5 . 4 . 2 A min imu m of 3 ch ar act eris t ics s h all be meas u red.

1 5 . 4 . 3 A min imu m of 30 par t s s hall be s elected.

1 5 . 4 . 4 Th e PSO team s h all determin e if t he meas u r in g pr oces s for
each ch ar act er is t ic iden t ified on t h e repor t is accept able.

1 5 . 4 . 5 . All iden t ified pr oces s an d/ or compon en t n on -
con for man ces , s h all h ave r oot cau s e an alys es perfor med an d
docu men t ed (an d cor rect ive act ion s appr oved by t h e PSO Team)
before PSO appr oval can be given .

37
PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY
1 6 . 1 Du r in g t h e Pre-PSO Meet in g, t he PSO Team (in clu din g t h e
Su pplier ) s h all r eview all plan s for requ ir ed pr odu ct ion r at es . At a
min imu m, t h e PSO Team s h all dis cu s s t h e requ ir ed Line Speed, Daily
Toolin g Capacit y, an d Net Oper at in g Time for DCC Par t s . Th es e
n u mber s s h all be ver ified wit h t he DCC Bu yer.

1 6 . 1 . 1 Th e PSO team s h all en s u re t h e Su pplier meet s t h e P. O.
Daily Toolin g Capacit y an d Oper at in g pat t er n .
NOTE: In s it u at ion s wh ere mu lt iple Pu r ch as e Or der s (P. O. s ) exis t

for t h e s ame par t (as is t he cas e for s ome h igh volu me par t s or
par t s s u pplied t o bot h US an d Mexican DCC as s embly plan t s ), t h e
Daily Toolin g Capacit ies fr om bot h P. O.s s h all be added t oget her
before deter min in g t h e requ ir ed Lin e Speed.
1 6 . 2 Th e Pr odu ct ion Demon s t r at ion Ru n (PDR) s h all be con du ct ed on

all pr odu ct ion lin es of recor d, u s in g pr odu ct ion t ools , pr odu ct ion
pr oces s es , an d fu lly t r ain ed oper at or s .

1 6 . 2 . 1 Th e PDR con s is t s of 300 pieces (i.e. , en d-item as s emblies )
or t wo h ou r s of pr odu ct ion , wh ich ever is mor e s t r in gen t . Th es e
r equ ir emen t s apply equ ally t o cas es in volvin g mu lt iple pr odu ct ion
lin es an d/ or mu lt iple s et s of t ools .

NOTE: Rewor k, repair , an d s cr ap s h all n ot be in clu ded in t he PDR
lin e s peed calcu lat ion . Th e lin e s peed calcu lat ion s h all on ly in clu de
complete as s emblies pr odu ced s u cces s fu lly. If t he lin e is empt y at
t h e s t ar t of t h e PDR, lin e fill t ime s h all n ot be in clu ded. Count
complet ed unit s only, s t art ing wit h t he firs t complet e d
as s embly off t he product ion line.

1 6 . 3 Th e PSO Team s h all wit n es s an d mon it or t h e PSO Lin e Speed
du r in g t h e PDR an d recor d t he dat a on t h e PRODUCTION
DEMONSTRATION RESULTS for m. For mu lt iple pr odu ct ion lin es
an d/ or t ools , t h e line s peed for each lin e an d t ool s h all be recor ded.

1 6 . 4 Pr oces s con s t r ain t s (bot t len ecks ), wh ich may impact qu a lit y
or pr odu ct ion s ch edu les s h all be docu men t ed on t h e COMMENTS
SHEET, an d con t in gen cy plan s s hall be docu men t ed an d s u bmit t ed t o
t h e PSO team for appr oval.

1 6 . 4 . 1 Wh en pr oces s con s t r ain t s ar e at t r ibu t ed t o h igh s cr ap,
r ewor k an d/ or repair (i.e. FTC < 90%), t h e is s u e s h all be
docu men t ed on t h e COMMENTS SHEET an d t h e Su pplier s h all
iden t ify r oot cau s e, implemen t per man en t cor rect ive act ion an d
ver ify cor rect ive act ion wit h a n ew PSO On -Sit e Vis it pr ior t o
r eceivin g A appr oval.
- Lin e s peed calcu lat ion
- Pr oces s con s t r ain t s
an d con t in gen cy plan s
- Fin a l au dit s a mplin g
plan

38
PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY, CONT.
1 6 . 5 Tes t s amples u s ed in Pr odu ct ion Validat ion (PV) t es t in g s h all
come fr om a s u cces s fu l PDR an d PSO On -Sit e vis it . However, t he PSO
Tea m may elect t o u s e tes t s amples fr om an u n appr oved PSO On -Sit e
vis it , pr ovided t he followin g r equ ir emen t s are met:
- All pr oces s an d pr odu ct per for man ce (P
P
an d P
PK
) requ ir emen t s
ar e met ;
- Th e PDR was con du ct ed u s in g t h e Daily Toolin g Capacit y an d
t h e requ ired Line Speed met ;
- All s u b-compon en t s an d mat er ials u s ed in t he PDR h ad an
appr oved PPAP (or equ ivalen t );
- Pr odu ct ion pr oces s es an d t oolin g were u s ed;
- All pr odu ct ion meas u r in g t ools h a d accept able gage R&R
r es u lt s .

1 6 . 6 Par t s made du r in g t h e PDR may be u s ed for PPAP if an d on ly if
all PPAP r equ ir emen t s , in clu din g s t at is t ica l r equ ir emen t s , h ave been
s u cces s fu lly completed.

Firs t Time Capabilit y (FTC)
1 6 . 7 Th e Su pplier s h all demon s t r at e a Fir s t Time Capabilit y (FTC) of
90% or greater. Deviat ion fr om t h is requ ir emen t s h all h ave s igned
appr oval fr om t h e DCC PSO Team and t h e ASQP Man ager .

NOTE: Th e FTC r equ ir emen t applies t o t h e primary pr odu ct ion lin e
on ly. Secon dar y, off-lin e, an d/ or s u ppor t pr oces s es do n ot need t o
meet t he 90% FTC r equ ir emen t , u n les s ot her wis e requ ir ed by t h e PSO
Tea m.

1 6 . 6 . 1 For mu lt iple pr odu ct ion lin es , t ools , an d/ or cavit ies , FTC
s h all be calcu lat ed s epar at ely for each one.

1 6 . 6 . 2 FTC is equ al t o t h e n u mber of accept able par t s pr odu ced
divided by t he n u mber of par t s rejected du r in g t h e PDR (s ee
Appen dix C FTC Calcu lat ion s .

NOTE: Rewor k an d repair are NOT cou n t ed in t he n u mber of
accept able par t s , n or are par t s in it ially r ejected by t he pr oces s bu t
fou n d t o be accept able after re-t es t in g.

39

PARTS PACKAGING AND SHIPPING SPECIFICATIONS
1 7 . 1 Th e par t s packagin g an d s h ippin g plan s h all in clu de t he t ypes of
con t ain er s (expen dable or ret u r n a ble) t h at will be u s ed t o s h ip pr odu ct
t o DCC or DCC-des ign at ed as s embly plan t s .

1 7 . 1 . 1 Specific con t ain er in for ma t ion s h a ll in clu de bu t is n ot
limit ed t o: ret u r n able an d/ or back-u p expen dable, con t ain er
dimen s ion s , con t ain er mat er ial, pieces per con t ain er , weigh t of fu ll
an d empt y con t ain er , n u mber of con t a in er s per pallet, et c.

1 7 . 1 . 2 Sh ippin g an d labelin g in s t r u ct ion s s h all con for m t o t h e
DCC Packagin g an d Sh ippin g In s t r u ct ion s ma n u al. Th is can be
obt ain ed t h r ou gh COVISINT or eCopier (84-263-8537).

1 7 . 1 . 3 Th e Su pplier s h all be res pon s ible for des ign in g,
man u fact u r in g, t es t in g an d docu men t in g expen dable packagin g
t es t dat a (s imu lat ed or act u al).

1 7 . 1 . 4 Tes t in g (e. g. s h aker t able, r ail or over t h e r oad et c. ) s h all
be perfor med bas ed u pon t h e mode of t r an s it .

1 7 . 2 Wh en ret u r n able con t ain er s ar e t o be u s ed, a Ret u r n able
Con t a in er Man agemen t plan s h all be developed wh ich in clu des :
- Tr a in in g an d acces s t o t he Daimler Ch r ys ler Con t ain er
Man agemen t Sys t em (CMS);
- A docu men t ed pr ocedu re for man dat or y dat a en t r y;
- In ven t or y con t r ol t o t r ack con t ain ers on h an d an d in t r an s it ;
- Docu men t ed pr ocedu res for man dat or y t r an s mit t al of con t ain er
an d/ or par t n u mber in for mat ion du r in g ASN s u bmis s ion s fr om
t h e Su pplier s facilit y; an d
- Det ail for iden t ificat ion an d dis pos it ion of con t amin at ed or
damaged con t ain er s .

1 7 . 3 Th e expen dable backu p plan s h all en s u re on -t ime s h ipmen t in
t h e even t of a s h or t age of ret u r n able con t ain er s . Back-u p expen dable
packagin g s h a ll ma in t ain t h e s ame dimen s ion s as t he ret u r n able
con t ain er an d h old t h e s ame n u mber of pieces .

1 7 . 3 . 1 Bot h expen dable an d ret u r n able packagin g s h all be s ized
n ot t o exceed t he DCC as s embly plan t r equ ir emen t of t wo-h ou r -of-
as s embly-plan t -pr odu ct ion per con t a in er . Deviat ion r equ ir es
appr oval fr om DCC MHE.

1 7 . 4 Simu lat ion t es t s an d/ or s h ippin g t es t s s h all be con du ct ed prior
t o S1 St art an d docu men t ed.

1 7 . 5 Wh en DCC des ign ed packagin g is u s ed (i.e., con t ain er s , r acks ,
et c. ), t he Su pplier is n ot res pon s ible for packagin g appr oval(s ).

1 7 . 6 PSO approval s hall not be delayed due t o a lac k of approval(s )
for DCC provided and/ or des igned pac kaging. An y qu es t ion s
con cer n in g appr oval of DCC des ign ed packagin g s h ou ld be refer red t o
t h e DCC Mater ial Han dlin g En gin eer in g gr ou p.
- Par t s packagin g an d
s h ippin g plan
- Packagin g an d
Sh ippin g Pr ocedu r es
- Packagin g, s h ippin g
an d labelin g
in s t r u ct ion s (t h es e
may be in clu ded wit h
Elemen t 10 Oper at in g
In s t r u ct ion s )
- Ret u r n able Con t ain er
Man agemen t Plan
- Bar coded labelin g
pr ocedu r e
- Sh ippin g label
example
- Simu la t ion or
Sh ippin g Tes t Res u lt s

40

PARTS PACKAGING AND SHIPPING SPECIFICATIONS, CONT.
Bar Code Labeli ng
1 7 . 7 Wh en bar code labelin g is don e as t h e fin al oper at ion of t he
as s embly pr oces s (i.e. at en d-of-lin e), t hey s h all be gener at ed one at a
t ime an d on ly followin g s u cces s fu l complet ion of t h e previou s
oper at ion (e. g. after pas s in g an end-of-lin e t es ter , after cor rect
s can n in g of t h e cor rect mat er ial, et c. ) On ly on e label s h all be pr in t ed
at a t ime.

1 7 . 8 Th e Su pplier s h all h ave logic in place t o preven t pr in t in g of
du plicat e bar code labels .

1 7 . 9 Th e Su pplier s h all en s u re (th r ou gh logic or er r or an d/ or mis t ake
pr oofin g) t h at par t bar code labels mat ch t h e par t for s can n in g
pu r pos es .

41

GAGE AND TEST EQUIPMENT EVALUATION
1 8 . 1 All gages u s ed in t h e pr oces s s h all be lis t ed on t h e Con t r ol Plan .

1 8 . 2 Th e Su pplier s h all r efer t o t h e Des ign an d/ or Pr oces s FMEA t o
deter mine t he appr opr iat e gage t o be u s ed (at t r ibu t e or var iable).

1 8 . 3 Th e Su pplier s h all h ave a procedu re t o validat e gages an d tes t
equ ipmen t pr ior t o releas e on t o t h e man u fact u r in g floor . See t he
Meas u remen t Sys tem An alys is AIAG man u a l.

1 8 . 4 All gages an d tes t in g equ ipmen t s h all h ave accept able R&R
s t u dies per for med pr ior t o t h e Pre-PSO Meet in g.

1 8 . 4 . 1 Tot a l R&R as a per cen t of par t t oler an ce s h all be u s ed for
n ew pr oces s es , wh ile t ot al R&R as a per cen t of pr oces s var iat ion
s h all be u s ed for pr oces s impr ovemen t .

1 8 . 4 . 2 Accept able gage R&R as a percen t age of t oler an ce s h all be
les s t h an 10%. Th e gage R&R as a per cen t of s t u dy var iat ion s h all
als o be les s t h an 10%. A gage R&R bet ween 10% an d 30% s h all
r equ ir e appr oval fr om t h e DCC PSO team. A gage R&R equ al t o or
gr eater t h an 30% is u n accept able.

1 8 . 4 . 3 For at t r ibu t e gages t he or gan izat ion s h all complet e a s t u dy
per t he AIAG Meas u r emen t Sys tem An a lys is man u a l or s h all u s e a
min imu m of 50 s amples , t h r ee oper at or s , an d t h r ee s et s of
meas u r emen t s fr om each oper at or . Th e s amples s h all in clu de par t s
t h at ar e clos e t o each s ide of t h e s pecificat ion (s ). All meas u r emen t s
t aken on par t s t h at ar e ou t of s pecificat ion s h a ll in dicat e t h at t h e
par t s ar e t o be rejected.

NOTE: At t r ibu t e gau gin g is on ly a llowed on s pecial ch ar act er is t ics
if appr oved by t he DCC PSO Tea m.

1 8 . 5 For var iable gages , t oler an ces u s ed for 100% ver ificat ion s h all be
r edu ced by t he exten t of Gage R&R.

1 8 . 6 All gages an d tes t equ ipmen t s h all be calibr at ed an d reflect t h e
las t calibr a t ion a n d expir at ion dat es . Calibr at ion s s h all be t r aceable t o
a kn own s ou r ce an d/ or s t an dar d.

1 8 . 7 A calibr a t ion s ch edu le s h all be es t ablis h ed for all gages an d tes t
equ ipmen t . Th ere s h all be det ailed pr ocedu res for calibr at ion of an y
equ ipmen t don e in t er n ally (i.e. at t h e Su pplier. )

1 8 . 7 . 1 Th e Su pplier s h all h ave an effect ive s ys tem t o en s u re t h at
t h e calibr at ion of equ ipmen t is don e per s chedu le. A react ion plan
s h all be es t ablis h ed for con t ain men t of equ ipmen t t h at is ou t of
calibr at ion .

1 8 . 7 . 2 3
r d
par t y s ou r ces u s ed for gage an d tes t equ ipmen t
calibr at ion s h a ll be evalu at ed by th e Su pplier an d be cer t ified t o
ISO/ IEC 17025. See ISO/ TS-16949 cl. 7. 6. 3. 2.
- Gage R&R res u lt s
- Gage layou t r es u lt s
- Gage an d tes t
equ ipmen t validat ion
pr ocedu r e
- Gage an d tes t
equ ipmen t calibr at ion
r ecor ds
- Calibr a t ion s ch edu le

42

PREVENTIVE MAINTENANCE PLANS
1 9 . 1 A Pr even t ive Main t en an ce (PM) plan s h all exis t for all equ ipmen t
an d t oolin g. Th e plan is a livin g docu men t wh ich s h all be reviewed an d
u pdat ed on a regu lar bas is or as cir cu ms t a n ces requ ir e. Referen ce
ISO/ TS-16949:2002 cl. 7. 5. 1. 4 Preven t ive an d Predict ive Main t en an ce.

1 9 . 2 Th e PM plan s h all in clu de s ch edu les , res pon s ibilit ies an d
in s t r u ct ion s for main t ain in g each it em of equ ipmen t . Addit ion ally, t h e
plan s h all ou t lin e h ow all frequ encies were es t ablis h ed for each piece
of t oolin g an d/ or equ ipmen t (e. g., qu an t it at ive h is t or ical dat a of
frequ en cies , mat er ial s pecificat ion s , et c. an d t heir collect ive impact on
equ ipmen t ).

1 9 . 3 PM s ch edu le con for mit y, ma ch in e perfor man ce is s u es an d an y
PM relat ed qu alit y is s u es s h all be r eviewed for pr oces s opt imiza t ion .
Th e PM plan is a livin g docu men t an d s h all in clu de les s on s lear ned
fr om s imilar t oolin g a n d/ or equ ipmen t

1 9 . 4 Th e Su pplier s h all develop a r obu s t PM pr oces s t h at en s u r es
pr even t ive main t en an ce is perfor med per t he es t ablis h ed PM s chedu le.
(e. g. , s oft ware-con t r olled PM t h at t r igger s an aler t when PM is du e).

1 9 . 5 New t oolin g an d/ or equ ipmen t s h all be added t o t h e PM s ch edu le
prior t o product ion releas e.

1 9 . 6 Th e PM plan s h all addr es s s t or age of t oolin g an d equ ipmen t
wh en n ot in u s e. Th is pla n s h all pr ovide a gu idelin e(s ) t o en s u r e DCC
pr oper t y is clean , well pr otected from damage an d en vir on men t al
s t r es s es , pr oper ly main t a in ed an d eas y t o locat e.

1 9 . 7 Each Su pplier s h all en s u r e t h at as t oolin g an d/ or equ ipmen t
appr oach es t he predeter min ed end of life cycle, appr opr iat e act ion s
ar e t aken . Th es e act ion s s h all en s u r e con for mit y t o DCC pr odu ct ion ,
as s embly, an d qu alit y r equ ir emen t s (e. g. in creas ed in s pect ion s ,
en h an ced detect ion meas u r es or met h odologies ).

1 9 . 8 Th e PM plan s h all addr es s 3r d par t y an d/ or ou t s ou r ced PM
act ivit ies when applicable.
- Toolin g a n d/ or equ ipmen t wit h 3rd Par t y ou t s ou r ced PM
act ivit ies s h all be u n iqu ely iden t ified on t he s chedu le.
- Th e 3r d Par t y s ou r ces s h all h ave a PM pr oces s equ al t o or
bet ter t h an t h at of t h e Su pplier .
- PM Plan (in clu des
s ch edu les , frequ en cies ,
in s t r u ct ion s , et c. )

43

INITIAL PROCESS STUDY
2 0 . 1 It is in ten ded t h at 100% of th e par t s fr om PDR be in clu ded in t h e
In it ial Pr oces s St u dy. Where t h is is n ot pr act ical, t h e PSO Team can
deviat e an d ch oos e a lower s ample s ize. All par t s amples u s ed for th e
In it ial Pr oces s St u dy, regar dles s of s ample s ize, s h all come fr om t h e
PDR.

NOTE: Th e n u mber of par t s t o be in clu ded in t h e In it ial Pr oces s St u dy
s h all be deter min ed an d docu ment ed by t he PSO Team du r in g t h e Pr e-
PSO Meet in g.

2 0 . 1 . 1 Th e Capabilit y Mat r ix (s ee Appen dix B) s h all be u s ed t o
deter mine t he P
P
an d P
PK
requ ir emen t s for t h e In it ial Pr oces s
St u dy. For at t r ibu t e ch ar act er is t ics , t he P
P
an d P
PK
requ ir emen t s
do n ot apply; h owever 100% of t h e par t s s h all be accept able.

2 0 . 1 . 2 All iden t ified s pecial ch ar act er is t ics s h all be in clu ded in t he
In it ial Pr oces s St u dy, as well as an y ot h er ch ar acter is t ics requ ir ed
by t h e PSO Team. An y ch ar act er is t ic or meas u r emen t
au t oma t ically t aken on 100% of par t s (e. g. EOL tes ter ch ecks ,
con t in u it y ch ecks , et c. ) s h all als o be in clu ded in t he s t u dy.

2 0 . 1 . 3 If t h e Pr oces s Capabilit y is les s t h an t h e es t ablis h ed
r equ ir emen t , t h en 100% ver ificat ion of s h ipped par t s is accept able
as an in t er im cor rect ive act ion only wit h DCC PSO Team appr oval;
h owever , t h e In it ial Pr oces s St u dy s h all be mar ked Reject on t h e
PSO SUMMARY for m. Per man en t cor r ect ive act ion s mu s t be
appr oved by t he DCC PSO Team, implemen ted by t he Su pplier,
an d an On -Sit e Vis it perfor med (an d appr oved) pr ior t o Z or A
appr oval bein g gr an t ed.

2 0 . 1 . 3 . 1 Special ch ar act er is t ics wh ich do n ot meet capabilit y
r equ ir emen t s s h all h ave a cor rect ive act ion plan appr oved by
t h e DCC PSO Team an d fu lly implemen ted (an d meet t h os e
capabilit y r equ ir emen t s ) before PSO appr oval can occu r .

NOTE: 100% mech an ical ver ificat ion (i. e. mis t ake pr oofin g) may be
accepted as per man en t cor rect ive act ion , at t h e dis cret ion of t he
DCC ASQP Specialis t .

2 0 . 1 . 4 P
P
an d P
PK
s h all be calcu la t ed in dividu a lly for each lin e,
t ool, an d/ or cavit y.
- In it ial Pr oces s St u dy
Res u lt s

44
PRODUCTION VALIDATION TESTING COMPLETE
2 1 . 1 Tes t s amples u s ed in Pr odu ct ion Validat ion (PV) t es t in g s h all
come fr om t h e Pr odu ct ion Demon s t r at ion Ru n .

2 1 . 1 . 1 Wh en a s in gle pr odu ct ion lin e an d/ or t ool will be qu alified,
or mu lt iple lin es an d/ or t ools qu a lified on s epar at e tes t s , t h e PV
t es t compon en t s s h all be s elected r an domly fr om t h e PDR for each
lin e or t ool.

2 1 . 1 . 2 Wh en mu lt iple pr odu ct ion lin es an d/ or t ools will be
qu a lified in a s in gle PV tes t , a port ion of t h e PV tes t compon en t s
s h all be r an domly s elected fr om each pr odu ct ion lin e an d/ or t ool
in pr opor t ion t o t h at lin es con t r ibu t ion .

2 1 . 1 . 3 Tes t s amples u s ed for PV tes t in g s h all meet t h e pr odu ct ion
des ign releas e con figu r at ion .

2 1 . 1 . 4 Wh en accept able rewor k or repair pr oces s es are agreed
u pon by t h e DCC PSO team, par t s fr om t he rewor k or repair
pr oces s s h all be in clu ded in PV tes t in g.

2 1 . 2 PV t es t res u lt s s h all be reviewed by t h e PSO Team an d s ign ed
an d appr oved by t he DCC Pr odu ct En gin eer (s ee Elemen t 3 Tes t
Sample Sizes an d Frequ en cies . )

2 1 . 3 Th e DVP&R s h all be u pdat ed wit h compon en t level PV tes t
r es u lt s .

2 1 . 4 Compon en t level PV tes t in g s h all h ave been s ucces s fully
complet ed on all t es t s amples . If on e (or mor e) tes t s amples fail, it is
unacc ept able t o ju s t r eplace t h os e s amples . Th e PV tes t plan s h all be
r edone on new s amples on ce cor rect ive act ion s ar e don e.

BSR/ NVH
2 1 . 5 BSR/ NVH t es t in g res u lt s s hall be in clu ded in t h e DVP&R,
r eviewed by t he PSO Team an d s ign ed an d appr oved by t h e DCC
Pr odu ct En gin eer (s ee 21. 2. )

2 1 . 5 . 1 An alys es s h all in clu de evalu a t ion s of in t er act ion s wit h
mat in g par t s t o r edu ce, elimin at e an d/ or mon it or object ion able
BSR or NVH ch ar act er is t ics . Poten t ia l cau s es s h all be addres s ed in
t h e D/ PFMEA, DVP&R, an d t he Con t r ol Pla n .

2 1 . 5 . 2 It is t he Su pplier s res pon s ibilit y t o en s u r e t h at t h eir par t s
do not s queak or rat t le in t h eir res pect ive envir on men t s .

2 1 . 5 . 3 Th e Su pplier s h all employ det ailed pr ocedu res an d/ or tes t
met h ods t o pr oper ly detect BSR an d NVH wit hout s ubject ivit y.
Th e pr ocedu res are t o recreat e BSR an d NVH, as fou n d t h r ou gh
DCC t es t in g an d/ or defin ed bou n dar y s amples (e. g. s ou n d
ch amber , s h aker an d act u at ion t es t s ).

2 1 . 5 . 4 Th e Su pplier s h all h ave t rain in g an d/ or cer t ificat ion for
employees con du ct in g BSR/ NVH oper at ion s (e. g. hear in g t es t s . )
- Compon en t level PV
t es t res u lt s (DVP&R)
- PV Tes t pr ocedu res

45

APPENDIX A
FORMS & INSTRUCTIONS

46

Document Checklis t Work Ins t ruct ions

Header: En t er Par t Name, Nu mber , Ch an ge Level, Pr ogr am, Su pplier ,
Mfg. Locat ion , Su pplier Code an d dat e. Header will copy t o
all pages .

Document En t er an X in t h e appr opr iat e box. Box will ch an ge color .
Or Tas k: (Gr een / Appr oved, Yellow/ Cor r ect ion s , Red/ Mis s in g,
Black/ Not Applicable)

Power way.com requ ir ed docu men t s ar e s h aded in Blu e.
NOTE 1: Cor r es pon din g box on Ch ecklis t will fill in .
NOTE 2: Th is for m is opt ion al. It is in t en ded as an aid in con du ct in g t h e
Pr e- PSO Docu men t at ion Review meet in g on ly.

47
PART NAME(S)
PART NUMBER(S)
CHANGE LEVEL(S)
0
1st Review Date:
2nd Review Date:
Sec.
D
/
V
/
F
*
Documentation / Task
0 1. Part Number, Description & Change Level
1.2 D Engineering Change procedure
1.2 D CN Tracking (list of CN's, desc. & implementation)
1.3 D Software level and Hardware level
1.3 D Part number Cross reference
1.4 D
List of applicable engineering standards
1.4 D Document Control procedure
1.5 D GD&T or Drawing
1.5 D Catia files,drawings,comments page,
0
0 2. Design FMEA
2.1 D
DFMEA
2.2 D Best Practice Procedure
0
0 3. Test Sample Sizes and Frequencies
3.2 V DCC Engineering signed DV and PV test plans
3.3 D
DCC Engineering signed DVP&R
3.4 V Continous Conformance testing documented
3.5 V DVP&R includes Test to Flailure Plans
3.6 D Annual Validation Procedure
0
0 4. Process FMEA
4.1 D
PFMEA
4.2 D Best Practice Procedure
4.5 D PFMEA Audit summary
0
0 5. Process Flow Diagram & Manufacturing Floor Plan
5.1 D
Process Flow diagram
5.2 D
Mfg. Floor Plan (Location of equipment and space used identified)
5.2 D Cell Layout
5.4 V Process Flow or Cell layout Including # of Operators
5.6 D DFMA (Design for Manufacturing Assembly)
0
0 6. Control Plan and Process Monitoring
6.1 D
Control Plan
6.2 D Defect Tracking sheets
6.2 D Control charts
6.2 D Process Performance charts
6.2 D Log sheets
6.3 D 1st piece approval procedure & records
0
0 7. Quality Planning
7.1 D AQP or APQP timeline/plan
7.2 D List with PPAP status of all sub components
7.2 D
Indented list or Easy Map of Sub-Suppliers (Name,
Manufacturing location, Part name, Part Number,
PPAP Status) To raw material supplier.
7.2 D Listed risk of all PIA and sub-tier processes
7.2 D
Level 3 PPAP documentation( for PIA and sub tier processes risked
medium or high
7.3 D Procedure to convey Lessons Learned
7.4 D
Copies od eCIMS or 8-Step Corrective Actions for issues
encountered in previous pilot builds.
7.6 D DOE
0
0 8. Incoming and Outgoing Material Qualification Plan
8.1 D Incoming Inspection Plan
8.3 D Sampling Plans
8.4 D Receiving Reports
8.4 D Inspection/test reports
8.6 D
Copies of sub-tier Certificate of Analysis for each specific PIA
8.6 D
Copies of sub-tier and supplier PSW's
8.8 D Copies of sub-tier Supplier ISO9001 certifcations
8.9 D Outgoing Inspection Plan
8.11 D
Part Inspection Standard
8.14 D Audit Work Instructions
8.14 D Shipping Reports
8.14 D Audit Records
PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE
SUPPLIER
SUPPLIER CODE
MFG. LOCATION
M
i
s
s
i
n
g
/
R
e
j
e
c
t
PROGRAM
Enter a "X" in the
appropriate box below.
N
o
t

A
p
p
l
i
c
a
b
l
e
A
l
l

D
o
c
u
m
e
n
t
s

A
p
p
r
o
v
e
d
PSO ON-SITE VISIT NUMBER
Required Action
A
p
p
r
o
v
e
d
C
o
r
r
e
c
t
i
o
n
s

48
0 9. Parts Handling Plan - WIP
9.1 D Parts Handling Plan
9.1 D Material handling Procedures
9.7 D Containment records
0
0 10. Operator Instructions
10.1 D Operator Instructions
10.1 D Set-up Sheets
10.1 D 1st Piece approval instructions
10.1 D Mistake proofing instructions
10.1 D Gage Instructions
10.2 D Operator Qualification process
10.3 D Visual Management Document control procedure
10.4 D Rework/repair instructions
0
0 11. Tooling, Equipment & Gages Identified
11.1 D
Tooling List (Including Capital Equipment)
11.2 D STR (List)(Printed from DCX system)
11.2 N
Note: "Property of DCX" and the STR number must be on all DCX
owned tooling (Fire Proof). The STR list printed from the DCX
system needs to be supplied to the specialist during the PSO Onsite
visit.
0
0 12. Special Product & Process Characteristics Identified
12.1 D Special Characteristics List
12.1 D PPSR (Pre-Production Sample Report) for vehicle builds
12.5 D
FPSC (First ProductionShipement Certification) Plan
-100% inspection of 1st 2000 GOOD parts for visual
defects and all Control plan checks (Or increased
frequency per team agreement)
0
0 13. Error & Mistake Proofing
13.1 D
Error & Mistake Proofing Plan
13.1 D
List of error and mistake proofing implmented by operation number
13.1 D Error & Mistake Proofing Studies
13.2 D Mistake Proofing Contingency Plan
0
0 14. Layered Process Audit Plan
14.2 D LPA Procedures
14.2 D LPA work instructions
14.3 D LPA Structure and Frequency chart
14.4 D LPA Process Control Audit checklist
14.4 D LPA Error Proofing Verifcation Audit Checklist
0
0 15. SRE Results and Evidence of Product Specifications
15.1 F
SRE "Supplier Readiness Evaluation" Run results
15.4 F Measurement Verification Report
0
0 16. Production Demonstration Run and FTC
16.1 F
Line Speed demonstration form completed
16.4 D Process Constraints & Contingency Plans
16.4 F Final audit sampling plan
0
0 17. Parts Packing & Shipping Specifications
17.1 D Parts packaging and shipping plan
17.1 D Packaging and Shipping procedures
17.1 D Packaging,shipping and labeling instructions
17.1 D Returnable Container management plan
17.1 D Barcoded Labeling Procedure
17.2 D Shipping label example
17.3 D Simulation or shipping test results
0
0 18. Gage & Test Equipment Evaluation
18.3 D
Gage R&R (All measurement devices) results
18.2 D Gage layout results
18.5 D Gage and test equipment validation procedure
18.5 D Gage and test equipment calibration records
18.6 D Calibration schedule
0
0 19. Preventative Maintenance Plans
19.1 D PM Plan (Everything on Tooling list is in System)
0
0 20. Initial Process Study
20.1 F
Initial Process Study results
0
0 21. Production Validation Testing Complete
21.1 D Component level PV test results
21.1 D PV test procedures
21.4 D Training/certification for BSR operators
21.4 D Applicable PF Standards
21.4 D Vibration Test Procedure
0
Key: D Document
F Completed PSO form
N Note
V View
Powerway required document

49
20 26
"N" "Z" "A"
PART NAME(S) SUPPLIER
MFG. LOCATION
SUPPLIER CODE
FPSC REVIEWED WITH SUPPLIER
Accept Reject N/A Accept Reject N/A
1. PART NUMBER, DESCRIPTION and CHANGE LEVEL 0 0 0
2. DESIGN FMEA 0 0 0
3. TEST SAMPLE SIZES and FREQUENCIES 0 0
4. PROCESS FMEA 0 0
5. PROCESS FLOW DIAGRAM and MFG FLOOR PLAN 0 0
6. CONTROL PLAN and PROCESS MONITORING 0 0
7. QUALITY PLANNING 0 0
8. INCOMING and OUTGOING MATERIAL QUALIFICATION PLAN 0 0
9. PARTS HANDLING PLAN 0 0
10. OPERATING INSTRUCTIONS 0 0
11. TOOLING, EQUIPMENT and GAGES IDENTIFIED 0 0
12. SPECIAL PRODUCT and PROCESS CHAR IDENTIFIED 0 0
13. ERROR and MISTAKE PROOFING 0 0
14. LAYERED PROCESS AUDIT 0 0
15. SUPPLIER READINESS EVAL and EVIDENCE OF PRODUCT SPECS 0 0
16. LINE SPEED DEMONSTRATION and FTC 0 0
17. PARTS PACKAGING and SHIPPING SPECS 0 0
18. GAGE and TEST EQUIPMENT EVALUATION 0 0
19. PREVENTIVE MAINTENANCE PLANS 0 0
20. INITIAL PROCESS STUDY 0 0
20 20 0
Accept Reject N/A Accept Reject N/A
21. PRODUCTION VALIDATION TESTING COMPLETE 0
24 15 2 2
Yes No Date
Yes No Date
Manufacturing Facility
PRINT NAME, SIGN AND DATE PRINT NAME, SIGN AND DATE
DATE
PART NUMBER(S)
0
PROCESS
PROGRAM
CHANGE LEVEL(S) 0
0
0
DOCUMENTATION
0
OPTION #
0 0
0
0
DAIMLERCHRYSLER PROCESS SIGN-OFF CHECKLIST
PSO APPROVAL STATUS:
CHECK IF PSO EXTENDED RUN:
1/0/1900
Process Sign-Off Team
ENGINEERING
0
0
PROCESS
SUPPLIER QUALITY
PSO PROCESS ELEMENTS REQUIRED FOR "Z" APPROVAL
CORRECTIVE ACTION REQUIRED
ON-SITE REVISIT REQUIRED
DOCUMENTATION
ADDITIONAL PSO PROCESS ELEMENTS REQUIRED FOR "A" APPROVAL

50
MFG. LOCATION
SUPPLIER CODE
0
TARGET
DATE
CLOSED
DATE
RESPONSIBILITY
0
0
1/0/1900
0
0
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROCESS SIGN-OFF
COMMENTS SHEET
0
0
0
PROGRAM
ITEM ISSUE/ACTION

51
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52
Supplier Readines s Evaluat ion Ins t ruct ions

Not e: Whe n reques t ing approval for mult iple manufac t uri ng lines , a SRE form s hall be
complet ed for eac h manufact uri ng line reques t ing approval.

Qu an t it y Deter min ed by Su pplier an d Daimler Ch r ys ler PSO Team: Nu mber of par t s agreed by
Daimler Ch r ys ler an d t he Su pplier pr ior t o t h e SRE r u n .

SRE Lin e Rate: Th e calcu lat ed lin e r at e for t h e Su pplier Readines s Evalu at ion r u n = SRE Par t
Qu an t it y Accepted Du r at ion of SRE r u n .

Sh ift : Th e man u fact u r in g s h ift t h e SRE was per for med. Recor d s h ift # an d h ou r s . (e. g. 1
s t
s h ift ,
6am-3pm)

Pr oces s Feat u re/ Par t Ch ar act er is t ic: Th e pr oces s feat u r e or par t char act er is t ic t h at is bein g
meas u r ed.

Pr oces s / Par t : Docu men t if dat a is for a pr oces s meas u remen t or a par t meas u r emen t .

Meas . Freq. : Meas u r emen t Frequ en cy. Recor d t h e n u mber of par t / pr oces s meas u remen t s t aken
per t ime in t er val.

USL: Upper Specificat ion Limit . Th e u pper limit of t h e par t or pr oces s s pecificat ion per t h e par t
dr awin g or pr oces s s t an dar d.

UCL: Upper Con t r ol Limit : Th e u pper limit es t ablis h ed by t he Su pplier for pr oces s / par t con t r ol.
NOTE: Th is n u mber s h ou ld be les s t h an t h e USL.

Par t / Pr oc. Avg.: Par t / Pr oces s Aver age. Th e aver age of all meas u r ed pr oces s feat u r es / par t
ch ar act er is t ics .

LCL: Lower Con t r ol Limit . Th e lower limit es t ablis h ed by t he Su pplier for pr oces s / par t con t r ol.
NOTE: Th is n u mber s h ou ld be les s t h an t h e LSL.

LSL: Lower Specificat ion Limit . Th e lower limit of t he par t or pr oces s s pecificat ion per t he par t
dr awin g or pr oces s s t an dar d.

P
P
: Th e calcu lat ed P
P
for all meas u r ed pr oces s feat u res / par t ch ar act er is t ics .

P
PK
PK
for all meas u r ed pr oces s feat u res / par t ch ar act er is t ics .

Qu an t it y At t empt ed: Th e t ot al n u mber of par t / pr oces s meas u remen t s t aken .

Qu an t it y Accepted: Th e t ot al n u mber of par t / pr oces s meas u r emen t s accept able per t h e
es t ablis h ed con t r ols (wit h in t h e LCL-UCL).

FTC per cen t (wit h ou t r epair s ): Calcu lat ed Fir s t Time Capabilit y. For fu r t h er det ails , pleas e s ee
Appen dix C.

% GR&R: Calcu la t ed per cen t age of Gage R&R for gage u s ed for par t/ pr oces s meas u remen t .

Acc/ Reject : Has t h e PSO team deter min ed t he s u pplier s dat a t o be accept able (acc) or
u n accept able (Reject )? [i.e. LCL <Pr oc Avg < UCL; Ppk > Ppk mat r ix requ ir emen t (s ee In it ial
Pr oces s St u dy elemen t ); FTC > 90%; GR&R < 10% ; 10< GR&R < 30 PSO team decis ion ].

53
MANUFACTURING LOC
PART NUMBER(S)
SUPPLIER CODE
CHANGE LEVEL(S)
Buyer concurrence (optional)
Calculation Witnessed information Input information
Data input from production P.O.:
Shared Line? Yes or No (Y/N)
A) Combined DCC P.O. Daily Tooling Capacity
A1) DCC P.O. Daily Tooling Capacity Part Number Pieces/day
Total (A1 + A5) Pieces/day
B) DCC P.O. Shift Pattern
B1) Number of shifts per day shifts
B2) Production hours per shift hours
B3) Number of production days per week days
Data input from manufacturing process:
C) Downtime per shift
C1) Lunches hours/shift
C2) Breaks hours/shift
C3) Changeover and/or set-up hours/shift
C4) Operating time dedicated to other customers hours/shift
Comments:
C5) Scheduled/unscheduled downtime (as applicable) hours/shift
Comments:
D) Parts attempted during the PDR attempted parts
E) First time through fallout during the PDR failed parts
F) Length of PDR in hours Start: Finish: hours
G) Acceptable parts witnessed at the PDR pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)] hours/shift
I) Available production hours/day [B1*H] hours/day
J) DCC required parts per hour at the PDR [A/I] parts/hour
K) Witnessed parts per hour at the PDR [G/F] parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100] Minimum requirement of 90% %
M) Difference between witnessed parts/hour and required parts/hour [K-J] pieces
Must be 0 or greater for approval
DCC FORMULA FOR PRODUCTION DEMONSTRATION RUN
PSO REQUIREMENT
0
0
0
0
0
0
0
0
0
PROGRAM 0
0
0

54
Sh ar ed Lin e? Yes or No (Y or N)
A) Th e combin ed DCC Daily Toolin g Capacit y s h ou ld be obt ain ed from t h e DCC Pu r ch as e Or der - "TOOL CAP"
If s h ar ed lin e = N:
A1 ) In pu t t h e Daily Toolin g Capacit y an d part n u mber from t he DCC Pu r ch as e Or der .
A2 -A5 ) Lea ve as t h e defau lt 0.
If s h ar ed lin e = Y, s h ared wit h DCC part s on ly:
A1 -A5 )
If s h ar ed lin e = Y, s h ared wit h ot h er cu s t omers :
A1 -A5 ) In pu t t h e Daily Toolin g Capacit y from t h e DCC Pu r ch as e Or der for t h e var iou s par t s bein g validat ed.
C4 ) In h ou r s / s hift , in pu t t h e t ime dedicat ed per s h ift t o ot h er cu s t omer s .
B) Th e s h ift pat t er n s h ou ld be obt a in ed from t h e DCC Pu r ch as e Or der - "SH/ HR/ DY"
B1 ) Nu mber of s h ift s per da y - "SH" on Pu r ch as e Order
B2 ) Pr odu ct ion h ou r s per s hift - "HR" on Pu rch as e Order
B3 ) Nu mber of pr odu ct ion days per week - "DY" on Pu rch as e Order
C) Down t ime pe r s hi ft
C1 ) Lu n ches - Th e amou n t of t ime, i n hours per s hi ft , t h at t h e produ ct ion proces s is n ot operat in g du e t o lu nch .
C2 ) Br eaks - Th e amou n t of t ime, i n hours pe r s hi ft , t h at t h e pr odu ct ion pr oces s is not oper at in g du e t o br eaks .
C3 )
C4 )
C5 )
D) Th e par t s at t empt ed du r in g t h e PDR ar e t h e t ot al n u mber of par t s t h e s u pplier pr odu ced in clu din g r eject s / s cra p.
E)
F)
G)
NOTE: Pleas e in dicat e when du rin g t h e pr odu ct ion pr oces s t h e ch an geover s will be implemen t ed (if t h ey are con du ct ed
du rin g t h e qu ot ed oper at in g pat t er n , or if t h ey ar e t o be con du ct ed du r in g "off s h ift s ").
Len gt h of PDR in h ou rs is t h e mea s u red t ime it t ook t o con du ct t h e produ ct ion demon s t r at ion r u n . Pleas e in pu t s t ar t an d
fin is h t ime in cells provided.
Schedu led/ u n s ch edu led down t ime n ot cons ider ed - Th e amou n t of downt ime, in hours per s hift , t h a t was n ot
con s idered. Th is cou ld be an y down t ime s u ch as PM, ch an geover , et c. t h at wa s n ot in clu ded in t h e developmen t of t h e
s h ift pa t t ern / pieces per day qu an t it y.
Schedu led/ u n s ch edu led down t ime s h ou ld be calcu lat ed on a per s h ift bas is (e.g. oper at in g t ime per week divided by
t h e n u mber of s h ift s per week = ch an geover t ime per s h ift ).
NOTE: Pleas e in pu t appr opr iat e commen t s in t h e blan ks pr ovided.
Oper at in g t ime dedicat ed t o ot h er cu s t omer s - Th e a mou n t of t ime, i n hours per s hi ft , t ha t t h e pr odu ct ion pr oces s is
oper at ing/ man u fact u rin g produ ct for ot h er cu s t omer s .
Oper at in g t ime dedicat ed t o ot h er cu s t omer s calcu lat ed on a per s hift bas is (e.g. oper at in g t ime per week divided by t he
n u mber of s hift s per week = ch an geover t ime per s h ift ).
Fir s t t ime t h rou gh fall ou t du rin g t h e PDR is t h e n u mber of par t s t h at wer e r eject ed fr om t h e man u fact u r in g proces s du ring
fi rs t evalu at ion . Th is is not t h e fin al n u mber of u na ccept able par t s , bu t on ly t h os e t h a t failed firs t t i me t h rou gh t h e
pr oces s . (Th is n u mber will be u s ed in t h e FTC calcu la t ion .)
NOTE: Th e as s u mpt ion for t h is calcu lat ion is t h at all of t h e par t n u mber s h ave t h e s ame oper at in g pat t er n a nd t h e s ame
t akt t ime.
Ch an geover an d/ or s et u p - Th e amou n t of t ime, i n hours per s hi ft , t h at t h e produ ct ion pr oces s is n ot oper at ing du e
t o ch an geover an d/ or s et u p act ivit ies . On ly ch an geovers t ha t wer e qu ot ed t o occu r du rin g t h e produ ct ion oper at in g
pa t t er n s h ou ld be con s ider ed for t h is calcu lat ion .
Ch an geovers or s et u p not con du ct ed ever y s hift s h ou ld be ca lcu lat ed on a per s h ift ba s is (e.g. Cha n geover t ime per
week divided by t he n u mber of s h ift s per week = ch an geover t ime per s h ift ).
Produc t i on De mons t rat i on Run Calc ulat i on Work Ins t ruct ions
Accept able part s wit n es s ed at t h e PDR ar e t h e t ot al n u mber of par t s , min u s an y reject s , wh ich wer e demon s t rat ed du r in g
t h e pr odu ct ion r u n . (May di ffer from fi rs t t i me t hrough fallout . )
NOTE: If t h e compon en t s bein g validat ed ha ve varyin g operat in g pat t er n s or differ en t t akt t imes , t h en s epar at e ca lcu lat ion
wor ks h eet s s h ou ld be complet ed for each par t .
NOTE: If t h e compon en t s bein g validat ed ha ve varyin g operat in g pat t er n s or differ en t t akt t imes , t h en s epar at e ca lcu lat ion
wor ks h eet s s h ou ld be complet ed for each par t .
NOTE: Th e as s u mpt ion for t h is calcu lat ion is t h at all of t h e par t n u mber s h ave t h e s ame oper at in g pat t er n a nd t h e s ame
t akt t ime.
In pu t t h e Daily Toolin g Capacit y an d part n u mber from t he DCC Pu r ch as e Or der for t h e var iou s pa rt s bein g
validat ed.

55
H)
I) Ava ilable pr odu ct ion h ou r s / day are t he n et h ou rs per day t h e s u pplier h a s available t o bu ild pr odu ct .
J)
K)
L)
If t h e DCC r equ ir emen t of 90% or gr eat er is met , t h e cell will t u r n gr een .
If t h e DCC r equ ir emen t is n ot met (les s t h an 90%), t h e cell will t u r n r ed.
M)
If t h e par t differen ce is les s t han 0, t h e cell will t u rn r ed in dicat in g t h e requ iremen t is n ot met . i.e. M < 0 t h e cell = r ed.
NOTE: In t he event (M) i s yellow, it i s s t rongly advis ed t o c onduct an Ext ended Run PSO t o s t res s t he s uppli er's
product i on li ne and i ncre as e confi dence i n t he s uppli er's abi li t y t o meet DCC requi re me nt s . PSO Ext ended Run
opt i ons are explai ne d i n t he PSO manual. Cont i nuous i mprove me nt act i ons s hould als o be deve lope d for bot t leneck
operat i ons or ot her operat i ons whi ch s howed poor performance duri ng t he PSO run.
NOTE: If t h e FTC is les s t h an 90%, t h e PSO t eam s h all t ake produ ct a nd proces s t ech n ology, complexit y, s u pplier
experien ce, an d t h e effect iven es s of defect con t ain men t act ion s in t o accou n t wh en decidin g wh et h er t h e demon s t r at ed lower
FTC valu es ar e accept able wit h a docu men t ed deviat ion . A DCC Su pplier Qu alit y Man ager's s ign ed appr oval is requ ired for
devia t ion from t h e PSO FTC requ iremen t .
Th e differ en ce bet ween r equ ir ed par t s / h ou r an d wit n es s ed pa rt s / h ou r gives t h e t ot al n u mber of par t s over or u n der t h e
DCC r equ ir emen t .
Produc t i on De mons t rat i on Run Calc ulat i on Work Ins t ruc t i ons , c ont .
If t h e par t differen ce is great er t h a n (t h e DCC r equ ir ed par t s per h ou r + 10%), t h e cell will t u r n green in dicat in g t h e
lin e s peed is accept able. i.e. (J + 10%) M, t h en cell = gr een (requ iremen t s met ).
If t h e par t differen ce is bet ween 0 an d (t h e DCC requ ired part s per hou r + 10%), t h e cell will t u r n yellow in dicat in g t h e
lin e s peed h as met r equ ir men t s , bu t t h e par t differen ce is ver y clos e an d may r equ ir e addit ion al a t t ent ion.
i.e. 0 <= M < (J +10%) t h en cell = yellow.
FTC (Fir s t Time Capabilit y) is t he per cen t age of accept able part s wit n es s ed at t h e pr odu ct ion demon s t r at ion ru n ou t t he
t ot al n u mber of par t s at t empt ed at t h e PDR.
Ava ilable pr odu ct ion h ou r s / s hift ar e t h e n et h ou r s per s h ift t h e s u pplier h as available t o bu ild pr odu ct n ot in clu din g a n y
s ch edu led down t ime.
DCC r equ ir ed par t s per h ou r at t h e PDR a re t h e t ot a l nu mber of a ccept able par t s t h e s u pplier mu s t pr odu ce, in an h ou r's
t ime, n eces s ar y t o s a t is fy DCC.
Wit n es s ed par t s per h ou r at t h e PDR ar e t h e n u mber of accept able part s wit n es s ed by t h e PSO t eam, which t he s u pplier
pr odu ced wit h in an h ou r' s t ime.

56

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57
Init ial Proc e s s St udy

Pr oces s Feat u r e/ Par t Ch ar act er is t ic: Th e pr oces s feat u r e or par t ch ar act eris t ic t h at is bein g meas u r ed.

Pr oces s/ Par t : Docu men t if dat a is for a pr oces s meas u r emen t or a par t meas u r emen t .

Meas . Fr eq.: Meas u r emen t Fr equ en cy. Record t h e n u mber of par t / pr ocess meas u r emen t s t aken per t ime
in t er val.

USL: Upper Specificat ion Limit . Th e u pper limit of t h e par t or pr oces s s pecificat ion per t h e par t dr awin g or
pr oces s s t an dar d.

UCL: Upper Con t r ol Limit : Th e u pper limit es t ablish ed by th e Su pplier for pr oces s/ par t con tr ol.
NOTE: This n u mber s h ou ld be les s th an t h e USL.

Par t / Pr oc. Avg.: Par t/ Pr oces s Aver age. Th e aver age of all measu r ed pr ocess feat u r es/ par t ch ar act eris t ics.

LCL: Lower Con t r ol Limit : Th e lower limit es t ablis h ed by t h e Su pplier for pr oces s/ par t con t r ol.
NOTE: Th is n u mber s h ou ld be les s th an t h e LSL.

LSL: Lower Specificat ion Limit . Th e lower limit of t h e par t or pr oces s specificat ion per th e par t dr awin g or
pr oces s s t an dar d.

P
P
P
for all meas u r ed pr oces s feat u r es/ par t ch ar act er is tics.

P
PK
PK
for all meas u red pr oces s feat u res / par t ch ar act er is tics .

Qu an t it y At t empt ed: Th e t ot al nu mber of par t/ pr oces s meas u r emen t s t aken .

Qu an t it y Accept ed: Th e t ot al n u mber of par t/ pr ocess meas u r emen t s accept able per t h e es t ablis h ed
con t r ols (wit h in t h e LCL-UCL).

FTC per cen t (with ou t repair s ): Calcu lat ed Fir s t Time Capabilit y. For fu r th er det ails , pleas e s ee Appendix C.

% GR&R: Calcu lat ed per cen t age of Gage R&R for gage u s ed for par t/ pr oces s meas u r emen t.

Acc/ Reject : Has t h e PSO t eam det ermined th e s u pplier s dat a t o be accept able (acc) or u n accept able?
[i.e. LCL <Pr oc Avg < UCL; P
P
> P
PK
mat r ix r equ ir emen t (s ee Init ial Pr ocess St u dy elemen t ); FTC > 90%;
GR&R < 10% ; 10%< GR&R < 30% PSO t eam decis ion].

58
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59

Meas urement Sys t em Report Ins t ruct ions

Th e MEASUREMENT SYSTEM VERIFICATION REPORT is u s ed t o docu men t t h e r es u lt s of t h e measu r emen t
au dit per formed du r in g t h e PSO On -Sit e Visit . Us e addit ion al copies of t he form or at t ach addit ion al pages
as n eeded t o accommodat e mor e ch ar act er is tics .

Nu mber of par t s wit n es sed: Th e n u mber of par t s t h e PSO h as per s on ally wit n ess ed t h e s u pplier meas u r e
ch ar act eris t ics .

Wit n ess ed by: Th e n ames of all t he DCC PSO t eam members wh o wit n ess ed t h e meas u r emen t au dit .

Ch ar act er is t ic: Meas u r emen t ch ar acter is t ics iden t ified by t h e t eam t o be meas u r ed.

Specificat ion: Th e docu men t ed specificat ion of th e ch ar act er is t ics as iden t ified on t h e par t dr awin g.

Met h od of Meas u r emen t : Th e gage, fixt u r e, or equ ipmen t u s ed t o meas u r e t h e iden t ified ch ar act er is t ics .

Qu an t it y At t empt ed: Th e t ot al nu mber of par t s ch os en t o be meas u r ed by th e t eam (t h is may exceed t h e
n u mber of par t s witn es s ed by t h e PSO t eam member s ).

Qu an t it y Accept ed: Th e n u mber of par t s wh ich wh os e ch ar act eris t ic was wit h in th e specificat ion .

FTC per cen t age (with ou t r epair ): Calcu lat ed FTC. For fu r t h er det ails , please s ee Appen dix C.

P
P
/ P
PK
P
/ P
PK
for th e qu an t it y of par t s at t empt ed.

Pr oces s Acc/ Reject: Has t h e PSO t eam det ermin ed t h e su pplier s meas u r emen t pr oces s t o be accept able
(acc) or u n accept able (Reject )?

Commen t s : An y waiver s / deviat ion s sh ou ld be r ecor ded h er e for docu men tat ion pu r pos es .

60
How t o find t he Daily Tooling Capac it y and Ope rat ing Pat t e rn

For DaimlerChrys le r Spe c ialis t s :
Log on t o t he Su pplier Qu a lit y Port a l a t
h t t ps :/ / gs p.ext r a .da imlerch r ys ler .com/ SQP/ s er vlet / SQPServlet
Move mou s e t o Su mma r ies an d click on Pa rt Su mma r y fr om t h e drop-down menu
En t er t h e pa rt n u mber a n d click on t he Fet ch box
Addit iona l MY in forma t ion ca n be fou n d by movin g t h e mou s e over t h e indica ted a rea

61

APPENDIX B
Ta bles a nd Exa mples

62

LOT ACCEPTANCE SAMPLING TABLE

NOTE 1 : THIS TABLE APPLIES TO ATTRIBUTE SAMPLING ONLY.
NOTE 2 : TWO OR MORE OF THE METHODS DESCRIBED IN ELEMENT 7 . 4 . 3 . 1 OF TS-1 6 9 4 9
SHALL BE USED, OTHERWISE, THIS TABLE APPLIES.

Charact eris t ics Defi nit ion

SAFETY <S>/EMISSION <E>: A ch ar act er is t ic t h at will affect complian ce wit h Daimler Ch r ys ler
Cor por at ion an d/ or Gover n men t al Veh icle Safet y/ Emis s ion r equ ir emen t s .

KEY <D>: A ch ar act er is t ic t h at is key t o par t fu n ct ion an d h as par t icu lar qu alit y, r eliabilit y, an d
du r abilit y s ign ifica n ce (Refer t o En gin eer in g Pr oces s St an dar d PS-7300).

Sample s ize s h all be bas ed u pon th e n or mal pr odu ct ion lot s ize. If th e lot s ize is tempor ar ily
r edu ced du e t o mat er ial s h or t ages or pr odu ct ion pr oblems , t h e s ample s ize will n ot ch an ge. If t h e
t empor ar ily r edu ced lot s ize is s maller t h an t h e requ ir ed, pr odu ct ion s ample s ize, in s pect 100%. A
lot is n ot t o exceed one s h ift or on e-day's pr odu ct ion wh ich ever is s maller .

PRODUCT QUALIFICATION

Sample Si ze Per Charact eris t i c Clas s ificat ion
Accept ance
Number = 0

Lot Size or Shipment
Size*

<S> / <E>

<D>

0-15

100% In s pect ion

16-25

26-50

51-75

50

76-125

75

65

126-225

90

75

226-425

100

85
426-1300 110 90
1301 an d u p 115 90

SAMPLE RESULTS

ACTIONS ON PROCESS

ACTIONS ON LOT

No Non con for min g u n it s

Con t in u e t o oper at e

Accept

On e or more
Non con for min g u n it s

Fin d Root Ca u s e(s ) an d
Cor r ect Pr oces s

Sor t 100% s in ce las t
con for min g lot

63
CAPABILITY MATRIX

Th er e ar e t wo r isks in h er en t in ever y decision , eit h er (1) we h ave accept ed bad par t s (con s u mer s r isk), or
(2) we h ave r eject ed good par t s (pr odu cer s ris k). Tes t plan s seek t o balan ce t h es e ris ks by specifyin g
s ample s ize and/ or accept an ce cr it er ia s o t h at n eit her th e con su mer n or th e pr odu cer carr ies th e high er
pr opor t ion of r isk.

Somet imes, for bu s in es s or ot h er r eas on s , it may be impor t an t t o h old on e r isk con s t an t an d allow t h e oth er
r isk t o float bas ed on s ample s ize. Su ch is t h e cas e for Pp an d Ppk. Daimler Chr ys ler wan t s t o min imize it s
r isk of accept in g a popu lat ion below 1.33Ppk.

Th e followin g t able pr es en t s t h e s ample size an d accept an ce cr it er ia th at keeps t h e r isk of accept in g a bad
popu lat ion (s 1.33) at 6.4% (93.6% t hat popu lation > 1.33 Ppk will be accept ed). Depen din g u pon s ample
s ize, th e r isk of r ejectin g a good popu lat ion (> 1.67) cou ld be ver y high . Th e t able allows for t r ade-offs
bet ween s ample s ize and pr odu cer s ris k t o be iden t ified.

Sample Size
Accept an ce Ppk
Cr it eria
Ris k of Accept in g a
Popu lat ion <= 1.33Ppk
Ris k of Rejectin g a
Popu lat ion >= 1.67Ppk
5 2.94 6.4 % 86.3%
10 2.10 6.4 % 77.3%
15 1.89 6.4 % 68.7%
20 1.78 6.4 % 60.7%
25 1.71 6.4 % 53.3%
30 1.67 6.4 % 46.5%
35 1.64 6.4 % 40.4%
40 1.61 6.4 % 34.9%
45 1.59 6.4 % 30.1%
50 1.58 6.4 % 25.8%
55 1.56 6.4 % 22.0%
60 1.55 6.4 % 18.7%
65 1.54 6.4 % 15.9%
70 1.53 6.4 % 13.4%
75 1.52 6.4 % 11.3%
80 1.52 6.4 % 9.5%
85 1.51 6.4 % 8.0%
90 1.50 6.4 % 6.7%
95 1.50 6.4 % 5.6%
100 1.49 6.4 % 4.7%
150 1.46 6.4 % 1.9%
200 1.44 6.4 % 1.0%
250 1.43 6.4 % 0.6%
300 1.42 6.4 % 0.3%

64
EXAMPLE: LPA FREQUENCY AND STRUCTURE

Assigned
Management
Category
(example)
Assigned
Management
Personnel
(example)
Audit
Assignment
D
e
p
a
r
t
m
e
n
t

A
D
e
p
a
r
t
m
e
n
t

B
D
e
p
a
r
t
m
e
n
t

C
D
e
p
a
r
t
m
e
n
t

D
D
e
p
a
r
t
m
e
n
t

E
D
e
p
a
r
t
m
e
n
t

F
1st Layer of
Management
Supervisors Supervisor 1 Own Department
1 per
shift
1 per
shift
Supervisor 2 Own Department
1 per
shift
1 per
shift
Supervisor 3 Own Department
1 per
shift
1 per
shift
2nd Layer of
Management
Area
Managers Area Manager 1 Own Area
2 per
week
2 per
week
2 per
week
2 per
week
Area Manager 2 Own Area
2 per
week
2 per
week
3rd Layer of
Management
Plant Staff
and Plant
Manager Engrng Mgr Rotate Depts.
Quality Mgr Rotate Depts.
Tooling Mgr Rotate Depts.
H.R. Mgr Rotate Depts.
Training Coord. Rotate Depts.
Plant Manager Rotate Depts.
1 per week
1 per week
1 per week
1 per week
1 per week
1 per week

65

FMEA GUIDELINES

Specia l At ten t ion Sh a ll Be Given To:

I. RPNs t h a t h a ve a Severit y > 8 r ega rdles s of RPN va lu e, Occu r r en ce level, or
Detect ion level.

II. RPN's t h a t h a ve Sever it y > 5 and a n Occu r ren ce > 2 rega r dles s of Detect ion a nd
RPN va lu e. (Th is equ a tes t o cu s t omer dis s a t is fact ion a nd C/ 1000 >1).

III. Detect ion = 10. (The poten t ia l defect is a llowed t o leave t he pla n t a n d r ea ch t he
field).

66


67

APPENDIX C
FTC Ca lcu la t ion s

68
Firs t Time Capabilit y

CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITHOUT
REPAIRS

PURPOSE
Fir s t Time Capabilit y (FTC) is par t of a pr oces s capabilit y s t u dy t h at iden t ifies h ow well it pr odu ces qu alit y
par t s . For mu lt iple as s embly lines or t ools , FTC s t u dies sh all be con du ct ed on each one. FTC can be an
impor t an t meas u r e, becau s e gen er ally t h e lower t h e valu e, t he great er t h e amou n t of r ework r equ ir ed. As
defect s and r ework in cr eas e, t h er e is a gr eat er pos s ibilit y t h at t he Su pplier will sh ip n on -conformin g par t s .

Daimler Ch r ysler s r equ ir emen t for FTC is 90% or great er . Followin g t h e PDR, t h e PSO Team sh all r eview t h e
FTC valu es for each oper at ion and t he over all pr oces s . If t he FTC is les s t han 90%, t h e PSO t eam s h all t ake
pr odu ct and pr oces s t ech n ology, complexit y, Su pplier exper ien ce, an d t h e effect iven es s of defect
con t ain men t act ions in t o accou n t when decidin g wh eth er t h e demon s t r at ed lower FTC valu es ar e accept able
wit h a docu men t ed deviat ion . A Su pplier Qu alit y Man ager s s ign ed appr oval is r equ ir ed for deviat ion fr om
t h e PSO FTC r equ ir emen t .

FTC can be u s ed t o pr ior it ize pr odu ct an d pr ocess impr ovemen t. If a Su pplier en cou n t er s a sit u at ion wh er e,
des pit e t h eir bes t effor t s, t h ey can n ot find a s olu t ion t o an inh er en t ly low FTC, Daimler Chr ys ler can as s is t
in t h e impr ovemen t effor t by su pplemen t in g t he Su pplier 's t eam wit h experien ced en gin eer in g an d
man u fact u r in g specialis t s fr om a wide var iet y of dis ciplin es .

DESCRIPTION
FTC is meas u red as th e nu mber of it ems pr oces s ed corr ect ly divided by t he t ot al n u mber of it ems
pr oces sed. Corr ect ly pr oces s ed means n o r epair s or r ewor k ar e allowed. Th er efor e, in a mu lt i-oper at ion
pr oces s, a high er FTC is expected for an oper at ion or zon e t h an for an en t ir e pr oces s.

DATA COLLECTION PROCEDURE
Th is t h r ee-s t ep pr ocedu r e is s u gges ted for calcu lat in g a pr odu ct ion lin e FTC.

1. Cr eat e a block diagr am for th e pr ocess s h owin g each oper at ion . Th e flow diagr am or floor layou t
pr ovided by t h e plan t can als o be u s ed.

2. Collect t h e followin g dat a fr om t h e PDR.
a. Qu an t it y of as s emblies at t empt ed.
b. Qu an t it y of r eject ed as s emblies fr om each oper at ion .
c. Qu an t it y of accept able as s emblies fr om t h e end of t he lin e. Do n ot in clu de r epair ed or r eworked par t s .

3. Calcu lat e t h e oper at ion and pr oces s FTC u s in g th e examples as a gu ide.

69
300 Pcs
30 Pcs
Rejected
270 Pcs
Operation 1
Firs t Time Capabilit y

CALCULATIONS & EXAMPLES


Example 1, Ser ies Pr oces s Flow wit h ou t Repair :
Du r in g a t ypical PSO Pr odu ct ion Demon s t r at ion Ru n , t h e goal is t o s h ow t h at t h e pr odu ct ion lin e
is capable of pr odu cin g par t s t h at meet DCC qu alit y a n d volu me requ ir emen t s . FTC an d Yield ar e
equ al for a pr oces s wit h ou t r epair s s o on ly FTC ca lcu lat ion s will be s h own in Sect ion I. For
es t ablis h ed pr odu ct ion lin es an d car r yover compon en t pr odu ct ion demon s t r at ion s t h a t may
in clu de rewor k, refer t o Examples 3 & 4.

Us in g t h e t h r ee-s tep, dat a collect ion pr ocedu re ou t lin ed above, t he followin g pr oces s ed an d
r ejected qu an t it y da t a were collect ed du r in g t h e PDR. Th e dat a ar e s h own on t h e pr oces s block
diagr am.

Figure 1
Example 1 - Se rie s Proc e s s Flow Diagram Wit h De mons t rat ion Dat a

Begin by calcu lat in g t h e FTC for each oper at ion . Oper at ion 1 is s h own h ere wit h it s res pect ive
PSO PDR dat a

Divide t h e qu an t it y complet ed at Oper at ion 1, 270 u n it s , by t h e
qu a n t it y at t empt ed at t h e oper at ion , 300 u n it s . Th e res u lt is t h e
oper at ion FTC.

% 90 or 90 . 0
300
270
Attempted Qty
Completed Qty
FTC
1 Op
= = =

Figu r e 1A

In a s imilar man n er , calcu lat e t he FTC for each oper at ion in t h e pr oces s u s in g Equ at ion 1. Th e
gener al oper at ion model is s h own in Figu r e 1B. Table 1 s h ows a s u mmar y of t h e qu an t it ies an d
FTCs for t he pr oces s in Example 1.

Attempted Qty
Completed Qty
FTC
OPERATION
=

Equat ion 1

(1) Figu r e 1B

300 Pcs
30 Pcs
Rejected
270 Pcs 243 Pcs 226 Pcs
9 Pcs
Rejected
217 Pcs
Operation 1
27 Pcs
Rejected
Operation 2
17 Pcs
Rejected
Operation 3 Operation 4
Quantity
Attempted
Quantity
Completed
Quantity
Rejected
Operation
Number

70

Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Comple t e d

FTC

1

300

270

0.90

2

270

243

0.90

3

243

226

0.93

4

226

217

0.96
TABLE 1
Quant it ie s and FTCs for Example 1

En t er t he calcu lat ed oper at ion FTCs in t h eir res pect ive oper at ion blocks of t he pr oces s diagr am.
Calcu lat e t h e pr oces s FTC by dividin g t h e qu an t it y completed for t h e pr oces s , 217 u n it s , by t h e
qu a n t it y at t empt ed 300 u n it s .
% 3 . 72 or 723 . 0
300
217
Attempted Qty Total
Completed Qty Total
FTC
PROCESS
= = =

En t er t he FTC
PROCESS
valu e on t h e pr oces s diagr am. Th e completed Example 1 pr oces s diagr am is
s h own in Figu r e 2. Th e diagr am can be in clu ded wit h t he fin al PSO docu men t s as a recor d of t he
pr oces s s t ar t in g capabilit y.

Figure 2
Example 1 - Se rie s Proc e s s Wit h Ope rat ion and Proc e s s FTC's Shown

Example 2, Ser ies / Par allel Pr oces s Flow wit h ou t Repair :
Us in g t h e t h r ee-s tep dat a collect ion pr ocedu r e ou t lin ed on page D. 2, t h e followin g pr oces s ed an d
r ejected qu an t it y da t a were collect ed du r in g t h e PDR. Th e dat a ar e s h own on t h e pr oces s diagr am
in Figu r e 3.

Figure 3
Example 2 - Se rie s / Paralle l Proc e s s Flow Diagram Wit h De mons t rat ion Dat a
300 Pcs
30 Pcs
Rejected
270 Pcs 243 Pcs 226 Pcs
9 Pcs
Rejected
217 Pcs
FTC = 72.3%
FTC
90%
Operation 1
27 Pcs
Rejected
FTC
90%
Operation 2
17 Pcs
Rejected
FTC
93%
FTC
96%
218 Pcs
300 Pcs
12 Pcs
Rejected
23 Pcs
Rejected
288 Pcs
265 Pcs
91 Pcs
10 Pcs
Rejected
96 Pcs
Operation 3
2 Pcs
Rejected
94 Pcs
81 Pcs
242 Pcs
Operation 4
78 Pcs
11 Pcs
Rejected
67 Pcs
Operation 5
Operation 6
24 Pcs
Rejected

71
Calcu lat e t h e FTC for each oper at ion in t h e pr oces s u s in g Equ at ion 1 an d t h e oper at ion model
s h own in Figu r e 1B on page 2. Ta ble 2 s h ows a s u mmar y of t h e qu an t it ies an d FTCs for t h e
oper at ion s in
Example 2.

Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Comple t e d

FTC

1

300

288

0.96

2

288

265

0.92

3

96

94

0.98

4

91

81

0.89

5

78

67

0.86

6

242

218

0.91
TABLE 2

Quant it ie s and FTCs for Example 2

En t er t he calcu lat ed oper at ion FTCs in t h eir res pect ive blocks on th e pr oces s diagr am. Calcu lat e
t h e pr oces s FTC by dividin g t h e t ot al qu an t it y complet ed, 218 Un it s , by t he qu an t it y at t empt ed,
300 u n it s . Th e res u lt is t h e FTC for t h e pr oces s .

% 73 or 726 . 0
300
218
Attempted Qty
Completed Qty
FTC
PROCESS
= = =

Add t h e pr oces s FTC t o t h e pr oces s diagr am. Th e completed diagr am for Example 2 is s h own in
Figu r e 4. Th e diagr am can be in clu ded wit h t h e PDR repor t t o docu men t t h e in it ial pr oces s
perfor man ce.

Figure 4
Example 2 Se rie s / Paralle l Proc e s s Wit h Ope rat ion and Proc e s s FTCs Shown

218 Pcs
FTC = 72.6%
300 Pcs
12 Pcs
Rejected
FTC
96%
23 Pcs
Rejected
288 Pcs
FTC
92%
265 Pcs
91 Pcs
FTC
89%
10 Pcs
Rejected
96 Pcs
Operation 3
FTC
98%
2 Pcs
Rejected
94 Pcs
81 Pcs
242 Pcs
FTC
90%
Operation 4
78 Pcs
FTC
86%
11 Pcs
Rejected
67 Pcs
Operation 5
Operation 6
24 Pcs
Rejected

72
CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITH REPAIRS

DATA COLLECTION PROCEDURE
Th e recommen ded pr ocedu re for dat a collect ion for a pr oces s wit h r epair is s imilar t o t h e
pr ocedu r e s h own in Sect ion I. Step #2 differ s becau s e of t he n eed to recor d rewor k qu an t it ies
r et u r ned t o t he pr oces s s t ream. St ep #3 differ s becau s e t h ere are t wo valu es t o calcu lat e, FTC a n d
yield.

1. Cr eate a block diagr am for t h e proces s s h owin g each oper at ion . Th e flow diagr am or floor
layou t pr ovided by t he plan t can als o be u s ed.

2. Collect t h e followin g dat a fr om t h e demon s t r at ion r u n .
a. Qu an t it y of as s emblies at tempt ed.
b. Qu an t it y of rejected as s emblies from each oper at ion .
c. Qu an t it y of rejected as s emblies t hat were repair ed for each oper at ion .
d. Qu an t it y of accept able as s emblies fr om t he en d of t he line.

3. Calcu lat e t h e oper at ion an d pr oces s FTC a n d yield u s in g t h e examples as a gu ide.


Example 3, Ser ies Pr oces s Flow wit h Repair :
In s ome in s t an ces , t h e PDR will be perfor med on an exis t in g pr odu ct ion lin e wit h rewor k
oper at ion s . Th es e s it u at ion s r equ ir e t h e abilit y t o deter mine FTC a n d Yield s epar at ely becau s e
FTC a n d Yield are n ot equ al wh en rewor k is in clu ded. Th e pr imar y goal for pr odu ct ion
demon s t r at ion is t o demon s t r at e th at t h e pr odu ct ion lin e is ready an d capable of pr odu cin g at t h e
r equ ir ed qu alit y a n d qu an t it y. Rewor k is n ot par t of pr odu ct ion demon s t r a t ion . Th er e are t imes ,
h owever , when we mu s t con s ider t h e impact of rewor k on pr oces s ou t pu t . For t h os e t imes , t h is
s ect ion s h ou ld be u s ed as a gu ide t o calcu lat e FTC an d Yield.

Us in g t h e t h r ee-s tep, dat a collect ion pr ocedu re ou t lin ed above, t he followin g pr oces s ed an d
r ejected qu an t it y da t a were collect ed du r in g a PDR. Th e dat a ar e s hown in Figu r e 5.

Figure 5
Example 3 Se rie s Proc e s s Diagram Wit h De mons t rat ion Dat a Adde d

300 Pcs
30 Pcs
Rejected
270 Pcs 268 Pcs 265 Pcs
10 Pcs
Operation 1
27 Pcs
Operation 2 Operation 3 Operation 4
Rework
2 Pcs
Scrap
25 Pcs
19 Pcs
Rework
3 Pcs
Scrap
16 Pcs
Rework
1 Pc
Scrap
9 Pcs
264 Pcs

73
Calcu lat e t h e FTC for each oper at ion . Oper at ion 1 is s h own here wit h it s r es pect ive pr odu ct ion
demon s t r at ion dat a.

Divide t h e qu an t it y complet ed, 270 pieces , by t h e qu an t it y at t empt ed,
300 pieces .
Not e: Equ a t ion 1 fr om Sect ion I can be u s ed for t h is oper at ion becau s e
r ewor k was n ot per for med.

Figu r e 5A % 90 or 90 . 0
300
270
Attempted Qty
Completed Qty
FTC
1 OP
= = =

Th e yield for Oper at ion 1 is t he s ame as t he FTC becau s e rewor k was n ot per for med. Th erefore,

% 90 or 90 . 0
300
270
Yield
1 OP
= =

For Oper at ion 2, s u bt r act t h e qu a n t it y r ejected, 27 u n it s , fr om t h e
qu a n t it y at t empt ed, 270 u n it s . Divide t h is t ot al by t h e qu an t it y
at t empt ed. For Oper at ion 2, Equ a t ion 2 will pr ovide t h e cor rect res u lt
becau s e rewor k was per for med.

% 90 or 90 . 0
270
243
270
27 270
FTC
Attempted Qty
jected Re Qty Attempted Qty
FTC
2 OP
2 OP
= =
=

Figu r e 5B Calcu lat e t h e yield for Oper at ion 2 by dividin g t h e qu an t it y complet ed,
268 u n it s , by t he qu an t it y a t t empt ed, 270 u n it s . Refer t o Equ at ion 3.

99% or 0.99 =
270
268
=
ted Qty Attemp
Completed Qty
=
Yield 2 OP

In a s imilar man n er , calcu lat e t he FTC an d Yield for t he remain in g oper at ion s u s in g Equ at ion s 2
an d 3. Th e gener al oper at ion model is s h own in Figu r e 5C. Table 3 s h ows t he qu an t it ies , FTCs
an d Yields for t he oper at ion s in Example 3.

ted Qty Attemp
Rejected Qty - ted Qty Attemp
=
FTCOperation

Equat ion 2

ted Qty Attemp
Completed Qty
=
YieldOperation

Equat ion 3
Figu r e 5C

268 Pcs
27 Pcs
Operation 2
Rework
2 Pcs
Scrap
25 Pcs
270 Pcs
300 Pcs
30 Pcs
Rejected
270 Pcs
Operation 1
Operation
Number
Quantity
Rejected
Rework
Quantity
Reworked
Quantity
Attempted
Quantity
Completed

74

Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Re je c t e d

FTC

Quant it y
Re worke d

Quant it y
Comple t e d

Yie ld

1

300

30

0.90

N/ A

270

0.90

2

270

27

0.90

25

268

0.99

3

268

19

0.93

16

265

0.99

4

265

10

0.96

9

264

0.996
TABLE 3
Quant it ie s , FTCs , and Yie lds for Example 3

A s implified s ket ch of t he s er ies oper at ion s t h at will be u s ed for t h e pr oces s FTC calcu lat ion is
s h own in Figu r e 6. En t er t he operat ion FTCs in t h eir res pect ive blocks on t he s ketch . Calcu lat e
t h e pr oces s FTC by mu lt iplyin g t h e in dividu al oper at ion FTCs t ogeth er .

Figure 6
Simplified Pr oces s Sket ch for Exa mple 3

3 . 72 or 723 . 0 % 96 % 93 % 90 % 90 FTC
) 4 Op FTC )( 3 Op FTC )( 2 Op FTC )( 1 Op FTC ( FTC
PROCESS
PROCESS
= =
=

Calcu lat e t h e pr oces s yield u s in g Equ a t ion 3.
88% or 0.880 =
300
264
=
Yield
ted Qty Attemp
Completed Qty
=
Yield
PROCESS
PROCESS

Add t h e oper at ion an d pr oces s FTCs an d Yields t o t he pr oces s diagr am. Th e completed pr oces s
diagr am for example 3 is s h own in Figu r e 7. Th e diagr am can be inclu ded as par t of pr odu ct ion
demon s t r at ion r epor t t o docu ment t h e s t ar t in g pr oces s capabilit y.

Figure 7
Example 3 - Se rie s Proc e s s Wit h Ope rat ion, Proc e s s FTC's , and Yie ld Shown

300 Pcs
FTC=90%
FTC=96%
264 Pcs
FTC=90%
Operation 2
FTC=93%
Operation 3
300 Pcs
30 Pcs
Rejected
270 Pcs 268 Pcs 265 Pcs
10 Pcs
FTC=90%
Yield=90%
Operation 1
27 Pcs
FTC=90%
Yield=99%
Operation 2
FTC=93%
Yield=99%
FTC=96%
Yield=99.6%
Rework
2 Pcs
Scrap
25 Pcs
19 Pcs
Rework
3 Pcs
Scrap
16 Pcs
Rework
1 Pc
Scrap
9 Pcs
FTC = 72.3%
YIELD = 88.0%
264 Pcs

75
Example 4, Ser ies / Par allel Pr oces s Flow wit h Repair :
Us in g t h e t h r ee-s tep, dat a collect ion pr ocedu re ou t lin ed on page 5, t h e followin g pr oces s ed an d
r ejected qu an t it y da t a were collect ed du r in g a demon s t r at ion r u n . Th e dat a are s h own in Figu r e 8.

Figure 8
Example 4 - Se rie s / Paralle l Proc e s s Wit h De mons t rat ion Dat a Adde d

Calcu lat e t h e FTC an d yield for each oper at ion u s in g Equ a t ion s 2 an d 3. Not ice t h at Oper at ion 1
does n ot in clu de an y rewor k s o FTC an d Yield will be t he s ame. Th is is n ot t r u e for an y ot h er
oper at ion in t h e Example 4 pr oces s . Th e gener al oper at ion model is s h own in Figu r e 5C. Table 4
s h ows a s u mmar y of t h e qu an t it ies , FTCs , an d Yields for t he oper at ion s in Example 4.

Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Re je c t e d

FTC

Quant it y
Re worke d

Quant it y
Comple t e d

Yie ld

1

300

12

0.96

N/ A

288

0.96

2

288

23

0.92

18

283

0.98

3

102

2

0.98

7

107

1.05

4

97

11

0.89

6

92

0.95

5

84

12

0.86

5

77

0.92

6

276

28

0.90

27

275

0.99
TABLE 4
Example 4 Quant it ie s , FTCs , and Yie lds

En t er t he FTCs an d yields t h at were calcu lat ed for Oper at ion s 1 t hr ou gh 6 in t h eir res pect ive
oper at ion blocks of t he pr oces s diagr am. Th e en t r ies for Example 4 ar e s h own in Figu r e 9.
283 Pcs 97 Pcs
11 Pcs
to Rwk*
92 Pcs
Operation 4
102 Pcs Operation 3
2 Pcs
to Rwk*
107 Pcs
84 Pcs
12 Pcs
to Rwk*
77 Pcs
Operation 5
300 Pcs
12 Pcs 23 Pcs
288 Pcs
Rework
18 Pcs
18 Pcs
5 Pcs
Scrap
Rework*
Op 3,4,& 5
7 Pcs
Scrap
276 Pcs
Operation 6
28 Pcs
Rework
27 Pcs
1 Pc
Scrap
275 Pcs
25 Pcs
Rework*

76

Figure 9
Example 4 - Proc e s s Wit h Ope rat ion FTC's and Yie lds Shown

Th e pr oces s s h own in Figu r e 9 h as t h r ee oper at ion s in par allel,
Oper at ion s 3, 4, an d 5. To s implify t h e FTC calcu lat ion , r edu ce t he
t h r ee par allel oper at ion s , s h own in Figu r e 9A, t o an equ ivalen t , s ingle
oper at ion as s h own in Figu r e 9B. Tot al t h e qu an t it y at t empt ed an d
qu a n t it y r eject ed, t hen en ter t h e valu es on an equ ivalen t oper at ion
s ket ch s u ch as 9B.
Qt y At t empt ed = 102 + 97 + 84 = 283
Qt y Rejected = 2 + 11 + 12 = 25

Figu r e 9 A Figu r e 9B

Calcu lat e t h e equ ivalen t oper at ion FTC
Eq 3,4, 5
. Th e equ ivalen t s in gle oper at ion FTC calcu lat ion
u s in g t h e t ot al at t empt ed qu an t it y, 283 u n it s , an d t h e t ot al rejected qu an t it y, 25 u n it s , is s h own
below.

91% or 0.912 =
283
258
=
283
25 - 283
=
) 84 + 97 + 102 (
) 12 + 11 + 2 ( - ) 84 + 97 + 102 (
=
FTC
Attempted Qty
jected Re Qty Attempted Qty
FTC
EQ
EQ
=

283 Pcs 97 Pcs
FTC=89%
Yield=95%
11 Pcs
to Rwk*
92 Pcs
Operation 4
102 Pcs Operation 3
FTC=98%
Yield=105%
2 Pcs
to Rwk*
107 Pcs
84 Pcs
FTC=86%
Yield=92%
12 Pcs
to Rwk*
77 Pcs
Operation 5
300 Pcs
12 Pcs
FTC=96%
Yield=96%
23 Pcs
288 Pcs
FTC=92%
Yield=98%
Rework
18 Pcs
18 Pcs
5 Pcs
Scrap
Rework*
Op 3,4,& 5
7 Pcs
Scrap
276 Pcs
FTC=90%
Yield=99%
Operation 6
28 Pcs
Rework
27 Pcs
1 Pc
Scrap
275 Pcs
25 Pcs
Rework*
97 Pcs
11 Pcs
to Rwk*
92 Pcs
Operation 4
Rework*
Op 3,4,& 5
7 Pcs
Scrap
84 Pcs
12 Pcs
to Rwk*
77 Pcs
Operation 5
18 Pcs
102 Pcs Operation 3
2 Pcs
to Rwk*
107 Pcs
25 Pcs
Rework*
283 Pcs
Equivalent
Operation 3,
4, & 5
25 Pcs
Rejected

77

A s implified s ket ch of t he pr oces s t h at will be u s ed for t he FTC calcu la t ion is s h own in Figu r e 9C.
Mu lt iply t h e in dividu al oper at ion FTCs t oget her t o obt ain t h e FTC for t h e pr oces s , FTC
PROCESS
.

Figure 9 C
Simplifie d Proc e s s Ske t c h for Example 4

72% or 0.723 = 90%) 91% 92% 96% ( =
FTC
)
FTC FTC FTC FTC
( =
FTC
PROCESS
6 EQ 2 1 PROCESS

Calcu lat e t h e pr oces s yield u s in g Equ a t ion 3 as s h own below.

% 92 or 917 . 0
300
275
Yield
Attempted Qty
Completed Qty
Yield
PROCESS
PROCESS
= =
=

Add FTC
PROCESS
an d Yield
PROCESS
t o t h e pr oces s diagr am. Th e complet ed diagr am for Example 4 is
s h own in Figu r e 10. Th e diagr am can be in clu ded wit h t h e fin al PSO docu men t s as a recor d of t he
s t ar t in g per for man ce.

Figure 1 0
Example 4 - Se rie s / Paralle l Proc e s s Wit h Ope rat ion and Proc e s s FTC's and Yie lds Shown
FTC=91%
Equivalent
Operation 3,
4, and 5
FTC=96% FTC=92%
FTC=90%
Operation 6
283 Pcs 97 Pcs
FTC=89%
Yield=95%
11 Pcs
to Rwk*
92 Pcs
Operation 4
102 Pcs Operation 3
FTC=98%
Yield=105%
2 Pcs
to Rwk*
107 Pcs
84 Pcs
FTC=86%
Yield=92%
12 Pcs
to Rwk*
77 Pcs
Operation 5
300 Pcs
12 Pcs
FTC=96%
Yield=96%
23 Pcs
288 Pcs
FTC=92%
Yield=98%
Rework
18 Pcs
18 Pcs
5 Pcs
Scrap
Rework*
Op 3,4,& 5
7 Pcs
Scrap
FTC = 72%
YIELD = 92%
276 Pcs
FTC=90%
Yield=99%
Operation 6
28 Pcs
Rework
27 Pcs
1 Pc
Scrap
275 Pcs
25 Pcs
Rework*

78


79

APPENDIX D
PSO Exten ded Ru n

80

PSO Ext e nde d Run
Th is act ivit y is in t ended for n ew vehicle lau nch es or major vehicle u pgr ades t o r edu ce th e r isk of t h e vehicle
lau n ch . It does n ot impact t h e PSO appr oval pr ocess des cribed in t h is man u al bu t is a s u pplemen t al
act ivit y t o fu r t h er as s u r e a Su pplier s r eadin es s t o s u ppor t t h e fu ll volu me pr odu ct ion wit h capable
pr oces ses (see Figu re 1).

Figure 1

It is impor t an t for t he PSO Team t o decide th e t ype of PSO Ext ended Ru n th at will be accomplis hed and th e
t imin g, s o it can be in t egr at ed in t o t he PSO plan nin g pr oces s . In s ome cases t h er e will be addit ion al pieces
bu ilt or mu lt iple sh ift s exer cis ed du r in g t h e Pr odu ct ion Demons t r at ion Ru n an d in ot her cas es t h er e will be
addit ion al vis it s made at lat er dat es to en s u re r eadin es s as lau n ch appr oach es .

Due t o t he variet y of manufact uring proces s es ut ilized at Suppliers , t he final det ails of a PSO
Ext ended Run for a part icular part are decided by t he PSO Team. The following reference opt ions (1 -
5 ) have his t orically been us ed but ot her, more applicable, opt ions may be developed as indicat ed in
opt ion number 6 .

Opt ion Number

Opt ion Des c ript ion Opt ion Bene fit

1
Expan ded pr odu ct ion of 1000
or mor e par t s du r in g t h e PSO
PDR.
High er con fiden ce level t h at t h e Su pplier can
s u s t ain lin e r at e over a lon ger per iod of t ime.
2
Per form 2 s epar at e PSO PDRs
wit h th e las t r u n occu r rin g
pr ior t o S2 MRD.
Con firms th at t h e Su pplier can s t ar t t h e pr oces s
u p on mu lt iple occasion s and meet capabilit y and
lin e r at e.
3
Per form 3 s epar at e PSO PDRs :
Pr ior t o S1 MRD
Pr ior t o S2 MRD
Pr ior t o V1 MRD
Ver ifies Su pplier s pr oces s con sis t en cy an d
validat es r eadin es s for V1 Lau n ch .
4
Per form PSO PDRs on mu lt iple
s h ift s at t he Su pplier .
En s u r es oper at ion al r eadin es s on all s h ift s .
5
In addit ion t o t h e Pr e-S1 PSO,
per form a pos t -lau n ch PSO
occu r rin g 2-5 weeks aft er V1
Lau n ch.
Validat es th e lin e r at e aft er s ever al weeks of
oper at ion.
6
An y combin at ion of t h e above 5
opt ion s or an appr opr iat e
var iat ion for t he s pecific
commodit y.
Allows flexibilit y t o accommodat e u n iqu e
cir cu ms t an ces .

Table 1

PSO Process as described in the PSO manual
PSO Extended Run
Increased
confidence of
Supplier
readiness on
selected parts

81

APPENDIX E
Forever Requ iremen t s

82
DCX Fore ve r Re quire ment s Proc e s s

1. Su pplier pr opos ed ch an ges an d/ or impr ovemen t s t h at may r equ ir e par t su bmis s ion .

2. If ch an ges an d/ or impr ovemen t s affect fit , form, fu n ct ion an d/ or r equ ir e DCX pr in t modificat ion sor
h ave as s ociat ed cos t s ; t h en t h e Su pplier mu s t follow th e DCX En gin eer in g CN pr oces s (i.e., r efer t o t h e
appr opriat e DCX pr ocedu r es).

3. All ot h er pr opos ed ch an ges (par t , pr oces s , Tier 2 s ou r ce, et c.) s h all follow th e For ever Requ ir emen t s
pr oces s ou t lin ed h er e. Table 3.1 in t h e PPAP 4
t h
Edit ion AIAG man u al gives s ome examples of s it u ation s
r equ ir in g For ever Requ ir emen t s s u bmis s ions .
4. Su pplier fills ou t page on e (1) of t he DCX For ever Requ ir emen t s/ ODD Box Act ivit y Form. Not e: Pleas e
be advis ed, t h at t his for m mu s t be s u bmit t ed a min imu m of t h ree (3) mon th s in advan ce of t h e plan n ed
ch an ge(s ) implemen t at ion dat e or with in su fficien t time for implemen t at ion (as det ermin ed by DCX).

5. Su pplier su bmit s en t ir e DCX For ever Requ ir emen t s / ODD Box Activit y Form t o t h e appr opr iat e
En gin eer . Not e: if th e ch an ge(s ) affects mu lt iple plat forms, t h en t h e Su pplier mu s t su bmit a copy of th e
DCX For ever Requ ir emen t s/ ODD Box Act ivit y Form t o each affect ed plat for m En gineer.

6. Th e En gin eer will fill ou t pa ge t wo (2) Sect ion 2.A. If a ppr oved by t h e En gin eer , t h e Su pplier will t h en s u bmit t h e
en t ir e DCX For ever Requ ir emen t s / ODD Box Act ivit y For m t o t h e a ppr opr ia t e Su pplier Qu a lit y Specia lis t . If t h e
ch a n ge(s ) wa s r eject ed by t h e En gin eer , t h en t h e Su pplier mu s t cor r ect t h e r eject ed it em(s ) a n d r es u bmit t h e DCX
For ever Requ ir emen t s / ODD Box Act ivit y For m t o t h e En gin eer . Fa ilu r e t o r es u bmit t h e for m t o t h e En gin eer for
a ppr ova l will en d t h e For ever Requ ir emen t s pr oces s for t h e pr opos ed ch a n ge(s ).

7. Aft er a ppr ova l by t h e En gin eer , t h e Su pplier Qu a lit y Specia lis t will fill ou t pa ge t wo (2) Sect ion 2.B. If a ppr oved by
t h e Su pplier Qu a lit y Specia lis t , t h e Su pplier will s u bmit t h e for m t o t h e a ppr opr ia t e Bu yer . If t h e ch a n ge(s ) wa s
r eject ed by t h e Su pplier Qu a lit y Specia lis t , t h en t h e Su pplier mu s t cor r ect t h e r eject ed it em(s ) a n d r es u bmit t h e
DCX For ever Requ ir emen t s / ODD Box a ct ivit y For m t o t h e Su pplier Qu a lit y Specia lis t . Fa ilu r e t o r es u bmit t h e
for m t o t h e Su pplier Qu a lit y Specia lis t will en d t h e For ever Requ ir emen t s pr oces s for t h e pr opos ed ch a n ge(s ).

8. Aft er a ppr ova l by t h e Su pplier Qu a lit y Specia lis t , t h e Bu yer will fill ou t pa ge t wo (2) Sect ion 2.C. If a ppr oved by
t h e Bu yer , t h e s u bmit t ed ch a n ge(s ) a r e fu lly a ppr oved by DCX. If t h e ch a n ge(s ) wa s r eject ed by t h e Bu yer , t h en t h e
Su pplier mu s t cor r ect t h e r eject ed it em(s ) a n d r es u bmit t h e DCX For ever Requ ir emen t s / ODD Box Act ivit y For m t o
t h e Bu yer . Fa ilu r e t o r es u bmit t h e for m t o t h e Bu yer will en d t h e For ever Requ ir emen t s pr oces s for t h e s u bmit t ed
ch a n ge(s ).

9. Th e appr oval (or r ejection ) pr oces s shou ld be conclu ded by all affect ed DCX pers on n el wit h in 10
bu s in es s days .

10. A fu lly s ign ed electr on ic DCX For ever Requ ir emen t s / ODD Box Activit y indicat es t h at DCX appr oves t h e
plan ONLY.

11. Aft er t he DCX Forever Requ ir emen t s/ ODD Box Act ivit y For m is appr oved, t h e Supplier(s ) will complet e
all remaining t asks including t he succes s ful complet ion of all PER, PSO, PPAP, and ot her required
act ivit ies including and appropriat e hard copy and/ or elect ronic not ificat ion as neces s ary.

12. Aft er appr oval by all affect ed DCX per s on n el, t he Su pplier will make copies of t h e DCX For ever
Requ ir emen t s/ ODD Box Activit y Form an d dis t ribu t e it t o all appr opriat e DCX per s on n el as indicat ed
by t h e Su pplier Qu alit y Specialis t . In addition , th e Su pplier will r et ain th e or igin al copy of t h e fu lly
appr oved DCX For ever Requ ir emen t s/ ODD Box Act ivit y For m.

13. Su pplier will su bmit fu lly appr oved for m(s )an d/ or informat ion in t o Powerway.com as requ ired.

Pleas e be advis ed, t he hard copy format is being replaced by an elect ronic Forever Requirement
(eFR CN Sys t em). Tent at ive dat e t ime frame is early 20 0 7 .

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Forever Requirement s Proces s Flow

1) Supplier Proposes Change
"Forever Requirements" process begins
Does the change affect fit, form,
function, or cost?
Follow DCX CN/ODD Box Procedure;
"Forever Requirements" process ends
Supplier completes page 1 of "DCX Forever
Requirement Activity" form and submits one
to DCC Product Engineer for each affected
vehicle/platform. Submission must be a
minimum of 90 days before the
proposed effective date of the
change(s).
DCC Product Engineer(s) completes
section 2.A. of the form
Approved by DCC Product
Engineer?
DCC Approval not provided;
Supplier provides
additional information
as required.
Supplier submits form to DCC ASQP
Specialist
DCC ASQP Specialist completes section
2.B. of the form (including Risk Level)
Approved by DCC ASQP Specialist?
Supplier provides
as required.
Need more
information
Need more
information
Yes
Yes
Yes
No
No
No
Supplier submits form to DCC Buyer
DCC Buyer completes section 2.C. of form
Approved by DCC Buyer?
Supplier provides
as required.
Need more
information
Yes
No
A

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Forever Requirement s Proces s Flow, cont .

A
Supplier given approval to proceed with
change(s). Timing of change(s), including
PSO, is determined/approved by the Team
(DCC Buyer, ASQP Specialist, and Product
Engineer, and the Supplier.)
Risk Level (section 2.B. of form)
Follow PSO process for DCC
Lead PSO
Follow PSO process for
Supplier Lead PSO
Low High
Supplier successfully completes all PSO
requirements, as well as all requirements
from DCC Product Engineering, ASQP
Specialist, and Buyer on page 2 of the form
Supplier completes all Powerway.com
requirements and submits PPAP (as
applicable)
Supplier implements change 100%

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86

87

APPENDIX F
DCC In tern a l PSO Requ irement s

88
Internal Powertrain PSO

3 Steps to Approval

PV
Testing
Production
Demonstration Run
(PDR) & Analysis

Documentation

89

Internal Powertrain PSO

Documentation
The following documentation will be supplied for final PSO approval by the following DCX groups; Product
Engineering, Advanced Manufacturing Engineering, and the internal Powertrain Plant.

Product Engineering
Release Part Prints w/ Change Verification/ Level Identified
CATIA comments sheet (list of Engineering standards on sheet)
A copy of applicable performance, process and material standards (PF Standards)
Engineerings procedure for documentation revision changes due to part number changes
Engineerings procedure for obtaining and distributing CATIA revisions
DFMEA
Internal best practice document for DFMEA development
DVP&R (DaimlerChrysler Engineering signed DV test plan, DaimlerChrysler Engineering signed
completed DVP&R for DV testing, DaimlerChrysler Engineering signed PV test plan)
Documented waivers for any testing
Engineering MQAS procedure for Problem Solving
Supplier definition of and internal requirements for special product and process characteristics
DaimlerChrysler Engineering signed DVP&R for PV test results (MANDATORY ENGLISH
DOCUMENT)
PV test procedures (MANDATORY ENGLISH DOCUMENT)
DaimlerChrysler Engineering approved BSR results (if applicable) (MANDATORY ENGLISH
DOCUMENT)

Advanced Manufacturing Engineering
AMEs procedure for documentation revision changes due to part number changes
PFMEA (MANDATORY ENGLISH DOCUMENT)
Internal best practice document for PFMEA development
Process Flow Diagram (MANDATORY ENGLISH DOCUMENT)
Manufacturing floor plan
Work Station Layout
Dimensional Control Plan
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
Authorization to Ship (ATS Package)-Equipment Qualification at the Plant
AME MQAS procedure for Problem Solving

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Tooling List
Tool Layouts
Assembly Graphics
Tool & Op Sheets
Spare Parts List
Error and mistake proofing plan. This includes a list of error and mistake proofing by operation
number
Line Speed Simulation
AME MQAS procedure for gauge identification
PM plan, schedule, procedure and work instructions

Plant Deliverables
Plants procedure for documentation revision changes due to part number changes
Plants procedure for obtaining and distributing CATIA revisions
Control Plan (MANDATORY ENGLISH DOCUMENT)
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
PPAP status list
Plant MQAS procedure for Problem Solving
Incoming inspection plan and procedures
Incoming sampling plans
Receiving reports
Material standards
Inspection/test reports
Parts Handling Plan
Material Handling procedures
Packaging Instructions
Maintenance plan for WIP (work in process) containers
Copy of Routing cards or travelers
Operator, 1st piece approval, mistake proofing, set-up, changeover, rework/repair, inspection and
packaging instructions
Record of operator training
Operator qualification process
Documentation control procedure
Visual management (displays & diagrams)
First Production Shipment Certification (FPSC) Plan (MANDATORY ENGLISH DOCUMENT)

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Control Charts (As Applicable)
Process Performance Charts (As Applicable)
Total Production Maintenance charts
Error and mistake proofing studies
Mistake Proofing Contingency Plan (in the event mistake proofing becomes inoperable)
Control Charts (As Applicable)
Process Performance Charts (As Applicable)
Total Production Maintenance charts
Log Sheets
Defect Tracking Sheets
Corrective Action Forms
1st Piece Approval Procedure & Records
Measurement System Verification Report (MANDATORY ENGLISH DOCUMENT)
Line Speed section on Production Demonstration Results form (MANDATORY ENGLISH
DOCUMENT)
Documented deviation to the 300 part or 2 hour requirement (if applicable)
Process Constraints (bottlenecks) documented on PSO COMMENTS SHEET
Final Audit Plan
Final Audit Procedure
Final Audit Work Instructions
Part Inspection Standard (if applicable) - (MANDATORY ENGLISH DOCUMENT)
Final Audit Sampling plan
Shipping Record Example
Audit Record Example
Containment Record Example
Parts Packaging and Shipping Plan
Packaging and Shipping Procedures
Packaging, shipping and labeling instructions
Returnable Container Management Plan
Barcode Labeling Procedure
Shipping Label example
Plant MQAS procedure for gauge identification
Gage Plan
Gage R&R results (MANDATORY ENGLISH DOCUMENT)
Gage and Test Equipment Calibration Records and validation plan

92
Calibration Schedule & reaction plan
Initial Process Study results (on Production Demonstration Results form) (MANDATORY
ENGLISH DOCUMENT)
Deviations to Initial Process Study requirements documented on the PSO COMMENTS SHEET (if
applicable) (MANDATORY ENGLISH DOCUMENT)
Deviation from FTC requirement w/Commodity Supplier Quality Manager signature (if applicable)
(MANDATORY ENGLISH DOCUMENT)
Simulation or shipping test results (Corp Mat Handling)
Warranty process flow diagram (MANDATORY ENGLISH DOCUMENT)
Warranty procedures
Annual Validation Schedule

Production Demonstration Run & Analysis
Internal Powertrain Programs must adhere to the requirements outlined in element 16 of the PSO Manual

PV Testing
Internal Powertrain Programs must adhere to the requirements outlined in element 21 of the PSO Manual.

Internal Powertrain PSO Sign-off Package Requirements

To assure that all Internal Powertrain PSO requirements have been met, the Internal Powertrain Process Sign-
off Package should include the following documents

Internal Powertrain Process Sign-off form along with the deviations list. The sign-off form should
include all necessary signatures.
The Internal Powertrain PSO work sheet.
Production Demonstration Run (PDR) Results Form. (This is a standard PSO document titled Line
Speed Demonstration Results Form)

All required forms and reference material can be found on the Internal Powertrain PSO website.
http://advmfg.appl.chrysler.com/mfg/stmpdash/pso/index.shtml

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FREQUENTLY ASKED QUESTIONS
Pleas e check h t t ps :/ / gs p.ext ra .da imlerch rys ler.com/ qlt y/ ps o/ in dex.h t ml for t h e mos t
cu r ren t ver s ion of t h e FAQ.

94
1 . How far down do we go wit h t he cert ificat ion of t he ext ended ent erpris e? 3 rd t ier? 4t h t ier?

Cer t ificat ion down t o t h e pr odu ct ion mat er ial Su pplier s and if applicable an y s econdar y
pr oces ses / ser vices (e.g. plat in g, heat t r eat in g, et c) wou ld be s u fficien t .

2 . What should our react ion plan be if Suppliers refus e t o conduct PSO's on t heir s ub-Suppliers ?

PSO is par t of Daimler Ch r ysler 's Su pplier evalu at ion and Pr odu ct ion Par t Appr oval Pr oces s .
Accor din g t o TS-16949 and t h e DCC Cu s t omer -Specific Requ ir emen t s for TS-16949,
Su pplier s ar e r es pon s ible for evalu at ion an d Pr odu ct ion Par t Appr oval of t h eir s u b-tier s. All
DCC Su pplier s wer e r equ ir ed t o be TS-16949 cer t ified. Not e t h at t his does n ot r equ ir e t h at
Su pplier s per form a PSO specifically, it does r equ ir e an evalu at ion an d/ or PSO-lik e act ivit y.
Failu r e t o condu ct evalu at ion s an d Pr odu ction Par t Appr oval of s u b-t ier s is a failu r e t o meet
TS-16949 r equ ir emen t s and may r esu lt in t h e los s of DCC bu s ines s . Not ify t h e Bu yer and
P&S Man agemen t of an y occu r r en ce of t h is sit u at ion .

3 . Suppliers don't follow t he Lot Accept ance Sampling Table. They always inspect about 5
part s/ lot , lot s ize is 1 , 00 0 pcs . Should we force t hem t o inspect as many as t he t able s ays ?

For at t ribu t e s amplin g, two or mor e of t h e in s pect ion cr it er ia in TS-16949 s h all be u sed,
ot h er wis e th e gu idelin es in t h e Lot Accept an ce Samplin g Table s h all be followed. For variable
s amplin g, t h e Su pplier s h all be con s is t en t wit h t h e St at is t ical Pr oces s Cont r ol man u al
r equ ir emen t s .

4 . Collaborat ive AQP ris ked part s require a PSO if s elect ed by t he PSO Team. If t he PSO Team
cons iders a product t o be Self Direct ed, is PSO required?

Yes . All Self Dir ect ed pr odu ct s sh all h ave a Su pplier in t er n ally led PSO t hat docu men t s and
es t ablish es t h eir pr odu ction r eadin ess . Th e Su pplier 's PSO docu men t at ion s h all be u ploaded
in t o Power way.com.

All Dir ect ed AQP r isked pr odu ct s will h ave bot h a Daimler Chr ysler led AQP an d PSO. All
Collabor at ive ris ked pr odu ct s will h ave a Daimler Chr ys ler led PSO and a Su pplier led APQP.

5 . Since AAR is a requirement for PPAP, s houldnt AAR be required for PSO approval if t he
proces s appreciably affect s color?

AAR is n ot a r equ ir emen t of PSO. Refer t o t h e AIAG PPAP man u al for an explan at ion of t h e
r elat ion sh ip bet ween PSO an d PPAP.

6 . If a Supplier changes a proces s , where does t he Supplier go t o st art t he PSO proces s , t he
Respons ible Des ign Engineer or t he Supplier Qualit y Specialist ? We've been t old bot h.

Befor e a Su pplier makes an y ch an ges t o t h eir as s embly pr oces s th ey sh all in it iat e a For ever
Requ ir emen t s form and obt ain approval fr om t h e DCC Releas e En gin eer , ASQP Specialis t ,
an d Bu yer . Th e ASQP Specialis t will det ermin e t h e ris k level of t h e ch an ge (if appr oved) and
cor r espondin g PSO act ivit y level.

7 . Mos t Suppliers us e CMM print out for inspect ion document at ion. Do we need t o t rans fer t his
dat a t o t he appropriat e form?

No, a copy can be at t ach ed or a s t at emen t pr ovided on t h e COMMENTS SHEET t h at t h e PSO
Team verified t h e meas u r emen t .

95
8 . In a mult i-cavit y t ool, s hould part s come from all cavit ies t o calculat e PP and PPK?

Par t s sh ou ld come fr om all cavit ies , however each cavit y (pr ocess s t ream) sh ou ld be
calcu lat ed individu ally as s t at ed in t he St at is t ical Pr oces s Con tr ol (SPC) man u al pu blis h ed by
AIAG.

9 . Our forms do not have a cont rol number or is s ue dat e. This is an ISO/ TS-1 6 94 9 requirement .
What should be done?

Th e forms are par t of t h e man u al, and t h ey ar e iden tified in Daimler Ch r ysler s Mas t er Record
Lis t .

1 0 . Why don't we t ake rework int o account when calculat ing FTC?

Gr eat er qu an t it ies of r eject s incr eas e t h e pot en tial for great er qu an tit ies of n on -con formin g
par t s sh ipped. Daimler Ch r ys ler PSO Teams will r eview FTC at each Su pplier t o confirm th at
defect s h ave been min imized. If r ework wer e in clu ded in t he FTC calcu lat ion , it wou ldn 't be a
meas u r e of Fir s t Time Capabilit y. While we r ecogn ize t h at r ework of in -pr oces s r eject s is
common , we wan t t o meas u r e t he t r u e Fir s t Time Capabilit y of t h e pr oces s in or der t o
qu an t ify t h e qu alit y pot en t ial.

Appen dix C, pr ovides a s t an dar d meth od and examples for calcu lat in g FTC for a new pr oces s
wit h n o r ewor k.

1 1 . Can t he PSO Team accept a Product ion Demonst rat ion Run which is les s t han 30 0 pieces/ 2
hours ?

Yes . Th e PSO Team s h all au t h orize an y deviat ion fr om requ iremen t s (min imu m of two h ou r s
or 300 pieces , which ever is mor e s t rin gen t ) and en t er an explan at ion on th e PSO
COMMENTS SHEET.

1 2 . Clarify IAA requirement s .

Informat ion r egardin g cu r r en t in t erim appr oval requ iremen t s is locat ed in DCC in t ern al
pr ocedu r e PSSP0108. Su ppliers do not h ave acces s t o t his pr ocedu r e and s h ou ld con t act
t h eir DCC ASQP Specialis t , Releas e En gin eer or Bu yer for mor e in for mat ion r egar din g IAAs .

1 3 . You don't have t o have PSO approval prior t o V1 if you have an IAA. Explain t he sys t em of
t ool payment aft er PSO element s 1-2 0 wit hout an approved PSW.

IAA is n ot an alt er n at ive t o PSO. An IAA indicat es failu r e t o meet pr ogr am r equ ir emen t s . It
en ables s h ipmen t s on an in t erim basis t o s u ppor t vehicle developmen t t imin g u n til cor rect ive
act ion (PSO appr oval) can be completed.

Aft er a Su pplier s u cces sfu lly completes t h e fir s t 20 elemen t s for bot h docu men t at ion an d
pr oces s, t h e ASQP Specialis t en t er s a Z dis pos ition in t o Power way.com wh ich , followin g t h e
s u bmis sion of a dimen s ion al war r an t, allows t ool paymen t at t h e dis cr et ion of t h e Pu r ch asin g
Agen t .

1 4 . Can part s us ed for PV t es t ing be s elect ed from a non-succes s ful Product ion
Demons t rat ion Run?

In gen er al, par t s for PV t es tin g sh all be s elect ed fr om a su cces s fu l Pr odu ction Demon s t r at ion
Ru n , h owever , th er e ar e except ions . Th e PSO Team will r eview an y deficien cies . A n on -

96
s u cces s fu l PDR can on ly be u s ed for PV t es t in g if t h e deficiencies ar e du e to docu men t at ion
dis cr epancies or appear an ce (n on -fu n ct ion al) is s u es n ot in volvin g finis h du r abilit y.

1 5 . Is t he 2 00 0 minimum quant it y for FPSC a negot iable amount ?

Yes , h owever , an y deviat ion fr om t h e 2000 min imu m sh all be explain ed u sin g t h e PSO
COMMENTS SHEET.

1 6 . If t he PSO is not approved does t his imply t hat t here is no FPSC?

No, FPSC is s t ill r equ ir ed, bu t it will pr obably ext en d t h e t ime per iod and qu an t it y of t h e
FPSC.

1 7 . Who get s t he FPSC form in t he plant ? Is t here an organizat ion t o handle t his?

Th e Su pplier s h all r eview t h e completed for m wit h t h e PSO t eam and u pload it in t o
Power way.com. Th e Su pplier s h all als o r et ain t h e or igin al for m for u p t o on e year followin g
t h e lau n ch .

1 8 . Regarding FPSC, what if we t ake a t ruck frame wit h 4 0 0 dimens ions , for example. How many
frames do we need t o meas ure? All 2 0 0 0?

Th e PSO Team, wor kin g with t h e Su pplier , will det er min e wh at sh all be an adequ at e plan t o s at is fy t h e
FPSC r equ ir emen t s.

1 9 . It 's crit ical t o know where part s are going - if t here are 3 t ruck plant s, it could mean 6 00 0
part s for FPSC.

FPSC r equ ir es t h at t h e fir s t 2000 part s s h ipped t o each cu s t omer facilit y be cer t ified. If t h er e
ar e 3 tr u ck plan t s , t h en 6000 par t s will r equ ir e FPSC.

2 0 . Expand t he FPSC explanat ion. Add examples for at t endees t o follow. Include a s lide t hat
explains a st at ist ical analys is of t he firs t 2 ,0 0 0 pieces is required which is different t han t he
3 0 0 piece PSO capabilit y st udy.

Th e 300 piece Pr odu ct ion Demon s t r at ion Ru n th at is par t of t h e PSO, s at is fies t he
compon en t r equ ir emen t s for PV t es tin g, ot h er t es t in g, S1 veh icles , and S2 veh icles . Th ese
compon en t s ar e n ot in t ended t o s at isfy t h e FPSC r equ ir emen t s. However , u n der cer t ain
cir cu ms t an ces , t h e PSO Team may allow t he r emain der of th es e PSO par t s, if an y, t o be
in clu ded wit h pr odu ct ion par t s s hipped t o t h e As s embly Plan t . Refer t o t h e Daimler Chr ys ler
FPSC pr ocedu r e PSSP0106.

2 1 . If an offs hore DaimlerChrys ler employee performs a PSO in his/ her local count ry, t his manual
requires t hem t o us e English for t he mas t er document at ion. This s hould be a t eam decis ion.

Daimler Ch r ysler is a global compan y. As s t at ed, En glis h is t h e official lan gu age of Daimler Chr ys ler an d
t h er efor e an En glis h tr an s lat ion h as to be available. It does n ot pr eclu de oth er lan gu age ver s ion s .

2 2 . Who pays for addit ional manpower needed t o s upport FPSC?
FPSC is a PSO requ iremen t and an y addit ion al manpower or t oolin g n eeded t o fu lfill t his
r equ ir emen t is t h e s ole r es pon s ibilit y of t h e Su pplier .

97
2 3 . At what level must packaging be s igned off?

Su pplier des ign ed packagin g sh all be s ign ed off by Daimler Chr ys ler Corpor at e an d th e
r eceivin g As s embly Plan t Mat erial Han dlin g En gin eer in g pr ior t o Z appr oval of t h e PSO
u s in g t he Un it Load Dat a (ULD) s h eet (available in t h e DCC Packagin g an d Sh ippin g
Ins t r u ction s man u al.) Act u al packagin g s h ippin g t es t s h all be s igned off by Daimler Chr ys ler
As s embly Plan t Mat er ial Handlin g Engin eerin g pr ior t o PSO A appr oval. Packagin g sh ippin g
s imu lat ion t es tin g sh all be sign ed off by Corpor at e Mat erial Han dlin g En gin eer in g prior t o
PSO A appr oval. For DCC des igned packaging, PSO approval must not be delayed due
t o a lack of approval(s). Any ques t ions concerning approval of DCC des igned packaging
s hould be referred t o t he DCC Mat erial Handling Group.

2 4 . Is it accept able for a Supplier t o add or remove operat ors from a product ion line during t he
line speed demonst rat ion?

Th e n u mber of oper at or s r equ ir ed for t h e pr odu ct ion line s h all be iden t ified on t he Pr oces s
Flow Ch ar t , Man u fact u r in g Layou t , an d/ or Works t at ion Layou t . Th e Su pplier may n ot
deviat e fr om t h is n u mber du r in g t h e PDR; lin e-balan cin g and ot h er er gon omic or efficien cy
s t u dies ar e expect ed t o be complet ed pr ior t o t he PSO On -Sit e vis it .

2 5 . If a reference charact eris t ic is s howing out -of-specificat ion on t he Init ial Proces s St udy, should
I approve t he PSO?

Th is depends on wh at is mean t by a r efer en ce ch ar act er is t ic. Str ictly s peakin g, a r efer en ce
dimen sion does n ot h ave a t oler an ce an d, t h er efor e, can n ot be ou t -of-s pecificat ion . Bas ic
dimen sion s , on t h e oth er h an d, u s e gen er al pr in t t oler an ces ; if t h ese ar e ou t -of-s pecificat ion ,
t h en t h e PSO mu s t be r eject ed. All dimen sion s on t h e des ign model mu s t meet and be
capable t o DCC specificat ion s, even th os e n ot r egu lar ly monit or ed.

2 6 . The Supplier has s everal required document s t hat t hey cons ider propriet ary, and will not allow
us t o review t hem. How do we handle t his?

As s t at ed in Elemen t 7 (cl. 7.7): Not e: For s ou r ce packages t h at r eflect propr iet ar y docu men t
exclu s ion s, t h os e docu men t s s it ed for exclu s ion ar e n ot r equ ir ed t o be u ploaded in t o
Power way.com. However , th es e docu men t s s h all be available for review at t h e r equ es t of t h e
DCC ASQP Specialis t . A cover page wit h t h e docu men t s t it le block, r evis ion level and dat e is
r equ ir ed t o be u ploaded in place of t he act u al docu men t . Review of t h e docu men t s may t ake
place at t h e Su pplier s locat ion or at a DCC locat ion , at t h e dis cr et ion of th e t eam. In t h os e
r ar e cas es wh en a Su pplier r efu s es t o allow DCC per s on n el t o r eview requ ir ed docu men t s at
all, t h e PSO sh ou ld be r eject ed and th e mat t er br ou gh t u p t o DCC man agemen t (ASQP,
En gin eer in g, and/ or Pu r ch as in g, as appr opriat e.)

98
REFERENCE MANUALS

Daimler Ch r ysler Man u als :

- Packagin g an d Shippin g In s tr u ct ions

- Pr odu ct As su r an ce Tes t in g

- Tes t Dat a An alys is man u al

- P&S 7-St ep Cor r ective Action Pr ocess man u al

Ava i l a bl e From: Lan ier Pr ofes s ion al Ser vices
Det r oit Pr odu ction Cen t er
2119 Au s t in Ave.
Roch es t er Hills , MI 48309
Ph on e: 248.564.4748
Fax: 248.564.4679

Cor por at e En gineerin g Pu blicat ions :
- CEP-002 CATIA St an dar ds Refer en ce Man u al
- CEP-010 Su pplier Pr odu ct Design In for mat ion Secu r it y Requ ir emen t s

Ava i l a bl e From: h t tps :/ / es s d.ext r a.daimlerchr ys ler .com/ ESSD/ Login.jsp

AME St an dar ds :
- AME St an dar ds -Gage St andards

Ava i l a bl e From: h t tps :/ / gsp.extr a.daimler chr ys ler .com/ mfg/ amedd/ gages / index.h t m

Ot h er Man u als :

- Pr odu ct ion Par t Appr oval Pr oces s (PPAP)

- Meas u r emen t Sys t ems An alys is (MSA) Man u al

- St at is t ical Pr ocess Con t r ol (SPC) Manu al

- Pot en t ial Failu r e Mode and Effect s An alys is (FMEA)

- Advan ced Pr odu ct Qu alit y Plann in g an d Con tr ol Plan (APQP) Man u al

- Qu alit y Sys t ems Requ ir emen t s for Au t omot ive Su pplier s (ISO/ TS 16949)

- Qu alit y Sys t ems Requ ir emen t s of VDA (VDA 6.3)

Ava i l a bl e From: Au t omot ive Indu s t r y Act ion Gr ou p (AIAG)
Ph on e No: (248) 358-3003

NOTE: Daimler Ch r ysler per s onn el can obt ain copies of th e man u al th r ou gh Daimler Chr ys ler 's eCopier
on Das hboardAn ywh er e.

99

GLOSSARY

100
ADVANCED QUALITY PLANNING (AQP): a s t r u ctu red met hod of defin in g a n d es t ablis h in g
t h e requ ired s teps neces s a r y t o a s s u re t h a t a pr odu ct s a t is fies t h e cu s t omer . AQP
embodies t he con cept s of defect pr even t ion a nd con t inu ou s impr ovemen t a s con t r a s ted
wit h defect detect ion .

AUTOMOTIVE INDUSTRY ACTION GROUP (AIAG): a gr ou p fou n ded in 1982 by
r epres en t a t ives fr om Da imlerCh r ys ler , Ford, a n d Gener a l Motor s . Th e pu r pos e of t h e
AIAG is to provide a n open foru m where members cooper a te in developin g a n d pr omot in g
s olu t ion s t h a t en h a n ce t he pr os per it y of t h e au t omot ive in du s t r y. AIAG's focu s is t o
con t in u ou s ly impr ove bu s ines s pr oces s es a n d pr a ct ices in volvin g t r a din g pa r t n er s
t h r ou gh ou t t h e s u pply cha in . Th e AIAG webs ite is a t h t t p:/ / www.a ia g.org/ .

BOUNDARY SAMPLES: pa r t s amples crea ted a s a vis u al in s pect ion a id for oper a tor s .
Sa mples a re t ypica lly crea ted at t h e s pecifica t ion limit s (e.g. go a nd n o-go) or a t t h e
wor s t -pos s ible a ccept able condit ion (e.g. n o wor s e t h a n .) Bou n da r y s a mples mu s t be
clea r ly ma r ked a nd/ or iden t ified t o preven t s h ipmen t t o t h e cu s t omer a n d pr oper ly
con t r olled t o preven t degr ada t ion a n d ens u re releva n ce.

BUZZ SQUEAK RATTLE (BSR): object ion able veh icle nois e a t t ribu t es . All BSR is s u es
a r e t r a cked by Veh icle Developmen t a n d s u bs equ en t ly a s s igned t o t he mos t r es pon s ible
pa r t y for r es olu t ion , be it En gin eer in g, Ma n u fact u r in g, or t h e Su pplier . Alt h ou gh
s omewh a t s u bject ive, BSR is s u es s h a ll be elimin a ted in order t o a ch ieve cu s t omer
s a t is fa ct ion .

CAPABILITY STUDY: is a s t a t is t ica l a n a lys is of t he ou t pu t fr om a ma ch ine or a pr oces s to
deter mine it s abilit y t o pr odu ce pr odu ct t h a t meet s s pecifica t ion s . Th is a n a lys is is
es pecia lly impor t a n t wh en a new pr odu ct is in t r odu ced s o pr odu ct qu a lit y a nd va r ia t ion
r edu ct ion ca n be a s s es s ed.

CATIA: is a compu ter a ided t h ree dimen s ion a l in ter a ct ive a pplica t ion s des ign a nd
ma n u fact u r in g s ys tem. Th is s oft wa r e wa s developed a n d is ma in t a ined by Das s au lt
Sys t emes of Fra n ce a nd is ma rketed in t h e Un ited St a tes by IBM. It is known a s a
CAD/ CAM s ys tem.

CHRYSLER DEVELOPMENT SYSTEM (CDS): CDS provides a fr a mewor k for a t ot a l
s ys tems appr oach t o Pr odu ct Cr ea t ion . Th is fr a mewor k will s hor t en t he over a ll t ime for
t h e developmen t a nd la u nch of a veh icle, wh ile providin g a for u m for s h a r in g. Cons is tency
a mon g pr odu ct t eams is a chieved by u s in g a s t a nda r d pr oces s . Th e CDS proces s keeps
t h e des ign win dow open for a lon ger per iod t o ens u re pr odu ct s meet or exceed exter n a l
r equ iremen t s . At t h e s ame t ime, it ens u res t h a t t h e des ign a nd fea s ibilit y for bot h produ ct
a n d proces s is complete pr ior t o execu t ion . Th is is key t o t he CDS pr oces s . By complet in g
des ign a nd fea s ibilit y pr ior t o execu t ion u s in g vir t u a l des ign t ools , cos t ly ch a n ges a re
elimin a ted in t h e execu t ion a nd la u nch ph as e. Th e CDS webs it e is a t
h t t p:/ / r oa dma p.t cc.ch r ys ler .com/ cds / wh a t _is _cds .h t m.

CONTINUING CONFORMANCE TESTING (CC): t es t s a n d eva lu a t ions per for med a fter
produ ct ion lau n ch t o mon it or t h e effect s of proces s in g a n d t o a s s u re con t inu ed
con for ma n ce t o en gineer in g requ iremen t s .

CONTROL PLANS: wr it ten des cr ipt ion s of t h e s ys tems for cont r ollin g pa r t s a n d proces s es .
Th ey a re wr it t en by Su ppliers t o a ddres s t h e impor t a n t ch a r a ct er is t ics a n d en gineer in g

101
r equ iremen t s of t h e pr odu ct . Ea ch pa r t s h a ll h a ve a Con t r ol Pla n , bu t in ma n y ca s es ,
fa mily Con t r ol Pla n s ca n cover a n u mber of pa r t s pr odu ced u s in g a common proces s .
Cu s t omer appr ova l of Con t r ol Pla n s ma y be requ ired pr ior t o pr odu ct ion pa r t s u bmis s ion .

COVISINT: A web ba s ed s ys tem t h a t gr a n t s qu a lified Su pplier u s er s a cces s t o s elected
por t ions of t h e Da imler Ch r ys ler Net wor k.

C
P
: capabilit y in dex t h a t compa r es t h e pr oces s ca pa bilit y t o th e ma ximu m a llowa ble
va r ia t ion a s indica ted by t he t oler a nce. Th is in dex pr ovides a mea s u re of h ow well t h e
proces s will s a t is fy t he va riabilit y requ iremen t s . C
P
is n ot impacted by pr oces s loca t ion .
Th is in dex ca n be ca lcu la ted on ly for t wo-s ided (bila tera l) t olera n ces . (St a t is t ica l Pr oces s
Con t rol Ma nu a l, pg. 132)

|
.
|
\
|

=
2
6
d
R
LSL USL
6
LSL - USL
=
C
C
P
o

Wh er e, USL = Upper Specificat ion Limit
LSL = Lower Specificat ion Limit
C
o
= Es t imat e of t he s t an dar d deviat ion of a s t able pr oces s u s in g t h e aver age
r an ge of s u bgr ou ped s amples t aken fr om t h e pr oces s
R
= Aver age r an ge of a s eries of s u bgr ou ps of con s t an t size
2
d = A divis or of
R
u s ed t o es t imat e t h e proces s s t an dar d deviat ion (see t h e
St at is t ical Pr ocess Con t r ol Man u al (AIAG) Appendix E.

C
PK
: ca pa bilit y in dex t h a t t a kes t h e proces s loca t ion as well as t h e capabilit y in t o
a ccou n t . (St a t is t ica l Proces s Con t rol Ma nu a l, pg. 132)

P PK
C C s

C
P
a n d C
PK
a re equ a l on ly when t h e pr oces s is cen tered.
C
PK
is ca lcu la ted a s t he min imu m of CPU or CPL, where:

|
.
|
\
|

=
2
3
3
d
R
X USL X - USL
= CPU
C
o
a n d

|
.
|
\
|
2
3
3
d
R
LSL X LSL X
= CPL
C
o

X
= Th e aver age of su bgr ou p aver ages (meas u r ed pr oces s aver age)
C
o
= Es t imat e of t he s t an dar d deviat ion of a s t able pr oces s u s in g t h e aver age
r an ge of s u bgr ou ped s amples t aken fr om t h e pr oces s
R
= Aver age r an ge of a s eries of s u bgr ou ps of con s t an t size
2
d = A divis or of
R
u s ed t o es t imat e t h e proces s s t an dar d deviat ion (see t h e
St at is t ical Pr ocess Con t r ol Man u al (AIAG) Appendix E.

102
CUSTOMER SATISFACTION AUDIT (CSA): a comprehen s ive review of a veh icles a s -
s h ipped qu a lit y a s it lea ves a n a s s embly pla n t . Th e CSA provides a reliable rea l-t ime
in dica tor of veh icle qu alit y.

DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA): for ma lized met h od for
qu a n t ifyin g t h e r is k a s s ocia ted wit h iden t ified poten t ia l des ign fa ilu r e modes . It is u s ed t o
iden t ify correct ive act ions requ ired t o preven t fa ilu res from rea ch in g t h e cu s tomer . Th e
DFMEA is a livin g docu men t t h a t is u pda ted a s t he des ign ch an ges a n d pr ogres s es
t h r ou gh des ign ver ifica t ion a n d pr odu ct ion .

DESIGN OF EXPERIMENTS (DOE): a s t a t is t ica l approa ch t o efficien t ly pla n a nd s t r u ct u re
a s er ies of con t r olled tes t s . In it s br oades t s ens e, it en compa s s es pla n n in g, s et t in g u p,
a n d r u n n in g t he t es t s , a n d a n alyzin g t h e da t a . The goa l is t o iden t ify t h e s ou r ces of
pr odu ct va r ia t ion t h a t s h ou ld be opt imized or a voided for cons is ten t pr odu ct per for ma nce
wit h a min imu m n u mber of t es t s .

DESIGN VERIFICATION PLAN AND REPORT (DVP&R): for malized tes t pla n n in g a nd
r epor t in g t ool. It lis t s a ll tes t ing n eces s a r y t o a s s u re t h a t fu n ct ion a l a n d reliabilit y cr iter ia
a n d t a r get r equ iremen t s a re defin ed in s pecific mea s u r a ble terms . It pr ovides a
con ven ien t r epor t in g for ma t for En gin eer in g Developmen t (ED), Des ign Ver ifica t ion (DV),
Pr odu ct ion Va lida t ion (PV) a nd Con t in u in g Con for ma n ce (CC) t es t in g.

DESIGN VERIFICATION (DV) TESTING: t es t in g ph a s e t h a t demon s t r a tes t he fin a l
r elea s ed componen t or a s s embly meets des ign in t en t . The t es t s , s a mple s izes , a nd
per for ma nce requ iremen t s a re det a iled in En gin eer in g Per for ma n ce St a nda r ds .

DRAWING CHANGE LEVEL (DCL): t h e la tes t des ign level of t h e relea s ed dr a win g. It is a
t wo digit a lph a field t h a t ca n be acces s ed on ODCICS2 t h r ou gh s cr een ENAA or ENJ A.

ELECTRONIC CORPORATE ISSUE MANAGEMENT SYSTEM (e-CIMS): DCCs elect r on ic
s ys tem for docu men t in g s er iou s is s u es t h a t a r is e du r in g veh icle pr ot ot ype, la u nch , or
volu me pr odu ct ion pha s es .

ENGINEERING STANDARDS: a r e wr it t en requ iremen t s t h a t des cr ibe ma ter ia ls ,
pr oces s es , per for ma n ce, reliabilit y, qu a lit y a n d/ or des ign requ ir emen t s for a ma ter ia l,
pr oces s , or pa r t or a fa mily of ma ter ia ls , pa r t s , or s ys tems .

ENGINEERING STANDARDS SUPPLIER DISTRIBUTION (ESSD): t he DCC compu ter
s ys tem t h a t gives Su ppliers acces s t o DCC En gin eerin g St a nda rds . It is a va ilable on -line
a t h t t ps :/ / es s d.ext r a .da imler ch r ys ler .com/ ESSD/ Login .js p.

ERROR PROOFING: Error proofin g is a met h od u s ed t o iden t ify poten t ia l proces s er r or s
a n d eit her des ign s t hem ou t of t h e produ ct or proces s , or elimin a t e t he pos s ibilit y t h a t t h e
er r or cou ld produ ce a defect . Exa mples of er r or pr oofin g in clu de:
- A r od clip des igned t o wor k in left - a nd r igh t -h a n ded pa r t s (a s oppos ed t o s epa r a te
clips for each ;
- A h ole or s lot des igned s o t h a t ma t in g pa r t s ca n on ly fit in t h e pr oper or ien t a t ion ;
- An oper a t ion t h a t will n ot fu n ct ion u n t il a ll componen t s a re pr es en t in t h e pr oper
or ien t a t ion .

103
EXTENDED ENTERPRISE' '' ': is a Da imlerCh r ys ler coordin a ted pr oces s t h a t u n ifies a nd
extends t he bu s ines s rela t ions h ips of Su pplier s a nd Su pplier t ier s in or der t o maximize
t h e effect ivenes s of veh icle developmen t , min imize tot a l s ys tem cos t s , a nd improve qu alit y
a n d cu s t omer a ccept a nce.

FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC): t he pu rpos e of FPSC is t o
ens u re t h a t in it ia l pr odu ct ion s h ipmen t s meet a ll DCC pr odu ct s pecifica t ion s . FPSC is
in t ended t o iden t ify pa r t problems a n d con t a in t he pa r t s a t t h e Su pplier s ma nu fa ct u r in g
fa cilit y du rin g t h e la u nch ph as e. FPSC requ ires t he Su pplier t o pr ovide s t a t is t ica l
eviden ce of con for ma n ce t o s pecia l pr odu ct a n d/ or pr oces s cha r a cter is t ics pr ior t o t h e
s h ipmen t of componen t s t o t he DCC (or DCC-des igna ted) as s embly pla n t . Cer t ifica t ion is
for a min imu m of 2000 pa rt s (per a s s embly pla n t ) or for a s pecified per iod of t ime as
iden t ified by t h e PSO tea m. 100% of t h e FPSC pa r t s a re t o be in s pected for con for ma nce
t o s pecia l produ ct a nd/ or proces s ch a r acter is t ics .

FIRST TIME CAPABILITY (FTC): FTC is equ a l t o t he n u mber of a ccept a ble pa r t s
pr odu ced divided by t he n u mber of pa r t s r ejected du r in g t he PDR. Rework a n d repa ir a re
NOT cou n ted in t h e nu mber of a ccept able pa r t s , n or a r e pa r t s in it ia lly r ejected by t he
proces s bu t fou n d t o be a ccept a ble a fter re-tes t in g. See Appen dix C for examples .

GAGE DIMENSIONING & TOLERANCING (GD&T): a s ys tem of s ymbols u s ed t o define
pa r t a n d pa r t fea t u re s ha pe, s ize, pos it ion , t oler a n ces , et c.

GAGE REPEATABILITY & REPRODUCIBILITY (R&R): a meth od u s ed t o r a te t h e
a ppr opr ia tenes s of a meas u remen t s ys tem a s a per cen t a ge of t h e pr odu ct t oler a n ce or
pr oces s va r ia t ion . Repea t abilit y is a mea s u re of t h e a bilit y of t h e ga ge to r epea t a given
mea s u remen t , a n d is eva lu a ted by repea tedly meas u r in g t he s a me pa r t s (equ ipmen t
va ria t ion ). Reprodu cibilit y is a mea s u re of t he a bilit y of people t o r eprodu ce a s er ies of
mea s u remen t s u s in g t he s ame ga ge, a n d is eva lu a ted by t wo or mor e opera t or s
in dependen t ly r epea t in g t h e ins pect ion of a s et of pa r t s (a ppra is er va r ia t ion ).

HOME LINE: Su pplier s a s s embly line loca ted in t he ma nu fa ct u r in g fa cilit y wh ere volu me
pr odu ct ion of t he pa r t (s ) t akes pla ce u s in g pr odu ct ion t oolin g a n d proces s es .

INTERIM APPROVAL AUTHORIZATION (IAA): docu men t a t ion a n d a ppr ova l t o tempor a r ily
u s e a pa r t t h a t does not meet PPAP a ppr ova l requ iremen t s for Pilot bu ilds , lau n ch , or
pr odu ct ion .

ISO/TS 1 6 9 4 9 : is a Tech n ica l Specifica t ion t h a t des cr ibes , in con ju nct ion wit h ISO
9001:1994, t h e Qu a lit y Sys t em Requ iremen t s for Au tomot ive Su pplier s . ISO/ TS 16949
h a s been prepa red by t he In ter n a t ion a l Au t omot ive Tas k For ce (IATF) for a ll pa r t icipa t in g
wor ldwide OEMs .

KEY <D> CHARACTERISTICS: des ign a ted by t he or <D> s ymbols on En gin eer in g
Sou r ce Docu men t s . Key Produ ct Ch a r a cter is t ics a re toler a n ced a n d mea s u r able
ch a ra cteris t ics (i.e. dimen s ion s , t orqu e et c.) of a pa r t , componen t or a s s embly t h a t ma y
ca u s e fa ilu re t o meet cu s t omer s a t is fa ct ion s pecifica t ions du e t o ma n u fact u r in g a n d/ or
a s s embly, a nd t h erefore, r equ ire s pecia l a t ten t ion t o ens u re accept able res u lt s . Referen ce
PS-7300 Key Produ ct Cha ra cteris t ics t he Us e of Dia monds for a ddit iona l in for ma t ion .

104
LINE SPEED: t he con t r a cted ma ximu m t ool capacit y r a t e deter min ed by dividin g t h e
Da ily Da imlerCh r ys ler Toolin g Capa cit y (Pieces per Hou r ) by t h e Su pplier s Net Oper a t in g
Time for Da imlerCh r ys ler Pa r t s (Hou r s / Da y). Th e Line Speed s h a ll be ver ified du r in g t he
Pr odu ct ion Demon s t r a t ion Ru n.

LOT: s pecific a mou n t of ma ter ia l or gr ou p of componen t s ; not t o exceed eigh t h ou r s or
one da ys pr odu ct ion , wh ichever is s ma ller .

MANUFACTURING FLOOR PLAN: a pict oria l la you t of t h e en tir e ma nu fa ctu r in g fa cilit y
dr a wn t o s ca le. It is t o in clu de a ll ma ch iner y, office s pace, la b s pa ce, s h ippin g-receivin g
a r ea s , qu a r a n t ine a rea s , h old ar eas , et c. The la you t s h a ll a ls o in dica te a n y pr opos ed a rea s
for expa n s ion a n d developmen t .

MISTAKE PROOFING: Mis t ake pr oofin g is a n approa ch u s ed to develop met hods t o
clea rly iden t ify errors t h a t ma y occu r a n d preven t t h em from becomin g non -
con for ma n ces . Exa mples of mis t a ke pr oofin g in clu de:
- Sens ors , opt ics , a nd/ or vis ion s ys tems t h a t detect mis s in g or in cor rect ly-as s embled
componen t s ;
- En d-of-line (EOL) tes ter s t h a t ch eck fu nct ion a l requ iremen t s ;
- Pick ligh t s or ba r codin g to a s s is t in pr oper pa r t s elect ion ;
- Con t inu it y t es t in g for elect r ica l componen t s .

NET OPERATING TIME FOR DAIMLERCHRYSLER PARTS: equ a l t o t he n u mber of h ou r s
(n or ma l work pa t ter n ), les s s chedu led down -t ime (e.g. breaks , s t a rt u p, preven t ive
ma in ten a n ce, s ha red pr odu ct ion , t ool ch a n geover s , s hu t -down , et c.) a n d t ime s chedu led
t o ru n ot her cu s tomers pa rt s an d/ or ot her DCC pa r t s .

NON-CONFORMANCE TRACKING (NCT) SYSTEM: DCCs elect r on ic s ys tem for
docu men t in g a n d t r a ckin g pa r t is s u es a t t h e ma nu fa ctu r in g pla n t s . It a ls o pr ovides a
met h od for r epla cemen t of t h os e pa r t s a n d for Su pplier dis pu te of t h e is s u e. Ser iou s
qu a lit y is s u es a re a ls o docu men t ed in t h e e-CIMS s ys tem.

NVH: Nois e Vibr a t ion Ha r s hn es s a re mea s u r a ble per cept ion s of veh icle a t t r ibu tes .
Th es e items a re u s u a lly dis covered a nd meas u red by Da imlerCh r ys ler s NVH la bor a tor y
fa cilit ies . NVH a t t ribu tes a re t ypica lly t u ned t o a cer t ain fr equ ency a n d amplitu de in or der
t o a ch ieve a n overa ll veh icle s ign a t u re fr equ ency. Th is s ign a t u r e is opt imized by veh icle
developmen t for t h e bes t cu s t omer r es pon s es .

OPERATOR INSTRUCTIONS: lis t s of s t eps in performin g a n opera t ion t h a t ma y con t a in
in s pect ion requ iremen t s , requ ir ed t ools a n d ga ges , SPC applica t ion s , s a mple s ize a n d
fr equ en cy, a nd a ccept a nce/ reject ion cr iter ia . Th ey s ha ll commu n ica te a ll r equ iremen t s
in volved in t h a t pa rt icu la r opera t ion . Th es e s h a ll be rea dily a va ila ble to t h e opera t or .

PACKAGING: ma ter ia l t h a t is u s ed t o s t ore a nd s h ip pa r t s . It pr ovides pr otect ion a n d
con t a in men t of pa r t s . It a ffect s eas e of h a ndlin g by ma nu a l or mech a n ica l mea ns .
Pa cka gin g ma y cons is t of ret u rn a ble or n on -ret u rn able items in clu din g du n n a ge.

PART CHANGE LEVEL (PCL): t h e la tes t des ign level of t h e pa r t (n ot n eces s a r ily t he
dr a win g). It is a t wo digit a lph a field fou nd on ODCICS2 t h r ou gh s cr een s ECCE or ENCZ.

105
PART SUBMISSION WARRANT (PSW): a n indu s t r y-s t a n da r d docu men t r equ ired for a ll
n ewly-t ooled or r evis ed pr odu ct s in wh ich t h e Su pplier con fir ms t h a t in s pect ion s a nd
t es t s on pr odu ct ion pa r t s s h ow con for ma nce t o cu s t omer requ ir emen t s .

PERISHABLE TOOLS: t ools wh ich a r e con s u med in t he pr oces s of produ cin g a pr odu ct ,
a n d a re u s u a lly a cos t it em, e.g., dr ill bit s , cu t t er s , s ockets , dr iver t ips , in s er t s , h obs ,
br oaches , weldin g t ips , et c.

P
P
: per for ma n ce index t h a t compa res t h e pr oces s per for ma nce t o t h e ma ximu m a llowable
va r ia t ion a s indica ted by t he t oler a nce. Th is in dex pr ovides a mea s u re of h ow well t h e
pr oces s will s a t is fy t he va r iabilit y r equ iremen t s . P
P
is n ot impa cted by pr oces s loca t ion .
(St a t is t ica l Proces s Con t rol Man u a l, pg. 133)

s
LSL USL
6
LSL - USL
=
P
P
P
6
=
o

P
o
= Es t imat e of t he s t an dar d deviat ion of a s t able pr oces s u s in g t h e s ample
s t an dar d deviat ion of a set of in dividu als abou t t h e aver age of t h e set .
s = Sample s t andard deviat ion for s u bgr ou ps or pr oces s es ; s ee t h e St at is t ical
Pr oces s Con t r ol manu al, Ch apt er II, Sect ion C or Ch apt er IV, Sect ion A.

P
PK
: per for ma nce in dex t h a t t a kes t h e pr oces s loca t ion a s well as t h e per for ma nce in t o
a ccou n t . (St a t is t ica l Proces s Con t rol Ma nu a l, pg. 133)

P PK
P P s

P
P
a n d P
PK
a re equ a l on ly when t h e pr oces s is cen tered.
P
PK
is ca lcu la ted a s t he min imu m of PPU or PPL, where:

s
X USL X - USL
= PPU
P
3 3
=
o
a n d

s
LSL X LSL X
= PPL
P
3 3
o

X
= Th e aver age of su bgr ou p aver ages (meas u r ed pr oces s aver age)
P
o
= Es t imat e of t he s t an dar d deviat ion of a s t able pr oces s u s in g t h e s ample
s t an dar d deviat ion of a set of in dividu als abou t t h e aver age of t h e set .
s = Sample s t andard deviat ion for s u bgr ou ps or pr oces s es ; s ee t h e St at is t ical
Pr oces s Con t r ol manu al, Ch apt er II, Sect ion C or Ch apt er IV, Sect ion A.

PRE-PSO DOCUMENTATION REVIEW: a meet in g condu cted by t h e PSO Tea m, ch a ired
a n d coordin a ted by t he ASQP Specia lis t , wit h t h e Su pplier . Th e meet in g is condu cted a t a
DCC s elected loca t ion prior t o t h e PSO On -Site vis it . The pu r pos e is t o review a ll of t he

106
Su pplier s r equ ired docu men t at ion in a s equ en t ia l wa y a nd det er mine t he Su pplier s
readines s for t h e Produ ct ion Demons t ra t ion Ru n (300 pcs .) a n d PSO On -Site Vis it .
Genera lly, a Pre-PSO meet in g is h eld for Directed a nd Collabor a t ive AQP a ct ivit y level
pr ogr a ms ; it is n ot a r equ iremen t for pr ogr a ms wit h a Self-Directed AQP a ct ivit y level.

PRE-PRODUCTION SAMPLE REPORT (PPSR): a dimen s ion a l a n d per for ma n ce ver ifica t ion
docu men t , s u bmit ted wit h a ll pa r t s a mples u s ed pr ior t o S1 St a r t .

PREVENTIVE MAINTENANCE (PM): a pla n ned s ys tem of a ct ion s performed t o preven t
breakdown of a mach ine or equ ipmen t a s a res u lt of n or ma l u s e.

PROCESS CAPABILITY: t h e 6
C
o
r a n ge of in heren t va r ia t ion in a s t a ble pr oces s . Referen ce
t h e St a t is t ica l Proces s Con t rol AIAG ma n u a l for more in for mat ion .

PROCESS PERFORMANCE: t he 6
P
o
r a n ge of t ot a l pr oces s va r ia tion . Reference t he
St a t is t ica l Proces s Con t rol AIAG ma nu a l for more in for ma t ion.

PROCESS FAILURE MODE & EFFECTS ANALYSIS (PFMEA): a s t r u ct u red met hod of
docu men t in g h is t or ica l or poten t ia l pr oces s fa ilu re modes , t h eir effect s , a n d t he con t r ols
t a ken t o en s u re t heir detect ion a n d/ or preven t ion . The PFMEA r a t in g s ys t em a llows
qu a n t ifica t ion of t h e r is k pres en t ed by each fa ilu re mode wit h t h e Ris k Preven t ion
Nu mber (RPN). The RPN is u s ed t o pr ior it ize recommended a ct ion s . Th e PFMEA is
developed by a cros s -fu n ct ion al t ea m a nd is u n iqu ely developed for ea ch pr oces s / pr odu ct .

PROCESS FLOW DIAGRAM: ch a r t t h a t illu s t r a t es t he flow of ma ter ia ls t h r ou gh t he
pr oces s . Th e dia gr a m genera lly s t a r t s a t r eceivin g, a nd in clu des wor k in pr oces s ,
pr odu ct ion , s h ippin g (in clu din g a n y s pecia l pr oces s in g wh ich ma y r es u lt fr om a
n on con for ma nce requ ir in g dis pos it ion ), a nd r ewor k or r epa ir oper a t ions .

PROCESS SIGN-OFF (PSO) ON-SITE VISIT: a s ys tema t ic a nd s equ en t ia l review of t h e
Su pplier s ma nu fa ct u r in g proces s con du cted by a PSO Team a t t h e Su ppliers produ ct ion
fa cilit ies . Th e ASQP Specia lis t is res pon s ible for leadin g t he PSO On -Site Vis it for Directed
a n d Collabora t ive AQP a ct ivit y level progra ms ; t he Su pplier lea ds t heir own for Self-
Directed AQP act ivit y level pr ogr a ms .

PRODUCTION DEMONSTRATION RUN (PDR): a pr odu ct ion ru n condu cted du r in g t h e
PSO On -Site Vis it con s is t in g of a t lea s t 300 pa r t s or 2 h ou r s of pr odu ct ion (wh ichever is
more s t rin gen t ). Th e PDR is on t h e produ ct ion line of r ecord, wit h t r a in ed oper a tor s , PPAP
(or equ iva len t ) approved compon en t s a nd ma ter ia ls , a n d r u n at a r a t e equ a l t o t h e da ily
ma ximu m t oolin g ca pa cit y. Th e DCC PSO Tea m will be on t he ma n u fact u r in g floor du r in g
t h e PDR for a ll Directed a nd Collabor a t ive AQP act ivit y level pr ogr a ms . PV tes t pa r t s a re
t a ken fr om t he PDR t o demon s t r a t e t h a t t h e pr odu ct ion pr oces s h a s n ot degr a ded t he
des ign per for ma nce t h a t wa s ver ified du r in g DV tes t in g.

PRODUCTION PART APPROVAL PROCESS (PPAP): proces s for en s u r in g t h a t pr odu ct ion
pa r t s a re ma nu fa ct u red t h a t meet cu s tomer requ iremen t s . Par t s PPAP s h a ll be t a ken fr om
a s ign ifica n t pr odu ct ion r u n . Da imlerCh r ys ler requ ires t h a t t h is r u n is a min imu m of t wo
(2) h ou rs or 300 pieces , wh ichever is more s t rin gen t , u n les s oth er wis e s t a ted in wr it in g by
t h e cu s t omer . Pa r t s fr om each pos it ion of a mu lt iple ca vit y die, mold, t ool or pa t ter n a re
t o be mea s u red a nd repres en t at ive pa r t s t es ted. Reference t he PPAP 4
t h
Edit ion AIAG

107
ma n u a l a n d t he Da imlerCh rys ler (Ch rys ler Grou p) Cu s t omer -Specific Requ iremen t s for
t h e PPAP 4
t h
Edit ion for more in for ma t ion .

PRODUCT SPECIFICATIONS: a ll en gineer in g dr a win g requ iremen t s in clu din g s t a nda r ds
referen ced on t h os e dra win gs an d wit h in t h e pre-s ou r ce package. Some of t hes e
requ iremen t s a re deter mined by t ea m con s en s u s du r in g Advan ced Qu a lit y Pla n n in g
meet in gs a nd Des ign Reviews an d ca n t a ke t he for m of Sa fet y St a n da r ds , Ma ter ia l
St a n da r ds , SRPCs , Tempor a r y St a n da r ds , Proces s St a n da r ds , La bor a t or y St a n da r ds ,
Relia bilit y St a n da r ds , or Per forma n ce St a nda r ds .

PRODUCTION VALIDATION (PV) TESTING: tes t s per for med t o va lida te des ign
con for ma n ce of in it ia l pr odu ct ion pa r t s ma nu fa ctu red wit h produ ct ion t ools a n d
pr oces s es .

REPAIR: act ion t a ken on n on-con formin g produ ct s o t h a t t h e produ ct will fu lfill it s
in t ended u s a ge, a lt h ou gh t h e pr odu ct ma y or ma y not con for m t o s pecifica t ion .

REWORK: a ct ion t a ken on n on-con for min g pr odu ct s o t h a t it will meet s pecifica t ion .

ROOT CAUSE: t h e as s ign able s ou rce of va ria t ion t h a t a ffect s a ll t h e in dividu a l va lu es of
t h e proces s ou t pu t or phenomen on bein g s tu died. Root cau s e is t h e rea s on for t h e
pr ima r y n on con for ma n ce, wh ich h a s in du ced ot her fa ilu res an d for wh ich effect ive
per ma nen t cor rect ive act ion can be implemen ted.

S0 START CDS Qu a lit y Ga te D
1
. S0 is t h e fir s t pilot bu ild pr ogr a m bas ed on produ ct
componen t s a nd s ys tems t h a t meet des ign s pecifica t ion , pr odu ced off t ools a n d
equ ipmen t a llowin g bu ild t o produ ct ion pr oces s in t en t . It in clu des veh icle a nd pr oper t y
bu ilds t h a t verify produ ct a n d proces s des ign a nd t r a in key pla n t per s on nel. Componen t s
ma y be bu ilt u s in g h a r d or s oft t ools , a s determined t o be a ppr opr ia te ba s ed on pa r t or
pr oces s kn owledge requ ired. Des ign ver ifica t ion (DV) tes t in g s h a ll be s u cces s fu lly
completed before pa r t s a re s u bmit t ed for S0.

S1 START: CDS Qu a lit y Ga te C. S1 is a h ome pla n t bu ild t o va lida te t oolin g, equ ipmen t
a n d ver ify fa cilit ies . Veh icles ar e bu ilt for t h e cer t ifica t ion t es t pla n . Componen t s for S1
a r e requ ired t o be PSO a nd PPAP appr oved.

S2 START: CDS Qu a lit y Ga te [n o let t er des ign a t ion ]. S2 is t h e home pla n t fa cilit y
va lida t ion bu ild. Veh icles a re bu ilt for fa s t feedba ck a nd ren t a l fleet feedba ck pr ogr ams ,
a n d for dea ler s .

SAFETY <S> CHARACTERISTICS: Des ign a ted by t he
S
or <S> s ymbols on En gin eer in g
Sou rce Docu men t s . Th ey a re pr odu ct ch a r a cter is t ics or ma nu fa ct u r in g proces s
pa r a meters wh ich ca n a ffect s afet y or complia n ce wit h gover nmen t r egu la t ions . See PF-
SAFETY Pr odu ct Sa fet y Us e of Sa fet y Sh ields <S> for mor e in for ma t ion .

SAMPLING PLAN: pla n t h a t defin es t he min imu m nu mber of pa r t s t h a t s h a ll be in s pected
fr om a given popu la t ion (s ee Da imler Ch r ys lers Lot Accept a nce Samplin g Table Pla n in
t h is ma n u a l).

SEQUENTIAL SENSING: t ype of s en s or t h a t detect s if a s er ies of opera t ion s a re
per for med in t h e cor rect order . Exa mple: A s t a t ion requ ires th a t a n a s s embly receives a

108
s crew, wa s her , a n d n u t (in t h at or der .) A s equ en t ia l s ens or wou ld detect a n d fla g
(t h r ou gh ligh t s , s t a t ion lock-ou t , et c.) if t h e n u t wa s pu t on befor e t he wa s her .

SPECIAL CHARACTERISTICS: pr odu ct ch a r acter is t ics or man u fa ct u r in g proces s
pa r a meters wh ich ca n a ffect s afet y or complia n ce wit h regu la t ion s , fit , fu n ct ion ,
per for ma nce or s u bs equ en t proces s in g of produ ct . Th ey in clu de a ll gover nmen t a l, Key
(dia mond) <D>, emis s ion s <E>, s a fet y (s h ield) <S>, t or qu e requ iremen t s , a nd
ch a ra cteris t ics iden t ified a s SPC poin t s on t he des ign model. See PS-7300 - Key Pr odu ct
Ch a r a cter is t ics t he Us e of Dia monds for more in for ma t ion r ega rdin g Key ch a r a cter is t ics
a n d PF-SAFETY for a ddit iona l in for ma t ion rega r din g Sa fet y cha r a cter is t ics .

STATISTICAL CONTROL: t he condit ion des cr ibin g a pr oces s fr om wh ich s pecia l ca u s es of
va r ia t ion h a ve been elimina ted. On ly common ca u s es rema in ; e.g., obs er ved va r ia t ion
cou ld be a t t ribu ted t o ch a nce ca u s es . On a con t r ol ch a r t , s t a t is t ica l con t r ol is eviden t by
t h e abs ence of poin t s beyond t h e con t rol limit s a nd by t he abs en ce of n on -r a ndom
pa t ter n s or t r ends wit h in t h e con t r ol limit s .

STATISTICAL PROBLEM SOLVING (SPS): t h e or ga n ized u s e of s pecia l problem s olvin g
t ools (e.g. Fis hbone Dia gr a ms , Pa ret o Ch a r t s , ANOVA, et c.), t o bet t er u nder s t a nd
pr oblems , t h eir r oot ca u s es a nd deter mine s olu t ions .

STATISTICAL PROCESS CONTROL (SPC): t h e u s e of s t a t is t ica l t ech n iqu es s u ch as
con t r ol ch a r t s t o a n a lyze a proces s or it s ou t pu t s t o t ake appropr ia te act ion s t o ach ieve
a n d ma in t a in a s t a te of s t a t is t ica l con t r ol a nd t o impr ove t he pr oces s ca pa bilit y.

SUB-COMPONENT: one or mor e pa r t s t h a t wh en a s s embled toget her r es u lt s in t he En d-
It em As s embly or modu le.

SUB-TIER SUPPLIER: s ee TIER 2 (& LOWER) SUPPLIER.

SUPPLIER READINESS EVALUATION (SRE) RUN: t he fir s t docu men ted bu ild a t t empt by
t h e Su pplier followin g ins t a lla t ion , s et u p, a n d t r you t of t he produ ct ion equ ipmen t a n d
t ools . The Su pplier Rea dines s Eva lu a t ion Ru n s hows t h a t t h e pr oces s is s et -u p,
debu gged, a nd rea dy for a Produ ct ion Demon s t ra t ion Ru n du rin g t h e PSO On -Site Vis it .
Th e Su pplier Readines s Eva lu at ion Ru n a n d a na lys is pr ovides t h e Su pplier wit h t h e
oppor t u n it y t o opt imize a nd r efin e t he proces s . Th e Su pplier , wit h t h e con cu r ren ce of t h e
DCC PSO Tea m, will determine t h e qu a n t it y of pa r t s t h a t a r e completed du r in g t h is r u n .
Th e pu rpos e of t h e SRE is t o provide pre-pr odu ct ion da t a t h at con fir ms t h e proper s et -u p,
opera t ion , a n d performa nce of t h e in s t a lled produ ct ion line. Da t a collected du r in g t h is
r u n t ypica lly in clu de meas u remen t da t a , ma ch ine cycle t imes , oper a t ion t imes , qu a n t it y
a t t empted, qu a n t it y a ccepted, et c. Fr om t h is da t a , es t ima ted pr odu ct ion r a tes , FTC,
yields , a nd P
P
a n d P
PK
for s pecia l ch a ra cteris t ics a re ca lcu la ted. Th ere a re n o min imu m
r equ iremen t s for pr oces s per for ma n ce, FTC, yields , or ot her in dica tor s a t t h is t ime. The
DCC PSO Tea m will eva lu a te t h e da t a fr om t h is r u n when decidin g whet her t o s chedu le
t h e PSO On-Site Vis it .

SUPPLIER TOOL RECORD (STR): A for m gener a ted by t h e crea t ion of a new TPO (Tool
Pu r cha s e Or der ) requ ir in g t h e iden t ifica t ion of Su pplier , or Daimler Ch r ys ler owned
t oolin g, a ffected by t he TPO.

109
SUPPLY CHAIN: in clu des a ll Su pplier s u s ed in pr odu cin g a given pa r t ; fr om t ier one to
t h e s ou r ce of pr odu ct ion ma teria ls .

SUPPLY CHAIN MAPPING: a met hod u s ed t o look a t t h e complexit y of t h e extended
en terpr is e va lu e cha in . Mappin g det a ils t he ma nu fa ct u r in g pr oces s , t r a n s por t a t ion a nd
ot her fa ct or s t h a t go in t o componen t pr odu ct ion .

TAKT TIME: The t ime in wh ich one veh icle, as s embly, or pa rt (t h e it em of in t eres t ) is t o
be made.
( (( ( ) )) ) Shift Per oduction Pr of Units in quirements Re Customer
Shift Per Time Operating Net
Time TAKT = == =

TIER 1 SUPPLIER: a Su pplier wh o is r es pon s ible for pr oviding componen t s , s er vices , or
ra w ma t eria l direct ly t o Da imlerCh rys ler. All referen ces t o Su pplier in t h is ma nu a l refer
t o a Tier 1 Su pplier , u n les s ot her wis e s pecified. Note t h a t in t h e ca s e of s ome modu les ,
t h e Su pplier of a modu le componen t ma y be t rea ted a s a Tier 1 Su pplier , even t h ou gh
t h ey do n ot s h ip direct ly t o DCC.

TIER 2 (& LOWER) SUPPLIER: a Su pplier wh o is res pon s ible for pr ovidin g componen t s ,
s er vices , or r a w ma ter ia l t o a not her Su pplier in t h e Su pply Ch a in . A Tier 2 s u pplies a Tier
1, a Tier 3 s u pplies a Tier 2, a n d s o on . All r eferen ces t o s u b-t ier or s u b-t ier s u pplier
in t h is ma n u a l refer t o a Tier 2 (or lower ) Su pplier , u n les s ot h er wis e s pecified.

VERIFICATION SAMPLES: s amples crea ted wit h kn own defect s in or der t o ver ify t h e
per for ma nce of Er r or a n d Mis ta ke pr oofin g. Ver ifica t ion s a mples mu s t be clea r ly ma r ked
a n d/ or iden t ified t o preven t s hipmen t t o t he cu s t omer a n d pr oper ly con t r olled t o preven t
degr ada t ion a nd en s u re relevan ce.

WORK IN PROCESS (WIP): produ ct t h a t h a s n ot gone t h r ou gh t h e en t ir e pr odu ct ion
proces s or is in complete in s ome wa y.

110


111
INDEX

Page(s )

Advan ce Qu alit y Plan nin g (AQP) ......................................................... .. 2, 3
A Appr oval ..................................................................................................... 3, 4, 37, 43, 97
Bar Code Labelin g................................................................................... ..40
BSR/ NVH.............................................................. ..14, 16, 44, 89, 100, 104
Capabilit y Mat r ix.................................................................................... ..63
Ch r ys ler Developmen t Sys t em (CDS) .............................14, 16, 20, 100, 107
Commen t s Sh eet ................................................................................................................. 50
Con t r ol Plan .......................................... 12, 18-19, 22, 23, 29, 30, 35, 41, 44, 89, 90, 100-101
Daily Toolin g Capacit y...................................................................... ..37, 60
Des ign FMEA ........................................................................................ 14, 18, 29, 31, 89, 102
Docu men t at ion Ch ecklis t.....................................................................46-48
DVP&R ........................................................................................... 12, 15, 18, 29, 44, 89, 102
Elect r o-St at ic Dis ch ar ge (ESD) Gu idelin es............................................... ..25
Elemen t Requ ir emen t s ..................................................................................................... 11-44
Er r or an d Mis t ake Pr oofin g .......................................................... 31-33, 90, 91, 102, 104, 108
Er r or an d Mis t ake Pr oofin g Requ ir emen t s for Electr ical Compon en t s ..................................... 33
Er r or an d Mis t ake Pr oofin g Requ ir emen t s for Modu les / Sequ en ced Par t Deliver y.................... 33
Fir s t Pr odu ction Sh ipmen t Cer t ificat ion (FPSC) ................................................ 30, 90, 96, 103
Fir s t Time Capabilit y (FTC) .......................................................... 1, 19, 37, 38, 67-77, 95, 103
Fir s t Time Capabilit y (FTC) Calcu lat ion Examples .................................... 67-77
For ever Requ ir emen t s ..................................................................................................... 81-86
Fr equ en t ly Asked Qu es t ion s ................................................................93-98
Gage an d Tes t Equ ipmen t Evalu at ion...................................................... ..41
Gage R&R........................................................................... ..38, 41, 91, 103
Glos s ar y ............................................................................................................... ..99-109
IAA ........................................................ 3, 4, 95, 103
Incomin g Mat erial Cer t ificat ion Plan........................................................ ..22
Init ial Pr oces s Stu dy................................................................................ 29, 43, 56-57, 92, 97
In t er n al PSO Requ iremen t s ..................................................................88-92
Layer ed Pr oces s Au dit ....................................................................... ..34, 64
Lot Accept an ce Samplin g Table ............................................................................................ 62
Meas u r emen t Sys t em Repor t ............................................................................... 29, 35, 58-59
N Appr oval ........................................................................................................................... 4
Net Oper at in g Time for DCC Par t s................................................... ..37, 104
Oper at in g In s t ru ct ion s.........................................................................26-27
Ou t goin g Mat er ial In spect ion Plan ........................................................... ..23
Packagin g Appr oval................................................................................. ..39
Par t Ins pection St andard ................................................................................................ 22, 23
Par t Nu mber , Descr ipt ion, & Ch an ge Level ....................................................................... 12-13
Par t s Han dlin g Plan .............................................................................24-25
Par t s Packagin g and Shippin g Specificat ion s ........................................39-40
Power way.com.......... ..3, 4, 7, 8, 9, 10, 20, 21, 34, 35, 46, 82, 94, 95, 96, 97
Pr oces s Per for man ce Indices (P
P
, P
PK
) ........................................... 35, 38, 43, 63, 95, 105, 108
PPAP ................................................ 1, 2, 3, 4, 5, 8, 9, 20, 22, 38, 82, 90, 94, 98, 103, 16-107
Pr e-PSO Docu men t at ion Review.................................. 1, 2, 3, 5, 7, 30, 35, 37, 41, 43, 105, 106
Pr even t ive Main t en an ce............................................................................ 42
Pr oblem Solvin g...................................................................................20-21
Pr oces s Flow Diagr am and Man u factu r in g Flow Ch ar t ............................. ..17
Pr oces s FMEA ........................................................................... 12, 16, 18, 29, 31, 44, 89, 106
Pr oces s Sign -Off Flowch ar t ..................................................... 6, 8
Pr oces s Sign -Off Respon s ibilit ies ................................................... 7, 9
Pr oces s Sign -Off Str at egy ............................................................ 5
Pr odu ct ion Demon s tr at ion Ru n (PDR) .............. 1, 3, 37, 38, 43, 53-55, 80, 92, 96, 97, 103, 106

112
Pr odu ct ion Validat ion (PV) Tes t in g ................................................................. 5, 44, 92, 95, 96
PSO Ch ecklis t ......................................................................................... ..49
PSO Ext en ded Ru n .......................................................................................................... 79-80
PSO On -Sit e Vis it .......... 1, 3, 4, 5, 7, 8, 9, 10, 21, 24, 28, 34, 35, 36, 37, 38, 97, 105, 106, 108
PSO Team Member s................................................................................................................ 2
Qu alit y Plann in g..................................................................................20-21
Refer ence Man u als ........................................................ .98
Rework and Repair In s tr u ct ion s an d Pr ocedu r es ...................................26-27
Safet y Ch ar act er is t ics ................................................................ ..29-30, 107
Special Ch ar act er is tics ....................... ..14, 16, 17, 18, 19, 26, 29-31, 34, 35, 36, 41, 43, 108
Su pplier Readin es s Evalu at ion (SRE) ...................................... ..2, 5, 35, 108
Su pply Bas e Man agemen t ....................................................................... ..20
Tes t Sample Sizes & Fr equ en cies ............................................................. ..15
Th ir d (3
r d
) Par t y Sou r ces................................................................... ..41, 42
Toolin g, Equ ipmen t , & Gages Iden t ified................................................... ..28
Z Appr oval .................................................... ..3, 4, 97

113
PSO 5 . 5 EDITION CHANGE LOG

REVISION
DATE
SECTION DESCRIPTION OF CHANGE
12/ 2006 En t ir e Docu men t Init ial Revis ion

84-231-1227 (REV. 12/2006) DaimlerChrysler Corporation PRINTED IN U.S.A.

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NOTE: In s it u at ion s wh ere mu lt iple Pu r ch as e Or der s (P. O. s ) exis t

1 6 . 2 Th e Pr odu ct ion Demon s t r at ion Ru n (PDR) s h all be con du ct ed on

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