Supplier Assessment Form New

Supplier
Supplier Quality
Quality &
& Techinical
Techinical Assesment
Assesment
Guidelines
Guidelines for
for Conducting
Conducting Assessments
Assessments
The
TheSupplier
SupplierAssessment
Assessmentisisto
tobebeaaprocess
processassessment
assessmentandandshould
shouldaccurately
accuratelyreflect
reflectthe
theSupplier's
Supplier's
actual
actualmanufacturing
manufacturingand andquality
qualityprocesses,
processes,as
asevidenced
evidencedononthe
themanufacturing
manufacturingfloor.
floor.The
TheAssessment
Assessment
should
shouldvalidate
validatethat
thatthe
theday-to-day
day-to-dayoperations
operationscomply
complywith
withthe
therequirements
requirementsdetailed
detailedininthe
theAssessment.
Assessment.
ItItisisinsufficient
insufficientfor
foraaSupplier
Supplierto
tohave
havedocumented
documentedprocedures
proceduresonly.
only.
Recognizing
Recognizingthatthatsome
somesuppliers
suppliershave
havethe
thecapacity
capacityto
toprovide
providemultiple
multiplecommodities,
commodities,ititisisencouraged
encouragedthat
that
the
theappropriate
appropriatetechnical
technicalassessment
assessmentbebecompleted
completedininparallel
parallelwith
withthe
thequality
qualityassessment
assessmentportion.
portion.There
There
isisalso
alsoaa"Quick
"QuickAssessment"
Assessment"worksheet
worksheetthatthatcan
canbebecompleted
completedas aspart
partof
ofaageneral
generaloverview
overviewor orvisit
visitof
ofaa
supplier's
supplier'sfacility.
facility.Recognizing
Recognizingthat
thatthis
thisisisaavery
verygeneral
generaloverview
overviewonly,
only,aadetailed
detailedquality
qualityand
andtechnical
technical
assessment
assessmentshould
shouldalways
alwaysbebecompleted
completedprior
priorto
toaward
awardofofnew
newbusiness,
business,substantial
substantialincrease
increaseofofexisting
existing
business
businessororininresponse
responsetotopoor
poorsupplier
supplierperformance
performanceand/or
and/orelevated
elevatedrisk.
risk.
For
Foreach
eachaudit
auditsection,
section,the
therequired
requiredevidence/documentation
evidence/documentationisisdescribed
describedon onthe
theAssessment
AssessmentForm.
Form.The
The
Assessor
Assessorshould
shouldalso
alsouse
usethe
the"Observations
"Observations&&Notes"
Notes"field
fieldto
tohelp
helpclarify
clarifyand
andexplain
explaintheir
theirfindings.
findings.AA
"High",
"High","Medium"
"Medium"or or"Low"
"Low"Risk
Riskstatus
statuswill
willautomatically
automaticallybe
begenerated
generatedby bythe
thescore
scoreassigned
assignedtotoeach
each
element.
element.The
TheSummary
SummaryScore
Scorefor
foreach
eachparticular
particularelement
elementofofthe
theOperational/Quality
Operational/Qualityportion,
portion,will
will
automatically
automaticallybebereflected
reflectedon
onthe
theAudit
AuditCover
CoverPage
Pageand
andthe
thetotal
totalnumber
numberof ofhigh
highrisk
riskelements
elementswill
willbe
be
shown. The risk summaries for each Quick and Technical assessment completed, should
shown. The risk summaries for each Quick and Technical assessment completed, should be manually be manually
entered
enteredononthe
thecover
coverpage,
page,as
aswell.
well.
All
Allareas
areasassessed
assessedasasHigh
HighRisk
Riskmust
musthave
haveaadefined
definedCorrective
CorrectiveAction
ActionPlan
Plandetailed,
detailed,asaswell
wellas
asdates
dates
defined for completion, prior to award of any new business. Aside from the "High" risk
defined for completion, prior to award of any new business. Aside from the "High" risk elements, elements,
corrective
correctiveaction
actionshall
shallbe
beat
atthe
thediscretion
discretionof
ofthe
theAssessor.
Assessor.The
Thegoal
goalofofCorrective
CorrectiveAction
Actionisistotoeliminate
eliminateall
all
"High" risk elements in addition to attaining a minimum score of 80% for each audit
"High" risk elements in addition to attaining a minimum score of 80% for each audit section. Thesection. The
"Corrective
"CorrectiveAction
ActionPlan"
Plan"contained
containedwithin
withinthe
theAssessment
Assessmentfile,
file,shall
shallbebeused
usedtototrack
trackall
allcorrective
correctiveaction
action
activity.
activity.
Subsequent
Subsequentfollow-up
follow-upactivity,
activity,and
andsubsequent
subsequentAssessments
Assessmentsto tovalidate
validateimplementation
implementationofof
Corrective
Corrective Action, shall be the responsibility of the originating Magna Groupand
Action, shall be the responsibility of the originating Magna Group andSupplier
Supplier
Quality/Development
Quality/DevelopmentEngineer,
Engineer,andandmust
mustbebeinitiated
initiatedwith
withthe
theaward
awardofofbusiness,
business,at
atthe
the
latest. If the Assessing Group does not source business with the Supplier, development
latest. If the Assessing Group does not source business with the Supplier, development
activity
activityshall
shallbecome
becomethetheresponsibility
responsibilityof
ofthe
thesourcing
sourcingGroup/Division,
Group/Division,asasdefined
definedby
bytheir
their
Business Rules
Business Rules. .
ItItisisat
atthe
thediscretion
discretionof ofthe
theparticular
particularMagna
MagnaGroups
Groupsto
tobase
basesourcing
sourcingdecisions
decisionson onthe
thefinal
finalscore
score
attained.
attained. Each Groups' Business Rules shall define the selection criteria to be used. Theaim
Each Groups' Business Rules shall define the selection criteria to be used. The aimofofan
an
Assessment
Assessment is not simply the generation of a score. The ultimate aim is to identify and addressareas
is not simply the generation of a score. The ultimate aim is to identify and address areasof
of
systemic failure driving undue risk to our Groups and Divisions, and therefore proper
systemic failure driving undue risk to our Groups and Divisions, and therefore proper resolution and resolution and
360520998.xlsx
closure
closureof of"High"
"High"risk
riskitems,
items,isiscritical.
critical.
Assessment
Assessmentresults
resultsare
arefor
forsite-specific
site-specificmanufacturing
manufacturingfacilities.
facilities.IfIfaasupplier
supplierhas
hastwo
twoor
ormore
more
manufacturing locations, all locations require a separate Assessment.
DATE OF
SUPPLIER ASSESSMENT AUDIT:
SUPPLIER NAME: Supplier Contact Name:
Supplier Contact Postion:

ADDRESS / CITY
/ STATE
Supplier Contact Phone:
FAX NUMBER: E-Mail Address
REASON FOR/TYPE AUDIT QUALITY / DELIVERY ISSUES NEW BUSINESS QUICK ASSESSMENT
ANNUAL ASSESSMENT FOLLOW-UP ASSESSMENT TECHNICAL ASSESSMENT
CUSTOMERS (AUTOMOTOVE): Customer PPM (YTD Avge.)

Previous Year PPM
Union Facility YES If Yes, Contract Expire:

NO
TS 16949 CERTIFICATION ISO 9001:2000 CERTIFICATION VDA/Other CERTIFICATION ISO 14001 CERTIFICATION
Certification EXPIRY DATE Certification EXPIRY DATE Certification EXPIRY DATE Certification EXPIRY DATE
YES YES YES Yes
NO NO NO NO
Has Certification ever been revoked? YES If Yes, State Reason:

NO Supplier has Liability Insurance? Y N
CQI Compliant? N/A Yes No CQI #: Next Assessment:

CQI #: Next Assessment:
PRODUCT FOCUS FOR ASSESSMENT
MAGNA PLANTS
SUPPLIED:
FULL OPERATIONAL/QUALITY ASSESSMENT RESULTS (Optional Comments)

Major Strengths of Organization:
0
10
79
80 1)
2)
60
3)
40
19
12
20
10
10
9
8
7
Major Concerns of Organization:

4
0 0 0 0 0 0 0 0 0 0
1)
2)
3)
QUICK/TECHNICAL ASSESSMENT RESULTS Level of Risk Observed Assessment Completed By:
TYPE COMPLETED: Name:

Completed by: Group:
(enter total number of elements at each risk level) E-Mail:
Phone:
Approvals (if required by Group):
Quality Purchasing Program Management
Name:
Title:
Signature:
360520998.xlsx Cover Sheet

Supplier Assessment Detailed
NOTES:
1. If a particular element is currently "N/A" (not applicable) and there is no curren
SUPPLIER ASSESSMENT FORM 2. If a particular element is currently "N/A" but there is the potential of future risk
General Organization and Management

Structure High Risk
No. ITEM 0
No formal organization chart.

Is the Management structure and Resource allocation Critical functions open.
1
sufficient to support all necessary disciplines
No formal health & safety program in effect

Lack of guarding and other safeties
Workplace Health and Safety practices are in place and Lack of cleanliness and organization
2
are consistently adhered to
No evidence of communication to employees

Does Management regularly communicate key No formal suggestion program in place
3 operational and performance information to all
employees
No formal continous improvement program

Management defines quality and performance Lack of key performance metrics
objectives that promote Continuous Improvement. Key
4
metrics should include all elements of the business and
establish target values.
No formal job descriptions at any level

Lack of evidence to support training
Responsibilities and authority are defined and evidence
5
supports effective employee training
360520998.xlsx 3 of 108
NOTES:
No awareness of customer requirements

Management has sufficient resources to effectively No evidence of training
manage Customer Requirements. Planning includes Lack of resources to support customer
6
sufficient resources that are trained and qualified and
meet planning requirements?
No formal LPA process

Does Management conduct regular internal process
7 audits (Layered Process Audits) that ensure compliance
to Customer requirements?
No formal process in place
Process to ensure detailed Contract Review, including

8
Design and Capability review
No formal process
Does the organization have a process, charter or Unaware of requirements
9 system to ensure the presence of acceptable global
working conditions in all its operations?
360520998.xlsx 4 of 108
NOTES:
Advanced Product Planning

High Risk
No. ITEM 0
No formal or documented system in place

Evidence of sporadic reviews
Does the Supplier have a process for managing No design or manufacturing feasibility studies
1 Advance Quality activity and sufficient resources to
manage activity?
No records of program reviews

Does this Supplier's APQP Plan include scheduled
formal Design Reviews, Management Reviews,
2
Program Reviews, etc with their Customer and
internally?
No electronic capability to communicate (eg. IGIS,

Does the Supplier have the capability to communicate Unigraphics, CATIA, ProEng etc.)
3 Product design and Engineering Data with Suppliers
and Magna?
No system or process to review packaging

requirements
Does this Suppliers APQP process / system include the No internal resources responsible
4
review of the customers packaging requirements?
No system or process to validate equipment

No evidence of run at rate studies
Does the Supplier conduct equipment validation and
5
performs run at rate in preparation for production?
360520998.xlsx 5 of 108
NOTES:
No system to ensure verification of material at start

Does the Supplier have a documented 'Safe-Launch' of program launch
6 plan? Does it include pre-first-shipment containment
and verification before any product is shipped?
No formal system to track changes and ensure

Does the Supplier have a defined process to control changes are managed through entire system
and react to changes impacting upon Product
7
Realization? Are key process characteristics identified
and capability tracked?
No focus on mistake proofing or error prevention

Focus is on detection and reliance on operators
Mistake-proofing and error-proofing used to control
8
critical characteristics and ensure product integrity?
Process Flow Diagram and actual production flow

do not match
Does this Suppliers Process flow diagram match the
9
actual production flow laid out for this facility?
No linkage between FMEA's, Control Plans and

Process Flows
Does this Suppliers FMEA's and Control Plan's match
10
the Process Flow diagram?
No tracking of critical and special characteristics

Does the FMEA include critical and/or significant
11 characteristics as well as all supplier identified Key
Characteristics?
Total or significant lack of risk numbers on FMEA's

Are Supplier FMEA's risk numbers for severity,
12 occurrence, and detection based on historical /
statistical data?
360520998.xlsx 6 of 108
NOTES:
No linkage between RPN's and mistake proofing

Are the mistake proofing opportunities initiated to
13
reduce high RPN numbers noted on the control Plan?
No reference to gauges, test equipment or test

frequency on control plans
Does the control plan identify all gauges and test
14 equipment required for inspection? Including test
frequency?
Are Work Instructions for all employees affecting No work or operator instructions posted, or
15 product quality, including for repair and re-work significant lack of instructions
operations available and posted?
No start up procedures defines
No evidence of start up controls - such as first-
Are controls in place to verify process start up and job piece, containment etc.
16
change-over?
No tracking system in place

Does the Supplier have a process to track PPAP
17
performance with the Customer and from Suppliers?
No documented system of communication in place

Does this Supplier have a process / system in place to
18 ensure that all design requirements / engineering
specifications are communicated to their supply base?
No documented system to qualify suppliers

Is there a process to ensure Tier Supplier product is No documented system to communicate critical
controlled to ensure compliance? Are all requirements characteristics
19
for safety critical characteristics clearly communicated
to all sub-suppliers?
360520998.xlsx 7 of 108
NOTES:
360520998.xlsx 8 of 108
NOTES:
Quality
High Risk
No. ITEM 0
Is this Supplier ISO or TS registered ? Are they current Supplier has no certifications at present
with their surveillance audit schedule?
1
Is this Supplier current to their internal audit schedule No formal internal schedule of review
including corrective actions for all findings?
2
Does this Supplier have a process / system in place to Multiple examples of posted documents not current
3 ensure that all product documentation reflects the to revision level for selected part(s)
current revision level?
Noticeable lack of formal process
Focus only on external issues
Multiple open issues and/or late responses
Does the Supplier have an effective Problem Resolution No cross-functional approach
4 process? Does the system address customer and
internal issues?
Does this Supplier have a process / system to identify Suspect material not clearly identified
and segregate non-conforming material at each phase Suspect material at production cells, with high
of the production process? potential for mix
5 Lack of effective containment process
360520998.xlsx 9 of 108
NOTES:
Lack of or poorly managed system

Multiple fixtures/gages with outdated calibration
Is there a system to identify, qualify and control Gages/fixtures not referenced on Control Plans
6
Measuring and Test Equipment?
Lack of instructions
Are Operators trained and qualified for any required Lack of operator training documentation
measurement and tests, including use of appropriate Missing, or no SPC where required
7 statistical techniques? Are there posted instructions
detailing inspection, test, SPC, work requirements and
re-work instructions at every station?
Are all inspection gauges and fixtures stored in a Evidence of gages/fixtures inappropriately stored
8 manner that protects them from environmental and / or and/or susceptible to damage
handling / storage damage? No designated storage
Does the supplier have sufficient internal capability and Significant lack of internal capability
equipment to ensure customer performance and High reliance on external sources
9 specification criteria can be met?
Does this Supplier have a process / system to measure No formal system in place
and track external quality performance with their
customers?
10
Does the supplier have a record retention process that No formal document retention system
ensures all necessary test, inspection and safety critical
records are retained for period as defined by the
11 Customer?
360520998.xlsx 10 of 108
NOTES:
Has this Supplier identified all of the special processes No, or minimal control over out-sourced processes
that will be required? Will any of these special
12 processes require outsourcing? Are additional controls
in place to manage outsources services?
360520998.xlsx 11 of 108
NOTES:
Materials and Logistics High Risk
No. ITEM 0
No formal system to ensure receipt/validity of

Does the Supplier have a documented system to customer releases
ensure receipt of Customer schedules and
1
requirements?
Does the supplier have a formal process to plan Poor inventory management system
material flow into and through the plant? Are materials No apparent flow to material movement
and components stored, packaged and transported so High risk of damage to materials & components
as to protect them from dirt and damage?
2
Does this Supplier have a material lot traceability No, or very minimal traceability evident
system?
3
Does the supplier have a system / process to validate No verification of materials prior to shipping
the contents, label accuracy, and quantities of all
containers shipped?
4
360520998.xlsx 12 of 108
NOTES:
Is there a process to manage the material ordering No apparent link between customer orders and
activity to ensure an adequate supply of raw material / orders/receipts of purchased materials
lower level components are available to meet
production requirements? Are all delivered and/or
5
surplus materials stored in packaging and conditions so
as to prevent damage or mix?
Does this Supplier have processes / systems in place to No evidence of min/max values set
confirm and manage inventory levels? No regular cycle or inventory counts
6
Does the supplier utilize off-site warehouses? If so, is Off-site warehouses used
inventory tracked? Are cycle counts conducted? No visible controls in place
7
Is the supplier capable of meeting AIAG labeling AIAG labelling requirements not being met
requirements as defined in Supplier Guidelines?
8
Does the Supplier utilize Advanced Shipping Notice's Supplier does not issue ASN on regular basis, or
(ASN's)? Does the supplier verify the ASN to the Bill of issues in excess of 30 minutes prior to shipment
9 Lading, and the customers order?
C-TPAT and PIP Security Compliance Program Supplier completely unaware of requirements
10
360520998.xlsx 13 of 108
NOTES:
Facilities & Tooling High Risk
No. ITEM 0
Does this supplier have a process / system to recertify No formal process or procedure in place
a tool after repair but before production is scheduled?
1
Does the supplier have a tooling database to track and No database or formal tracking system for tools
manage tooling?
Is all Tooling being stored in a location that is protected Lack of designated storage for tooling
from environmental / handling damage?
3
Does the supplier conduct a Tooling inventory and No regular inventory

compare the results against the Tooling database?
4
Is there a system to track new tooling on order to No formal review process in place
support Customer schedules and targeted
5 implementation dates?
360520998.xlsx 14 of 108
NOTES:
Does the supplier have a formal Preventive No formal preventive maintenance plan in place
Maintenance management system at this facility? Does
it include all production equipment, Tooling and
6 supporting fixtures? Can it track specific Tools? Is
maintenance completed per schedule?
Very little or no knowledge of capacity available
Does the Supplier have a process to monitor tooling

7
and equipment capacities?
360520998.xlsx 15 of 108
NOTES:
Purchasing High Risk
No. ITEM 0
Supplier lacks internal expertise on product or

Supplier capability/competency for existing and quoted process technology to support Magna business
1 Magna business. Magna represents >50% of supplier's overall
business
Does Magna face undue risk by entering / increasing Supplier is a direct competitor to Magna, with
2 business with this Supplier as a result of the share of same OE Customer base
business they do with other OEMs?
Does this Supplier have a process / system to track and No system in place to track quote response
manage RFQ's to ensure that quotes are submitted by No system to ensure cross-functional review
3 the requested due date?
How does this Supplier communicate customer No formal process in place

4 requirements (drawings, specifications, etc) to their Primary method of communication is verbal
suppliers during the quoting process?
Is this Suppliers facility unionized? If yes, what union Supplier is unionized
represents the bargaining unit? When does the current Contract expiry is in <3months
5 contract expire? No contingency planning in place at this time
Is this Supplier's facility owned or leased? Is it Inadequate coverage for damage or loss
adequately protected from catastrophic loss due to Fire, No coverage on customer owned tooling or
6 Flood, etc? Does the insurance coverage include equipment
customer owned goods and/or equipment?
Does the Supplier have access to required Magna No knowledge of websites or available resources
7 websites? Does the supplier understand what
information is available on applicable websites?
360520998.xlsx 16 of 108
NOTES:
Does this Supplier have a process / procedure for the No formal procedure for selection of suppliers
selection, qualification, approval, and management of No, or minimal tracking of supplier performance
their supply base?
8
Does this Supplier have a process / system in place to No formal system in place
disqualify their suppliers based on performance? Supplier performance not monitored or,
No reaction to poor supplier performance
9
NAFTA and Customs Compliance process No internal resources with appropriate knowledge
of NAFTA
10
360520998.xlsx 17 of 108
NOTES:
Operations High Risk
No. ITEM 0
From an overall perspective, is this Suppliers facility Poor housekeeping practices

clean, well maintained and organized both inside and No evidence of 5S principles in place
outside? Is there a formal 5S and lean manufacturing Risk to employees health & safety
process in place?
1
Does this Supplier have a formal capacity plan and Supplier has no formal capacity review or planning
analysis methodology? Is it being used, are reports available
current?
2
Does this Supplier have a process / system to track and No formal process to track scheduled or
manage scheduled and unscheduled downtime for this unscheduled downtime
facility?
3
Does this Supplier have documented / published No formal process in place to track performance of
performance goals, Key Performance Metrics, for this key measurables and drive improvement
4 facility? How is the supplier performing to these goals?
360520998.xlsx 18 of 108
NOTES:
Does this Supplier have an up-to-date plant layout that No layout or mapping of production flow, available
shows current product flow?
5
Is there a formal defined safety program? No formal safety program in place

Elevated level of risk for employees
6
Is there a process to address absenteeism? No formal tracking of absenteeism
Does this Supplier have a process / system in place to No formal training program
train new employees?
360520998.xlsx 19 of 108
NOTES:
Engineering
High Risk
No. ITEM 0
Does this Supplier have the latest Customer drawings No formal tracking system in place
and specifications for all parts in the program? Does the Informal system in place but high potential for
system ensure drawing/specifications are at the latest obsolete drawings/specifications in the system
1 level?
If required by Customer and/or Government regulations No system to track validation requirements

is there proof of annual recertification testing and
compliance to DOT regulations, FMVSS standards,
PPAP submission, etc.
2
Is the electronic design program (software) used by the Supplier unable to communicate engineering data,
supplier (with design / Tool design responsibilities) internally
3 appropriate and compatible with Magna systems?
360520998.xlsx 20 of 108
NOTES:
Does this supplier have a system to manage and track No formal system in place, or informal system
Engineering Changes and Deviations? allowing high chance of error
360520998.xlsx 21 of 108
N/A" (not applicable) and there is no current risk to Magna, enter score of "3" for that element and add a note of explanantion in the "Notes" s
N/A" but there is the potential of future risk to Magna, enter score of "2" for that element and add a note of explanation in the "Notes" section
Score
Moderate to High Risk Low to Moderate Risk
1 2
Organization chart in place. Organization chart in place.

Some functions open - critical positions filled Some functions open - critical positions filled
Plans to secure additional resources
Safety program in place Safety program in place

Inconsistent application of health & safety rules Generally consistent application of health & safety
Lack of cleanliness and organization rules
Plant is generally clean and organized
Some evidence of communication to employees Consistent evidence of communication

Evidence of customer requirements communicated Key Customer performance indicators reviewed
to employees regularly
Employee suggestion program in place
Evidence of continuous improvement program Evidence of continuous improvement program

Key operational metrics identified Key operational metrics identified
Evidence of regular management reviews
Job descriptions for all production functions Job descriptions for all levels of the organization
Evidence of training for production functions Evidence of training at all levels
360520998.xlsx 22 of 108
Aware of customer requirements Aware of customer requirements

Some level of support in place to support Customer support availabel in language of
Customer and available for 24 hrs as needed
No formal process Formal process in place

Some evidence of layered audits Evidence of audits completed
No formal process Formal process in place

Some evidence of design or contract reviews Evidence of contract reviews
Evidence of review & understanding of Key/Critical
characteristics
No formal process or procedure Formal process in place to ensure global working

Evidence of internal systems to ensure health & conditions internally
safety, competitive wages, working conditions etc
Total High Risk elements for General Organization and Management Structu
360520998.xlsx 23 of 108
Score
1 2
Documented system in place Documented system in place

Evidence of systemic reviews Evidence of systemic reviews
Proper feasibilities completed Proper feasibilities completed
Evidence of cross functional teams
Documented procedure for program reviews Documented procedure for program reviews
some records of completed program reviews Records of completed program reviews
Inconsistent or no tracking of open issues Open issues tracked
Some electronic capability Some electronic capability

Unable to support all customers electronically Use outside/contract source, as necessary
Unable to support all customers electronically
No review of packaging unless driven by the Process to ensure review and approvel of
cusomer packaging
Limited or no internal knowledge/resources Sufficient internal knowledge/resources
Evidence of equipment validation prior to start of Evidence of equipment validation prior to start of
production production
No evidence or limited evidence of run at rate Evidence suggests run at rate conducted in most
studies to verify meeting capacity requirements situations, but lack of formal process
360520998.xlsx 24 of 108
Evidence of some containment in place, but only Product containment plan is defined as part of
on a limited basis program launch process
Supplier only implements containment when Production control plans used - no pre-launch
directed by the Customer plans
Changes are tracked but lack formal system to Formal change management system in place
ensure documentation is updated, accordingly All changes assessed for impact on product and
Not all changes are officially managed system
All affected documentation updated
Heavy reliance on operators, but some focus on Significant focus on error prevention
automated error detection High use of mistake proofing in manufacturing
process
Process flow and manufacturing basically match, Process flow and manufacturing process match
but some out of sequence steps noted but inspection points out of sequence
Process Flow and Process Control Plan match, but Process Flow and Process Control Plan match and
no obvious link to FMEA's evident match to FMEA's
Criticial characteristics are tracked Critical/Special characteristics tracked consistently

Control is focussed on product only, not process on FMEA, PCP, PFD, Instructions etc.
Required statistical controls in place
Risk numbers assigned on FMEA's, but no evident Risk numbers assigned on FMEA's
linkage to customer requirements Risk numbers linked to customer requirements
360520998.xlsx 25 of 108
Evidence of improvements to mistake proofing, but Evidence of link between addition of mistake
no visible link to RPN's proofing and reduction plan for RPN's
Control plans identify required gauging, test Control plans identify required gauging, test
equipment and frequencies equipment and frequencies
Only minor exceptions noted No visible exceptions noted
Work instructions posted or available for operators Work instructions posted or readily available
No rework/repair instructions Repair/rework instructions posted or available
Instructions do not match level of Control Plans
Start up process defined Start up process defined
First-off samples available at all appropriate First-off samples available at all appropriate
operations - some exceptions noted operations - no exceptions noted
System in place to track Customer PPAP System in place to track Customer PPAP
submissions submissions
Evidence of some PPAP samples available Evidence of all PPAP samples available
Process in place to communicate design Process in place to communicate design

requirements and engineering specifications to requirements and engineering specifications to
suppliers suppliers
Minor exceptions noted No exceptions noted
No documented system to qualify suppliers Documented system to qualify suppliers

System in place to communicate critical System in place to communicate critical
characteristics to suppliers characteristics to suppliers
360520998.xlsx 26 of 108
Total High Risk elements for Advance Product Planni
360520998.xlsx 27 of 108
Score
1 2
Supplier has minimum of ISO certification Supplier has all applicable certifications, including
Lacks TS/VDA certification ISO, TS, VDA, CQI - as applicable
No formal schedule of review Formal schedule of review over 12 month period

Some evidence of completed internal audits Evidence of audits completed on schedule
Documented system in place Documented system in place

Several documents posted not current to revision Only one or two documents posted not current to
level revision level
Documented procedure Documented procedure
Issues addressed in timely manner Timely response to internal & external issues
Lack cross-functional approach Cross functional approach used
Suspect material identified but not properly Suspect material clearly identified & segregated
segregated Effective containment process internally, at
Some evidence of containment in place suppliers and at customer(s)
Lack of or poor system to verify final disposition of No evidence of signatures detailing disposition
all suspect material and/or lack of secure containment area
360520998.xlsx 28 of 108
Formal, but manual system in place Formal automated system in place

Very few, or no fixtures/gages past due System generates reminders of calibration due
Fixtures and gages referenced on control plans No evidence of past due calibrations
Fixtures/gages referenced in control plans
Evidence of effective GR&R on all gages
Gage instructions in place, as required Operator gage instruction in place

Evidence of some training records Operator training records available and current
Some use of SPC, but possibly inconsistent SPC data current, where required
Re-work gage instructions missing or not posted
Storage has been designated but is insufficient Adequate storage for gages/fixtures
Medium to high potential for damage Some, but minimal opportunity for damage
Sufficient resources to monitor most dimensional Internal resources can support dimensional and
and material specifications material requirements
Some reliance on external sources Some performance or specialty requirements are
sourced externally
Some customer performance measures in place System in place to track external quality
Some customers have no performance data All customers are tracked but, some customer
performance data not current
Some corrective actions not addressed in timely
manner
Document retention system in place Document retention system in place

Records not easily retrievable Records easily retrievable
No system to ensure timely destruction of No system to ensure timely destruction of
documents, as per legal or customer requirements documents, as per legal or customer requirements
Records not protected from damage Records protected from damage
360520998.xlsx 29 of 108
Sub-tier suppliers have at least partial evaluation Sub-tier suppliers evaluated prior to sourcing
prior to sourcing Performance of sub-tiers monitored regularly
No regular performance reviews No detailed records of review of requirements prior
to sourcing
Total High Risk elements for Qual
360520998.xlsx 30 of 108
Score
1 2
System in place to receive customer orders, but no System in place to receive and verify customer
verified back up system orders
No regular tracking of delivery performance Regular monitoring of delivery performance
Back up system for receiving orders but system is
not tested regularly
Material flow sufficient, from receiving through Good material flow throughout manufacturing
manufacturing and shipping facility - no apparent bottlenecks
Evidence ofsome material congestion in places Material identified at all stages of the process
No apparent FIFO System in place to monitor inventory levels
Potential for material damage Lacking evidence of effective FIFO
Traceability on finished product but lacking on raw Full material traceability on raw and finished
materials and components materials
Maximum period of traceability is >8 hours, or one
shift
Traceability indicated on shipping labels
Validation prior to shipping is limited to verification System in place to verify shipments, but limited to:
of part number, only - part number
- part quantity
360520998.xlsx 31 of 108
Raw materials/components inventories tracked Raw materials/components tied to customer

and ordered according to min/max values releases
No linkage to customer orders or releases Storage sufficient to prevent damage or mixing
System in place to provide warning for low
inventories
Min and max values set on inventory Min and max values set on inventory
No inventory counts conducted on regular basis Inventory counts conducted on regular basis
Off-site warehouses used No off-site warehouse used, or

Regular counts of inventory received, but not Warehouse used but regular inventory counts
validated regularly monitored
Warehouse protects agains damage or loss
AIAG standard met only when demanded by Labelling meets AIAG requirements
Customer All shipped material meets AIAG standard
Customer approval not obtained prior to shipping
Supplier almost always issues ASN but at times in Supplier issues ASN for all shipments
excess of 30 minutes prior to shipment ASN issued at maximum of 30 minutes prior to
shipment
Supplier notified of need to comply (by division) Supplier working on compliance with division
Minimal progress towards compliance Supplier on track with timing to achieve
compliance
Total High Risk elements for Materials& Logisti
360520998.xlsx 32 of 108
Score
1 2
Documented system to qualify tool/fixture repairs Documented system to qualify tool/fixture repairs
No formal sign off procedure System ensures sign off by qualified personnel
Adequate tracking system for tooling Adequate tracking system for tooling
Missing asset tags on tools Customer ownership validated via asset tags
Tool maintenance records missing or not available Tool maintenance records maintained and
at all available for review
Designated storage for tooling Designated storage for tooling

Storage allows for damage from environment or Storage protects against damage from
handling environment or handling
Regular inventory completed at a prescribed Regular inventory completed at a prescribed

frequency frequency
Inventory matched to customer asset records
Documented system to track tooling orders Documented system to track tooling orders
Minimal evidence of customer updates Tooling tracked to implementation timeline
Evidence of customer updates
360520998.xlsx 33 of 108
Preventive maintenance in place Evidence of an effective preventive maintenance

Maintenance driven by tooling/equipment program in place
downtime Records validate maintenance occurs as
Maintenance includes production tooling, scheduled
equipment and fixtures
Supplier has knowledge of available capacity Supplier has knowledge of available capacity
Capacity forecast driven by high level factors such Evidence of current capacity studies on equipment
as floor space, total hours available
No detail on equipment capacity
Total High Risk elements for Facilities & Tooli
360520998.xlsx 34 of 108
Score
1 2
Supplier has full technical capability to support Supplier has full technical capability to support
Magna business Magna business
Magna represents >35% but <50% of supplier's Some secondary processing out-sourced
overall business Magna represents >35% but <50% of supplier's
overall business
Supplier is a direct competitor to Magna, but with Supplier is competitor with Magna, but with
different OE Customer base different technology and/or products
Cross functional team reviews quotes for feasibility Cross functional team reviews quotes for feasibility
No formal tracking system in place Formal tracking system in place
Formal RFQ/SOW sent to suppliers Formal RFQ/SOW sent to suppliers

Suppliers asked to sign off on feasibility
Supplier is unionized Supplier is unionized

Contract expiry is in 3-6 months Contract expiry is in 3-6 months
No contingency planning in place at this time Contingency planning in place at this time
Facility on long-term lease Facility on long-term lease

Some insurance but likely inadequate to cover full Proof available to verify adequate insurance
loss Customer owned capital insured (Bailee Bond)
Some, but minimal knowledge of websites Full knowledge of Magna and/or Group website
Limited or no use of sites as directed by division
360520998.xlsx 35 of 108
Procedure defines selection of supplier Procedure defines selection of supplier

Supplier performance is measured/monitored Supplier assessments conducted
No evident signs of supplier development Supplier performance is measured/monitored
Minimal supplier development activity
No formal system in place Formal system in place

Supplier performance monitored, but no reaction to Supplier performance monitored
poor performance Development activities evident with poor
performing suppliers
NAFTA compliance manual/procedures in place NAFTA compliance manual/procedures in place

Lack of adequate resources to manage NAFTA Adequate resources to manage NAFTA activity
activity
Total High Risk elements for Purchasi
360520998.xlsx 36 of 108
Score
1 2
Some areas of good housekeeping, but very Formal 5S program and review process in place
sporadic Majority of manufacturing area is clean and
Some risk to employees health & safety organized
Opportunity for improvement in office areas, or
shipping or warehouse areas
Minor risk to employee health & safety
No formal capacity review avaialbe Supplier has capacity planning as part of business
Supplier appears to have open manufacturing process
capacity available Capacity planning based on customer
requirements
Scheduled downtime tracked Scheduled and unscheduled downtime is tracked

Lack of detailed tracking of unscheduled downtime Lack of documented response to address
unscheduled downtime
Customer not notified if downtime anticipated to
affect Customer
Key measurables are tracked Key measurables are tracked

Lack of formal plans to drive improvement Formal plans in place to drive improvement
360520998.xlsx 37 of 108
Plant layout available Plant layout available

Current production flow differs from existing plant Current layout matches existing production flow
layout
Formal program in place Formal safety program in place

Insufficient records of safety audits Records of safety audits available and current
Some evidence of protective equipment not being
worn/used in areas of the plant
Absenteeism is tracked to a defined target Absenteeism is tracked to a defined target

Lack of documented plans to address absenteeism Documented plans to address absenteeism above
above target target
Evidence of training for new employees Evidence of training program for new employees
Training includes health and safety training Training includes health and safety training
Training is sufficient to ensure job requirements Training is sufficient to ensure job requirements
can be met can be met
Evidence of cross-training
Total High Risk elements for Operatio
360520998.xlsx 38 of 108
Score
1 2
Informal or manual system in place Formal system in place to track drawing and
System is fairly robust with minimal opportunity for specification levels
mistakes All appropriate documentation and control plans
reference latest drawings available
System in place to track validation requirements System in place to track validation requirements
Some validations completed as per schedule, but Validations completed as per requirement,
numerous validations delinquent including (but not limited to):
- PPAP
- FMVSS/Regulatory
- CQI
Supplier has system to communicate engineering Supplier has system to communicate engineering
data data
Majority of service is out sourced to a 3rd party Majority of communication is via interna systems
Portion of service is out sourced to a 3rd party
360520998.xlsx 39 of 108
Formal system in place Formal system in place

Verification that drawings/specifications at latest Verification that drawings/specifications at latest
level level
Change control managed by single individual or Change control managed by cross functional team
department
Total High Risk elements for Engineeri
360520998.xlsx 40 of 108
ment and add a note of explanantion in the "Notes" section.

and add a note of explanation in the "Notes" section.
Negligible to No Risk
3 Score Risk Notes
Organization chart in place and is current

All functions filled
High
Succession planning in place
Evidence of strong health & safety program in

place
Consistent application of health & safety rules High
Plant is clean and organized
Consistent evidence of communication

Key Customer and internal performance indicators
reviewed regularly High
Employee suggestion program in place
Evidence of continuous improvement program

Goals defined in Business Plan
Key operational metrics identified
Evidence of regular management reviews High
Evidence of Cost of Quality analysis & tracking
Job descriptions for all levels of the organization

Evidence of training at all levels
Training needs defined and tracked High
Cross-training matrices available
360520998.xlsx 41 of 108

Aware of customer requirements

Customer support availabel in language of
Customer and available for 24 hrs as needed High
Support available on all shifts and supplier
accounts for absenteeism
Formal process in place
Evidence of audits completed
Evidence of corrective action implemented High
Evidence of continuous improvement via LPA
Formal process in place

Evidence of contract reviews
Evidence of review & understanding of Key/Critical High
characteristics
Evidence of Cross-functional teams
Formal process in place to ensure global working

conditions internally and at supplier locations
High
s for General Organization and Management Structure = 9
360520998.xlsx 42 of 108

3 Score Risk Notes
Documented system in place

Evidence of systemic reviews
Proper feasibilities completed
Evidence of cross functional teams High
Evidence of regular, scheduled reviews
Documented procedure for program reviews

Records of completed program reviews
Reviews include Customer, as appropriate High
Open issues tracked and closed in timely manner
Full capability to communicate electronically with

all existing customers
High
Process to ensure review and approval of

packaging
Internal resources with sufficient knowledge High
Customer approval obtained
Process to ensure equipment validation

Records verify completion of run at rate studies
Evidence of customer sign-off/approvals High
360520998.xlsx 43 of 108

Product containment plan is defined as part of

program launch process
Pre-launch control plans in place High
Failure modes analyzed and corrective action
implemented
Formal change management system in place

All changes assessed for impact on product and
system - use cross functional approach
High
All affected documentation updated
KPC's identified and capability is tracked
Significant focus on error prevention

High use of mistake proofing in manufacturing
process High
Mistake proofing driven by FMEA and RPN
reduction
Process flow diagram matches actual production

flow of materials and manufacturing process,
including all inspection points High
Process Flow and Process Control Plan match and

evident match to FMEA's
Evidence of periodic reviews High
Critical/Special characteristics tracked consistently

on FMEA, PCP, PFD, Instructions etc.
Required statistical controls in place
High
Control is on both product and process
Risk numbers assigned on FMEA's

Risk numbers linked to customer requirements
Evidence that risk numbers are revised, based on High
historical or statistical data, or issues
360520998.xlsx 44 of 108

Evidence of link between addition of mistake

proofing and reduction plan for RPN's
Focus on RPN reduction for both product and High
process
Control plans identify required gauging, test

equipment and frequencies
No visible exceptions noted
High
Frequencies are adjusted based on issues and
historical data
Work instructions posted or readily available

Repair/rework instructions posted or available High
Instructions match level of Control Plans
Start up process defined
First-off samples available at all appropriate
operations High
Evidence of first piece approval/signature
System in place to track Customer and supplier

PPAP submissions
Evidence of all PPAP samples available High
PPAP issues properly addressed
Process in place to communicate design

requirements and engineering specifications to
suppliers
High
Suppliers sign off/acknowledge requirements
No exceptions noted
Documented system to qualify suppliers

System in place to communicate critical
characteristics to suppliers
Records of supplier audits High
Records of design/characteristic reviews
360520998.xlsx 45 of 108

otal High Risk elements for Advance Product Planning = 19
360520998.xlsx 46 of 108

3 Score Risk Notes
All required certifications are current, including

ISO, TS, VDA, CQI etc.
No current open corrective actions from last audit High
Formal schedule of review over 12 month period

Evidence of audits completed on schedule
All corrective actions completed on time High
Documented system in place

No examples of outdated documents found High
Documented, formal problem resolution process

that includes:
- both external (customer) and internal issues
- cross-functional team approach
- thorough 8D/5 Why process in place High
- timely response to all issues
- corrective action drives update to all related
documents
All suspect/defective material clearly marked

Suspect material segregated in secure area
Suspect material clearly accounted for, with
appropriate disposition and signatures High
Procedures define proper containment activities
internally, at suppliers and at customer(s)
360520998.xlsx 47 of 108

Formal automated system in place

System generates reminders of calibration due
No evidence of past due calibrations
High
Fixtures/gages referenced in control plans
Effective MSA system in place
Operator gage instruction in place

Operator training records available and current
SPC data current, where required
Adequate re-work gage instructions available at all High
production and re-work stations
Dedicated storage for gages/fixtures, when not in

use High
Storage prevents damage or abuse
Internal resources can support dimensional,
material and performance requirements
Only specialty requirements are sourced externally High
Documented system in place to measure external

quality
Performance data is current and includes
appropriate PPM and incident data, at minimum
High
Corrective actions in place to address under
performance issues
Document retention system in place

Documents are protected from damage and readily
accessible
Process ensures destruction as per schedule High
Records include both paper and data records
360520998.xlsx 48 of 108

Sub-tier suppliers are evaluated prior to sourcing

Performance of sub-tiers monitored regularly
Record of detailed review of requirements with High
sub-tier suppliers, prior to sourcing
Total High Risk elements for Quality = 12
360520998.xlsx 49 of 108

3 Score Risk Notes
System in place to receive and verify customer

orders
Regular monitoring of delivery performance
Back up system for receiving orders and system is High
tested regularly
Good material flow throughout manufacturing

facility - no apparent bottlenecks
Material identified at all stages of the process
System in place to monitor inventory levels
High
Plans in place to reduce inventory
Evidence of effective FIFO in place
Full material traceability on raw and finished

materials
Maximum period of traceability is <8 hours, or one
High
shift
Traceability indicated on shipping labels
System in place to verify each customer shipment

for:
- quantity
- correct part High
- proper labelling
- part damage
360520998.xlsx 50 of 108

Raw materials/components tied to customer

releases
Storage sufficient to prevent damage or mixing
System in place to provide warning for low
High
inventories
Customers proactively notified of order concerns
Min and max values set on inventory

Inventory counts conducted on regular basis
Inventory turns are at acceptable level, or as High
defined in the business plan
No off-site warehouse used, or
Warehouse used but regular inventory counts
monitored High
Inventory validated through periodic count
Warehouse protects agains damage or loss
Labelling meets all AIAG requirements

Labelling approved by Customer prior to first
shipment High
All shipped material meet AIAG standard
Supplier issues ASN for all shipments
ASN issued at maximum of 30 minutes prior to
shipment High
Process in place to verify ASN to Bill of Lading to
Customer order
Supplier is C-TPAT/PIP compliant

Records support compliance High
Total High Risk elements for Materials& Logistics = 10
360520998.xlsx 51 of 108

3 Score Risk Notes
Documented system to qualify tool/fixture repairs

System ensures sign off by qualified personnel
System ties in to production first-off procedure High
Adequate tracking system for tooling

Customer ownership validated via asset tags
Proper storage location for tooling not in
production High
Tool maintenance records maintained and
available for review
Designated storage for tooling

Storage protects against damage from
environment or handling High
Storage in an area readily accessible
Regular inventory completed at a prescribed
frequency
Inventory matched to customer asset records High
Tooling engineering levels validated annually, as
required
Documented system to track tooling orders

Monitored as part of APQP
Customer updated on potential issues High
360520998.xlsx 52 of 108

Evidence of TPM (Total Productive Maintenance)
High
Supplier has knowledge of available capacity

Evidence of current capacity studies on equipment
OEE studies available for review
Sufficient resource planning is evident High
Total High Risk elements for Facilities & Tooling = 7
360520998.xlsx 53 of 108

3 Score Risk Notes
Supplier has full technical capability to support

Magna business
No out-sourcing of secondary processing High
Magna represents <35% of supplier's overall
business
Supplier does not compete with Magna

Supplier is not an OE supplier High
Cross functional team reviews quotes for feasibility

Formal tracking system in place
Supplier is meeting timing requirements High
Formal RFQ/SOW sent to suppliers

Suppliers asked to sign off on feasibility High
Only qualified/approved suppliers are used
Supplier is not unionized or,
Contract expiry is minimum of 12 months away
Contract expiry in 6-12 months, but contingencies High
being planned
Facility is owned
Proof available to verify adequate insurance
Customer owned capital insured (Bailee Bond) High
Full awareness of website

Accesses and uses specific sites as directed by High
division(s)
360520998.xlsx 54 of 108

Procedure defines selection of supplier

Supplier assessments conducted
Supplier performance is measured/monitored
Adequate resources to manage supply base High
Evidence of supplier development activity
Formal system in place

Supplier performance monitored
Development activities evident with poor
performing suppliers High
Process in place to prevent new business to poor
performing suppliers
NAFTA compliance manual/procedures in place

Adequate resources to manage NAFTA activity
Alternate resources also familiar enough with High
NAFTA to provide back up
Total High Risk elements for Purchasing = 10
360520998.xlsx 55 of 108

3 Score Risk Notes
Formal 5S program and review process in place

Lean manufacturing program in place
All areas clean and organized, including:
- manufacturing
- office areas High
- shipping & receiving and warehouse
- maintenance and lab areas (if applicable)
No obvious risk to employee health & safety
Supplier has capacity planning as part of business

process
Capacity planning based on customer
requirements High
Capacity planning includes both manufacturing
capacity as well as human resources
Scheduled and unscheduled downtime is tracked

Evidence of documented response to address and
reduce unscheduled downtime
Customer notified if downtime anticipated to affect High
Customer
Key measurables are tracked

Formal plans in place to drive improvement
Supplier is generally meeting improvement targets High
360520998.xlsx 56 of 108

Plant layout available

Current layout matches existing production flow
System in place to ensure Customer notified when High
production process/flow is changed
Formal safety program in place

Safety audits on file and are current
Safety/protective equipment being used throughout High
the plant
Low level of risk for employees
Absenteeism is tracked to a defined target

Documented plans to address absenteeism above
target High
Evidence of sufficient cross-training to prevent
absenteeism presenting risk to customer
Evidence of training program for new employees

Training includes health and safety training
Training is sufficient to ensure job requirements
can be met
Evidence of cross-training
Training effectiveness is monitored High
Evidence of training needs analysis on regular
basis
Total High Risk elements for Operations = 8
360520998.xlsx 57 of 108

3 Score Risk Notes
Formal system in place to track drawing and

specification levels
All appropriate documentation and control plans
reference latest drawings available High
System ensures annual review/validation with
customer
System in place to track validation requirements

Validations completed as per requirement,
including (but not limited to):
- PPAP
- FMVSS/Regulatory
- CQI High
System is proactive and issues notices of due
validations
Supplier has system to communicate engineering

data
All communication is via internal systems High
360520998.xlsx 58 of 108

Formal system in place

Verification that drawings/specifications at latest
level
Change control managed by cross functional team
Effective tracking system in place to ensure all
changes are addressed, including all
documentation High
Evidence of sign off by cross functional team
Total High Risk elements for Engineering = 4
360520998.xlsx 59 of 108
"H" - Observations indicate high risk - minimal standards, systems in place
QUICK ASSESSMENT "M" - Observations indicate moderate risk - standards/systems in place but improvement recommended
"L" - Observations indicate low/minimal risk - standards/systems appear robust and effective
No. ITEM EVIDENCE/ DOCUMENTATION REQUIRED OBSERVATIONS/NOTES Score CORRECTIVE ACTION
Employees are wearing safety equipment as prescribed in plant health and

safety standards
Evidence of effective lock-out procedure in place, and observed
1 Safety & Housekeeping
Good housekeeping practices, including implementation of 5S
Aisle ways are clear and well lit
Emergency exits are clearly marked and easily accessed
Evidence of sufficient storage and loading areas

Evidence of effective FIFO system and stock rotation
2 Materials & Logistics No areas of significant clutter or bottlenecks
Product is well marked and no evidence of damage to materials or containers
Minimal storage of materials at production lines
Evidence of effective and updated communications with employees

Evidence that management spends sufficient time on shop floor
3 Management
Employee turnover is at rate that is competitive with regional industry
Employee training/development in place and utilized
Supplier is certified to latest required standards, including ISO/TS

Performance metrics and KPI performance is posted and visible
Training matrices are in place at operator stations
4 Quality System
Operator instructions are posted, readily available and updated
Evidence of an effective system to manage and monitor sub-suppliers
Evidence of sufficient use of mistake-proofing
Supplier has a detailed process to manage new programs and advance quality
planning
5 Advance Planning
There are sufficient resources in place to manage new program activity
There are regular reviews of status on all new programs
Material is tagged at all stages of the operation

Plant floor is clear of parts or materials
Segregation area is secure and suspect material is contained
6 Material Control
Manufacturing process is set up to prevent contamination by suspect material
First-off samples are evident and tagged
Dedicated area set up for containment inspection and GP 12
All measuring and test equipment is properly tagged

7 Measuring & Test Equipment All measuring and test equipment is calibrated
Operator instructions are clearly evident where testing or gauging occurs
Defective parts are reviewed with appropriate personnel

8 Problem Solving KPI in place to monitor customer performance and issues
Evidence of application of lessons-learned and read-across
Facility is well organized and can accommodate additional capacity

9 General Observations Employees appear to be satisfied and are open and approachable
Supplier has the capability to be a good supplier to Magna
Indicate total number of elements per risk level, in summary on Cover Page
Page60 of 108 360520998.xlsx

"F" = Full Compliance /Evidence "P" = Partial Compliance/Evidence "N" = No Compliance/Evidence
Technical Assessment - Die Casting N/A = Not Applicable
- number and size of die cast machines supports capacity planned.

The Supplier has the proper type and - Machine size is adequate for size of parts being produced.
volume of equipment to support - Melting system is adequate for part to be produced.
1
current and quoted production - All post processing - trim presses, pre-machining, etc. is adequate for part to
capability. be processed.
- sufficient capacity on equipment planned for Magna business
- Similar products are now produced

- Technical capabilities exist to support manufacturing capability
The Supplier has adequate technical
2 - Design and Tooling Engineering support technical requirements
capability to produce the parts quoted
- Review current PPM for similar product
- machines have closed-loop control

The Supplier has Process Controls to
- Water cooling systems are adequately monitored and controlled.
3 ensure conformance to product design
- Evidence of SPC Controls in place and being used
and requirements
- die cast machines are adequately sized for products produced
- Incoming metal properly certified and to specifications

- metal chemistries monitored and maintained
Material processing parameters are
4 - Melt temperatures properly set & monitored
controlled and monitored
- Die cast machine parameters measured and monitored
- Die cast lubrication parameters measured and monitored
- Die cast machine pre-heat, lubrication, cooling systems are controlled

- Die cast lubrication controlled
- Metal ladling into shot sleeve and Shot plunger "fast" and "slow" velocity
controlled for specific part
Critical cycling parameters are
5 - Intensification Pressure and Rise time monitored and controlled to part
monitored and maintained
specific parameters
- Biscuit length monitored to part specific length
- Die locking pressure monitored and controlled
- Ejection system (robot) monitored and controlled
-Maintenance schedule for die cast and trim machines, cooling systems, shot
Evidence of proper Preventive
6 plunger, and furnaces are in evidence
Maintenance for equipment
- Check lists exist for regular equipment checks by skilled tradesman
- die cast machine guides are not worn

Physical examination of equipment - die cast machine locks are not worn
7 supports overall effectiveness of - die cast platens are clean, level, and properly shimmed for mating
equipment maintenance - die cast lubrication and ejection robots clean and properly running
- No excessive dross build up around pouring system equipment
Proper methods in place to control

- Die maintenance cycle count and preventative maintenance in place and
dies, die cast machines, trim presses,
8 operating
metal shot sleeve and plunger system,
- Molten metal preparation, cleaning, and pouring are evident
molten metal furnaces
- die Cavities are cleaned and checked at timely intervals

Supplier has adequate methods of tool - trim Press machine cleaned
9
storage and maintenance - Tools are properly identified with Customer I.D.
- Storage is adequate to protect tooling
- Adequate number and skill level of tool engineers
- Design capability, including ability to translate
Supplier has adequate tool design and math data (CATIA, UG, Pro-Eng etc.)
10
manufacturing capability - Condition of equipment (EDM, Lathes, mills, etc) shows evidence of
maintenance and good repair
- Floors are clear of spills, pellets or hazardous items

Supplier shows good housekeeping
- Temperature and humidity are controlled to ensure integrity of product
11 discipline and shop floor operations
- All safety gates are in place and operational
are maintained
Page61 of 108 360520998.xlsx

"F" = Full Compliance /Evidence "P" = Partial Compliance/Evidence "N" = No Compliance/Evidence
Technical Assessment - Die Casting N/A = Not Applicable

- Tools are designed for maximum effectiveness.
Supplier utilizes technology, as - Use of automation & robotics is appropriate
12
appropriate, to maximize efficiency - Secondary processing is minimal
Page62 of 108 360520998.xlsx

"F" = Full Compliance/Evidence "P" = Partial Compliance /Evidence "N" = No Compliance/Evidence
Technical Assessment - Electrical/Electronics N/A = Not Applicable
EVIDENCE/ DOCUMENTATION
No. ITEM OBSERVATIONS/NOTES Score CORRECTIVE ACTION
REQUIRED
The Supplier has the proper type and - Number of machines can support capacity
volume of equipment to support - Type of machines used are appropriate for
1
current and quoted production dispensing of the subcomponents such as the
capacity. Resistors / Capacitors

- Technical capabilities exist to support
The Supplier has adequate technical manufacturing capability
2
capability to produce the parts quoted - Design and Tooling Engineering support technical
requirements
- Review current PPM for similar product in use
- Machines are covered to prevent contamination

from outside dust or contaminants
- Evidence of SPC Controls
- Printed Circuit Boards are according to product and
The Supplier has Process Controls to Stencil design
3 ensure conformance to product design - The supplier has 5s in place and they are using the
and requirements following for processing: latex gloves, antistatic
bags, antistatic tape, ESD shoes, hairnets, and ESD
Straps when handling the circuit boards
- Magazines for the Circuit Boards are maintained
clean
- Reflow Oven Temperature is maintained according

to the specifications
- Cross Check the temperature against the Thermal
profile
4 - Monitor the Conveyor speed in the Reflow Oven
- Automatic Optical Inspection - Ensure that the
Software (library and the teaching system) in correct
alignment to ANSI IPC-A-610.
- Correct Numbers are stored in the database
- Soldering Paste speed and pressure are used for

controlled of thickness
Critical cycling parameters are - Maintain Soldering Iron Temperature according to
5
monitored and maintained the specification according to the Control Plan
- Proper nozzle used for specific paste
-Maintenance schedule for The soldering Paste,

machine, Subcomponent Population machines,
Reflow Oven, Speed of the conveyor belt for the
6 Reflow Oven, Ultrasonic Welding Equipment,
Soldering Irons
- Check list for regular equipment checks
- Operators must have gone through the ANSI IPC-

A-610 training to perform Analysis and the Rework
- Review of solder joints/presence/position/polarity
7 Analysis and Rework and the presence of tomb stones.
- Rework if any must be approved in writing from the
customer
- Ensure that the paste is not expired, and that it is

Refrigerator is used to store the
placed outside at the Room Temperature prior to use
8 soldering paste, as necessary and
in processing
maintained in good condition
Page 63 of 108 360520998.xlsx

Technical Assessment - Electrical/Electronics N/A = Not Applicable
REQUIRED
- All material specifications are available & known
- Lot numbers are controlled and traceable
- Boxes and drums are clean and sealed
Proper methods in place to control - Correct Set Up and adjustments - Paste
9
Soldering Paste other and raw material Temperature -Machine Temperature -Wiping
Frequency -Set up Procedure
- One Piece flow (Avoid Part Stacking) - Gloves,

jewelery protection - Store Red Rabbits in secondary
nests to keep nests clean between runs - Good
Supplier follows good assembly
10 work cell house keeping - Robust PM procedures
processes
keeps machine downtime to a minimum avoiding
part back-ups at bottlenecks
- Tools are properly identified with Customer I.D.

Supplier has adequate methods of tool - Storage is adequate to protect tooling
11
storage and maintenance
- Prevention of scratches, gouges, marring, dirt and

other visual marks on the surface finish
- Bent or broken fasteners and locators, material
degradation due to unapproved chemical cleaners
used during the assembly process
12 Material controls and parts damage - Evidence of deep cleaning of all magazines,
conveyors, (schedule daily/weekly, certify with labels
- Daily/Weekly scheduled cleaning of station ego
arms, staging tables, fixtures etc.
- Floors are clear of spills, pellets or hazardous items

Supplier shows good housekeeping - Temperature and humidity are controlled to ensure
13 discipline and shop floor operations integrity of product
are maintained - All safety gates are in place and operational
- Minimal handling during assembly

- Use of automation & robotics wherever
Supplier utilizes technology, as appropriate
14
appropriate, to maximize efficiency - Secondary processing (Rework ) is minimal
Page 64 of 108 360520998.xlsx

"F" = Full Compliance/Evidence "P" = Partial Compliance/Evidence "N" = No Compliance/Evidence
Technical Assessment - Forging N/A = Not Applicable
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volume of equipment to support c. Type of press is appropriate for product i.e.
2
current and quoted production mechanical, hydraulic, wedge roll, hammer
capability. d. Choice for automation or manual loading is
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3
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5
and monitored approved otherwise
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applicable and similar products etc are working
equipment maintenance c. No questionable noises coming from equipment
Page 65 of 108 360520998.xlsx

-- Key personnel
Presence
APQP Documentation have inspection
meets AIAG
- Plant Tier 2/3
Review is current
clean,
Supplier
EVIDENCE/ orderly
completion
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ismonitored
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after cracks,
run,
Supplier has adequate controls in including repair,
including end crackspolish, or replacement as required
9 place for storage and maintenance of c. Evidence of periodic checks for bell mouth
standard tooling condition at i.d. interface
d. Inventory levels maintained
e. Tools are properly identified with Customer I.D. if
applicable
a. Tooling area is organized, tools are stored for

easy access
b. Tooling is cleaned and reviewed after each run,
including repair, polish, or replacement as required
Supplier has adequate controls in c. Inventory levels are maintained with min/max or
10 place for storage and maintenance of similar tracking method, that includes estimated tool
perishable tooling life.
d. Extrusion dies, mandrels, etc are CVD/PVD Tin
coated, or similar type coating.
e. Tools are properly identified with Customer I.D.,
and applicable part number.
a. Adequate number and skill level of tool engineers
Supplier has adequate tool design b. Design capability, including ability to translate
11
capability math data (CATIA,
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for completion
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Supplier has adequate tool room
c. CMM onsite
12 equipment for maintenance and
d. Adequate inspection equipment available
inspection of tooling
e. Inspection equipment calibration is up to date
f. Tool drawings are available in tool room and are
controlled
a. Floors are clear of spills, pellets or hazardous

items
b. Temperature and humidity are controlled to
ensure
integrity of product as required
are maintained
c. All safety gates are in place and operational
d. Work areas are free of debris, only required
tooling, gages, etc at work areas
a. Quick Die Change tooling designs

Supplier utilizes technology, as
14 b. Use of automation & robotics is appropriate
appropriate, to maximize efficiency
c. Secondary processing (de-flashing) is minimal
a. Correct Shot Size

Shot Blast process parameters are
15 b. Shot condition
controlled
c. Blast time
a. Chemical Concentration
Phosphate Line parameters are
16 b. Tank Temperature
controlled
c. Submersion Time
Page 66 of 108 360520998.xlsx

-- Key personnel
Presence
APQP Documentation have inspection
meets AIAG
- Plant Tier 2/3
Review is current
clean,
Supplier
EVIDENCE/ orderly
completion
DOCUMENTATION
- knowledge
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equipment
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standard
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job
levels of
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isplace
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(e.g.
Engineering
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Approved
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Inspection
Audit reflect
CMM,
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submitted
Schedule
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machine
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on plans
packages
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latest
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and
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17 Warm Forge Specific c. Forgings
including endmonitored
cracks and controlled for cracks,
including end cracks
d. Lubrication sprayers working properly if applicable
- Billet temperature is controlled and monitored

- Forgings monitored and controlled for Laps &
flats
- Forgings monitored and controlled for cracks,
Page 67 of 108 360520998.xlsx

Technical Assessment - Forging Machining N/A = Not Applicable
-- Presence
APQP Documentation
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current and quoted production
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a. Similar products are now produced

b. Technical capabilities exist to support
The Supplier has adequate technical manufacturing complexity
2 capability to produce the parts quoted c. Design and Tooling Engineering support technical
requirements
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The Supplier has Process Controls to a. CNC controls are used where applicable
ensure conformance to product design b. Equipment is capable of meeting design
3 -- Presence
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tolerances of critical inspection
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and requirements - Tier 2/3 Supplier PPAP
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standard pressures
Work holding are monitored
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4 proofing, gaging, & supplementary c. Check valves, hydraulics
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appropriate concentration levels
Physical examination of equipment a. No visible oil leaks

5 supports overall effectiveness of b. Various gages, led readouts, etc are working
equipment maintenance c. No questionable noises coming from equipment
a. Tooling is organized and stored for easy access

b.Tooling is cleaned and reviewed for damage / wear
Supplier has adequate controls in after each run
6 place for storage and maintenance of c. Tool Boss or similar inventory tracking system in
place
fixturing and tooling d. Tool setting equipment used where applicable
e. Tools are properly identified with Customer I.D. as
required
a. Adequate number and skill level of tool engineers

Supplier has adequate tool design b. Design capability, including ability to translate
7 capability math data (CATIA,
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for completion
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of TrackingforLog.
- Evidence
PPAP of is
documentsappropriate
Lessons-Learned
reflect latest component
to
level
drive
- Application
Record of of
complexity daily
corrective
verification
action of
across
error
allproof
- Manufacturing Documents at latest level
improvement
Supplier has adequate inspection b.applicable
CMM onsiteand similar products
8 equipment for scope of work c. Is production gaging suitable for inspection in
serial production
d. Adequate engineering support as required
a. Use of Quick Change tooling designs

Supplier utilizes technology, as b. Use of automation & robotics is appropriate
9 appropriate, to maximize efficiency c. Balance of cycle times between operations
Page 68 of 108 360520998.xlsx

-- Presence
APQP Documentation
meets AIAG
Tier 2/3current
8Ds for completion
- equipment
Hydraulic
standard
Engineering
Records pressures
of
EVIDENCE/ Audits
Records
DOCUMENTATION
No. ITEM Records
- Evidence
All ofofAdvance
Error-proofing
material CFT to Quality
specifications
onresolve
line arePlanning
availablewith
ejector
--(e.g.
Engineering
Records
Approved
ReviewCMM,
load.
Inspection
Audit submitted
ofInstructions
Schedule packaging
Material
Early
software
basedPPAP
Product
Tester
on
REQUIRED plans
packages
(e.g.
are etc.)
processCATIA,
requirements
Tier
- Record
Lot
Poka 2/3
of Suppliers
numbers
Yoke Customer
are controlled
Non-conformance
-- Containment
IGIS
In
Availability
Run-at-Rate
Warehouse
Program
accuracy
process
latest
(High etc.)
level Review
Customerand
drawings
isto
clean
or
completeness
3rdOEE
PPM, Process
&are
Party
orderly
Documents
controlled
FailureCertified
Flow etc.)
Modes Test
Records
- Boxes
Lock
status. of drums
boxes
and regular
Evidence Supplier
for defects
of
are
Tracking Audits
clean and Log. and
sealed
a. Single
-- Center
CAE,
Review
Records
PPAP
Evidenceturret
Packaging
Organization
Facilities
Mold
benches
documents
of vs.Chart
Pre-Launch
of
ensures
flow, double
Program
available
Stress turret
protection
Control
Lessons-Learned
reflectshowing
Review
for
Analysis
Plans
latestTIR
of
to Meetings
product
checks
level
driveetc.
Equipment complexity is appropriate -development
b. Application
Record of of
Work/holding daily
corrective
verification
isDocuments
appropriateaction of
across
errorallproof
10 for scope of work -improvement
Flash
Inspection/Test
resources
under fill
Manufacturing records
is monitored
to at
validate
latest testing
level
c. applicable
Tool load and similar
detection on products
equipment
- Responses to out of specification conditions
d. Auto tool compensation
a. Broaches are tagged with tool life documented

b. Controls in place to prevent double hits
11 Broaching specific items c. Multiple spindles used depending on volume
requirements
d. Needles not targeted over high limit (wear factor)
a. Speeds and Feeds documented per part

b. Drill life re-sharp requirement documented
12 Gun Drill specific items c. PM for drill bushings in place and followed
d. Chip conveyance adequate
e. Cutting fluid levels maintained

13 Hobbing specific items b. Cutting fluid properly maintained

b. Cutting fluid properly maintained
c. Type of cutter appropriate for scope of work
d. Supplier has both vertical and horizontal mills
e. Equipment has appropriate # of axes
14 Milling Specific items f. Supplier has CNC programming capabilities at
machine
g. Supplier has CAM CNC programming capabilities
h. Supplier has hard milling capabilities and
experience

b. Coolant fluid properly maintained
c. Dress frequency document per application
15 Grinding Specific items d. Supplier has experience with all types of
abrasives & super abrasives i.e.. CBN, diamond
e. Supplier has experience in all type of grinding i.e.
creep grinding, form grinding,

16 EDM Specific items b. Supplier has experience in conventional EDM
c. Supplier has experience in wire EDM
Page 69 of 108 360520998.xlsx

-- Presence
APQP Documentation
meets AIAG
Tier 2/3current
8Ds for completion
- equipment
Hydraulic
standard
Engineering
Records pressures
of
EVIDENCE/ Audits
Records
DOCUMENTATION
No. ITEM Records
- Evidence
All ofofAdvance
Error-proofing
material CFT to Quality
specifications
onresolve
line arePlanning
availablewith
ejector
--(e.g.
Engineering
Records
Approved
ReviewCMM,
load.
Inspection
Audit submitted
ofInstructions
Schedule packaging
Material
Early
software
basedPPAP
Product
Tester
on
REQUIRED plans
packages
(e.g.
are etc.)
processCATIA,
requirements
Tier
- Record
Lot
Poka 2/3
of Suppliers
numbers
Yoke Customer
are controlled
Non-conformance
-- Containment
IGIS
In
Availability
Run-at-Rate
Warehouse
Program
accuracy
process
latest
(High etc.)
level Review
Customerand
drawings
isto
clean
or
completeness
3rdOEE
PPM, Process
&are
Party
orderly
Documents
controlled
FailureCertified
Flow etc.)
Modes Test
Records
- Boxes
Lock
status. of drums
boxes
and regular
Evidence Supplier
for defects
of
are
Tracking Audits
clean and Log. and
sealed
-- Center
CAE,
Review
Packaging
Organization
Records
Facilities
PPAP Mold
Evidence benches
Pre-Launch
of
ensures
documents
of flow,
Program
Chart
available
Stress
protection
Control
Lessons-Learned
reflectshowing
Review
for
Analysis
Plans
latestTIR
of
to Meetings
product
checks
level
driveetc.
-development
Application
Record of of daily
corrective
verification
action of
across
errorallproof
-improvement
Flash
Inspection/Test
resources
/ under fill
Manufacturing records
is monitored
Documents to at
validate
latest testing
level
a. applicable and
Speeds andtoFeeds similar products
- Responses out ofdocumented
specificationper part
conditions
b. Work holding is adequate for scope of work
c. Supplier has experience in wire EDM
d. Supplier has CNC programming capabilities at
17 Turning Specific items machine
e. Supplier has CAM CNC programming capabilities
f. Supplier has Hard Turning capabilities and
experience
Page 70 of 108 360520998.xlsx

Technical Assessment - Lost Foam
No. ITEM
REQUIRED
- Number of foam molding machines can support

capacity
- Envelope size is adequate for size of part to be
The Supplier has the proper type and
produced
volume of equipment to support
1 - Cast Line & Melting system is adequate for part to
be produced
capability.
- All post processing equipment is adequate for part
to be produced
- No conflict with suppliers other customers volumes

manufacturing capability
The Supplier has adequate technical
2 - Design and Tooling Engineering support technical
capability to produce the parts quoted
requirements
- Machines have closed-loop control

The Supplier has Process Controls to - Evidence of SPC Controls in use
3 ensure conformance to product design - Foam Mold Machines are adequately sized
and requirements - Cast Line parameters are sufficient
- Melt temperatures properly set & monitored

- EPS molding materials parameters measured and
monitored
4 - Coating parameters measured and monitored
- Cast line molding media parameters measured and
monitored
Page 71 of 108 360520998.xlsx

No. ITEM
REQUIRED
- Mold machine pre-heat, auto-clave, cooling
parameters controlled
- Coating Robot Dipping and Draining routine
controlled
Critical cycling parameters are - Cluster insertion, and fill & compaction of molding
5
monitored and maintained media controlled
- Pouring routine - dip, drain, pour controlled
- Pressure solidification cycle controlled
- Heat treat parameters controlled
-Maintenance schedule for mold machines, cast

Evidence of proper Preventive line, sand system, heat treat are in evidence
6
Maintenance for equipment - Check list for regular equipment checks
- Foam mold machine guides are not worn

- Mold assemble machine platens are clean, level,
and properly shimmed
- Coating mixing propellers specification for wear
exist
Physical examination of equipment
- Cluster drying oven gages for temperature and
7 supports overall effectiveness of
humidity
equipment maintenance
- No severe sand leaks in Sand System or at
compaction station
- No excessive dross build up around pouring
system equipment

8 EPS beads, steam, coating, molding
- Crates and drums are clean and sealed
media, metal
Page 72 of 108 360520998.xlsx

No. ITEM
REQUIRED
- Coating mix-down procedures are evident
Proper methods in place to control - Molten metal preparation, cleaning, and pouring
9 required material mixing and are evident
processing - Cast line Molding media additions are controlled
- Vents are checked & cleaned

- Cavities are cleaned
Supplier has adequate methods of tool - Assembly machine printer plates cleaned
10
- Storage is adequate to protect tooling

11
manufacturing capability - Condition of equipment (EDM, Lathes, mills, etc)
shows evidence of maintenance and good repair
- Floors are clear of spills, pellets or hazardous

items
- Temperature and humidity are controlled to ensure
integrity of product
are maintained
- Tools are designed for maximum effectiveness.

Supplier utilizes technology, as - Use of automation & robotics is appropriate
13
Indicate total number of elements per risk level, in summary on Cov
Page 73 of 108 360520998.xlsx

N/A = Not Applicable
OBSERVATIONS/NOTES Score
Page 74 of 108 360520998.xlsx

Page 75 of 108 360520998.xlsx

ate total number of elements per risk level, in summary on Cover Page
Page 76 of 108 360520998.xlsx

pliance/Evidence "N" = No Compliance/Evidence
pplicable
CORRECTIVE ACTION
Page 77 of 108 360520998.xlsx

pplicable
CORRECTIVE ACTION
Page 78 of 108 360520998.xlsx

pplicable
CORRECTIVE ACTION
Page 79 of 108 360520998.xlsx

Technical Assessment - Machining N/A = Not Applicable
REQUIRED
Are there adequate controls for
Confirm system for receiving inspection and
1 receiving inspection of incoming
identification of incoming material.
material.
Must record all casting lots loaded on machine

Is lot traceability maintained for
2 with their Lot number, Date, Time, Supplier
received components
name
Are critical dimensions

Confirm identification of critical dimensions on
3 determined/documented between
print/Characteristics list
the supplier and Customers
Are Machining/layout datums

Confirm datum scheme identified with print
requirements
Are Pass through features

Confirm identification of PTC's on
print/Characteristics list
Review supplier machining plan to ensure

What equipment will be used to
machines are adequate to machine part. Are the
manufacture the part (i.e.. 3axis, 5
machines new or old? What parts have been
axis, horizontal, vertical, SPM etc )
6 machined before? Review overall condition of
Is it adequate for proposed
equipment (ie.spindles, turrets, machine slides)
machining process?
Define last major repairs that can help
determine condition of equipment.
What is the # of operations, how is

Review supplier process flow and machining
7 part nested in each operation, what
plan
is machined at each station?
Review supplier Fixturing plan including type of

How will the part be clamped for fixturing *manual or hydraulic, look at areas that
8
machining ? can cause vibration to see if there is proper
work support, tooling
Does the machining plan meet the

9 Review supplier cycle time studies
capacity requirements?
Review supplier handling of parts to ensure one

10 One Piece FLOW
piece flow to prevent mishandling of parts
What datum strategy would Confirm supplier datum scheme matches with
11 supplier require in order to process print requirements and datums selected on
the part in planned equipment assembly pallets
Review supplier controls for detecting part

What error proofing will be used to
seated on casting datums without any gaps.
12 ensure each casting is seated on
How does supplier verify effectiveness?
cast datums within fixture
Pass/Fail Masters?
What datum strategy would Confirm supplier datum scheme matches with
13 supplier require in order to inspect print requirements and datums selected on
the part in planned equipment inspection fixtures (i.e. CMM/Gauges)
Does Supplier equipment have

Review supplier controls for unauthorized
system to prevent unauthorized
14 changes. How are programs backed up and
machine adjustment. (i.e...lockout,
controlled?
password, etc..)
Page 80 of 108 360520998.xlsx

REQUIRED
Does Supplier equipment have
Review supplier controls to protect part from
fixturing to guarantee part presence
15 mis-loads and damage. (i.e.. Poke-Yokes,
and proper position during process.
clamping damage etc)
(no mis-load)
Review supplier work instructions or check
Does supplier identify and
16 sheets for identification of controlled process
document machine settings
parameters
Is Machine/fixture ID identified on
Review supplier controls for clear identification
each part for duplicate processes.
17 of parts from m/c to m/c and fixture to fixture
(i.e...two machines making same
(ie.traceability for any containment purposes)
part)
Review supplier controls for clear tooling

Are Supplier fixtures/tooling poke identification of tools and fixtures for each
18 yoke to prevent tooling mix-up at machining operation. Review handling of tool
setup. from presetting to setup. Is tooling common or
machine specific to prevent mis-tooling?
Will there be part traceability to

each fixture in the process? What
19 Review lot traceability procedure?
about traceability to date of
manufacture?
What are supplier controls for
Review Supplier TPM schedule/ PM schedule /
20 Predictive/Preventive machine
Signed off completed work order
maintenance and repair.
Review supplier controls for
What are supplier controls for changing/monitoring machining coolant. Is the
21
controlling machining coolant coolant checked for its machining qualities by
coolant suppler lab?
Are tool presetting, tool changes
Review supplier controls for tool presets, tool
22 and tool offsets done by skilled
changes and tool offsets
technicians?
Review if machines have alarm for tool life or
other means to monitor tool life
How supplier monitors and control
23 (software/machine control) Are first off
frequency of tool changes.
inspections done after each adjustment/offset or
setup?
What are supplier plan to complete

24 Review supplier plan
tool life frequency study.
Does supplier have documented

operation standard to recover Review supplier recovery plan and confirm if
equipment in the event of tool last piece produced before tool interruption and
25
interruption during production first piece before continued production is
(i.e...power outage, tool breakage, verified.
etc..).
What controls supplier has to

Review the packaging. (Potential of cardboard
ensure parts are free from
dust , shaving from parts rubbing) Review line
26 contamination which could impact
layout (proximity to chip blowing or other
the functionality of the part or the
sources of contamination)
mating parts.
Review supplier controls for controlling /
27 removing burrs. Process needs to robust to
control / remove burrs
prevent handling damage.
Page 81 of 108 360520998.xlsx

REQUIRED
Review supplier controls for protecting part from
rust (Applying rust inhibitor, protecting in
28 packaging, shelf life for rust inhibitor, packaging
protect part from rust
mat'l will not escalate rust issues if part
touches)
What controls supplier has to Review if part requires special packaging /
29 protect part from damages on protective aids to prevent from damages in-
machine surfaces house and during transit
What are supplier plans to maintain Review supplier controls. Is there 100%
30 capability on critical dimensions inspection for critical dimensions and PTC's or
and PTC's? demonstrated process capability?
Quality checks must be done as per frequency

Does supplier have adequate
in control plan. Review the strategy in
31 inspection frequencies to control
determining frequencies versus level of
part features.
risk(PFMEA). Does the frequency reflect this?
Threaded holes must be verified with a thread

Does supplier have an adequate gage. Minor thread diameter in internal threads
32
method for thread checking? must also be confirmed with a plug gage to
assure proper thread engagement.
Review supplier gauging plan (inspection in
Does the part inspection plan
constrained/un constrained condition, using
33 considered measuring part as
correct datums, scanning/touch probing , gage
intended in print
capability to check dimensions,etc.)
What are supplier plan to compare

measurement strategies and do a
34 Review supplier plan
gauge correlation study with
Customer.
What are supplier controls for What are plans? Borescope, Ball check, flow
35
detecting blocked channels testing.
What are supplier controls for
detecting casting issues at Any planned receiving inspection? What
36 receiving and identified after features? Are there planned boundary samples,
machining (i.e. porosity, non-clean templates for porosity checking etc.)
up etc)
Page 82 of 108 360520998.xlsx

Technical Assessment - Powder Metal N/A = Not Applicable
REQUIRED
Material mixing and Storage

- Proper tools /Gauges available to prepare recipes
Material Mixing / Blending parameters
1 - Lot numbers are controlled and traceable
are controlled and monitored - Packaging containers are clean and sealed
- Mixed powder stored in temperature /Humidity

controlled environment
- There is no exposure to the outside temperature
2 Incoming / Mixed Powder Storage
variations and moisture.
- The storage area is not close to shipping area
Compacting and Sizing

3
manufacturing capability - Condition of equipment (EDM, Lathes etc) shows
evidence of maintenance and good repair
- Number of machines can support capacity

The Supplier has the proper type and - Tonnage of machines is appropriate for product
volume of equipment to support - Number of levels in the Press
4
current and quoted production - Type of Press Mechanical / CNC Hydraulic
capability. - Adequate tonnage at each platen

The Supplier has adequate technical manufacturing capability
5 capability to produce the parts as - Design and Tooling Engineering support technical
quoted requirements
- Press tonnage is monitored

- Gripper clamping pressure is monitored
The Supplier has Process Controls to - Proper controls to monitor weight / density
6 ensure conformance to product design - Proper material handling to prevent green cracks
and requirements - Proper inspection systems to check microstructure
and cracks.
-Maintenance schedule for machines, check

Evidence of proper Preventive valves, hydraulics
7
Maintenance for equipment - Check list for regular equipment checks
- For manual stations - Not too many parts on the

table. Parts should not be hitting each other.
- Parts are packed in proper dunnage one part at a
Handling of Compacted / green stage
8 time.
Parts - Pick and place unit on the compacting press must
have pressure control.
- The drop height should be minimal
Page 83 of 108 360520998.xlsx

REQUIRED

items
9 discipline and shop floor operations are
maintained - All safety gates are in place and operational
Supplier utilizes technology, as

10
- Tools are properly identified with Customer I.D.

Supplier has adequate methods of tool - Die halves are properly marked
11
storage and maintenance - Storage is adequate to protect tooling
Sintering
- The controls used to adjust temperature ,gas

pressure, belt speed must be locked / password
protected to ensure no unauthorized process
Furnace setup parameters locked / parameter adjustments.
12
password protected. - The furnace should have audible and visual alarm
setup.
- Machine should raise alarm if process parameters
goes out of control limits.
- Furnace profile study must be have been done on

similar parts.
- The study should ensure that the parts from left
corner , middle and right corner of the furnace belt
have same properties of hardness , microstructure
13 Furnace profile study completed.
etc.
- Minimum 9 parts have been taken for study. ( 3
parts each from front , middle and end of furnace
belt ).
- Manual loading vs. automated loading

Green part loading system on the - Parts should not hit each other while loading.
14
sintering furnace belt. - Load pattern should be consistent.
- Quality System in place to maintain material lot#

traceability for automated loading process
Material traceability and Lot control
15 - Quality system in place to detect parts when two
maintained
different material lot# being processed in sintering.
- Furnace should be properly maintained and it

should have scheduled preventive maintenance.
The PM records are readily available.
16 Condition of Furnace - There should not be visible leakage of heat / gas
- The furnace atmosphere is maintained and there is
no issue of parts oxidation.
Page 84 of 108 360520998.xlsx

REQUIRED
Page 85 of 108 360520998.xlsx

Technical Assessment - Plastic Injection N/A = Not Applicable
- Key personnel have required

- PlantEVIDENCE/
is clean, orderly and well lit
DOCUMENTATION
No. ITEM - knowledge
Goals
Job descriptions
defined to perform
in the
for all
Business
job
levels ofPlan the OBSERVATIONS/NOTES Score CORRECTIVE ACTION
- Posted
Organization
5S disciplines
information
Chart
are inwith
isplace
REQUIRED appropriate
key
- organization
requirements
Goals reflect continuous
- and
positions
Appropriate
current filled
machine
(includingguarding
Customer
and safeties
Ratings)
are
- improvement
Training
Sufficient language
Records skills(Including
to support
Contract)
the
- Evidence
Resources
Number ofofappear
communication
machinesadequate sessions
to fulfill
can support all tasks
capacity
- Customer
Minutes oftraining
Employee Managementdefined Review
& implemented
Meetings
The Supplier has the proper type and -- Tonnage
Established
Employee
evident Suggestion
of plan for succession
machines Program
is appropriate for product
volume of equipment to support --- Type
Provision
Evidence
Cross-Training
offor
of screw
No signs
CostMatrix
24ofhour
used
of visible
Quality
is Customer
pollution
Analysis & Tracking
appropriate
or spills
1 support system is appropriate for design of
- Clamping
capability. product

The Supplier has adequate technical - Design and Tooling Engineering support technical
2
capability to produce the parts quoted requirements
- Machines have closed-loop control

- Evidence of SPC Controls in use
The Supplier has Process Controls to - Shot size is appropriate for products
3 ensure conformance to product design - Shot size is monitored
and requirements - Hydraulic pressures are monitored
- PPAP is received from sub-supplier

- C of A is received with each material shipment
- Independent 3rd party validation of C of A takes
The supplier has Sub-supplier controls place on specified frequency
4 - Certified 3rd party labs are used and certificates
in place.
are available.
- Receiving inspection in place
- Presence of critical inspection equipment (e.g.

Supplier has critical inspection CMM, Material Tester etc.)
5 equipment on site - Availability 3rd Party Certified Test and measuring
Facilities
- Set up parameters for each part number is

documented and available
6 - Set up process is conducted and documented
- First off sample is produced and validated
Proper set up processes are in place
- Melt temperatures properly set & monitored
- Die temperatures are monitored with pyrometer
- Dew point meter used to monitor moisture
7 - Residence time for material in barrel is minimal
---Shot to barrel
Presence
APQP of capacity
Documentation maintained
critical inspection
meets AIAG between 40 &
- Tier 2/3 Supplier PPAP
70%
equipment
standard
Material processing parameters are --Water
Records of Advancegauges
temperature Qualityon Planning with
all machines
controlled and monitored --(e.g.
Engineering
Records
Approved
ReviewCMM,
submitted
ofpackaging
Material
Early
software
PPAP
Product
Tester
plans
packages
(e.g. etc.)
CATIA,
for
Tier 2/3 Suppliers
--Containment
IGIS
Availability
Run-at-Rate
Warehouse
Program
accuracy
etc.)Review
and
isto
clean
or
completeness
3rd
OEE
Process
&Party
orderly
Documents
Certified
Flow Test
-- CAE,
Review
Packaging
Organization
Records
Facilities
Mold
Pre-Launch
of
ensures
flow,
Program
Chart
Stress
protection
Control
showing
Review
Analysis
Plans
of Meetings
product
etc.
development
- Air
Inspection/Test records to validate testing size
flow
resources (cfm) proper for material and hopper
-- Fill speed and
Responses pressure
to out are used for
of specification controlled
conditions
8 viscosity are monitored
- Cavity fill and cavity pressure is monitored
- Check for optimal gate freeze (min/max weight)
Critical cycling parameters are - Proper nozzle used for specific material
monitored and maintained
-Maintenance schedule for machines, screw, check
valves, hydraulics
- Check list for regular equipment checks
- Thermolator maintenance is conducted on
9 specified frequency
- All maintenance is documented
360520998.xlsx

- PlantEVIDENCE/
DOCUMENTATION
Goals
Job descriptions
definedto perform
in the
for all
Business
job
levels ofPlanthe OBSERVATIONS/NOTES Score CORRECTIVE ACTION
- Posted
Organization
5S disciplines
information
Chart
are inwith
isplace
key
- organization
requirements
- and
positions
Appropriate
currentfilled
machine
(includingguarding
Customer
and safeties
Ratings)
are
- improvement
Training
Sufficient language
Records skills
(Including
to support
Contract)
the
- Evidence
Resourcesofappear
communication
adequate sessions
to fulfill all tasks
- Customer
Minutes oftraining
Employee Management
defined Review
& implemented
Meetings
- Employee
Established
evident Suggestion
plan for succession
Program
- Provision
Evidence offor
Cross-TrainingCostMatrix
24ofhour
Quality
Customer
Analysis & Tracking
- No signsbands
Heater of visible pollutionand
are working or spills
controllers are
support
calibrated
- Thermocouples are in place and in good condition
- Platens are clean and smooth with bolt holes in
good condition
10
- There are adequate and correct size mold clamps
- No evidence of score marks on tie bars and barrel
carriage
- No signs of nozzle leaks
Physical examination of equipment - All checks are documented
supports overall effectiveness of
- Use of insulated hoses

- Desiccant is changed regularly (every 3000 hrs)
- Filters are cleaned regularly (daily/weekly)
- Air inlet thermometer is used to monitor
temperature
11 - Dry air is monitored with a Dew Point Meter
(Maintains between 0F and 40F)
- Material containers have covers when in use
- Part numbers clearly labeled on boxes and stored
in allocated areas
Material Dryers are in use and appear
in good condition
12 - Check for proper function of chillers

Chillers are used, as necessary and - Evidence of maintenance on chiller system
maintained in good condition
13 - Material containers have covers when in use
- Part numbers clearly labeled on boxes and stored
in allocated areas
resin and raw material
- System ensures correct material is delivered to

14 machine
- system identifies material being used in each
machine
- error proofing is in place to ensure wrong material
Material delivery system is robust is not used
- Color concentrate ratios are correct

- Tumbler used to mix colour concentrate
15 - Regrind percentages are maintained to Customer
specifications
Proper methods in place to control - Proper methods used to control regrind %
required material mixing and - Proper purging methods as part of setup
processing
360520998.xlsx

- PlantEVIDENCE/
DOCUMENTATION
Goals
Job descriptions
definedto perform
in the
for all
Business
job
levels ofPlan the OBSERVATIONS/NOTES Score CORRECTIVE ACTION
- Posted
Organization
5S disciplines
information
Chart
are inwith
isplace
key
- organization
requirements
- and
positions
Appropriate
currentfilled
machine
(includingguarding
Customer
and safeties
Ratings)
are
- improvement
Training
Sufficient language
Records skills
(Including
to supportContract)
the
- Evidence
Resourcesofappear
communication
adequate sessions
to fulfill all tasks
- Customer
Minutes oftraining
Employee ManagementdefinedReview
& implemented
Meetings
- Employee
Established
evident Suggestion
plan for succession
Program
-- Provision
Maintenance
Evidence
Cross-Training
offor isMatrix
Cost performed
24 ofhour
Quality in-house
Customer
Analysis & Tracking
-- Tool
No signs of visible is
maintenance
support
pollution
scheduled or spills
based on cycle
times of mold
- Vents are checked & cleaned after change-over
16 - Cavities and cores are cleaned
- Cooling channels are checked and cleaned
- Any tool repairs and maintenance are documented
- Tool storage locations are clearly identified
Supplier has adequate methods of tool

storage and maintenance

- Design capability, including ability to translate math
17 data (CATIA, UG, Pro-Eng etc.)
- Condition of equipment (EDM, Lathes etc) shows
Supplier has adequate tool design and evidence of maintenance and good repair

items
18 - Temperature and humidity are controlled to ensure
Supplier shows good housekeeping integrity of product
discipline and shop floor operations - All safety gates are in place and operational
are maintained
- Tools are designed for maximum efficiency (hot vs.

cold runner, number of cavities)
19
- Use of automation & robotics is appropriate
Supplier utilizes technology, as - Secondary processing (de-flashing) is minimal
360520998.xlsx
Technical Assessment - Screw Machining N/A = Not Applicable
The Supplier has the proper type and - Number of machines and spindle type can support
volume of equipment to support capacity
1
current and quoted production - Vertical or Horizontal turrets in use
capability. - Machines are fully automated, as appropriate

- Technical capabilities exist to support manufacturing
The Supplier has adequate technical capability
2
capability to produce the parts quoted - Design and Tooling Engineering support technical
requirements
The Supplier has Process Controls to - Machine size is appropriate for product
3 ensure conformance to product design - Evidence of SPC Controls in use
and requirements - Bar diameter and size is appropriate for products
- PPAP is received from sub-supplier

- C of A is received with each material shipment
- Independent 3rd party validation of C of A takes place
The supplier has Sub-supplier controls on specified frequency
4
in place. - Certified 3rd party labs are used and certificates are
available.
- Receiving inspection in place
- heat #s are recorded
- Presence of critical inspection equipment (e.g. CMM,

Supplier has critical inspection air gauge, contour gauge, surface tester)
5 equipment on site - measuring capabilities for GD&T are in place
- Availability 3rd Party Certified Test and measuring
Facilities
- Set up parameters for each part number is

- Set up process is conducted and documented
- Front end and rear end of bar is scrapped
- All set up pieces are scrapped
6 Proper set up processes are in place - Set up parameters for each part number is
- Set up process is conducted and documented
- Front end and rear end of bar is scrapped
- All set up pieces are scrapped
- Proper Feed rate

Critical parameters are monitored and
7 - Tool sharpness is maintained
maintained
- Maintenance schedule for machines

8 - Check list for regular equipment checks
- All maintenance is documented
- Gear boxes and drive gears are in good condition

- Lead cam is properly maintained and replaced when
Physical examination of equipment required
9 supports overall effectiveness of - Turret is in good working condition
equipment maintenance - Spindle is in good condition
- Control station/monitoring is working correctly- - All
checks are documented
Page 89 of 108 360520998.xlsx

Technical Assessment - Screw Machining N/A = Not Applicable

- Lot numbers are controlled and traceable including heat
Proper methods in place to control numbers
10
raw material - Bar stock is labeled and colour coded for size or
material
- Maintenance is performed in-house

- Tool maintenance or adjustments are scheduled based
on parts produced frequency
Supplier has adequate tool
11 - Vents are checked & cleaned after change-over
maintenance program
- Any tool adjustments and maintenance are
documented
- Perishable tooling is available and properly identified

Supplier has adequate methods of tool - Storage is adequate to protect tooling
12
storage - Tool storage locations are clearly identified

13
manufacturing capability - Condition of equipment (EDM, Lathes etc) shows
evidence of maintenance and good repair
- Floors are clear of spills, metal shavings or hazardous

items
are maintained
- Tools application for maximum efficiency

Supplier utilizes technology, as - Use of automation is appropriate
15
Page 90 of 108 360520998.xlsx

-- Key personnel
Presence
APQP Documentation haveinspection
meets AIAG Technical Assessment - Seals N/A = Not Applicable
- PlantTier 2/3
Review is current
clean,
Supplier orderly
completion
- knowledge
Goals
Job descriptions
equipment
Hydraulic
standard defined
Engineering
Records toChange
pressures
of perform
Auditsin thefor
areallBusiness
job
levels of
monitored
Records Planthe
for tonnage,
- Posted
Organization
5S disciplines
Records information
of
Error-proofing
All
Evidence
material CFTChart
ofAdvance are
specifications
to in with
isplace
Quality
onresolve
line appropriate
arekey
Planning
availablewith
problems & known
No. ITEM -ejector
-organization
requirements
Goals
Billet/bar
(e.g.
Records
Approved
Review
Inspection
Audit reflect
Engineering
CMM,
load. temperature
submitted
Schedule continuous
ofInstructions
packaging
Material
Early
software
based
EVIDENCE/ PPAP
Productcontrolled
Tester
on plans
packages
(e.g.
areprocessetc.)(hot/warm
CATIA,
requirements
DOCUMENTATION REQUIRED OBSERVATIONS/NOTES Score CORRECTIVE ACTION
- and positions
Appropriate
Tier
Lot
Record
Poka current
2/3 filled
machine
(including
of Suppliers
numbers
Yoke Customer
are guarding
controlled Customer
andand
traceableRatings)
are&
reports
-process)
- improvement
Training
Sufficient
IGIS
Containment
In
Availability
Run-at-Rate
Warehouse
Program
accuracy
process
latest
(High etc.)
level language
Records
CustomerReview
drawings
and
istoclean
or skills
(Including
completeness
3rd
PPM,OEEProcess
&are
Party to Certified
orderly support
Documents
controlled
Failure FlowContract)
Modes theTest
etc.)
- Billet
Resources
Evidence
Records
Boxes
Lock
status. ofofappear
temperature
boxes
and communication
regular
Evidence
drums adequate
is
for defects
of controlled
Supplier
areTracking
clean and sessions
toLog.
fulfill
and
Audits and
sealed all tasks
monitored
-- Forgings
Customer
Tonnage
Minutes
Employee
Center
CAE,
Review
Packaging
PPAP
Organization
Records
Facilities
Mold and
training
Management
benches
Pre-Launch
of
documents
of ejector
ensures
flow,
Program
Chart defined
availableforce
Stress Review
protection
Lessons-LearnedControl
reflect
and showing&
monitored
Review
for implemented
Analysis
Plans
latest TIR
of
to Meetings
Meetings
product
level
controlled checks
drive etc.
for Laps &
a. -development
Established
Employee
evident
Application
Record ofSuggestion
plan
of
daily for
Program
verificationaction of across
error allproof
-improvement
Provision
Evidence
Cross-Training
Flash offor
Raw /material
Inspection/Test
resources under
Manufacturing
flats Cost Matrix
24
fill isofhour
rubber
recordsQuality
monitored
Documents Customer
to Analysis
ingredients latestare
validate
at & reviewed.
Tracking Where applicable, hardness of
testing
level
- applicable
No signs of
purchased and
steelvisible
similar
cores, pollution
products
springs, or etc.
spillsis reviewed.
-- support
Responses
Forgings to out
monitored of and
specification
controlled conditions
for cracks,
b. Is thereend
including evidence
crackssystem in place to insure stored rubber chemicals do not
exceed shelf life prior to processing.
c. Raw material certification sheets are reviewed and filed, including IMDS and
The Supplier has adequate
Safety Data Sheets
1 controls to assure quality and
d. Raw material is color coded when received
accuracy of incoming mat'l
e. Verification of material chemistry is verified minimally quarterly, or as specified
f. FIFO in place, material segregated by heats, including WIP.
g. Is incoming inspection size and frequency based on AQL tables (military
standard, etc..)
h. Are PSW's for all components available and not older than 1 year
a. Number of molding prep machines.

The Supplier has the proper type
b. Number of rubber molding machines can support capacity.
and volume of equipment to
2 c. Where applicable, number of stamping presses is appropriate for product.
support current and quoted
d. Where applicable, phosphate line can support capacity.
production capability.
e. Choice for automation or manual loading is rational for type of product.
a. Similar products are now produced.

b. Technical capabilities exist to support manufacturing complexity.
c. Design and Tooling Engineering support technical requirements.
d. Qualified chemist is on staff to support rubber making process.
d. Error proofing exist for molding operations.
The Supplier has adequate
Tonnage sensors, short feed sensors, die guides, etc. are in place for stamping
3 technical capability to produce
operations.
the parts quoted
e. Review current PPM for similar product
- APQP Documentation f. Are diameters (OD and ID) the right ones for shaft and bore size for the
meets AIAG assembly
-- Presence
g. APQP Documentation
of critical
Is Elastometer well PPAP inspection
meets
selected AIAG
for the application (Temperature, type of oil,
standard - Tier 2/3 Supplier
- equipment
Hydraulic
standardpressures are monitored for tonnage,
application)?
- Review submitted PPAP - Records of Advance Quality Planning with
--(e.g.
Billet/bar
ejector
Engineering
Records
Approved
ReviewCMM,
load.temperature
submitted
ofpackaging
Material
Early
software PPAP controlled
Product
Tester
plans
packages
(e.g. etc.)(hot/warm
CATIA,
for
packages for Tier 2/3 Suppliers
-process)
- Containment
IGIS
In
Availability
Run-at-Rate
Warehouse
Program
accuracy
process
etc.)Review
drawings
and
istoclean
or
completeness
3rdOEE
Process
&are
Party
orderly
Documents
controlled
Certified
Flow Test
accuracy and completeness a. - Records of regular
Are all molding Supplier Audits
parameters clearlyand
defined and available at presses?
-- Tonnage
Center
CAE,
Review
Packaging
Organization
Records
Facilities
Mold and
benches ejector
Pre-Launch
of
ensures
flow,
Program
Chart force
available
Stress
protection
Control monitored
showing
Review
for
Analysis
Plans
TIR
of Meetings
product
checks
etc.
- Organization Chart b. Where applicable are stamping parameters defined?
development
- Flash
Inspection/Test
resources
/ under fill records
is monitored
c. Is process for removing excess flashto validate testing
automated to insure consistency for flash
showing
- Responses to out of specification conditions
removal?
Theresources
Supplier has Process d. Is a tool change log present at machine where applicable?
Controls to ensure conformance e. In process drawings are controlled.
4
to product design and f. Gauging in place for all critical, significant features.
requirements g. Control charts available for critical features and being filled out properly.
h. Perform weights are closely monitored to control Flash / under fill of seal.
a. All rework processes are identified on P Flow, CP, FMEA & PPAP'd.
b. Standardized Work for all rework operations..
Secondary operations are c. Are all molding parameters clearly defined and available at presses?
5
controlled and monitored d. Is process for removing excess flash automated to insure consistency for
excess flash removal?
Page 91 of 108 360520998.xlsx

-- Key personnel
Presence
- PlantTier 2/3
Review is current
clean,
Supplier orderly
8Ds PPAP forand well lit
completion
- knowledge
Goals
Job descriptions
equipment
Hydraulic
standard defined
Engineering
Records toChange
pressures
of perform
Auditsin the for
areall Business
job
levels of
monitored
Records Planthe
for tonnage,
- Posted
Organization
5S disciplines
Records information
of
Error-proofing
All
Evidence
material CFTChart
ofAdvance are
specifications
to in with
isplace
Quality
onresolve
line appropriate
arekey
Planning
availablewith
problems & known
No. ITEM -ejector
-organization
requirements
Goals
Billet/bar
(e.g.
Records
Approved
Review
Inspection
Audit reflect
Engineering
CMM,
load. temperature
submitted
Schedule continuous
ofInstructions
packaging
Material
Early
software
based
EVIDENCE/ PPAP
Productcontrolled
Tester
on plans
packages
(e.g.
areprocess (hot/warm
etc.)
CATIA,
requirements
- and positions
Appropriate
Tier
Lot
Record
Poka current
2/3 filled
machine
(including
of Suppliers
numbers
Yoke Customer
are controlledguarding
Customer
andand
traceableRatings)
are&
reports
-process)
- improvement
Training
Sufficient
IGIS
Containment
In
Availability
Run-at-Rate
Warehouse
Program
accuracy
process
latest
(High etc.)
level language
Records
Customer Review
drawings
and
istoclean
or skills
(Including
completeness
3rd
PPM,OEE Process
&are
Party to Certified
orderly support
Documents
controlled
Modes theTest
etc.)
- Billet
Resources
Evidence
Records
Boxes
Lock
status. ofofappear
temperature
boxes
and communication
regular
Evidence
drums is
for defects
of adequate
are controlled
Supplier
Tracking
clean and sessions
toLog.
fulfill
and
Audits and
sealed all tasks
monitored
-- Forgings
Customer
Tonnage
Minutes
Employee
Center
CAE,
Review
Packaging
PPAP
Organization
Records
Facilities
Mold and
training
benches
documents
of Management
Pre-Launch
of ejector
ensures
flow,
Program
Chart defined
available force
Stress
Lessons-Learnedprotection
Control
reflect
and Review
showing&
monitored
Review
for implemented
Analysis
Plans
latest TIR
of
to Meetings
Meetings
product
checks
level
controlled drive etc.
for Laps &process i.e..: Mill roll temp.;
a. -development
Established
Employee
evident of
Application
Record
Controls inSuggestion
plan
of
daily for
corrective
place succession
Program
verification action ofacross
error allprep
proof
-improvement
Provision
Evidence
Cross-Training
Flash of
Inspection/Test
resources
/ under
Manufacturing for
Cost
fill isoffor
Matrix
24 hour
records
Documents monitoring
Quality
monitoredCustomer
to validate
at rubber
Analysis
latest & Tracking
testing
level
-flats
perform No signs
applicable ofand
tooling visible
similar pollution
products or spillsweight verification; poppet die size; shape /
Material processing parameters -- support
Responses
Forgings to temp.;
monitoredout of and cutter speed,
specification
controlled conditions
for cracks,
6 wedge cut; specific gravity;
are controlled and monitored including
d. FIFO inend place cracks
for coated mat'l.
e. Identification for FIFO and WIP is in place.
- Billet/bar temperature controlled (hot/warm
process)
- Tonnage and ejector force monitored
a. Maintenance schedule for presses.
b. Ram alignment.
Evidence of proper Preventive c. Check valves, hydraulics.
Maintenance for equipment, d. Check list for regular equipment checks (Weekly, monthly, semi-annually,
7
error proofing, gaging, & annually).
supplementary equipment e. Adequate spare part inventory on hand for all equipment.
f. All gages and masters calibrated.
g. All rabbits
- Review or challenge
current 8Ds forparts according to the process are calibrated.
completion
- Engineering
Records of Audits Change Records
- Error-proofing
Evidence of CFT to onresolve
line problems
- Audit
Inspection
Schedule
Instructions
based onare process
changedrequirements
to reflect
- Record
latest level
(High Customer PPM, Failure Modes etc.)
- Lock
status.
boxes
Evidence
for defects
of Tracking Log.
Physical examination of - Evidence
PPAP documents
of Lessons-Learned
drive
- Application
a. Record ofoil
No visible of
daily
corrective
leaksverification
underaction
moldingof
across
errorallproof presses.
or stamping
equipment supports overall - Manufacturing Documents at latest level
improvement
8 b.applicable and similar
Various gages, productsetc are working.
led readouts,
effectiveness of equipment
c. No questionable noises coming from equipment.
maintenance
a. Compression Rings, Sleeves, etc. are organized and stored for easy access.
b.Tooling is cleaned and reviewed after each run, including repair, polish, or
Supplier has adequate controls
replacement as required.
9 in place for storage and
c. Evidence of periodic checks for bell mouth condition at i.d. interface.
maintenance of standard tooling
d. Inventory levels maintained.
e. Tools are properly identified with Customer I.D. if applicable.
a. Tooling area is organized, tools are stored for easy access.

b. Tooling is cleaned and reviewed after each run, including repair, polished, or
Supplier has adequate controls
replacement as required.
in place for storage and
10 c. Inventory levels are maintained with min/max or similar tracking method, that
maintenance of perishable
includes estimated tool life.
tooling
d. Extrusion dies, mandrels, etc are CVD/PVD Tin coated, or similar type coating.
e. Tools are properly identified with Customer I.D., and applicable part number.
a. Adequate number and skilled tool engineers onsite to support mfg. plant.
Supplier has adequate tool b. Design capability, including ability to translate math data (CATIA, UG, Pro-Eng
11
design capability etc.)
c. Adequate CAD licenses for scope or work.
a. Equipment (Grinders, Lathes, etc) shows evidence of PM's being performed

b. Equipment is adequate for required scope of work.
Supplier has adequate tool room
c. CMM onsite
12 equipment for maintenance and
d. Adequate inspection equipment available.
inspection of tooling
e. Inspection equipment calibration is up to date
f. Tool drawings are available in tool room and are controlled.
Page 92 of 108 360520998.xlsx

-- Key personnel
Presence
- Plant Tier 2/3
Review is current
clean,
Supplier orderly
completion
- knowledge
Goals
Job descriptions
equipment
Hydraulic
standard defined
Engineering
Records toChange
pressures
of perform
Auditsin the for
areall Business
job
levels of
monitored
Records Planthe
for tonnage,
- Posted Organization
5S disciplines
Records information
of
Error-proofing
All
Evidence
material CFTChart
ofAdvance are
specifications
to in with
isplace
Quality
onresolve
line appropriate
arekey
Planning
availablewith
problems & known
No. ITEM -ejector
-organization
requirements
Goals
Billet/bar
(e.g.
Records
Approved
Review
Inspection
Audit reflect
Engineering
CMM,
load. temperature
submitted
Schedule continuous
ofInstructions
packaging
Material
Early
software
based
EVIDENCE/ PPAP
Productcontrolled
Tester
on plans
packages
(e.g.
areprocess (hot/warm
etc.)
CATIA,
requirements
- and positions
Appropriate
Tier
Lot
Record
Poka current
2/3 filled
machine
(including
of Suppliers
numbers
Yoke Customer
are guarding
controlled Customer
andand
traceableRatings)
are&
reports
-process)
- improvement
Training
Sufficient
IGIS
Containment
In
Availability
Run-at-Rate
Warehouse
Program
accuracy
process
latest
(High etc.)
level language
Records
CustomerReview
drawings
and
istoclean
or skills
(Including
completeness
3rd
PPM,OEEProcess
&are
Party to Certified
orderly support
Documents
controlled
Modes theTest
etc.)
- Billet
Resources
Evidence
Records
Boxes
Lock
status. ofofappear
temperature
boxes
and communication
regular
Evidence
drums
for defects
ofadequate
is controlled
Supplier
areTracking
clean and sessions
toLog.
fulfill
and
Audits and
sealed all tasks
monitored
a. - - Customer
Tonnage
Minutes
Employee
Center
CAE,
Review
Packaging
PPAP
Evidence
Forgings
Floors of
Organization
Records
Facilities
Mold and
training
Management
benches
Pre-Launch
of
documents
of ejector
ensures
flow,
Program
Chart defined
available force
Stress
protection
Lessons-Learned
monitored Control
reflect
and Review
showing&
monitored
Review
for implemented
Analysis
Plans
latest TIR
of
to Meetings
Meetings
product
checks
level
controlled drive
foretc.
Laps & items.
evidentare
-development
Established
Employee
Application
Record of clear
Suggestion
plan
of
daily ofverification
for
corrective spills, pelletsof
succession
Program
action orerror
across hazardous
allproof
-improvement
Provision
Evidence
Cross-Training
Flash offor
Inspection/Test
resources
/ under
24
fill isofhumidity
hour
records
Documents Quality
monitoredCustomer
to Analysis
validate
at latest & Tracking
testing
level
Supplier shows good b. -flatsTemperature
No signs ofand
applicable and
visible
similar pollution
productsare controlled
or spills to ensure integrity of product as
housekeeping discipline and -- support
required. Responses
Forgings to out of and
monitored specification
controlledconditions
for cracks,
13
shop floor operations are c. including
All safetyend cracks
gates are in place and operational
maintained d. Work areas are free of debris, only required tooling, gages, etc at work areas.
e. Is 5S program on site and is it followed accordingly?
a. Quick Die Change tooling designs.

Supplier utilizes technology and
b. Use of automation & robotics is appropriate.
14 methods, as appropriate, to
c. Secondary processing (de-flashing) is minimal.
maximize efficiency
d. Standardized work charts on site.
a. Temperature for curing is adequate for the seal.

b. Time of curing is adequate for the seal.
c. Is there an automated controlled process.
Cure process controls are
15 d. Is there a check list to verify all parameters are correct?
monitored
e. Are instructions for the associate or operator available and visible?
f. Safety requirements on site.
g. Post curing stock is controlled with IDs and FIFO
a. Parameter control check list and follow up (pressure, humidity, speeds, density)
Wax, Oil or Borettite application b. Control charts available for critical features.
16
is controlled. c. Inspection methods according to the characteristic
d. Preventive maintenance plan for nozzles, pipes, heaters.
a. Chemical Concentration and Ph level.

b. Tank Temperature.
Phosphate Line parameters are
17 c. Submersion Time.
controlled
d. Phosphate control charts for thickness on site (if required).
e. Hardness inspection frequency (if required).
a. Solution ratio.
Bonding agent parameters are
18 b. Temperature.
controlled
c. Time.
- Billet temperature is controlled and monitored

- Forgings monitored and controlled for Laps Indicate
& total number of elements per risk level, in summary on Cover Page
flats
- Forgings monitored and controlled for cracks,
Page 93 of 108 360520998.xlsx

Technical Assessment - Stamping N/A = Not Applicable
REQUIRED
- Number of machines can support capacity.
The Supplier has the proper type and - Tonnage of machines is appropriate for product
volume of equipment to support
1
capability.
- Similar products are now produced.

manufacturing.
The Supplier has adequate technical - Design and Tooling Engineering support technical
2
capability to produce the parts quoted. requirements.
- Review current PPM for similar product.
- Tonnage sensors, short feed sensors, die guides,

The Supplier has process controls to etc.
3 ensure conformance to product design - Die design supports volume.
and requirements (Error Proofing)
- Tonnage monitors are considered gages, and must

be treated as such in accordance to AIAG
requirements.
The supplier has documentation for - Tonnage monitors should be used for predictive
4 verifying tonnage monitoring calibrator process control, as well as press and die protection.
by an A2LA Lab
- Supplier has thoroughly documented procedures

to ensure all critical items (die space, datum's, lifter
Does supplier have dynamic/static buy operations, etc.) are reviewed and addressed. This
off procedures for procurement of new procedure should cover all aspects of die
5
tools and implementation of construction and production readiness.
engineering changes.
- Supplier has system for preventative maintenance

performed and recorded on equipment?
- All records are maintained electronically or
recorded manually. Evidence PM is being
Evidence of proper preventative performed per OEM recommendations.
maintenance for equipment - Evidence PM checks sheets are maintained are
6 are up to date for daily lubrication, belts that drive fly
Daily, weekly, monthly equipment wheels, grease fittings, wear plates, etc.
maintenance.
- Is there evidence work orders are generated for

die preventative maintenance.
Are records maintained electronically or recorded
Evidence of proper preventative manually. Is there evidence PM is being performed
maintenance for Dies. based on number of hits being monitored.
Are nitrogen systems (self-contained) - All nitrogen systems must be part of a predictive
7 part of supplier predictive maintenance maintenance program (based on hits, not time) to
plan? ensure that no non-conforming product can be
produced as a result of low or excessive tonnage.
Page 94 of 108 360520998.xlsx

REQUIRED
- Stamping presses appear to be in good working
Physical examination of equipment order. There is no evidence of oil leaks on floor, etc.
8 supports overall effectiveness of
- Supplier shows evidence of customer owned

Does die have customer asset tag tooling.
9 attached or is customer name
engraved in die?
- All suppliers must utilize draw lubricants that are

listed on an approved lubricant list to ensure
Are supplier draw lubes listed compatibility with all subsequent Magna systems.
10
unapproved source list.
- Receiving inspection records include verification of

chemistries on certs, as well as dimensional and
Supplier has proper methods in place visual verification of material.
to insure raw materials meet - All material specifications are available & known.
11
specifications. Material issued to - Lot numbers are controlled and traceable.
presses follows FIFO.
- Evidence process is designed to insure parts exit

on opposite sides of the press or opposite ends of
What error proofing is in place to the press to prevent possible mixing.
12 address right and left hand (two out
dies)?
- Evidence records are maintained after each

production run to show tool was reviewed.
- Supplier sharpens tools, and or replaces punches
where applicable based on the monitoring of number
Supplier has adequate methods of tool of hits.
13
- Die halves are properly marked.
- Storage is adequate to protect tooling.
- Adequate number and skill level of tool engineers.

math data (CATIA, UG, Pro-Eng etc.)
Supplier has adequate tool design and - Condition of equipment (EDM, Lathes, etc.) shows
14
manufacturing capability. evidence of maintenance and good repair.
Note: If tooling is outsourced, supplier can provide
name of tooling vendor, and credentials.
- Floors are clear of spills, metal scraps or

Supplier shows good housekeeping hazardous items
15 discipline and shop floor operations - All safety gates are in place and operational.
are maintained
Is there evidence operator work instructions are

available for operator and set-up access? Are they
current and does the revision on the production floor
match master copy revision?
Do operator instructions and /or press Press set-up and/or operator instructions should
16 set-up instructions match production include shut height parameter, nitrogen system
parameters? pressure, counter balance pressure, feed rate and
total/per corner tonnage at a minimum. This will
insure consistent set-up from shift to shift, as well as
help in the troubleshooting process.
Page 95 of 108 360520998.xlsx

REQUIRED
Supplier shows evidence first piece reports are
What parameters are checked for placed at press, or are easily accessible for operator
17 startup (Dimensional, PLC, etc.). First review.
piece approval posted.
- Tools are designed for maximum efficiency.

Supplier utilizes technology, as - Use of automation & robotics is appropriate.
18
- Supplier shows evidence press safety features are

in place such as: Light curtains, guard plates, run
19 Safety features utilized on equipment and stop buttons, etc.
- Use of automation & robotics is appropriate.
Page 96 of 108 360520998.xlsx

Customer PDCA PLANNING WORKSHEET
PLAN DO
Task Timing
Status No. Issue Description Actions Taken Responsibility Start Target
Date Date
Project name
Materials -
= 1Behind
= 2O.K.
= 3Completed
4
5
6
Quality -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Manufacturing -
1
2
3
4
5
6
= Behind
= O.K. Engineering -
= 1Completed
2
3
4
5
6
7
8
9
10
11
12
13
Systemics - Plantwide Initiatives

1
2
3
4
5
6
7
8
9
10
Magna PPM
300
250
200
150
100
50
0
40553 40585 40617 40649 40681 40713 40745 40777 40809
EET PDCA Update 06/21/10
Check / Measure / Actions Effective?

ask Timing
Closed Results/Conclusions Comments
Date
me
g-
-
e Initiatives
Row 4
0777 40809 40841 40873 40905 40937

Month Jan-11 Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11
Magna PPM
Oct-11 Nov-11 Dec-11 Jan-12
Revision Summary
Previous Level New Level Page # Element # Description

8/29/2005 9/26/2005 Guidelines Language changed/added to paragraphs 2, 5 & 6
8/29/2005 9/26/2005 2 9 Certified 3rd Party Test Facility added
"Customer" added before "Non-Conformance" and
8/29/2005 9/26/2005 3 27 Tracking Log added
"PPAP Documents & "Manufacturing Documents"

8/29/2005 9/26/2005 3 24 added
8/29/2005 9/26/2005 4 30 Additional elements defined

8/29/2005 9/26/2005 Cover Approvals added (if required)
8/29/2005 9/26/2005 Cover PPM Changed to show Current PPM
8/29/2005 9/26/2005 Cover "Optional" added to Strengths & Weaknesses
8/29/2005 9/26/2005 Cover Liability Insurance question added
8/29/2005 9/26/2005 4 29 Lack of bottlenecks or constraints added
8/29/2005 9/26/2005 3 25 Verification of error-proofing added
8/29/2005 9/26/2005 3 20 "authorized bysignature" added
8/29/2005 9/26/2005 4 29 "in a secure and segregated area" added
8/29/2005 9/26/2005 4 29 "in identified containers" added
8/29/2005 9/26/2005 4 30 "check for use of bar code labelling" added
8/29/2005 9/26/2005 2 17 Approved Supplier List added
8/29/2005 9/26/2005 2 16 Records of Supplier Audits added
8/29/2005 9/26/2005 3 23 Requirements for statistical control added
8/29/2005 9/26/2005 Guidelines Final paragraph added re: Site specific assessments
9/26/2005 2/27/2006 Heat Treat Technical Assessment Added
Plastic Injection Technical Assessment Added
Cover Technical Assessment Rating Added
2/27/2006 3/20/2006 Plating/Coating Technical Assessment Added
3/20/2006 7/25/2008 H/Treat Section Removed - Use CQI Certification
3/20/2006 7/25/2008 Plating Section Removed - Use CQI Certification
3/20/2006 9/23/2008 Cover Risk level reporting for Financial/Technical revised
Financial assessment revised - risk level added and
3/20/2006 9/23/2008 Finance financial results metrics added
9/23/2008 9/26/2008 Previous update used wrong assessment
Reference Ratios added to Pg2 and Finance Data

9/26/2008 10/1/2008 Finance modified
10/1/2008 2/10/2010 Finance Financial assessment tab removed

Organization 10 & 11 Global Working Conditions added
2/10/2010 9/27/2010 Plastic Inj Plastic Injection tab removed
9/27/2010 10/31/2010-V10 All All Scoring corrected, Technical Assessments added
10/31/2010-V10 11/01/2010-V11 All All High Risk element tracking and scoring added
360520998.xlsx
11/01/2010-V11 02/18/2011-V12 Cover Union and CQI information added
Quality Added - Previous Sections redefined
Facilities/ Added - Previous Sections redefined
Tooling
Purchasing Added - Previous Sections redefined
Operations Added - Previous Sections redefined
Engineering Added - Previous Sections redefined
Quick Scoring method revised
Assessment
Detailed Scoring method revised
Quality Ass't.
Materials 14 C-TPAT & PIP requirements added
Purchasing 12 NAFTA/Customs requirements added
02/18/2011-V12 03/14/2011-V13 Formatting & printing settings improved
Corrective
03/14/2011-V13 04/15/2011-V14 Format changed to PDCA Tracker
Acition
04/15/2011-V14 05/04/2011-V15 All All Scoring method revised
Advance Q. 19 Revised
7 Revised
Materials 7 Revised
3 Revised
Operations 6 Added
Organization 4 Revised
6 Revised
7 Added
Purchasing 3 Revised
10 Added
Quality 3 Added
6 Revised
10 Revised
16 Added
05/04/2011-V15 09/30/2011-V16 Cover Supplier contact information added
Detailed
All Scoring method revised and descriptions added
Quality Ass't.
All "Notes" added to header of each section
360520998.xlsx
cription
to paragraphs 2, 5 & 6
cility added
Non-Conformance" and
Manufacturing Documents"
dded
d
ed)
rrent PPM
ths & Weaknesses
n added
straints added
g added
added
ed area" added
dded
labelling" added
ded
added
l control added
Site specific assessments
ssment Added
Assessment Added
ng Added
Assessment Added
QI Certification
QI Certification
ancial/Technical revised
sed - risk level added and
ded
ng assessment
Pg2 and Finance Data
emoved
added
ed
al Assessments added
and scoring added
360520998.xlsx
added
redefined
redefined
redefined
redefined
redefined
s added
ents added
ngs improved
Tracker
n added
d descriptions added
f each section
360520998.xlsx

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Supplier

SUPPLIER NAME: Supplier Contact Name:

Supplier Contact Postion:

FAX NUMBER: E-Mail Address

CUSTOMERS (AUTOMOTOVE): Customer PPM (YTD Avge.)

Union Facility YES If Yes, Contract Expire:

YES YES YES Yes

Has Certification ever been revoked? YES If Yes, State Reason:

CQI Compliant? N/A Yes No CQI #: Next Assessment:

PRODUCT FOCUS FOR ASSESSMENT

FULL OPERATIONAL/QUALITY ASSESSMENT RESULTS (Optional Comments)

Major Concerns of Organization:

QUICK/TECHNICAL ASSESSMENT RESULTS Level of Risk Observed Assessment Completed By:

TYPE COMPLETED: Name:

360520998.xlsx Cover Sheet

General Organization and Management

No formal organization chart.

No formal health & safety program in effect

No evidence of communication to employees

No formal continous improvement program

No formal job descriptions at any level

No awareness of customer requirements

No formal LPA process

No formal process in place

Process to ensure detailed Contract Review, including

Advanced Product Planning

No formal or documented system in place

No records of program reviews

No electronic capability to communicate (eg. IGIS,

No system or process to review packaging

No system or process to validate equipment

No system to ensure verification of material at start

No formal system to track changes and ensure

No focus on mistake proofing or error prevention

Process Flow Diagram and actual production flow

No linkage between FMEA's, Control Plans and

No tracking of critical and special characteristics

Total or significant lack of risk numbers on FMEA's

No linkage between RPN's and mistake proofing

No reference to gauges, test equipment or test

No tracking system in place

No documented system of communication in place

No documented system to qualify suppliers

Lack of or poorly managed system

Materials and Logistics High Risk

No formal system to ensure receipt/validity of

Facilities & Tooling High Risk

Does the supplier conduct a Tooling inventory and No regular inventory

Very little or no knowledge of capacity available

Does the Supplier have a process to monitor tooling

Purchasing High Risk

Supplier lacks internal expertise on product or

How does this Supplier communicate customer No formal process in place

Operations High Risk

From an overall perspective, is this Suppliers facility Poor housekeeping practices

Is there a formal defined safety program? No formal safety program in place

Is there a process to address absenteeism? No formal tracking of absenteeism

If required by Customer and/or Government regulations No system to track validation requirements

Organization chart in place. Organization chart in place.

Safety program in place Safety program in place

Some evidence of communication to employees Consistent evidence of communication

Evidence of continuous improvement program Evidence of continuous improvement program

Aware of customer requirements Aware of customer requirements