Chrysler

ADVANCE QUALITY PLANNING

INTRODUCTION

Tell us about yourself 

Your name



Your job and how long you’ve been doing it



Your role in the AQP process



What you would like to know about AQP?

INTRODUCTION

Tell us about yourself 

Your name



Your job and how long you’ve been doing it



Your role in the AQP process



What you would like to know about AQP?

OBJECTIVES

1.Wha 1. Whatt is AQP? AQP? 2. Why should should we do it? 3. How do we do it?

FOUNDATION OF AQP: CPCP

C h r y s l er Pr o d u c t Cr eat i o n P r o c es s

Sourcin g (Purchasing L ead)

Produ ct Design (Engineering L ead) IRE (Approx. timing)

Proc ess Desig n / A QP (SQ Lead)



AQP: WHAT IS IT?

A process that will “ensure parts that meet all requirements are delivered on time to designated manufacturing facilities.”

AQP PSO

– AQP/PSO Manual 7 th Edition, page 1

AQP: WHAT IS IT? A Q P f o c u s e s o n t h e d e s i g n /d e v e l o p m e n t o f t h e to e n s u r e t h a t i t i s c a p ab l e o f p r o d u c i n g p a r t s t h a t m e e t d e s i g n r e q u i r e m e n t s a t t h e q u o t e d tooling capacity

• Corrective Actions • Lessons Learned

• Process Sign-Off / PV Testing

• Customer requirements / CPCP timing

• AQP Meetings

• VP Build • Trial Runs (SRE)

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

AQP: WHY DO IT? 

Minimize / reduce late changes to the part and process



Reduce / eliminate quality spills at all stages of production



Reduce / eliminate warranty



Increase customer satisfaction

In short, to eliminate waste and save money!

WHAT IS NEEDED: INPUTS

What do we need before we can begin AQP? 

Sourced part or module (Supplier must be known)



Source package



CPCP Program Timing



Design Model



Engineering specifications



Engineering Change Notices (CNs), if applicable



Lessons Learned from previous programs

AQP: HOW DO WE DO IT? Milestone

D

B

A

PSO On-Site Visit & Production Demonstration Run

PSO Result

1-4 (N)

Complete corrective actions; reschedule On-Site Visit / PDR as necessary

5 (Z)

Complete PPAP requirements & submit Dimensional PSW/PPAP

5 + PVT (A)

Pre-Volume Production (PVP)

Submit final PSW/PPAP

Volume Readiness Phase

Job 1 Offline

Launch Phase

Commercial Launch

Lessons Learned

End & Forever Requirements

C

Source Evaluation On-Site Source Evaluation

New Supplier (Also new management/ organization structure)

New Location New Process, Commodity or Technology New Product or Project Has Not Shipped Product for More Than 24 Months

Events

Source Evaluation Identification

1. Review list of possible suppliers. 2. Analyze Fiat and Chrysler suppliers with existing ratings or evaluations. 3. Screen supplier preevaluation data. 4. Determine strategic suppliers needing evaluations.

Task Clarification

Visit Preparation

1. Clarify scope of tasks related to product, site, technology and supplier performance data. 2. Prepare decision making recommendation and obtain management approval for task.

1. Form the cross functional team. 2. Hold kickoff meeting and assign roles and responsibilities. 3. Preliminary discussion of supplier pre-evaluation package. 4. Schedule on-site visit and confirm trip details.

On-Site Visit 1. Perform on-site evaluation. 2. Inspect facility. 3. Collate and coordinate analysis results and scoring. 4. Conduct closing meeting with supplier with verbal feedback of major observations. 5. Resolve/clarify discrepancies.

Results and Reporting 1. Finalize summary report and defined criteria. 2. Calculate evaluation pass/fail rating and identify any risk factors. 3. Report to approved managers. 4. Upload information to GPSIS.

Closure

1. Complete gap analysis form if supplier can be considered for business. 2. Assign supplier target dates on action items. 3. Track progress to gap close and follow-up meetings. 4. Notify approved managers of completed status. 5. Re-load updated SE form in GPSIS.

SOURCE EVALUATION • Check if Fiat has a PSA (Potential Supplier Assessment) Supplier Source Evaluation Toolkit Instructions for using this tool appear below

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

– If so, use PSA result

• Pre-Evaluation form sent to Supplier for completion • Buyer sends Request form to SQ Commodity Manager • SQ Commodity Manager determines the SQE to lead the Source Evaluation

General Navigation

• SQE assembles team – SQE, Engineering are mandatory

– Purchasing, Supply recommended but may delegate The tabs on this tool are arranged by function. Tan tabs are general information and Cover Sheet Green tabs are for the area-specific questions and data input Dark Blue tabs are for reporting Light Blue tabs are reference material

SOURCE EVALUATION Date:

• •

Team reviews Pre-Evaluation information Team holds on-site review at the Supplier with the SE tool

Supplier Source Evaluation Toolkit Sname City, ST

Supplier Name Address (Assessed Location) Address 2 City, State Country

•

•

Gap analysis completed with action items and target dates for unacceptable items SE result determines if Supplier can be sourced or not

Sname Address Address City, ST Country

Zip / Postal Code DUNS Code

Commodity Name

Name Jim Buyer Comm name

Small Business Y/N

N

Woman Owned Y/N

N

Sheltered Workshop Y/N

N

Author Name Buyer Name

eMail/Nic: eMail/Nic: Commodity Code

12345 123456789 email jb@chrysl er.com DC4321

Supplier Profile Minority Classification Country Foreign Ownership Percentage

Supplier Contacts Position

Name

Phone #

E-mail Address

Main Contact CEO / President Mailing Executive Head of Sales Account Rep Quality Manager Plant Manager TrafficManager After Hours Contact MaterialsManagement HR/Safety

Union Information Total

Hourly

Management

Number of Employees at facility? Union Representation Y/N

N

Expiration Date:

Name and Local #

Dedicated to the Product Line

SOURCE EVALUATION • Score each question (or “N/A”) – 0, 15, or 30 pts possible

• Click on question number to go directly to applicable workbook section

SOURCE EVALUATION • Summary tab shows results for each section, plus an overall percentage score • Overall percentage score determines if Supplier can be sourced • SEs for commodities with safety characteristics require a higher score • Individual items that are RED still require corrective actions!

SOURCE EVALUATION SCORING <60%

60-80%

>80%

<70%

70-90%

>90%

"Safety" components are any part that contains characteristics with Safety shields () and/or governmental safety regulations.

Green: OK to bid / source business Yellow: Requires SQ Sr. Manager or Commodity Manager’s approval to bid / source business Red: Cannot bid / source business unless SQ Director’s approval is given

INITIAL RISK EVALUATION (IRE) What is the IRE? • An assessment of the inherent risks in a new or modified part •

•

Determines Chrysler involvement with the AQP and PSO for the new or modified part Required to be completed within 14 business days of the part appearing in CQMS

Initial Risk Evaluation

LOW

MEDIUM

HIGH

AQP: Supplier PSO: Supplier

AQP: Supplier PSO: Chrysler

AQP: Chrysler PSO: Chrysler

IRE RISK DRIVERS •

Are there issues preventing Production Tools Complete by the required date? – Expectation: Review the planned Tooling Kickoff (TKO) and Production Tools Complete (PTC) dates. PTC is required by Verification of Process (VP).

– Guidelines: Tooling completion affects numerous AQP deliverables, such as PV Testing, Process Sign-Off, PPAP, etc. Late tooling should equate to a higher risk l evel; completion after Pre Volume Production (PVP) should be an automatic High risk.

•

Will PPAP be completed by the required date? – Expectation: Review the planned PPAP date. PPAP completion is required by PVP. – Guidelines: Late PPAP may equate to a higher risk level. Late engineering changes that push PPAP beyond PVP or Job 1 should be re-evaluated to determine if the ris k level of the part should increase. As soon as it is known that PPAP will be after PVP, follow the "PPAP Submission Delay - Escalation" process in the Book of Knowledge .

•

Is the design complete? – Expectation: Part design / CAD should be complete and attached as part of the original Source Package. – Guidelines: If the Supplier submitted an RFQ to an incomplete or non -existent design, there is increased risk to the program. TKO without a complete design also represents


Has historical design stability (e.g., high CN activity) been considered? – Expectation: Review Lessons Learned from previous programs (both from the Supplier and on similarly-designed parts) for CN activity. Were engineering changes minimal and minor in scope? – Guidelines: A high incidence of CNs on the part, or one or more major part redesigns, should reflect a higher risk level.

•

What is the customer impact if the part fails? (Safety, Appearance, functionality, etc.) – Expectation: Determine the potential customer impact if the part fails . Would it cause injury, result in vehicle breakdown, or negatively impact customer perception? – Guidelines: Parts with a high degree of customer interface should have correspondingly higher risk levels. Examples include Safety components, parts that could result in a "walk-home" condition, or parts in high-visibility areas with Appearance requirements.

•

What is the level of process technology (e.g., established, widespread, innovative)? – Expectation: Review the proposed manufacturing process. – Guidelines: Processes that are using technologies new to the Supplier, Chrysler, or the industry may require a higher risk level.


Is this a new manufacturing location? –

–

•

Have there been historical quality problems with similar parts? –

–

•

Expectation: Manufacturing locations new to Chrysler r equire a Source Evaluation performed with an acceptable score. Ensure open issues from Source Evaluation have been closed. If the Supplier received an unacceptable rating, were the proper overrides obtained? Guidelines: New Suppliers to Chrysler represent a higher risk to the program. Lack of an acceptable Source Evaluation for a new Supplier should be an automatic High risk. Expectation: Review the quality history (Nonconformance Tickets, yardholds/PRIs, warranty issues and field actions) of the part in question (if applicable) or parts with a similar design. Review the Master PFMEA for this commodity to ensure these issues have been addressed. Have there been repeat issues? Guidelines: A high incidence of NCTs, a high c's/1000 rating, or ANY PRIs or field actions on similar parts represents a higher risk. Repeat issues or lack of corrective actions in the Master PFMEA also indicate a higher program risk.

What is the Supplier's Supplier Quality Bid List score? –

–

Expectation: The Supplier should be "green" per the Supplier Quality Bid List ( SQBL). Their overall score includes AQP/NCT, 3CPR (Level 1 and Level 2 incidences; reference ), yardholds, Forever Requirement Violations (reference ), ISO/TS-16949 Certification, and New Business Hold (NBH; reference ). "Yellow" or "Red" scores on the SQBL require a written override from a SQ Director for the Supplier to receive business. Guidelines: A Supplier with a "yellow" or "red" SQBL score indicates potential additional risk to the program.


What is the Supplier's Warranty history? – Expectation: Review the Supplier's warranty history with the Customer Satisfaction Team (CST). Are they meeting their targets? Have they had any recent warranty spikes or field actions? – Guidelines: If the Supplier's warranty has been increasing, or if they have had a fi eld action recently, it may indicate additional risk.

•

What is the Supplier's ability to successfully conduct AQP activities? – Expectation: Assess the Tier 1 Supplier's ability to manage AQP / APQP activities. Review PSO Element 1, requirements 1.2 through 1.2.4 ("Supply Base Management"); the Tier 1 should have all requirements met. Review if the Supplier location has required multiple PSO visits in the past before receiving approval. – Guidelines: A lack of sub-tier Supplier management processes indicates high program risk, as does a history of failing to meet deliverable due dates. Multiple PSO visits in the past can also indicate poor AQP management.

IRE RISK LEVELS 





High Risk (H) 

Chrysler SQE leads the AQP



Chrysler SQE leads the PSO

Medium Risk (M) 

Supplier leads the AQP



Chrysler SQE leads the PSO

Low Risk (L) 

Supplier leads the AQP



Supplier leads the PSO

DESIGNATING THE IRE IN CQMS

Review and acknowledge the IRE risk drivers!

• •

Use the “Part Information” tab in CQMS

Select Part Risk

DESIGNATING THE IRE IN CQMS To Enter Initial Risk Evaluation f or a Sing le Part:

1.Logon to CQMS with your TID and user password. 2.Click Part Information tab. Then, click the link. Part Risk 3.Type the full Chrysler part number in the Part Number field. 4.Check the box for Unassigned Risk 5.Click Find. 6.Click the radio button for the Supplier Code where you want to apply Initial Risk. 7.Select a risk value from the Initial Risk drop down. N o t e : Do not make a separate selection for Current risk. The initial risk value will automatically populate to “Current” risk when updated. 8.Check the box to Acknowledge Risk Drivers 9.Click Update.

To Enter Initial Risk Evaluation fo r One or More Parts:

1. Click the Part Information tab. Then, click the Part Risk link. 2. Logon to CQMS with your TID and user password. 3. Enter valid Chrysler Supplier Quality Deck Code Note: SQE Deck Code is populated by default, where applicable. Select “Clear” to enter a new value. 4. Check the box for Unassigned Risk 5. To limit the results, enter a value for one or more “Optional” filters. 6. Click Find. 7. Click the radio button(s) for the parts where you want to apply a single Initial Risk value. 8. Select a risk value from the Initial Risk drop down. Note : Do not make a separate selection for Current risk. The initial risk value will automatically populate to “Current” risk when updated. 9. Check the box to Acknowledge Risk Drivers 10.Click Update.

DESIGNATING THE IRE IN CQMS To Chang e Current Part Risk fo r a Single Part:

1. 2. 3. 4. 5. 6.

Logon to CQMS with your TID and user password. Click Part Information tab. Then, click the Part Risk link. Type the full Chrysler part number in the Part Number field. De-select the check box for Unassigned Risk Click Find. Click the radio button for the Supplier Code where you want to change Current Risk. Note: Current Risk can only be changed once the Initial Risk has been captured. Do not select rows where the Current risk value is the same as the new risk value. 7. Select a risk value from the Current Risk drop down. make a separate selection for Initial risk. The initial risk value cannot be Note: D o n o t changed once it is captured. If you attempt to enter a value for Initial risk, you will receive an error message. 8. Click Update. To Change Curr ent Part Risk fo r One or More Parts:

1. Logon to CQMS with your TID and user password. 2. Click the Part Information tab. Then, click the Part Risk link. 3. Enter valid Chrysler Supplier Quality Deck Code Note : SQE Deck Code is populated by default, where applicable. Select “Clear” to enter a new value. 4. De-select the check box for Unassigned Risk 5. To limit the results, enter a value for one or more “Optional” filters.

QUALITY PLANNING / AQP MEETINGS What are AQP Meetings? • Regular reviews of the program status • A way to ensure progress of CPCP milestone deliverables

• Ensures communication between AQP team members

1. AQP Kick-off Meeting 2. Hold regular AQP Meetings and track status with Executive Summary, Timing Chart

WHEN / WHERE ARE AQP MEETINGS HELD? • Required for all programs following the AQP process – All components with a “High” IRE – Recommended for “Medium” and “Low” IRE programs, although the Supplier may also use the APQP process (see the AIAG’s Advanced Product Quality Planning and Control Plan Manual, 2nd Edition)

• Regular, frequent schedule – Recommended weekly

• No mandatory location – If possible, it is strongly recommend that some meetings are held at the Tier 1 manufacturing location, critical Tier 2 or lower Suppliers, and at the Chrysler manufacturing facility

WHO’S IN CHARGE?

• The Chrysler SQE leads the AQP Meetings for “High” IRE programs • The Supplier leads their own AQP/APQP Meetings for “Medium” and “Low” IRE programs

The Chrysler SQE can require AQP Meetings for any program on an “as needed” basis

THE AQP “KICK-OFF” MEETING

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

• Should include all AQP Team members Extended Team Core Team •

•

•

Chrysler Supplier Quality Engineer Chrysler Product Engineer Supplier Personnel

•

• • •

•

Chrysler SQ Manager / Vehicle Lead Chrysler Buyer Chrysler Supply Other Chrysler Personnel as needed Sub-Tier Suppliers as needed

THE AQP “KICK-OFF” MEETING AGENDA

• Review the IRE – Gain additional team input – Review issues/risk drivers that gave the highest risk

• Establish team roles and responsibilities (including responsibilities between Tier 1 and Directed/Consigned Suppliers) “Directed” Tier II

Standard Tier II

“Consigned” Tier II

Part PO

Tier I

Part PO

Tier I

Part PO

Chrysler

Tool PO

Tier I

Tool PO

Chrysler

Tool PO

Chrysler

AQP/PSO Resp.

Tier I

AQP/PSO Resp.

Chrysler

AQP/PSO Resp.

Chrysler

Release/Logistics

Tier I

Release/Logistics

Tier I

Release/Logistics

Chrysler

Receiving Location

Tier I

Receiving Location

Tier I

Receiving Location

Tier I

NCT Issued to:

Tier I

NCT Issued to:

Tier I

NCT Issued to:

Tier II

eCIMS Issued to:

Tier I

eCIMS Issued to:

Tier II

eCIMS Issued to:

Tier II


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

• Confirm core AQP Team members – Chrysler SQE – Chrysler Engineer – Supplier Personnel (Quality and Program Management, at a minimum)

• Review the source package – Ensure requirements are accurate – Engineering specifications – Prototype build requirements

• Review volume assumptions (e.g., shift pattern agreement with P.O. volumes) – Get an early idea of SRE/PSO cycle time & line speed requirements – Identify potential capacity issues up-front


• Establish and review program timing / major CPCP milestones – Prototype (VP, PVP) and Launch (Job 1) build dates and Material Required Dates (MRD) – Dates for deliverables (including, but not limited to): 

PFMEA Acceptance



Part I/S Draft & Final Complete



Production Tools Complete



Pre-PSO Meeting



Equipment, Fixtures, Facilities, and Gages Complete



PSO On-Site Visit



PSO Complete



Gage R&R



IMDS Submitted



Supplier Readiness Evaluation (SRE)



PV Testing Start / Complete



Dimensional Capability



PPAP submission

When initial program timing is developed, deliverables for milestones that are already past due shall be included for completion. These deliverables shall be distributed into appropriate, future milestones as determined by the AQP Team.


• Establish AQP/Process Sign-Off (PSO) expectations – Maintenance of AQP forms and documents – SRE/PDR part run quantities – Extended Run PSO? – Etc.

• Confirm manufacturing location

GENERAL AQP MEETINGS Agenda should include: • Program timing and major milestones – If timing slips, an appropriate Risk Mitigation Plan shall be developed and implemented to manage the risk

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

• Open issues – Prototype quality issues (NCTs, eCIMS, etc.) – Current or proposed Engineering Changes, IAAs – Sub-tier Supplier status – Etc.

GENERAL AQP MEETINGS

Sometimes broken up into two types: “High -level” AQP and “Working-level” AQP High-level – Agenda based on Milestones / Timing – Focus on process-readiness vs. product design – Team provides brief updates on status

Working-level – Agenda targets specific deliverables – Team members “do the work” during these meetings (i.e., develop PFMEA, Part Inspection Standard, Control Plan, etc.)

AQP MEETING FORMS AND DOCUMENTS AQP Timing Chart  Supplier must maintain and update for each AQP meeting  Tracks progress towards completion of all PSO elements, plus key Supplier Quality deliverables and AQP tasks (IRE, PPAP, etc.)  Details item status and customer responsible lead  Required for all programs following AQP (and all Fiat parts managed by Chrysler) ADVANCE QUALITY PLANNING (AQP) TIMING CHART

SUPPLIER: SUPPLIER CODE: PART NUMBER(S):

MY/VEHICLE FAMILY:

REVISION:

CHRYSLER AQP STATUS

PART NAME(S):

#NUM!

FIAT PROGRAM REVIEW STATUS

PART RISK (H/M/L):

AQP MEETING DATE: AQP MEETING LOCATION:

Build Name

R E M O T D S A PSO U E Element C L

REVISION DATE:

#NUM!

KEY MATERIAL/BUILD DATES

AQP ACTIVITIES

Build Date

MRD

# of Veh

# of Days

VP PVP Job 1

SUPPLIER RESPONSIBLE

Month-Date Program & Style Approval

BEGIN P LAN

ACT

END P LAN

EF

ACT

Initial Risk Evaluation (IRE)

SQE

-

SQE

1

Advance Quality Planning

SQE

-

Confirm composition and commitment of Core AQP Team Members

ENG

-

Source Package Review

SQE

-

Volume, ramp-up curve, and product mix verified and capable - CPV, P.O, SP

SQE

-

eCIMS / Lessons Learned Reviewed

SQE

-

Prior PSO Review (similar products)

SQE

-

Verify deliverables timing to CPCP timing

0

Month-Date

YEAR Month-Date Step 2 Style Freeze EF

Month-Date Step 3 Tooling Kickoff EF

Month-Date

Month-Date

Step 5 Prod. Designs Complete EF

Month-Date

Month-Date

YEAR Month-Date Month-Date

Verification of Process EF

VP

Month-Date

Pre Volume Production EF PVP

Month-Date

Month-Date

Job 1 Offline

Commercial Launch

EF

EF

STATUS

Enter 1-5

RISK MITIGTION PLAN

If status is 1, 2, or 3 (Red or Yellow), you must provide a Risk Mitigation Plan

AQP TIMING CHART

1. Item or activity title • Key AQP tasks and SQ deliverables (IRE, Production Tools Complete, IMDS, PPAP) • All PSO Elements

2. Tracks Supplier responsibility for each item, with begin/end dates 3. Key build/MRD dates 4. Details Chrysler lead for each item

Build Name

R E M O T D S A U E C L

KEY MATERIAL/BUILD DATES

PSO Element

AQP ACTIVITIES

Build Date

VP PVP Job 1

SUPPLIER RESPONSIBLE

MRD

-

SQE

1

Advance Quality Planning

SQE

-

Confirm composition and commitment of Core AQP Team Members 1

ENG

-

Source Package Review

SQE

-


SQE

-


SQE

-

Prior PSO Review (similar products)

SQE

4

-

Verify deliverables timing to CPCP timing

SQE

-

PTS

-

Supplier Quality Risk Assessment (SQRA)

ENG

-

Part Development Plan Complete

ENG

-

Design Review - Customer Perception targets

ENG

-

Production Tooling Complete (PTC)

SQE

-

TAG Review (Chrysler-purchased tooling only)

ENG

-

Review CNs and IAAs (including associated Risk)

ENG

3

Design FMEA

ENG

4

Test Sample Sizes and Frequencies

SQE

-

Confirm Supplier PPAP Self-Certification status

Status of Open Issues from Technical Review Risk Assessment (FIAT parts only)

# of Days

3 BEGIN P LAN

Initial Risk Evaluation (IRE)

SQE

# of Veh

2

A CT

END P LAN

AC T

AQP TIMING CHART 5. Indicate the status of the task. Score

Chrysler Definition

1

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

2

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

3

4 5

STATUS

Incomplete and: • Late to required milestone • Risk Mitigation Plan exists and is acceptable • Low Risk to milestone/vehicle launch Incomplete and: • Progressing according to r equired milestone timing • No Risk to milestone/vehicle launch Complete and approved

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

Enter 1-5

5

RISK MITIGTION PLAN


6

AQP TIMING CHART Month-Date

Month-Date

YEAR Month-Date Step 2 Style Freeze

Program & Style Approval

EF

EF

Month-Date Step 3 Tooling Kickoff

EF

Month-Date

Month-Date

Step 5 Prod. Designs Complete

EF

Month-Date

Month-Date

YEAR Month-Date Month-Date

Verification of Process

Month-Date

Pre Volume Production

EF PVP

EF VP

Month-Date

Month-Date

Job 1 Offline

Commercial Launch

EF

7 High risk; PO + 8 wks All Other

7. Use this section to track progress of each item towards completion – – – –

Shows suggested AQP start and finish CPCP milestones (solid black line) Shows current progress (gold dotted line; manually adjusted) Use solid red line to show current date (manually adjusted) Details required deliverable dates (black diamonds)

EF

AQP TIMING CHART Sample of task directions: 10

AQP Activities [Specific] Initial Risk Evaluation (IRE) Advance Quality Planning

Follow the instructions listed below:

The SQE performs the Initial Risk Evaluation and determines the part risk to be High, Medium, or Low. PSO Element 1. Includes overall program timing, Supply Base Management, Problem Solving, and most supporting processes. Verify timing for tooling, fixtures, gages, testing requirements, and sub-components. Regularly review and update timing plans, as needed. Review risk assessments for sub-components. Ensure the Tier 1 Supplier has a process for tracking S ub-Tier Supplier quality and delivery, and t hat poor-performing suppliers have been replaced or are receiving commensurate additional attention during the development phase. Review the Tier 1 Supplier's plan for PSO on sub-components, and verify back-up plans exist for SubTier Suppliers with a high risk for supply issues. Confirm composit ion and commitment of Core AQP Verify the core AQP Team members: Supplier Quality, Engineering, Plant Quality Center (for Part I/S), and key Team Members Suppler team members (Quality, Program Management/Engineering). Identify non-core AQP Team members that may need to provide input, such as Purchasing, Logistics/Supply, Supplier Sales Representative, etc. Complete, and keep up-to-date, a contact list with all AQP Team members, their phone numbers, and email addresses. S ourc e P ac kage Revi ew A t t he AQP Kic k-Off Meet ing, revi ew t he complet ed Sourc e P ac kage, not ing key informat ion and program deliverables. Ensure engineering specifications and Quality and Supply requirements are understood by the Supplier. Volume, ramp-up curve, and product mix verified and Review program volume requirements, planned product mix, and planned launch ramp-up curve. Ensure t he capable - CPV, P.O, SP Supplier understands the requirements. Support the Buyer in timely Purchase Order issuance, and ensure the quoted Daily Tooling Capacity is sufficient to meet Chrysler's needs. eCIMS / Lessons Learned Reviewed Review quality spills from previous and similar products/processes. Use the eCIMS system, NCT system, and completed 8-steps. Ensure issues are accounted for when developing Design and Process FMEAs. Verify that issues resulting in past yardholds, PRIs, or Field Actions are adequately error-proofed or completely designed out of the part in the new process. Prior PSO Review (similar products) Review Process Sign-Off (or PCPA, for Fiat parts) results from previous programs, both on similar product and from the same Supplier. Account for issues that may have resulted in lack of PSO approval so that do not reoccur, and make sure all open issues have been closed. Verify deliverables timing to CPCP timing Ensure the AQP Team has the most current CPCP timing, including all milestones. Verify that Supplier promise dates for all deliverables are consistent with CPCP timing and are not late. Reference the "Supplier Quality Deliverables Timing" form on the AQP/PSO website. Status of Open Issues from Technical Review Risk Applicable for FIAT parts only. Review the status of open issues created from the Risk Assessment during the Assessment (FIAT parts only) Technical Review (part of the FIAT Sourcing process). Verify progress and ensure it is consistent with what was planned. Supplier Quality Risk Assessment (SQRA) Review the status and issues from the Supplier Quality Risk Assessment (SQRA) with the Product Team SQE. Ensure the AQP Executive Summary form is kept updated after each AQP Meeting with potential launch risks and Risk Mitigation plans.

Used in FIAT Program Review? No

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

No

AQP TIMING CHART Scoring Examples: Task

Issue

Production Tooling Complete (PTC)

Late design release means the Supplier will not have production tools ready by VP. They plan to build parts with prototype tooling, using production intent materials and gages. Tools will be available in time to provide parts for PSO and the Pre-series build. (Suggested score = 3)

Process FMEA

In a review of the PFMEA, the SQE discovers that the Supplier has not implemented error/mistake-proofing on several safety-related items. In addition, an overall audit using the Supplier PFMEA Audit form returns a “red” result. (Suggested score = 1 or 2, depending on when this is discovered)

AQP MEETING FORMS AND DOCUMENTS AQP Open Issues – Open Issues must be created and maintained throughout the program – SQE has responsibility to maintain, but can delegate to the Supplier – Key Points: 1. ONE Individual as responsible for an item 2. Dates: when the issue was opened, target for completion, and actual completion or closed 3. Priority or risk level (recommended) 4. Updates and comments

– AQP Open Issues are considered quality records  Kept

for life of the program, plus one year

 Who

retains them? (SQE)

PART INSPECTION STANDARD (PART I/S) PART INSPECTION STANDARD

Provides clear communication and agreement between the Chrysler Manufacturing Plant, Engineering, Supplier Quality and the Supplier in regards to:

VEHICLE MY / FAMILY:

DATE:

PART NO:

PART NAME/DESC:

SUPPLIER CODE:

SUPPLIER NAME:

DRAFT FINAL MANUFACTURING LOCATION:

DRAWING NO. / REVISION LEVEL: DRAWING/SKETCH

• Characteristics on the design model which the Chrysler Manufacturing Plant considers to be most important • The measurement method, sample size, and frequency with which the Supplier checks those characteristics REV. #

REVISION / DESCRIPTION

DATE

CHRYSLER PLANT QC

SQE

SUPPLIER ENG

QLTY MGR

INITIAL SIGN-OFF / APPROVAL TITLE Plant QC Eng. - Chrysler SQE - Chrysler Engineer - Chrysler Quality Mgr. - Supplier Engineering - Supplier

NAME

SIGNATURE

DATE

ENG

PART I/S PART INSPECTION STANDARD VEHICLE MY / FAMILY:

DATE:

PART NO:

PART NAME/DESC:

SUPPLIER CODE:

SUPPLIER NAME:

 Provides the Chrysler

DRAFT FINAL MANUFACTURING LOCATION:

DRAWING NO. / REVISION LEVEL: ITEM #

CHARACTERISTIC / INSPECTION POINT

SPECIFICATION / TOLERANCE

MEAS. METHOD

SAMPLE SIZE

FREQ.

REMARKS / INSPECTION METHOD

Manufacturing Plant a tool to more quickly identify a problem and responsibility when a quality issue occurs  Gives the AQP team an

INITIAL SIGN-OFF / APPROVAL TITLE Plant QC Eng. - Chrysler SQE - Chrysler Engineer - Chrysler Quality Mgr. - Supplier

NAME

SIGNATURE

DATE

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

PART I/S TEAM Team Members (minimum):

• Chrysler:  Supplier Quality

Engineer  Engineer

• Supplier:  Quality Manager  Engineering / Program

Manager

 Plant Quality Center

Engineer Additional team members may be added, as needed. Examples include the Chrysler Dimensional Engineer, Design Office, TAG representative, etc.

PART I/S RASIC

r l i e p p S u Selection of Parts Confirm Assembly vs Part Datum Scheme Alignment 1

Selection of Critical Dimensions Sample Size and Frequency determination Measurement Method of Critical Dimensions 1 Selection of Appearance Specs/Characteristics Boundary Sample Creation and Review/Sign-off 1 Selection of Functional Specs/Characteristics Completion of Part I/S form Retention of Completed Part I/S

g r i n e ) i n e n t g a l n P ( t E y t n i a l n e i n g u o r p e Q t y e i n e a l i o m i n g g u r C f i c n f u Q t & E O r c n m f a l e l i e c g e u p i i t n s p h s a S u S y M V e D e

C

CS

C

RA

R/S R/S R R

C C A S

C/R C/R C A

A A C C

R/S R R/S R RA

C S C S I

C/R C C/R

A A A CA I

I

C

C S

S S

I

I

Responsible - Those who do the work to achieve the task. There is typically one role with a participation type of Responsible Accountable - Final Approving Authority Support - Resources allocated to Responsible Informed - Those who are kept up-to-date on progress, often only on completion of the task or deliverable; and with whom there is just one way Consulted -Those whose opinions are sought; and with whom there is two-way communication NOTES 1: Dependant upon which party is design-responsible

HOW IS THE PART I/S DONE?

Chrysler Product Creation Process (CPCP)

IRE

FPSC

CREATION

PSO & PPAP

DRAFT

FINAL

PART INSPECTION STANDARD


Part I/S Creation Phase • Scope of the program is defined (parts identified, critical characteristics identified, etc.) • Document is created

Identify Parts & Provide Information

Create Part I/S

Team Review

Revise & Sign


Part I/S Draft Phase • Use of the Part I/S Draft to check parts for the VP and PVP pilot builds • Follows the same basic flow for each build:

Implement & Collect Data

Build Event

Team Review

Revise & Resubmit


Part I/S Final Phase • Part I/S is finalized for Job 1 and continuing volume production • The Part I/S remains a living document and can be revised as needed

The Part I/S do es no t replace either th e Contro l Plan o r FPSC at any prog ram stage.

PART I/S AND OTHER DOCUMENTS • The Part I/S should be developed alongside other quality documents, especially the PFMEA, Control Plan, and FPSC plan  The Part I/S do es

re p l a c e o r s u p e r s e d e an y o t h e r q u a l i t y

documents! 

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

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

PART I/S AND OTHER DOCUMENTS

FPSC: “Safe Launch”; checks/inspections over and above Control Plan Control Plan: Controls (w/ frequency, sample size) for entire process Part I/S: Ties controls for the final product characteristics with visual representation (GD&T) and allows for measurement scheme agreement with the Chrysler Manufacturing Plant

PART I/S AND OTHER DOCUMENTS

Question: If we’re instituting 100% inspection for VP (or other pilot build), with a gradual lessening of frequency as we move into production, should the Part I/S reflect this? 

No. The Part I/S is a tool to communicate how the Supplier will check parts in production. As such, it should reflect the production control plan inspection frequencies and sample sizes. If the team is requiring 100% inspection for a pilot build, this should be reflected on the FPSC plan, NOT Part I/S. Per the RASIC on slide 8, SQ has the final approving authority on sample sizes and frequencies.

PART I/S FLAG IN CQMS

PFMEA ACCEPTANCE

Part Inspection Standard (Part I/S)

PFMEA Acceptance

What is “significant” PFMEA Acceptance? •

An audit or assessment of the Supplier’s Process FMEA

• Applicable for any part that also requires a Part I/S 

•

All parts with a “High” IRE and those parts selected by the Assembly Plant

Required to be completed 14 weeks prior to VP

PFMEA ACCEPTANCE Supplier Quality Engineer (SQE)

Supplier

3rd Party

Identify Significant PFMEA Acceptance parts (Notify Supplier)

3rd Party Review required?

NO

YES

Forward PFMEA to SQE

Forward PFMEA to 3P (copy SQE)

Review PFMEA using "Supplier PFMEA Audit Summary" form

Review PFMEA using "Supplier PFMEA Audit Summary" form

YELLOW

Audit Result?

Audit Result?

YELLOW RED RED

Make corrections to PFMEA (work with Chrysler SQE)

Make corrections to PFMEA (work with 3P)

YELLOW RED

Audit Result?

GREEN GREEN

Enter Actual Date in CQMS

End

GREEN

Dispute Process If Supplier and/or SQE disagrees with 3P assessment: 1. Submit PFMEA to Sr. Manager -SQ Operations 2. Sr. Manager -SQ Operations reviews PFMEA 3. If result matches 3P, 3P assessmentstandsand rocess is

• SQE determines if audit will be done by themselves or 3 rd Party • Auditor uses the “Supplier PFMEA Audit Summary” form • If not “green”, Supplier makes corrections and resubmits per the flowchart

PFMEA ACCEPTANCE Criteria for using a 3 rd Party Auditor include (but is not limited to):  Suppliers

who are "Red" in the Quality Bid List system

 Suppliers

who are on New Business Hold

 Suppliers

on the “Top Problem Supplier Locations” list

 Parts

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

The SQE makes the final decision for whether or not a Supplier must use a 3rd Party auditor for this process

PFMEA ACCEPTANCE Dispute Process If the Supplier and/or SQE disagrees with the 3 rd Party assessment: 1. Submit the PFMEA to the Sr. Manager - SQ Operations 2. The Sr. Manager - SQ Operations reviews the PFMEA with “Supplier PFMEA Audit Summary” form 3. If the result matches the 3rd Party, the assessment stands and process is followed as normal 4. If the result differs, the Audit Result is changed and the process follows the process flow for the new result

PFMEA ACCEPTANCE S u p p l i er P r o c e s s F M E A : A u d i t S u m m a r y ( b a s e d o n Fo u r t h E d i t i o n F M E A M a n u a l )

• If you don’t know if something has been done, answer , “No” then follow up later.

MY/Program N a m e o f C o m p o n e n t ( s ) , S u b -S y s t e m ( s ) o r S y s t e m ( s ) : Part Number(s): Responsible Supplier: Responsible Chrysler Supplier Quality Engineer: Name of Auditor: Date Reviewed: Date of PFMEA audited (Later of Original or Rev. Level):

Rating Detail Header: Non-Header sections (2 through 13):

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

Result

Criteria "Yes" if all answers in section 1 are "Yes." "No"___ "E/I"___ Count # of sections 2-13 "No" and # "E/I." Header "Yes" overall and no more than three sections "E/I" overall = "Green" Neither "Green" nor "Red" criteria met = "Yellow" Six or more non-Header sections "No" overall = "Red"

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

1 1a 1b 1c 1d 1e

Header Yes E/I No N/A Auditor Comments Name of Vehicle(s)/Program(s) included? Model Year of Program(s) included? Name of Supplier included? Part Number and Description included? Core Team includes (at a minimum): Chrysler: Supplier Quality Engineer and design-responsible Engineer. Supplier: Quality Engineer and Plant Mfg. Engineer? Names and titles or area of responsibility are included? Note: Phone #'s recommended, but not mandatory for this audit. 1f Key Date shown is PPDC date or P.O. issuance + 60 days, whichever is later (for new vehicle programs), or does not exceed PPAP date (for programs already in production )? Note: Contact Chrysler SQE, if required. 1g FMEA Date (Orig.) is shown? 1h FMEA "(Rev.)" date within past 60 days? Note: "N/A" if "(Orig.)" date is within 60 days. Additonal Comments (not to impact audit results): If all answers "Yes," check "Yes." If one or more "No," check "No." Note 1: "E/I" = only minor "E"xceptions or require ment "I"nconsistently applied (approx . 25% or less) and correction still required . Note 2: Do not allow a "No" answer to one question (e.g., Detection ranking too low) resu lt in a "No" answer to another related question (e.g., lack of "Recommended Actions" or "Action Results"). Evaluate each question based only on their own merits.

• Ask “how?” and “when?” vs. “yes/no” questions when assessing certain questions, (i.e., “Did the Designresponsible Engineer provide input on Effects?”). • Be sure to read and understand the “Notes” to help ensure consistency.

Additional Comments on the PFMEA •

PFMEAs shall incorporate lessons learned from past programs or similar parts, internal and external nonconformance data related to the parts, and customer (Chrysler) inputs, as outlined in the Supplier PFMEA Audit Summary.

•

For the parts requiring PFMEA Acceptance in the Chrysler Quality Management System (CQMS), the SQE and Supplier shall jointly audit the PFMEA no later than (14) weeks prior to VP SOF. In addition, the result of the PFMEA audit shall be "Green" before the Actual Date is entered in CQMS.

• All PFMEAs, regardless of the risk level, shall be rated "Green" per the "Supplier PFMEA Audit Summary" form as part of PSO requirements. Please refer the “PFMEA Acceptance” pro cess standard in t he B o o k o f K n o w l ed g e f o r m o r e d e ta il s .

3rd Party PFMEA Audits The responsible SQE is expected to provide following support: •

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

•

If the 3rd party audit obtains a "Red” result, the Supplier is required to contract one of the 3rd Party Auditors and start coaching and audits within (2) weeks. The Supplier works with the 3rd Party Auditor until a "Green" result is achieved. –

•

The supplier may be issued a Forever Requirement Violation (FRV) as “Failure to follow/respond to Chrysler requirements or requests” if they refuse t o seek coaching within (2) weeks of receiving a “Red” audit result.

If the supplier needs to dispute the audit result, the Supplier and/or SQE shall submit the PFMEA audit form as originally completed by the auditor and an explanation for the dispute to the PFMEA Auditor Facilitator, Stanley Zhou ([email protected]).

P l ea s e r ef e r t o t h e P F M EA 3 r d P a r t y A u d i t s a n d C o a c h i n g p r o c e s s s t a n d a rd i n t h e B o o k o f K n o w l ed g e f o r m o r e d e t ai l s .

FIRST PRODUCTION SHIPMENT CERTIFICATION What is FPSC? • “Safe Launch” activities • Audit / inspection above and beyond standard process controls • Records retained by the Supplier; may be requested by Chrysler personnel at any time

FPSC BASICS • FPSC includes all Special Characteristics – Product characteristics or manufacturing process parameters which can affect safety or compliance with regulations, fit, function, performance or subsequent processing of a product 

Key characteristics



Torque requirements



Safety characteristics



SPC points



Emissions characteristics



Others deemed critical by the Supplier or Chrysler

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

S

FPSC BY PROGRAM NEW PROGRAMS

•

Begins with first shipment for VP build

•

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

•

Plan, results for VP, and effectiveness of the FPSC reviewed during the Pre-PSO Meeting

MODIFIED PROGRAMS / FR CHANGES / RESOURCING • Begins with first shipment to a Chrysler (or Chrysler-designated) facility • Duration is until 1 st shipment + 90 days has passed (minimum) • Plan reviewed during PSO

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

OTHER FPSC INFORMATION The Supplier is responsible for ensuring that FPSC (or equivalent) activities are implemented through the Supply Chain (Tier 2 and lower). The duration of FPSC (or equivalent) at sub-tier suppliers shall match that of the Tier 1 Supplier's FPSC. FPSC is not a replacement for the Part I/S or Control Plan, nor is the Part I/S or Control Plan a replacement for FPSC. FPSC is intended to be an additional level of inspections or audits to protect the Chrysler (or Chrysler-designated) manufacturing facility during the pilot and launch phases.

PART QUALIFICATION PROCESS • Plant validation of BIW/QAF (Interior & Exterior Quality Assurance Fixtures) components (internal and external suppliers) to fulfill the customer requirements, Quality standards, Build Objectives (EBO) and Design intent. Validation includes Dimensional control. • Plant Metrology Center lead; SQE supports the plant by ensuring Supplier submits parts and data when required and corrective actions are completed

75% of Tolerance 75%-100% of Tolerance

Over 100% of Tolerance

PART QUALIFICATION PROCESS • Supplier (Internal & External) Requirements for Part Submission (preferred two Weeks prior to MRD) for each build phase • Plan Do Check Act (PDCA)/Quick Kaizen required for any “red” points

• More loops should be repeated as

Supplier submits part data from 5 parts and transfer to Plant

Supplier incorporates Changes in Manufacturing Process if req.

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

Mark up two parts with measured data to bring to plant

corrective action timing permits

• Parts and Data need to be characterized :

• Part made from Soft Tool / Hard Tool • Tools are on Home Line / Temp Line • Special Means were /were not • Gage R&R

Supplier Creates new PDCA if required

Meet with Plant to review parts and data

PART QUALIFICATION PROCESS Mass Production

Vehicle Development Phase

Continuous Loops S1/VP

Loop 1

S1A - Framing

S2/PVP

V1

S2A - Framing

•

• Parts shall be dimensionally correct for S1 / VP • Parts shall meet PP/PPK per Appendix B of the AQP/PSO Manual at S2 / PVP (min 30 pc sample) • Parts shall meet CP/CPK of 1.33 at V1 and later (min 30 pc Sample)

•

Additional loops will be required within each build phase (S1A, S1B etc.) according to: – Part achievement of Dimensional Compliance – Engineering changes – Part availability (Pilot Build Phase) – Measurement schedule – Process changes (e.g. soft to hard tools) Must have knowledge of part production process – hard tools/soft tools , maturity of supplier process

NOTE: Supplier should build in small batches for each burst build in the pilot phase to accommodate continuous improvement plans NOTE: Submission due date - preferred 2 weeks prior to MRD – First submission for each Pilot Phase must be complete before A Phase framing NOTE: Request 2 additional parts for each pilot phase to accommodate submission requirement

PART QUALIFICATION PROCESS PART NUMBER

SUPPLIER NAME

PART DESCRIPTION

MFG. LOCATION

MY/VEHICLE

SUPPLIER CODE

PART AVG. WEIGHT

SUBMISSION DATE:

SUBMISSION:

BUILD:

Supplier Completes Part Data Submission formRequirement of Submission prior to MRD PHASE:

FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC)

S1 / VP

PART QUALIFICATION

S2 / PVP

Phase A Phase B

PART INSPECTION STANDARD (PART I/S)

V1 / Job 1

Other

INITIAL PROCESS STUDY

Post-V1 / Post-Job 1

OTHER PROCESS:

TOOLING

ASSEMBLY PROTOTYPE

SPECIAL MEANS

PRODUCTION

TEMP LINE

Production Tooling Complete Date:

HOME LINE

YES

Home Line Complete Date:

NO

Special Means Not Required Date:

MEASUREMENT RESULTS S UMMARY Char #

Characteristic

Specification / Tolerance

Classif.

Variable / Attribute

• Metrology Center will notify supplier of Disposition • Green = Dimensionally Correct (< 75% of Tolerance) • Yellow – Dimensionally Correct (>75% and < 100% of Tolerance) • Red = Dimensionally incorrect - Quick Kaizen/PDCA needed with data submission • Metrology Center will notify supplier of Part Validation Meeting • Green Part = Metrology Center will notify supplier of next build phase submission and give approval for next batch build • Red Part = Suppliers corrective action will determine next submission (PDCA needed documenting plan)

Dim. 1 Correct?

PP

2

P PK

2

CP

3

CPK

3

Gage R&R ACC/REJ Acc?

Free State Fit

QAF

M eis ter bo ck

NOTES:

COMMENTS:

1

Parts shall be dimensionally correct for S1 / VP

2

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

3

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

Chrysler SQE/ASME

Phone

(

)

Email

Chrysler Plant QE

Phone

(

)

Email

Chrysler Engineer

Phone

(

)

Email

Plant Mgr. (Supplier)

Phone

(

)

Email

Quality Mgr. (Supplier)

Phone

(

)

Email

Data Prepared by:

Phone

(

)

Email

R /Y/ G

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

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

PART QUALIFICATION PROCESS

PART QUALIFICATION PROCESS Dimensional Compliance Team: -Product Release Engineer -Have the released model/GD&T up to date -Ensure CN is complete to document dimensional revisions

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

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

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

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

PART QUALIFICATION PROCESS Escalation Process: After 1 Day late Escalates to SQ Manager/Metrology Manager

After 3 Days

Escalates to Plant Manager , Director, and Plant Metrology Center Manager Level

After 5 Days

Escalates to VP level, Manufacturing , P & SQ, Engineering

PART DATA SUBMISSION FORM Data Sheet

PART DATA SUBMISSION FORM PART NUMBER

SUPPLIER NAME

PART DESCRIPTION

MFG. LOCATION

MY/VEHICLE

SUPPLIER CODE

PART AVG. WEIGHT

SUBMISSION DATE:

SUBMISSION:

BUILD:

Results sheet PHASE:

FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC)

S1 / VP

Phase A

PART QUALIFICATION

S2 / PVP

Phase B

PART INSPECTION STANDARD (PART I/S)

V1 / Job 1

Other

INITIAL PROCESS STUDY

Post-V1 / Post-Job 1

Form used to submit data for:

OTHER PROCESS:

TOOLING

ASSEMBLY P ROT OT YP E

SPECIAL MEANS

PRODUC TI ON

TEM P LINE

Production Tooling Complete Date:

HOME LINE

YES

Home Line Complete Date:

NO

Special Means Not Required Date:

MEASUREMENT RESULTS SU MMARY Char #

Characteristic

Specification / Tolerance

Classif.

Variable / Att ribute

Dim. Correct?1

P P2

P PK 2

CP 3

C PK 3

Gage R&R Build Use? Acc?

Free State Fit

QAF

M eis terbo ck

R /Y/ G

• • • •

FPSC Part Qualification Part I/S Initial Process Study

Information carried over from data sheet NOTES:

COMMENTS:

1

Parts shall be dimensionally correct f or S1 / V P

2

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

3

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

Chrysler SQE/ASME

Phone

(

)

Email

Chrysler Plant QE

Phone

(

)

Email

Chrysler Engineer

Phone

(

)

Email

CRAFTSMANSHIP REVIEWS

WHAT IS CRAFTSMANSHIP? INFLUENCES AND CONCEPTS

8 CRAFTSMANSHIP INFLUENCES

• Design: tolerance stackup, mating parts have different form (Eng) • AAR: colour, gloss, grain (PDO) • Appearance Standards: AS-10169, objective standard which must be met for conformance (Supplier) • Supplier Process: no spec, boundary samples required, flow lines, sink marks, squeezeout, etc. (Supplier, SQ) • HMI: human-machine interface, tactile feel of buttons and controls, sounds made while functioning, efforts to press buttons, etc. (All) • Chrysler Assembly Process: internal practices, mallet scuff marks, ISD, missing/loose/shy, etc. (Mfg) • Nonconforming Parts: (Supplier, SQ) • Cleanliness: smudge marks, dirt, dust, etc.(All) • What else?

Interior vs Exterior Craftsmanship Philosophies within Chrysler • Both follow the same principles • Interior – managed by dedicated Interior Quality and Craftsmanship department, interior SQE is part of team • Exterior – historically managed by SQ and started later in product development phase, craftsmanship reviews held during S2 timeframe

Exterior Craftsmanship Reviews Main areas of Concentration

• Appearance Standards: AS-10169, objective standard which must be met for conformance (Supplier) • Supplier Process: no spec, boundary samples required, flow lines, sink marks, squeezeout, etc. (Supplier, SQ) • Nonconforming Parts: dimensional issues, improper materials used, (Supplier, SQ)

CRAFTSMANSHIP FOLLOW UP

• Document results of review on PIS • Schedule follow up visits • Maintain craftsmanship PDCA • Ask for boundary samples during supplier visits to gauge current production • Maintain good communication between advance and current SQ post-review

PROCESS SIGN-OFF What is PSO? •

Verification that the AQP activities have been successfully completed

• A review of the Supplier’s process, from beginning to end

SupplierReadiness Evaluation (SRE)

Production Validation Phase

Verification of Process (VP)


Part Qualification Process (Assembly Plant Lead)

PV Testing

FirstProduction ShipmentCe rtification (FPSC)

Pre-PSO Meeting

PSO On-Site Visit & Production Demonstration Run

PSO Result

1-4 (N)

Complete corrective a ctions; reschedule On-Site Visit / PDR as necessary

5 (Z)

CompletePPAP requirements & submit Dimensional PSW/PPAP

5 + PVT (A)

PROCESS SIGN-OFF: BRIEF SUMMARY FOUR BASIC ACTIVITIES TO PSO: 1.Trial Runs / Supplier Readiness Evaluation (SRE) • Readiness for the PSO On-Site Visit • Yields parts for PV Testing

2.Pre-PSO Meeting • Document review • Evaluate SRE results • Schedule PSO On-Site Visit

PROCESS SIGN-OFF: BRIEF SUMMARY 3. PSO On-S On-Siite Visit sit •

Revi Review ew of Supp Suppli lier er’s ’s pro proce cess ss and and fac facil ilit itie ies s

•

Production Demonstration Run

•

Initial Process Study

4. PV Testing •

Functional testing, et. al.

•

Select component & system PV (Production Validation) level testing required by VP: •

•

Only that testing required to ensure the components function as intended, and which have been agreed upon between the supplier and the Chrysler Product Engineer at Production Design Clean-up (PDC), and documented in the Design Verification Plan and Report (DVP&R).

Concurrent with other PSO activities

MORE INFORMATION

F o r f u l l in i n f o r m a t i o n a n d t r a in in i n g o n t h e P r o c e s s S ig i g n - O f f , p l e as as e s i g n u p f o r PSQPSO200 in TEDS

PPAP PSO “Z” APPROVAL

•

•

Supplier can submit the dimensional PSW

SQE can enter the dimensional PPAP into CQMS

•

Receive partial tool payment (at the discretion of purchasing)

•

Still needs an IAA to ship parts

PSO “A” APPROVAL

•

Supplier can submit the full PSW

•

SQE can enter full PPAP into CQMS

•

Receive full tooling payment

•

Can ship parts normally

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

M ed i u m & H ig h r i s k p a rt s  SQE

reviews the PSW for proper information • Verifies correct part number, CN, IMDS number present, etc.

 SQE

enters PPAP dates & disposition into CQMS

L o w r i s k p ar t s  Supplier

enters PPAP dates & disposition into CQMS

CQMS - PPAP Submission Enter a Chrysler part number, click Find. Check box indicates row(s) to update. Enter dates as MM/DD/YYYY or use the calendar icon. The Disposition is required with Actual Dates.

CQMS - PPAP Mass Update Select an Update Element: Blank Promise Dates, Promise Due Next 30 Days, Not Approved or All. Enter a CN or enter a Supplier Code and CN Model Year. Click Find. Optionally enter a Commodity Code or a Deck Code (with Supplier Code and CN Model Year) for additional filters.

CQMS - PPAP Mass Update Check box indicates row(s) to update. Enter dates as MM/DD/YYYY or use the calendar icon. The Disposition is required with Actual Dates.

LESSONS LEARNED •

Ensure lessons learned from the current program are carried forward into new programs – Corrective actions for issues documented in FMEAs, Control Plans, etc. and added to the quality documents of other, similar products – Hold a “Things Gone Right / Things Gone Wrong” review meeting (30-60 days post launch) • Document TGR/TGW and retain in an accessible location • Review prior to beginning new programs – Review AQP meeting minutes and open issues from previous programs – Keep the Master PFMEA updated as issues occur

FOREVER REQUIREMENTS 1. Proactively communicate with Chrysler. Know when to raise the red flag. 2. Request approval from Chrysler p r i o r to implementing any anticipated process changes. 3. Request approval from Chrysler p r i o r to implementing any internal or Sub-Tier manufacturing location changes. 4. Watch for sub-tier Supplier issues and tell Chrysler about them. 5. Notify Chrysler of potential supply / capacity issues AQP/PSO 7th Edition Manual, Appendix E

FOREVER REQUIREMENTS •

Changes to the process post-PSO require submission to Chrysler via the Forever Requirements system

•

The Tier 1 Supplier is responsible to ensure all of their sub-tier Suppliers follow the Forever Requirements – Submissions to Chrysler always come from the Tier 1, regardless of what level of subtier is making the change

•

Full information and training on the Forever Requirements can be found in MQCFRR200, available through TEDS

AQP TIMING CHART

Group Activity – AQP Timing Chart scoring

SQ DELIVERABLES & TIMING SQ Deliverable Initial Risk Evaluation (IRE) Complete

Part I/S Parts Identified

Chrysler Product Creation Process (CPCP) Milestone N/A (Source Identified in CQMS + 2 weeks) 22 weeks prior to VP Start of Frame

PFMEA A ccepted [PFMEA]

14 weeks prior to VP Start of Frame

Part Inspection Standard (draft) [Part I/S (d)]

10 weeks prior to VP Start of Frame

Component-level Production Validation (PV) Testing Complete

VP - Verification of Process Build

Equipment, Fixtures, Facilities, and Gages Complete


First Production Shipment Certification (FPSC) Start


Gage R&R Complete [Gage R&R]


IMDS Subm itted


Production Tooling Complete [PTC]


Station Cycle Time / FTC Compliant



VP, PVP, & Job 1 Offline

Dimensional Capability Complete [Dim Cap]

PVP - Pre-Volume Production (Pre-Series)

Error / Mistake Proofing Implemented


Key Personnel Hiring/Training Complete


Produc tion Demon stration Run (PDR) Comp lete [PDR]


Produc tion Validation (PV) Testing Co mp lete [PVT]


PPAP Comp lete [PPAP]


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

Job 1 Offline

Shaded deliverables require promise and actual date entries into, or are managed through, the Chrysler Quality Management System (CQMS)

ADDITIONAL TRAINING Register through TEDS Process Sign-Off Forever Requirements / Resourcing Chrysler Quality Management System Advanced PFMEA Nonconformance Tracking System eCIMS Warranty Management 3 Legged 5 Why Part Inspection Standard

PSQPSO200 MQCFRR100 MQCQMS100 DQIFMA210 MQCNCT100 DQCZRO100 MQCSWM100 MQCTLW100 PSQPIS100

ADDITIONAL TRAINING Training CDs available • DQIFMA201 - PFMEA • DQISPC350 - Statistical Process Control • DQIPCA300 - Process Capability Analysis • DQIMPT300 - Error Mistake Proofing • DQICPD400 - Control Plan Development • DQIFMA275 - Design FMEA Contacts: Sheri De Hesselle

[email protected]

722-1370

Paula Mack

[email protected]

722-1370

QUESTIONS? P l ea s e v is i t t h e A Q P /P SO w e b s i t e f o r e le c t r o n i c v e r s i o n s o f t h e f o l lo w i n g : • The AQP/PSO 7 th Edition Manual • AQP Executive Summary and Open Issues forms (including the PTLR) • AQP Timing Chart

• PSO forms • FPSC form • Part I/S form • Appearance Approval form and instructions • Supplier PFMEA Audit Summary • Supplier Quality Deliverables Timing Requirements • Part Data Submission form

https://gsp.extra.chrysler.com/qlty/pso/index.html Suppliers can access through the Chrysler Portal “Reference” section of COVISINT

BACKUP

Special Notes for Chrysler SQEs Managing parts for FIAT

Chrysler SQEs Managing Fiat Parts Macro phases legend Approach / Style / initiative Approval / Sourcing Technical / Technological Development Industrialization Production Ramp Up Production – Tracking (6 months minimum) / Supplier Containment / Continuos Improvement

DaP = OK to Ship PSO = Process Sign-Off (w/ PDR) IRE = Initial Risk Evaluation PS = Pre Series CSE = Chrysler Source Evaluation TFU = Tooling Follow Up VP = Process Verification AQP TC = AQP Timing Chart Review SRE = Supplier Readiness Eval. FPSC = First Prod. Shipment Cert.



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

Card 0 Product Card

Main Deliverables Main Milestones SQ Tools

Qualification Samples - Selfqualific ation /PPAP (SQ) - Integrative tests (E&D) - Plant Approval (Plant)

Informative System VDDP IRE AQP TC

CSE

….

Pre-PSO

SRE

PSO

TFU - Start AQP TC 1m

FPSC 2m

5 - 6 months

Recommendation

VP Supplier Tooling Sign Off

2m

PS

Job1 DaP

> 6 months

9 - 10 months

1m

Commercial Launch

Fiat Sourcing Process Opening of the Sourcing Agenda

The Chrysler SQE is required to support the Fiat Sourcing Process in the same manner as Fiat SQEs Process steps requiring SQE involvement

Extraction to the Roll Out PACKAGES creation Input Check Key Stakeholders Meeting PRE-RFQ Input Check RFQ dispatch Quotation analysis Technical review Target setting Negotiation Recommendation

•102

Key Stakeholders Meeting (KSM)

•

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

•

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

•

It’s goal is to ensure that all the quotations received after the RFQ are comparable and compliant to the requirements

PRE RFQ - Supplier Preliminary Data Profile •

The SPDP is a survey where we ask a potential supplier to provide all the general information regarding its organizational size and structure

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

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

PRE RFQ - Quality Bid List

•

All the suppliers involved in the sourcing process shall be included in the Quality Bid List. If they are not, the SQE must complete a Business Case

•

The suitable suppliers will receive the RFQ from the buyer

•

An approved Business Case is requested for every new supplier, containing data about its Quality System, benchmarks for similar parts and the PSA (Chrysler personnel will use the CSE)

Chrysler Source Evaluation SCORING

Potential Supplier Assessment <60%

60-80%

>80%

<70%

70-90%

>90%

Source Evaluation Tool <60%

60-80%

>80%

<70%

70-90%

>90%

The new SE tool defaults to the standard part scores. In the future, we will add a box to check for safety components that will switch the formatting.

PRE RFQ - Quality Bid List

80 + = green (ok to bid) 60-79 = yellow (need SQ Sr. Manager or Commodity Manager’s (Chrysler) approval to bid) Below 60 = red (need SQ Director’s approval to bid)

PRE RFQ - Quality Statement of Requirements 



Goals of the QSR: 

Inform the supplier about Fiat quality requirements, including those special requirements linked to the part construction technology and/or the specific supplier



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



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

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

Technical Review 



Attendees 

Purchasing: Lead Buyer, SQE, TAG,



E&D,



Logistics: SCD



Technologies: (mandatory only in case of Stampings)

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

Technical Review procedure regarding the SQE 









The SQE receives the Quality SOR from the supplier and prepares related questions prior to the meeting, then verifies the agreement Any partial agreement from the supplier to our Quality SOR must be discussed and could result in the supplier’s exclusion from the subsequent stages Neither the buyer nor the SQE may accept any technical deviation from the requirements (e.g. Reliability targets, metrics like ICP and TOC, Customer profile) without the approval of the model Vehicle line Team/Platform When the RASI chart is required, the SQE takes care that the document is properly shared. Any deviation in the Technical documentation, with all the underlying risks, must be accepted under the approval of the MR only, with the updated documentation itself

Quality Risk Assessment QUALITY RISK ASSESSMENT Supplier Name: Part Number:

Supplier Code: Part Description:

Project: Supplier Quality Engineer: Buyer: Design Engineer:

ISSUE (OBLIGATORY FOR CONDITIONAL RATING)

ASSESSMENT CATEGORY 1.

New Process, Technology and/or Capacity

2.

Supplying Location

3.

Facilities/Equipment

4.

New Design Responsibility

5.

6.

7.

Commodity (C;E;M;P): Co-design? (Y/N):

Quality History Key Characteristics Mgt. (Important, Critical, Safety/Report & Legal) Quality Targets (PPM, IPTV, Quality Tracking ICP/TOC)

8.

Timing Concerns

9.

Program Management

10.

Other (SQE)

11.

Other (TAG)

RATING

ASSES SMENT #

A = Approved; C = Conditional; NS = Not Sourceable. A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable. A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable A = Approved; C = Conditional; NS = Not Sourceable

ASSESSMENT PARTICIPANTS:

DATE:

SQE (Surname & Signature)

TAG (Surname & Signature)

DATE:

Buyer (Surname & Signature)

Design Engineer (Surname & Signature)

Supplier Project Responsible – Name & Signature (Obligatory for Conditional Rating)

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

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

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

Key Characteristics Mgt. (Important, Critical, Safety/Report & Legal) used to manage key characteristics good for important characteristics, not used to S/R characteristics not used to manage key characteristics

Facilities/Equipment existing facility new addition/rearrangement to existing building new building new plant New Design Responsibilities carryover design customer is design responsible source is design & production responsible contract house is design responsible

Quality Targets (PPM, R/100, Quality Tracking ICP/TOC) It means how are the Supplier performances with respect to the targets Timing Concerns no timing concerns late release/source to plan PPAP/Qualificazioni late but before Material Required Date Full approval after start of saleable vehicles Program management past successful launches Advanced IP new source; unknown APQP program mgt ability launch problems/Launch Major Disruptions or Launch IP limited program management team capacity issues with past programs

Initial Risk Evaluation (IRE) • The IRE shall be completed within 1 month of the sourcing Recommendation 

Report the equivalent Monitoring Level to Fiat at this time, using the following chart: IRE Result Monitoring Level High Total Medium Partial Low



Document the part risk level from the IRE on the AQP Timing Chart; the IRE will NOT be added in CQMS SUPPLIER: SUPPLIER CODE: PART NUMBER(S):

PART NAME(S):

PART RISK (H/M/L):

ADVANCE Q TI CHRYSLER AQP STATUS

#NU

Advance Quality Planning (AQP) • The AQP Kick-Off Meeting shall be held within 1 month of the sourcing Recommendation. 

Complete the first revision of the AQP Timing Chart, including a status for each applicable task.



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

ADVANCE QUALITY PLANNING (AQP) TIMING CHART CHRYSLER AQP STATUS

#NUM!

FIAT PROGRAM REVIEW STATUS

#NUM!

Advance Quality Planning (AQP) General Notes: •

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

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

•

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

•

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

•

The Part Inspection Standard process is not applicable and not required for Fiat parts. Completion of a Part I/S is at the discretion of the Chrysler SQE (Fiat Assembly Plants do not currently follow the Part I/S process).

Using the AQP Timing Chart form

STATUS

RISK MITIGTION MITI GTION PLAN


Enter 1-5

S cor e

1 2 3 4 5

Chrysler Definit ion Incomplete/non-e Incomplete/non-exis xis tant; no recovery recovery pl an i n pla ce and Hi gh Ri s k to l a unc h Incomplete w/ inadequate recovery recovery pla n in pla ce or Hi gh Ri s k to l a unc h Incomplete w/ recovery plan in place or minor issues a nd Low ri s k to l a unc h Incomplete but progressi progressi ng accordi ng to plan w/ no or very mi nor i s s ues

FIAT Definition Job Stopper Job Stopper ri s k 2 nd Level I s s ue Pl a nned Ac ti vi ty a c cordi ng to P roj ec t

Using the AQP Timing Chart form ADVANCE QUALITY PLANNING (AQP) TIMING CHART CHRYSLER AQP STATUS

#NUM!

FIAT PROGRAM PROGRAM REVIEW STATUS

#NUM!

Includes only the 29 tasks shown below

Tasks used in calculating the FIAT Program Review status: Advance Advance Quality Quality Planning Planning

Test Sample Sizes and Frequencies

Confirm composition and commitment of Core AQP Team Members

Confirm Supplier PPAP Self-Certification status


Process FMEA Process Flow Diagram & Mfg. Floor Plan


Control Plan and Process Monitoring

Prior PSO Review (similar products) products)

Incoming Incoming & Outgoing Material Certificati Ce rtification on Plan

Verify deliverables deliverables timing to CPC P timing

Operating Instructions

Status of Open Issues from Technical Review Risk Assessment (FIAT (FIAT parts only only)) Part Number, Description, and Change Level Design Model S tatus tatus review Design Review - C ustomer Perception targets targets Production Tooling Complete (PTC)

Non-Chrysler Suppliers will not have this; for Fiat parts, verify the Supplier ’s testing facilities have been appropriately certified.

Special Characteristics Identified and FPSC Error and Mistake Proofing Production D emonstration Run Parts Packaging and Shipment Specifications

Use this task to track Fiat SelfQualification and Integrative testing

Gage and Test E quipment Evaluation Evaluation

TAG Review (Chrysler-purchased tooli ng only) only)

Production Validation Testing Complete

Review CNs and IAAs (including (including associated Risk)

Part Qualification Process (PQP)

Use this task to track Fiat Benestare and matchability

Chrysler

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