Professional Documents
Culture Documents
Red Flags Survey
Red Flags Survey
Background
This Red Flags Survey is designed for a first time visit to a potential direct or indirect material supplier to
evaluate their in-house quality system and decide if they are advanced enough to be considered as a
potential supplier for John Deere. It is designed to be completed in a half-day visit (2 to 4 hours) of the
potential new source. It is intended to be conducted by Deere personnel familiar with the JDS-G223 Supplier
Assessment Questionnaire.
The Red Flags Survey is NOT designed to be a complete detailed quality system audit to the JDS-G223
standard. Use the Supplier Quality System Audit Questionnaire located in the JDS-G223 Supplier Quality
Manual after a potential new supplier has been selected for sourcing to conduct a thorough review of the
supplier's quality system.
Instructions
Review the supplier's quality system by using the scorecard worksheet and asking pertinent questions to
each dimension listed in the left hand column. Categorize the supplier's response into the answer that best
fits the level of activity for the dimension, "Not Used", "Primitive", "Partial Use", or "Fully Utilized". Notice that
some questions require a YES or NO response. The first two answer columns are the YES / NO boxes to
use. Type an "X" in the appropriate cell based on the response for that dimension. There can be only one
selection per question.
The worksheet scorecard is divided into three sets of questions. The supplier must pass the first two
questions to proceed. After scoring the next set of questions (dimension numbers 3 through 16 with the
green background) review the auto-summed total score at the bottom of the worksheet. If the score is less
than 33, the rest of the questions will not be needed as the supplier is not in compliance based on the initial
set of questions. If the score is 33 or higher, complete the rest of the survey scorecard.
When the scorecard is complete, the total score at bottom of the worksheet will correspond to Level I, II, III,
or IV Quality System. At the bottom of the worksheet there is a tab named "Level Definitions" which describe
the attributes that you will see for the corresponding supplier quality system. This worksheet also provides
recommendations on the sourcing decision depending on the supplier's survey results. To complete the
survey, document your findings, notes, and recommendation of whether or not to source parts from this
supplier. Be very descriptive in your notes so that others reviewing this document understand why you rated
the supplier as you did. John Deere Units (enterprise-wide) will look at your findings and base decisions
upon your recommendations.
The PV&V Assessment section is mainly used for new suppliers, providing Quality Plan Level 3 or 4 parts.
These suppliers are primarily responsible for the design and the reliability of their components. The supplier
should score a 2 or above on all questions to be considered as a potential supplier capable of design and
PV&V activities.
Instructions: Page 1 of 6
Revised: 12Mar09
John Deere Red Flags Survey for Supplier Quality Systems - Instructions
Instructions: Page 2 of 6
Revised: 12Mar09
John Deere Red Flags Survey for Supplier Quality Systems Survey
Supplier Name:
Audit Date(s):
Supplier Number:
Supplier Representative(s):
Supplier Address:
Supplier Phone Number:
Supplier E-Mail:
JD Survey Lead:
Position:
Phone:
Not Scored
Score: 0
Primitive
or YES
Partial
Use
Fully
Utilized
In-Process Gauging
10
Data Generation
11
Gauge R&R's
12
SPC application
13
Process Controls
John Deere Red Flags Survey for Supplier Quality Systems Survey
3 of 6
Points
Notes / Comments
Printed: 04/01/2016
14
Written Procedures
15
Control Plans
16
17
18
19
Training program
20
21
22
ISIR utilization
23
Document Control
24
25
26
27
28
29
30
31
32
33
34
Level I:
Level II:
Level III:
Level IV:
<= 32
33 - 64
65 - 96
> 96
Not Used
or NO
Primitive
or YES
Partial
Use
Fully
Utilized
Points
35
36
37
38
39
40
41
42
John Deere Red Flags Survey for Supplier Quality Systems Survey
Notes / Comments
4 of 6
Printed: 04/01/2016
John Deere Red Flags Survey for Supplier Quality Systems - Definitions & Recommendations
Level
Level I
Level II
Level III
Level IV
Quality
System
Start Up
Beginning
Mature
Highly
Developed
Survey
Score
<= 32
33 - 64
65 - 96
> 96
Recommended Action(s)
No Process Control
No Written Procedures
No Data
No FMEA
No Gage R&R
No Control Plan
No PV&V Plan
No Tracking of PV&V Execution
ISO Registration
Well Documented Procedures
SPC Implemented
COQ (Cost of Quality) Utilized
Corrective Actions Utilize Root Cause
Analysis
Well Defined PV&V Plan
Good PV&V Process Execution
Continually Updated Driving PV&V Metrics
Low PPM
Sourcing of work to this
Company Driven by Metrics
supplier is recommended.
QFD (Quality Function Deployment) Utilized
PPAP (Production Part Approval Plan)
Utilized
Poke Yoke (Mistake Proof) Technique
Utilized
Independent and Partner PV&V
Organization
to Design Engineering
World Class PV&V Staffing in relation to
Design Engineering
Notes / Comments
John Deere Restricted Materials List
Gauge R&R's
SPC application
Process Controls
Written Procedures
Control Plans
Parts Per Million or Cost of Poor Quality Metrics that are tracked over
time.
Parts Per Million Defects of Cost of Poor Quality have an improvement
trend over time (going down).
Preventive Action is defined as action to eliminate the causes of
potential noconformities in order to prevent their occurrence.
Inspection is used (instead of process control) to check for
nonconformance
Quality is directly controlled by the operator, not by otherprocess
control methods such as mistake proofing, check fixtures, gaging, etc.
Rework is analyzed to define Corrective Action Plans to prevent future
problems.
Gages that are built into the process to stop the flow if out-of-control
conditions exist.
Data is collected, analyzed, and used to define continuous
improvement activities.
Gage Repeatability and Reproducibility. Repeatability is the cariation
in measuremnts obtained with one measurement instrument, when
used several times by one appraiser, while measuring the indentical
characteristic on the same part. Reproducibility is the cariation in the
average of teh measurements mde by different appraisers, using hte
same measurement instrument, used several times by each appraiser,
while measuring the identical characteristic on the same part.
SPC Control Charts are used as a basis to make decisions about a
process. Control determiniations are made by comparing the values of
statistical measures of an ordered series of samples, or subgroups,
with control limits.
Various techniques used to control the variation within the process
The documents that tell the who, what and when of the manuals.
A Control Plan is a written description of the system for controlling
parts and processes. The Control Plan describes the actions that are
required at each phase of the process, from receiving to shipping, to
assure that all process outputs remain in a state of control. The
Control Plan reflects a strategy that is responsive to changing process
considitions, and is maintained and used throughout the product life
cycle.
Action taken to eliminate the cause of nonconformities in order to
prevent recurrence.
Analytical method for determining the risk level of the design or
process.
FMEAs are completed on key characteristics. High RPN scores on
FMEAs have been mitigated. As a result of the FMEA a control plan is
developed.
Initial Sample Inspection Plan (First Piece Inspection) for new parts
and set-ups.
Quality Registration by an certified registration agency. The
regristration must not have expired.
Documents are up-to-date in all areas of the factory. All revision levels
are current, and if a change is made the revision is made by the date
that is required.
Costs as a result of poor quality are quantified, such as reclaim and
scrap. (May include engineering costs, material handling, inventory,
etc.)
A mission statement and quality policy should be published, and
communicated with the work force.
Quality metrics, such as PPM or cost of poor quality should be posted
in areas so that the work force can view, and see trends over time.
The goals should also be defined.
An effective process for finding the cause(s) of an event. This tool
enables more thorough corrective actions.
The training requirements should be available, and implemented.
Quality Planning on new parts should cover how to handle key
characteristics and all product features. FMEAs, Control Plans, Work
Instructions should clearly defined how to prevent defects.
Define, Measure, Analysis, Improve and Control methodology used to
solve problems and work on continuous improvement.
FMEAs are updated if problems occur. The FMEA should define the
failure mode and control to address. The control plan should be
updated to prevent the problem in the future.
Key Characteristics are those product or process parameters for which
variation is likely to significantly affect customer satisfaction with the
product such as its safety, fit, form, function or appearance. Key
Characteristics apply to components and assemblies.
Structured approach for determining customer needs and translating
those needs into the origanization's language.
Production Part Approval Process that is used to assure that a new or
changed product or process meets specifications.
A method to eliminate potential operator error from the process.
Quality Registration to QS 9000 or ISO/TS16949 by a certified
registration agency. The certificate must not have expired.