Process Planning & Audit v3.0 QRA Sourcing Risk: Monitoring Level Review: PA - Process Eval.

EMEA / LATAM QRA Program Risk: Date: Review #:

Supplier Supplier
Part Number: OdM:
Code: Name:
Part Supplier
MY: Vehicle: SQE: sfgs
Description: Plant:
PROCESS VERIFICATION (VP) PRE-SERIES (PS) PROD. RELEASE APP. (PRA) CURRENT PRODUCTION
Material Req. Date: Material Req. Date: Material Req. Date: Material Req. Date:
PROCESS AUDIT Full Approval
PROCESS EVALUATION Planning
Build Date / Avail.: Build Date / Avail.: Build Date / Avail.: Build Date / Avail.:

2 - PROCESS 3 - QUALITY CONTROL 4 - QUALITY CONTROL 6 - LOGISTICS & 8 - QUALITY CONTROL

1 - PART DESIGN 5 - MANUFACTURING 7 - VERIFICATION 9 - FULL APPROVAL
DEVELOPMENT (PROCESS) (PROCESS) CUSTOMER SERVICE (SYSTEMS)

Source Package & Technical

Program
Review
Management & Timing
Control Plan & 8 Stages Process Monitoring Environment & Safety (Workplace)
Material Handling Capacity, Volume & PDR Non-Conformance Management
Planning
& Corrective
of Self-Qualification
Actions Tests

A
0 0 0 0 0 0 0 0

Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue

Design FMEA Process Flow Diagram Sub-tier Incoming Inspection

Layered Process Audit Maintenance Traceability & Part Identification
Process Performance & Capability
Sub-Tier Management Planning of Integrative Tests

B
0 0 0 0 0 0 0 0
Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue

Design Model & Release Process FMEA Error & Mistake Proofing Safety & Report Characteristics
Workplace Organization Packaging SQE Audit Lessons Learned Planning of Matchability / Benestare

C
0 0 0 0 0 0 0 0 0
Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue

Special Characteristics Tooling & Equipment Management

Gages & Measuring DevicesFirst Piece Approval Training & Development Sequenced Part Delivery Sub-Component Approval Warranty IMDS

D
0 0 0 0 0 0 0 0
Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue

Change Management Sub-Component Development

Work Instructions Special Processes Continuous Improvement CAPMAN & Supply ChainAnnual
Management
Validation & Periodic
Quality
Recertification
Certifications & RecordPPA
Retention
ELEMENTS
E
Number
0 0 0 0 0 0 0 0
Approved 0
Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue Open
Open Issue
Issue

NA
NA -- NOT
NOT 11 -- JOB
JOB 22 -- JOB
JOB 33 -- MEDIUM
MEDIUM PPR Exec. PPR Contacts PROCESS AUDIT CHECKLIST
% Complete 0%
SCORING
STOPPER 44 -- LOW
LOW RISK
RISK 55 -- APPROVED
APPROVED PPR Exec. PPR Contacts
SCORING APPLICABLE
APPLICABLE STOPPER
STOPPER STOPPER RISKRISK RISK
RISK PA OI Perf. Req. # Answered 0 % Approved ###
PA OI Perf. Req.

SQE / SQ CMS /
Supplier: Plant Manager Signature Supplier: Quality Manager Signature FCA: Supplier Quality Engineer Signature FCA: Engineer or Other Signature

Process Audit v1.0 April 2012

Item # Name

Source Package &

1A Technical Review

1B Design FMEA
 Design Model &
1C Release
 Special
1D Characteristics

Change
1E Management
 Change
1E Management

Program
2A Management &
Timing
 Process Flow
2B Diagram

2C Process FMEA
2C Process FMEA

Tooling &
2D Equipment
Management
 Tooling &
2D Equipment
Management

Sub-Component
2E Development
 Control Plan & 8
3A Stages
 Sub-tier Incoming
3B Inspection
 Error & Mistake
3C Proofing
 Error & Mistake
3C Proofing

Gages & Measuring

3D Devices
 Gages & Measuring
3D Devices
3E Work Instructions
4A Process Monitoring
 Layered Process
4B Audit

Safety & Report

4C Characteristics
 Safety & Report
4C Characteristics

4D First Piece Approval

4E Special Processes
 Environment &
5A Safety (Workplace)
5B Maintenance
 Workplace
5C Organization
 Training &
5D Development
 Continuous
5E Improvement

6A Material Handling
 Traceability & Part
6B Identification
 Traceability & Part
6B Identification
6C Packaging
6C Packaging

Sequenced Part
6D Delivery
 Supply Chain
6E Management

Capacity, Volume,
7A & PDR
 Capacity, Volume,
7A & PDR

Process
7B Performance &
Capability
7C SQE Audit
 Sub-Component
7D Approval

Annual Validation
7E & Periodic
Recertification
 Non-Conformance
8A Management &
Corrective Actions
 Sub-Tier
8B Management

8C Lessons Learned
8D Warranty

Quality
8E Certifications &
Record Retention

Planning of Self-
9A Qualification Tests
 Planning of
9B Integrative Tests

Planning of
9C Matchability /
Benestare

9D IMDS
 Requirements for Closure Documents Required

The Supplier shall have available and have reviewed the Source Package, Additional * Source Package
Quality Requirements (AQR), Master PFMEA, Supplier-completed Manufacturing * AQR
Feasibility Assessment (MFA) for the part (signed by all applicable FCA and Supplier *MPFMEA
representatives), and for EMEA/LATAM the signed Statement of Requirements * Signed MFA
(SoR). All requirements listed in the AQR shall be incorporated into the * Signed Statement of
manufacturing process and included in the design model, test plan, Control Plan, or Requirements (SoR) -
other technical documentation, as applicable. EMEA/LATAM

A Quality Risk Assessment shall be completed for each part, with Sourcing
percentage provided to Purchasing for the Quality First process and Program Risk * Quality Risk Assessment
entered into the applicable FCA systems by required FCA timing.

A Design Failure Mode & Effects Analysis (DFMEA) shall be available for all parts. It
shall be created using all FCA guidelines and the AIAG Potential Failure Mode &
Effects Analysis (4th Edition) manual. NOTE: Approval of the Process Audit shall not * Design FMEA
be withheld if a DFMEA does not exist for a FCA-designed part; in such a situation,
mark this item "NA".

The DFMEA shall be reviewed and accepted by the FCA Engineering representative.
The Supplier shall ensure the DFMEA meets all requirements, including but not
limited to:
- inclusion of all special characteristics;
- inclusion of all applicable sub-components;
- inclusion of all error-proofing; * Design FMEA
- inclusion of all reliability targets and requirements;
- review of all potential BSR/NVH situations;
- special attention given to items with high severity (8+), an inability to be detected
(10), or high end-customer dissatisfaction (severity 5+ and occurrence 4+).

The Supplier shall have a procedure for development of DFMEAs and records that
ensure all DFMEAs are periodically reviewed and evaluated for continuous
improvement of failure modes. Failure modes identified as the highest risk shall be
addressed first. The procedure shall also include: * Procedure for development of
- determination of severity, occurrence, and detection values; FMEAs
- regular reviews and updates for lessons learned (e.g., yardholds, field campaigns)
and internal / external benchmarking;
- updates of the DFMEA upon receipt of a Customer engineering change.
The drawing / design model shall have all required information for the part,
including but not limited to:
- engineering/technical standards, specifications, and norms (plus any deviations
from those requirements);
- Geometric Dimensioning & Tolerancing (GD&T) / dimensional requirements;
- engineering Build Objectives or Table of Tolerances/Profiles; * Drawing / Design Model
- identified special characteristics;
- a list of sub-components (with part number, revision, and quantity).
Datum schemes shall be agreed upon by the applicable FCA representative and be
consistent with part mating/attachment points and part Primary Locating Points
(PLPs).

The Supplier shall have access to all FCA standards, through the applicable FCA
systems. The Supplier shall have a procedure that requires regular reviews to
ensure they have the most recent released versions of the standards, and requires
communication to their various departments in the event of a revision update. If * Procedure for review of
Supplier internal specifications or standards are referenced (e.g., on the design customer standards
model, on sub-component drawings, etc.), those standards must be clearly linked to
the applicable FCA standard or specification.

Supplier-responsible designs shall be approved by the FCA Engineer prior to release. * Approved design
For NAFTA, the Design Acceptance Checklist (DAC) is required to be completed by * Design Acceptance Checklist
Steps 2, 3, and 5. (DAC) - NAFTA

Design responsible Suppliers shall consider Design for Serviceability, which ensures
ease of disassembly of product with minimal cost and time. The Supplier shall meet * Service engineering design
all applicable FCA standards for structure or serviceability (e.g., CEP standards), with approval
FCA Service Engineering approval of the design.
Special characteristics for the part and process shall be identified. These include
product or process characteristics that can affect safety, fit, form, function,
performance, regulation compliance, or subsequent part processing. Characteristics
that fall into this category include, but are not limited to: Regulatory (Safety <S> /
Emissions <E> / Homologation <H>, Report, PQC-S), Functional (Qf), Important (Qi,
Qd), torque and welding requirements, characteristics identified as SPC points on * Drawing / Design Model
the design model, and "legacy" characteristics (diamonds <D> / stoplights, Qh, Qc, * List of Special Characteristics
Q+, PQC X, CPC X). They shall also be shown on the design model, in all applicable
quality documents (D/PFMEAs, Control Plan, work/inspection instructions, etc.), and * Part Inspection Standard (Part
I/S) - NAFTA
included in the Safe-Launch Plan, SQE Audit (7C), and Initial Process Study after the
PDR Stage 1. For NAFTA, all special characteristics shall be identified on the Part
Inspection Standard included in the Source Package, and approved by the FCA
Engineer and Plant Quality. NOTE 1: It is not mandatory that all parts have special
characteristics. NOTE 2: Special characteristics are not exclusively dimensional, they
can also include functional, material, appearance, etc.

If the part does not have special characteristics identified on the design model, the
Supplier and Process Audit team shall select characteristics that affect close
tolerances, fit, function, finish, reliability, durability or characteristics affected by * List of selected characteristics
process parameters and/or characteristics that affect the successive/final process to
include in the SQE Audit and process performance and capability studies.

For all fastener joints, the Supplier shall have a defined torque strategy in place. For
M6 and above, the Supplier shall develop a torque plus angle strategy unless
explicitly told otherwise by an FCA Engineering representative. The torque plus * Torque Strategy
angle strategy shall include error or mistake proofing such as lock out features in
the event the torque and angle requirements are not met, etc.

The drawing or design model shall reflect the change level and revision level of the * Drawing / Design Model
part(s) undergoing the Process Audit. All applicable quality documents (including, * All applicable quality
but not limited to, the Process Flow Chart, D/PFMEA, Control Plan, and all
Instructions) shall also reflect the correct change level and revision level. documents
The Supplier shall have a procedure for proper change management, including:
- receipt of FCA approval (Change Notice or OdM);
- notification to the Customer of any risk or impact on timing, program milestones,
tooling, or resources;
- updates of all applicable quality documents;
- removal of uncontrolled or out-of-date documents;
- quarantine/disposition/obsolescence of out-of-date material (product produced
* Change Management
prior to the engineering change); procedure
- record or log of the first production shipment and retention of that data for
traceability; * Authorized engineering
- and communication of changes to all applicable sub-tier suppliers. It is the Tier 1 change documents
Supplier's responsibility to ensure the finished part is at the correct change and
revision level.
NOTE: The Supplier shall not make any changes without DOCUMENTED approval
from FCA Engineering (i.e., voicemail, e-mail, etc. are UNACCEPTABLE). Failure to
adhere to this may result in a Forever Requirement Violation, initiation of 3CPR/CSL,
addition to TPSL or NBH, or other penalty as determined by FCA.

The Supplier shall have a Product Development Plan for the program that includes
the following:
- dates and timing for all key FCA milestones (such as design approval, Material
Required Dates (MRD), pilot builds, launch, etc.);
- planned and actual dates for all key FCA deliverables (such as the Process Audit * Product Development Plan
Readiness Evaluation, PA Process Evaluation visit, PDR Stage 1 and 2, Full Approval
(PPAP or Qualificazione), etc.);
- Risk Mitigation activities for any deliverables that are late / potentially late to their
required due dates.

The Supplier's Product Development Plan shall include all details related to tooling
and tool construction. This includes:
- planned and actual dates for key tooling deliverables (such as Tooling Kick-Off
(TKO), total tool construction time, Off Tool, Off Tool Off Process (OTOP), etc.); * Product Development Plan
- expected tooling and part status at each pilot build and pilot build stage;
- Risk Mitigation activities for any deliverables that are late / potentially late to their * Tooling Kick-off forms
required due dates;
- identification of the FCA TAG individual responsible for each tool (when
applicable).

The Supplier shall have access to the eSupplierConnect portal and support all
required FCA systems (e.g., MaPS, CQMS, SQP, NCT, GIMS, etc.). They shall have at
least 2 fully trained individuals able to access each system. Contact information shall
be current and updated.

The Supplier shall provide adequate resources to the program to ensure

deliverables and/or risk mitigation activities are completed per their required dates. * Program contact list
A Process Flow Diagram is required for all parts. It shall:
- reflect the entire process, beginning at the receiving area and continuing through
shipping;
- include all labeling, product storage, rework/repair, and gaging/inspection areas,
whether they are a part of the primary process or off-line (secondary) processes;
- identify stations which measure special characteristics and/or contribute to
significant nonconformances;
- ensure that process and material flow is designed to avoid missing of operations or
mixing of parts with similar products; * Process Flow Diagram
- include the processing sequence, method, and equipment used at each station
(including inspection and repair/rework stations), with unique machine numbers
identified;
- indicate the flow of repaired or reworked material back into the normal process to
ensure the parts pass through all required controls for all rework / repair stations;
- identify the number of operators required per station (including float operators, as
applicable);
- indicate any bottleneck or constraint operations.

A work station layout or manufacturing floor plan shall be available that details the
following: operation to operation flow, all manufacturing / inspection equipment * Work station layout /
and tooling used in the process, identified material storage locations (for WIP /
buffers, nonconforming material / scrap, rework / repair, and raw material / sub- manufacturing floor plan
components).

The Supplier shall have a procedure describing how temporary rework/repair

operations are created and controlled. This procedure shall include:
- identification of all personnel responsible for creating temporary rework/repair
operations, instructions, and controls. * Procedure for development of
- notification and approval from FCA Engineering and SQ (and Plant, as required) rework/repair operations
prior to initiating temporary rework/repair via the appropriate process.
- requirements that rework/repair parts go through controls (including Error and
Mistake Proofing) equivalent or superior to the primary production line.

A Process Failure Mode & Effects Analysis (PFMEA) shall be available for all parts. It
shall be created using all Customer guidelines and required FMEA reference * Process FMEA
manuals. The PFMEA shall be reviewed by the SQE and rated "Green" per the * Supplier PFMEA Audit
Summary
"Supplier PFMEA Audit Summary" form.
The Supplier shall have a procedure for development of PFMEAs and records that
ensure all PFMEAs are periodically reviewed and evaluated for continuous
improvement of failure modes. Failure modes identified as the highest risk shall be
addressed first. The procedure shall also include: * PFMEA review / evaluation
- determination of severity, occurrence, and detection values;
- regular reviews and updates for lessons learned (e.g., yardholds, field campaigns) procedure & records
and internal / external benchmarking;
- updates of the PFMEA upon receipt of a Customer engineering change notice (as
necessary).

Potential causes and effects of "Buzz / Squeak / Rattle" and "Noise / Vibration / * Process FMEA
Harshness" (BSR/NVH) shall be addressed in the FMEAs, Control Plan, and Test Plan.
Analyses shall include evaluations of interactions with mating parts to reduce, * Control Plan
eliminate, and/or monitor objectionable BSR or NVH characteristics. It is the * DVP&R - NAFTA
* AQF/PI test plans - EMEA /
Supplier’s responsibility to ensure their parts do not exhibit any BSR/NVH conditions
within their environments. LATAM

The Supplier shall have a complete list of all dies/tooling, equipment, and gages
used in the process. This list shall indicate ownership of the tooling, unique
identification numbers, and location of the item. The SQE shall verify the presence
of all tooling (including number of cavities), equipment, and gages identified on the * Supplier Tool Record
list. Tooling and equipment, when not in use, shall be properly identified and stored * List of Tooling and Equipment
to avoid confusion in the flow management of components/products being
manufactured. There shall be a Supplier Tool Record which lists all FCA-owned
tooling, with tooling number and location.

The Supplier shall have a process for tooling design and development that includes:
- application of lessons learned and best practices from previous programs with
input from applicable departments and the Customer; * Tooling design process
- root cause and corrective actions for equipment downtime issues, with feedback * Equipment downtime
to the preventive maintenance plan;
- tracking, reporting, and continuous improvement of tooling related metrics, such corrective actions
as equipment start up, OEE %, project and life cycle cost, and quality (machine
capability).

The SQE shall verify die/tooling, equipment, and gage status in terms of: timing
(completion, try-out, sampling, etc.), function, and part availability for key program
milestones. Tools and equipment shall be built following all requirements in the
AQR, as applicable. The Process Audit Readiness and Process Evaluations and PDR
shall be run on finished production tools using definitive production processes.
Assembly tool PLPs shall be coordinated throughout the entire assembly process on
all required tooling and fixtures.

All FCA-owned tooling shall have a Tooling Kick-off from the appropriate FCA
representatives. Tooling developed/followed by the FCA Tooling Analysis Group * Approved Tooling Kick-Off
(TAG) shall have a tooling sign-off from the applicable TAG representative.
The Supplier shall perform machine capability studies (CM/CMK) for special
* Machine capability studies
characteristics on all tooling and meet FCA requirements.

FCA-owned tooling, equipment, and gages shall be identified and marked per FCA
requirements and shall be used only for the production of FCA products.
EMEA/LATAM: Tooling identification shall meet the requirements in FGP procedure
24.
NAFTA: Tools shall be clearly and permanently marked as follows:
- "Property of FCA" (older tools may be marked "Property of Chrysler"),
- Tool Identification number (from the Supplier Tool Record (STR)),
- Lead Part Number or Part Description (the FCA Lead Part Number can be
contained within the tool ID #)
- Optional: Identical tools (such as racks) may be marked "Property of FCA" with an
identifier (2 of 35, 3 of 35, etc.).
Acceptable methods of marking include, but are not limited to: engraving,
embossing, stamping, etching, scribing, and fastened metal tags with rivets, screws,
or welds. Unacceptable (non-permanent) methods include: stenciling, painting,
inking, paper tags, etc.
NOTE: tools too small to adequately mark individually are exceptions to the above
and may be handled as follows:
- A tool photo overwritten with: a) "Property of FCA" or “Property of Chrysler”, b)
Tool ID number, c) Lead Part # or Part Description,
- Tool sets too small to individually mark may be kept in a bin or cabinet marked
with: a) "Property of FCA" or “Property of Chrysler”, b) Tool ID number, c) Lead Part
# or Part Description

The Supplier shall have a process for evaluating the risk of each purchased sub-
component and raw material used in the part. The Supplier shall also have a process
for conducting Process Planning Reviews, Process Audits, and Production * Sub-component risk
Demonstration Runs (or use equivalent tools) on sub-components that are not * Sub-component PPR/PA/PDR
considered "Low" risk. In addition, the Supplier shall have a plan for performing procedures and plan
these activities in order to support FCA's pilot builds and other milestones with the
required level of approved parts.

The Supplier shall have available a Supply Chain diagram. The diagram shall outline
the entire Supply Chain, beginning with raw materials and ending with the FCA or
FCA-designated facility. All secondary processes and/or services (e.g. plating, heat * Supply Chain diagram
treating, etc.) shall be shown, including off-site storage and shipping locations.
Value-stream mapping shall be used to identify bottlenecks, stock lead-times, and
to optimize and improve Supplier processes.

For sub-tier suppliers and sub-components, the supply of sub-components shall be

ensured through backup plans; e.g., safety stock, alternate transportation,
availability of alternate PPAP approved sub-components, etc. NOTE: switching sub- * Sub-component backup plans
tier suppliers requires notification and approval from FCA (via appropriate system or
process, such as the Forever Requirements) at all times.
A Control Plan shall be available for all parts. It shall be created using all FCA
guidelines and the AIAG APQP & Control Plan manual. The Control Plan shall be
"Green" per the "Supplier Control Plan: Document Audit Summary" form, as
reviewed by the SQE.
The control frequencies, sample sizes and measurement methods shall be based
upon the effect of the characteristic on the functionality of the product as defined
by preliminary analysis (e.g., DFMEA, PFMEA) and process stability. Higher risk items * Control Plan
on the FMEAs shall have correspondingly higher sample sizes/frequencies.
NOTE: When inspections are done "per lot", lot size shall be determined based
upon the capacity plan of the supplier and compared to the FCA facility; minimizing
days on hand and maintaining flow and WIP. However, lot size shall NOT exceed
one shift or one production run, whichever is less. This includes incoming
inspections on sub-components, as well as in-process inspections and inspections
on final assemblies.

The SQE shall verify that the Supplier is following the controls as listed in the
Control Plan, and that frequency, sample sizes, measurement methods, equipment * Control Plan
* Control Plan Process Audit
recording, reaction plans, etc. are adequate. For NAFTA, the Control Plan shall be Checklist - NAFTA
"Green" per the "Control Plan Process Audit Checklist" form.

The Supplier shall have an acceptable Outgoing Material Inspection plan (or Product
Audit Plan) that includes adequate outgoing inspection frequencies, sample sizes,
and measurement methods and documented in the Control Plan. Inspection
frequency, sample size, and measurement method shall be determined based upon
risk level (e.g., per the PFMEA) and importance of the characteristic (e.g., * Control Plan
Safety/Report, other special, etc.). Audits shall be random, with statistical analysis
of results (as applicable). The Supplier shall have reaction plans in place in the event
a nonconformance is detected, which includes proper notification of FCA when the
potential exists that nonconforming material was shipped.

Repair/rework parts shall pass through controls equal to or exceeding those of the
primary production line. * Control Plan

The Supplier shall be familiar with the 8 Stages of Incoming Material and have
available:
- A completed Process Control Map and 5 Questions for Zero defects for each part
or assembly; * Process Control Map
* 5 Questions for Zero Defects
- A plan to strengthen process control for all critical part characteristics at Stage 4 (one for each characteristic)
or less;
- Use of error/mistake-proofing devices in place of human inspection for critical
characteristics
The SQE shall review the Supplier's Safe-Launch Plan (SLP), included on the Control
Plan, for ensuring parts meet specifications during the pilot and launch phases. This
includes inspections and controls over and above those of standard production
(e.g., increased frequencies, sample sizes, etc.) for special, BSR/NVH, and other
required characteristics. The SQE shall also review any data collected for SLP prior to
the Process Audit and stations or inspection areas used for the activity. Stations or * Safe-Launch Plan
inspection areas used for SLP activities shall be considered part of the normal * Data from previous SLP
process (i.e., included in the Control Plan), and have adequate lighting (at least shipments
equivalent to that used by the FCA assembly plant's CPA inspection area), inspection
instructions, boundary samples, etc. Duration of SLP is Job 1 plus 90 days (new
programs) or first shipment plus 90 days (all other situations). If a defect is
discovered, the SLP duration shall be repeated in full. Parts inspected as part of the
Safe-Launch activities shall be identified per FCA's requirements.

The Supplier shall have a plan for Incoming Material Certification / Inspection for all
purchased components and raw materials. Sub-tier suppliers may be placed on Self-
Qualification (i.e., "dock-to-stock") if they have quality system certification (e.g.,
ISO/TS-16949, ISO 9001), have acceptable quality performance, and an approved * Incoming Inspection Plan
Process Audit and PDR for that component (see Sub-tier Approval); the Tier 1 (Control Plan)
Supplier shall have records of all of these items. When it is necessary to purchase
from non-qualified or unapproved sub-tier suppliers, effective controls, using an * Incoming Inspection Results
* Self-Qualification procedures
adequate sampling plan, shall be exercised both in the Incoming Inspection area
and the manufacturing process to prevent/block the use of nonconforming parts or
raw material. Inspection results and records shall be available for review by the
customer at all times.

Self-Qualification status on sub-tier suppliers shall be removed when

nonconformances occur. Details for re-acquiring Self-Qualification status shall be
defined, and require a minimum of three previous, consecutive, defect-free
shipments. A method of identifying parts from a Self-Qualified sub-tier supplier shall * Self-Qualification procedures
be defined and appear on the material shipping documents, product identification
sheet, and on the package. While Self-Qualification status is suspended or
withdrawn, the Tier 1 Supplier shall implement full incoming inspection on material
from that sub-tier, with increased sample sizes, frequencies, etc.

When applicable, Incoming Inspection sampling plans shall be included in the

Control Plan with adequate frequencies, sample sizes, and measurement methods.
Inspection frequency, sample size, and measurement method shall be determined
based upon risk level of the sub-component (e.g., per the PFMEA), importance of * Control Plan
the characteristic (e.g., Safety/Report, other special, etc.), and historical quality
performance of the sub-tier supplier. Audits shall be random, with statistical
analysis of results (as applicable).

Computerized systems used to manage incoming and outgoing product (inspection,

production/lot control, shipping, etc.) shall have backups in case the primary system
fails.
The Supplier shall have a process for Error and Mistake Proofing which describes the
development, implementation, use, and maintenance of Error and Mistake Proofing * Error and Mistake Proofing
within the organization. The process shall include the procedure for creation of process
Verification samples for all failure modes identified in the Design and Process * Error and Mistake Proofing
FMEAs and use of those samples with the Error and Mistake Proofing Verification Verification Audit procedures,
Audit to ensure the proper functioning of Error and Mistake Proofing. When instructions, checklist
possible, failure to perform the Verification Audit at production start shall result in * DFMEA
line / station lock out. During the Process Audit, all Verification Samples shall be run * PFMEA
through the process and successfully detected as defective.

Error/Mistake Proofing is required for all items identified in the Design and Process * DFMEA
FMEAs with a severity of 8 or higher, as well as for all identified special * PFMEA
characteristics (or per FCA requirements, if more stringent).

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

Line or station lock out shall be implemented at all process steps to prevent failed
operations from proceeding to a subsequent station or into finished product.
Audible and visual indicators shall notify of the failed operation. Corrective actions
shall be implemented prior to restarting the line or station. The Supplier shall have a * Error and Mistake Proofing
contingency plan (which includes WIP storage of parts and development of contingency / backup plans
alternative inspections) in the event the production Mistake Proofing is not
operable. A visual and/or audible alert shall signify the Mistake Proofing is
inoperable. The plan shall include notification to FCA via the applicable system to
approve the inspection plan.

Error and Mistake Proofing software shall be tested for all known failures and
bypass scenarios.

Final verification ("end-of-line") stations shall:

- ensure parts cannot skip this station;
- leave a unique mark showing the part successfully passed through;
- verify the end item is correct and complete and ensure all components are present
(verifying components are in the machine prior to assembly and assuming they are
on the finished assembly is insufficient)
Error or Mistake Proofing shall verify:
- all functions, efforts, and travel 100%;
- sub-component selection 100%;
- all cylinders applying staking or components for full stroke;
- flow, amount, and location of critical lubrication and adhesive points, liquids, and
gases;
- leak testing for all liquids and gases 100%;
- proper assembly and packaging when machines accommodate multiple parts
(right/left, front/rear, etc.);
- loose foreign objects are prevented from entering the assembly area;
- continuity and function on electrical components and connections 100%, with line
stop / lockout if continuity is failed;
- sequential sensing is used when the process includes independent cells making up
one process flow;
- torque and angle requirements for all required fasteners, with automatic line lock-
out if those requirements are not met (see 1D).

Electrical terminal contact for in-process manufacturing (harness assembly, engine

testing, device testing, etc.) shall meet the following:
- pogo pins shall not violate the contact area of the terminal(s) being tested;
- pogo pins shall be maintained and inspected regularly;
- the test fixture shall align the connector to the test fixture prior to engagement of
the pogo pins;
- when pogo pin access is not provided and spring member contact is the only
option, the probe used to contact the terminal spring member shall be smaller in
thickness than the minimum blade thickness (including tolerances) of the terminal
being tested. If round pin terminals are being tested, the male pin probe shall be
smaller than the minimum diameter (including tolerances) of the pin;
- the depth of insertion of the probe shall be the minimum necessary for electrical
contact testing.

The Supplier shall have a process that ensures Master samples, gages, measuring
devices, and test equipment are available for use (at the inspection station, when
required), adequately identified, and properly handled and stored when not in use. * Gage handling process
* Control Plan
Master samples used to verify the operating condition of gages shall be used * Gage work instructions
according to the frequencies set in either the Control Plan or gage work
instructions.
Gages and measuring devices shall be appropriate to the requirements of drawings,
regulations and importance of the characteristics (as defined by the characteristic
classification, Design or Process FMEA, etc.). All Special Characteristics (see 1D)
require variable gages, unless otherwise agreed to by FCA. FCA-owned gages shall
meet all FCA requirements, including gage requirements listed in the AQR; when
required by FCA, gages shall be built to reflect the part in actual vehicle position.
The Supplier shall have a process for validating gages and measuring devices prior * Gage R&R studies
to release on the manufacturing floor, including Repeatability and Reproducibility
(R&R) studies for all. For new parts and processes, gage R&R as a percentage of
Total Tolerance shall be used; for process improvements, gage R&R as a percentage
of Total Variation shall be used. Acceptable gage R&R shall be <10% in either case. A
gage R&R between 10% and 30% shall require approval from the FCA team before
being released for production. R&R results > 30% are unacceptable.

When gages or measuring devices are used for 100% inspection, the tolerances shall
be reduced by the extent of the gage R&R to ensure out-of-specification parts are * Gage R&R studies
not passed.

The Supplier shall have sufficient resources (gages, measuring devices, and
personnel) to carry out the controls listed on the Control Plan.

The Supplier shall have a process or system for calibration of gages and measuring
devices. This process shall:
- ensure all gages, gage blocks, reference samples, and test equipment are
calibrated, traceable to a known source and national standard, and reflect the last
calibration and expiration dates;
- ensure metrological traceability and calibration expiration dates are clearly * Calibration procedures and
marked (via calibration stickers, color code, etc.) on applicable gages, equipment, work instructions
etc.; * Re-calibration schedule and
- include a re-calibration schedule that includes all gages and measuring devices, procedures
with detailed procedures or work instructions for performing the re-calibration;
- ensure re-calibration is done per the schedule, with a reaction plan and
containment for any equipment that is past-due;
- ensure the continuance of controls and inspections while the primary equipment
is undergoing re-calibration.

3rd party sources used for gage and test equipment calibration shall be evaluated
by the Supplier and be certified to ISO/IEC 17025.
Work stations, inspection areas, etc. shall have clear operation, set-up, changeover,
First Piece Approval, Mistake Proofing, rework/repair, gage operation, inspection,
and packaging instructions according to the needs and method of production.
Instructions shall be visible and easily accessed (at eye-level) by operators, * Work Instructions: operation,
inspectors, and other necessary personnel. During the planning and development of set-up, changeover, 1st Piece
these instructions, special attention shall be given to operations where inspections
occur, and all special characteristics identified. Instructions shall be clearly identified Approval, Mistake Proofing,
regarding their usage (e.g. classification, colors, pictures / sketches / drawings, etc.) rework/repair, gage, inspection,
packaging
to avoid any possible mistake. Visual management techniques (e.g. displays,
pictures, diagrams, etc.) shall be used whenever possible. In cases where the facility
workforce is multi-lingual, visual-based work instructions shall be used in place of
multiple, translated copies.

All operators, inspectors, set-up/changeover personnel, etc. shall be fully trained

* Work Instructions: operation,
and knowledgeable of the work instructions applicable to their area of set-up, changeover, 1st Piece
responsibility. They shall be able to apply all of the procedures and instructions
contained within. The instructions shall enable any adequately trained person to Approval, Mistake Proofing,
perform the described operation or inspection. The SQE shall verify the rework/repair, gage, inspection,
packaging
effectiveness and adequacy of visual controls.

Work instructions and procedures shall be developed for reworking or repairing

nonconforming parts and require FCA approval. The instructions shall define:
- the rework/repair process;
- criteria for determination of what parts shall undergo rework/repair (as opposed
to being scrapped);
- the equipment and material to be used; * Rework/repair procedures and
- the methods of identification (all reworked/repaired product shall be clearly and instructions
uniquely identified);
- controls used on the reworked/repaired product. Reworked and repaired product
shall have controls and Error/Mistake Proofing equivalent, or superior to, the
primary production line.
The SQE shall verify the process and instructions are followed during the Process
Audit.

Set-up and changeover instructions shall include acceptable control limits for
process parameters (e.g. temperature, pressure, etc.) and verification of those
parameters during process set-up and/or re-start. Where applicable, quick die * Set-up, changeover instructions
change methodology shall be used to ensure adequate changover times to support
capacity requirements. They shall detail all required steps, including off-line
activities such as gage management.
The Supplier shall be responsible for maintaining manufacturing process
performance/capability and have a procedure for the detection of process drift,
degradation, and out-of-control measurements and immediate corrective action on
the process. Data recording methods shall be suitable for the checks being * Control charts
performed and control limits used shall be calculated based on the requirements in * Process monitoring results &
the Statistical Process Control manual. The Supplier shall have a process for the easy data
identification of conforming products produced (lot breaker, control charts, etc.). * Corrective actions for out-of-
Nonconforming, out-of-control conditions, or special causes of variation shall be control items
clearly identified, documented and linked to a corrective action process that is
responsive to the operator. A process shall be in place to provide notice to
maintenance when machines breakdown or become out of control.

Process/machine parameters subject to significant variation over time (e.g.

temperatures, hold times, speed, pressures, etc.) shall be systematically monitored
with respect to set tolerances (as designated "Quality Points"). They shall have
controllers with closed loop feedback systems maintaining established process
limits. Control limits / process parameters shall be determined using preliminary * Process monitoring results &
process analyses (e.g., assembly FMEA, DOE, knowledge of successive processes, data
knowledge of how the product is used, engineering specifications and standards,
etc.) and show evidence of continual improvement. At a minimum, the Supplier * Corrective actions for out-of-
shall analyze process parameters that affect close tolerances, fit, function, finish, control items
reliability, durability, or that affect the successive/final process. All machine
parameters shall have effective means to prevent unauthorized personnel from
making changes to them (e.g., passwords, lockouts, etc.).
NOTE: Ensure control limits are not confused with tolerances.

The Supplier shall have all required technical documentation (work instructions,
Control Plan, SPC charts, inspection logbooks, etc.) available and accessible at the
applicable work stations. There shall be visual displays of process performance (e.g.,
* Process performance results
OEE, FTC, scrap, machine downtime, etc.) visible and up-to-date on the and plans
manufacturing floor using White Boards or equivalent. The Supplier shall have
process performance targets identified for each metric, with plans and progress
towards achieving the targets documented and tracked.

The Supplier shall have a process for creation, approval, and proper storage and
handling of Boundary Samples or Appearance Manual used for inspection. Approval
shall include Plant Perceived Quality (CPA), plus other appropriate FCA
representatives (SQ, Engineering, Corporate Quality, etc.). This process shall also
include periodic review of Boundary Samples (minimum every 3 months, or as * Boundary Sample / Appearance
agreed to by FCA) to ensure acceptability. When requested, copies of Boundary Manual procedure
Samples shall be made available to the FCA facility and Quality personnel. Parts with
Class ‘A’ surfaces shall have a master sample available at the inspection station
equivalent (or superior) to the ATAR sample or Craftsmanship sample agreed to
with the Assembly Plant CPA team.
When used for inspection, Boundary Samples or Appearance Manuals shall be
available at the inspection station and accessible to the inspection operator. They
shall be clearly identified with: part name, part number, date that it is valid until, * Appearance Manual
description of its purpose, and appropriate Supplier management signature (and
FCA signature, as required). When not in use, Boundary Samples and Appearance
Manuals shall be maintained in a secure place to prevent damage.

The Supplier shall conduct LPAs on all processes that produce production parts or
modules for FCA and any supporting processes. They shall have procedures and
work instructions for creating and conducting LPAs which adhere to the AIAG's CQI-
8 Layered Process Audits and include:
- meeting all ISO/TS-16949 Customer Specific Requirements for LPAs;
- creation and implementation of the Process Control Audit for each process and
supporting process;
- creation and implementation of the Error and Mistake Proofing Verification Audit
for each process and supporting process; * LPA Procedures and Work
- detail of the roles and responsibilities for all levels of management; Instructions
- schedules and frequencies for all audits, and for each level of management
- records of results and reaction plans for nonconformances discovered during any
audit;
- updating the applicable audit for any nonconformances discovered at FCA
facilities;
- a requirement for regular top management reviews of audits and their results,
with meeting minutes and open issues;
- obtaining FCA approval prior to removing any item from the LPA

The Process Control Audit shall be done once per shift by a group leader or
supervisor. Management audits shall be done weekly. Manufacturing areas shall be *procedures,
Process Control Audit
instructions,
divided and auditors rotated so that all areas are included. The SQE shall witness at checklist
least one Process Control Audit during the Process Audit.

The Error and Mistake Proofing Verification Audit (see 3C) shall be completed once
per shift or product change-over (whichever comes first) and whenever an
unscheduled disruption occurs in the production line. The audit shall be performed * Error and Mistake Proofing
by qualified, trained personnel only. The SQE shall witness at least one Error and Verification Audit procedures,
Mistake Proofing Verification Audit during the Process Audit, performed prior to the instructions, checklist
PDR Stage 1.

For parts with Safety/Report characteristics and/or subject to Homologation, the

Supplier shall have a process to identify, develop, and implement controls on those
characteristics (with results recorded and retained per FCA and regulatory
requirements). Controls for safety/report characteristics shall be identified on the
Control Plan (and other quality documents), both on the step in which the * Control Plan
characteristic is generated and in a special annex that summarizes these controls. * Safety/Report records
Controls performed by Tier 2 (or lower) Suppliers shall also be identified and
maintain the same level of record management. The Supplier shall meet all FCA
requirements regarding Safety / Report characteristics, as required (NAFTA: PF-
SAFETY / EMEA / LATAM: FCA norm 9.01120).
Safety / Report characteristics shall have a primary check performed 100% by
Error/Mistake Proofing, as well as a secondary measurement audit performed by
Quality Auditors at specific sample sizes and frequencies and results recorded on * Control Plan
* Safety/Report audit data and
statistical charts. The acceptable checking method, sample size and frequency for results
establishing lot control within the Supplier’s facility shall be determined by the
Supplier’s Control Plan and/or as directed by the FCA PPA Team.

Nonconformances on Safety/Report characteristics shall be tracked, with immediate

containment of all product. Root Cause Analysis and Corrective Action procedures
shall be implemented immediately following containment. The Supplier shall notify * Corrective Action procedures
FCA (SQE, Plant Quality, etc.) immediately upon detecting a potential issue on safety
parts.

The Supplier shall have a documented First Piece Approval procedure and
instructions which verify proper set-up at each station and that parts made meet
applicable specifications. The procedure shall include:
- part approval by responsible personnel with specific approval instructions;
- analysis of all special characteristics and process parameters (for conformance,
drift, out-of-control conditions, etc.);
- 'OK to produce' given by responsible personnel after verification of conformity to * First Piece Approval procedure
specifications of the first parts produced with a steady process;
- requirements for First Piece Approval at the beginning of each shift, production and instructions
* First Piece Approval results
run, and following any changes to the production process;
- retention of the First Piece Approval sample until the end of the production
run/shift and verification of the last piece produced at the end of the shift or
production run against the approved First Piece Approval sample;
- retention of the last piece produced at the end of the shift or production run until
verified against the First Piece sample of the next shift or production run;
- documented evidence of First Piece Approval results
Manufacturing facilities handling components that must be protected from
Electrostatic Discharge (ESD) shall have the following:
- ESD production areas separated from other areas of the facility, with climate
controls as necessary;
- ESD mats and/or floors;
- Heel and/or wrist straps (ESD certified shoes are acceptable);
- ESD testers for operators to verify heel and wrist straps, and/or shoe effectiveness;
- ESD testers with up-to-date operator instructions (including mandatory testing of * ESD procedures and
all personnel prior to entering the floor), included in the calibration procedures, instructions
schedule, and Preventive Maintenance plan;
- Clearly-identified ESD containers (e.g. bags, totes, etc.) for transporting ESD
sensitive product;
- ESD workbenches that are grounded with plugs for wrist straps, if applicable;
- ESD gloves and/or finger cots for handling of PCB's (e.g. rejects);
- ESD certification schedule mandating annual recertification, and record retention,
of equipment, tools, testers, containers, and personnel.

Suppliers with welding operations and processes shall meet all requirements in CQI-
15 “Special Process: Welding System Assessment”, including conducting regular self-
assessments and audits. In addition, they shall meet the following:
- All welding technicians, operators, and inspectors shall be trained and certified (to
all applicable FCA, ANSI, AWS, UNI EN, etc. standards), with re-training, re-
qualification or re-certification as necessary;
- Include all welding cells in the Suppliers LPA Process Control Audit to ensure
conformance to requirements;
- The Supplier shall have objective evidence of a working weld conformance system
for a period of at least one year demonstrating control and corrective action on a * Welding Assessment and Audit
daily basis; procedures and records
* Welding training plan,
- All weld audits, assessments, and Control Plans shall include cut and etch as well certifications, and records
as microscopic inspection;
- The Control Plan cut and etch frequency for each weld shall be determined by the * LPA Process Control Audit
PPA Team and be adequate to ensure that each lot of material has had welds * Control Plan
validated prior to shipment from the facility (i.e., four-wall containment). This
applies at the Supplier’s facility.
Suppliers with other special processes (e.g., heat treating, plating, painting, etc.)
shall have a process in place that includes the following:
- Operator training and certification;
- Inclusion of the process in the Supplier's LPA program;
- Conducting self-assessments to industry standards (as required);
- Process monitoring and data recording requirements.
The Supplier shall have a process for workplace Safety, including:
- cross functional root cause analysis of safety incidents;
- a method to
identify highest incident areas of injury by plant location with continuous
improvement activities (e.g., Kaizens);

- use of visual-based Safety standards (including lockout tagout locations, at eye

level);
- Identification of areas dedicated to development of security in relation to * Workplace Safety process
accidents, natural disasters, or security incidents (e.g., tornado shelters, evacuation * Safety audit
routes, active shooter protocols, etc.); results (Mgmt).
- identification of standard pedestrian walkways when applicable; * Continuous Improvements /
- definition of criteria for assignment and use of individual protection devices (e.g., Kaizens
safety glasses, steel-toed shoes, etc.);
- method for Safety Audits conducted by management with schedule posted and up
to date;
- tracking and reporting on Safety metrics / KPIs (near misses, unsafe acts and
conditions, lost time, etc.);
- availability / posting of safety information, procedures, metrics, and equipment
(e.g., extinguishers, emergency exits, etc.) for all personnel;
- a plan for safety training for all personnel.

The Supplier shall have a process for management of environmental concerns. This
process shall include:
- a method to identify and prevent environmental risks with continuous * Environmental management
improvement activities (e.g., Kaizens);
process and forms
- tracking and reporting the number of environmental incidents; * Continuous Improvements /
- a method to analyze root causes of environmental issues; Kaizens
- monitoring of the environmental impact of all plant processes;
- tracking and continuous improvment of environmental metrics / KPIs (energy
consumption, material recycling, etc.)

EMEA: the Supplier shall have a Fire Prevention License (or equivalent). * Fire Prevention License
The Supplier shall have a Preventive / Predictive Maintenance plan which includes:
- identification of maintenance requirements and frequencies for all tooling,
equipment, Error/Mistake Proofing, and gages used in the process, based on risk
(past history, AQR, MPFMEA, PFMEA, lessons learned, manufacturing specifications,
break-downs, etc.);
- identification of critical process equipment and dedicated resources;
- Standard maintenance procedures / instructions with diagrams, defined PM
activities to perform, required skill level, tools required, frequency, duration, and
visual aids developed;
- a PM calendar for recording machine break downs, with break downs longer than
10 minutes requiring root cause analysis and continuous improvement activity (e.g.,
Kaizens);
- the PM Calendar shall also include graphics from the technical drawing of machine
systems (electrical, pneumatic, hydraulic etc) and components with PM activity,
duration, and frequency;
- addition of new tooling to the plan prior to production release;
- detail for the preservation and storage of tooling, equipment, and gages; * PM plan
- a spare parts list for all new and dediciated machines, based upon Mean Time To * PM Calendar
Between Failure (MTBF) and Mean Time To Replace (MTTR), for critical or long-lead
equipment that could result in plant shutdowns; * Spare parts list & availability
- identification of maintenance / downtime issues with root cause analysis to the
component level; * Standard maintenance
- a method for documenting corrective actions and lessons learned and reading procedures
across to other processes and equipment; * Continuous Improvement /
- recording, reporting, and tracking of maintenance data (via logbook, ledger, etc.) Kaizens
and metrics / KPIs (OEE %, MTBF, MTTR, increase in planned maintenance, etc.) and
continual improvement activities;
- reviews and updates of the plan on a regular basis.

The Supplier shall ensure that the planned maintenance activities are performed
per the established schedule.

The Supplier shall have a process for maintenance activites, performed by

operators, that includes:
- identification of where such activities are performed;
- a method to restore equipment back to basic conditions;
- a method to identify sources of contamination, hard to access areas, and safety
issues in the work cell for continuous improvements (e.g., Kaizen);
- visual-based instructions for performing the activities;
- availability of all equipment necessary to perform the activities at the operator
workstation;
- use of an equipment Cleaning, Inspecting, Lubricating and fastener Re-tightening * Process for operator-
(CILR) calendar in the FCA production cell which defines activity frequencies and performed maintenance
continuous improvements (e.g., Kaizen) to eliminate sources of contamination and * CILR Calendar
hard to access areas; * Continuous Improvements /
- recording, reporting, and tracking of metrics / KPIs (Reduction in cleaning, Kaizens
inspecting, lube and retighten time, reduction in equipment breakdown due to lack
of basic conditions (contamination), etc.).
Maintenance records and related quality issues shall be analyzed to identify any
weakness in the equipment and/or in the maintenance plan and optimize the * Maintenance records
process.

There shall be a trained maintenance team, internal or external, available in case of

emergency during all production hours. All unplanned or special maintenance * Preventive Maintenance plan
activities, in any part of the Supplier's facility, shall be recorded and tracked by the * Maintenance records
Supplier.

The Supplier shall ensure that, as tooling and/or equipment approaches the
predetermined end of life cycle, appropriate actions are taken to ensure conformity
to requirements (e.g. increased inspections, enhanced detection measures or
methodologies).

The SQE shall verify the environment where dies/tooling, equipment, and gages are
stored when not in use. Items shall be clean, well-protected from damage and
environmental stresses, properly maintained, and easy to locate to ensure
functionality through the life of the program.

The Supplier shall have a process for workplace organization / lean manufacturing
in the production cell. This includes:
- 5S (see below)
- identification of top non-value added activities (NVAA) in work cells, with
continuous improvement activities (e.g., KAizens); * Workplace organization process
* Continuous Improvement /
- ergonomic analyses and classification of unnatural movements in the workcell; Kaizens
- application of "Golden Zone" and "Strike Zone" concepts (see 6A)
- development of standard cycle times across shifts;
- evidence of cell
rebalancing activities where applicable;

- tracking and reporting of metrics / KPIs (productivity, reduction in human errors,

ergonomic improvements, % of plant 5S certified, etc.).

The Supplier shall have a process to ensure workstation cleanliness (5-S) which is
implemented daily (at a minimum). This includes:
- clean and organized work stations with identified bins for waste, dirty rags,
recyclables, etc.;
- necessary items on or near workstations (e.g. tools, sub-component stock) shall
be stored in designated areas;
- small tools, required resources, or similar items secured to the workstation and * 5-S process and checklists
visible;
- a plan for protection of equipment / personnel, and containment and clean up of
spills, for potentially hazardous materials (e.g., oil drip pans, exhaust fume hoods,
etc.);
- availability of a system for material restock of the area;
- logbook showing evidence of completion of the 5-S activities.
The Supplier shall have a process for training based on employee skill weaknesses
and plant needs. It shall enable the development of skills to promote error free
operations. It shall include:
- a process to train and qualify key personnel (operators, supervisors, maintenance
personnel, etc.) using class-room / lecture as well as "on-the-job" training with a
skilled operator with evaluation of skill using testing prior to performing production
operations and evaluation of at set points after (e.g., 30/60/90 day evaluations);
- use of training videos and visual samples whenever possible;

- escalation and re-training / certification when performance is deemed insufficient

or unsatisfactory;
- identification of skill / training requirements for all unique positions and * Training process
monitoring of gaps with a clear training plan to close the gap; * Training records /
- identification of training needs based on top cost, safety and quality losses / charts
issues;
- evidence of periodic (minimum semi-annual) reviews , and updates of
requirements, materials and records;
- employee training records and charts (e.g., radar) developed and maintained;
- identification of which employees are certified to perform applicable tasks /
operations;
- tracking and reporting of employee involvement and related metrics / KPIs
(suggestions submitted and implemented, absenteeism, etc.).

Operations or processes requiring special certification or licensing, and those

personnel who are certified/licensed to perform them, shall be identified. This
includes, but is not limited to:
- Operations or inspections using visual identification or appearance checks (e.g., * List of operations and
color/gloss checks); operators requiring special
- Operations or inspections using audial inspections (e.g., checks for BSR/NVH);
- Inspections and checks on Safety/Report characteristics; certifications
* Skill matrix or records
- Rework/repair operations;
- Inspections or checks using specialized testing equipment or machinery (e.g., X-
ray, magnetoscopes, etc.);
- Operations and processes sensitive to Electrostatic Discharge (ESD)

At the Process Audit, all key personnel needed to ensure that the Supplier’s
process(es) can meet the required volume at launch shall be hired and fully trained,
and a plan shall be in place to support full production volume.
NOTE: All operators used to run the PDR shall be intended production operators. * Personnel plan for support of
When required by FCA, the Supplier shall fully detail their plan for hiring and production
training production personnel on the form included in the PDR Toolkit. The FCA SQE *PDR Toolkit
shall audit the Supplier to the plan as required; failure to adhere to the plan may
result in a Forever Requirement Violation, initiation of 3CPR/CSL, addition to TPSL or
NBH, or other penalty as determined by FCA.
The Supplier shall have a process for identifying and ranking opportunities for
continuous improvements. This includes:
- identification of waste/loss and non-value added activities (NVAA);
- use of corrective actions (e.g., Kaizen) to eliminate waste/loss and NVAA;
- analysis and reporting on continuous improvement metrics.

The Supplier shall have a structured approach to problem solving to ensure correct
resources and proper use of tools are addressing the most critical plant issues and
resolving them permanently. The process shall include:
- use of the Plan Do Check Act (PDCA) or similar method internally as well as FCA- * Examples of Kaizens /
mandated formats for external issues (8-Step, 8D; see 8A); continuous improvement
- an active employee suggestion program; projects
- prioritization and implementation (as applicable) of employee suggestions for
improvment;
- Kaizen / continuous improvement training of personnel;
- use of cross-functional teams for continuous improvement projects;
- tracking and reporting on related metrics / KPIs (# projects completed, employee
suggestions submitted and implemented, scrap %, FTC %, etc.)

The Supplier shall have a process material handling and inventory management /
material re-stock (e.g. pull system, Kan-Ban), including:
- development of standard part display racks, standard part quantity, and standard
part labeling in the work cell, with parts and assembly tools at the operator's waist
level, with no extended bending, reaching, or turning;
- storage areas shall be sized to accomodate the number of days of inventory for
finished goods, empty containers, and components the supplier plans to maintain
as "float" or buffer, and be documented on the manufacturing floor plan per the
container foot print and stack height;
- fixed routes (standard most efficient route) and material located in a logical way to * Material handling plan for
minimize non-value added activities (NVAA); every part
- material flow analyses (material supply method from warehouse to line) in * Material classificaiton
development of work cells; * Value stream mapping
- guidelines to classify all materials by cost, size and variations to recommend * Material flow analysis
lineside stock display level, and material flow types;
- use of First-In-First-Out (FIFO) for inventory control for all material, with an
effective backup process if the primary method is computerized;
- development of a plan for every unique part number (managing stock FIFO,
material handling, packaging requirements and floor space);
- use of value stream mapping to evaluate internal and external logistic routes to
reduce non-value added travel or waiting times;
- tracking and reporting on related metrics / KPIs (working capital, inventory levels,
inventory turns, production lead times, etc.).
The SQE shall verify that material handling procedures are followed during the
Process Audit. Material storage locations shall be clearly identified and adequate for
process requirements. Pallets, shelves, etc. shall be clean and well-maintained.
Storage areas shall be sufficiently sized to contain the material, located in a logical
way with respect to process flow, and adequate to contain and protect the product
with easy access and safe handling. Handling, transport and containing means
(forklifts, pallets, etc.) shall be efficient and operated under proper safety
conditions. When applicable for employee safety, material train "tuggers" shall be
used instead of forklifts.

The Supplier shall have a procedure for maintaining part traceability. Part
traceability shall be independent of inventory control processes (i.e., shall not be
FIFO-dependent). The Supplier shall demonstrate part traceability on all parts
through all stages of production, from raw materials through the finished assembly
and including sub-tier suppliers and shipping. NOTE: Some parts also require * Traceability procedures
traceability codes / bar code labels to be present on the finished assembly. These
will be defined by the FCA engineering standards (typical parts include those
covered by government regulations, Safety, Powertrain, and those required by
contract).

For parts with Safety/Report characteristics or subject to homologation, it shall be

possible to trace back the results of inspections and tests per FCA requirements and
government regulations.

When required by FCA specifications, the finished part shall include the Supplier's
alphanumeric code, with proper modes (label, printing, molded in the part, etc.).
Also when required by FCA specifications, parts delivered before the granting of Full
Approval / PPAP or before Start of Production (whichever comes first) shall have a
“Traceability Code” as defined by that standard.

Parts inspected by Quality department audits shall be clearly identified and

traceable to the inspection process, auditor, gages, and personnel. Product
undergoing inspections shall be clearly segregated and identified as to:
- product waiting to be inspected;
- product inspected and accepted with the acceptance date (year, month, day, * Quality inspection procedures
and instructions
numeric sequence);
- product waiting for a disposition;
- nonconforming product;
- product to be scrapped (i.e., non-reworkable or repairable)
All materials used in the process shall be clearly identified and differentiated (set-up
parts, rework/repair, scrap, Work in Process (WIP), sub-components, etc.).
Identification labels shall be clearly visible on each container, with lot number, date,
quantity, and part number, at a minimum. WIP shall also be identified with
operator/supervisor, operation number, number of pieces entering/exiting the * Material handling procedures
operation, number of pieces reworked/ repaired, number of pieces scrapped,
operation number and shift. Identification shall be clear, even after the partial use
of the lot. Parts used for set-up or inspection purposes shall be clearly identified
and stored in a way that prevents accidental shipment.

Parts shall be identified per FCA requirements, in a manner consistent with the risk
of the part/process. Product identification/marking shall be written, in case of
assemblies, on all components of the assembly, if they are available loose on the
spare parts market.

Sorted, reworked or repaired material shall be traceable back to the sort, rework or
repair process. In addition, parts undergoing rework/repair shall adhere to the
following:
- when a sub-component is replaced which has Safety/Report characteristics, the lot
from which the replacement sub-component came shall be identified and linked
with the final assembly on which it was used;
- when a sub-component is removed from an assembly which has been returned
from an FCA facility and re-used in another assembly, the lot code of all sub-
components with Safety/Report characteristics shall be identified and traceable to
the new assembly in which the component was used;
- traceability maintained if a part returned from an FCA assembly plant is to be re-
sent without rework or repair performed (e.g. parts sorted as “good” from a
returned, quarantined lot).
NAFTA: There shall be a link between packaging labels (for both internal and
external containers) and the product, lot, packing list, quantity, revision level, sub-
components and other relevant information. For purposes of traceability and
identification, one lot shall not exceed one shift or one production run, whichever is
less.
EMEA / LATAM: There shall be a link between packaging labels (for both internal
and external containers) and the product, lot, packing list, quantity, revision level,
sub-components and other relevant information.
The Supplier shall also send to FCA EMEA plants (including Powertrain and IRF
Poles) AVIEXP/ASN (advance shipment notice) for each physical shipment (telematic
and physical shipment at the same time) according to CGA and following FCA
procedure 71092 rules.
Not sending (or sending partial) Aviexp/ASN will result in SQP penalization as
written into FCA procedure 08018. AVIEXP/ASN can be sent via EDI connection or
Web portal (all information can be found on the FCA Logistic Portal at
https://fiat4suppliers.fiat.com/LOGISTICS)
NOTE: AVIEXP transmission is mandatory. AVIEXP provides FCA plant detailed
information about actual deliveries and facilitates material receiving process.

The Supplier shall specify all containers used in the process, both internally and
externally, in the packaging or work instructions. Specific information shall include
container dimensions, material, pieces per container, weight of container (full and
empty), containers per pallet, maximum stacking height, etc. All packaging and
labeling for product being shipped to FCA shall conform to all FCA requirements.
* Packaging instructions
During receiving, shipping, and storage operations, environmental conditions shall
be such as to protect the integrity of the part and packaging. The SQE shall verify
during the PA that all requirements for packaging listed in the SourcePackage (e.g.,
pieces per container, pack size, expendable dunnage, etc.) match the actual
packaging used.

For all Supplier-designed packaging (internal and external):

- the Supplier shall be responsible for designing, manufacturing, testing, and
documenting expendable packaging test data (simulated or actual);
- packaging shall be designed to ensure, even in the case of repackaging, the
integrity of the single component until its use in the production cycle;
- testing (e.g. shaker table, rail or over the road etc.) shall be performed based upon
the mode of transit;
- simulation tests and/or shipping tests shall be conducted prior to VP (Verification
of Process) and be documented.
The Supplier shall have a procedure for the management of returnable containers
and dunnage. This procedure shall include:
- access and training for the appropriate FCA container management system;
- mandatory data entry into the appropriate FCA system;
- inventory control procedures to track containers on-hand and in-transit from FCA;
- procedures for mandatory transmittal of container and/or part number
information during computer submissions from the Supplier; * Returnable container
- procedures for identification and disposition of contaminated or damaged management procedure
containers received;
- an expendable back-up plan in the event of a shortage of returnable containers.
Back-up expendable packaging shall maintain the same dimensions as the
returnable container (and contain the same number of pieces).
NOTE: The Supplier is not responsible for the approval of FCA-designed and
mandated packaging.

The Supplier shall not use FCA-owned and provided containers for internal
handling or WIP.

Bar code labels shall:

- be generated one at a time and only following successful completion of the
previous operation (e.g. after passing an end-of-line tester, after correct scanning of
the correct material, etc.) when done at the final operation;
- have logic in place to prevent printing of duplicate bar code labels;
- have logic or error proofing to ensure labels match the part for scanning purposes

For parts that follow Sequenced Part Delivery (SPD), the Supplier shall:
- maintain SPD sequence throughout the entire process (including repair/rework);
- have backup systems to ensure receipt of the broadcast / EDI;
- use barcodes and/or pick lights with break beams to ensure correct part selection
and assembly;
- use vision systems or color sensing to ensure correct components and color match
(as applicable);
- ensure components with Safety or Report characteristics are traceable to the VIN
sequence;
- employ additional tracking to maintain sequence and delivery in cases of
rebroadcast due to non-repairable conditions
EMEA/LATAM: The matrix score evaluation in function of CAPMAN output
0% has to be evaluated 1
1% - 59% have to be evaluated 2
60% - 89% have to be evaluated 3
90% - 94% or any percentage but with and mean age < 7gg have to be evaluated 4 CAPMAN System
95% - 100% have to be evaluated 5
Action plan to be considered: from 1 to 100 Part numbers: two weeks; more than
100 PN: Three weeks
NOTE: The CAPMAN score doesn't contribute to the final PA score

NAFTA: The Supplier shall complete the SCM Readiness Checklist and have a
process for supply chain management that includes:
- designating a responsible user for SCM specific systems / applications, and ensure
access to each;
- establishing an EDI X12 Interchange within 30 days after a PO is received. * SCM Readiness checklist
- SCM Supplier Training on FCA systems / applications for each user;
- completing and submitting an Materials Management Operations Guidelines / * MMOG/LE self-assessment
Logistics Evaluation (MMOG/LE) Self-Assessment annually;
- designation of a Supplier Corporate Delivery Champion (CDC) with responsibility to
lead delivery performance improvement initiatives across all associated
manufacturing and ship sites.

The Contract capacity shall be enough to meet FCA requirements (including

Service / MOPAR). If the Increased Contract Capacity (EMEA/LATAM) or Capacity
Planning Volume (CPV; NAFTA) exceeds the Contract capacity, it shall be temporary
and the Supplier shall be able to meet these requirements through standard means
(e.g., overtime, weekend runs, etc.). When running higher volumes, the Supplier
shall still be able to do all required maintenance activities, quality controls, etc.
When multiple parts share a single constraint, the Supplier shall set up a Common
Process Group (CPG) within the Capacity Database to inform FCA. The Supplier is
still responsible for ensuring FCA program mixes and volumes are adequately met,
and the SQE shall verify the CPG is correctly entered into the system.
The Stage 1 Production Demonstration Run (PDR) shall be completed during the
Process Audit. The Process Audit and PDR shall be run on finished production tools
using definitive production processes (i.e., "homeline"). The Supplier shall meet the
required line speed based on the Contract Capacity, and shall run a minimum of 300
parts or 2 hours of production per part number, whichever is more. First Time
Capability (FTC) for the final process shall be 90% or greater, and Line Utilization
* Contract
90% or less. FTC shall be calculated separately for multiple production lines or tools. * PDR Tool Kit
NOTE 1: Deviating less than the 300 parts or 2 hours of production requirement
requires the approval of the FCA Engineer, SQE, and SQ Manager. Deviating from
the FTC or Line Utilization requirements also requires the approval of the FCA
Engineer, SQE, and SQ Manager.
NOTE 2: For the Readiness Evaluation trial run, the Supplier and FCA Engineer and
SQE shall agree upon the number of parts to run.

The Supplier shall demonstrate process performance / capability for all identified
special characteristics. All parts used in this study shall come from the PDR.
Performance/capability shall meet FCA requirements as defined in the PDR and in
the "Performance Requirements" tab and results recorded on or attached to the
PDR Toolkit forms. Special characteristics (see 1D) require variable data; any using
attribute data shall be agreed to by the FCA team and 100% of the parts shall be
acceptable.
NOTE 1: For new programs, process performance should be used (P P/PPK). For * PDR Tool Kit
current production processes, process capability should be used (CP/CPK). * Performance / capability data &
Performance / capability should be calculated individually for each assembly line, results
tool, and tool cavity.
NOTE 2: Process capability on special characteristics is monitored over time to
guarantee ongoing stability. This should be done using adequate SPC techniques
and/or recalculations at fixed intervals. Reference the applicable FCA standards or
manuals.
NOTE 3: All characteristics on the part, regardless of classification, shall meet FCA
requirements.

If the process performance / capability is less than the established requirement,

then 100% verification of the product shall be performed. Permanent corrective
actions shall be implemented before the Process Audit can be approved. Corrective
actions shall include:
- periodic reviews of data and control limits; * Manufacturing Feasibility
Assessment
- review and updates/increases of sample sizes and frequencies as necessary; * Performance / capability data &
- recording/documentation of actions taken; results
- verification of the effectiveness of actions taken.
If the process is determined to be unable to maintain process * Corrective action records
performance/capability, Error or Mistake Proofing shall be implemented for 100%
mechanical verification and can be considered the Permanent Corrective Action at
the FCA team's discretion.
Machine capability (CM/CMK) shall be used for "Shoot-and-ship" parts or when
analyzing a characteristic unique to a particular machine. Machine capability shall * PDR Tool Kit
be re-calculated when there are any modifications to the product or process, * Performance / capability data &
significant maintenance is done on the machine, or when the machine is moved. results
Machine capability shall be calculated on all FCA-owned tooling.

The SQE shall perform an audit or inspection on sub-components and finished parts
during the course of the Process Audit. The SQE shall:
- determine the number of parts checked at each area / operation, based upon risk
level and significance of the characteristic (15 is recommended);
- verify that inspection personnel are adequately trained in the inspection process; * Control Plan
* Inspection / gage instructions
- verify inspection methods are performed in a way that is consistent and adequate
with the inspection requirements;
- evaluate the adequacy of the measurement method;
- ensure the selected parts are conforming.

In the Incoming or Receiving Material Area select one or more sub-components

from previously accepted/approved lots and witness the Supplier inspect them per * Control Plan
the Control Plan. The SQE shall also verify that the raw material being used meets * Inspection / gage instructions
FCA requirements.

In the Manufacturing Area, the SQE shall select in-process or finished parts from a
minimum of three different machines/processes and different operators and * Control Plan
witness the execution of the inspections (per the Supplier's Control Plan), checking * Inspection / gage instructions
the consistency of the results with previously recorded inspections, and comparing
them to the specifications.

In the Shipping Area the SQE shall select finished samples from previously * Control Plan
accepted/approved lots that are ready to be shipped and witness the Supplier * Inspection / gage instructions
* FPSC plan or Strengthened
inspect them per the Control Plan and Safe-Launch activities. Control Plan

Nonconformances found while performing the SQE Audit shall have root cause
analyses performed, and corrective actions approved (by the SQE and Supplier * Corrective Actions
Management) and implemented prior to Process Audit approval.

The SQE shall verify the Supplier's ability to maintain traceability on the finished
product. The Supplier shall demonstrate, on one finished assembly, the traceability
back to the raw materials or applicable sub-tier supplier on one or more sub-
components selected by the SQE.

Sub-components not considered low risk shall have a Process Audit (or equivalent) * PA/PDR results for M/H risk
and Production Demonstration Run led by the Supplier and followed with a Level 3 sub-components
PPAP submission (or equivalent approval) to the Supplier (see 2E). Sub-components * Sub-component PPAP
considered low risk shall be submitted with a Level 1 PPAP (or equivalent) to the
Supplier, at a minimum. submissions & samples
If sub-component approval is granted via deviation, it shall be temporary and shall
indicate the quantity and/or the valid time period. Deviation on sub-components
must be approved by the FCA Engineer first, then approved by the applicable
Supplier department(s). NOTE: Violation of this requirement requires immediate * Sub-component Deviations
placement of the Supplier on 3CPR (NAFTA) or CSL (EMEA/LATAM) Level 2. Process
Audit approval will not be given if any sub-component is under a deviation and/or
not approved (except for Directed or Consigned components; see below).

Quality planning, Process Audit, and PDR activities on Directed Tier 2 components
shall be led by FCA, supported, as necessary, by the Tier 1 Supplier. The Tier 1
Supplier shall be responsible for the on-going quality of the Tier 2 components
following PPAP. The Directed Tier 2 Supplier shall provide pilot, launch, and ongoing
production support to the Tier 1 Supplier in the same manner they would FCA.
NOTE (NAFTA): Process Audit Approval for modules containing Directed or
Consigned sub-components, shall not be withheld due to a lack of PPAP on the FCA-
led Directed / Consigned sub-component. A “Directed” component is classified as a
component given the “VT” lineup code in CQMS. A “Consigned” component is
classified as a component given the “VX” lineup code in CQMS.

The Supplier shall have a process that ensures annual validation / recertification as
required by FCA. The process shall include:
- full part layout(s) to dimensional requirements; * Annual Validation process
- all testing as detailed in the DVP&R or AQF;
- ensuring annual validation / recertification is done on-time and that conflicts are * DVP&R (NAFTA)
avoided in the event of multiple parts being due at the same time; * AQF (EMEA / LATAM)
- obtaining a written waiver from the FCA representative if annual validation is not
required. This waiver is required for each year in which validation is not performed.
The Supplier shall have a process for Non Conformance Corrective Action. This shall
include:
- training and use of appropriate Problem Solving and Root Cause Analysis tools
(e.g. 3 Legged 5 Why, Critical Thinking, LUA/LUR, etc.);
- use of the appropriate FCA tool / system for documentation (GIMS, SQP, PDCA,
Kaizen);
- identification and containment of nonconformities including inspection of parts
back to the last 'in-control' or acceptable point (at a minimum);
- development of interim and long-term corrective actions with clear target dates
and escalation procedures when target dates are not met;
- verification of corrective action effectiveness;
- a system of defects prioritization with all defects collected and recorded (internal /
Customer), prioritized based upon cost (scrap / labor); frequency; and point of
detection, analysis based upon point of creation, and evaluated according to Man;
Material; Machine; Method; Design; and Environment; * Corrective Action procedures
- a method to determine capability of the process in preventing occurrence and
release of a defect in station to subsequent stations;
- ensuring updates of applicable quality documents (PFMEA, Control Plan, Work
Instructions, etc.);
- ensuring the communication of lessons learned, “best practices,” and known
systemic weaknesses throughout the facility (and all other facilities within the
company);
- assignment of the corrective action to an individual, with target and actual dates;
- tracking the progress of implementation of corrective actions;
- ensuring communication of quality and manufacturing issues across shifts,
departments, and personnel;
- management involvement in the reporting of quality issues and tracking and
approval of corrective actions.

The Supplier shall have procedures for handling of nonconforming product,

including receiving, internally produced, and returned material from the FCA Plant.
These procedures shall include:
- defect tracking methods at all inspection stations/areas (e.g., tally or scrap sheets);
- proper identification of returned, rejected, or scrapped material;
- proper storage of quarantined material in a locked or controlled area, with
quarantined material identified with part number, number of pieces, date * Nonconforming handling
quarantined, reason for quarantine, and expected disposition date; procedures
- maximum amount of time allowed for disposition of quarantined product;
- coordination with the FCA Plant or sub-tier supplier to purge suspect material and
replacement of that material;
- immediate implementation of Corrective Action procedures;
- notification to the FCA Plant and SQE immediately upon identifying shipped
suspect material.
The Supplier shall have a list of approved sub-tier suppliers for each sub-
component, raw material, commodity, technology, or purchased service.
Performance (quality, delivery, etc.) of each sub-tier supplier used shall be
monitored and tracked on a regular basis (minimum monthly). Sub-tier suppliers * Approved sub-tier supplier lists
with unacceptable performance shall not receive new business from the Supplier
until corrective actions have been implemented and verified, and performance has * Sub-tier supplier performance
improved. All toolmakers used by the Supplier shall be ISO-9001 certified, at
minimum. NOTE: If the material, commodity, etc. has an FCA Engineering Approved
Supplier List (EASL), the Supplier shall only use sub-tier suppliers from that list.

The Supplier shall have individuals with the assigned responsibility of managing the
quality of sub-tier suppliers (e.g., a Supplier Quality organization). This includes
performing quality planning and process audits for new programs and management
of current quality performance and issues.

The Supplier shall ensure all FCA quality requirements (e.g., AQR, quality planning,
Process Audit, Forever Requirements, etc.) are communicated throughout the
Supply Chain. The Supplier shall request approval from FCA for all process changes
using the appropriate system or process (e.g., the Forever Requirements system)
prior to implementing a change. In addition, the Supplier shall ensure these
requirements are communicated down throughout the Supply Chain. The Tier 1
Supplier is ultimately responsible for all changes initiated by their sub-tier suppliers
and the Supply Chain.

The Supplier shall have a process for documenting lessons learned and ensuring
they are carried forward to future programs and all sister facilities within the same
company. This includes obtaining and reviewing the FCA Master PFMEA (if available) * Lessons Learned process
at the beginning of the program. * Master PFMEA (if applicable)
All collected lessons learned and Best Practices shall be implemented in the
Supplier's process and design, as applicable.
The Supplier shall have a process for warranty analysis and prevention which
includes review/analysis of samples from the field, root cause analysis, and
implementation of corrective actions. This process shall include accessing and
reviewing information in the applicable FCA warranty systems on a regular basis.
Tier 2 and lower suppliers shall be included in the reviews and corrective actions, as * Warranty process
applicable. The Supplier shall also meet any additional FCA-specific warranty
requirements. NAFTA Suppliers shall meet the requirements in the AIAG's CQI-14
Consumer Centric Warranty.

The Supplier shall be certified to ISO/TS-16949 or IATF-16949 and have their * ISO/TS-16949 or IATF-16949
certificate uploaded into the applicable FCA system(s) Certification

The Supplier shall have a process for retention of quality documents, records,
inspection results, etc. that follows ISO/TS-16946 4.2.3 and 4.2.4, FCA, and * Records Retention process
regulatory requirements.

Has the Self-Qualification test plan been shared? If not, are there clear corrective
actions or risk mitigation plans to complete the test plan? Have the reliability
targets been validated virtually or physically (on bench) with the characteristics * AQF plan
defined and results reviewed by Engineering? NOTE: If a 3rd Party lab will be used
for performing testing, layouts, etc. it shall be certified to ISO/IEC 17025. NOTE 2:
Parts for Self-Qualification testing shall be OTOP (Off-Tool Off-Process).

Have the reliability targets been identified in the product card? Have they been
compared to historical data on similar parts / processes? If yes, has the root cause * Reliability Plan
of any gaps been included in the DFMEA and PFMEA?
Have the samples for Integrative Testing been delivered? If not, has a delivery date * Integrative Test Plan
been planned? * Reliability Plan

Have the samples for Matchability and Benestare been delivered? If not, has a
delivery date been planned? 0

The Supplier shall have a process for Material/Substance Composition reporting via
the International Materials Data System (IMDS), and be registered at
www.mdsystem.com. This process shall include:
- reference to all FCA requirements for IMDS;
- communication with sub-tier suppliers regarding sub-component IMDS data, and
retention of sub-tier documentation;
- communication to FCA of any changes/updates to IMDS data and retention of any * IMDS Process
documentation submitted or received;
- ensuring traceability of components before and after a material/substance of
concern change or elimination;
- updating the IMDS every time a significant variation of total weight of the product
(>10%) occurs or a variation of the composition of the product (including surface
treatments) occurs.

All parts undergoing the Process Audit shall have an approved IMDS submission.
The Supplier is responsible for the IMDS data on their parts, as well as sub-tier * IMDS Submission
supplier data for materials/components.
 Target for
Target to Start PPR Kick-Off Meeting Activities
Completion

Review the completed Source Package, AQR, MPFMEA,

MFA, and for EMEA/LATAM the SoR, noting key
information and program deliverables. Verify all issues
After source selection Prior to TKO raised by potential Suppliers during the sourcing phase
have been discussed and adequately addressed.
Ensure engineering specifications and Quality,
Reliability, and Supply requirements are understood by
the Supplier.

Technical Review (or Review the results of the Quality Risk Assessment
Process Technical Prior to Source (QRA) with the team. Verify the progress of any
Selection
Review) planned corrective actions from QRA open issues.

Verify the responsibility for the part design and Design

FMEA between FCA Engineering and the Supplier.
Review initial DFMEA with FCA Engineering and
Initial design concept Prior to TKO Supplier. Ensure Supplier has access to any applicable
FCA guidelines for creation of DFMEAs. Note: if FCA is
design responsible and no DFMEA exists, mark this
"N/A"

Ensure the FCA Engineer has reviewed the DFMEA (if

Supplier-responsible) and agrees to the contents.
Ensure it was developed taking into account lessons
learned from previous programs and action plans exist
for items with the highest risk. Verify inclusion of all
Initial design concept Prior to TKO special characteristics, BSR/NVH items, and sub-
components. Verify items with a Severity greater than
or equal to 8 have adequate error-proofing planned or
actions are taken to minimize the severity via design.
Document any open issues or concerns.

Systemic Review procedure for concurrence to r

 Review the design release date. Ensure it is consistent
with temporary tool availability and with the program
Initial design concept Prior to TKO timing. Ensure the latest mathematics are available
and are consistent with the latest release. Review the
proposed datum schemes and ensure they are
consistent with vehicle/part mating points.

Systemic Review for concurrence to the Req

Verify the Engineer concurs with the latest released

design. For NAFTA, review the engineering Design
Acceptance document with the FCA Engineer at Step 2,
Step 2 (Vehicle) Step 5 (Vehicle) Step 3, and Step 5 (or MR1, MR2, and PRC for
Powertrain). Ensure corrective actions or risk
MR1 (Powertrain) PRC (Powertrain) mitigation activities are in place for any open issues.
Issues that receive a score of 1 (Job Stopper) or 2 (Job
Stopper Risk) should have corrective actions in place
before proceeding with TKO.

Review serviceability requirements with Supplier and

Initial design concept Prior to TKO FCA Engineering.
 Review the list of special characteristics (Product Card -
EMEA/LATAM or Part I/S - NAFTA) from the Source
Package with the Supplier, FCA Engineer, and FCA
Initial design concept Prior to TKO Plant Quality. Ensure all special characteristics are
included (dimensional, functional, appearance, etc.) in
the development of the Supplier's Control Plan and
Safe-Launch Plan.

Process Audit Verify with the Supplier, FCA Engineering, and FCA
Final PPR before RE Readiness Evaluation Plant Quality that the part or parts do not require
special characteristics.

Review torque and angle strategy for all fastener

Technical Review Prior to TKO joints, as required. Review planned error and mistake
proofing.

Verify Supplier has the latest release. Ensure that as

changes occur, appropriate modifications are made to
On-going program timing and other deliverables, as required.
Also verify appropriate risk mitigation activities are
planned when deliverables become late to their
required milestones.
 Systemic Review procedure for concurrence to r

Review the Supplier's plan for program timing. Ensure

they are aware of all key milestones, and that key
program deliverables are scheduled according to their
required milestones. Review specific dates for the
following: PA Readiness Evaluation, PV / Self-
Entire Program Qualification Testing Start & Finish, PA Process
Evaluation, Stage 1 PDR, Full Approval, and Stage 2
PDR. Develop or review Risk Mitigation plans for any
deliverables that are or are expected to be late to their
required due dates.

Review the Tooling Kick-off date and ensure

consistency with program deliverable timing. Ensure
the timing allows for parts off of production tooling by
the required build / milestone. Note that the Tooling
Kick-off date is the date that tools actually begin
construction (i.e., "cutting steel"). Once tools are
Entire Program
kicked-off, follow their progress. Ensure toolmakers
are aware of the latest design changes. If tool
completion timing changes, ensure adequate risk
mitigation plans are in place (as required). Note: for
tooling followed by TAG, obtain status updates from
the TAG representative.

Systemic Verify Supplier has appropriate resources and acce

Systemic Review the Supplier's team and resources devoted to the program. Are enough resources g
obligations respected? Is the contact list complete?
 Ensure the Process Flow Diagram, floor plan, and work
station layout reflect the planned process. All
processes and sub-processes shall be included, from
raw material receiving to final assembly shipping,
including rework/scrap areas. Verify that all are at the
Technical Review Process Audit Process latest level of the process. Ensure unique machine or
Evaluation
tool numbers are included in the Process Flow. Ensure
all rework/repair operations have been included.
Review operators required for the process. Ensure
suspected bottleneck operation / constraint is
identified.

Technical Review Process Audit Process Review work station layout and manufacturing floor
Evaluation plan.

Systemic Review the temporary rework/repair procedure for c

Initial review of PFMEA. Ensure it was developed

taking into account the Master PFMEA and lessons
learned from previous programs and action plans exist
for items with the highest risk. Verify items with a
Technical Review Prior to TKO Severity greater than or equal to 8 (or per FCA
requirements, if more stringent) are adequately error-
proofed or actions are taken to minimize the severity
via design.
 Systemic Review procedure for concurrence to r

Process Audit Ensure the Supplier's PFMEA has incorporated

Technical Review Readiness Evaluation potential causes of BSR/NVH. Ensure initial control
plans and DV test plans include appropriate tests.

Verify that FCA tooling & equipment (complete or

under construction) is consistent with that which was
determined needed during the sourcing phase. Any
modifications (e.g., more tools required, some tools
Issuance of the OTOP not needed/built, etc.) with respect to which was
Contract
declared during sourcing shall be promptly reported to
the Buyer. Review the Supplier's plan / procedure for
release of tools and equipment to the production
floor.

Systemic Review procedure for concurrence to r

Review the Supplier's plan for delivery of parts from

temporary tools. Ensure quantities and timing are
Tooling Kick-Off Process Audit Process included. Make sure the plan includes evaluation of
Evaluation
part quality (measurement of special characteristics,
etc.).

Tooling Kick-Off Tooling Kick-Off Review plan for TKO.

Verification of Process Pre Series

Process Audit Process

Tooling Kick-Off Evaluation N/A

Review the list of component suppliers, raw material

suppliers, and tool makers that the Supplier will be
using. Ensure all sub-tier suppliers have been
Process Audit approved and the appropriate risk assessments have
Technical Review Readiness Evaluation been done on the components or materials, and that
tool makers are properly certified. Review that the
Supplier's timing for Process Audits / PDRs and PPAP of
the sub-components supports overall program timing,
and check the status of each component and material.

Review preliminary Supply Chain diagram for potential

supply concerns (e.g., long distances, multiple border
PPR Kick-Off Process Audit Process crossings, etc.). If potential supply issues or risks (e.g.,
Evaluation long distance) exist, ensure that appropriate risk
mitigation activities are in place (e.g., safety stock,
expediting, etc.)

Review preliminary Supply Chain diagram for potential

supply concerns (e.g., long distances, multiple border
Process Audit Process crossings, etc.). If potential supply issues or risks (e.g.,
PPR Kick-Off Evaluation long distance) exist, ensure that appropriate risk
mitigation activities are in place (e.g., safety stock,
expediting, etc.)
 Regularly review the status and content of the
Supplier's Control Plan, both for Prototype (if
applicable) and Production processes using the
Control Plan Document Audit form. Verify the linkage
After source selection Process Audit Process between the Process Flow Diagram, PFMEA, and
Evaluation Control Plan. Ensure controls are adequate and match
those described in the Design and Process FMEAs, and
verify high risk items have correspondingly higher
sample sizes, frequencies, etc. Verify that the Control
Plan is updated to the latest design revision level.

Process Audit Process Audit Process

N/A
Readiness Evaluation Evaluation

Review outgoing inspection plan and control plan.

After source selection Process Audit Process Review planned inspection frequencies, sample sizes,
Evaluation and measurement methods to ensure adequacy.
Review nonconformance reaction plans.

Process Audit Process Ensure Supplier plans for rework / repair parts to go
After source selection Evaluation through controls equivalent to or better than the
primary line.

After source selection Process Audit Process Review initial 8 Stages analysis.
Evaluation
 Review the Supplier's initial SLP. Ensure all special
Prior to VP (Vehicle) Job 1 + 90 days characteristics are included. Identify whether the
(Vehicle) standard duration will be followed or if it will be
Prior to Gamma SoP + 90 days extended. Identify if the part/program will follow
(Powertrain) (Powertrain) launch containment (such as Launch Risk Mitigation).
Identify method of identification of parts for SLP.

Review the Supplier's plan for certification of incoming

and outgoing material. Review list of sub-tier suppliers
After source selection Process Audit Process who are planned to have Self-Qualification status;
Evaluation verify they have acceptable quality performance and
appropriate Process Audit activities are planned.
Review plans for non-qualified sub-tier suppliers.

Systemic Review procedure for concurrence to r

After source selection Process Audit Process Review incoming inspection plan and control plan.
Review planned inspection frequencies, sample sizes,
Evaluation and measurement methods to ensure adequacy.

Systemic Review computerized systems and verify ba

Technical Review Process Audit Process Review the Error and Mistake Proofing process and
plan. Review the plan for creation of Verification
Evaluation
Samples.

Review plan and ensure all items on the D/PFMEAs

Process Audit Process with severity of 8 or higher, as well as all special
Technical Review Evaluation characteristics, have adequate Error and Mistake
Proofing planned.

Prior to Process Audit Process Audit Process Ensure adequate storage and handling of Verification
Readiness Evaluation Evaluation Samples is planned.

Review the Error and Mistake Proofing process and

plan. Ensure Supplier has planned appropriate
Process Audit Process line/station lock out and audible/visual indicators.
Tooling Kick-Off
Evaluation Ensure the Supplier has an adequate back-up plan in
the event that applicable Error and Mistake Proofing
fails

Prior to Process Audit Process Audit Process Review the Error and Mistake Proofing process and
Readiness Evaluation Evaluation plan.

Process Audit Process Review the Error and Mistake Proofing process and
Tooling Kick-Off Evaluation plan. Ensure Supplier has planned appropriate
functions for the End of Line (EOL) tester, if applicable.
Tooling Kick-Off Process Audit Process Review the Error and Mistake Proofing process and
plan. Ensure Supplier has planned to cover all
Evaluation applicable requirements.

Process Audit Process Review the Error and Mistake Proofing process and
Tooling Kick-Off Evaluation plan. Ensure Supplier has planned to cover all
applicable requirements.

Review Supplier's process for gage, measuring device,

When design is Prior to Process Audit test equipment, et. al. handling. Ensure planned
finalized Readiness Evaluation storage locations are adequate to protect the
equipment from damage.
 Review planned gages and measuring devices for
adequacy and appropriateness for measuring the
When design is Prior to Process Audit characteristic (special characteristics require variable
finalized Readiness Evaluation data unless otherwise agreed to by FCA). Determine
which gages, if any, need to be built to reflect the part
in vehicle position. Review AQR and identify gage and
measuring device requirements.

When design is Prior to Process Audit Identify gages that will be used for 100% inspection.
finalized Readiness Evaluation

Prior to Process Audit Identify planned resources for inspection and control
Technical Review Readiness Evaluation (gages, equipment, personnel). Determine need for
additional resources, if any.

Systemic Review Supplier's calibration and re-calibration

process, along with reaction plans.

Systemic Identify 3rd Parties used for calibrations and verify I

 Process Audit Review temporary or draft work instructions. Ensure
Tooling Kick-Off Readiness Evaluation visual techniques are used wherever possible.

Process Audit Review temporary or draft work instructions. Ensure

Tooling Kick-Off Readiness Evaluation visual techniques are used wherever possible.

Process Audit Identify any proposed "permanent" rework or repair

Tooling Kick-Off Readiness Evaluation activities that will be used in the process.

Tooling Kick-Off Process Audit Review temporary or draft work instructions. Ensure
Readiness Evaluation visual techniques are used wherever possible.
 Review the Supplier's procedures for process monitoring and methods of data collection an
Review actual data and results from other processes at the facility to verify conformance to
Systemic place for the new process and records data during the Process Audit.
Review which supporting processes are required for the part (e.g., painting, plating, heat tr
the Supplier's plan for management and control of these processes? Are the specifications

Review the Supplier's procedures for process monitoring and methods of data collection
Systemic Review actual data and results from other processes at the facility to verify conformance
place for the new process and records data dur

Systemic N/A

Systemic Review Suppliers process for Boundary Samples for co

Process Audit Process Audit Process Identify what Boundary Samples will be needed for the
Readiness Evaluation Evaluation program.

Systemic Review the Supplier's process for Layered Process Audits f

Systemic Review an example of a Process Control Audit from

another process.

Review an example of an Error and Mistake Proofing

Systemic Verification Audit from another process.

Review list of expected Safety/Report characteristics,

Technical Review Process Audit Process along with planned controls. Identify any monitored or
controlled by sub-tier suppliers, along with planned
Evaluation controls. Review Supplier's record retention to ensure
data is appropriately retained.
 Review list of expected Safety/Report characteristics,
Technical Review Process Audit Process along with planned controls. Ensure Error/Mistake
Evaluation Proofing is planned for each, as well as a defined
secondary measurement audit.

Systemic Review Nonconformance and Corrective Action procedures to ensure they m

Process Audit Process Audit Process Review the Supplier's First Piece Approval process for
Readiness Evaluation Evaluation conformance to requirements.
 Process Audit Process Review the Supplier's plan for any areas handling parts
Technical Review Evaluation with ESD requirements.

Process Audit Process Review Supplier's plan for control of parts with
Technical Review Evaluation welding requirements.
Systemic Verify compliance to requirements

Systemic Verify compliance to requirem

Systemic Verify Fire Prevention License, if r

 Review Supplier's general maintenance plan and
Tooling Kick-Off Tool completion records on previous programs.

Identify process steps and machines where activities

Tooling Kick-Off Tool completion
can be performed.
 Review Supplier's general maintenance plan and
Tool try-outs On-going
records on previous programs.

Verify Supplier has a trained maintenance team available for all shifts that the Supplier r
Systemic documented and tracked, with continuous improv

Systemic Review Supplier's process for "end-of-life" tooling for robustn

Tool try-outs Process Audit Process N/A

Evaluation

Verify compliance to requirements. At the Process

Systemic
Audit, verify that workstation 5S is being followed.
 Systemic Review the Supplier's training plan and records.
Participate in training sessions when possible.

Technical Review Process Audit Process Identify any operations or portions of the process that
Evaluation will require special training or certification.

Process Audit Process Audit Process Review plan for hiring of key personnel, if necessary.
Readiness Evaluation Evaluation
Systemic Review Supplier's FIFO procedures and plan to add applicable components and raw mat
Supplier's backup plan for computerized systems, if applicable.
 Prior to VP MRD
Technical Review (Vehicle) Review plan for part traceability. Ensure it includes all
Prior to Gamma MRD stages, back through raw materials.
(Powertrain)

Prior to VP MRD
Technical Review (Vehicle) Review list of Safety/Report characteristics and
Prior to Gamma MRD applicable requirements and regulations.
(Powertrain)

Prior to VP MRD
Tooling Kick-Off (Vehicle) Review FCA standards for part ID requirements.
Prior to Gamma MRD
(Powertrain)

Systemic Review Supplier's Quality inspection procedures and instructions. Ensure they allow for tra
inspector and tools used. Ensure product is identified as indicated in the requi
 Prior to VP MRD
After source selection (Vehicle) Review Supplier's plan for identification of materials at
Prior to Gamma MRD all stages of production.
(Powertrain)

Prior to VP MRD
(Vehicle)
Design completion Review FCA standards for part ID requirements.
Prior to Gamma MRD
(Powertrain)

Process Audit Process Review plan for traceability of reworked and repaired
Tooling Kick-Off Evaluation parts.
 Prior to VP MRD
After source selection (Vehicle) Review intended packaging labels for internal and
Prior to Gamma MRD external containers.
(Powertrain)

Prior to VP MRD
(Vehicle) Review initial packaging plan. Determine responsibility
Technical Review
Prior to Gamma MRD for packaging containers /racks (FCA or Supplier).
(Powertrain)

Prior to VP MRD Review initial packaging plan. Determine responsibility

Technical Review (Vehicle) for packaging containers /racks (FCA or Supplier). For
Prior to Gamma MRD Supplier-designed packaging, review test plan and
(Powertrain) timing.
 Review returnable container management plan and verify conformance to requiremen
Systemic requirements as the primary returnab

N/A Emphasize requirement to Supplier.

Prior to VP MRD
Technical Review (Vehicle) Review labeling requirements and plan for meeting
Prior to Gamma MRD those requirements.
(Powertrain)

Prior to VP MRD
Technical Review (Vehicle) Determine if the Supplier will be required to perform
Prior to Gamma MRD SPD ("just-in-time"). Review initial plan if yes.
(Powertrain)
 Systemic Verify Supplier is using CAPMAN to upload req

Review SCM process and Readiness Checklist. Direct

supplier to SDD Contact list for action plan fulfillment.
After source selection Process Audit Process Find document on eSupplierConnect: FCA / NAFTA /
Evaluation Corporate Focus Areas / Supply Chain Management:
Supplier SCM Readiness Checklist & Supplier SCM
Guidelines Chart.
 Verify the Supplier has the latest information about
the requested volumes, the sequence of the launching
version, the ramp-up curve, and the product mix.
Determine if a CPG is necessary for the parts. Review
the quoted Contract Capacity with the Supplier and
4 weeks prior to determine the required line speed for the Readiness
Technical Review launch Evaluation and PDR. Verify that the quoted Contract
capacity is sufficient to meet FCA requirements,
including Service / MOPAR. Review the shift pattern to
ensure that it supports production and allows enough
time for PM activities. Determine the timing and run
requirements for the Stage 2 PDR.

Review and agree upon characteristics that will be

Process Audit Process Audit Process required to be measured at the Process Audit / PDR.
Ensure all special and critical characteristics are
Readiness Evaluation Evaluation included. Determine number of parts that will be
measured.

Review the Manufacturing Feasibility Assessment.

Technical Review Process Audit Process Identify any potential concerns where performance /
Evaluation capability may not be able to be met. Review
corrective action plans for addressing this issue.
Technical Review Process Audit Process Identify characteristics to be measured for machine
Evaluation capability.

Process Audit Process Evaluation N/A

Process Audit Process Evaluation N/A

Process Audit Process Evaluation N/A

Process Audit Process Evaluation N/A

Process Audit Process Evaluation N/A

Process Audit Process Evaluation N/A

Process Audit
After source selection Readiness Evaluation See 2E
Systemic N/A

Identify if any sub-components are Directed or

Systemic Consigned. Review the timing plan for those parts, if
known.

Systemic Review plan for concurrence to requirements. Audit one or more parts on past programs t
 Review Supplier's Corrective Action procedure and tools used for conformance to requirem
Systemic necessary.

Systemic Review Nonconformance Handling procedure for conformance to requirements.

 Verify Supplier's process for monitoring sub-tier
suppliers and raw material suppliers. Review the list of
sub-tier/raw material suppliers and toolmakers to be
Systemic used on the program and verify that they have
acceptable performance, and that they are on any
EASLs that apply. Ensure toolmakers are ISO-9001
certified.

Systemic Review Supplier's organization for monitoring sub-tier performance and acceptability.

Systemic Review Supplier's process for communicating FCA requirements throughout the Supply Cha
Chain understand and adhere to the FCA Forever Requirements process.

Review the Master PFMEA for this part/commodity

and ensure all potential failure modes have been
accounted for in the Supplier's PFMEA and process.
Review quality spills and lessons learned from previous
and similar products / processes. Verify that issues
resulting in past quality spills, yardholds, or Field
Actions are adequately error-proofed or completely
designed out of the part in the new process. Review
the risk that the current part configuration will result
Systemic in a high evaluation on internal indicators for quality
perception audits (e.g., CPA, TOC, ICP). Ensure that
issues resulting in high scores on previous programs
for similar products have been evaluated and
corrected in the design, DFMEA, and PFMEA, as
appropriate. Ensure the new process design has all
applicable lessons learned input from previous
programs (e.g., (material handling, ergonomics,
maintenance, work place organization, process data
collection, etc.).
 Systemic Review the Supplier's warranty process for conformance to the guidelines.

Systemic Verify certification has been sent to or uploaded to the applicable FCA system.

Systemic Review records retention process.

Review the Supplier's testing facilities and equipment.

Review any appropriate certifications. If the Supplier is
not able to perform the tests and/or dimensional
layouts expected of them, review their plan to use 3rd
party ISO/IEC 17025 certified labs. Review the
Supplier's Self-Qualification plan. Is the forecasted
After source selection Process Audit Process closing date of Self Qualification Tests consistent with
Evaluation the timing of Project? Does the Supplier's testing plan
take into account the reliability requirements and
tests? Is it updated according to the development level
of the Project? Has the plan been shared with FCA
Engineering? Review the status of the testing
(completed tests, on-going tests, approval status, etc.).
For on-going tests, what is the risk of a negative result?

Process Audit Process

After source selection Evaluation Review reliability test plan and ensure all requirements are met.
 Review the forecasted delivery date of Integrative
Process Audit Process Tests samples to ensure consistency with the timing of
After source selection Evaluation Project (taking into account also the lead time of FCA
Labs). Evaluate the risk of a negative result of
Integrative Tests.

Review the plan for obtaining Benestare approval.

Ensure the forecasted delivery date of samples is
consistent with program timing (taking into account
the lead time of the Plant Lab / Metrology Center).
VP Build DaP Review the plan for matchability submission. Is the
availability of samples consistent with the timing of the
Project? Ensure that there is a timing "safety factor" in
the event of reoccurrence of the tests due to failures.

Review the Supplier's plan for management of International Materials Data System (IMDS)
Systemic and that they keep copies and records of their submissions. Verify they have appropriate c
and are aware whenever a sub-tier supplier makes a change that could require a new subm

Prior to PPAP / Full

Prior to Pilot Builds Approval Review timing for IMDS submission.
 Ongoing PPR Activities
Ensure Supplier is incorporating AQR requirements
into the process, as applicable. Review open issues
from the MFA and (for EMEA / LATAM) SoR to ensure
closure.
Verify the progress of any planned corrective actions
from QRA open issues.
Verify the DFMEA has been updated to the latest
design release. Note: if FCA is design responsible and
no DFMEA exists, mark this "N/A"
Track and follow open issues.
Review procedure for concurrence to requirements.
Process Audit Activities Score
Verify all requirements listed in the AQR
and MPFMEA have been incorporated into
the process, including the PFMEA, Control
Plan, and Error and Mistake-Proofing.
Verify planned corrective actions from QRA
open issues are complete.
Verify the DFMEA has been updated to the
latest design release. Note: if FCA is design
responsible and no DFMEA exists, mark the
item "N/A"
Ensure open issues have been closed.
Ensure the FCA Engineer has accepted the
latest version of the document. Verify all
planned error and mistake-proofing, and
ensure all controls listed in the DFMEA
have been applied.
Verify the Supplier has the latest design model. Ensure
the latest mathematics are available and are
consistent with the latest release. Verify the design
status of all sub-components.
Verify the Supplier has the latest design
model. Ensure the latest mathematics are
available and are consistent with the latest
release. Verify the final released drawing
meets all requirements for closure.

Review for concurrence to the Requirements

Verify the Engineer concurs with the latest released

design. For NAFTA, review the engineering Design
Acceptance document with the FCA Engineer at Step 2, Ensure all open issues relating to design
Step 3, and Step 5 (or MR1, MR2, and PRC for and DAC, for NAFTA) are closed and the
Powertrain). Ensure corrective actions or risk
mitigation activities are in place for any open issues. FCA Engineer has approved the latest
design release.
Issues that receive a score of 1 (Job Stopper) or 2 (Job
Stopper Risk) should have corrective actions in place
before proceeding with TKO.

Review the design with the FCA Service engineer. Ensure no issues remain open
Review latest design model against the list of special
characteristics, Control Plan, and Safe-Launch Plan and
ensure agreement with FCA Engineering and FCA Plant
Quality. Verify all special characteristics are included in
other applicable quality documents as they are
developed.
At final PPR meeting before the Process Audit
Readiness Evaluation, select, with FCA Engineering and
the Supplier, a list of characteristics to check during
the SQE Audit and Initial Process Study.
Review latest design model against the torque and
angle strategy.
Verify Supplier has the latest release. Ensure that as
changes occur, appropriate modifications are made to
program timing and other deliverables, as required.
Also verify appropriate risk mitigation activities are
planned when deliverables become late to their
required milestones.
Verify all special characteristics are
included in the applicable quality
documents (especially Control Plan and
Safe-Launch Plan) and the Initial Process
Study.
Use the selected characteristic list during
the SQE Audit (see 7C) and ensure the
Supplier follows the list for the Initial
Process Study (see 7B).
Verify torque and angle requirements are
being met on all fastener joints.
Verify Supplier has the latest release and
that it matches the part undergoing
PA/PDR. Verify all risk mitigation activities
have been successfully closed.
 Review procedure for concurrence to requirements.

Review and update the Supplier's plan for program

timing. Develop or review Risk Mitigation plans for Ensure all Risk Mitigation plans are
any deliverables that are or are expected to be late to successfully closed.
their required due dates.

Review the Tooling Kick-off date and ensure

consistency with program deliverable timing. Ensure
the timing allows for parts off of production tooling by
the required build / milestone. Note that the Tooling
Kick-off date is the date that tools actually begin
construction (i.e., "cutting steel"). Once tools are Ensure all Risk Mitigation plans are
kicked-off, follow their progress (updated every 2 successfully closed.
weeks, at a minimum). Ensure toolmakers are aware of
the latest design changes. If tool completion timing
changes, ensure adequate risk mitigation plans are in
place (as required). Note: for tooling followed by TAG,
obtain status updates from the TAG representative.

rify Supplier has appropriate resources and access to Customer systems.

devoted to the program. Are enough resources given? Is the commitment of the members adequate? Are the
mplete?
 Ensure the Process Flow Diagram, floor plan, and work
station layout reflect the planned process. All
processes and sub-processes shall be included, from
raw material receiving to final assembly shipping,
including rework/scrap areas. Verify that all are at the
latest level of the process. Ensure unique machine or
tool numbers are included in the Process Flow. Ensure
all rework/repair operations have been included.
Review operators required for the process. Ensure
suspected bottleneck operation / constraint is
identified.
Review work station layout and manufacturing floor
plan.
w the temporary rework/repair procedure for conformity to requirements.
Review PFMEA as changes occur to design. Ensure
adherence to FIAT norm 00271.
Verify by witnessing on the manufacturing
floor that the Process Flow Diagram and
Work Station Layout reflect the actual
process and that facilities, equipment,
lighting, etc. are adequate. Verify actual
tool/machine numbers match the Process
Flow Diagram. Verify rework/repair
processes follow the identified process
flow. Verify number of operators
performing the PA/PDR match the Process
Flow Diagram. Verify bottleneck or
constraint operation.
Verify actual plant and process layout
match the documentation.
Ensure PFMEA has been updated to latest
design revision level. Review using FIAT
norm 00271 to verify document is
acceptable. Verify PFMEA has been
updated to account for most recent
version of Master PFMEA.
Review procedure for concurrence to requirements.

Review BSR/NVH test results. Update PFMEA, Control Verify BSR/NVH causes and effects have
Plan, and test plans accordingly. been adequately addressed into the
PFMEA, Control Plan, and test plans.

Verify that FCA tooling & equipment (complete or

under construction) is consistent with that which was
determined needed during the sourcing phase. Any
modifications (e.g., more tools required, some tools
not needed/built, etc.) with respect to which was Verify completed tooling matches FCA
records and Supplier's tooling list.
declared during sourcing shall be promptly reported to
the Buyer. Review the Supplier's plan / procedure for
release of tools and equipment to the production
floor.

Review procedure for concurrence to requirements.

Review the Supplier's plan for delivery of parts for the

applicable Pilot builds. Ensure it includes quantities
and timing (for each phase). Review tooling
construction status. Ensure parts off of production
tools will be available for the required milestone (e.g.,
VP or Pre-Pilot). If not, review the risk mitigation plan,
especially if temporary tooling will need to be used
instead. Verify Supplier has included all applicable
requirements from the AQR.
Verify the Process Audit Process Evaluation
and PDR are run on homeline with
production tooling. If this is a Risk
Mitigation Run, ensure any tooling being
used can support volumes for launch and
production until final tooling is complete.

Review TKO status and form. N/A

Review requirements for Customer tools with the
Supplier to ensure they understand. Verify tools are marked per FGP norm 24.

Review status of all high and medium risk sub-

components and materials. If any are late, ensure See item 7D
appropriate risk mitigation activities are in place.

Update Supply Chain diagram and back-up plans / risk Verify final Supply Chain diagram.
mitigation activities as necessary.

Update Supply Chain diagram and back-up plans / risk Verify back-up plans for critical
mitigation activities as necessary. components.
Review all phases of the control plan. Ensure it is
updated as changes occur to the part or process, and
as changes occur to the Process Flow Chart and
PFMEA. As changes to the DFMEA and PFMEA occur,
ensure controls in the Control Plan reflect the risk of
the changed items.
Verify the Supplier is incorporating controls into the
process as it is developed.
Review and update control plan as necessary.
Ensure Supplier plans for rework / repair parts to go
through controls equivalent to or better than the
primary line.
Review 8 Stages analysis and update as necessary.
Provide to plant SQ for approval.
Verify Control Plan meets all requirements
and is "Green" per the Control Plan
Document Audit form. Verify that the team
agrees with Control Plan sample sizes and
frequencies for high risk items.
Review the Control Plan against the actual
process. For NAFTA, make sure the Control
Plan is "Green" per the Control Plan
Process Audit document. Ensure resources
dedicated to the controls are adequate.
Witness and verify that the Tier 1 Supplier
is performing inspections at the listed
frequencies and sample sizes, using the
agreed upon measurement methods.
Verify that the audits are random and have
appropriate analysis of the results.
Verify rework/repair parts do go through
controls equivalent to or better than the
primary line.
Finalize 8 Stages analysis and ensure Plant
SQ approval.
 Review initial SLP data. Verify the Supplier
Review the Safe-Launch Plan and update as necessary. is following the plan for all shipments
through the specified duration.

Verify that all Self-Qualified sub-tier

Review and update plans for Self-Qualified and non-
qualified sub-tier suppliers.
suppliers have Process Audit approved
components and acceptable quality
performance. Verify Tier 1 Supplier is
following the inspection plan for non-
qualified sub-tier supplier components.

Review procedure for concurrence to requirements.

Witness and verify that the Tier 1 Supplier

Review and update control plan as necessary.
is performing inspections at the listed
frequencies and sample sizes, using the
agreed upon measurement methods.
Verify that the audits are random and have
appropriate analysis of the results.

Review computerized systems and verify backups are in place.


Review and update the Error and Mistake Proofing
plan as required.
Review and update the Error and Mistake Proofing
plan as required.
Ensure adequate storage and handling of Verification
Samples is planned.
Review and update the Error and Mistake Proofing
plan as required.
Review and update the Error and Mistake Proofing
plan as required.
Review and update the Error and Mistake Proofing
plan as required.
Verify all planned Error and Mistake
Proofing has been implemented. Witness
the Error and Mistake Proofing Verification
Audit prior to starting the Stage 1 PDR.
Ensure that all Verification Samples are
detected correctly or prevent manufacture
of the defect.
Verify all planned Error and Mistake
Proofing has been implemented.
Verify all Verification Samples are properly
identified and stored to prevent accidental
mixing with production parts.
During the Error and Mistake Proofing
Verification Audit, ensure line and station
lock-outs, as well as audible and visual
indicators, are working correctly each time
a sample is run. This should be a part of
the Supplier's checklist, as well. Verify the
Supplier's backup plan is robust and
functioning.
Verify Error and Mistake Proofing software
during the Error and Mistake Proofing
Verification Audit.
Verify EOL tester during the Error and
Mistake Proofing Verification Audit. This
should also include parts that are known
acceptable, as well.
Review and update the Error and Mistake Proofing Verify Error and Mistake Proofing
requirements are covered during the Error
plan as required. and Mistake Proofing Verification Audit.

Review and update the Error and Mistake Proofing Verify Error and Mistake Proofing
plan as required. requirements are covered during the Error
and Mistake Proofing Verification Audit.

Verify that all Master samples, gages,

As gages and equipment become available, ensure measuring devices, etc. are identified and
they are identified, stored, etc. as per the gage stored appropriately. Ensure Master
handling plan. samples are used according to frequencies
established in the Control Plan.
 Review status and timing of gages and equipment, and
ensure they are at the latest revision level. Review
(and witness, if able) Gage R&R studies performed at
the gage manufacturer and at the Supplier. Ensure
planned gages include AQR requirements.
Identify gages that will be used for 100% inspection.
Review and update planned resources, as necessary.
Ensure gages and measuring devices are calibrated as
they become available.
tify 3rd Parties used for calibrations and verify ISO/IEC 17025 certification.
Verify gages are at the latest design level.
Confirm all gages and measuring devices
have acceptable R&R results. Verify AQR
requirements for gages have been met.
Verify gages used for 100% inspection have
tolerances reduced by the extent of the
R&R.
Verify planned resources have been
acquired and allocated.
Verify all gages and measuring devices to
be used are calibrated and not expired.
Review traceability and witness a
demonstration of the re-calibration
process and reaction plan for past due
items.

Review and update work instructions as necessary.
Ensure they are updated to the latest revision level.
Ensure appropriate Supplier personnel approve final
work instructions prior to the Readiness Evaluation
and release to the manufacturing floor.
Review and update work instructions as necessary.
Ensure they are updated to the latest revision level.
Ensure appropriate Supplier personnel approve final
work instructions prior to the Readiness Evaluation
and release to the manufacturing floor.
Develop procedures and instructions for permanent
rework stations. Confirm the method that
reworked/repaired parts will be identified. Develop
the training requirements and process for operators
who will be performing the rework and repair.
Review and update work instructions as necessary.
Ensure they are updated to the latest revision level.
Ensure appropriate Supplier personnel approve final
work instructions prior to the Readiness Evaluation
and release to the manufacturing floor.
Verify work instructions are followed while
the Stage 1 PDR occurs. Ask operators,
inspectors, etc. questions to ensure
understanding and knowledge. Ensure
work instructions are available to all
applicable personnel and they know where
to locate.
Verify work instructions are followed while
the Stage 1 PDR occurs. Ask operators,
inspectors, etc. questions to ensure
understanding and knowledge. Ensure
work instructions are available to all
applicable personnel and they know where
to locate.
Witness the rework/repair process during
the PDR. Ensure the Supplier is following
all approved instructions and marking
parts in the agreed upon manner.
Verify set-up/changeover instructions are
followed during initial set-up and at least
one changeover during the PDR (if
possible). Ensure the instructions are
accessible to personnel and they know
where to locate.
ss monitoring and methods of data collection and reaction plans for out-of-control or nonconforming results.
processes at the facility to verify conformance to the procedures. Ensure the Supplier has plans and forms in
during the Process Audit.
uired for the part (e.g., painting, plating, heat treat, surface treatments for corrosion protection, etc.). What is
ntrol of these processes? Are the specifications clearly defined?

cess monitoring and methods of data collection and reaction plans for out-of-control or nonconforming results.
er processes at the facility to verify conformance to the procedures. Ensure the Supplier has plans and forms in
place for the new process and records data during the Process Audit.

Ensure technical documentation is

available at applicable work stations.
Review draft documentation as it becomes available. Review visual displays of process
performance, with metrics and targets.

w Suppliers process for Boundary Samples for conformance to requirements.

 Review Boundary Samples to ensure they
Identify what Boundary Samples will be needed for the are properly identified, handled, and
program. stored. Ensure they have had proper
approval from both the Supplier and FCA.

Supplier's process for Layered Process Audits for conformance to requirements.

Review the draft Process Control Audit form for the Witness at least one level of a Process
process. Control Audit.

Review the draft Error and Mistake Proofing Witness the Error and Mistake Proofing
Verification Audit form for the process. Verification Audit prior to starting the PDR.

Verify final list of Safety/Report

Update list and planned controls as needed. characteristics along with controls and
data retention.
 Verify all Safety/Report characteristics
Update list and planned controls as needed. have effective Error/Mistake Proofing and
witness the secondary Quality Audit.

d Corrective Action procedures to ensure they meet requirements for Safety/Report characteristics.

Witness the Supplier performing the First

Piece Approval process during the PDR.
Update First Piece Approval process as required. Ensure the entire process is followed, even
if the PDR is shorter than a normal
production run or shift.
Review status of areas and equipment for handling
parts with ESD requirements. Ensure all necessary
equipment and facilities are available in time for parts
for the first pilot build.
Review status of plan and update as necessary.
Verify ESD facilities and equipment meet
requirements as listed. Ensure all parts run
during the PDR have appropriate
protection and all operators are trained
properly.
Verify parts with welding requirements
have the required controls and those
controls are followed by the Supplier.
 Verify compliance to requirements.

Verify Fire Prevention License, if required.

 Verify Supplier is following the
maintenance activities as planned, and
Ensure tooling, gages, and equipment are added to the documenting results. Ensure all tooling,
maintenance plan as they become available (and prior
to release to the Supplier's manufacturing floor). gages, and equipment have been included
Review initial maintenance plan for adequacy. in the maintenance plan. Audit tooling,
gages, and equipment on other processes
to verify conformance to the plan.

Review procedures. Update as required for new

Verify compliance to requirements.
machinery / process steps.

Review any maintenance done during tool try-outs or
pilot builds. Ensure information is carried back as
lessons learned to improve the plan.
Verify Supplier is following the
maintenance activities and documenting
results. Audit tooling, gages, and
equipment on other processes to verify
conformance to the plan.

ce team available for all shifts that the Supplier runs. Ensure emergency/unplanned maintenance activities are
cumented and tracked, with continuous improvement activities in place.

er's process for "end-of-life" tooling for robustness and conformity to requirements.

Review storage facilities for tooling and

N/A gages to ensure items are properly
protected.
Update training plan to include program-specific Verify training of operators used during
requirements. Ensure personnel used for the Process the Process Audit Readiness Evaluation
Audit Readiness Evaluation and Process Evaluation will and Process Evaluation. Review records
be trained in time for those runs. and ensure they have been updated.

Review plan to train and certify required personnel for

the identified operations. Ensure personnel used for Verify personnel performing identified
operations have been appropriately
the Process Audit Readiness Evaluation and Process trained and certified.
Evaluation will be trained in time for those runs.

Verify personnel needed to satisfy launch

Review and update plan for hiring of key personnel, if requirements are available, and review
necessary.
plan for supporting full production volume.
plan to add applicable components and raw materials. Review the Witness and verify the Supplier's FIFO
plan for computerized systems, if applicable. process.
 Witness and verify the Supplier's material
handling and re-stock procedures. Review
storage locations for adequate protection,
organization, and space.

Verify the part traceability by taking a

Review and update plan as necessary. finished assembly and having the Supplier
demonstrate on each component (see 7C).

Verify Supplier's ability to trace results of

Review Supplier's plan for tracing results of inspections tests and inspections on Safety/Report
or tests to the associated part.
characteristics to the associated part.

Review Supplier's plan for part ID. Ensure Supplier

accounts for FCA ID requirements in the tool or Review part ID against print and
process prior to kick-off, as applicable. specifications.

Verify Supplier follows the inspection

dures and instructions. Ensure they allow for traceability back to the procedures and instructions. Verify
re product is identified as indicated in the requirements. product undergoing or waiting for
inspection is appropriately identified.
Review and update the plan, as necessary. Review Verify materials used in the process are
internal and external labeling prior to the first pilot appropriately segregated and
builds. identified/labeled. Ensure identification
meets minimum requirements as listed.

Review Supplier's plan for part ID. Ensure Supplier Review part ID against print and
accounts for FCA ID requirements in the tool or
process prior to kick-off, as applicable. specifications.

Verify rework/repair parts are traceable

Review and update plan as necessary. per the requirements, as applicable.
Review and update the plan, as necessary. Review
internal and external labeling prior to the first pilot
builds.
Review and update packaging plan, as necessary.
Complete packaging instructions. Ensure packaging
availability for pilot builds.
Review packaging test plan and timing; update as
necessary. Ensure completion prior to required pilot
build.
Verify labels meet the requirements listed.
Verify Supplier is following packaging
instructions. Review shipping/receiving
and storage areas / warehouses and verify
packaged parts are adequately protected.
Verify that internal containers (i.e., for
Work-in-Process) are adequate and
prevent damage to parts stored within.
Verify testing for Supplier-designed parts
was completed successfully and all open
issues have been closed (if any). Ensure
adequate quantities of packaging are
available for plant part releases.
ent plan and verify conformance to requirements. Verify that back-up expendable packaging meets the same
requirements as the primary returnable packaging.

Emphasize requirement to Supplier. Verify FCA-owned packaging is not being

used improperly.

Verify Supplier is meeting all bar code

Ensure Supplier has appropriate bar code labeling in labeling requirements and has appropriate
place prior to the first pilot build. error and mistake proofing in place.

Witness Supplier build to the broadcast.

Review and update plan, as necessary. Ensure all Ensure all requirements for SPD are being
requirements are in place prior to the required pilot met and Supplier has adequate error-
build. proofing to prevent incorrect part
selection.
Verify Supplier is using CAPMAN to upload required logistics data.

Verify that suppliers have provided SCM Readiness

Checklist to SDD (Supplier Delivery Development team)
with commitment dates for completion. Verify that Supplier's SCM Readiness
Reach SDD specialist based on your commodity. Checklist was approved by SDRM.
Contact information can be found at DRIVe home
page.
 Readiness Evaluation: run agreed upon
number of parts. If parts are to be used for
Update volume, capacity, and launch ramp-up testing, ensure required line speed is met
information as necessary, including associated CPGs. (and parts meet all other requirements;
Verify required line speed for PDR. Identify potential see 9A).
constraints and bottlenecks, with appropriate action Process Evaluation: run the Stage 1 PDR
plans to minimize their effect. Review launch ramp-up and confirm dates and requirements for
plan. the Stage 2 PDR. Review launch ramp-up
plan. Verify Supplier meets volumes in
associated CPGs, if applicable.

Review performance / capability study

results. Ensure all agreed-upon
characteristics on the correct number of
Update characteristics that will require measurement parts have been measured. Verify parts
as necessary. Review preliminary data for prototypes meet the performance / capability
and early pilot builds. If the component doesn't meet requirements based on the criticality of
the quality requirements for the program milestones, the characteristic. If the component
review the level of risk for the issuing of an interim doesn't meet the quality requirements for
approval for the use of the part. Ensure adequate risk the program milestones, review the level
mitigation activities are in place when an interim of risk for the issuing of an interim
approval is required. Review the status of any existing approval for the use of the part. Ensure
interim approvals (and corresponding engineering adequate risk mitigation activities are in
changes). place when an interim approval is
required. Review the status of any existing
interim approvals (and corresponding
engineering changes).

Review preliminary data for prototypes and early pilot Review performance / capability study
builds. Implement corrective actions to address any results. Implement corrective actions for to
items that do not meet the requirements. address any items that do not meet the
requirements.
Review machine capability data on special Review machine capability data on special
characteristics before releasing tooling from the characteristics before releasing tooling
toolmaker to the Supplier. Re-evaluate after any tool from the toolmaker to the Supplier. Re-
changes or moves. evaluate after any tool changes or moves.

N/A

N/A
Select the sub-components, in-process
operations, and final assemblies to be
checked, plus the quantity. Select one part
for traceability / lot control demonstration.
Perform the SQE Audit per the
N/A requirements.

N/A

N/A

N/A

Verify all sub-components have been

approved for use. Review PPAP packages
of selected sub-components for
See 2E conformance with requirements. Verify
there are no capacity issues with any sub-
components or raw materials.
 Review status of sub-components prior to VP build.
Determine if any require deviations or interim
approvals to be used (and if therefore, the final
assembly also requires a deviation). Implement risk
mitigation plans as required.
Review the status of Directed and Consigned
components and plan for the pilot builds. Review risk
mitigation plans, as applicable.
nts. Audit one or more parts on past programs to verify that annual validation / recertification is performed.
Ensure no sub-components being used are
under a deviation. If so, make the
determination if the PA/PDR will need to
be run again.
Review the status of Directed and
Consigned components and plan for the
pilot builds. Review risk mitigation plans,
as applicable.
ure and tools used for conformance to requirements. Review and approve corrective actions as they become

Review Nonconforming hold area and

ensure it meets requirements. Verify
ure for conformance to requirements. Supplier follows when nonconforming
material is discovered at FCA, internally,
and shipped in from sub-tier suppliers.
 Review sub-tier supplier list and
Review sub-tier supplier list and performance. performance. Verify continued
conformance.

ng sub-tier performance and acceptability.

ng FCA requirements throughout the Supply Chain. Verify that they have ensured that all levels of the Supply
orever Requirements process.

Update Master PFMEA as required and ensure Verify all items in the Master PFMEA have
associated Supplier DFMEA and PFMEA is updated, as been accounted for in the Supplier's
required. PFMEA, Error and Mistake Proofing, etc.
conformance to the guidelines.

aded to the applicable FCA system.

Review the Supplier's Self-Qualification plan. Is the

forecasted closing date of Self Qualification Tests
consistent with the timing of Project? Has the plan
been shared with FCA Engineering? Review the status Verify the status of the Self-Qualification
of the testing (completed tests, on-going tests, and Integrative Test samples.
approval status, reliability verification - virtual or
physical, etc.). For on-going tests, what is the risk of a
negative result?

equirements are met.

 Review and update timing plan for Integrative Tests
and reliability. Verify status of Integrative Test samples.

Review the plan for obtaining Benestare

Review the plan for obtaining Benestare approval.
Ensure the forecasted delivery date of samples is
consistent with program timing (taking into account
the lead time of the Plant Lab / Metrology Center).
Review the plan for matchability submission. Is the
availability of samples consistent with the timing of the
Project? Ensure that there is a timing "safety factor" in
the event of reoccurrence of the tests due to failures.
approval. Ensure the forecasted delivery
date of samples is consistent with program
timing (taking into account the lead time of
the Plant Lab / Metrology Center). Review
the plan for matchability submission. Is the
availability of samples consistent with the
timing of the Project? Ensure that there is
a timing "safety factor" in the event of
reoccurrence of the tests due to failures.

t of International Materials Data System (IMDS) submission. Ensure they are registered to www.mdssystem.com,
heir submissions. Verify they have appropriate controls in place to manage sub-tier supplier IMDS submissions
r makes a change that could require a new submission.

Review timing for IMDS submission. Ensure Supplier is

beginning to collect required information. Verify IMDS submission is complete.
 Reference
* Applicable Source Package
* Source Package Boilerplate (NAFTA)
* FGP 01 (EMEA / LATAM)

* Quality First process

* FGP 01 (EMEA / LATAM)

* Potential Failure Mode & Effects Analysis

manual (4th Edition)
* FIAT Norm 00270 / 00271
* ISO/TS-16949 7.3.3.2

* Potential Failure Mode & Effects Analysis

manual (4th Edition)
* FIAT Norm 00270 / 00271
* ISO/TS-16949 7.3.3.2

* Potential Failure Mode & Effects Analysis

manual (4th Edition)
* FIAT Norm 00270 / 00271
* ISO/TS-16949 7.3.3.2
* Engineering Standards Supplier Distribution
(ESSD) - NAFTA
* BeStandard (ORANGE) - EMEA / LATAM
* ISO/TS-16949 cl. 7.2.1.1, 7.3.1.1, 7.3.2.3,
7.3.3.1
* FCA US LLC Customer Specific Requirements
for ISO/TS-16949
* FCA Italy Customer Specific Requirements for
ISO/TS-16949
* EMEA / LATAM - Specifications series
9.01102/## about Characteristics Classification
and 9.01102/20 (Report Characteristics )
* CS.00071 Classification of Characteristics
* AIAG Statistical Process Control (SPC) Manual
* Performance Requirements (in this document)

* Production Demonstration Run (PDR) Tool Kit

* ISO/TS-16949, cl. 4.2.3.

* FCA program timing (CPCP / GVD, GPD)

* FCA norm 07740 - EMEA / LATAM

* FCA program timing (CPCP / GVD, GPD)

* FCA norm 07740 - EMEA / LATAM
* Potential Failure Mode & Effects Analysis
manual (4th Edition) AIAG
* ISO/TS-16949 7.3.3.2
* Supplier PFMEA Audit Summary form
* FCA Norm 00271 - EMEA / LATAM
* Potential Failure Mode & Effects Analysis
manual (4th Edition) AIAG
* ISO/TS-16949 7.3.3.2
* FCA Norm 00271 - EMEA / LATAM

* Potential Failure Mode & Effects Analysis

manual (4th Edition) AIAG
* ISO/TS-16949 7.3.3.2
* Supplier PFMEA Audit Summary form
* FCA Norm 00271 - EMEA / LATAM

* CG Business Processes - Part Requirements for

VP & PS Pilot Builds - NAFTA

* CG Business Processes - Readiness of Design -

To Start Supplier Tooling Kick-Off - NAFTA
* TAG Tooling Kick-Off - EMEA/LATAM
* FCA contract Terms & Conditions
* FGP norm 24 - EMEA / LATAM
* Advanced Product Quality Planning & Control
Plan manual (2nd Edition)
* FCA norm 9.01102 - EMEA / LATAM
* ISO/TS-16949 7.5.1.1
* ISO/TS-16949 App. A

* Advanced Product Quality Planning & Control

Plan manual (2nd Edition)
* FCA norm 9.01102 - EMEA / LATAM
* ISO/TS-16949 7.5.1.1
* ISO/TS-16949 App. A

* Advanced Product Quality Planning & Control

Plan manual (2nd Edition)
* FCA norm 9.01102 - EMEA / LATAM
* ISO/TS-16949 7.5.1.1
* ISO/TS-16949 App. A
* Advanced Product Quality Planning & Control
Plan manual (2nd Edition)
* FCA norm 9.01102 - EMEA / LATAM
* ISO/TS-16949 7.5.1.1
* ISO/TS-16949 App. A

* Advanced Product Quality Planning & Control

Plan manual (2nd Edition)
* FCA norm 9.01102 - EMEA / LATAM
* ISO/TS-16949 7.5.1.1
* ISO/TS-16949 App. A
* FCA US LLC Customer Specific Requirements
for ISO/TS-16949
* ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.3-8.2.4.2
* FCA norm 70100/00 - EMEA / LATAM
* FCA procedure 71018 - EMEA / LATAM
* FCA procedure 1 - EMEA / LATAM
* Measurement Systems Analysis manual (4th
Edition) - NAFTA
* FCA US LLC CS.00118 - NAFTA
* ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.3-8.2.4.2

* FCA norm 70100/00 - EMEA / LATAM

* FCA procedure 71018 - EMEA / LATAM
* FCA procedure 1 - EMEA / LATAM
* Measurement Systems Analysis manual (4th
Edition) - NAFTA
* FCA US LLC CS.00118 - NAFTA
* ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.3-8.2.4.2

* ISO/TS-16949 cl. 7.6 - 7.6.3.2, 8.2.4-8.2.4.2

* ISO/IEC 17025
* ISO/TS-16949 cl. 7.5.1.2 & 7.5.1.3

* ISO/TS-16949 cl. 7.5.1.2 & 7.5.1.3

* ISO/TS-16949 cl. 7.5.1.3

* Statistical Process Control manual (2nd
Edition) AIAG - NAFTA
* FCA norm 9.01102/08 - Statistical Process
Control, Guide Lines - EMEA / LATAM
* ISO/TS-16949 cl. 8.2.3 - 8.2.3.1

* Statistical Process Control manual (2nd

Edition) AIAG - NAFTA
* FCA norm 9.01102/08 - Statistical Process
Control, Guide Lines - EMEA / LATAM
* ISO/TS-16949 cl. 8.2.3 - 8.2.3.1

* ISO/TS-16949 cl. 7.5.1.2, 8.2.3 - 8.2.3.1

* CQI-8 Layered Process Audits (AIAG)
* FCA US LLC Customer-Specific Requirements
for ISO/TS-16949 cl. 4.12.2 - NAFTA

* CQI-8 Layered Process Audits (AIAG)

* FCA US LLC Customer-Specific Requirements
for ISO/TS-16949 cl. 4.12.2 - NAFTA

* CQI-8 Layered Process Audits (AIAG)

* FCA US LLC Customer-Specific Requirements
for ISO/TS-16949 cl. 4.12.2 - NAFTA

* PF-SAFETY - NAFTA
* FCA norm 9.01120 - EMEA / LATAM
* PF-SAFETY - NAFTA
* FCA norm 9.01120 - EMEA / LATAM

* PF-SAFETY - NAFTA
* Supplier Notification of Shipment of
Nonconforming Parts process - NAFTA
* FCA norm 9.01120 - EMEA / LATAM
* CQI-15 Special Process: Welding System
Assessment (AIAG)
* FCA US LLC Customer-Specific Requirements
for ISO/TS-16949 cl. 4.12.3 - NAFTA
* FCA welding norms 9.5017#/## - EMEA /
LATAM
* Applicable Standards, Certifications, and
licenses (per FCA, ANSI, AWS, UNI EN, etc.)
* Basic Requirements Checklist
* ISO/TS-16949 cl. 7.5.1.4
* ISO/TS-16949 cl. 7.5.1.5

* Basic Requirements Checklist

* ISO/TS-16949 cl. 6.2.2 - 6.2.2.4

* ISO/TS-16949 cl. 6.2.2 - 6.2.2.4

* ISO/TS-16949 cl. 7.5.5.1

* ISO/TS-16949 cl, 7.5.3 & 7.5.3.1

* PF-SAFETY, PF-HOMOLOGATION, & PF-

EMISSIONS - NAFTA
* FCA norm 9.01102 - EMEA / LATAM

* FIAT norm 07611

* FIAT norm 07170
* Basic Requirements Checklist

* PS-4480 - NAFTA
* FCA norm 9.01106/02 - EMEA / LATAM
* Module Source Package Boilerplate - NAFTA
* FIAT norm 71029 - EMEA / LATAM
* Materials Management Operations
Guidelines / Logistics Evaluation (MMOG/LE)
* AIAG Statistical Process Control manual (2nd
Edition) - NAFTA
* FCA norm 9.01102 - EMEA / LATAM
* CS.00071
* FCA Process Planning & Audit Manual,
Appendix B
* PDR Toolkit "Performance-Capability Reqs."

* AIAG Statistical Process Control manual (2nd

Edition) - NAFTA
* FCA norm 9.01102 - EMEA / LATAM
* CS.00071
* FCA Process Planning & Audit Manual,
Appendix B
* PDR Toolkit "Performance-Capability Reqs."
* AIAG Statistical Process Control manual (2nd
Edition) - NAFTA
* FCA norm 9.01102 - EMEA / LATAM
* CS.00071
* FCA Process Planning & Audit Manual,
Appendix B
* PDR Toolkit "Performance-Capability Reqs."

* Production Part Approval Process manual (4th

Edition)
* ISO/TS-16949, cl. 7.5.2
* FCA US LLC Customer Specific Requirements
for ISO/TS-16949, cl. 4.13 - NAFTA
* FCA norm 07740 - EMEA / LATAM
* ISO/TS-16949 cl. 8.5.2-8.5.2.4

* ISO/TS-16949 cl. 8.3 - 8.3.4

* ISO/TS-16949 cl. 7.4.1.2 & 7.4.1.3
* FCA US LLC Customer Specific Requirements
for ISO/TS-16949 cl. 4.7 - 4.7.4 - NAFTA

* ISO/TS-16949 cl. 7.4.1.2 & 7.4.1.3

* FCA US LLC Customer Specific Requirements
for ISO/TS-16949 cl. 4.7 - 4.7.4 - NAFTA

* ISO/TS-16949 cl. 7.4.1.2 & 7.4.1.3

* FCA US LLC Customer Specific Requirements
for ISO/TS-16949 cl. 4.7 - 4.7.4 - NAFTA
* ISO/TS-16949 cl. 8.2.1 & 8.2.1.1
* FCA US LLC Customer Specific Requirements
for ISO/TS-16949 cl. 4.10 - 4.10.5 - NAFTA

* NAFTA Suppliers send ISO/TS-16949 and ISO

14001 certifications to: ts16949@fcagroup.com
* EMEA/LATAM Suppliers upload ISO/TS-16949
and ISO 14001 certifications to the SQP system
available through eSupplierConnect.com

* ISO/TS-16949 cl. 4.2.3 & 4.2.4

* ISO/IEC 17025
* www.mdssystem.com
* Fiat Cap. 9.01102 – Fiat Cap. 9.01108 - EMEA /
LATAM
CS-9003

* www.mdssystem.com
* Fiat Cap. 9.01102 – Fiat Cap. 9.01108 - EMEA /
LATAM
 BACK TO PPA
MATRIX HIDE UNUSED ROWS SHOW ALL
BACK TO PPA HIDE UNUSED ROWS SHOW ALL
MATRIX
AUDITOR REMARKS (SQE)

BOX SCORE BOX NAME OPEN ISSUE / OBSERVATION CORRECTIVE ACTION RESPONSIBLE DEPARTMENT OPEN DATE TARGET DATE CLOSED DATE STATUS* COMMENTS
1A Source Package & Technical Review
1B Design FMEA
1C Design Model & Release
1D Special Characteristics
1E Change Management
2A Program Management & Timing
2B Process Flow Diagram
2C Process FMEA
2D Tooling & Equipment Management
2E Sub-Component Development
3A Control Plan & 8 Stages
3B Sub-tier Incoming Inspection
3C Error & Mistake Proofing
3D Gages & Measuring Devices
3E Work Instructions
4A Process Monitoring
4B Layered Process Audit
4C Safety & Report Characteristics
4D First Piece Approval
4E Special Processes
5A Environment & Safety (Workplace)
5B Maintenance
5C Workplace Organization
5D Training & Development
5E Continuous Improvement
6A Material Handling
6B Traceability & Part Identification
6C Packaging
6D Sequenced Part Delivery

6E CAPMAN & Supply Chain Management

7A Capacity, Volume & PDR

7B Process Performance & Capability
7C SQE Audit
7D Sub-Component Approval
Annual Validation & Periodic
7E Recertification
Non-Conformance Management &
8A Corrective Actions
8B Sub-Tier Management
8C Lessons Learned
8D Warranty

8E Quality Certifications & Record Retention

 9A Planning of Self-Qualification Tests
9B Planning of Integrative Tests
9C Planning of Matchability / Benestare
9D IMDS

Customer Approved Deviations

Box REQUIREMENT DEVIATION

Supplier Quality Engineer (Name/Date) Engineer (Name/Date) Supplier Quality Manager (Name/Date)

*Status: 25% Identified problem; 50% Action Plan proposed; 75% Action Plan implemented; 100% Solved issue
 Process Planning Review Kick-Off Meeting

Meeting Location: Date:

MY / Program: Supplier:
Parts / Description:

Item Topic Lead Time

Team Introductions - Core Team Members / Supporting Team

1
Members
2 PPR Meeting Cadence & Location
Team Responsibilities - Directed & Sub-Tier Supplier support, Open
3 Issue tracking, Core Team responsibilities, Support Team
responsibilities
4 Quality Risk Assessment (QRA) Review
5 Source Package Review - AQR, MPFMEA, & MFA
Program Timing Review - Major milestones and target dates (TKO,
6
OTOP, PDR, PA, PPAP, etc.)

Volume & Capacity Review - Planned volumes, operating pattern,

7
daily tooling capacity, expected PDR line speed requirements

8 Complete remaining PPR items

9 Complete Open Issues
10 Confirm next meeting

Attendees
Name Title / Company Name Title / Company
 Executive PPR Kick-Off Meeting
One Page Summary
HEADER
Supplier Name:
Supplier Code:
Model Year / Program:
Part Number(s):
Date of Meeting:
TEAM LIST
Supplier
VP of Quality:
Plant Manager:
Quality Manager:
Program/Project Manager:
Sales Manager:
Other:
Other:
Other:
Name Phone

BACKGROUND INFORMATION
QRA Program Risk:
Current Bid List Score:
TPSL / NBH:
Date of Last PA (if app.):

SOURCE PACKAGE & PART DESIGN

QUESTION YES PARTIAL NO
Have all applicable open issues from the Technical Review
been closed ("Green")?
Have all applicable open issues from the QRA been closed
("Green")?
Have all applicable concerns and open issues from the
MFA been closed ("Green")?
Is the quoted OEE value achievable with the planned
production process?
Has the Supplier reviewed and agreed to all requirements
in the AQR and Source Package?
Has the Supplier defined their Program Management
team, with adequate resources?
Does the Supplier have an adequate process for internal
and external communication?
Has the Supplier identified a single-point contact to
communicate roadblocks and critical issues?
 PROGRAM & TOOLING TIMING
QUESTION YES PARTIAL NO
Are the following deliverables expected to meet the program timing milestones?
Tooling Kick-off (TKO)
Gages & Measurement Devices complete
Tooling completion
Off-Tool Off-Process (OTOP)
PV / Self-Qualification Test Start
PV / Self-Qualification Test Complete
Production Demonstration Run (PDR)
PPAP / Full Approval
Have plans for the following deliverables been developed with adequate timing?
Error and Mistake Proofing
Sub-tier Supplier selection and quality planning
Sub-component approval
Is the Supplier's quoted tooling capacity sufficient to meet
launch ramp-up and planned production volumes?
Has the Supplier verified that all sub-tier Suppliers'
development timing (including required PA/PDR activity) is
sufficient to meet program milestones?
Have sub-tier Suppliers committed adequate capacity to
meet launch ramp-up and planned production volumes?
QUALITY IMPLEMENTATION
QUESTION YES PARTIAL NO
Does the Supplier's PFMEA process ensure that failure
modes from the DFMEA and MPFMEA are considered?
Has the Supplier agreed to implement all lessons learned
from the applicable MPFMEAs?
Does the Supplier's Control Plan creation process ensure
output from the PFMEA is addressed?
Does the Supplier have internal facilities for performing PV
/ Self-Qualification tests?
If no, do they use a certified sister facility or Third Party
Laboratory for testing?

Supplier Top Management: FCA SQ Manager: FCA Buyer / Commodity Manager:

Name:_____________________ Name:_______________________ Name:______________________

Sign. _____________________ Sign. ________________________ Sign. _______________________

PPR Kick-Off Meeting
Page Summary
HEADER
Supplier Location:
Region:
Commodity / BICEEP:
Part Description:
Date of Follow-up:
TEAM LIST
Customer
SQ VP or Director:
SQ Sr. Manager:
SQ Manager:
SQE:
Buyer / Commodity Mgr:
Buyer:
Engineer / R&D Mgr:
Engineer:
Name Phone

KGROUND INFORMATION
Initial PPR Score (if app.):
SEA Score (if app.):
TPSL / NBH Trend:
Last PA Score (if app.):

PACKAGE & PART DESIGN

COMMENTS / ACTIONS RESP. / DATE
RAM & TOOLING TIMING
COMMENTS / ACTIONS RESP. / DATE
nes?

ming?

LITY IMPLEMENTATION
COMMENTS / ACTIONS RESP. / DATE

FCA Buyer / Commodity Manager: FCA Engineering Manager:

Name:______________________ Name:_______________________

Sign. _______________________ Sign. ________________________

Score Classification Advance Quality Definition

• Very late to required milestone and will cause other required deliverables t
their required milestone/vehicle launch
• Risk Mitigation Plan does not exist
1 JOB STOPPER • Cannot provide parts to the build / certain to cause delay in milestone/vehi
• Has resulted in critical build/launch issues and certain to cause critical quali
production (yardholds, PRIs, field campaigns, etc.)
• Total lack of quality system or systemic control

• Late to required milestone and may cause other deliverables to be late to th

milestone/vehicle launch
• Risk Mitigation Plan exists but is not acceptable or requires unrealistic timin
JOB STOPPER milestone
2
RISK • May cause delay in milestone/vehicle launch
• Has resulted in moderate build/launch issues or may cause critical quality sp
production (yardholds, PRIs, field campaigns, etc.)
• Chronic quality system or systemic control failures

• Potentially late to required milestone

• Risk Mitigation Plan exists and is acceptable
• Moderate Risk to milestone/vehicle launch
3 MODERATE RISK • May result in moderate quality spills in production not impacting critical / s
characteristics
• Non-chronic quality system or systemic control failures

• Progressing according to required milestone timing

4 LOW RISK • Low Risk to milestone/vehicle launch
• Isolated documentation issue

IMPLEMENTED
5 Complete and approved
ACTIVITY

NA NOT APPLICABLE Ite

y Definition

other required deliverables to be late to

ause delay in milestone/vehicle launch

certain to cause critical quality spills in
)

r deliverables to be late to their required

e or requires unrealistic timing to meet

r may cause critical quality spills in

)
res

tion not impacting critical / safety

failures

ming

Item does not apply for this audit

 BACK TO PPA MATRIX
BACK TO PPA MATRIX

Current Production Definition

• Has resulted in critical quality spills (yardholds, PRIs, field campaigns, etc.)
• Corrective Action Plan does not exist.
• Results in process producing defective material with no adequate controls in place
• Total lack of quality system or systemic control

• Has resulted in moderate quality spills (NCTs, Bills, etc.) or may result in critical quality
spills in the future
• Corrective Action Plan exists but is not acceptable; needs containment action
• Can result in process producing defective material with inadequate controls in place
• Chronic quality system or systemic control failures

• May result in moderate quality spills in the future not impacting critical / safety
characteristics
• Corrective Action Plan exists and is acceptable
• Can result in process becoming unstable (may need additional controls added)
• Non-chronic quality system or systemic control failures

• Low risk for quality spills

• Corrective Action Plan / corrective actions initially implemented; verification on-going
• Continuous improvement activities ongoing
• Isolated documentation issue

• Complete and approved

es not apply for this audit

 BACK TO PPA
MATRIX
BACK TO PPA
MATRIX

Contact List
Attended
[Y/N] NAME COMPANY TITLE
Contact List
TELEPHONE MOBILE
NUMBER NUMBER
E-MAIL
Date Revision Number
01-Sep-14 1.0

19-Feb-15 1.1

30-Jun-15 1.2
06-Nov-15 2.0
18-Dec-15 2.1

28-Feb-17 3.0
Revision Description
Initial Release
Revised logo to FCA for all sectors
Revised sector names to regional names
Changed Open Issues to only hide rows that have received a "5"
Deactivated QRA Program Risk for EMEA / LATAM, APAC (EMEA / LATAM sourced), and Powertrain
(EMEA)
1D Special Characteristics: added "FPSC" and Strengthened Control Plan" to list of items critical
characteristics need to be included on

2D Tooling: revised requirements for marking tools for FCA US LLC (metal tags now acceptable)

3E Safe-Launch Activities: Added "(at least equivalent to that used by the Customer's CPA inspection
area)" to the first item; added "Data shall be collected by the Supplier and forwarded to the
Customer SQE and Plant."
4A Process Monitoring: added "When requested, copies of Boundary Samples shall be made
available to the Customer facility and quality personnel." in the 4th item.
Fixed 7B where "pages XX & XXX" in reference column is replaced with "Appendix B"
Updated Open Issues to allow selection of Box (allows more than one issue per box)
Updated "Customer" to "FCA"
1A - Commonized by adding MFA to all regions, and specifying SoR for EMEA/LATAM; added
references; revised QRA add providing Sourcing % for Quality First; changed target for completion to
"Prior to Source Selection"
1B - added requirement for DFMEA development procedure to include benchmarking and updating
for yardholds and field campaigns; changed target to start for second paragraph to "Initial design
concept"
1C - minor revision to second paragraph for clarity; third paragraph updated for commonality and
clarity.
1D - removed "Key Product Characteristics" as a designation (only "special" will be used); clarified
definition of special characteristics; revised to remove Part I/S final document; revised for clarity and
current characteristic classification

1E - added "- notification to the Customer of any risk or impact on timing, program milestones,
tooling, or resources;" and "- record or log of the first production shipment and retention of that
data for traceability;" to second item; clarified approval from FCA Engineering is required to make
an engineering change

2A - revised references; clarified deliverables in first paragraph; added requirement for Supplier to
update tooling status every 2 weeks minimum for "Ongoing PPR Activities"; added requirement to
identify TAG individual, when applicable
2B - combined Process Flow Diagram elements into a specific list
2C - updated PFMEA development procedure to match DFMEA development procedure; changed
EMEA/LATAM suggested completion to "Prior to TKO"; matched EMEA/LATAM requirements to
NAFTA requirements
2D - Added clarification to second paragraph that Readiness and Process Evaluation portions of the
Process Audit are required on production tools and process
2E - Removed "critical" from sub-tiers required to have backup plans; added "or process" to fourth
paragraph
3A - clarified in second paragraph that the Control Plan Process Audit checklist is a NAFTA
requirement; removed requirements for Final Part I/S

3B - clarified that a PDR is also required (besides PA) on sub-tier Suppliers for Sel-Qualification

3D - Added "When required by FCA, gages shall be built to reflect the part in actual vehicle position."
to the first paragraph; added "Determine which gages, if any, need to be built to reflect the part in
vehicle position." to "PPR Kick-Off Meeting Activities" in the first line; rewrote paragraph 4 as a
checklist for clarification; added requirements from fourth paragraph into first paragraph and
deleted fourth
3E - Rewritten to commonize as SLP
4A - changed approvals required for Appearance Manual / Boundary samples to read (paragraph 3):
"Approval shall include Plant Perceived Quality (CPA), plus other appropriate Customer
representatives (SQ, Engineering, Corporate Quality, etc.).;
4B - added requirement to adhere to CQI-8 to first paragraph; added clarification statement to thrid
paragraph that the E/M-proofing audit shall be performed prior to the PDR

4E - added "- ESD production areas separated from other areas of the facility, with climate controls
as necessary;" to first paragraph; added "Suppliers with other special processes (e.g., heat treating,
plating, painting, etc.) shall have a process in place that includes the following:
- Operator training and certification;
- Inclusion of the process in the Supplier's LPA program;
- Conducting self-assessments to industry standards (as required);
- Process monitoring and data recording requirements." to second paragraph

5B - added " based on past history, AQR, MPFMEA, PFMEA, etc." to first bullet of the first paragraph

5C - added "- criteria for determination of what parts shall undergo rework/repair (as opposed to
being scrapped);" to first paragraph
5E - deleted second paragraph regarding ISO 14001 (this is still a requirement, but is out of scope for
PPR or PA); clarified that the Fire Prevention License is EMEA requirement
7B - added reference to performance tab
7D - added definition of 3CPR as NAFTA and CSL as EMEA/LATAM; clarified deviation must be
approved by FCA Engineer; clarified CQMS note in last paragraph applies to NAFTA
8A - added "LUA/LUR" to examples of tools, "with clear target dates and escalation procedures
when target dates are not met", and "Work Instructions" to list of quality documents needing to be
updated; added clarification to second paragraph of Customer responsibility; added GIMS and SQP
to list of systems
8B - added FR to list of quality requirements
8D - added clarification that NAFTA Suppliers must meet AIAG CQI-14
8E - changed reference link for SQP to access via eSupplierConnect.com
9A - added second paragraph regarding reliability to EMEA/LATAM users;
Added Performance Requirements chart
Added tab for Executive PPR Kick-Off form
Made "QRA Program Risk" on Matrix viewable for all regions
Added tab for Sample PPR Kick Off agenda
Introduced World Class terminology in "Requirements for Closures" colomn.
Sheet
All
All
All
Open Issues

PPA Matrix

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Open Issues
Entire document

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Requirements Worksheet
Requirements Worksheet

Requirements Worksheet

Requirements Worksheet
Requirements Worksheet
Requirements Worksheet
Requirements Worksheet
Performance Requirements
Executive PPR KO
PPA Matrix
Sample PPR KO Agenda
Requirements Worksheet
1A
1B
1C
1D
1E
2A
2B
2C
2D
2E
3A
3B
3C
3D
3E
4A
4B
4C
4D
4E
5A
5B
5C
5D
5E
6A
6B
6C
6D
6E
7A
7B
7C
7D
7E
8A
8B
8C
8D
8E
9A
9B
9C
9D