PSO

Process Sign-Off

Edition 5.5


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION













Edit ion 5 . 5

December 2 0 0 6






















PROCESS SIGN-OFF
(PSO)

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COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
Proc e s s Sign-Off (PSO)

FOREWARD TO THE 5.5 EDITION


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

In or der t o a ch ieve a n appreciable impr ovemen t in pa r t qu a lity, t h is ma n u a l h a s been
modified t o reflect Da imlerCh rys ler Corpora t ion ’s cu rren t PSO ph ilos oph y. Emph a s is is
pla ced on t h e impor t a n ce of adh er in g t o ou r Pr odu ct Crea t ion Pr oces s , i.e. t h e Ch r ys ler
Developmen t Sys t em (CDS). Th is ma n u a l s h ou ld be reviewed ca r efu lly a n d in it s en t iret y
t o a s s u re t h a t a ll PSO requ iremen t s a re known a n d u n ders t ood. Th e 25 PSO Proces s
Elemen t s iden t ified in t he 5
t h
Edit ion PSO Ma n u a l were re-evalu a ted a n d, in s ome cas es ,
modified or r emoved.

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION



ACKNOWLEDGMENTS




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

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

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


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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION


PROCESS SIGN-OFF (PSO)

Ta ble of Con ten t s



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

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

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

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

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

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

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

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

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

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

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

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

In dex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
1
Proc e s s Sign-Off (PSO)

INTRODUCTION

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


PROCESS SIGN-OFF DEFINITION

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

Ea ch PSO in clu des eva lu a t ion of a s s ocia ted produ ct ion fa cilit ies , r ela ted
ma n power , equ ipmen t , ma ter ial, met h ods , procedu res , s oft wa r e level(s ) a nd
t oolin g. Th e PSO is u t ilized t o s cr u t in ize t he Su pplier’s en t ire pr odu ct ion
proces s , in clu din g a ll in-h ou s e a n d s econda r y s ys tems t h a t s u ppor t pr ima r y
pr odu ct ion line(s ).

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

2. PSO On -s ite Vis it
Th e DCC PSO t ea m s ha ll wit n es s a t lea s t one Pr odu ct ion Demon s t r a t ion
Ru n (PDR) u t ilizin g completed pr odu ct ion t ools a s pa r t of t h e PSO pr oces s
for a ll Collabor a t ive a nd Direct ed AQP Act ivit y Level pa r t s . PSO a ct ivit ies
s h a ll be condu cted by t h e Su pplier for a ll Self-Directed AQP Act ivit y Level
pa r t s . Da t a collect ion , a n a lys is , a n d s u mma r iza t ion a re t he t r u e meas u res
of pa r t qu a lit y a nd pr odu ct ion ca pa bilit ies . Obs er vin g t he PDR s h ou ld
r evea l is s u es s u ch a s bot t lenecks a nd inefficien cies . Pr odu ct ion Pr oces s
r eview a n d mea s u remen t s will pr ovide t he produ ct ion r a t e, Fir s t Time
Capabilit y (FTC) a n d ot her s t a t is t ics t h a t va lida te ea ch Su pplier ’s a bilit y t o
effect ively pr odu ce bot h t he requ ired qu a lit y a nd pr odu ct qu an t it ies .


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2
Fu ll complia n ce wit h a ll PSO requ iremen t s a nd pr ocedu res en s u res t h a t
t h e Su pplier’s ma n u fact u rin g proces s is s t a ble, in con t rol a nd ca pa ble of
pr odu cin g pa r t s t h a t meet a ll r equ iremen t s .

3. Va lida t ion Tes t in g
Pr odu ct ion Va lida t ion (PV) Tes tin g, of t h e Pr odu ct ion Demon s tr a t ion pa r t s ,
will va lida te t he Su pplier ’s s ys tem a n d pr ovide eviden ce t h a t t h e pa r t s
meet en gineerin g, qu a lit y, du rabilit y, a n d r elia bilit y r equ iremen t s
con t a ined in t h e Per for ma nce, Pr oces s , a nd Ma ter ia l Specificat ion s .
Pa cka gin g a nd s h ippin g or s imu la t ion tes t approva ls a re requ ir ed by
Ma ter ia l Ha n dlin g En gin eer in g if a pplica ble.


WHY IS A PSO NECESSARY?
Proces s Sign -Off is a n effect ive met h od of ver ifyin g a Su pplier’s qu a lit y
pla n n in g proces s es . It con fir ms t h a t t h e pr oces s es ca n a nd will (wh en
pr oper ly a n d s u cces s fu lly execu ted) pr odu ce qu a lit y pa r t s in s u fficien t
qu a n t it ies for produ ct ion .


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


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

Th e pu r pos e of t h e PSO is to demons t r a t e Su pplier proces s ca pabilit y a n d pr odu ct ion
ca pa cit y. Th e PSO demon s t ra t ion s h a ll produ ce dimen s ion a lly correct pa rt s on t he h ome-
lin e wit h pr odu ct ion toolin g. Th e requ iremen t is t o complete a ll PSO’s a nd PPAP
s u bmis s ions pr ior t o s u pplyin g pa r t s for S1 St a r t . If PPAP is n ot complete pr ior t o S1

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


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

- Pre -PSO Mee t ing:
Th e DCC ASQP Specia lis t will in it ia t e PSO dia logu e wit h t he DCC Produ ct
En gin eer a n d t he Su pplier (i.e., for Dir ected a nd Collabor a t ive PSO’s ).
Toget her, t h ey will s chedu le a nd coordina te t h e Pre-PSO Meet in g a s well as
t h e PSO On-Site Vis it . Th e ASQP Specia lis t will a dvis e t he Su pplier of t he
docu men t a t ion t he tea m will wa n t t o r eview a nd whet her t he pa r t h a s been
s elected for a PSO Ext ended Ru n .

- Proce s s Sign-Off On-Sit e Vis it :
Th e PSO Tea m s ha ll complete t h e fir s t 20 elemen t s of t h e PSO SUMMARY
REPORT a t t h e Su pplier ’s ma nu fa ct u r in g fa cilit y. Th e PSO Tea m s h a ll a ls o
ver ify t h e Su pplier’s complia nce t o a ll 21 elemen t s of PSO Edit ion 5.5
before fu ll appr ova l is given . An y devia t ion s s h a ll be recor ded on t h e PSO
COMMENTS SHEET. A s u cces s fu l PDR s h a ll yield pa r t s for Pr odu ct ion
Va lida t ion (PV) Tes t in g.

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

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

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


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

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

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

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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CONDUCT PRE-PSO
MEETING (REVIEW
SUPPLIER’S
DOCUMENTATION & SRE)
PSO TEAM CONDUCTS
PSO ON-SITE VISIT or
SUPPLIER PERFORMS
PRODUCTION
DEMONSTRATION RUN
(Self Directed AQP)
SUPPLIER CONDUCTS
PV TESTING
PSO TEAM
COMPLETES
PROCESS SIGN-OFF
SUPPLIER SUBMITS PPAP
PART SUBMISSION
WARRANT
PROCESS SIGN – OFF STRATEGY
REVIEW PSO
REQUIREMENTS WITH
PSO TEAM
& SUPPLIER
SUPPLIER PERFORMS
READINESS EVALUATION
RUN
SUPPLIER COMPLIES WITH
CONTINUOUS
CONFORMANCE
REQUIREMENTS

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

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

b

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
7
PROCESS SIGN-OFF

FLOWCHART RESPONSIBILITIES

RESPONSIBILITY
LEGEND PROCESS NAME
D
C
C


P
R
O
C
U
R
E
M
E
N
T


D
C
C


E
N
G
I
N
E
E
R
I
N
G

D
C
C

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

D
C
C


A
S
Q
P


S
U
P
P
L
I
E
R

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
8
11
PSO ON-SITE VISIT or
SUPPLIER CONDUCTS
PRODUCTION
DEMONSTRATION RUN
12
ELEMENTS 1-20
ACCEPTABLE?
A
YES
NO
c
NO
19
PSO APPROVED,
“A” DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
YES
d
NO
Figure 2.2
b
17
INVESTIGATE REASON
FOR FAILURE AND ROOT
CAUSE ELIMINATION
15
SUPPLIER CONDUCTS
ELEMENT 21
16
ELEMENT 21
ACCEPTABLE?
20
SUPPLIER SUBMITS
PPAP WARRANT & ENTERS
PPAP DATE IN
POWERWAY.COM
12A
PSO ON-SITE REVISIT
NECESSARY?
13
SUPPLIER CONDUCTS
CORRECTIVE ACTION
AND SUBMITS
DOCUMENTATION
NO
18
REPETITION
OF ELEMENT 21
SUFFICIENT?
YES
YES
14
“Z” DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
19A
SUPPLIER CONDUCTS
PSO IN ACCORDANCE
WITH PSO MANUAL
AND ENTERS PSO
DATE & DISPOSITION
INTO POWERWAY.COM

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
9
PROCESS SIGN-OFF
FLOWCHART RESPONSIBILITIES


RESPONSIBILITY
LEGEND PROCESS NAME
D
C
C

P
R
O
C
U
R
E
M
E
N
T

D
C
C


E
N
G
I
N
E
E
R
I
N
G

D
C
C

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

D
C
C


A
S
Q
P


S
U
P
P
L
I
E
R

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


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

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

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

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

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

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

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
10
























INTENTIONALLY LEFT BLANK


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
11
























PSO ELEMENT REQUIREMENTS





















COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
12
PART NUMBER, DESCRIPTION AND CHANGE LEVEL
Element Requirement s Document at ion
1 . 1 Th e PSO team s h all r eview all PSO relat ed docu men t s t o ens u r e
all docu men t s h ave t he cor rect par t n u mber , des cr ipt ion an d ch an ge
level pres en t or cr os s -referen ced (s ee ISO/ TS-16949 cl. 4. 2. 3 Con t rol
of Docu men t s ).

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

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

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

1 . 3 Wh ere t he pr odu ct iden t it y is n ot in h er en t ly obviou s , t he Su pplier
s h all employ an in t er n al n u mber in g s ys tem an d pr ovide a cr os s
r eferen ce wh ich en ables u s er s t o iden t ify t he DCC par t n u mber an d
r evis ion level wh ich cor res pon ds t o t h e Su pplier ’s n u mber in g an d
r evis ion s ys tem.

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

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

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

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

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




COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
13







































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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
14

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

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

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

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

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

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

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

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

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

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

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

NOTE: Special at t en t ion (as defined by DCC En gin eer in g) s h all be
given t o failu r e modes wit h :
- A Sever it y 8, regar dles s of Occu r r en ce or Detect ion valu es .
- A Sever it y 5 and Occu r r en ce 2, regar dles s of Detect ion (t h is
equ at es t o cu s t omer dis s at is fact ion an d c’s / 1000 > 1. )
- A Detect ion of 10.
See Appen dix B “FMEA Gu idelin es ”.
- DFMEA (MANDATORY
ENGLISH)
- “Bes t Pr act ice”
pr ocedu r e


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
15






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

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

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

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

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

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

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

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

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

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

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

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

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




COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
16
PROCESS FMEA
Element Requirement s Document at ion
4 . 1 Pr oces s FMEAs (PFMEAs ) s h all be created u s in g t h e lat es t AIAG
an d DCC gu idelin es . If AIAG an d DCC gu idelin es dis agree, DCC
gu idelin es t ake preceden ce.

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

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

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

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

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

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

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

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

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

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

NOTE: Special at t en t ion s h all be given t o failu r e modes wit h :
- A Sever it y 8, regar dles s of Occu r r en ce or Detect ion valu es .
- A Sever it y 5 and Occu r r en ce 2, regar dles s of Detect ion valu e
(t h is equ at es t o cu s t omer dis s at is fact ion an d c’s / 1000 > 1. )
- A Detect ion of 10.
See Appen dix B an d t he “Su pplier PFMEA Au dit Su mmar y” s h eet
(in t er n al DCC wor k in s t r u ct ion PSWI-1047; Su pplier s do n ot h ave
acces s an d s h ou ld obt ain a copy fr om t h eir ASQP Specialis t . )
- PFMEA (MANDATORY
ENGLISH)
- PFMEA Au dit
Su mmar y
(MANDATORY
ENGLISH)
- “Bes t Pr act ice”
pr ocedu r e




COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
17













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

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

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

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

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

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

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

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

5 . 4 Th e flow diagr am, man u fact u r in g floor plan an d/ or t h e wor k
s t at ion layou t s h all in clu de t h e n u mber of oper at or s , in clu din g floa t
oper at or s , requ ir ed per s t at ion (in clu din g r epair / rewor k s t at ion s ). Th e
PSO t eam s h all ver ify t he n u mber of oper at or s du r in g t h e On -Sit e
Vis it .

5 . 5 Th e flow diagr am, man u fact u r in g floor plan an d/ or t h e wor k
s t at ion layou t s h all iden t ify bot t len eck oper at ion s or s t at ion s .

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
18
CONTROL PLAN & PROCESS MONITORING
Element Requirement s Document at ion
6 . 1 Th e Con t r ol Pla n s h all des cr ibe each s tep of t he man u fact u r in g
pr oces s in clu din g: receivin g, mater ial h a n dlin g a n d s t or age, in -
pr oces s oper at ion s , t es t in g, in s pect ion s , rewor k/ repair , s h ippin g,
t empor ar y or in t er im off-s t an dar d oper at ion s (e. g. back-u p
oper at ion s ), an d con t in u ou s con for man ce. Refer t o t he AIAG
Advan ced Pr odu ct Qu alit y Plan n in g man u al.

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

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

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

6 . 1 . 4 Th e Su pplier s h all h ave a pr oces s wh ich lin ks t h e Su pplier ’s
DFMEA an d PFMEA t o t h e Con t r ol Plan . Th is pr oces s s h all en s u r e
t h at con t r ols , les s on s lear n ed, etc. det ailed in t h e DFMEA an d
PFMEA, ar e car r ied forwar d in t o t h e Con t r ol Plan .

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

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

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

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

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

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





COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
19
CONTROL PLAN & PROCESS MONITORING, CONT.
Element Requirement s
6 . 3 . 1 Th e pr ocedu re s h all requ ir e Fir s t Piece Appr oval at t h e
begin n in g of each s h ift or pr odu ct ion r u n a n d aft er an y ch an ges
ar e made t o t he pr odu ct ion pr oces s (e. g. t oolin g modificat ion s , SPC
adju s t men t s , et c. )

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

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

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

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

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

6 . 6 Wh ere SPC met h ods are u s ed, t he Su pplier is requ ir ed t o main t ain
a h is t or y of compon en t pr odu ct ion s equ en ce, pr odu ct ion lin e,
pr odu ct ion t ool an d ch ar act er is t ics ’ valu es t o as s is t in as s embly plan t ,
war r an t y an d field ret u r n r oot cau s e in ves t igat ion s . See t he
“Daimler Ch r ys ler Cu s t omer -Specific Requ ir emen t s ” for ISO/ TS-16949,
cl. 4.1. 1.

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

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








COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
20
QUALITY PLANNING
Element Requirement s Document at ion
7 . 1 All Adva n ce Pr odu ct Qu alit y Plan s (APQPs ) s h all coor din a t e with
DCC Ch r ys ler Developmen t Sys t em (CDS) t imin g for each applicable
pr ogr am. Th e plan s h all iden t ify major miles t on e even t s , requ ir ed
pr odu ct or pr oces s deliver ables , res pon s ible or gan izat ion s , as well as
s ch edu led an d act u al t imin g dat es . Referen ce t he AIAG Advan ced
Pr odu ct Qu alit y Plan n in g a n d Con t r ol Plan (APQP) ma n u al an d CDS at
h t t p:/ / r oadmap. t cc. ch r ys ler . com/ cds / .

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

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

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

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

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

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

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

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





COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
21
QUALITY PLANNING, CONT.
Element Requirement s
7 . 5 Th e PSO team s h all r eview cor r ect ive act ion s for an y n on -
con for man ces or tes t failu r es en cou n t er ed pr ior t o t he PSO vis it (e.g.
du r in g pilot bu ilds , DV tes t in g, etc. ) Th e t eam s h all en s u re t h at all
cor r ect ive act ion s h ave been completed an d implemen ted (e. g. t h r ou gh
er r or an d/ or mis t ake pr oofin g, proces s or des ign ch an ges , etc. )

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

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

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

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

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

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

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

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

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










COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
22
INCOMING & OUTGOING MATERIAL QUALIFACTION/ CERTIFICATION PLAN
Element Requirement s Document at ion
Incomi ng Mat erial Cert ific at ion Plan
8 . 1 Th e In comin g Mat er ial Cer t ificat ion Pla n s h all in clu de pr ocedu r es
u s ed t o qu alify an d cer t ify in comin g mat er ial pr ior t o r eleas in g in t o
pr odu ct ion .

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

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

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

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

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

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

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

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

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

8 . 8 Th e Su pplier s h all h ave copies of t heir s u b-t ier s ’ ISO 9001
cer t ificat ion on file.
- In comin g in s pect ion
plan
- Samplin g pla n s
- Receivin g Repor t s
- In s pect ion / t es t repor t s
- Copies of s u b-t ier
Su pplier Cer t ificat es of
An a lys is for each
s pecific s u b-
compon en t
- Copies of s u b-t ier
Su pplier PSW’s (Par t
Su bmis s ion War r an t )
- Copies of s u b-t ier
Su pplier ISO-9001
cer t ificat ion s
- Ou t goin g In s pect ion
Plan
- Par t In s pect ion
St an dar d
- Au dit Wor k
In s t r u ct ion s
- Sh ippin g r epor t s
- Au dit Recor ds










COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
23

























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

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

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

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
24

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

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

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

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

NOTE: Daimler Ch r ys ler does n ot pr ocu r e ret u r n able con t ain er s for
Su pplier ’s WIP (Wor k in Pr oces s ) or s u b-t ier Su pplier s . Con t ain er s for
t h es e compon en t s are t he res pons ibilit y of t h e Su pplier. Us e of DCC
con t ain er s for t h is pu r pos e is cons idered mis appr opr iat ion of DCC
cor por at e as s et s and is unac cept able. If t h e PSO Team detect s a
con t ain er violat ion du r in g t h e PSO On -Sit e Vis it , Elemen t 9 “Par t s
Han dlin g Plan ” on t h e PSO SUMMARY REPORT s h a ll be mar ked
REJ ECT in t h e Pr oces s colu mn a n d an explan at ion added t o t he
COMMENTS SHEET.

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

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

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

9 . 4 . 2 . 1 Wh en t he t r aceabilit y pr oces s is FIFO-depen den t , t he
Su pplier ’s s h ippin g pr oces s an d all s u b-t ier s s h all con for m t o
FIFO.

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
25

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

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

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

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

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

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

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

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

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

9 . 8 . 4 Th e ESD man u fact u r in g pr oces s s h all be in clu ded in t h e
Su pplier ’s Layered Pr oces s Au dit plan .



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
26
OPERATING INSTRUCTIONS
Element Requirement s Document at ion
1 0 . 1 Oper at or , s et -u p, ch an geover , 1
s t
piece appr oval, mis t ake
pr oofin g, rewor k/ repair , gage oper at in g, in s pect ion an d packagin g
in s t r u ct ion s s h all be appr oved and s ign ed by t h e appr opr iat e Su pplier
depar t men t s (e. g. Qu alit y, En gin eer in g, Man u fact u r in g, et c. ) Th ey
s h all be dated an d t r aceable t o t he level of par t s bein g pr odu ced, an d
s h all in clu de s ample s izes an d frequ en cies .

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

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

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

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

1 0 . 2 . 2 Vis u a l in s pect ion s t at ion s s h all h ave met h ods es t ablis h ed
t o ver ify t he oper at or ’s abilit y t o fin d defect s (e. g. per iodic tes t in g,
r ecer t ificat ion , et c. )

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

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

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

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

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







COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
27
OPERATING INSTRUCTIONS, CONT.
Element Requirement s
1 0 . 4 . 2 Th e rewor k/ repair pr ocedu r e an d in s t r u ct ion s s h all s t a t e
t h at wh en a s u b-compon en t is replaced wh ich h as Safet y <S>
ch ar act er is t ics an d a n ew s u b-compon en t is in s t alled, t he lot fr om
wh ich t h e replacemen t s u b-compon en t came s h all be iden t ified
an d it s h all be lin ked on e-t o-on e wit h t h e fin al as s embly or lot on
wh ich t h e s u b-compon en t was u s ed.

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

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


































COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
28

















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

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

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

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

1 1 . 2 . 2 Ver ificat ion of t h e STR aga in s t t h e Su pplier ’s
man u fact u r in g facilit y s h a ll be per for med by t he PSO team du r in g
t h e PSO On -Sit e Vis it . In t h e event t oolin g, gages an d/ or fixt u res
r es ide at t he Su pplier ’s s u b-t ier, th e s u b-t ier locat ion s h all be
in dicat ed on t h e STR.

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

1 1 . 3 All t oolin g, fixt u r es , equ ipmen t an d gages u s ed in t h e
man u fact u r in g pr oces s (e. g. fr om t h e labor at or y, pr odu ct ion , t ool
r oom, main t en an ce, qu alit y, et c. ) s h all be iden t ified in t he Su pplier ’s
main t en an ce, s t or age, an d calibr at ion pr ocedu res .
- Toolin g lis t
- Su pplier Tool Recor d
(STR)

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
29
SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC
Element Requirement s Document at ion
1 2 . 1 A lis t of s pecial ch ar act er is t ics s h all be developed u s in g DCC
in pu t as well as Su pplier kn owledge of t he pr odu ct . Special
ch ar act er is t ics are pr odu ct ch ar act er is t ics or man u fact u r in g pr oces s
par amet er s wh ich can affect s afety or complian ce wit h regu lat ion s , fit ,
fu n ct ion , perfor man ce or s u bs equ en t pr oces s in g of pr odu ct . Th ey
in clu de all gover n men t al, Key (diamon d) <D>, an d Sh ield (s afet y <S>
an d emis s ion s <E>) ch ar act er is t ics . Tor qu e requ ir emen t s an d
ch ar act er is t ics iden t ified as SPC poin t s on t h e des ign model s h all als o
be con s idered s pecial ch ar act er is tics . Ot her ch ar act er is t ics deemed
cr it ical t o t h e pr oces s or en d-item as s embly may als o be des ign at ed as
s pecial ch ar act er is t ics by t h e Su pplier an d/ or PSO Team. Referen ce
t h e AIAG PPAP (4
t h
ed. ) man u a l a n d cl. 4. 2. 1. 3, 4. 2. 1.4, an d 4. 2.1.5 of
t h e DCC Cu s t omer -Specific Requ ir emen t s for ISO/ TS-16949.

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

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

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

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

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

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

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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
30

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

1 2 . 4 . 1 . 1 . 3 Th e accept able checkin g met h od, s ample s ize
an d s ample frequ en cy for es t ablis h in g lot con t r ol wit h in t h e
Su pplier ’s facilit y s h all be deter min ed by t he Su pplier ’s
Con t r ol Plan an d/ or as dir ected by DCC.

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

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

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

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

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

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

1 2 . 5 . 3 All complet ed FPSC’s for Collabor at ive an d Directed AQP
act ivit y level pr ogr ams s h all be reviewed wit h t h e DCC PSO team.






COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
31
ERROR AND MISTAKE PROOFING
Element Requirement s Document at ion
1 3 . 1 Th e Er r or an d Mis t ake Pr oofin g Plan s h a ll des cr ibe h ow t he
Su pplier addres s es er r or pr oofin g an d mis t ake pr oofin g fr om an
or gan izat ion a l level.

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

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

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

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

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

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

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

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

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

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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
32
ERROR AND MISTAKE PROOFING, CONT.
Element Requirement s
1 3 . 6 Er r or an d mis t ake pr oofin g ver ificat ion s h all be addres s ed in t h e
Pr even t ive Main t en an ce Plan .

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

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

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

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

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

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

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

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

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

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

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

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

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






COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
33




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

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

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

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

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

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

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

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
34
LAYERED PROCESS AUDIT PLAN
Element Requirement s Document at ion
1 4 . 1 Layered Pr oces s Au dit (LPA) is a s ys tem of au dit s perfor med by
mu lt iple levels of man agemen t per t h e Su pplier ’s or gan izat ion ch ar t .
Special ch ar act er is t ics (an d ot h er ch ar act er is t ics des ign at ed by t he
Su pplier an d/ or PSO Team) ar e au dit ed t o ver ify pr oces s con for man ce.
Th e pu r pos e of LPA is t o en s u re con t in u ou s con for man ce t h ereby
impr ovin g pr oces s s t abilit y an d fir s t -t ime capabilit y. Referen ce t he
DCC Cu s t omer -Specific Requ iremen t s for ISO/ TS-16949 cl. 4. 2. 9.1
an d t h e LPA Fundamentals cou r s e (available t h r ou gh TEDS) for
addit ion al LPA r equ ir emen t s .

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

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

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

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

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

1 4 . 4 . 3 Aft er PSO appr oval, n o item s h all be removed fr om t he LPA
ch ecklis t s wit h ou t t h e DCC ASQP Specialis t ’s appr oval r egar dles s
of in it ia l AQP Act ivit y Level.

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

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

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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
35

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

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

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

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

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

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

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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
36
SUPPLIER READINESS EVALUATION & EVIDENCE OF PRODUCT SPECIFICATIONS, CONT.
Element Requirement s
1 5 . 4 . 1 Th e PSO team s h all decide t h e ch ar act er is t ics an d qu an t it y
of par t s t o be wit n es s ed for meas u r emen t ver ificat ion pr ior t o t h e
PSO On -Sit e Vis it (s ee below for min imu ms . ) All s pecial
ch ar act er is t ics s h all be in clu ded. Elemen t 12 “Special Pr odu ct an d
Pr oces s Ch ar act er is t ics , ” cl. 12. 2.

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

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

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

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




































COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
37
PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY
Element Requirement s Document at ion
1 6 . 1 Du r in g t h e Pre-PSO Meet in g, t he PSO Team (in clu din g t h e
Su pplier ) s h all r eview all plan s for requ ir ed pr odu ct ion r at es . At a
min imu m, t h e PSO Team s h all dis cu s s t h e requ ir ed Line Speed, Daily
Toolin g Capacit y, an d Net Oper at in g Time for DCC Par t s . Th es e
n u mber s s h all be ver ified wit h t he DCC Bu yer.

1 6 . 1 . 1 Th e PSO team s h all en s u re t h e Su pplier meet s t h e P. O.
Daily Toolin g Capacit y an d Oper at in g pat t er n .

NOTE: In s it u at ion s wh ere mu lt iple Pu r ch as e Or der s (P. O. s ) exis t
for t h e s ame par t (as is t he cas e for s ome h igh volu me par t s or
par t s s u pplied t o bot h US an d Mexican DCC as s embly plan t s ), t h e
Daily Toolin g Capacit ies fr om bot h P. O.s s h all be added t oget her
before deter min in g t h e requ ir ed Lin e Speed.

1 6 . 2 Th e Pr odu ct ion Demon s t r at ion Ru n (PDR) s h all be con du ct ed on
all pr odu ct ion lin es of recor d, u s in g pr odu ct ion t ools , pr odu ct ion
pr oces s es , an d fu lly t r ain ed oper at or s .

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

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

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

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

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








COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
38
PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY, CONT.
Element Requirement s
1 6 . 5 Tes t s amples u s ed in Pr odu ct ion Validat ion (PV) t es t in g s h all
come fr om a s u cces s fu l PDR an d PSO On -Sit e vis it . However, t he PSO
Tea m may elect t o u s e tes t s amples fr om an u n appr oved PSO On -Sit e
vis it , pr ovided t he followin g r equ ir emen t s are met:
- All pr oces s an d pr odu ct per for man ce (P
P
an d P
PK
) requ ir emen t s
ar e met ;
- Th e PDR was con du ct ed u s in g t h e Daily Toolin g Capacit y an d
t h e requ ired Line Speed met ;
- All s u b-compon en t s an d mat er ials u s ed in t he PDR h ad an
appr oved PPAP (or equ ivalen t );
- Pr odu ct ion pr oces s es an d t oolin g were u s ed;
- All pr odu ct ion meas u r in g t ools h a d accept able gage R&R
r es u lt s .

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

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

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

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

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

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
















COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
39

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

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

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

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

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

1 7 . 2 Wh en ret u r n able con t ain er s ar e t o be u s ed, a Ret u r n able
Con t a in er Man agemen t plan s h all be developed wh ich in clu des :
- Tr a in in g an d acces s t o t he Daimler Ch r ys ler Con t ain er
Man agemen t Sys t em (CMS);
- A docu men t ed pr ocedu re for man dat or y dat a en t r y;
- In ven t or y con t r ol t o t r ack con t ain ers on h an d an d in t r an s it ;
- Docu men t ed pr ocedu res for man dat or y t r an s mit t al of con t ain er
an d/ or par t n u mber in for mat ion du r in g ASN s u bmis s ion s fr om
t h e Su pplier ’s facilit y; an d
- Det ail for iden t ificat ion an d dis pos it ion of con t amin at ed or
damaged con t ain er s .

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

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

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

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
40





































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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
41

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

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

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

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

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

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

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

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

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

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

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
42











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

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

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

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

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

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

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
43












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

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

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

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

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

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
44
PRODUCTION VALIDATION TESTING COMPLETE
Element Requirement s Document at ion
2 1 . 1 Tes t s amples u s ed in Pr odu ct ion Validat ion (PV) t es t in g s h all
come fr om t h e Pr odu ct ion Demon s t r at ion Ru n .

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

2 1 . 1 . 2 Wh en mu lt iple pr odu ct ion lin es an d/ or t ools will be
qu a lified in a s in gle PV tes t , a port ion of t h e PV tes t compon en t s
s h all be r an domly s elected fr om each pr odu ct ion lin e an d/ or t ool
in pr opor t ion t o t h at lin e’s con t r ibu t ion .

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

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

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

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

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

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

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

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
45

























APPENDIX A
FORMS & INSTRUCTIONS

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
46

Document Checklis t Work Ins t ruct ions


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

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

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




COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
47
PART NAME(S)
PART NUMBER(S)
CHANGE LEVEL(S)
0
1st Review Date:
2nd Review Date:
Sec.
D
/
V
/
F
*
Documentation / Task
0 1. Part Number, Description & Change Level
1.2 D Engineering Change procedure
1.2 D CN Tracking (list of CN's, desc. & implementation)
1.3 D Software level and Hardware level
1.3 D Part number Cross reference
1.4 D
List of applicable engineering standards
1.4 D Document Control procedure
1.5 D GD&T or Drawing
1.5 D Catia files,drawings,comments page,
0
0 2. Design FMEA
2.1 D
DFMEA
2.2 D Best Practice Procedure
0
0 3. Test Sample Sizes and Frequencies
3.2 V DCC Engineering signed DV and PV test plans
3.3 D
DCC Engineering signed DVP&R
3.4 V Continous Conformance testing documented
3.5 V DVP&R includes Test to Flailure Plans
3.6 D Annual Validation Procedure
0
0 4. Process FMEA
4.1 D
PFMEA
4.2 D Best Practice Procedure
4.5 D PFMEA Audit summary
0
0 5. Process Flow Diagram & Manufacturing Floor Plan
5.1 D
Process Flow diagram
5.2 D
Mfg. Floor Plan (Location of equipment and space used identified)
5.2 D Cell Layout
5.4 V Process Flow or Cell layout Including # of Operators
5.6 D DFMA (Design for Manufacturing Assembly)
0
0 6. Control Plan and Process Monitoring
6.1 D
Control Plan
6.2 D Defect Tracking sheets
6.2 D Control charts
6.2 D Process Performance charts
6.2 D Log sheets
6.3 D 1st piece approval procedure & records
0
0 7. Quality Planning
7.1 D AQP or APQP timeline/plan
7.2 D List with PPAP status of all sub components
7.2 D
Indented list or Easy Map of Sub-Suppliers (Name,
Manufacturing location, Part name, Part Number,
PPAP Status) To raw material supplier.
7.2 D Listed risk of all PIA and sub-tier processes
7.2 D
Level 3 PPAP documentation( for PIA and sub tier processes risked
medium or high
7.3 D Procedure to convey Lessons Learned
7.4 D
Copies od eCIMS or 8-Step Corrective Actions for issues
encountered in previous pilot builds.
7.6 D DOE
0
0 8. Incoming and Outgoing Material Qualification Plan
8.1 D Incoming Inspection Plan
8.3 D Sampling Plans
8.4 D Receiving Reports
8.4 D Inspection/test reports
8.6 D
Copies of sub-tier Certificate of Analysis for each specific PIA
8.6 D
Copies of sub-tier and supplier PSW's
8.8 D Copies of sub-tier Supplier ISO9001 certifcations
8.9 D Outgoing Inspection Plan
8.11 D
Part Inspection Standard
8.14 D Audit Work Instructions
8.14 D Shipping Reports
8.14 D Audit Records
PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE
SUPPLIER
SUPPLIER CODE
MFG. LOCATION
M
i
s
s
i
n
g
/
R
e
j
e
c
t
PROGRAM
Enter a "X" in the
appropriate box below.
N
o
t

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

D
o
c
u
m
e
n
t
s

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
48
0 9. Parts Handling Plan - WIP
9.1 D Parts Handling Plan
9.1 D Material handling Procedures
9.7 D Containment records
0
0 10. Operator Instructions
10.1 D Operator Instructions
10.1 D Set-up Sheets
10.1 D 1st Piece approval instructions
10.1 D Mistake proofing instructions
10.1 D Gage Instructions
10.2 D Operator Qualification process
10.3 D Visual Management Document control procedure
10.4 D Rework/repair instructions
0
0 11. Tooling, Equipment & Gages Identified
11.1 D
Tooling List (Including Capital Equipment)
11.2 D STR (List)(Printed from DCX system)
11.2 N
Note: "Property of DCX" and the STR number must be on all DCX
owned tooling (Fire Proof). The STR list printed from the DCX
system needs to be supplied to the specialist during the PSO Onsite
visit.
0
0 12. Special Product & Process Characteristics Identified
12.1 D Special Characteristics List
12.1 D PPSR (Pre-Production Sample Report) for vehicle builds
12.5 D
FPSC (First ProductionShipement Certification) Plan
-100% inspection of 1st 2000 GOOD parts for visual
defects and all Control plan checks (Or increased
frequency per team agreement)
0
0 13. Error & Mistake Proofing
13.1 D
Error & Mistake Proofing Plan
13.1 D
List of error and mistake proofing implmented by operation number
13.1 D Error & Mistake Proofing Studies
13.2 D Mistake Proofing Contingency Plan
0
0 14. Layered Process Audit Plan
14.2 D LPA Procedures
14.2 D LPA work instructions
14.3 D LPA Structure and Frequency chart
14.4 D LPA Process Control Audit checklist
14.4 D LPA Error Proofing Verifcation Audit Checklist
0
0 15. SRE Results and Evidence of Product Specifications
15.1 F
SRE "Supplier Readiness Evaluation" Run results
15.4 F Measurement Verification Report
0
0 16. Production Demonstration Run and FTC
16.1 F
Line Speed demonstration form completed
16.4 D Process Constraints & Contingency Plans
16.4 F Final audit sampling plan
0
0 17. Parts Packing & Shipping Specifications
17.1 D Parts packaging and shipping plan
17.1 D Packaging and Shipping procedures
17.1 D Packaging,shipping and labeling instructions
17.1 D Returnable Container management plan
17.1 D Barcoded Labeling Procedure
17.2 D Shipping label example
17.3 D Simulation or shipping test results
0
0 18. Gage & Test Equipment Evaluation
18.3 D
Gage R&R (All measurement devices) results
18.2 D Gage layout results
18.5 D Gage and test equipment validation procedure
18.5 D Gage and test equipment calibration records
18.6 D Calibration schedule
0
0 19. Preventative Maintenance Plans
19.1 D PM Plan (Everything on Tooling list is in System)
0
0 20. Initial Process Study
20.1 F
Initial Process Study results
0
0 21. Production Validation Testing Complete
21.1 D Component level PV test results
21.1 D PV test procedures
21.4 D Training/certification for BSR operators
21.4 D Applicable PF Standards
21.4 D Vibration Test Procedure
0
Key: D Document
F Completed PSO form
N Note
V View
Powerway required document


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
49
20 26
"N" "Z" "A"
PART NAME(S) SUPPLIER
MFG. LOCATION
SUPPLIER CODE
PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE
PSO ON-SITE VISIT NUMBER
FPSC REVIEWED WITH SUPPLIER
Accept Reject N/A Accept Reject N/A
1. PART NUMBER, DESCRIPTION and CHANGE LEVEL 0 0 0
2. DESIGN FMEA 0 0 0
3. TEST SAMPLE SIZES and FREQUENCIES 0 0
4. PROCESS FMEA 0 0
5. PROCESS FLOW DIAGRAM and MFG FLOOR PLAN 0 0
6. CONTROL PLAN and PROCESS MONITORING 0 0
7. QUALITY PLANNING 0 0
8. INCOMING and OUTGOING MATERIAL QUALIFICATION PLAN 0 0
9. PARTS HANDLING PLAN 0 0
10. OPERATING INSTRUCTIONS 0 0
11. TOOLING, EQUIPMENT and GAGES IDENTIFIED 0 0
12. SPECIAL PRODUCT and PROCESS CHAR IDENTIFIED 0 0
13. ERROR and MISTAKE PROOFING 0 0
14. LAYERED PROCESS AUDIT 0 0
15. SUPPLIER READINESS EVAL and EVIDENCE OF PRODUCT SPECS 0 0
16. LINE SPEED DEMONSTRATION and FTC 0 0
17. PARTS PACKAGING and SHIPPING SPECS 0 0
18. GAGE and TEST EQUIPMENT EVALUATION 0 0
19. PREVENTIVE MAINTENANCE PLANS 0 0
20. INITIAL PROCESS STUDY 0 0
20 20 0
Accept Reject N/A Accept Reject N/A
21. PRODUCTION VALIDATION TESTING COMPLETE 0
24 15 2 2
Yes No Date
Yes No Date
Manufacturing Facility
PRINT NAME, SIGN AND DATE PRINT NAME, SIGN AND DATE
PRINT NAME, SIGN AND DATE PRINT NAME, SIGN AND DATE
PRINT NAME, SIGN AND DATE PRINT NAME, SIGN AND DATE
PRINT NAME, SIGN AND DATE PRINT NAME, SIGN AND DATE
DATE
PART NUMBER(S)
0
PROCESS
PROGRAM
CHANGE LEVEL(S) 0
0
0
DOCUMENTATION
0
OPTION #
0 0
0
0
DAIMLERCHRYSLER PROCESS SIGN-OFF CHECKLIST
PSO APPROVAL STATUS:
CHECK IF PSO EXTENDED RUN:
1/0/1900
Process Sign-Off Team
ENGINEERING
0
0
PROCESS
SUPPLIER QUALITY
PSO PROCESS ELEMENTS REQUIRED FOR "Z" APPROVAL
CORRECTIVE ACTION REQUIRED
ON-SITE REVISIT REQUIRED
DOCUMENTATION
ADDITIONAL PSO PROCESS ELEMENTS REQUIRED FOR "A" APPROVAL


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
50
PART NAME(S) SUPPLIER
MFG. LOCATION
SUPPLIER CODE
PRE-PSO MEETING DATE
PSO ON-SITE VISIT DATE
PSO ON-SITE VISIT NUMBER
0
TARGET
DATE
CLOSED
DATE
RESPONSIBILITY
0
0
1/0/1900
0
0
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROCESS SIGN-OFF
COMMENTS SHEET
0
0
0
PROGRAM
ITEM ISSUE/ACTION


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
51
P
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COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
52
Supplier Readines s Evaluat ion Ins t ruct ions

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Acc/ Reject : Has t h e PSO team deter min ed t he s u pplier ’s dat a t o be accept able (acc) or
u n accept able (Reject )? [i.e. LCL <Pr oc Avg < UCL; Ppk > Ppk mat r ix requ ir emen t (s ee In it ial
Pr oces s St u dy elemen t ); FTC > 90%; GR&R < 10% ; 10< GR&R < 30 – PSO team decis ion ].


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
53
PART NAME(S) SUPPLIER
MANUFACTURING LOC
PART NUMBER(S)
SUPPLIER CODE
PRE-PSO MEETING DATE
CHANGE LEVEL(S)
PSO ON-SITE VISIT DATE
PSO ON-SITE VISIT NUMBER
Buyer concurrence (optional)
Calculation Witnessed information Input information
Data input from production P.O.:
Shared Line? Yes or No (Y/N)
A) Combined DCC P.O. Daily Tooling Capacity
A1) DCC P.O. Daily Tooling Capacity Part Number Pieces/day
A2) DCC P.O. Daily Tooling Capacity Part Number Pieces/day
A3) DCC P.O. Daily Tooling Capacity Part Number Pieces/day
A4) DCC P.O. Daily Tooling Capacity Part Number Pieces/day
A5) DCC P.O. Daily Tooling Capacity Part Number Pieces/day
Total (A1 + A5) Pieces/day
B) DCC P.O. Shift Pattern
B1) Number of shifts per day shifts
B2) Production hours per shift hours
B3) Number of production days per week days
Data input from manufacturing process:
C) Downtime per shift
C1) Lunches hours/shift
C2) Breaks hours/shift
C3) Changeover and/or set-up hours/shift
C4) Operating time dedicated to other customers hours/shift
Comments:
C5) Scheduled/unscheduled downtime (as applicable) hours/shift
Comments:
D) Parts attempted during the PDR attempted parts
E) First time through fallout during the PDR failed parts
F) Length of PDR in hours Start: Finish: hours
G) Acceptable parts witnessed at the PDR pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)] hours/shift
I) Available production hours/day [B1*H] hours/day
J) DCC required parts per hour at the PDR [A/I] parts/hour
K) Witnessed parts per hour at the PDR [G/F] parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100] Minimum requirement of 90% %
M) Difference between witnessed parts/hour and required parts/hour [K-J] pieces
Must be 0 or greater for approval
DCC FORMULA FOR PRODUCTION DEMONSTRATION RUN
PSO REQUIREMENT
0
0
0
0
0
0
0
0
0
PROGRAM 0
0
0



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
54
Sh ar ed Lin e? Yes or No (Y or N)
A) Th e combin ed DCC Daily Toolin g Capacit y s h ou ld be obt ain ed from t h e DCC Pu r ch as e Or der - "TOOL CAP"
If s h ar ed lin e = N:
A1 ) In pu t t h e Daily Toolin g Capacit y an d part n u mber from t he DCC Pu r ch as e Or der .
A2 -A5 ) Lea ve as t h e defau lt 0.
If s h ar ed lin e = Y, s h ared wit h DCC part s on ly:
A1 -A5 )
If s h ar ed lin e = Y, s h ared wit h ot h er cu s t omers :
A1 -A5 ) In pu t t h e Daily Toolin g Capacit y from t h e DCC Pu r ch as e Or der for t h e var iou s par t s bein g validat ed.
C4 ) In h ou r s / s hift , in pu t t h e t ime dedicat ed per s h ift t o ot h er cu s t omer s .
B) Th e s h ift pat t er n s h ou ld be obt a in ed from t h e DCC Pu r ch as e Or der - "SH/ HR/ DY"
B1 ) Nu mber of s h ift s per da y - "SH" on Pu r ch as e Order
B2 ) Pr odu ct ion h ou r s per s hift - "HR" on Pu rch as e Order
B3 ) Nu mber of pr odu ct ion days per week - "DY" on Pu rch as e Order
C) Down t ime pe r s hi ft
C1 ) Lu n ches - Th e amou n t of t ime, i n hours per s hi ft , t h at t h e produ ct ion proces s is n ot operat in g du e t o lu nch .
C2 ) Br eaks - Th e amou n t of t ime, i n hours pe r s hi ft , t h at t h e pr odu ct ion pr oces s is not oper at in g du e t o br eaks .
C3 )
C4 )
C5 )
D) Th e par t s at t empt ed du r in g t h e PDR ar e t h e t ot al n u mber of par t s t h e s u pplier pr odu ced in clu din g r eject s / s cra p.
E)
F)
G)
NOTE: Pleas e in dicat e when du rin g t h e pr odu ct ion pr oces s t h e ch an geover s will be implemen t ed (if t h ey are con du ct ed
du rin g t h e qu ot ed oper at in g pat t er n , or if t h ey ar e t o be con du ct ed du r in g "off s h ift s ").
Len gt h of PDR in h ou rs is t h e mea s u red t ime it t ook t o con du ct t h e produ ct ion demon s t r at ion r u n . Pleas e in pu t s t ar t an d
fin is h t ime in cells provided.
Schedu led/ u n s ch edu led down t ime n ot cons ider ed - Th e amou n t of downt ime, in hours per s hift , t h a t was n ot
con s idered. Th is cou ld be an y down t ime s u ch as PM, ch an geover , et c. t h at wa s n ot in clu ded in t h e developmen t of t h e
s h ift pa t t ern / pieces per day qu an t it y.
Schedu led/ u n s ch edu led down t ime s h ou ld be calcu lat ed on a per s h ift bas is (e.g. oper at in g t ime per week divided by
t h e n u mber of s h ift s per week = ch an geover t ime per s h ift ).
NOTE: Pleas e in pu t appr opr iat e commen t s in t h e blan ks pr ovided.
Oper at in g t ime dedicat ed t o ot h er cu s t omer s - Th e a mou n t of t ime, i n hours per s hi ft , t ha t t h e pr odu ct ion pr oces s is
oper at ing/ man u fact u rin g produ ct for ot h er cu s t omer s .
Oper at in g t ime dedicat ed t o ot h er cu s t omer s calcu lat ed on a per s hift bas is (e.g. oper at in g t ime per week divided by t he
n u mber of s hift s per week = ch an geover t ime per s h ift ).
NOTE: Pleas e in pu t appr opr iat e commen t s in t h e blan ks pr ovided.
Fir s t t ime t h rou gh fall ou t du rin g t h e PDR is t h e n u mber of par t s t h at wer e r eject ed fr om t h e man u fact u r in g proces s du ring
fi rs t evalu at ion . Th is is not t h e fin al n u mber of u na ccept able par t s , bu t on ly t h os e t h a t failed firs t t i me t h rou gh t h e
pr oces s . (Th is n u mber will be u s ed in t h e FTC calcu la t ion .)
NOTE: Th e as s u mpt ion for t h is calcu lat ion is t h at all of t h e par t n u mber s h ave t h e s ame oper at in g pat t er n a nd t h e s ame
t akt t ime.
NOTE: Pleas e in pu t appr opr iat e commen t s in t h e blan ks pr ovided.
Ch an geover an d/ or s et u p - Th e amou n t of t ime, i n hours per s hi ft , t h at t h e produ ct ion pr oces s is n ot oper at ing du e
t o ch an geover an d/ or s et u p act ivit ies . On ly ch an geovers t ha t wer e qu ot ed t o occu r du rin g t h e produ ct ion oper at in g
pa t t er n s h ou ld be con s ider ed for t h is calcu lat ion .
Ch an geovers or s et u p not con du ct ed ever y s hift s h ou ld be ca lcu lat ed on a per s h ift ba s is (e.g. Cha n geover t ime per
week divided by t he n u mber of s h ift s per week = ch an geover t ime per s h ift ).
Produc t i on De mons t rat i on Run Calc ulat i on Work Ins t ruct ions
Accept able part s wit n es s ed at t h e PDR ar e t h e t ot al n u mber of par t s , min u s an y reject s , wh ich wer e demon s t rat ed du r in g
t h e pr odu ct ion r u n . (May di ffer from fi rs t t i me t hrough fallout . )
NOTE: If t h e compon en t s bein g validat ed ha ve varyin g operat in g pat t er n s or differ en t t akt t imes , t h en s epar at e ca lcu lat ion
wor ks h eet s s h ou ld be complet ed for each par t .
NOTE: If t h e compon en t s bein g validat ed ha ve varyin g operat in g pat t er n s or differ en t t akt t imes , t h en s epar at e ca lcu lat ion
wor ks h eet s s h ou ld be complet ed for each par t .
NOTE: Th e as s u mpt ion for t h is calcu lat ion is t h at all of t h e par t n u mber s h ave t h e s ame oper at in g pat t er n a nd t h e s ame
t akt t ime.
In pu t t h e Daily Toolin g Capacit y an d part n u mber from t he DCC Pu r ch as e Or der for t h e var iou s pa rt s bein g
validat ed.


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
55
H)
I) Ava ilable pr odu ct ion h ou r s / day are t he n et h ou rs per day t h e s u pplier h a s available t o bu ild pr odu ct .
J)
K)
L)
If t h e DCC r equ ir emen t of 90% or gr eat er is met , t h e cell will t u r n gr een .
If t h e DCC r equ ir emen t is n ot met (les s t h an 90%), t h e cell will t u r n r ed.
M)
If t h e par t differen ce is les s t han 0, t h e cell will t u rn r ed in dicat in g t h e requ iremen t is n ot met . i.e. M < 0 t h e cell = r ed.
NOTE: In t he event (M) i s yellow, it i s s t rongly advis ed t o c onduct an Ext ended Run PSO t o s t res s t he s uppli er's
product i on li ne and i ncre as e confi dence i n t he s uppli er's abi li t y t o meet DCC requi re me nt s . PSO Ext ended Run
opt i ons are explai ne d i n t he PSO manual. Cont i nuous i mprove me nt act i ons s hould als o be deve lope d for bot t leneck
operat i ons or ot her operat i ons whi ch s howed poor performance duri ng t he PSO run.
NOTE: If t h e FTC is les s t h an 90%, t h e PSO t eam s h all t ake produ ct a nd proces s t ech n ology, complexit y, s u pplier
experien ce, an d t h e effect iven es s of defect con t ain men t act ion s in t o accou n t wh en decidin g wh et h er t h e demon s t r at ed lower
FTC valu es ar e accept able wit h a docu men t ed deviat ion . A DCC Su pplier Qu alit y Man ager's s ign ed appr oval is requ ired for
devia t ion from t h e PSO FTC requ iremen t .
Th e differ en ce bet ween r equ ir ed par t s / h ou r an d wit n es s ed pa rt s / h ou r gives t h e t ot al n u mber of par t s over or u n der t h e
DCC r equ ir emen t .
Produc t i on De mons t rat i on Run Calc ulat i on Work Ins t ruc t i ons , c ont .
If t h e par t differen ce is great er t h a n (t h e DCC r equ ir ed par t s per h ou r + 10%), t h e cell will t u r n green in dicat in g t h e
lin e s peed is accept able. i.e. (J + 10%) M, t h en cell = gr een (requ iremen t s met ).
If t h e par t differen ce is bet ween 0 an d (t h e DCC requ ired part s per hou r + 10%), t h e cell will t u r n yellow in dicat in g t h e
lin e s peed h as met r equ ir men t s , bu t t h e par t differen ce is ver y clos e an d may r equ ir e addit ion al a t t ent ion.
i.e. 0 <= M < (J +10%) t h en cell = yellow.
FTC (Fir s t Time Capabilit y) is t he per cen t age of accept able part s wit n es s ed at t h e pr odu ct ion demon s t r at ion ru n ou t t he
t ot al n u mber of par t s at t empt ed at t h e PDR.
Ava ilable pr odu ct ion h ou r s / s hift ar e t h e n et h ou r s per s h ift t h e s u pplier h as available t o bu ild pr odu ct n ot in clu din g a n y
s ch edu led down t ime.
DCC r equ ir ed par t s per h ou r at t h e PDR a re t h e t ot a l nu mber of a ccept able par t s t h e s u pplier mu s t pr odu ce, in an h ou r's
t ime, n eces s ar y t o s a t is fy DCC.
Wit n es s ed par t s per h ou r at t h e PDR ar e t h e n u mber of accept able part s wit n es s ed by t h e PSO t eam, which t he s u pplier
pr odu ced wit h in an h ou r' s t ime.




COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
56


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i
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n

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
57
Init ial Proc e s s St udy

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Acc/ Reject : Has t h e PSO t eam det ermined th e s u pplier ’s dat a t o be accept able (acc) or u n accept able?
[i.e. LCL <Pr oc Avg < UCL; P
P
> P
PK
mat r ix r equ ir emen t (s ee Init ial Pr ocess St u dy elemen t ); FTC > 90%;
GR&R < 10% ; 10%< GR&R < 30% – PSO t eam decis ion].


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
58
P
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l
e
r

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
59

Meas urement Sys t em Report Ins t ruct ions

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

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

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

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

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

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

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

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

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

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

Pr oces s Acc/ Reject: Has t h e PSO t eam det ermin ed t h e su pplier ’s meas u r emen t pr oces s t o be accept able
(acc) or u n accept able (Reject )?

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
60
How t o find t he Daily Tooling Capac it y and Ope rat ing Pat t e rn

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




COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
61
























APPENDIX B
Ta bles a nd Exa mples

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
62

LOT ACCEPTANCE SAMPLING TABLE

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

Charact eris t ics Defi nit ion

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

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

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

PRODUCT QUALIFICATION


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

Lot Size or Shipment
Size*

<S> / <E>

<D>

0-15

100% In s pect ion

16-25



26-50





51-75



50

76-125

75

65

126-225

90

75

226-425

100

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

SAMPLE RESULTS

ACTIONS ON PROCESS

ACTIONS ON LOT

No Non con for min g u n it s

Con t in u e t o oper at e

Accept

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

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
63
CAPABILITY MATRIX


Th er e ar e t wo r isks in h er en t in ever y decision , eit h er (1) we h ave accept ed “bad” par t s (con s u mer ’s r isk), or
(2) we h ave r eject ed “good” par t s (pr odu cer ’s ris k). Tes t plan s seek t o balan ce t h es e ris ks by specifyin g
s ample s ize and/ or accept an ce cr it er ia s o t h at n eit her th e con su mer n or th e pr odu cer carr ies th e high er
pr opor t ion of r isk.

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

Th e followin g t able pr es en t s t h e s ample size an d accept an ce cr it er ia th at keeps t h e r isk of accept in g a “bad”
popu lat ion (s 1.33) at 6.4% (93.6% t hat popu lation > 1.33 Ppk will be accept ed). Depen din g u pon s ample
s ize, th e r isk of r ejectin g a “good” popu lat ion (> 1.67) cou ld be ver y high . Th e t able allows for t r ade-offs
bet ween s ample s ize and pr odu cer ’s ris k t o be iden t ified.


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





COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
64
EXAMPLE: LPA FREQUENCY AND STRUCTURE



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

A
D
e
p
a
r
t
m
e
n
t

B
D
e
p
a
r
t
m
e
n
t

C
D
e
p
a
r
t
m
e
n
t

D
D
e
p
a
r
t
m
e
n
t

E
D
e
p
a
r
t
m
e
n
t

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






COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
65

FMEA GUIDELINES





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

I. RPN’s t h a t h a ve a Severit y > 8 r ega rdles s of RPN va lu e, Occu r r en ce level, or
Detect ion level.

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

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



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INTENTIONALLY LEFT BLANK

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APPENDIX C
FTC Ca lcu la t ion s

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68
Firs t Time Capabilit y

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


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

Daimler Ch r ysler ’s r equ ir emen t for FTC is 90% or great er . Followin g t h e PDR, t h e PSO Team sh all r eview t h e
FTC valu es for each oper at ion and t he over all pr oces s . If t he FTC is les s t han 90%, t h e PSO t eam s h all t ake
pr odu ct and pr oces s t ech n ology, complexit y, Su pplier exper ien ce, an d t h e effect iven es s of defect
con t ain men t act ions in t o accou n t when decidin g wh eth er t h e demon s t r at ed lower FTC valu es ar e accept able
wit h a docu men t ed deviat ion . A Su pplier Qu alit y Man ager ’s s ign ed appr oval is r equ ir ed for deviat ion fr om
t h e PSO FTC r equ ir emen t .

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

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

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

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

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

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















COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
69
300 Pcs
30 Pcs
Rejected
270 Pcs
Operation 1
Firs t Time Capabilit y

CALCULATIONS & EXAMPLES

CALCULATIONS & EXAMPLES

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

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



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


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


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

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

Figu r e 1A

In a s imilar man n er , calcu lat e t he FTC for each oper at ion in t h e pr oces s u s in g Equ at ion 1. Th e
gener al oper at ion model is s h own in Figu r e 1B. Table 1 s h ows a s u mmar y of t h e qu an t it ies an d
FTC’s for t he pr oces s in Example 1.


Attempted Qty
Completed Qty
FTC
OPERATION
=

Equat ion 1


(1) Figu r e 1B

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Comple t e d


FTC

1

300

270

0.90

2

270

243

0.90

3

243

226

0.93

4

226

217

0.96
TABLE 1
Quant it ie s and FTC’s for Example 1

En t er t he calcu lat ed oper at ion FTC’s in t h eir res pect ive oper at ion blocks of t he pr oces s diagr am.
Calcu lat e t h e pr oces s FTC by dividin g t h e qu an t it y completed for t h e pr oces s , 217 u n it s , by t h e
qu a n t it y at t empt ed 300 u n it s .
% 3 . 72 or 723 . 0
300
217
Attempted Qty Total
Completed Qty Total
FTC
PROCESS
= = =

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



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

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


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

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Calcu lat e t h e FTC for each oper at ion in t h e pr oces s u s in g Equ at ion 1 an d t h e oper at ion model
s h own in Figu r e 1B on page 2. Ta ble 2 s h ows a s u mmar y of t h e qu an t it ies an d FTC’s for t h e
oper at ion s in
Example 2.



Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Comple t e d


FTC

1

300

288

0.96

2

288

265

0.92

3

96

94

0.98

4

91

81

0.89

5

78

67

0.86

6

242

218

0.91
TABLE 2


Quant it ie s and FTC’s for Example 2



En t er t he calcu lat ed oper at ion FTC’s in t h eir res pect ive blocks on th e pr oces s diagr am. Calcu lat e
t h e pr oces s FTC by dividin g t h e t ot al qu an t it y complet ed, 218 Un it s , by t he qu an t it y at t empt ed,
300 u n it s . Th e res u lt is t h e FTC for t h e pr oces s .

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


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


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



218 Pcs
FTC = 72.6%
300 Pcs
12 Pcs
Rejected
FTC
96%
23 Pcs
Rejected
288 Pcs
FTC
92%
Operation 1 Operation 2
265 Pcs
91 Pcs
FTC
89%
10 Pcs
Rejected
96 Pcs
Operation 3
FTC
98%
2 Pcs
Rejected
94 Pcs
81 Pcs
242 Pcs
FTC
90%
Operation 4
78 Pcs
FTC
86%
11 Pcs
Rejected
67 Pcs
Operation 5
Operation 6
24 Pcs
Rejected

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

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

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

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

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

CALCULATIONS & EXAMPLES

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

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



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





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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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Calcu lat e t h e FTC for each oper at ion . Oper at ion 1 is s h own here wit h it s r es pect ive pr odu ct ion
demon s t r at ion dat a.

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

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


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

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


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


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



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

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


In a s imilar man n er , calcu lat e t he FTC an d Yield for t he remain in g oper at ion s u s in g Equ at ion s 2
an d 3. Th e gener al oper at ion model is s h own in Figu r e 5C. Table 3 s h ows t he qu an t it ies , FTC’s
an d Yields for t he oper at ion s in Example 3.



ted Qty Attemp
Rejected Qty - ted Qty Attemp
=
FTCOperation


Equat ion 2


ted Qty Attemp
Completed Qty
=
YieldOperation


Equat ion 3
Figu r e 5C



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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Re je c t e d


FTC

Quant it y
Re worke d

Quant it y
Comple t e d


Yie ld

1

300

30

0.90

N/ A

270

0.90

2

270

27

0.90

25

268

0.99

3

268

19

0.93

16

265

0.99

4

265

10

0.96

9

264

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

A s implified s ket ch of t he s er ies oper at ion s t h at will be u s ed for t h e pr oces s FTC calcu lat ion is
s h own in Figu r e 6. En t er t he operat ion FTC’s in t h eir res pect ive blocks on t he s ketch . Calcu lat e
t h e pr oces s FTC by mu lt iplyin g t h e in dividu al oper at ion FTC’s t ogeth er .




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



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


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


Add t h e oper at ion an d pr oces s FTC’s an d Yields t o t he pr oces s diagr am. Th e completed pr oces s
diagr am for example 3 is s h own in Figu r e 7. Th e diagr am can be inclu ded as par t of pr odu ct ion
demon s t r at ion r epor t t o docu ment t h e s t ar t in g pr oces s capabilit y.


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

300 Pcs
FTC=90%
Operation 1 Operation 4
FTC=96%
264 Pcs
FTC=90%
Operation 2
FTC=93%
Operation 3
300 Pcs
30 Pcs
Rejected
270 Pcs 268 Pcs 265 Pcs
10 Pcs
FTC=90%
Yield=90%
Operation 1
27 Pcs
FTC=90%
Yield=99%
Operation 2
FTC=93%
Yield=99%
Operation 3 Operation 4
FTC=96%
Yield=99.6%
Rework
2 Pcs
Scrap
25 Pcs
19 Pcs
Rework
3 Pcs
Scrap
16 Pcs
Rework
1 Pc
Scrap
9 Pcs
FTC = 72.3%
YIELD = 88.0%
264 Pcs

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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Example 4, Ser ies / Par allel Pr oces s Flow wit h Repair :
Us in g t h e t h r ee-s tep, dat a collect ion pr ocedu re ou t lin ed on page 5, t h e followin g pr oces s ed an d
r ejected qu an t it y da t a were collect ed du r in g a demon s t r at ion r u n . Th e dat a are s h own in Figu r e 8.



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

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




Ope rat ion

Quant it y
At t e mpt e d

Quant it y
Re je c t e d


FTC

Quant it y
Re worke d

Quant it y
Comple t e d


Yie ld

1

300

12

0.96

N/ A

288

0.96

2

288

23

0.92

18

283

0.98

3

102

2

0.98

7

107

1.05

4

97

11

0.89

6

92

0.95

5

84

12

0.86

5

77

0.92

6

276

28

0.90

27

275

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


En t er t he FTC’s an d yields t h at were calcu lat ed for Oper at ion s 1 t hr ou gh 6 in t h eir res pect ive
oper at ion blocks of t he pr oces s diagr am. Th e en t r ies for Example 4 ar e s h own in Figu r e 9.
283 Pcs 97 Pcs
11 Pcs
to Rwk*
92 Pcs
Operation 4
102 Pcs Operation 3
2 Pcs
to Rwk*
107 Pcs
84 Pcs
12 Pcs
to Rwk*
77 Pcs
Operation 5
300 Pcs
12 Pcs 23 Pcs
288 Pcs
Operation 1 Operation 2
Rework
18 Pcs
18 Pcs
5 Pcs
Scrap
Rework*
Op 3,4,& 5
7 Pcs
Scrap
276 Pcs
Operation 6
28 Pcs
Rework
27 Pcs
1 Pc
Scrap
275 Pcs
25 Pcs
Rework*

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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Figure 9
Example 4 - Proc e s s Wit h Ope rat ion FTC's and Yie lds Shown


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




Figu r e 9 A Figu r e 9B

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



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


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

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A s implified s ket ch of t he pr oces s t h at will be u s ed for t he FTC calcu la t ion is s h own in Figu r e 9C.
Mu lt iply t h e in dividu al oper at ion FTC’s t oget her t o obt ain t h e FTC for t h e pr oces s , FTC
PROCESS
.


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



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



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


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



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

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

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INTENTIONALLY LEFT BLANK

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APPENDIX D
PSO Exten ded Ru n

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PSO Ext e nde d Run
Th is act ivit y is in t ended for n ew vehicle lau nch es or major vehicle u pgr ades t o r edu ce th e r isk of t h e vehicle
lau n ch . It does n ot impact t h e PSO appr oval pr ocess des cribed in t h is man u al bu t is a s u pplemen t al
act ivit y t o fu r t h er as s u r e a Su pplier ’s r eadin es s t o s u ppor t t h e fu ll volu me pr odu ct ion wit h capable
pr oces ses (see Figu re 1).









Figure 1

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

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



Opt ion Number

Opt ion Des c ript ion Opt ion Bene fit

1
Expan ded pr odu ct ion of 1000
or mor e par t s du r in g t h e PSO
PDR.
High er con fiden ce level t h at t h e Su pplier can
s u s t ain lin e r at e over a lon ger per iod of t ime.
2
Per form 2 s epar at e PSO PDRs
wit h th e las t r u n occu r rin g
pr ior t o S2 MRD.
Con firms th at t h e Su pplier can s t ar t t h e pr oces s
u p on mu lt iple occasion s and meet capabilit y and
lin e r at e.
3
Per form 3 s epar at e PSO PDRs :
Pr ior t o S1 MRD
Pr ior t o S2 MRD
Pr ior t o V1 MRD
Ver ifies Su pplier ’s pr oces s con sis t en cy an d
validat es r eadin es s for V1 Lau n ch .
4
Per form PSO PDRs on mu lt iple
s h ift s at t he Su pplier .
En s u r es oper at ion al r eadin es s on all s h ift s .
5
In addit ion t o t h e Pr e-S1 PSO,
per form a pos t -lau n ch PSO
occu r rin g 2-5 weeks aft er V1
Lau n ch.
Validat es th e lin e r at e aft er s ever al weeks of
oper at ion.
6
An y combin at ion of t h e above 5
opt ion s or an appr opr iat e
var iat ion for t he s pecific
commodit y.
Allows flexibilit y t o accommodat e u n iqu e
cir cu ms t an ces .

Table 1

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

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APPENDIX E
Forever Requ iremen t s

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DCX “Fore ve r Re quire ment s ” Proc e s s

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

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

3. All ot h er pr opos ed ch an ges (par t , pr oces s , Tier 2 s ou r ce, et c.) s h all follow th e “For ever Requ ir emen t s ”
pr oces s ou t lin ed h er e. Table 3.1 in t h e PPAP 4
t h
Edit ion AIAG man u al gives s ome examples of s it u ation s
r equ ir in g “For ever Requ ir emen t s ” s u bmis s ions .

4. Su pplier fills ou t page on e (1) of t he ‘DCX For ever Requ ir emen t s/ ODD Box Act ivit y Form’. Not e: Pleas e
be advis ed, t h at t his for m mu s t be s u bmit t ed a min imu m of t h ree (3) mon th s in advan ce of t h e plan n ed
ch an ge(s ) implemen t at ion dat e or with in su fficien t time for implemen t at ion (as det ermin ed by DCX).

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

6. Th e En gin eer will fill ou t pa ge t wo (2) – Sect ion 2.A. If a ppr oved by t h e En gin eer , t h e Su pplier will t h en s u bmit t h e
en t ir e ‘DCX For ever Requ ir emen t s / ODD Box Act ivit y For m’ t o t h e a ppr opr ia t e Su pplier Qu a lit y Specia lis t . If t h e
ch a n ge(s ) wa s r eject ed by t h e En gin eer , t h en t h e Su pplier mu s t cor r ect t h e r eject ed it em(s ) a n d r es u bmit t h e ‘DCX
For ever Requ ir emen t s / ODD Box Act ivit y For m’ t o t h e En gin eer . Fa ilu r e t o r es u bmit t h e for m t o t h e En gin eer for
a ppr ova l will en d t h e For ever Requ ir emen t s pr oces s for t h e pr opos ed ch a n ge(s ).

7. Aft er a ppr ova l by t h e En gin eer , t h e Su pplier Qu a lit y Specia lis t will fill ou t pa ge t wo (2) – Sect ion 2.B. If a ppr oved by
t h e Su pplier Qu a lit y Specia lis t , t h e Su pplier will s u bmit t h e for m t o t h e a ppr opr ia t e Bu yer . If t h e ch a n ge(s ) wa s
r eject ed by t h e Su pplier Qu a lit y Specia lis t , t h en t h e Su pplier mu s t cor r ect t h e r eject ed it em(s ) a n d r es u bmit t h e
‘DCX For ever Requ ir emen t s / ODD Box a ct ivit y For m’ t o t h e Su pplier Qu a lit y Specia lis t . Fa ilu r e t o r es u bmit t h e
for m t o t h e Su pplier Qu a lit y Specia lis t will en d t h e For ever Requ ir emen t s pr oces s for t h e pr opos ed ch a n ge(s ).

8. Aft er a ppr ova l by t h e Su pplier Qu a lit y Specia lis t , t h e Bu yer will fill ou t pa ge t wo (2) – Sect ion 2.C. If a ppr oved by
t h e Bu yer , t h e s u bmit t ed ch a n ge(s ) a r e fu lly a ppr oved by DCX. If t h e ch a n ge(s ) wa s r eject ed by t h e Bu yer , t h en t h e
Su pplier mu s t cor r ect t h e r eject ed it em(s ) a n d r es u bmit t h e ‘DCX For ever Requ ir emen t s / ODD Box Act ivit y For m’ t o
t h e Bu yer . Fa ilu r e t o r es u bmit t h e for m t o t h e Bu yer will en d t h e For ever Requ ir emen t s pr oces s for t h e s u bmit t ed
ch a n ge(s ).

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

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

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

12. Aft er appr oval by all affect ed DCX per s on n el, t he Su pplier will make copies of t h e ‘DCX For ever
Requ ir emen t s/ ODD Box Activit y Form’ an d dis t ribu t e it t o all appr opriat e DCX per s on n el as indicat ed
by t h e Su pplier Qu alit y Specialis t . In addition , th e Su pplier will r et ain th e or igin al copy of t h e fu lly
appr oved ‘DCX For ever Requ ir emen t s/ ODD Box Act ivit y For m’.


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

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





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“Forever Requirement s ” Proces s Flow

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

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“Forever Requirement s ” Proces s Flow, cont .

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

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APPENDIX F
DCC In tern a l PSO Requ irement s

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Internal Powertrain PSO

3 Steps to Approval















PV
Testing
Production
Demonstration Run
(PDR) & Analysis


Documentation

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Internal Powertrain PSO

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

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

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

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

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

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

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

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

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

Internal Powertrain PSO Sign-off Package Requirements

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

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


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



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

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

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


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

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


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

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


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

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

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


5 . Since AAR is a requirement for PPAP, s houldn’t AAR be required for PSO approval if t he
proces s appreciably affect s color?

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


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

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


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

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



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

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


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

Th e forms are par t of t h e man u al, and t h ey ar e iden tified in Daimler Ch r ysler ’s Mas t er Record
Lis t .


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

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

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


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

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


1 2 . Clarify IAA requirement s .

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


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

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

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

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

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

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


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

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


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

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


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

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


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

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


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

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


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

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


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

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


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


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

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


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

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


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

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

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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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REFERENCE MANUALS


Daimler Ch r ysler Man u als :

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

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

- Tes t Dat a An alys is man u al

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


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


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

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


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

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


Ot h er Man u als :

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

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

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

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

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

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

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


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


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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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GLOSSARY

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

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

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

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

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

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

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

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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r equ iremen t s of t h e pr odu ct . Ea ch pa r t s h a ll h a ve a Con t r ol Pla n , bu t in ma n y ca s es ,
“fa mily” Con t r ol Pla n s ca n cover a n u mber of pa r t s pr odu ced u s in g a common proces s .
Cu s t omer appr ova l of Con t r ol Pla n s ma y be requ ired pr ior t o pr odu ct ion pa r t s u bmis s ion .

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

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


|
.
|

\
|
÷
=
2
6
d
R
LSL USL
6
LSL - USL
=
C
C
P
o


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

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


P PK
C C s

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

|
.
|

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

|
.
|

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


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

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CUSTOMER SATISFACTION AUDIT (CSA): a comprehen s ive review of a veh icle’s a s -
s h ipped qu a lit y a s it lea ves a n a s s embly pla n t . Th e CSA provides a reliable rea l-t ime
in dica tor of veh icle qu alit y.

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

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

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

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

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

ELECTRONIC CORPORATE ISSUE MANAGEMENT SYSTEM (e-CIMS): DCC’s elect r on ic
s ys tem for docu men t in g s er iou s is s u es t h a t a r is e du r in g veh icle pr ot ot ype, la u nch , or
volu me pr odu ct ion pha s es .

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

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

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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EXTENDED ENTERPRISE' '' ': is a Da imlerCh r ys ler coordin a ted pr oces s t h a t u n ifies a nd
extends t he bu s ines s rela t ions h ips of Su pplier s a nd Su pplier t ier s in or der t o maximize
t h e effect ivenes s of veh icle developmen t , min imize tot a l s ys tem cos t s , a nd improve qu alit y
a n d cu s t omer a ccept a nce.

FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC): t he pu rpos e of FPSC is t o
ens u re t h a t in it ia l pr odu ct ion s h ipmen t s meet a ll DCC pr odu ct s pecifica t ion s . FPSC is
in t ended t o iden t ify pa r t problems a n d con t a in t he pa r t s a t t h e Su pplier ’s ma nu fa ct u r in g
fa cilit y du rin g t h e la u nch ph as e. FPSC requ ires t he Su pplier t o pr ovide s t a t is t ica l
eviden ce of con for ma n ce t o s pecia l pr odu ct a n d/ or pr oces s cha r a cter is t ics pr ior t o t h e
s h ipmen t of componen t s t o t he DCC (or DCC-des igna ted) as s embly pla n t . Cer t ifica t ion is
for a min imu m of 2000 pa rt s (per a s s embly pla n t ) or for a s pecified per iod of t ime as
iden t ified by t h e PSO tea m. 100% of t h e FPSC pa r t s a re t o be in s pected for con for ma nce
t o s pecia l produ ct a nd/ or proces s ch a r acter is t ics .

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

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

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

HOME LINE: Su pplier ’s a s s embly line loca ted in t he ma nu fa ct u r in g fa cilit y wh ere volu me
pr odu ct ion of t he pa r t (s ) t akes pla ce u s in g pr odu ct ion t oolin g a n d proces s es .

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

ISO/TS 1 6 9 4 9 : is a Tech n ica l Specifica t ion t h a t des cr ibes , in con ju nct ion wit h ISO
9001:1994, t h e Qu a lit y Sys t em Requ iremen t s for Au tomot ive Su pplier s . ISO/ TS 16949
h a s been prepa red by t he In ter n a t ion a l Au t omot ive Tas k For ce (IATF) for a ll pa r t icipa t in g
wor ldwide OEM’s .

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



COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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LINE SPEED: t he con t r a cted ma ximu m t ool capacit y r a t e deter min ed by dividin g t h e
Da ily Da imlerCh r ys ler Toolin g Capa cit y (Pieces per Hou r ) by t h e Su pplier ’s Net Oper a t in g
Time for Da imlerCh r ys ler Pa r t s (Hou r s / Da y). Th e Line Speed s h a ll be ver ified du r in g t he
Pr odu ct ion Demon s t r a t ion Ru n.

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

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

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

NET OPERATING TIME FOR DAIMLERCHRYSLER PARTS: equ a l t o t he n u mber of h ou r s
(n or ma l work pa t ter n ), les s s chedu led “down -t ime” (e.g. breaks , s t a rt u p, preven t ive
ma in ten a n ce, s ha red pr odu ct ion , t ool ch a n geover s , s hu t -down , et c.) a n d t ime s chedu led
t o ru n ot her cu s tomers ’ pa rt s an d/ or ot her DCC pa r t s .

NON-CONFORMANCE TRACKING (NCT) SYSTEM: DCC’s elect r on ic s ys tem for
docu men t in g a n d t r a ckin g pa r t is s u es a t t h e ma nu fa ctu r in g pla n t s . It a ls o pr ovides a
met h od for r epla cemen t of t h os e pa r t s a n d for Su pplier dis pu te of t h e is s u e. Ser iou s
qu a lit y is s u es a re a ls o docu men t ed in t h e e-CIMS s ys tem.

NVH: Nois e – Vibr a t ion – Ha r s hn es s a re mea s u r a ble per cept ion s of veh icle a t t r ibu tes .
Th es e items a re u s u a lly dis covered a nd meas u red by Da imlerCh r ys ler ’s NVH la bor a tor y
fa cilit ies . NVH a t t ribu tes a re t ypica lly t u ned t o a cer t ain fr equ ency a n d amplitu de in or der
t o a ch ieve a n overa ll veh icle s ign a t u re fr equ ency. Th is s ign a t u r e is opt imized by veh icle
developmen t for t h e bes t cu s t omer r es pon s es .

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

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

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


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

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

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



s
LSL USL
6
LSL - USL
=
P
P
P
6
÷
=
o


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


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


P PK
P P s

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

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

s
LSL X LSL X
= PPL
P
3 3
÷
=
÷
o


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

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

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Su pplier ’s r equ ired docu men t at ion in a s equ en t ia l wa y a nd det er mine t he Su pplier ’s
readines s for t h e Produ ct ion Demons t ra t ion Ru n (300 pcs .) a n d PSO On -Site Vis it .
Genera lly, a Pre-PSO meet in g is h eld for Directed a nd Collabor a t ive AQP a ct ivit y level
pr ogr a ms ; it is n ot a r equ iremen t for pr ogr a ms wit h a Self-Directed AQP a ct ivit y level.

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

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

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

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

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

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

PROCESS SIGN-OFF (PSO) ON-SITE VISIT: a s ys tema t ic a nd s equ en t ia l review of t h e
Su pplier ’s ma nu fa ct u r in g proces s con du cted by a PSO Team a t t h e Su pplier’s produ ct ion
fa cilit ies . Th e ASQP Specia lis t is res pon s ible for leadin g t he PSO On -Site Vis it for Directed
a n d Collabora t ive AQP a ct ivit y level progra ms ; t he Su pplier lea ds t heir own for Self-
Directed AQP act ivit y level pr ogr a ms .

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

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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ma n u a l a n d t he Da imlerCh rys ler (Ch rys ler Grou p) Cu s t omer -Specific Requ iremen t s for
t h e PPAP 4
t h
Edit ion for more in for ma t ion .

PRODUCT SPECIFICATIONS: a ll en gineer in g dr a win g requ iremen t s in clu din g s t a nda r ds
referen ced on t h os e dra win gs an d wit h in t h e pre-s ou r ce package. Some of t hes e
requ iremen t s a re deter mined by t ea m con s en s u s du r in g Advan ced Qu a lit y Pla n n in g
meet in gs a nd Des ign Reviews an d ca n t a ke t he for m of Sa fet y St a n da r ds , Ma ter ia l
St a n da r ds , SRPC’s , Tempor a r y St a n da r ds , Proces s St a n da r ds , La bor a t or y St a n da r ds ,
Relia bilit y St a n da r ds , or Per forma n ce St a nda r ds .

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

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

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

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

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

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

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

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

SAMPLING PLAN: pla n t h a t defin es t he min imu m nu mber of pa r t s t h a t s h a ll be in s pected
fr om a given popu la t ion (s ee Da imler Ch r ys ler’s Lot Accept a nce Samplin g Table Pla n in
t h is ma n u a l).

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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
108
s crew, wa s her , a n d n u t (in t h at or der .) A s equ en t ia l s ens or wou ld detect a n d fla g
(t h r ou gh ligh t s , s t a t ion lock-ou t , et c.) if t h e n u t wa s pu t on befor e t he wa s her .

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

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

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

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

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

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

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

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


COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
109
SUPPLY CHAIN: in clu des a ll Su pplier s u s ed in pr odu cin g a given pa r t ; fr om t ier one to
t h e s ou r ce of pr odu ct ion ma teria ls .

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

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

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

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

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

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

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INDEX




Page(s )

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

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

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PSO 5 . 5 EDITION CHANGE LOG

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






















































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

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION

PROCESS SIGN-OFF (PSO)

Edition 5.5
December 2006

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION

INTENTIONALLY LEFT BLANK COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION .

it is intended to indicate both external and internal Tier 1 Suppliers.. functional and (where necessary) appearance requirements. which manufacture Mercedes-Benz. Emphasis is placed on the importance of adhering to our Product Creation Process. including sub-tier Suppliers.. please contact your DaimlerChrysler Advance Supplier Quality Planning Specialist (ASQP Specialist). This manual should be reviewed carefully and in its entirety to assure that all PSO requirements are known and understood. DCC and Supplier). Effective 01/01/2007. modified or removed. material. The PSO. Freightliner or other brand vehicles or products. The name “DaimlerChrysler” and “DCC”. In addition. In order to achieve an appreciable improvement in part quality. refer to DaimlerChrysler Corporation (i. this manual has been modified to reflect DaimlerChrysler Corporation’s current PSO philosophy.Process Sign-Off (PSO) FOREWARD TO THE 5.e. as used in this manual. all requirements stated in this document apply to all DaimlerChrysler Production Suppliers. in some cases. ISO/TS-16949 and Chrysler Development System (CDS) will form the foundation for Supplier readiness to assure proactive Advanced Product Quality Planning. The 25 PSO Process Elements identified in the 5th Edition PSO Manual were re-evaluated and.e. This manual does not apply to other DaimlerChrysler AG subsidiaries or operations. The term “PSO team” indicates all individuals involved in the PSO process (i. A Supplier’s certification to ISO/TS-16949 alone is not sufficient for PSO approval.e. all PSO requirements must be met in order to assure conformance to dimensional. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION . it denotes DaimlerChrysler Employee involvement only. i. Dodge and Jeep® brand vehicles.5 EDITION This manual shall define the requirements for Process Sign-Off (PSO) and detail the documentation required to verify conformance to DaimlerChrysler's (DCC) Quality System Standards. Where the word “Supplier” is used in this manual. which manufacture Chrysler. Where the term “DCC PSO Team” is utilized. the Chrysler Development System (CDS). it should be noted that every external Supplier of production parts to DaimlerChrysler Corporation shall be ISO/TS-16949:2002 third party registered. For questions or comments concerning the Process Sign-Off manual. DCC formerly known as Chrysler Corporation) and its subsidiaries.

Interior ASQP .Graz ASQP .ACKNOWLEDGMENTS PROCESS SIGN-OFF (PSO) Edition 5.5 Revision Team COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION .AQP Strategy & Processes AQP Strategy & Processes AQP Strategy & Processes AQP Strategy & Processes ASQP .AQP/PSO University Supplier Quality .Mexico Requests for revisions or changes to the manual should be directed to the PSO 5.Chassis ASQP .5 Process Sign-Off 5.Powertrain CDS Corporate Quality Manufacturing Quality Powertrain Quality Process Quality Engineering Supplier Quality .BIW/Exterior ASQP .Electrical/Electronics ASQP .5 Revision Team Members David Eller Bryan Book Nance Taylor Vic Randolph Eric Helgeson Larry D'Agostino Simon Kissonergis Cris Miller Neil Murphy Ida Goodwill Dennis Fett Chris Cottam Lynn Yang Mary Clor Arno Reiter Dave Koski Hector Magaña Mgr .

81 Appendix F Internal PSO Requirements ................................................................................................................................................................ 93 Reference Manuals...................... 79 Appendix E Forever Requirements ................................ 61 Appendix C FTC Calculations .......................................................................................................... 1 Process Sign-Off Flow Chart & Responsibilities ............... 87 Frequently Asked Questions .........................................................................................................................................PROCESS SIGN-OFF (PSO) Table of Contents Page Introduction ........................................................................................................................................................................... 67 Appendix D PSO Extended Run ............................................................ 11 Appendix A Forms and Instructions ... 98 Glossary .. 45 Appendix B Tables and Examples ............................... 6 Process Sign-Off Element Requirements..................................................................................................................................................... 111 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION ............................................... 99 Index.............................................................................................................................................................

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procedures. The PSO is utilized to scrutinize the Supplier’s entire production process. PSO activities shall be conducted by the Supplier for all Self-Directed AQP Activity Level parts. New and/or additional production lines (e. Data collection. material.Process Sign-Off (PSO) INTRODUCTION SCOPE: Process Sign-Off (PSO) shall be performed on all new or modified parts with PPAP requirements or parts that have been out of production for 12 months or longer. equipment. 2. Production line moves. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 1 . capacity increases). PSO On-site Visit The DCC PSO team shall witness at least one Production Demonstration Run (PDR) utilizing completed production tools as part of the PSO process for all Collaborative and Directed AQP Activity Level parts. software level(s) and tooling. The DaimlerChrysler PSO is composed of three primary activities: 1. within a year of PSO approval. This process verifies a Supplier’s ability to manufacture production material at the daily tool capacity (as noted on the Production Purchase Order or as provided in writing by the DCC Production Buyer). Pre-PSO Meeting The DCC PSO Team shall review PSO documentation during AQP meetings and again during the Pre-PSO Meeting for compliance to PSO requirements.g. Carry-over parts which have experienced a Supplier responsible yard hold within the past calendar year. Any product or process change that occurs during the lifecycle of a part or system. including all in-house and secondary systems that support primary production line(s). PROCESS SIGN-OFF DEFINITION WHAT IS A PSO? Process Sign-Off is a formal review of the Supplier's production manufacturing process. analysis. Production Process review and measurements will provide the production rate. Additional conditions that may result in a PSO being required are: Carry-over parts with historically high warranty and/or quality problems. Each PSO includes evaluation of associated production facilities. First Time Capability (FTC) and other statistics that validate each Supplier’s ability to effectively produce both the required quality and product quantities. related manpower. and summarization are the true measures of part quality and production capabilities. methods. Observing the PDR should reveal issues such as bottlenecks and inefficiencies.

The DCC ASQP Specialist has lead responsibility for the PSO for parts or modules with Collaborative and Directed AQP Activity Levels. Process. The Supplier shall identify Supplier PSO team members for both the DaimlerChrysler led PSO’s. setup.Full compliance with all PSO requirements and procedures ensures that the Supplier’s manufacturing process is stable. quality. as well as for Supplier led Self-Directed PSO’s. the DCC ASQP Specialist. Other PSO team members may include but are not limited to. The purpose of the PSO is to demonstrate Supplier process capability and production capacity. It confirms that the processes can and will (when properly and successfully executed) produce quality parts in sufficient quantities for production. and reliability requirements contained in the Performance. and Vehicle Specialist. Packaging and shipping or simulation test approvals are required by Material Handling Engineering if applicable. durability. DCC Product Engineer and Supplier(s) Representatives. The Supplier has lead responsibility for parts with Self-Directed AQP Activity Levels. SRE is complete and the results have been documented and are acceptable to the team. On-Site Visit shall be scheduled by the PSO Team following the Pre-PSO Documentation Review. at a minimum. and Material Specifications. 3. WHEN IS THE PSO PERFORMED? The Process Sign-Off. Validation Testing Production Validation (PV) Testing. in control and capable of producing parts that meet all requirements. and The production operators are trained and capable of running at the required line speed. when the PSO Team agrees that: All required Supplier documentation has been reviewed and is acceptable. will validate the Supplier’s system and provide evidence that the parts meet engineering. the DCC Buyer. The requirement is to complete all PSO’s and PPAP submissions prior to supplying parts for S1 Start. WHY IS A PSO NECESSARY? Process Sign-Off is an effective method of verifying a Supplier’s quality planning processes. The PSO demonstration shall produce dimensionally correct parts on the homeline with production tooling. Production tooling is complete. WHO CONDUCTS THE PSO? The PSO Team consists of. on-site at the Supplier's Plant. Center of Competence (COC) Engineer. If PPAP is not complete prior to S1 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 2 . of the Production Demonstration parts. debugged and the Supplier Readiness Evaluation (SRE) performed.

for Directed and Collaborative PSO’s). indicates that the first 20 PSO elements have been completed and approved. they will schedule and coordinate the Pre-PSO Meeting as well as the PSO On-Site Visit.1 and 2. When appearance approvals are required. The ASQP Specialist is responsible for entering the “A” approval into Powerway. A successful PDR shall yield parts for Production Validation (PV) Testing. HOW IS THE PSO PERFORMED? Refer to Figure 1 for the PSO strategy and Figures 2. This code. Suppliers do not have access to this procedure and should contact their DCC ASQP Specialist or Engineer for additional information regarding IAAs.com.5 before full approval is given. PSO “A” Approval: The “A” Approval is an internal code within Powerway. Process Sign-Off On-Site Visit: The PSO Team shall complete the first 20 elements of the PSO SUMMARY REPORT at the Supplier’s manufacturing facility.. The Supplier is then eligible for full tooling payment.2 for a step-bystep flowchart and responsibility matrix for the PSO process. This code. the Supplier shall obtain a signed Appearance Approval Report (AAR) prior to PPAP submission. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 3 .com for Self-Directed AQP Activity Level parts. The ASQP Specialist will advise the Supplier of the documentation the team will want to review and whether the part has been selected for a PSO Extended Run.com system. the Supplier may be eligible for partial tooling payment (for further tool payment information. “Z” approval authorizes the Supplier to submit the Dimensional Part Submission Warrant (PSW) into Powerway. reference the source package and the DCC Purchasing contact noted there in). The Supplier is responsible for entering the “A” approval into Powerway. Together. in conjunction with the submission of a dimensional Part Submission Warrant (PSW).e. an Interim Approval Authorization (IAA) is required.com. refer to P&S procedure PSSP0108 as well as any special requirements of the specific DCC Product Team. Pre-PSO Meeting: The DCC ASQP Specialist will initiate PSO dialogue with the DCC Product Engineer and the Supplier (i. At this point.com for Directed and Collaborative AQP Activity Level parts. PSO “Z” Approval: “Z” Approval is an internal code within the Powerway. in conjunction with the submission of a material and/or functional PSW (and an AAR. The Supplier is responsible for entering the “Z” approval into Powerway. Refer to the AIAG PPAP manual and DCC Engineering Standards CS-9022 and PS-4559 for further guidance. The PSO Team shall also verify the Supplier’s compliance to all 21 elements of PSO Edition 5.Start. Any deviations shall be recorded on the PSO COMMENTS SHEET.com for Directed and Collaborative AQP Activity Level parts. For specific requirements regarding IAA submission. The ASQP Specialist is responsible for entering the “Z” approval into Powerway. if required) confirms that all PSO and PPAP requirements have been met.com for Self-Directed AQP Activity Level parts.

an IAA is still required.com. NOTE 2: Any deviations to the PSO requirements outlined in this manual must be requested and approved in writing by the DCC ASQP Specialist and Product Engineer. Failure to submit PPAP before S1 Start will require an Interim Approval Authorization (IAA). Reference the internal DCC procedure PSSP0108.com. PSO “N” Approval: The “N” disposition is an internal code within Powerway. NOTE 1: Even with “Z” Approval.com prior to the Supplier submitting the Warrant (PSW) and entering the PPAP date and PPAP “A” disposition. This requirement is true for all parts.The PSO date and an “A” disposition are required to be entered into Powerway. PSO “A” approval is a prerequisite for PPAP approval.com by the Supplier. PPAP approvals are submitted through Powerway. Suppliers do not have access to this procedure and should contact their DCC ASQP Specialist or Engineer for additional information regarding IAAs. A new PSO planned visit date (or corrective action completion date) is required to be entered into Powerway. This code indicates that the PSO On-Site Visit was unsuccessful and corrective action is required by the Supplier. Interim Approval Authorization All parts require full PSO and PPAP approval. Approval(s) must be obtained from DCC before completion of the PSO process. regardless of AQP Activity Level. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 4 . Requested deviation(s) shall be formally outlined in detail within the COMMENT SHEET of the completed PSO. REGARDLESS OF AQP ACTIVITY LEVEL.

PROCESS SIGN – OFF STRATEGY REVIEW PSO REQUIREMENTS WITH PSO TEAM & SUPPLIER SUPPLIER PERFORMS READINESS EVALUATION RUN CONDUCT PRE-PSO MEETING (REVIEW SUPPLIER’S DOCUMENTATION & SRE) PSO TEAM CONDUCTS PSO ON-SITE VISIT or SUPPLIER PERFORMS PRODUCTION DEMONSTRATION RUN (Self Directed AQP) SUPPLIER CONDUCTS PV TESTING PSO TEAM COMPLETES PROCESS SIGN-OFF SUPPLIER SUBMITS PPAP PART SUBMISSION WARRANT SUPPLIER COMPLIES WITH CONTINUOUS CONFORMANCE REQUIREMENTS COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 5 .

COM 5 PSO REQUIREMENTS REVIEW WITH PSO TEAM AND SUPPLIER 6 SUPPLIER PREPARES DOCUMENTATION AND CONDUCTS READINESS EVALUATION RUN 8 SUPPLIER MODIFIES AND SUBMITS DOCUMENTATION AND/OR CONDUCTS READINESS EVALUATION RUN NO 7 PRE-PSO MEETING: DOCUMENTATION/SRE ACCEPTABLE? YES 9 SCHEDULE PSO ON SITE VISIT 10 SUPPLIER FINALIZES LINE AND APPROVES EVIDENCE OF PRODUCTION READINESS a b c d Figure 2.1 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 6 .PROCESS SIGN-OFF FLOWCHART 1 PART ENTERS POWERWAY.COM Self Directed AQP 2 INITIAL RISK EVALUATION & AQP LEVEL Collaborative/Directed AQP 3 SUPPLIER LED PSO 4 DAIMLERCHRYSLER LED PSO 3A SUPPLIER UPLOADS DOCUMENTS INTO POWERWAY.

com Initial Risk REMARK COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 7 .PROCESS SIGN-OFF FLOWCHART RESPONSIBILITIES DCC PROCUREMENT DCC ENGINEERING DCC MANUFACTURING DCC ASQP SUPPLIER L P P P P P P/ S P P P P S S S S S P P P P P/ S P P P L S L L S S L S S L S L S S S S S L S L S L RESPONSIBILITY LEGEND L = LEAD RESPONSIBILITY S = SUPPORT TO P = PROVIDES INFORMATION P/S = DEPENDS ON COMPOSITION OF PSO TEAM 1 2 3& Supplier led PSO 3(A) DaimlerChrysler led 4 PSO PSO Requirements 5 Review Supplier prepares 6 documentation and readiness evaluation Pre-PSO 7 Documentation Reviews Supplier modifies and 8 submits documentation Schedule PSO On9 Site Visit Supplier finalizes line 10 and approves evidence production PROCESS NAME Part enters Powerway.

A b c 11 PSO ON-SITE VISIT or SUPPLIER CONDUCTS PRODUCTION DEMONSTRATION RUN d YES 12A PSO ON-SITE REVISIT NECESSARY? NO 12 ELEMENTS 1-20 ACCEPTABLE? NO YES 14 “Z” DISPOSITION AND COMPLETION DATE ENTERED IN POWERWAY.COM 17 INVESTIGATE REASON FOR FAILURE AND ROOT CAUSE ELIMINATION 16 ELEMENT 21 ACCEPTABLE? NO YES 19 PSO APPROVED.2 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 8 . “A” DISPOSITION AND COMPLETION DATE ENTERED IN POWERWAY.COM Figure 2.COM 20 SUPPLIER SUBMITS PPAP WARRANT & ENTERS PPAP DATE IN POWERWAY.COM 13 SUPPLIER CONDUCTS CORRECTIVE ACTION AND SUBMITS DOCUMENTATION 15 SUPPLIER CONDUCTS ELEMENT 21 YES 18 REPETITION OF ELEMENT 21 SUFFICIENT? NO 19A SUPPLIER CONDUCTS PSO IN ACCORDANCE WITH PSO MANUAL AND ENTERS PSO DATE & DISPOSITION INTO POWERWAY.

PROCESS SIGN-OFF FLOWCHART RESPONSIBILITIES RESPONSIBILITY LEGEND 11 PROCESS NAME PSO On-Site Visit DCC PROCUREMENT DCC ENGINEERING DCC MANUFACTURING DCC ASQP SUPPLIER P/ S P/ S S P/S L S P/S L S P P S P L L S L P P P/ S P P/ S P/ S S P S L P L L S P/S L S P S S P/S S S P/S L P P/ S S P/S S L P S P S L REMARK L = LEAD 12 Acceptance of Elements RESPONSIBILITY &12(A) 1-20 S = SUPPORT TO P = PROVIDES INFORMATION Supplier conducts corrective action and P/S = DEPENDS 13 submits documentation. ON ASQP provides approval COMPOSITION OF PSO TEAM "Z" code entered into 14 Powerway. Supplier enters Dimensional PPAP & date Supplier conducts 15 Element 21 Acceptance of Element 16 21 Investigate reason for 17 failure and root cause elimination 18 Repetition of Element 21 PSO "A" disposition & date entered into 19 Powerway.com Refer to PPAP Manual for further details COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 9 .com. Supplier enters Material/ Functional PPAP & date Supplier conducts PSO and enters “A” 19A disposition & date into Powerway.com.com 20 Supplier submits PPAP warrant and date into Powerway.

INTENTIONALLY LEFT BLANK COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 10 .

PSO ELEMENT REQUIREMENTS COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 11 .

3 Control Information Pages (PIP) of Documents).jsp. DESCRIPTION AND CHANGE LEVEL Element Requirements Documentation 1. drawings.1 DCC approval for all deviations from listed standards shall be documented on the CATIA Comment page/PIP and DVP&R. 1. the Supplier shall employ an internal numbering system and provide a cross reference which enables users to identify the DCC part number and revision level which corresponds to the Supplier’s numbering and revision system.5 A process shall be in place to obtain revisions to all DCC.com/ESSD/Login.3.daimlerchrysler. 1. eprocedure mail.1 This process shall address notification to all applicable departments of standard changes as they occur. Part level present or cross-referenced (see ISO/TS-16949 cl.2 This procedure shall include the receipt of an approved DCC applicable) Change Notice. but not limited to. This process shall also include the frequency and responsibility for reviewing the standards (not to exceed two working weeks.) 1. description and change Comment page.) are updated and level) (MANDATORY applicable testing is performed for each change. etc.2. (including list of applicable engineering 1. Safety <S>. etc.2. cl.3 Where the product identity is not inherently obvious.1 Engineering Specifications.4 The Supplier shall have a procedure which prevents nonstandardized or out of date documents and instructions from existing on the manufacturing floor (e. 4. and other product related standards and specifications. are UNACCEPTABLE).) 1.3 Control of Documents. ENGLISH) Gage Dimensioning & 1.6. Refer to ISO/TS16949.2.1 This procedure shall include communication and notification Tolerancing (GD&T) of changes throughout the Supply Chain. 4. governmental. cl. Document audit). Control Plan. Part number cross reference sheet (if 1. DCC standards are available via Engineering Standards Supplier Distribution (ESSD) at https://essd. Document Control procedure 1.2.g.PART NUMBER.extra. This procedure shall also ensure level and hardware affected documents (e. those shown on the source package and signed DVP&R (see Element 3 “Test Sample Sizes and Frequencies”.5. PFMEA. The Supplier shall not make any changes Engineering Change without DOCUMENT approval from the customer (voicemail.6 The PSO Team shall verify that the CATIA Comment page or Part Information Page (PIP) lists all applicable standards.1 The PSO team shall review all PSO related documents to ensure CATIA files. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 12 . software revision level as changes occur.g. Engineering Standards Identified 1.2. all documents have the correct part number. including.2 A procedure shall be in place to assure correct part number and standards. The Tier 1 Supplier is sheets (MANDATORY ultimately responsible to ensure product shipped to DCC (or other ENGLISH) designated manufacturing facility) is the latest revision level. 4. reference ISO/TS16949.

3 The PSO Team shall verify that all dimensional requirements are defined on the GD&T sheets and attached to the design model. CONT. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 13 .PART NUMBER. quantity. and revision level. This listing shall include DCC part number (if applicable).6. Supplier part number. 1. The Supplier shall consistently apply a mutually agreed upon (with the DCC PSO Team) datum scheme throughout the part development process. Element Requirements 1. DESCRIPTION AND CHANGE LEVEL.2 The PSO Team shall verify that the CATIA Comment page or PIP lists all sub-components of the end-item assembly.6.

2.tcc. 2. CSA. The DCC Product Engineer has the lead responsibility for ensuring that the DFMEA meets all requirements. eCIMS. 2. 2.com/cds/ for specific timing.g. 2. See Appendix B “FMEA Guidelines”.chrysler.) A Detection of 10.2 The procedure shall include use of the “Rolling Top 20” rule for continuous improvement. regardless of Detection (this equates to customer dissatisfaction and c’s/1000 > 1.) 2.5 A DFMEA shall be completed for each unique Supplier-designed product. 2.4 The DFMEA is a living document and shall be traceable to all design changes.) 2. and detection numbers were developed. A Severity 5 and Occurrence 2. 2.2. regardless of Occurrence or Detection values. etc. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION Documentation DFMEA (MANDATORY ENGLISH) “Best Practice” procedure 14 . The procedure shall include documentation and data which explains how the DFMEA severity.7 The Supplier shall ensure all failures observed during Engineering Development (ED) and Design Verification (DV) testing are captured within the DFMEA.2.3 Error proofing and controls shall be identified in the DFMEA. NOTE: Special attention (as defined by DCC Engineering) shall be given to failure modes with: A Severity 8. If AIAG and DCC guidelines disagree.6 The DFMEA shall include all sub-components of the end-item assembly. Reference the CDS Quality Gate Book at http://roadmap.1 This procedure shall be reviewed periodically for effectiveness and shall include lessons learned with inputs from past issues (e. timely completion and approval of all DFMEA activities shall be completed on or before required quality gate timing. yard holds. NCT.1 Design FMEAs (DFMEAs) shall be created using the latest AIAG and DCC guidelines. occurrence.DESIGN FMEA Element Requirements 2. if applicable. 2. It shall contain all special characteristics from Element 12 “Special Product/Process Characteristics Identified”. Additionally. This requires the Supplier to Pareto failure modes and address the top 20% using RPN values (regardless of actual RPN value. warranty.8 The Supplier shall ensure the occurrence and detection ability of failures observed during DV testing correlate with the occurrence and detection numbers documented on the DFMEA.9 Buzz-Squeak-Rattle (BSR) and Noise-Vibration-Harshness (NVH) issues shall be addressed. DCC guidelines take precedence.2 The Supplier shall have an internal “best practice” procedure that is utilized in the development of DFMEAs.

etc. NOTE: A written waiver is required each model year that annual validation will not be performed. Description. changes to test sample sizes.1 The Supplier shall have a procedure to ensure on-time Annual Validation. 7. 3. 3. Reference ISO/TS-16949. prevent scheduling conflicts and fixture/testing shortages in the event of multiple Annual Validations.2 Continuous Conformance testing shall be documented on the DVP&R when applicable. cl.5. or other formability analysis. 3. Documentation DCC Engineering signed DVP&R (MANDATORY ENGLISH) Applicable Engineering Standards (MANDATORY ENGLISH) DCC Engineering signed DV and PV test plans (MANDATORY ENGLISH) Annual Validation procedure COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 15 .” 3. and acceptance criteria shall have testing requirements included in a Design Verification Plan and Report (DVP&R). and Change Level. 3.2 Design Verification (DV) and Production Validation (PV) test plans shall be signed by the DCC Product Engineer PRIOR to testing.g.2.” 3. 3. is required for PSO approval on stamped components if required by the DCC ASQP Specialist and/or Engineer. test frequencies.4.6.4 DCC internal stamped components shall follow the requirements in MQAS 90-6710 “Dimensional Buy-Off Procedure for Upgrading Stamped Parts During Die/Tool Development.1 Deviations from the Performance Standards shall be identified and visible on the CATIA Comment page or PIP and DVP&R (e. 3.4. test waivers.4. 3. 3.TEST SAMPLE SIZES AND FREQUENCIES Element Requirements 3.) See Element 1 “Part Number.3 A "circle grid analysis".4 All functional requirements shall be defined in the DVP&R and verified against applicable Performance Standards for accuracy.3 Completed DV and PV test results shall be signed by the DCC Product Engineer.6 Annual validation testing shall be completed each model year as specified in the Product Assurance Testing manual and applicable Performance Standards. Reference the Product Assurance Testing manual. unless waived in writing by the DCC Product Engineer and ASQP Specialist.1 Products covered under a Performance Standard (PF) that specifies test sample sizes.5 All testing failures shall be documented on the DVP&R and addressed with a DCC 8-Step Corrective Action plan (available on the “Forever Requirements” webpage and through COVISINT). including a “Test to Failure” verification plan.4.

2 The Supplier shall have an internal “best practice” procedure that is utilized in the development of PFMEAs. NCT.) Documentation PFMEA (MANDATORY ENGLISH) PFMEA Audit Summary (MANDATORY ENGLISH) “Best Practice” procedure COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 16 .) 4.7 The Supplier shall ensure that all failure modes observed during all pre-production runs are captured on the PFMEA. 4. 4. 4. etc. NOTE: Special attention shall be given to failure modes with: A Severity 8. See Appendix B and the “Supplier PFMEA Audit Summary” sheet (internal DCC work instruction PSWI-1047.5 The DCC ASQP Specialist has the lead responsibility for ensuring that the PFMEA meets all requirements (“green”) per the “Supplier PFMEA Audit Summary” sheet. occurrence. This requires the Supplier to Pareto failure modes and address the top 20% using RPN values (regardless of actual RPN value. eCIMS.2. DCC guidelines take precedence.1 The Supplier shall ensure the rate of occurrence and ability to detect failures observed during pre-production runs correlate with occurrence and detection numbers documented on the FMEA.1 This procedure shall be reviewed periodically for effectiveness and shall include lessons learned with inputs from past issues (e.chrysler. A Severity 5 and Occurrence 2. If AIAG and DCC guidelines disagree.tcc.) A Detection of 10. timely completion and approval of all PFMEA activities shall be completed on or before required quality gate timing.4 The PFMEA is a living document and shall be traceable to all process changes. The process shall include documentation and data which explains how the PFMEA severity.6 The PFMEA shall reflect the entire manufacturing process from receiving through shipping. yard holds. CSA.1 Process FMEAs (PFMEAs) shall be created using the latest AIAG and DCC guidelines.). and detection numbers were developed. warranty. It shall contain all special characteristics from Element 12 “Special Product/Process Characteristics Identified”. Also. 4.7.2. 4.2 The procedure shall include use of the “Rolling Top 20” rule for continuous improvement. Suppliers do not have access and should obtain a copy from their ASQP Specialist. 4.3 Mistake proofing and controls shall be identified in the PFMEA.com/cds/for specific gate deliverables.8 BSR and NVH issues shall be addressed if applicable. regardless of Occurrence or Detection values. 4. Reference the CDS Quality Gate Book at http://roadmap. 4.PROCESS FMEA Element Requirements 4.g. 4. regardless of Detection value (this equates to customer dissatisfaction and c’s/1000 > 1.

5. manufacturing floor plan and/or the work station layout shall include each unique machine number. 5.2 The manufacturing floor plan shall show the layout of the facility and the station-by-station flow of the manufacturing process. manufacturing floor plan and/or the work station layout shall identify bottleneck operations or stations. flow diagram.6 All production equipment appearing on the manufacturing floor plan.5 The flow diagram. and scrap material storage locations. 5.1 The manufacturing floor plan shall highlight all production equipment used. including main-line assembly processes as well as all off(MANDATORY line supply processes.3 A work station layout shall exist which identifies all work stations. including float operators. 5.1 The process flow diagram shall represent the entire Process flow diagram manufacturing process from receiving through shipping (or equivalent) operations. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 17 . ENGLISH) Manufacturing floor 5. method and equipment used at each station (including Work Station Layout inspection and repair/rework stations). required per station (including repair/rework stations). 5.3 The flow diagram. The PSO team shall verify the number of operators during the On-Site Visit.1.2 The manufacturing floor plan shall show Work in Process (WIP). 5.2.2 Stations which measure special characteristics and/or contribute to significant customer issues shall be identified.4 The flow diagram.1. 5.2. and work station layout shall be verified by the PSO team. manufacturing floor plan and/or the work station layout shall include the number of operators. raw material.1 The process flow diagram shall include the processing plan sequence. 5.2. 5.PROCESS FLOW DIAGRAM AND MANUFACTURING FLOOR PLAN Element Requirements Documentation 5.

number of pieces. 6. rework/repair. and/or design requirements identified in the DFMEA and PFMEA shall be included in the Control Plan.1. shipping.4 The Supplier shall have a process which links the Supplier’s DFMEA and PFMEA to the Control Plan. and correct parameter setting.. yard holds) and include any applicable preventive actions in the Control Plan. 6. Process Monitoring 6.7 All special characteristics identified in the GD&T sheets and the DVP&R and any special characteristics that describe materials.1.1. shall be verified by the PSO Team during the Production Demonstration Run. material handling and storage. detailed in the DFMEA and PFMEA.g. lessons learned. 6. testing. e-CIMS.2 The Supplier is responsible for maintaining manufacturing process capability and shall have a procedure requiring documented corrective actions for all out of control measurements.1 The Control Plan shall describe each step of the manufacturing process including: receiving. inspections. NCTs.g. and continuous conformance. back-up operations). This process shall ensure that controls. warranty. temporary or interim off-standard operations (e.6 All process and product control parameters and tolerances shall be documented in the Control Plan. All reaction plans shall include containment of suspected non-conforming product and 100% inspection as approved by the PSO Team. 6. 6. 6.3 The Control Plan shall address verification of Mistake Proofing (e. Refer to the AIAG Advanced Product Quality Planning manual.1. 6.g.1 Measurement and inspection frequencies detailed in the Control Plan.8 Sample sizes shall be based on industry-standard statistical sampling plan tables or shall use Statistical Process Control (SPC).1. 6. processes.5 The Supplier shall reference known issues from similar products (e. inprocess operations.1. reliability. Documentation Control Plan (MANDATORY ENGLISH) 1st piece approval procedure & records Control Charts Process Performance Log Sheets Defect Tracking Sheets COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 18 . etc. proper machine set-up.1. 6. are carried forward into the Control Plan. performance.CONTROL PLAN & PROCESS MONITORING Element Requirements 6. quality.1.). etc.2 Repair/rework stations shall have controls equivalent to those of the primary production line. frequency. including all inspections for appearance requirements.3 A documented First Piece Approval procedure shall exist which verifies product at each station is being made according to specification.

SPC adjustments. 6. 6. studio quality photos for any “conditions” deviating from design intent. etc..1 Suppliers shall have an Appearance Manual for all components with appearance requirements. condition resolution tracking matrix. revision history.7 Suppliers shall have a Craftsmanship Quality Initiative Procedure for all components with appearance requirements.3. production line.5 Visual displays of process performance (e.1 Targets shall be identified for each measurable with documented plans for achieving those targets.3 Documented evidence of First Piece Approval process execution shall be maintained. and all Craftsmanship worksheets (photos of conditions.2 The process shall include the retention of the first piece until the end of the production run or shift and identification of the first piece sample(s) and analysis of special characteristics identified by the PSO Team and the Supplier during the AQP process. downtime. 4. table of contents. general appearance characteristics acceptance specification). along with supporting documentation. See the “DaimlerChrysler Customer-Specific Requirements” for ISO/TS-16949.5. retention of an Appearance Manual. This procedure shall include: team members. Element Requirements 6. containment and permanent correction actions. regular scheduled Craftsmanship reviews and audits.1. scrap and rework) and total production maintenance (e. production tool and characteristics’ values to assist in assembly plant. 6. etc.) 6.1 The procedure shall require First Piece Approval at the beginning of each shift or production run and after any changes are made to the production process (e. the Supplier is required to maintain a history of component production sequence. The Supplier shall record the part number.6 Where SPC methods are used. This manual shall include: appropriate documentation (sign-off sheet.) COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 19 . 6.) 6.3. and any additional information as required by the PSO Team. studio quality photos of product shown in appropriate views.7.g. etc) shall be present on the manufacturing floor and reflect current quality data.g. CONT. 6.4 All inspection stations shall have a method of defect tracking (e.CONTROL PLAN & PROCESS MONITORING. and containment procedures and guidelines. tooling modifications.1. warranty and field return root cause investigations. 6.3. FTC.g. tally sheets.g. manufacturing date. scrap sheets. cl.

including off-site storage or shipping locations.g. Supply Base Management 7. Additional documentation may be requested by the DCC ASQP Specialist.2.2 Each component listed on the Bill of Material corresponding to the DCC part number shall have an Initial Risk Evaluation (or equivalent) performed.2. (Reference ISO/TS-16949.chrysler.com.7.1 Problem Solving.5. All secondary processes and/or services (e. 7. The criteria for risking components shall take into consideration the DCC risk drivers. Quality Management Systems).3 The Supplier shall have a process which monitors and documents the quality of all sub-tiers.com/cds/.) are through the DCC eCIMS system and/or the 8-Step Corrective Action form.) shall be shown.3 of ISO/TS-16949. Level 3 PPAP documentation for all sub-components and sub-tier processes risked medium or high.2. 7.4.2 The Supplier shall cascade quality planning throughout all subtiers (see cl. 8.4 The acceptable methods for documenting root cause analyses and corrective actions (for all non-conformances.1 The plan shall include an “Easy Map” diagram.3 The Supplier shall have a procedure to convey lessons learned and corrective actions back through their facility.QUALITY PLANNING Element Requirements 7. DCC risk drivers are found on the Initial Risk Evaluation document in Powerway.1 Each sub-component determined to be “medium” or “high” risk (or equivalent) shall be accompanied by a PSO (or equivalent process) conducted by the Supplier. test failures. etc. Documentation AQP or APQP timeline/plan List with PPAP status of all sub-components. plating. Problem Solving 7. Level 3 PPAP documentation is also required.tcc. This diagram should outline the entire Supply Chain.2. The plan shall identify major milestone events.2. 7. responsible organizations. as well as scheduled and actual timing dates.3. DOE (Design of Experiments) Copies of eCIMS or 8Step Corrective Actions for issues encountered in previous pilot builds. “Easy Map” can be found on the COVISINT website. and all other facilities within the same company. required product or process deliverables.) 7. etc. heat treating.1 Corrective action shall be implemented across the entire manufacturing plant for every applicable DCC production line.2.1 All Advance Product Quality Plans (APQPs) shall coordinate with DCC Chrysler Development System (CDS) timing for each applicable program. Lessons Learned Communication procedure COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 20 . “Easy Map” Supply Chain diagram Listed risk of all subcomponents and subtier processes. 7. cl. beginning with raw materials and ending with the DCC or the DCC-designated manufacturing facility. 7. Reference the AIAG Advanced Product Quality Planning and Control Plan (APQP) manual and CDS at http://roadmap.

NonConformance Ticket (NCT) system.7 The Supplier shall support all DCC systems (e. etc. etc. COVISINT. CONT.g.com. these documents shall be available for review at the request of the DCC ASQP Specialist. etc.) The team shall ensure that all corrective actions have been completed and implemented (e. PRAS. through error and/or mistake proofing. Powerway.7. DV testing. as required. 7.2 When the Supplier is a DCC directed sub-tier. 7. Additional contact information may be obtained by DCC personnel (only) through the ODIMS system via the p12 screen. Support is to begin at Gate G1 Theme Selection and continue though the life of the program. However. COVISINT.1 Contact names shall be provided by the Supplier upon request.5 The PSO team shall review corrective actions for any nonconformances or test failures encountered prior to the PSO visit (e. Non-Conformance Ticket system. 7. during pilot builds. 7.com. process or design changes.8. which ensures ease of disassembly of product with minimal cost and time. the Supplier Representative(s) shall support the Tier 1 in the same manner as they would DCC.) 7.1 The Supplier shall have at least 2 individuals with valid SIDs and passwords for each applicable DCC eSystem (e.g. A cover page with the documents title block. PRAS.) All individuals shall be fully trained in the use of each system for which they access. those documents sited for exclusion are not required to be uploaded into Powerway.QUALITY PLANNING. Powerway. revision level and date is required to be uploaded in place of the actual document.com.) NOTE: For source packages that reflect proprietary document exclusions.g. 7. 7. Element Requirements 7. DOE (or similar activities) shall be conducted to identify and establish the optimal process parameters for all new and modified parts prior to the PSO On-Site Visit. eCIMS.g.6 The Supplier shall have a procedure for conducting Design of Experiments (DOE).8. to assist DCC personnel throughout the life of the program.8 The Supplier shall provide both a Plant and Warranty Quality Representative. eCIMS.9 Design responsible Suppliers are responsible for Design for Serviceability. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 21 . etc.

2. month.3 The plan shall include incoming acceptance sampling plans.1 The plan shall include an escalation process which component increases the inspection frequency when a defect is found. 7. 8. whichever is smaller. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 22 . Copies of sub-tier Supplier PSW’s (Part 8.3. SPC is superior and if used. Two or more of the methods Standard described in cl.2 When the plan includes “dock to stock” (i. 8.2 The plan shall have a product validation procedure which Copies of sub-tier determines the frequency of inspection based on component and subSupplier Certificates of tier history.e. Receiving Reports Inspection/test reports 8. Lot size shall not exceed one Audit Records shift or one production run.1 The Incoming Material Certification Plan shall include procedures plan used to qualify and certify incoming material prior to releasing into Sampling plans production.5 The lot acceptance date (or date the lot was inspected) shall include the year. otherwise.8 The Supplier shall have copies of their sub-tiers’ ISO 9001 certification on file.INCOMING & OUTGOING MATERIAL QUALIFACTION/CERTIFICATION PLAN Element Requirements Documentation Incoming Material Certification Plan Incoming inspection 8.1 of ISO/TS-16949 shall be used.4.2.6 Components or production materials used in the assembly of parts for DCC shall have full PPAP (or equivalent). 8. shall require three previous consecutive shipments to Supplier ISO-9001 have been defect-free and without subsequent internal or external certifications non-conformances. etc. The PSW for each subcomponent in the end-item assembly shall be easily accessible. for Part Inspection both attribute and variable data.7 Certificates of Analysis shall comply with DCC Engineering Standards identified on the CATIA Comment page or PIP. ships parts Submission Warrant) directly out of the receiving area without inspection) the process. the Audit Work minimum requirements found in the Lot Acceptance Sampling Table Instructions (see Appendix B) apply.4 The plan shall identify all processes performed by sub-tiers (e. plating. Analysis for each specific sub8. the sampling quantities in the Lot Acceptance Sampling Table need not be followed. NOTE: The requirements in the Lot Acceptance Sampling Table are for attribute sampling only. heat-treating. 8.g.) and include records indicating inspection/test results that relate to the appropriate lot code. at Copies of sub-tier a minimum. 8. Inspection frequencies and sampling plans Shipping reports shall be documented in the Control Plan. day and numeric sequence. Outgoing Inspection Plan 8.

Inspection frequencies and sampling plans shall be documented in the Control Plan. Element Requirements Outgoing Material Inspection Plan 8. 8. 8. Reference DCC internal procedures PSSP0301 “Part Inspection Standard” for specific instructions on completing the Part Inspection Standard and PSSP0600 “Key Component Designation for Supplier Quality”. Suppliers do not have access to these procedures and should contact their ASQP Specialist for further information. shall comply with DCC Engineering Standards identified on the CATIA comments page or PIP.14 Shipping. if required by DCC for the finished product. Audit. day and numeric sequence.INCOMING & OUTGOING MATERIAL QUALIFACTION/CERTIFICATION PLAN. for both attribute and variable data. 8. 8.11 Components or modules that have been designated as “key” shall have a Part Inspection Standard completed. month.9 The Outgoing Material Inspection Plan shall include procedures used by outgoing inspection to qualify outgoing product prior to shipment to the customer. and Containment Records shall be documented and maintained. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 23 .13 Certificates of Analysis. CONT.10 The plan shall include outgoing acceptance sampling plans. The Part Inspection Standard form is available on-line through COVISINT. 8.12 The lot acceptance date (or date the lot was inspected) shall be identified by the year.

if applicable). the Supplier’s shipping process and all sub-tiers shall conform to FIFO.g.2 The plan shall describe the types of containers used throughout the internal manufacturing process (including any external processing such as heat treating. 9. whichever is smaller.1 of ISO/TS-16949.1 Information shall include lot number. operation number and shift. NOTE: DaimlerChrysler does not procure returnable containers for Supplier’s WIP (Work in Process) or sub-tier Suppliers.) Each container type shall be clearly defined with material dimensions.g.PARTS HANDLING PLAN Element Requirements 9. ergonomic requirements.1 The Parts Handling Plan shall include procedures that detail all internal material handling operations.5. Element 9 “Parts Handling Plan” on the PSO SUMMARY REPORT shall be marked REJECT in the Process column and an explanation added to the COMMENTS SHEET.6 All parts shall have lot control and traceability. 7.1 When the traceability process is FIFO-dependent. weight.2.4.g. plating. 9. etc. etc. quantity per container. travelers.4. 9. routing cards. scrap.4 The plan shall include the procedures for in-process raw material re-stock (e.3 A method shall exist to clearly identify and differentiate rework/repair.1 Material storage locations shall be clearly identified. See Element 10 “Operating Instructions”.5 The plan shall have a procedure by which material is tracked and transferred from one process to another (e.4. part numbers.3 & 7. 9. Kan.5. WIP bins. FIFO). Containers for these components are the responsibility of the Supplier. 9.3. the Supplier shall have an effective method of ensuring FIFO stock rotation throughout the manufacturing facility 9. Use of DCC containers for this purpose is considered misappropriation of DCC corporate assets and is unacceptable. throughout all stages of production (and shipping. stack height limits (static & mobile). COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION Documentation Parts Handling Plan Material handling procedures Containment Records 24 . and be documented and verified (cl. If the PSO Team detects a container violation during the PSO On-Site Visit. date. NOTE: Container information may be included as a part of the Packaging Instructions. 9.5.) Lot size shall not exceed one shift or one production run. 9. number of pieces scrapped. etc. etc.Ban) and inventory control (e. number of pieces entering/exiting the operation.2 When FIFO is used as a method of inventory control.) 9. number of pieces reworked/repaired.

4 The ESD manufacturing process shall be included in the Supplier’s Layered Process Audit plan.2 Work instructions for ESD testers shall mandate testing of everyone as they enter the ESD production floor.) 9.7. CONT. 9. as well as the Preventive Maintenance plan. 9. reason for quarantine. etc. and personnel on an annual basis (minimum. rework or repair process.1 The plan shall address part handling and part identification for nonconforming product.7 The plan shall address containment of non-conforming material.2 The plan shall detail the maximum amount of time allowed for disposition of quarantined product.8. and expected disposition date. 9. number of pieces. and/or shoe effectiveness.6. ESD workbenches that are grounded with plugs for wrist straps (if applicable).8. 9.) Product in the holding area shall be clearly identified with part number. and inprocess. totes.8. 9.) Records of the certification and the recorded measurements shall be kept. 9.7. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 25 . ESD gloves and/or finger cots for handling of PCB's (e.) ESD testers for operators to verify heel and wrist straps. date quarantined.g.8. Element Requirements 9. Clearly-identified ESD containers (e.g.8 Any manufacturing facility handling components that must be protected from ESD shall have the following: ESD mats and/or floors. quarantined. tools. containers. testers.3 The Supplier shall have a locked and/or controlled area for holding non-conforming.7. This shall also include the use of the DaimlerChrysler Supplier Notification of Potential Nonconformance process outlined in the Forever Requirements located on the COVISINT website.) for ESD sensitive product to be transported to and from the line.1 All ESD operators shall be properly trained and be identified in some way (e.1 Sorted. engineering samples. from receiving of returned material back from the customer to final disposition. rejects. Electro-Static Discharge (ESD) Guidelines 9. All ESD testers shall have up-to-date operator instructions and be included in the calibration procedures and schedule. buttons. reworked or repaired material shall be traceable back to the sort.) 9. etc.g.g. or non-production product (e. badges.PARTS HANDLING PLAN. Heel and/or wrist straps (ESD certified shoes are also acceptable. bags.3 An ESD certification schedule shall exist which mandates recertification of all ESD equipment.

displays. defect tracking sheets.2. mistake proofing.1 Operator. See Element 9 “Parts Handling Plan”. 10. The Supplier shall also have a procedure which periodically verifies the condition of designated conforming Boundary samples to ensure the samples are still acceptable.) shall be used whenever possible. 10. and reactions shall be located adjacent to the process. cl.g.) 10. 10. etc.5. etc. inspection and packaging instructions shall be approved and signed by the appropriate Supplier departments (e.1.4 The DCC PSO team shall approve all rework and repair operations. 7. classes.) They shall be dated and traceable to the level of parts being produced. 10. rework/repair. changeover. log sheets.) 10. recertification. control charts. and shall include sample sizes and frequencies. Operator training shall be documented and maintained. Engineering.1. diagrams.4. Quality. periodic testing. rework/repair. Manufacturing.2 Work Instructions. visible to the operator and legible (reference TS-16949.2 All instructions shall enable any adequately trained person to perform the described operation.1 Special characteristics shall be identified in the appropriate instructions.1.g. etc.1 Sample parts used as visual displays shall be identified and maintained to the correct revision level.3 Operations requiring special certification shall be identified and operators certified to perform that operation shall be identified (e.2 The Supplier shall have a process for training and qualifying operators prior to operators performing production processes (e. 10.3.3 All instructions.). pictures. 10.OPERATING INSTRUCTIONS Element Requirements 10. procedures and work instructions. set-up. gage operating.) Visual management techniques (e. 10.1 A list of training requirements for each unique workstation shall be maintained.2. etc.2.g. temporary supervision. Rework and Repair Instructions and Procedures 10.g. mentorship.2 Visual inspection stations shall have methods established to verify the operator’s ability to find defects (e. Documentation Operator instructions Set up sheets Inspection instructions 1st piece approval instructions Mistake proofing instructions Rework/repair instructions Operator Qualification process Gage instructions COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 26 .g. 1st piece approval.1 All reworked/repaired products shall be clearly and uniquely identified.

g. quarantined lot.4.) COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 27 .OPERATING INSTRUCTIONS. 10.2 The rework/repair procedure and instructions shall state that when a sub-component is replaced which has Safety <S> characteristics and a new sub-component is installed.4.3 The rework/repair procedure and instructions shall state that when a sub-component is removed from an assembly which has been returned from a DCC facility which is to be re-used in another assembly. parts sorted as “good” from a returned. the lot code of all sub-components with Safety <S> characteristics shall be identified and linked one-to-one with the new assembly or lot in which the component will be used.4.4 The rework/repair procedure and instructions shall require traceability and/or part identification in the event that any part returned from a DCC assembly plant is to be re-sent without rework or performed (e. Element Requirements 10. CONT. 10. the lot from which the replacement sub-component came shall be identified and it shall be linked one-to-one with the final assembly or lot on which the sub-component was used.

(STR) 11. the sub-tier location shall be indicated on the STR. EQUIPMENT. NOTE: DaimlerChrysler owned tooling shall be used for the production of DaimlerChrysler product(s) only. 11. gages and fixtures shall possess unique identification numbers. paper tags.chrysler. AND GAGES IDENTIFIED Element Requirements Documentation 11. and/or temporary tooling and equipment used in Supplier Tool Record the production process. are unacceptable methods of marking.1 Gages shall be manufactured and approved per the DCC gage standards identified on the Advance Manufacturing Engineering (AME) website http://ame.2 All DCC owned tooling. other OEM.) for each item listed.1.g.ctc.4 Customer Property and the DCC Purchase Order. etc. Reference ISO/TS-16949 cl.) shall be identified in the Supplier’s maintenance.com/gages.3 All tooling. quality.1 The Supplier shall establish a tooling list which includes all Tooling list production. 11. and be identified “Property of DaimlerChrysler”. 11. tool room.5. Supplier owned.g. 7. etc. fixtures. gages and/or fixtures reside at the Supplier’s sub-tier. ink.1 The list shall indicate ownership (e.2.2 Verification of the STR against the Supplier’s manufacturing facility shall be performed by the PSO team during the PSO On-Site Visit. equipment. and calibration procedures. storage. interim. The method used to mark the tools shall be non-degradable and fireproof (paint. etc. fixtures.2. maintenance. The STR can be obtained from the DCC Buyer. production. equipment and gages used in the manufacturing process (e. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 28 .TOOLING. and gages shall be clearly and permanently marked with the same tool number as identified on the Supplier Tool Record (STR) and the Tool Purchase Order.) All tooling. 11. In the event tooling. from the laboratory.

DVP&R. 12.2. SPC is not required unless specified by the PSO team. 12. Refer to PF-SAFETY for additional requirements and information regarding Safety (<S>) characteristics.4.1.) manual and cl. and 4. Control Plan.4. All special characteristics shall be included in the MEASUREMENT SYSTEM REPORT and the INITIAL PROCESS STUDY.1.2. and Shield (safety <S> ENGLISH DOC) and emissions <E>) characteristics. equipment. as determined locally. etc. Other characteristics deemed Certification) critical to the process or end-item assembly may also be designated as (MANDATORY special characteristics by the Supplier and/or PSO Team. 12. Key (diamond) <D>. DFMEA. Engineering Standards shall be shown or referenced on affected procedures and work instructions for processing and verification during production. gages. See Element 15 “Evidence of Product Specifications” and Element 20 “Initial Process Study”. dies.1 Each Safety (<S>) designation shall have both a (100%) primary measurement process and a secondary QC Audit measurement process designed to maintain lot control.4. Special characteristics characteristics are product characteristics or manufacturing process PPSR (Pre-Production parameters which can affect safety or compliance with regulations.1.4 A system shall be established and maintained to track Safety (<S>) related activities including a listing of all Safety (<S>) characteristics (also referred to as a Master Tracking List).1 The Supplier shall use SPC reporting for all Safety (<S>) characteristics that shall be made available to DCC representatives upon request.5 of the DCC Customer-Specific Requirements for ISO/TS-16949.3. Sample Report) function.2. fixtures.1.1. performance or subsequent processing of product. tools.2 The Supplier shall have documented definitions of internal special characteristics and the requirements for selection. 12.1.4. fit. They (MANDATORY include all governmental. 4. control and monitoring of them.1 All special characteristics shall be noted on all applicable quality documents (e.1 A list of special characteristics shall be developed using DCC List of special input as well as Supplier knowledge of the product. 4. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 29 . PFMEA.SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC Element Requirements Documentation 12. Safety Characteristics 12.2.1. Reference ENGLISH DOC) the AIAG PPAP (4th ed. and set-up and operator instruction sheets).3 For special characteristics not identified as Safety (<S>) characteristics or SPC points on the design model. 12.1. 12.1 The primary measurement is performed by production operators or skilled trades / Manufacturing Engineering (ME) personnel for robotics. This list is used to provide overall Safety related coordination and to assist in developing primary and secondary measurements.g. Torque requirements and FPSC (First characteristics identified as SPC points on the design model shall also Production Shipment be considered special characteristics. 12.

12. or a specified time period as identified by the DCC PSO team.4.3 The acceptable checking method.1.1 Detection of any non-conformance during sample verifications shall result in the immediate quarantine of all product. Suppliers do not have access to this procedure and should contact their DCC ASQP Specialist for additional information. sample size and sample frequency for establishing lot control within the Supplier’s facility shall be determined by the Supplier’s Control Plan and/or as directed by DCC. and carrying forward lessons learned (to be included in FMEAs.4. control plans. 100% of the FPSC parts are to be inspected for conformance to special characteristic requirements. existing and future DCC programs.5 The FPSC plan requires the Supplier to provide statistical evidence of conformance to special characteristics.4. DCC may perform audits and/or elect to have a third party audit completed. with disposition determined by the PSO Team. Reference the internal DCC procedure PSSP0106 “First Production Shipment Certification (FPSC)”. 12.5. 12. etc. In addition. 12. regardless of risk or AQP activity level.4.2. 12.1 The Supplier shall provide the FPSC plan for PSO team approval at the Pre-PSO meeting.2 A process shall be in place and maintained which tracks any non-conformances related to a Safety (<S>) characteristic including proper corrective action notification.3 Periodic system audits related to Safety characteristics shall be performed as a part of the overall control plan OR as specified by DCC. 12. etc. shall meet FPSC requirements.SPECIAL PRODUCT & PROCESS CHARACTERISTICS IDENTIFIED AND FPSC. implementation verification.5. Certification is for a minimum of the first 2000 parts shipped to each DCC or other designated plant.1.2 The secondary measurements (QC Audit) shall have Quality Auditors performing visual and/or physical checks at specific sample sizes and frequencies and recording results on statistical charts. Element Requirements 12.3 All completed FPSC’s for Collaborative and Directed AQP activity level programs shall be reviewed with the DCC PSO team.1.5. CONT. from each Supplier production line and cavity.) 12. First Production Shipment Certification (FPSC) Plan 12. The FPSC quantity may be adjusted by the DCC PSO team based on such factors as low production volumes.4.2 All parts and components. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 30 .1.

1.1. They shall be stored separate from WIP or finished product in a clearly marked container or designated area.1. Mistake proofing identifies errors in production and prevents them from becoming non-conformances.ERROR AND MISTAKE PROOFING Element Requirements 13.7. 13.1 A contingency plan shall be documented in the event the production mistake proofing is not operable.1. 13. A visual and/or audible alert shall signify the mistake proofing is inoperable. 13. See Element 14 “Layered Process Audit Plan”.5 All reworked or repaired product shall pass through error and mistake proofing equivalent to that on the primary production line.2 and the DCC CustomerSpecific Requirements for ISO/TS-16949 cl. 13.2. 13.1 The Error and Mistake Proofing Plan shall describe how the Supplier addresses error proofing and mistake proofing from an organizational level. The plan shall include notification of the DCC ASQP Specialist per the Forever Requirements. 13. 13. 13. by design.3 All Verification Samples shall be clearly marked. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION Documentation Error and Mistake Proofing Plan List of error and mistake proofing implemented by operation number Error and Mistake Proofing studies Mistake Proofing Contingency Plan 31 . labeled and controlled to prevent mixing with production materials. major disruptions. 13. Verification shall occur once per shift or per production changeover (whichever is more frequent) at minimum. Audible and visual indicators shall notify of the failed operation. etc. 4. NOTE: Error proofing eliminates.1.2 Verification Samples shall be verified on the production line as frequently as needed to ensure mistake proofing is operational.4 Error and/or mistake proofing shall be used on all special characteristics.1 The plan shall include the creation of Verification Samples for verification of mistake proofing. Frequency of verification shall take into account start of shift. 14. cl.2 Line or station lock out shall be implemented in the manufacturing process at all steps to prevent failed operations from proceeding to a subsequent station or into finished product. tooling maintenance.4 Error and Mistake Proofing software shall be tested for all possible failures and bypass scenarios. These shall include all failure modes identified in the DFMEA and PFMEA. NOTE: It is strongly recommended that error and mistake proofing verification also occur whenever the production line experiences an unplanned disruption and/or down-time.2. production changeover. the possibility of producing a specific defect.3 Error and/or mistake proofing shall exist for all failure modes with severity of 8 and higher in the PFMEA and DFMEA.9.

13. Element Requirements 13.) with closed loop feedback systems and process limits established. shall have 100% verification of proper part selection through error and/or mistake proofing. vision station. 13.11 All cylinders applying components or performing staking shall be verified for full stroke. Heat staking. Error and/or mistake proofing shall ensure that parts cannot skip this operation.) shall leave a unique. “end-of-line” (EOL) tester.7 Sequential sensing shall be used when the process utilizes physically independent cells making up one process flow.g.13 All critical lubrication.1 Mistake proofing shall verify that the end-item assembly is complete with correct content.12 Manufacturing processes (e. MACO etc. and location.) shall have controllers (e. which are sorted for specific application (content or function). etc. 13.8 Any station used as a final verification (e. etc.ERROR AND MISTAKE PROOFING. 13. NOTE: The process flow shall accommodate separate paths of right and left parts if deemed necessary by the PSO team. 13. Injection Molding. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 32 . 13. 13. 13.1 Leak testing for liquids and gas shall be automated and measured 100% on line.14 Assembly machines that accommodate right and left parts in the same process shall have error and/or mistake proofing to prevent assembly and packing errors. CONT. 13. identifiable mark indicating that the part has successfully passed through the entire process. RJG.10 All sub-components.g.g. adhesive points. amount. 13.6 Error and mistake proofing verification shall be addressed in the Preventive Maintenance Plan.13. NOTE: Verifying that the component is in the machine prior to assembly. and then assuming it is on the finished product after the machine cycle is not acceptable.9 All functions. Welding.8. efforts and travel shall be exercised and measured 100% on line to their full extent. 13.15 The Supplier shall have error and/or mistake proofing to prevent loose foreign objects in assembly. liquids and gases shall be automated and have error and mistake proofing for proper flow.

13. 13. engine testing.18 When making terminal contact for in-process manufacturing (harness assembly.21 “Push click pull” method shall be utilized for all electrical and other applicable connections. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 33 . tactile or visual feedback. 13. the probe used to contact the terminal spring member shall be smaller in thickness than the minimum blade thickness (including tolerances) of the terminal being tested. Requirements for Modules/Sequenced Part Delivery (SPD) 13. 13. and correct components (where applicable). Pogo pins shall be maintained and inspected regularly. etc.17 All electrical components and connections shall have continuity and functional check with automated line stop/lockout if continuity is not achieved to verify integrity of the connection.ERROR AND MISTAKE PROOFING. 13.24 Components with Safety <S> characteristics shall be traceable to the VIN sequence.20 Vision systems or color sensing shall ensure correct color match of components. 13.16 All electrical connections shall have a positive detent that can be identified through audio. the male pin probe shall be smaller than the minimum diameter (including tolerances) of the pin.23 The Supplier shall have redundant systems to ensure receipt of broadcast.) the following requirements shall be followed: Pogo pins shall not violate the contact area of the terminal(s) being tested. When pogo pin access is not provided and spring member contact is the only option.19 Barcodes and/or pick lights with break beams (or equivalent) shall be used to ensure the correct part is picked and assembled per the broadcast. device testing. CONT. including rework and repair.25 An assembly requiring rebroadcast due to a non-repairable condition shall have additional tracking to maintain sequence and timely delivery. Element Requirements Requirements for Electrical Components 13. The depth of insertion of the probe shall be the minimum depth required to make electrical contact for testing.22 SPD part sequence shall be maintained throughout the entire process. 13. The test fixture shall provide features to align the connector to the test fixture prior to engagement of the pogo pins. If round pin terminals are being tested. 13.

14. The audit shall be on the process undergoing the PSO.4.3 The LPA plan shall require top management reviews of LPA results. Reference Element 13 “Error and Mistake Proofing” cl. 14. implementing and updating the LPA plan.3 After PSO approval. no item shall be removed from the LPA checklists without the DCC ASQP Specialist’s approval regardless of initial AQP Activity Level.4. 13.1 and the LPA Fundamentals course (available through TEDS) for additional LPA requirements.5 The Supplier shall demonstrate at least one level of an LPA during the PSO On-Site Visit.LAYERED PROCESS AUDIT PLAN Element Requirements 14.9. 14. for PSO visits on multiple parts. 14.1 Layered Process Audit (LPA) is a system of audits performed by multiple levels of management per the Supplier’s organization chart. Special characteristics (and other characteristics designated by the Supplier and/or PSO Team) are audited to verify process conformance. etc. the LPA review shall include every process.4. NOTE: On-going LPA results are NOT a requirement for PSO approval.4 The Supplier shall complete a Process Control Audit Checklist and an Error and Mistake Proofing Verification Audit Checklist. The audit must be performed by qualified. not necessarily every part. Manufacturing areas shall be divided and auditors rotated so that all areas are included. Examples of each can be found in the LPA course training manual.1 The Process Control Audit shall be done once per shift (or as agreed to by the PSO Team) by a group leader.2 The Error and Mistake Proofing Verification Audit shall be done once per shift or product change-over (whichever comes first) and whenever an unscheduled disruption occurs in the production line. 14. The Team shall also be responsible for uploading on-going LPA results into Powerway. supervisor.3. 14.4 All non-conformances discovered at DCC manufacturing facilities (at any program stage) shall be included in the LPA.6 The Supplier shall maintain a list of trained “LPA Team” members who shall be responsible for developing. trained personnel only. The purpose of LPA is to ensure continuous conformance thereby improving process stability and first-time capability. The plan shall also address handling of nonconformances discovered during the audit and include a detailed schedule frequency and structure chart. 14.2 The LPA plan shall have procedures and work instructions for each level of management which details their roles and responsibilities. 14.4. Management audits shall be done weekly. 14. 4.2. Reference the DCC Customer-Specific Requirements for ISO/TS-16949 cl. It shall state the frequency of management reviews and require documented meeting minutes and/or open issues.1. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION Documentation LPA procedures LPA work instructions LPA Structure and Frequency Chart LPA Process Control Audit Checklist LPA Error Proofing Verification Audit Checklist 34 .com quarterly.

g. 15. Reference Element 12 “Special Product and Process Characteristics”. 15. by the DCC PSO team and DCC ASQP Manager before the SRE is run. uploaded into Powerway. mold pressure or temperature for a molded part Solder-ability. PSO Team members are required to randomly select and witness the measurement of product and/or process characteristics (other than those on the end-item assembly)utilizing the MEASUREMENT SYSTEM VERIFICATION REPORT form.2 The Supplier shall conduct SRE activities on the latest released Production Part Number(s) with an approved Purchase Order (P. and reviewed by the DCC PSO Team before or during the Pre-PSO Meeting. Additionally.4 During the PSO On-Site Visit.. 15.com. The DCC PSO Team shall determine SRE results to be acceptable before scheduling the PSO On-Site Visit.3 During the SRE run.3. measured once per shift etc. process performance calculations are required for each line and/or tool.2. the PSO team Measurement System shall determine (and agree upon) the required Line Speed (see 16.O. SRE results shall be recorded on the DCC SUPPLIER READINESS EVALUATION form.1 Process performance calculations (PP and PPK) are required for all special characteristics. Measurement System Report 15. Report as well as the number of components and characteristics to be inspected.1.1 All tooling and equipment shall be at production level.2 In the case of multiple production lines and tools.) The stated part number level(s) shall have a corresponding Production Tool P. with related tooling capable of meeting the required capacity and associated line speed(s).1 Prior to the Pre-PSO Meeting. This audit is typically completed before the Product Demonstration Run. shall determine part quantity for the results Supplier Readiness Evaluation (SRE) run.1). 15. regardless of stated Control Plan frequency (e.3. NOTE: The Supplier shall present SRE results for each production line and/or tool. unless otherwise approved.SUPPLIER READINESS EVALUATION AND EVIDENCE OF PRODUCT SPECIFICATIONS Element Requirements Documentation Supplier Readiness Evaluation (SRE) Supplier Readiness 15. These performance values will be used as an indication of the beginning performance. Examples: Stock thickness for a stamped part Moisture content. the Supplier shall measure and document all characteristics on all parts per the Control Plan. with concurrence Evaluation (SRE) Run from the DCC PSO team. dimensional checks or reflow oven profile for an electronic printed circuit board assembly COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 35 . the Supplier.) 15. in writing.O.

CONT.2 A minimum of 3 characteristics shall be measured.4.2. 15. Element 12 “Special Product and Process Characteristics.) All special characteristics shall be included. Element Requirements 15.1 The PSO team shall decide the characteristics and quantity of parts to be witnessed for measurement verification prior to the PSO On-Site Visit (see below for minimums. 12. 15.SUPPLIER READINESS EVALUATION & EVIDENCE OF PRODUCT SPECIFICATIONS.4.4 The PSO team shall determine if the measuring process for each characteristic identified on the report is acceptable.3 A minimum of 30 parts shall be selected.4.4. All identified process and/or component nonconformances. shall have root cause analyses performed and documented (and corrective actions approved by the PSO Team) before PSO approval can be given. 15. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 36 . 15.4.” cl.5.

16. end-item assemblies) or two hours of production. Daily Tooling Capacity and Operating pattern.O.O.s) exist for the same part (as is the case for some high volume parts or parts supplied to both US and Mexican DCC assembly plants). Count completed units only. These requirements apply equally to cases involving multiple production lines and/or multiple sets of tools. line fill time shall not be included.4. implement permanent corrective action and verify corrective action with a new PSO On-Site Visit prior to receiving “A” approval. 16. the issue shall be documented on the COMMENTS SHEET and the Supplier shall identify root cause. At a Process constraints minimum.4 Process constraints (bottlenecks).PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY Element Requirements Documentation 16. the Daily Tooling Capacities from both P.1 The PSO team shall ensure the Supplier meets the P.s shall be added together before determining the required Line Speed. These Final audit sampling numbers shall be verified with the DCC Buyer. whichever is more stringent. If the line is empty at the start of the PDR. and scrap shall not be included in the PDR line speed calculation. rework and/or repair (i. production processes. repair. 16. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 37 . Daily and contingency plans Tooling Capacity. 16. and contingency plans shall be documented and submitted to the PSO team for approval. and fully trained operators. The line speed calculation shall only include complete assemblies produced successfully. using production tools.O. and Net Operating Time for DCC Parts. the PSO Team (including the Line speed calculation Supplier) shall review all plans for required production rates.e.1 During the Pre-PSO Meeting.1 The PDR consists of 300 pieces (i. NOTE: Rework.3 The PSO Team shall witness and monitor the PSO Line Speed during the PDR and record the data on the PRODUCTION DEMONSTRATION RESULTS form.1. 16. FTC < 90%). the line speed for each line and tool shall be recorded..2.1 When process constraints are attributed to high scrap.e. which may impact quality or production schedules shall be documented on the COMMENTS SHEET. For multiple production lines and/or tools. plan 16.2 The Production Demonstration Run (PDR) shall be conducted on all production lines of record. the PSO Team shall discuss the required Line Speed. NOTE: In situations where multiple Purchase Orders (P. starting with the first completed assembly off the production line.

have been successfully completed. However. NOTE: The FTC requirement applies to the primary production line only. The PDR was conducted using the Daily Tooling Capacity and the required Line Speed met. and/or support processes do not need to meet the 90% FTC requirement.6 Parts made during the PDR may be used for PPAP if and only if all PPAP requirements.6.1 For multiple production lines.5 Test samples used in Production Validation (PV) testing shall come from a successful PDR and PSO On-Site visit.6. unless otherwise required by the PSO Team. Element Requirements 16. 16. All sub-components and materials used in the PDR had an approved PPAP (or equivalent). the PSO Team may elect to use test samples from an unapproved PSO On-Site visit. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 38 . including statistical requirements. and/or cavities. NOTE: Rework and repair are NOT counted in the number of acceptable parts. off-line. FTC shall be calculated separately for each one. CONT. Secondary.2 FTC is equal to the number of acceptable parts produced divided by the number of parts rejected during the PDR (see Appendix C – FTC Calculations. First Time Capability (FTC) 16. 16. All production measuring tools had acceptable gage R&R results. Deviation from this requirement shall have signed approval from the DCC PSO Team and the ASQP Manager.PRODUCTION DEMONSTRATION RUN AND FIRST-TIME CAPABILITY. Production processes and tooling were used. tools. nor are parts initially rejected by the process but found to be acceptable after re-testing. 16.7 The Supplier shall demonstrate a First Time Capability (FTC) of 90% or greater. provided the following requirements are met: All process and product performance (PP and PPK) requirements are met.

pieces per container..3 The Supplier shall be responsible for designing. container material.).1.4 Testing (e.1 Both expendable and returnable packaging shall be sized not to exceed the DCC assembly plant requirement of “two-hour-ofassembly-plant-production” per container.) shall Shipping Test Results be performed based upon the mode of transit. etc. testing and documenting expendable packaging Shipping label test data (simulated or actual).3 The expendable backup plan shall ensure on-time shipment in the event of a shortage of returnable containers. containers.3. procedure manufacturing. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 39 .g.1 Specific container information shall include but is not Packaging. 17.1 The parts packaging and shipping plan shall include the types of Parts packaging and containers (expendable or returnable) that will be used to ship product shipping plan to DCC or DCC-designated assembly plants. container and labeling dimensions. 17. 17.1. Back-up expendable packaging shall maintain the same dimensions as the returnable container and hold the same number of pieces.1. A documented procedure for mandatory data entry.2 Shipping and labeling instructions shall conform to the Instructions”) DCC Packaging and Shipping Instructions manual.PARTS PACKAGING AND SHIPPING SPECIFICATIONS Element Requirements Documentation 17.e.1. 17. etc. racks. 17. Packaging and Shipping Procedures 17. Documented procedures for mandatory transmittal of container and/or part number information during ASN submissions from the Supplier’s facility. shaker table.6 PSO approval shall not be delayed due to a lack of approval(s) for DCC provided and/or designed packaging. Any questions concerning approval of DCC designed packaging should be referred to the DCC Material Handling Engineering group.5 When DCC designed packaging is used (i. shipping limited to: returnable and/or back-up expendable. Inventory control to track containers on hand and in transit. the Supplier is not responsible for packaging approval(s). a Returnable Container Management plan shall be developed which includes: Training and access to the DaimlerChrysler Container Management System (CMS).2 When returnable containers are to be used. This can be Returnable Container obtained through COVISINT or eCopier (84-263-8537). weight of full instructions (these and empty container. Management Plan Bar coded labeling 17. and Detail for identification and disposition of contaminated or damaged containers. example Simulation or 17.4 Simulation tests and/or shipping tests shall be conducted prior to S1Start and documented. rail or over the road etc. may be included with Element 10 “Operating 17. 17. number of containers per pallet. Deviation requires approval from DCC MHE.

after passing an end-of-line tester.9 The Supplier shall ensure (through logic or error and/or mistake proofing) that part bar code labels match the part for scanning purposes. after correct scanning of the correct material.7 When bar code labeling is done as the final operation of the assembly process (i. Element Requirements Bar Code Labeling 17. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 40 .PARTS PACKAGING AND SHIPPING SPECIFICATIONS.) Only one label shall be printed at a time.g. etc. at end-of-line). 17.8 The Supplier shall have logic in place to prevent printing of duplicate bar code labels. 17. CONT. they shall be generated one at a time and only following successful completion of the previous operation (e.e.

18. while total R&R as a percent of process variation shall be used for process improvement. NOTE: Attribute gauging is only allowed on special characteristics if approved by the DCC PSO Team.5 For variable gages.4.2 The Supplier shall refer to the Design and/or Process FMEA to determine the appropriate gage to be used (attribute or variable). and three sets of measurements from each operator. 18.6. The samples shall include parts that are close to each side of the specification(s).3 For attribute gages the organization shall complete a study per the AIAG Measurement System Analysis manual or shall use a minimum of 50 samples. three operators. See the Measurement System Analysis AIAG manual.4 All gages and testing equipment shall have acceptable R&R studies performed prior to the Pre-PSO Meeting.7.3.e.GAGE AND TEST EQUIPMENT EVALUATION Element Requirements 18. tolerances used for 100% verification shall be reduced by the extent of Gage R&R. All measurements taken on parts that are out of specification shall indicate that the parts are to be rejected. 7.2 Acceptable gage R&R as a percentage of tolerance shall be less than 10%.2.4.3 The Supplier shall have a procedure to validate gages and test equipment prior to release onto the manufacturing floor.1 Total R&R as a percent of part tolerance shall be used for new processes.4. A gage R&R between 10% and 30% shall require approval from the DCC PSO team. 18. The gage R&R as a percent of study variation shall also be less than 10%.6 All gages and test equipment shall be calibrated and reflect the last calibration and expiration dates. 18. 18.2 3rd party sources used for gage and test equipment calibration shall be evaluated by the Supplier and be certified to ISO/IEC 17025.7 A calibration schedule shall be established for all gages and test equipment. A gage R&R equal to or greater than 30% is unacceptable. See ISO/TS-16949 cl. 18. 18.) 18. A reaction plan shall be established for containment of equipment that is out of calibration. 18. 18.1 All gages used in the process shall be listed on the Control Plan. There shall be detailed procedures for calibration of any equipment done internally (i. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION Documentation Gage R&R results Gage layout results Gage and test equipment validation procedure Gage and test equipment calibration records Calibration schedule 41 .7.1 The Supplier shall have an effective system to ensure that the calibration of equipment is done per schedule. at the Supplier. Calibrations shall be traceable to a known source and/or standard. 18.

6 The PM plan shall address storage of tooling and equipment when not in use. The PM plan is a living document and shall include lessons learned from similar tooling and/or equipment 19.4 The Supplier shall develop a robust PM process that ensures preventive maintenance is performed per the established PM schedule.3 PM schedule conformity. responsibilities and instructions for maintaining each item of equipment. This plan shall provide a guideline(s) to ensure DCC property is clean.7 Each Supplier shall ensure that as tooling and/or equipment approaches the predetermined end of life cycle. well protected from damage and environmental stresses.4 Preventive and Predictive Maintenance.1. 19. 7.5. properly maintained and easy to locate. machine performance issues and any PM related quality issues shall be reviewed for process optimization. (e.5 New tooling and/or equipment shall be added to the PM schedule prior to production release. etc. Tooling and/or equipment with 3rd Party outsourced PM activities shall be uniquely identified on the schedule. etc. software-controlled PM that triggers an alert when PM is due).g. 19.) COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 42 . 19.1 A Preventive Maintenance (PM) plan shall exist for all equipment and tooling.g. 19. frequencies. The 3rd Party sources shall have a PM process equal to or better than that of the Supplier. These actions shall ensure conformity to DCC production. assembly. 19. material specifications. increased inspections.8 The PM plan shall address 3rd party and/or outsourced PM activities when applicable. the plan shall outline how all frequencies were established for each piece of tooling and/or equipment (e. and their collective impact on equipment). instructions. appropriate actions are taken..2 The PM plan shall include schedules. Reference ISO/TS-16949:2002 cl.g. enhanced detection measures or methodologies). and quality requirements (e. Additionally. 19. quantitative historical data of frequencies.PREVENTIVE MAINTENANCE PLANS Element Requirements 19. The plan is a living document which shall be reviewed and updated on a regular basis or as circumstances require.. Documentation PM Plan (includes schedules.

4 PP and PPK shall be calculated individually for each line. Permanent corrective actions must be approved by the DCC PSO Team. and/or cavity. 20. continuity checks. at the discretion of the DCC ASQP Specialist. All part samples used for the Initial Process Study.1 Special characteristics which do not meet capability requirements shall have a corrective action plan approved by the DCC PSO Team and fully implemented (and meet those capability requirements) before PSO approval can occur.1.2 All identified special characteristics shall be included in the Initial Process Study. tool. 20. as well as any other characteristics required by the PSO Team. For attribute characteristics.1. 20.) shall also be included in the study. Where this is not practical. 20. then 100% verification of shipped parts is acceptable as an interim corrective action only with DCC PSO Team approval.1 The Capability Matrix (see Appendix B) shall be used to determine the PP and PPK requirements for the Initial Process Study. the PSO Team can deviate and choose a lower sample size. however 100% of the parts shall be acceptable.g.1. however. the PP and PPK requirements do not apply. etc.3 If the Process Capability is less than the established requirement.1. “EOL” tester checks. 20. Documentation Initial Process Study Results COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 43 . and an On-Site Visit performed (and approved) prior to “Z” or “A” approval being granted. NOTE: 100% mechanical verification (i.1.3. mistake proofing) may be accepted as permanent corrective action.INITIAL PROCESS STUDY Element Requirements 20. shall come from the PDR. implemented by the Supplier.1 It is intended that 100% of the parts from PDR be included in the Initial Process Study. regardless of sample size. the Initial Process Study shall be marked “Reject” on the PSO SUMMARY form.e. Any characteristic or measurement automatically taken on 100% of parts (e. NOTE: The number of parts to be included in the Initial Process Study shall be determined and documented by the PSO Team during the PrePSO Meeting.

The procedures are to recreate BSR and NVH.5. as found through DCC testing and/or defined boundary samples (e.1 Test samples used in Production Validation (PV) testing shall Component level PV come from the Production Demonstration Run.3 The Supplier shall employ detailed procedures and/or test methods to properly detect BSR and NVH without subjectivity. 21. test results (DVP&R) PV Test procedures 21.1 Analyses shall include evaluations of interactions with mating parts to reduce.g. parts from the rework or repair process shall be included in PV testing. DVP&R.5.) COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 44 . hearing tests.g. and the Control Plan. 21. 21.1.1.2 PV test results shall be reviewed by the PSO Team and signed and approved by the DCC Product Engineer (see Element 3 “Test Sample Sizes and Frequencies”.5.1.3 The DVP&R shall be updated with component level PV test results.) 21.) 21.5. it is unacceptable to just replace those samples. 21. If one (or more) test samples fail. shaker and actuation tests). or multiple lines and/or tools qualified on separate tests. eliminate and/or monitor objectionable BSR or NVH characteristics. 21. reviewed by the PSO Team and signed and approved by the DCC Product Engineer (see 21. The PV test plan shall be redone on new samples once corrective actions are done.4 Component level PV testing shall have been successfully completed on all test samples. 21.3 Test samples used for PV testing shall meet the production design release configuration.4 The Supplier shall have training and/or certification for employees conducting BSR/NVH operations (e.5 BSR/NVH testing results shall be included in the DVP&R. Potential causes shall be addressed in the D/PFMEA.4 When acceptable rework or repair processes are agreed upon by the DCC PSO team.2.1 When a single production line and/or tool will be qualified. sound chamber. 21.1. 21. the PV test components shall be selected randomly from the PDR for each line or tool. a portion of the PV test components shall be randomly selected from each production line and/or tool in proportion to that line’s contribution.2 It is the Supplier’s responsibility to ensure that their parts do not squeak or rattle in their respective environments. BSR/NVH 21. 2 When multiple production lines and/or tools will be qualified in a single PV test.PRODUCTION VALIDATION TESTING COMPLETE Element Requirements Documentation 21.

APPENDIX A FORMS & INSTRUCTIONS COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 45 .

Location. (Green/Approved. Program. Red/Missing. Change Level. NOTE 1: Corresponding box on Checklist will fill in. Supplier. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 46 . Mfg. It is intended as an aid in conducting the Pre. Enter an “X” in the appropriate box. Header will copy to all pages. Box will change color.Document Checklist Work Instructions Header: Enter Part Name. Yellow/Corrections.PSO Documentation Review meeting only.com required documents are shaded in Blue. Black/Not Applicable) Document Or Task: Powerway. NOTE 2: This form is optional. Supplier Code and date. Number.

Floor Plan (Location of equipment and space used identified) 5. Incoming and Outgoing Material Qualification Plan 8. LOCATION SUPPLIER CODE PRE-PSO MEETING DATE PSO ON-SITE VISIT DATE PSO ON-SITE VISIT NUMBER 0 All Documents Approved Enter a "X" in the appropriate box below.2 D 5. Quality Planning 7.4 5.5 D GD&T or Drawing 1. Process Flow Diagram & Manufacturing Floor Plan 5.1 D Control Plan 6.3 D 1st piece approval procedure & records 0 7.drawings.4 7.comments page.6 D Cell Layout V Process Flow or Cell layout Including # of Operators D DFMA (Design for Manufacturing Assembly) 0 0 0 6.2 V DCC Engineering signed DV and PV test plans 3. 7.9 8.4 D List of applicable engineering standards 1. Documentation / Task 0 1. Description & Change Level 1.14 8.14 D D D D D D D Copies of sub-tier and supplier PSW's Copies of sub-tier Supplier ISO9001 certifcations Outgoing Inspection Plan Part Inspection Standard Audit Work Instructions Shipping Reports Audit Records COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 47 .3 D Software level and Hardware level 1.2 D Process Performance charts 6.2 7. Design FMEA 2.1 D Incoming Inspection Plan 8.14 8.11 8.2 5.6 D 8.2 D List with PPAP status of all sub components Indented list or Easy Map of Sub-Suppliers (Name.1 D PFMEA 4. Test Sample Sizes and Frequencies 3.2 D Control charts 6.3 D Part number Cross reference 1.6 D Listed risk of all PIA and sub-tier processes Level 3 PPAP documentation( for PIA and sub tier processes risked D medium or high D Procedure to convey Lessons Learned Copies od eCIMS or 8-Step Corrective Actions for issues D encountered in previous pilot builds.1 D AQP or APQP timeline/plan 7.3 D DCC Engineering signed DVP&R 3.4 D Document Control procedure 1. Control Plan and Process Monitoring 6.4 D Inspection/test reports Copies of sub-tier Certificate of Analysis for each specific PIA 8.6 8.2 7. Manufacturing location. Part name.1 D Process Flow diagram Mfg. D DOE 0 0 0 8. & implementation) 1.2 D Engineering Change procedure 1. Missing/Reject Not Applicable Corrections D/V/F* Approved 1st Review Date: 2nd Review Date: Required Action Sec.5 3. desc.1 D DFMEA 2.2 D CN Tracking (list of CN's.2 D Defect Tracking sheets 6.2 D Log sheets 6.PART NAME(S) PART NUMBER(S) CHANGE LEVEL(S) PROGRAM SUPPLIER MFG. 0 2.5 D PFMEA Audit summary 0 5. Part Number.2 D Best Practice Procedure 0 3.2 D Best Practice Procedure 4.4 D Receiving Reports 8.8 8. Part Number.4 3.6 V Continous Conformance testing documented V DVP&R includes Test to Flailure Plans D Annual Validation Procedure 0 0 0 0 4. Process FMEA 4.2 D PPAP Status) To raw material supplier.3 7. 7.5 D Catia files.3 D Sampling Plans 8.

1 D PPSR (Pre-Production Sample Report) for vehicle builds FPSC (First ProductionShipement Certification) Plan -100% inspection of 1st 2000 GOOD parts for visual defects and all Control plan checks (Or increased 12. Parts 17.1 F Initial Process Study results 0 21.1 D Parts Handling Plan 9.1 D PV test procedures 21. Error & Mistake Proofing 13.5 D frequency per team agreement) 0 0 0 0 0 13.1 D Error & Mistake Proofing Plan List of error and mistake proofing implmented by operation number 13.2 D 17.2 D LPA work instructions 14.1 D 1st Piece approval instructions 10.4 F Final audit sampling plan 0 17.4 D LPA Process Control Audit checklist 14.1 D Material handling Procedures 9.1 F 15.1 D Set-up Sheets 10.6 D Packing & Shipping Specifications Parts packaging and shipping plan Packaging and Shipping procedures Packaging.1 D 17.2 D STR (List)(Printed from DCX system) Note: "Property of DCX" and the STR number must be on all DCX owned tooling (Fire Proof). SRE Results and Evidence of Product Specifications SRE "Supplier Readiness Evaluation" Run results 15. 0 12.2 D Error & Mistake Proofing Studies D Mistake Proofing Contingency Plan 0 0 14.5 D 18. Production Demonstration Run and FTC 16.1 D 13.1 D 17. Layered Process Audit Plan 14.1 D PM Plan (Everything on Tooling list is in System) 0 20.2 D 18. Initial Process Study 20.3 D 18.1 D Mistake proofing instructions 10.1 D Tooling List (Including Capital Equipment) 11.1 D Special Characteristics List 12. Preventative Maintenance Plans 19.1 D 17.2 D Operator Qualification process 10.2 N system needs to be supplied to the specialist during the PSO Onsite visit.4 D Process Constraints & Contingency Plans 16. The STR list printed from the DCX 11. Equipment & Gages Identified 11.5 D 18.1 D Component level PV test results 21.1 D 17.4 D Rework/repair instructions 0 11.1 D Operator Instructions 10.1 D Gage Instructions 10.4 D Applicable PF Standards 21. Special Product & Process Characteristics Identified 12.0 9. Tooling.4 F Measurement Verification Report 0 0 0 16.1 F Line Speed demonstration form completed 16.shipping and labeling instructions Returnable Container management plan Barcoded Labeling Procedure Shipping label example Simulation or shipping test results 0 & Test Equipment Evaluation Gage R&R (All measurement devices) results Gage layout results Gage and test equipment validation procedure Gage and test equipment calibration records Calibration schedule 0 0 0 0 19.7 D Containment records 0 10.1 13. Gage 18.3 D 18.4 D Vibration Test Procedure 0 0 0 Key: D F N V Document Completed PSO form Note View Powerway required document COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 48 .WIP 9. Production Validation Testing Complete 21. Operator Instructions 10.3 D Visual Management Document control procedure 10.2 D LPA Procedures 14.4 D LPA Error Proofing Verifcation Audit Checklist 0 15.1 D 17.3 D LPA Structure and Frequency chart 14. Parts Handling Plan .4 D Training/certification for BSR operators 21.

PART NUMBER. LINE SPEED DEMONSTRATION and FTC 17. SIGN AND DATE COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 49 . SIGN AND DATE PRINT NAME. SIGN AND DATE PRINT NAME.DAIMLERCHRYSLER PROCESS SIGN-OFF CHECKLIST PSO APPROVAL STATUS: "N" 20 "Z" 26 "A" CHECK IF PSO EXTENDED RUN: OPTION # PART NAME(S) 0 PART NUMBER(S) 0 CHANGE LEVEL(S) PROGRAM 0 0 SUPPLIER MFG. LAYERED PROCESS AUDIT 15. SIGN AND DATE PRINT NAME. OPERATING INSTRUCTIONS 11. TOOLING. SIGN AND DATE PRINT NAME. QUALITY PLANNING 8. LOCATION 0 0 0 1/0/1900 0 0 0 SUPPLIER CODE PRE-PSO MEETING DATE 0 PSO ON-SITE VISIT DATE PSO ON-SITE VISIT NUMBER FPSC REVIEWED WITH SUPPLIER DATE PSO PROCESS ELEMENTS REQUIRED FOR "Z" APPROVAL DOCUMENTATION Accept Reject N/A Accept PROCESS Reject N/A 1. GAGE and TEST EQUIPMENT EVALUATION 19. TEST SAMPLE SIZES and FREQUENCIES 4. EQUIPMENT and GAGES IDENTIFIED 12. PARTS HANDLING PLAN 10. CONTROL PLAN and PROCESS MONITORING 7. PROCESS FMEA 5. SUPPLIER READINESS EVAL and EVIDENCE OF PRODUCT SPECS 16. SIGN AND DATE SUPPLIER QUALITY PRINT NAME. PARTS PACKAGING and SHIPPING SPECS 18. PROCESS FLOW DIAGRAM and MFG FLOOR PLAN 6. INCOMING and OUTGOING MATERIAL QUALIFICATION PLAN 9. SIGN AND DATE PRINT NAME. SIGN AND DATE PRINT NAME. ERROR and MISTAKE PROOFING 14. DESCRIPTION and CHANGE LEVEL 2. SPECIAL PRODUCT and PROCESS CHAR IDENTIFIED 13. PREVENTIVE MAINTENANCE PLANS 20. PRODUCTION VALIDATION TESTING COMPLETE 0 24 15 2 2 CORRECTIVE ACTION REQUIRED ON-SITE REVISIT REQUIRED Yes Yes No No Date Date Process Sign-Off Team Manufacturing Facility ENGINEERING PRINT NAME. INITIAL PROCESS STUDY 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 0 0 0 ADDITIONAL PSO PROCESS ELEMENTS REQUIRED FOR "A" APPROVAL DOCUMENTATION Accept Reject N/A Accept PROCESS Reject N/A 21. DESIGN FMEA 3.

PART NAME(S) 0 PART NUMBER(S) 0 CHANGE LEVEL(S) PROGRAM 0 0 0 0 SUPPLIER MFG. LOCATION SUPPLIER CODE PRE-PSO MEETING DATE PSO ON-SITE VISIT DATE PSO ON-SITE VISIT NUMBER 0 0 0 1/0/1900 0 0 PROCESS SIGN-OFF COMMENTS SHEET ITEM ISSUE/ACTION RESPONSIBILITY TARGET DATE CLOSED DATE COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 50 .

Quantity Attempted Quantity Accepted FTC Percent (without repairs) % GR&R ACC/ REJ Item # Process Feature /Part Characteristic Process /Part1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 51 . USL UCL LCL LSL Pp Ppk Part/Proc Avg. LOCATION 0 0 1/0/1900 0 0 0 PRE-PSO MEETING DATE 0 0 PSO ON-SITE VISIT NUMBER PSO ON-SITE VISIT DATE SUPPLIER CODE SUPPLIER NAME 0 0 PART NUMBER(S) 0 5th Edition CHANGE LEVEL(S) PROGRAM SUPPLIER READINESS EVALUATION SRE LINE RATE: SHIFT: QUANTITY DETERMINED BY SUPPLIER AND COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION DAIMLERCHRYSLER PSO TEAM: PERFORMANCE RESULTS Meas.PART NAME(S) 0 MFG. Freq.

(e. NOTE: This number should be less than the USL. Ppk Ppk matrix requirement (see Initial Process Study element). UCL: Upper Control Limit: The upper limit established by the Supplier for process/part control. LSL: Lower Specification Limit. The lower limit established by the Supplier for process/part control.Supplier Readiness Evaluation Instructions Note: When requesting approval for multiple manufacturing lines. Acc/Reject: Has the PSO team determined the supplier’s data to be acceptable (acc) or unacceptable (Reject)? [i. Process/Part: Document if data is for a process measurement or a part measurement. GR&R < 10% . FTC percent (without repairs): Calculated First Time Capability. NOTE: This number should be less than the LSL. The upper limit of the part or process specification per the part drawing or process standard. Part/Proc. % GR&R: Calculated percentage of Gage R&R for gage used for part/process measurement. 1st shift. SRE Line Rate: The calculated line rate for the Supplier Readiness Evaluation run = SRE Part Quantity Accepted ÷ Duration of SRE run. Quantity Attempted: The total number of part/process measurements taken. Avg.: Part/Process Average. Quantity Determined by Supplier and DaimlerChrysler PSO Team: Number of parts agreed by DaimlerChrysler and the Supplier prior to the SRE run. please see Appendix C. LCL <Proc Avg < UCL. FTC 90%.e. 6am-3pm) Process Feature/Part Characteristic: The process feature or part characteristic that is being measured. Freq. Record shift # and hours. For further details. Shift: The manufacturing shift the SRE was performed. a SRE form shall be completed for each manufacturing line requesting approval. USL: Upper Specification Limit. PPK: The calculated PPK for all measured process features/part characteristics. Quantity Accepted: The total number of part/process measurements acceptable per the established controls (within the LCL-UCL). Meas.g. The lower limit of the part or process specification per the part drawing or process standard. The average of all measured process features/part characteristics. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 52 . LCL: Lower Control Limit.: Measurement Frequency. PP: The calculated PP for all measured process features/part characteristics. Record the number of part/process measurements taken per time interval. 10< GR&R < 30 – PSO team decision].

Daily Tooling Capacity A2) DCC P. Daily Tooling Capacity B) DCC P.O.O. Daily Tooling Capacity A3) DCC P. Daily Tooling Capacity A4) DCC P.DCC FORMULA FOR PRODUCTION DEMONSTRATION RUN PSO REQUIREMENT PART NAME(S) 0 0 PART NUMBER(S) 0 0 CHANGE LEVEL(S) PROGRAM 0 0 SUPPLIER MANUFACTURING LOC SUPPLIER CODE PRE-PSO MEETING DATE PSO ON-SITE VISIT DATE PSO ON-SITE VISIT NUMBER 0 0 0 0 0 0 Calculation Data input from production P.O.O.O.O.: Shared Line? Yes or No (Y/N) A) Combined DCC P. Daily Tooling Capacity A1) DCC P. Shift Pattern B1) Number of shifts per day B2) Production hours per shift B3) Number of production days per week Input information Part Number Part Number Part Number Part Number Part Number Total (A1 + A5) Pieces/day Pieces/day Pieces/day Pieces/day Pieces/day Pieces/day shifts hours days Data input from manufacturing process: C) Downtime C1) Lunches C2) Breaks C3) Changeover and/or set-up C4) Operating time dedicated to other customers C5) Scheduled/unscheduled downtime (as applicable) hours/shift hours/shift hours/shift hours/shift hours/shift D) Parts attempted during the PDR E) First time through fallout during the PDR F) Length of PDR in hours G) Acceptable parts witnessed at the PDR Start: Finish: attempted parts failed parts hours pieces In process calculations: H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)] I) Available production hours/day [B1*H] J) DCC required parts per hour at the PDR [A/I] K) Witnessed parts per hour at the PDR [G/F] hours/shift hours/day parts/hour parts/hour Requirements: L) FTC calculation [((D-E)/D)*100] M) Difference between witnessed parts/hour and required parts/hour [K-J] % pieces COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 53 . Daily Tooling Capacity A5) DCC P.O.O.

This is not the final number of unacceptable parts. If shared line = Y. NOTE: If the components being validated have varying operating patterns or different takt times. (May differ from first time through fallout.) F) Length of PDR in hours is the measured time it took to conduct the production demonstration run. C3) Changeover and/or set up ."TOOL CAP" If shared line = N: A1) Input the Daily Tooling Capacity and part number from the DCC Purchase Order. Downtime per shift C1) Lunches . NOTE: If the components being validated have varying operating patterns or different takt times.g. This could be any downtime such as PM. that was not considered. Operating time dedicated to other customers calculated on a per shift basis (e. in hours per shift. shared with DCC parts only: A1-A5) Input the Daily Tooling Capacity and part number from the DCC Purchase Order for the various parts being validated."DY" on Purchase Order NOTE: Please input appropriate comments in the blanks provided. shared with other customers: A1-A5) Input the Daily Tooling Capacity from the DCC Purchase Order for the various parts being validated. Changeovers or set up not conducted every shift should be calculated on a per shift basis (e."HR" on Purchase Order B3) Number of production days per week . but only those that failed first time through the process.g.The amount of time. etc. that the production process is operating/manufacturing product for other customers. NOTE: Please input appropriate comments in the blanks provided. (This number will be used in the FTC calculation. then separate calculation worksheets should be completed for each part. NOTE: Please input appropriate comments in the blanks provided. then separate calculation worksheets should be completed for each part. in hours per shift.The amount of time. B) The shift pattern should be obtained from the DCC Purchase Order . C4) Operating time dedicated to other customers . that the production process is not operating due to breaks. operating time per week divided by the number of shifts per week = changeover time per shift).) COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION C) 54 . C4) In hours/shift. Changeover time per week divided by the number of shifts per week = changeover time per shift).Production Demonstration Run Calculation Work Instructions Shared Line? Yes or No (Y or N) A) The combined DCC Daily Tooling Capacity should be obtained from the DCC Purchase Order . C5) Scheduled/unscheduled downtime not considered . A2-A5) Leave as the default 0. that was not included in the development of the shift pattern/pieces per day quantity. input the time dedicated per shift to other customers. in hours per shift. minus any rejects. C2) Breaks . NOTE: The assumption for this calculation is that all of the part numbers have the same operating pattern and the same takt time. Only changeovers that were quoted to occur during the production operating pattern should be considered for this calculation.g. NOTE: Please indicate when during the production process the changeovers will be implemented (if they are conducted during the quoted operating pattern. Please input start and finish time in cells provided. or if they are to be conducted during "off shifts"). which were demonstrated during the production run.The amount of time. in hours per shift. changeover. NOTE: The assumption for this calculation is that all of the part numbers have the same operating pattern and the same takt time. E) First time through fall out during the PDR is the number of parts that were rejected from the manufacturing process during first evaluation. operating time per week divided by the number of shifts per week = changeover time per shift)."SH" on Purchase Order B2) Production hours per shift . If shared line = Y. in hours per shift. G) Acceptable parts witnessed at the PDR are the total number of parts. D) The parts attempted during the PDR are the total number of parts the supplier produced including rejects/scrap. that the production process is not operating due to lunch.The amount of downtime. Scheduled/unscheduled downtime should be calculated on a per shift basis (e. that the production process is not operating due to changeover and/or set up activities.The amount of time."SH/HR/DY" B1) Number of shifts per day .

i. it is strongly advised to conduct an Extended Run PSO to stress the supplier's production line and increase confidence in the supplier's ability to meet DCC requirements. M < 0 the cell = red. necessary to satisfy DCC. NOTE: If the FTC is less than 90%. L) FTC (First Time Capability) is the percentage of acceptable parts witnessed at the production demonstration run out the total number of parts attempted at the PDR. J) DCC required parts per hour at the PDR are the total number of acceptable parts the supplier must produce. complexity. If the DCC requirement of 90% or greater is met. H) Available production hours/shift are the net hours per shift the supplier has available to build product not including any scheduled downtime. If the part difference is greater than (the DCC required parts per hour + 10%). which the supplier produced within an hour's time. the cell will turn green. and the effectiveness of defect containment actions into account when deciding whether the demonstrated lower FTC values are acceptable with a documented deviation. I) Available production hours/day are the net hours per day the supplier has available to build product. If the part difference is less than 0. the cell will turn yellow indicating the line speed has met requirments. in an hour's time.e. cont. PSO Extended Run options are explained in the PSO manual. then cell = green (requirements met). the cell will turn red indicating the requirement is not met. i.Production Demonstration Run Calculation Work Instructions. Continuous improvement actions should also be developed for bottleneck operations or other operations which showed poor performance during the PSO run. the cell will turn red.e. supplier experience. M) The difference between required parts/hour and witnessed parts/hour gives the total number of parts over or under the DCC requirement. If the DCC requirement is not met (less than 90%). the cell will turn green indicating the line speed is acceptable. the PSO team shall take product and process technology. A DCC Supplier Quality Manager's signed approval is required for deviation from the PSO FTC requirement. i. 0 <= M < (J+10%) then cell = yellow. (J + 10%) M.e. If the part difference is between 0 and (the DCC required parts per hour + 10%). COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 55 . K) Witnessed parts per hour at the PDR are the number of acceptable parts witnessed by the PSO team. NOTE: In the event (M) is yellow. but the part difference is very close and may require additional attention.

70% ACC ACC 2 P025 Gap .Machine 67 Part Item # 1 Process Feature / Part Characteristic USL UCL Part/Proc Avg. Quantity Attempted Quantity Accepted FTC Percent (without repairs) % GR&R ACC/ REJ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 56 .5 2.0851 0.00895 0.0874 0.0851 0. LCL LSL Pp Ppk Process /Part Meas.Machine 66 Part 2/Shift 0.0874 0. Freq.077 2.41 30 2/Shift 0.37% 12.097 0.PART NAME(S) 0 MFG.00895 0. LOCATION 0 0 1/0/19005th Edition 0 0 0 PRE-PSO MEETING DATE 0 0 PSO ON-SITE VISIT NUMBER PSO ON-SITE VISIT DATE SUPPLIER CODE 0 SUPPLIER 0 DaimlerChrysler PART NUMBER(S) 0 CHANGE LEVEL(S) PROGRAM INITIAL PROCESS STUDY Summary Example 1 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION Meas. USL UCL Part/Proc Avg.54 2. Freq.097 0.077 2.28 30 30 30 100% 100% 9. LCL LSL Pp Ppk Quantity Attempted Quantity Accepted FTC Percent (without repairs) % GR&R ACC/ REJ Item # Process Feature / Part Characteristic Process /Part 1 P025 Gap .

NOTE: This number should be less than the LSL. Quantity Accepted: The total number of part/process measurements acceptable per the established controls (within the LCL-UCL). FTC percent (without repairs): Calculated First Time Capability. PP PPK matrix requirement (see Initial Process Study element). Process/Part: Document if data is for a process measurement or a part measurement. GR&R < 10% . Acc/Reject: Has the PSO team determined the supplier’s data to be acceptable (acc) or unacceptable? [i. The lower limit of the part or process specification per the part drawing or process standard. The average of all measured process features/part characteristics. Avg. Quantity Attempted: The total number of part/process measurements taken.Initial Process Study Process Feature/Part Characteristic: The process feature or part characteristic that is being measured. FTC 90%. UCL: Upper Control Limit: The upper limit established by the Supplier for process/part control. LCL: Lower Control Limit: The lower limit established by the Supplier for process/part control. For further details. 10%< GR&R < 30% – PSO team decision].: Measurement Frequency. % GR&R: Calculated percentage of Gage R&R for gage used for part/process measurement. Freq. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 57 . Record the number of part/process measurements taken per time interval. please see Appendix C.: Part/Process Average. LSL: Lower Specification Limit. PPK: The calculated PPK for all measured process features/part characteristics. USL: Upper Specification Limit. LCL <Proc Avg < UCL. PP: The calculated PP for all measured process features/part characteristics. Meas.e. NOTE: This number should be less than the USL. Part/Proc. The upper limit of the part or process specification per the part drawing or process standard.

02 mm) CALIPER CMM MACHINE 30 30 30 28 100% 93% 1.6 2.Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual) for Ppk requirements.A minimum of 30 randomly selected samples shall be checked during the PSO on-site visit.7.For attribute data.2 REJ ACC Number of parts witnessed: DATA SPECIFICATION METHOD OF MEASUREMENT QUANTITY ATTEMPTED QUANTITY ACCEPTED FTC PERCENTAGE (without repair) PP / PPK PROCESS ACC/REJ CHARACTERISTIC COMMENTS: 58 . . .6 . For any given part. . SUMMARY EXAMPLE SPECIFICATION METHOD OF MEASUREMENT QUANTITY ATTEMPTED QUANTITY ACCEPTED FTC PERCENTAGE (without repair) PP / PPK PROCESS ACC/REJ CHARACTERISTIC Length Hole Size Witnessed By: (3. the number of characteristics selected depends upon the complexity.A minimum of 3 characteristics are to be checked.0 ± 0.3/2. the actual measurement process must be witnessed by the PSO Team. LOCATION PART NUMBER(S) DaimlerChryler 0 CHANGE LEVEL(S) PROGRAM COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION MEASUREMENT SYSTEM REPORT As part of the PSO. or process.7/1. .5 mm) (2. . .PART NAME(S) 0 0 0 1/0/1900 0 0 0 PRE-PSO MEETING DATE 0 0 PSO ON-SITE VISIT NUMBER PSO ON-SITE VISIT DATE SUPPLIER CODE 0 0 SUPPLIER NAME MFG.Variable data is preferred but attribute data is acceptable. assembly. a 30 piece sample with one or more non-conformances is unacceptable.All deviations shall be listed in the COMMENTS section of this document.

Quantity Attempted: The total number of parts chosen to be measured by the team (this may exceed the number of parts witnessed by the PSO team members). Witnessed by: The names of all the DCC PSO team members who witnessed the measurement audit. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 59 . PP/PPK: The calculated PP/PPK for the quantity of parts attempted. For further details. Specification: The documented specification of the characteristics as identified on the part drawing. FTC percentage (without repair): Calculated FTC. Process Acc/Reject: Has the PSO team determined the supplier’s measurement process to be acceptable (acc) or unacceptable (Reject)? Comments: Any waivers/deviations should be recorded here for documentation purposes. Use additional copies of the form or attach additional pages as needed to accommodate more characteristics. Quantity Accepted: The number of parts which whose characteristic was within the specification. Number of parts witnessed: The number of parts the PSO has personally witnessed the supplier measure characteristics. fixture. please see Appendix C. Characteristic: Measurement characteristics identified by the team to be measured.Measurement System Report Instructions The MEASUREMENT SYSTEM VERIFICATION REPORT is used to document the results of the measurement audit performed during the PSO On-Site Visit. or equipment used to measure the identified characteristics. Method of Measurement: The gage.

How to find the Daily Tooling Capacity and Operating Pattern For DaimlerChrysler Specialists: Log onto the Supplier Quality Portal at https://gsp.daimlerchrysler.com/SQP/servlet/SQPServlet Move mouse to “Summaries” and click on “Part Summary” from the drop-down menu Enter the part number and click on the “Fetch” box Additional MY information can be found by moving the mouse over the indicated area COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 60 .extra.

APPENDIX B Tables and Examples COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 61 .

LOT ACCEPTANCE SAMPLING TABLE
Sample Size Per Characteristic Classification Acceptance Number = 0 <S> / <E> 0-15 16-25 26-50 51-75 76-125 126-225 226-425 426-1300 1301 and up 75 90 100 110 115 50 65 75 85 90 90 100% Inspection <D>

Lot Size or Shipment Size*

NOTE 1: THIS TABLE APPLIES TO ATTRIBUTE SAMPLING ONLY. NOTE 2: TWO OR MORE OF THE METHODS DESCRIBED IN ELEMENT 7.4.3.1 OF TS-16949 SHALL BE USED, OTHERWISE, THIS TABLE APPLIES. Characteristics Definition SAFETY <S>/EMISSION <E>: A characteristic that will affect compliance with DaimlerChrysler Corporation and/or Governmental Vehicle Safety/Emission requirements. KEY <D>: A characteristic that is key to part function and has particular quality, reliability, and durability significance (Refer to Engineering Process Standard PS-7300). Sample size shall be based upon the normal production lot size. If the lot size is temporarily reduced due to material shortages or production problems, the sample size will not change. If the temporarily reduced lot size is smaller than the required, production sample size, inspect 100%. A lot is not to exceed one shift or one-day's production whichever is smaller. PRODUCT QUALIFICATION SAMPLE RESULTS No Nonconforming units One or more Nonconforming units ACTIONS ON PROCESS Continue to operate Find Root Cause(s) and Correct Process ACTIONS ON LOT Accept Sort 100% since last conforming lot

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CAPABILITY MATRIX
There are two risks inherent in every decision, either (1) we have accepted “bad” parts (consumer’s risk), or (2) we have rejected “good” parts (producer’s risk). Test plans seek to balance these risks by specifying sample size and/or acceptance criteria so that neither the consumer nor the producer carries the higher proportion of risk. Sometimes, for business or other reasons, it may be important to hold one risk constant and allow the other risk to “float” based on sample size. Such is the case for Pp and Ppk. DaimlerChrysler wants to minimize its risk of accepting a population below 1.33Ppk. The following table presents the sample size and acceptance criteria that keeps the risk of accepting a “bad” population ( 1.33) at 6.4% (93.6% that population > 1.33 Ppk will be accepted). Depending upon sample size, the risk of rejecting a “good” population ( 1.67) could be very high. The table allows for trade-offs between sample size and producer’s risk to be identified.

Sample Size

Acceptance Ppk Criteria

Risk of Accepting a Population <= 1.33Ppk

Risk of Rejecting a Population >= 1.67Ppk

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 150 200 250 300

2.94 2.10 1.89 1.78 1.71 1.67 1.64 1.61 1.59 1.58 1.56 1.55 1.54 1.53 1.52 1.52 1.51 1.50 1.50 1.49 1.46 1.44 1.43 1.42

6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 % 6.4 %

86.3% 77.3% 68.7% 60.7% 53.3% 46.5% 40.4% 34.9% 30.1% 25.8% 22.0% 18.7% 15.9% 13.4% 11.3% 9.5% 8.0% 6.7% 5.6% 4.7% 1.9% 1.0% 0.6% 0.3%

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION

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EXAMPLE: LPA FREQUENCY AND STRUCTURE
Department A Department B Department C Department D Department E Department F

Assigned Management Category (example) 1st Layer of Management

Assigned Management Personnel (example)

Audit Assignment

Supervisors Supervisor 1 Supervisor 2 Supervisor 3 2nd Layer of Management Area Managers

1 per Own Department shift Own Department Own Department 2 per week

1 per shift 1 per 1 per shift shift 1 per 1 per shift shift 2 per 2 per 2 per week week week 2 per 2 per week week

Area Manager 1 Own Area Area Manager 2 Own Area

3rd Layer of Management

Plant Staff and Plant Manager

Engrng Mgr Quality Mgr Tooling Mgr H.R. Mgr Training Coord. Plant Manager

Rotate Depts. Rotate Depts. Rotate Depts. Rotate Depts. Rotate Depts. Rotate Depts.

1 per week 1 per week 1 per week 1 per week 1 per week 1 per week

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION

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(The potential defect is allowed to leave the plant and reach the field). RPN’s that have a Severity Detection level. III. (This equates to customer dissatisfaction and C/1000 >1).FMEA GUIDELINES Special Attention Shall Be Given To: I. RPN's that have Severity 5 and an Occurrence 2 regardless of Detection and RPN value. 8 regardless of RPN value. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 65 . Detection = 10. Occurrence level. or II.

INTENTIONALLY LEFT BLANK COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 66 .

APPENDIX C FTC Calculations COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 67 .

First Time Capability CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITHOUT REPAIRS PURPOSE First Time Capability (FTC) is part of a process capability study that identifies how well it produces quality parts. 2. a. the PSO Team shall review the FTC values for each operation and the overall process. 3. the greater the amount of rework required. Correctly processed means no repairs or rework are allowed. Create a block diagram for the process showing each operation. Calculate the operation and process FTC using the examples as a guide. If a Supplier encounters a situation where. If the FTC is less than 90%. there is a greater possibility that the Supplier will ship non-conforming parts. Collect the following data from the PDR. because generally the lower the value. A Supplier Quality Manager’s signed approval is required for deviation from the PSO FTC requirement. Supplier experience. DATA COLLECTION PROCEDURE This three-step procedure is suggested for calculating a production line FTC. DaimlerChrysler can assist in the improvement effort by supplementing the Supplier's team with experienced engineering and manufacturing specialists from a wide variety of disciplines. they cannot find a solution to an inherently low FTC. b. despite their best efforts. c. Quantity of rejected assemblies from each operation. the PSO team shall take product and process technology. FTC studies shall be conducted on each one. a higher FTC is expected for an operation or zone than for an entire process. 1. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 68 . Quantity of acceptable assemblies from the end of the line. in a multi-operation process. complexity. and the effectiveness of defect containment actions into account when deciding whether the demonstrated lower FTC values are acceptable with a documented deviation. For multiple assembly lines or tools. DESCRIPTION FTC is measured as the number of items processed correctly divided by the total number of items processed. FTC can be used to prioritize product and process improvement. FTC can be an important measure. The flow diagram or floor layout provided by the plant can also be used. DaimlerChrysler’s requirement for FTC is 90% or greater. Quantity of assemblies attempted. Following the PDR. As defects and rework increase. Therefore. Do not include repaired or reworked parts.

Series Process Flow Diagram With Demonstration Data Begin by calculating the FTC for each operation. by the quantity attempted at the operation. Operation Number Quantity Attempted Quantity Completed FTCOPERATION Qty Completed Qty Attempted Quantity Rejected Equation 1 (1) Figure 1B COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 69 .90 or 90% Figure 1A In a similar manner. The data are shown on the process block diagram. 300 units. refer to Examples 3 & 4. The result is the operation FTC. FTC and Yield are equal for a process without repairs so only FTC calculations will be shown in Section I. Series Process Flow without Repair: During a typical PSO Production Demonstration Run. calculate the FTC for each operation in the process using Equation 1. data collection procedure outlined above. FTCOp 1 Qty Completed Qty Attempted 270 300 0. the following processed and rejected quantity data were collected during the PDR. Operation 1 is shown here with its respective PSO PDR data Operation 1 270 Pcs 300 Pcs 30 Pcs Rejected Divide the quantity completed at Operation 1. Operation 1 270 Pcs 300 Pcs 30 Pcs Rejected Operation 2 243 Pcs Operation 3 226 Pcs Operation 4 217 Pcs 27 Pcs Rejected 17 Pcs Rejected 9 Pcs Rejected Figure 1 Example 1 . Table 1 shows a summary of the quantities and FTC’s for the process in Example 1.First Time Capability CALCULATIONS & EXAMPLES CALCULATIONS & EXAMPLES Example 1. The general operation model is shown in Figure 1B. 270 units. Using the three-step. For established production lines and carryover component production demonstrations that may include rework. the goal is to show that the production line is capable of producing parts that meet DCC quality and volume requirements.

by the quantity attempted 300 units. The data are shown on the process diagram in Figure 3.90 0.90 0. Series/Parallel Process Flow without Repair: Using the three-step data collection procedure outlined on page D. Operation 3 96 Pcs 94 Pcs 2 Pcs Rejected Operation 1 288 Pcs Operation 2 265 Pcs 91 Pcs 300 Pcs 12 Pcs Rejected 23 Pcs Rejected 10 Pcs Rejected Operation 5 78 Pcs 11 Pcs Rejected 67 Pcs 24 Pcs Rejected 81 Pcs Operation 4 242 Pcs 218 Pcs Operation 6 Figure 3 Example 2 .3% 27 Pcs Rejected 17 Pcs Rejected 9 Pcs Rejected Figure 2 Example 1 . 217 units. The completed Example 1 process diagram is shown in Figure 2. The diagram can be included with the final PSO documents as a record of the process starting capability.723 or 72.Series Process With Operation and Process FTC's Shown Example 2. the following processed and rejected quantity data were collected during the PDR.Operation 1 2 3 4 Quantity Attempted 300 270 243 226 Quantity Completed 270 243 226 217 FTC 0.Series / Parallel Process Flow Diagram With Demonstration Data COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 70 .2.96 TABLE 1 Quantities and FTC’s for Example 1 Enter the calculated operation FTC’s in their respective operation blocks of the process diagram.3% Total Qty Attempted 300 Enter the FTCPROCESS value on the process diagram. Total Qty Completed 217 FTCPROCESS 0. Calculate the process FTC by dividing the quantity completed for the process.93 0. Operation 1 FTC 90% 300 Pcs 30 Pcs Rejected 270 Pcs Operation 2 FTC 90% 243 Pcs Operation 3 FTC 93% 226 Pcs Operation 4 FTC 96% 217 Pcs FTC = 72.

89 0.726 or 73% Add the process FTC to the process diagram. The completed diagram for Example 2 is shown in Figure 4. 300 units.92 0.96 0.91 TABLE 2 Quantities and FTC’s for Example 2 Enter the calculated operation FTC’s in their respective blocks on the process diagram. 96 Pcs Operation 3 94 Pcs FTC 98% 2 Pcs Rejected Operation 1 FTC 96% 300 Pcs 12 Pcs Rejected 23 Pcs Rejected 10 Pcs Rejected Operation 5 FTC 86% 11 Pcs Rejected 24 Pcs Rejected 288 Pcs Operation 2 FTC 92% 265 Pcs 91 Pcs Operation 4 FTC 89% 242 Pcs 81 Pcs Operation 6 FTC 90% 218 Pcs FTC = 72. FTCPROCESS Qty Completed Qty Attempted 218 300 0.Calculate the FTC for each operation in the process using Equation 1 and the operation model shown in Figure 1B on page 2. Quantity Attempted 300 288 96 91 78 242 Quantity Completed 288 265 94 81 67 218 Operation 1 2 3 4 5 6 FTC 0. Table 2 shows a summary of the quantities and FTC’s for the operations in Example 2.6% 78 Pcs 67 Pcs Figure 4 Example 2 – Series / Parallel Process With Operation and Process FTC’s Shown COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 71 . by the quantity attempted. 218 Units. The result is the FTC for the process.86 0.98 0. Calculate the process FTC by dividing the total quantity completed. The diagram can be included with the PDR report to document the initial process performance.

Operation 1 270 Pcs Operation 2 268 Pcs Operation 3 265 Pcs Operation 4 264 Pcs 300 Pcs 30 Pcs Rejected 27 Pcs 25 Pcs 16 Pcs 19 Pcs 9 Pcs 10 Pcs Rework Rework Rework 2 Pcs Scrap 3 Pcs Scrap 1 Pc Scrap Figure 5 Example 3 – Series Process Diagram With Demonstration Data Added COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 72 . this section should be used as a guide to calculate FTC and Yield. Quantity of rejected assemblies from each operation. 1. CALCULATIONS & EXAMPLES Example 3. c. Collect the following data from the demonstration run. Quantity of acceptable assemblies from the end of the line. For those times. Step #2 differs because of the need to record rework quantities returned to the process stream. the PDR will be performed on an existing production line with rework operations. a. The flow diagram or floor layout provided by the plant can also be used. Quantity of assemblies attempted. There are times. Step #3 differs because there are two values to calculate. Quantity of rejected assemblies that were repaired for each operation. b. 3. the following processed and rejected quantity data were collected during a PDR. d. These situations require the ability to determine FTC and Yield separately because FTC and Yield are not equal when rework is included. data collection procedure outlined above. however.CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITH REPAIRS DATA COLLECTION PROCEDURE The recommended procedure for data collection for a process with repair is similar to the procedure shown in Section I. Series Process Flow with Repair: In some instances. when we must consider the impact of rework on process output. The primary goal for production demonstration is to demonstrate that the production line is ready and capable of producing at the required quality and quantity. Using the three-step. 2. FTC and yield. Calculate the operation and process FTC and yield using the examples as a guide. Create a block diagram for the process showing each operation. Rework is not part of production demonstration. The data are shown in Figure 5.

90 or 90% The yield for Operation 1 is the same as the FTC because rework was not performed. 270 pieces. Operation 1 is shown here with its respective production demonstration data. Table 3 shows the quantities. 27 Pcs 25 Pcs FTCOP 2 Rework Qty Attempted Qty Re jected Qty Attempted 270 27 270 243 270 0. Quantity Attempted Operation Number Quantity Completed FTCOperation = Qty Attemp ted . Operation 1 270 Pcs 300 Pcs 30 Pcs Rejected Divide the quantity completed. 27 units. from the quantity attempted.Calculate the FTC for each operation. Equation 2 will provide the correct result because rework was performed.99 or 99% Qty Attemp ted 270 In a similar manner. For Operation 2. by the quantity attempted.Qty Rejected Qty Attemp ted Equation 2 Quantity Reworked Quantity Rejected Rework YieldOperation = Qty Completed Qty Attemp ted Equation 3 Figure 5C COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 73 . subtract the quantity rejected. 268 units. Divide this total by the quantity attempted. 270 units. YieldOP 2 = Qty Completed 268 = = 0.90 or 90% FTCOP 2 2 Pcs Scrap Figure 5B Calculate the yield for Operation 2 by dividing the quantity completed. The general operation model is shown in Figure 5C. 300 pieces. calculate the FTC and Yield for the remaining operations using Equations 2 and 3. by the quantity attempted.90 or 90% 270 Pcs Operation 2 268 Pcs For Operation 2. Figure 5A FTC OP 1 Qty Completed Qty Attempted 270 300 0. 270 units. FTC’s and Yields for the operations in Example 3. Refer to Equation 3. Therefore. Note: Equation 1 from Section I can be used for this operation because rework was not performed. YieldOP 1 270 300 0.

The completed process diagram for example 3 is shown in Figure 7.996 TABLE 3 Quantities. Operation 1 FTC=90% Yield=90% 270 Pcs Operation 2 FTC=90% Yield=99% 268 Pcs Operation 3 FTC=93% Yield=99% 265 Pcs Operation 4 FTC=96% Yield=99.90 0. Calculate the process FTC by multiplying the individual operation FTC’s together. Process FTC's.96 Quantity Reworked N/A 25 16 9 Quantity Completed 270 268 265 264 Yield 0. Enter the operation FTC’s in their respective blocks on the sketch.Series Process With Operation.90 0.3% YIELD = 88.90 0. FTC’s.6% 264 Pcs FTC = 72.99 0.99 0. and Yield Shown COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 74 .Operation 1 2 3 4 Quantity Attempted 300 270 268 265 Quantity Rejected 30 27 19 10 FTC 0. The diagram can be included as part of production demonstration report to document the starting process capability.3 Qty Completed Qty Attemp ted 264 = 0.723 or 72. YieldPROCESS = Add the operation and process FTC’s and Yields to the process diagram.93 0.880 or 88% 300 YieldPROCESS = Calculate the process yield using Equation 3.0% 300 Pcs 30 Pcs Rejected 27 Pcs 25 Pcs 16 Pcs 19 Pcs 9 Pcs 10 Pcs Rework Rework Rework 2 Pcs Scrap 3 Pcs Scrap 1 Pc Scrap Figure 7 Example 3 . Operation 1 FTC=90% Operation 2 FTC=90% Operation 3 FTC=93% Operation 4 264 Pcs FTC=96% 300 Pcs Figure 6 Simplified Process Sketch for Example 3 FTCPROCESS FTCPROCESS (FTC Op 1)(FTC Op 2)(FTC Op 3 )(FTC Op 4 ) 90% 90% 93% 96% 0. and Yields for Example 3 A simplified sketch of the series operations that will be used for the process FTC calculation is shown in Figure 6.

Example 4.05 0. The entries for Example 4 are shown in Figure 9. Notice that Operation 1 does not include any rework so FTC and Yield will be the same. Operation 1 2 3 4 5 6 Quantity Attempted 300 288 102 97 84 276 Quantity Rejected 12 23 2 11 12 28 FTC 0.98 1.99 TABLE 4 Example 4 Quantities.96 0. and Yields for the operations in Example 4. FTC’s. 102 Pcs Operation 3 107 Pcs 2 Pcs to Rwk* Operation 1 288 Pcs Operation 2 283 Pcs 97 Pcs Operation 4 92 Pcs 276 Pcs Operation 6 275 Pcs 300 Pcs 12 Pcs 23 Pcs 84 Pcs Rework 18 Pcs 5 Pcs Scrap Rework* Op 3.95 0. The general operation model is shown in Figure 5C.90 Quantity Reworked N/A 18 7 6 5 27 Quantity Completed 288 283 107 92 77 275 Yield 0.Series / Parallel Process With Demonstration Data Added Calculate the FTC and yield for each operation using Equations 2 and 3. Table 4 shows a summary of the quantities. data collection procedure outlined on page 5. the following processed and rejected quantity data were collected during a demonstration run. and Yields Enter the FTC’s and yields that were calculated for Operations 1 through 6 in their respective operation blocks of the process diagram.4. Series/Parallel Process Flow with Repair: Using the three-step.89 0.& 5 12 Pcs to Rwk* 1 Pc Scrap 11 Pcs to Rwk* Operation 5 Rework 18 Pcs 27 Pcs 28 Pcs 77 Pcs 25 Pcs Rework* 7 Pcs Scrap Figure 8 Example 4 .92 0.96 0.92 0. The data are shown in Figure 8.98 0. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 75 . This is not true for any other operation in the Example 4 process.86 0. FTC’s.

Qty Attempted = 102 + 97 + 84 = 283 Qty Rejected = 2 + 11 + 12 = 25 11 Pcs to Rwk* 84 Pcs Operation 5 77 Pcs 18 Pcs 12 Pcs to Rwk* Rework* Op 3. FTCEQ FTCEQ = Qty Attempted Qty Re jected Qty Attempted ( 102 + 97 + 84 ) . single operation as shown in Figure 9B.& 5 Equivalent Operation 3.4.Process With Operation FTC's and Yields Shown 102 Pcs Operation 3 107 Pcs 2 Pcs to Rwk* 97 Pcs Operation 4 92 Pcs The process shown in Figure 9 has three operations in parallel. Operations 3.( 2 + 11 + 12 ) 283 .102 Pcs Operation 3 FTC=98% Yield=105% 107 Pcs 2 Pcs to Rwk* Operation 1 FTC=96% Yield=96% 288 Pcs Operation 2 FTC=92% Yield=98% 283 Pcs 97 Pcs Operation 4 FTC=89% Yield=95% 276 Pcs 92 Pcs Operation 6 FTC=90% Yield=99% 275 Pcs 300 Pcs 12 Pcs 23 Pcs 84 Pcs Rework 18 Pcs 5 Pcs Scrap Rework* Op 3. and the total rejected quantity.912 or 91% ( 102 + 97 + 84 ) 283 283 76 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION .25 258 = = = 0. 5. 4. & 5 283 Pcs 25 Pcs Rework* 7 Pcs Scrap 25 Pcs Rejected Figure 9 A Figure 9B Calculate the equivalent operation FTCEq 3. to an equivalent. is shown below. Total the quantity attempted and quantity rejected. reduce the three parallel operations. shown in Figure 9A.4. 283 units. then enter the values on an equivalent operation sketch such as 9B. The equivalent single operation FTC calculation using the total attempted quantity. 4. and 5. 25 units. To simplify the FTC calculation.& 5 12 Pcs to Rwk* 1 Pc Scrap 11 Pcs to Rwk* Operation 5 FTC=86% Yield=92% 18 Pcs 27 Pcs 28 Pcs 77 Pcs Rework 25 Pcs Rework* 7 Pcs Scrap Figure 9 Example 4 .4.

917 or 92% Add FTCPROCESS and YieldPROCESS to the process diagram.4. 4. and 5 FTC=91% Operation 1 FTC=96% Operation 2 FTC=92% Operation 6 FTC=90% Figure 9C Simplified Process Sketch for Example 4 FTCPROCESS = ( FTC1 FTC2 FTCEQ FTC6 ) FTCPROCESS = ( 96% 92% 91% 90%) = 0.& 5 12 Pcs to Rwk* 1 Pc Scrap 11 Pcs to Rwk* Operation 5 FTC=86% Yield=92% 18 Pcs 27 Pcs 28 Pcs 77 Pcs Rework 25 Pcs Rework* 7 Pcs Scrap Figure 10 Example 4 . The diagram can be included with the final PSO documents as a record of the starting performance.A simplified sketch of the process that will be used for the FTC calculation is shown in Figure 9C. YieldPROCESS YieldPROCESS Qty Completed Qty Attempted 275 300 0. The completed diagram for Example 4 is shown in Figure 10. Equivalent Operation 3.Series / Parallel Process With Operation and Process FTC's and Yields Shown COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 77 . FTCPROCESS. Multiply the individual operation FTC’s together to obtain the FTC for the process.723 or 72% Calculate the process yield using Equation 3 as shown below. 102 Pcs Operation 3 FTC=98% Yield=105% 107 Pcs 2 Pcs to Rwk* Operation 1 FTC=96% Yield=96% 288 Pcs Operation 2 FTC=92% Yield=98% 283 Pcs 97 Pcs Operation 4 FTC=89% Yield=95% 276 Pcs 92 Pcs Operation 6 FTC=90% Yield=99% 275 Pcs FTC = 72% YIELD = 92% 300 Pcs 12 Pcs 23 Pcs 84 Pcs Rework 18 Pcs 5 Pcs Scrap Rework* Op 3.

INTENTIONALLY LEFT BLANK COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 78 .

APPENDIX D PSO Extended Run COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 79 .

perform a post-launch PSO occurring 2-5 weeks after V1 Launch. Option Number Option Description Expanded production of 1000 or more parts during the PSO PDR. Any combination of the above 5 options or an appropriate variation for the specific commodity. In addition to the Pre-S1 PSO. In some cases there will be additional pieces built or multiple shifts exercised during the Production Demonstration Run and in other cases there will be additional visits made at later dates to ensure readiness as launch approaches. the final details of a PSO Extended Run for a particular part are decided by the PSO Team. Due to the variety of manufacturing processes utilized at Suppliers. Validates the line rate after several weeks of operation. so it can be integrated into the PSO planning process. Option Benefit Higher confidence level that the Supplier can sustain line rate over a longer period of time. Perform 3 separate PSO PDRs: Prior to S1 MRD Prior to S2 MRD Prior to V1 MRD Perform PSO PDRs on multiple shifts at the Supplier. options may be developed as indicated in option number 6. Perform 2 separate PSO PDRs with the last run occurring prior to S2 MRD. It does not impact the PSO approval process described in this manual but is a supplemental activity to further assure a Supplier’s readiness to support the full volume production with capable processes (see Figure 1). Table 1 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 80 .PSO Extended Run This activity is intended for new vehicle launches or major vehicle upgrades to reduce the risk of the vehicle launch. The following reference options (15) have historically been used but other. more applicable. Verifies Supplier’s process consistency and validates readiness for V1 Launch. Ensures operational readiness on all shifts. 1 2 3 4 5 6 Allows flexibility to accommodate unique circumstances. PSO Process as described in the PSO manual PSO Extended Run Figure 1 Increased confidence of Supplier readiness on selected parts It is important for the PSO Team to decide the type of PSO Extended Run that will be accomplished and the timing. Confirms that the Supplier can start the process up on multiple occasions and meet capability and line rate.

APPENDIX E Forever Requirements COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 81 .

the submitted change(s) are fully approved by DCX. Failure to resubmit the form to the Supplier Quality Specialist will end the Forever Requirements process for the proposed change(s).C. form.B.e. After the DCX Forever Requirements/ODD Box Activity Form is approved.) shall follow the “Forever Requirements” process outlined here. The Engineer will fill out page two (2) – Section 2. etc. Supplier fills out page one (1) of the ‘DCX Forever Requirements/ODD Box Activity Form’. 5. 12. 3. Failure to resubmit the form to the Engineer for approval will end the Forever Requirements process for the proposed change(s). the Supplier will submit the form to the appropriate Buyer. 11. function and/or require DCX print modifications or have associated costs. 2. then the Supplier must follow the DCX Engineering CN process (i. If the change(s) was rejected by the Buyer. 4. process. then the Supplier must correct the rejected item(s) and resubmit the ‘DCX Forever Requirements/ODD Box activity Form’ to the Supplier Quality Specialist. PSO. In addition. Note: if the change(s) affects multiple platforms. that this form must be submitted a minimum of three (3) months in advance of the planned change(s) implementation date or within sufficient time for implementation (as determined by DCX). 13. the “hard copy format” is being replaced by an electronic Forever Requirement (eFR CN System). Tentative date time frame is early 2007. If changes and/or improvements affect fit. the Supplier Quality Specialist will fill out page two (2) – Section 2. The approval (or rejection) process should be concluded by all affected DCX personnel within 10 business days. Note: Please be advised. Supplier proposed changes and/or improvements that may require part submission. Please be advised.com as required. PPAP. 9. refer to the appropriate DCX procedures). Supplier submits entire ‘DCX Forever Requirements/ODD Box Activity Form’ to the appropriate Engineer. then the Supplier must correct the rejected item(s) and resubmit the ‘DCX Forever Requirements/ODD Box Activity Form’ to the Engineer. then the Supplier must correct the rejected item(s) and resubmit the ‘DCX Forever Requirements/ODD Box Activity Form’ to the Buyer. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 82 . Supplier will submit fully approved form(s) and/or information into Powerway. 6. A fully signed electronic DCX Forever Requirements/ODD Box Activity indicates that DCX approves the plan ONLY.1 in the PPAP 4th Edition AIAG manual gives some examples of situations requiring “Forever Requirements” submissions. and other required activities including and appropriate hard copy and/or electronic notification as necessary.DCX “Forever Requirements” Process 1.. then the Supplier must submit a copy of the ‘DCX Forever Requirements/ODD Box Activity Form’ to each affected platform Engineer.A. If approved by the Buyer. If the change(s) was rejected by the Engineer. Failure to resubmit the form to the Buyer will end the Forever Requirements process for the submitted change(s). 8. 7. If approved by the Engineer. the Supplier will retain the original copy of the fully approved ‘DCX Forever Requirements/ODD Box Activity Form’. All other proposed changes (part. If approved by the Supplier Quality Specialist. the Buyer will fill out page two (2) – Section 2. the Supplier(s) will complete all remaining tasks including the successful completion of all PER. 10. the Supplier will make copies of the ‘DCX Forever Requirements/ODD Box Activity Form’ and distribute it to all appropriate DCX personnel as indicated by the Supplier Quality Specialist. the Supplier will then submit the entire ‘DCX Forever Requirements/ODD Box Activity Form’ to the appropriate Supplier Quality Specialist. After approval by the Engineer. Table 3. If the change(s) was rejected by the Supplier Quality Specialist. After approval by all affected DCX personnel. After approval by the Supplier Quality Specialist. Tier 2 source.

C. of the form Need more information Approved by DCC Product Engineer? Yes No Supplier submits form to DCC ASQP Specialist Supplier provides additional information as required. of the form (including Risk Level) Need more information Approved by DCC ASQP Specialist? No Yes DCC Approval not provided. DCC Product Engineer(s) completes section 2. Submission must be a minimum of 90 days before the proposed effective date of the change(s). form. "Forever Requirements" process ends No Supplier completes page 1 of "DCX Forever Requirement Activity" form and submits one to DCC Product Engineer for each affected vehicle/platform. DCC Buyer completes section 2.B. of form Need more information Approved by DCC Buyer? No Yes A COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 83 . Supplier provides additional information as required. or cost? Yes Follow DCX CN/ODD Box Procedure. DCC ASQP Specialist completes section 2.A. "Forever Requirements" process ends Supplier submits form to DCC Buyer Supplier provides additional information as required.“Forever Requirements” Process Flow 1) Supplier Proposes Change "Forever Requirements" process begins Does the change affect fit. function.

A Supplier given approval to proceed with change(s). including PSO.) High Risk Level (section 2. and Buyer on page 2 of the form Supplier completes all Powerway. is determined/approved by the Team (DCC Buyer. ASQP Specialist. and the Supplier.“Forever Requirements” Process Flow. and Product Engineer. Timing of change(s).com requirements and submits PPAP (as applicable) Supplier implements change 100% "Forever Requirements" process ends COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 84 . cont. ASQP Specialist.B. of form) Low Follow PSO process for DCC Lead PSO Follow PSO process for Supplier Lead PSO Supplier successfully completes all PSO requirements. as well as all requirements from DCC Product Engineering.

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 85 .

COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 86 .

APPENDIX F DCC Internal PSO Requirements COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 87 .

Internal Powertrain PSO
3 Steps to Approval

PV Testing

Production Demonstration Run (PDR) & Analysis

Documentation

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Internal Powertrain PSO Documentation
The following documentation will be supplied for final PSO approval by the following DCX groups; Product Engineering, Advanced Manufacturing Engineering, and the internal Powertrain Plant. Product Engineering Release Part Prints w/ Change Verification/ Level Identified CATIA comments sheet (list of Engineering standards on sheet) A copy of applicable performance, process and material standards (PF Standards) Engineering’s procedure for documentation revision changes due to part number changes Engineering’s procedure for obtaining and distributing CATIA revisions DFMEA Internal best practice document for DFMEA development DVP&R (DaimlerChrysler Engineering signed DV test plan, DaimlerChrysler Engineering signed completed DVP&R for DV testing, DaimlerChrysler Engineering signed PV test plan) Documented waivers for any testing Engineering MQAS procedure for Problem Solving Supplier definition of and internal requirements for special product and process characteristics DaimlerChrysler Engineering signed DVP&R for PV test results – (MANDATORY ENGLISH DOCUMENT) PV test procedures – (MANDATORY ENGLISH DOCUMENT) DaimlerChrysler Engineering approved BSR results (if applicable) – (MANDATORY ENGLISH DOCUMENT) Advanced Manufacturing Engineering AME’s procedure for documentation revision changes due to part number changes PFMEA – (MANDATORY ENGLISH DOCUMENT) Internal best practice document for PFMEA development Process Flow Diagram – (MANDATORY ENGLISH DOCUMENT) Manufacturing floor plan Work Station Layout Dimensional Control Plan Best Practice document for developing Control plans (input from FMEA & Control plans for similar products) Authorization to Ship (ATS Package)-Equipment Qualification at the Plant AME MQAS procedure for Problem Solving
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Tooling List Tool Layouts Assembly Graphics Tool & Op Sheets Spare Parts List Error and mistake proofing plan. This includes a list of error and mistake proofing by operation number Line Speed Simulation AME MQAS procedure for gauge identification PM plan, schedule, procedure and work instructions Plant Deliverables Plant’s procedure for documentation revision changes due to part number changes Plant’s procedure for obtaining and distributing CATIA revisions Control Plan – (MANDATORY ENGLISH DOCUMENT) Best Practice document for developing Control plans (input from FMEA & Control plans for similar products) PPAP status list Plant MQAS procedure for Problem Solving Incoming inspection plan and procedures Incoming sampling plans Receiving reports Material standards Inspection/test reports Parts Handling Plan Material Handling procedures Packaging Instructions Maintenance plan for WIP (work in process) containers Copy of Routing cards or travelers Operator, 1st piece approval, mistake proofing, set-up, changeover, rework/repair, inspection and packaging instructions Record of operator training Operator qualification process Documentation control procedure Visual management (displays & diagrams) First Production Shipment Certification (FPSC) Plan – (MANDATORY ENGLISH DOCUMENT)
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Control Charts (As Applicable) Process Performance Charts (As Applicable) Total Production Maintenance charts Error and mistake proofing studies Mistake Proofing Contingency Plan (in the event mistake proofing becomes inoperable) Control Charts (As Applicable) Process Performance Charts (As Applicable) Total Production Maintenance charts Log Sheets Defect Tracking Sheets Corrective Action Forms 1st Piece Approval Procedure & Records Measurement System Verification Report – (MANDATORY ENGLISH DOCUMENT) Line Speed section on Production Demonstration Results form – (MANDATORY ENGLISH DOCUMENT) Documented deviation to the “300 part or 2 hour” requirement (if applicable) Process Constraints (bottlenecks) documented on PSO COMMENTS SHEET Final Audit Plan Final Audit Procedure Final Audit Work Instructions Part Inspection Standard (if applicable) .– (MANDATORY ENGLISH DOCUMENT) Final Audit Sampling plan Shipping Record Example Audit Record Example Containment Record Example Parts Packaging and Shipping Plan Packaging and Shipping Procedures Packaging. shipping and labeling instructions Returnable Container Management Plan Barcode Labeling Procedure Shipping Label example Plant MQAS procedure for gauge identification Gage Plan Gage R&R results – (MANDATORY ENGLISH DOCUMENT) Gage and Test Equipment Calibration Records and validation plan COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 91 .

The Internal Powertrain PSO work sheet.appl. Production Demonstration Run (PDR) Results Form. (This is a standard PSO document titled Line Speed Demonstration Results Form) All required forms and reference material can be found on the Internal Powertrain PSO website.shtml COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 92 .chrysler. Internal Powertrain PSO Sign-off Package Requirements To assure that all Internal Powertrain PSO requirements have been met. the Internal Powertrain Process Signoff Package should include the following documents Internal Powertrain Process Sign-off form along with the deviations list. The sign-off form should include all necessary signatures. http://advmfg.com/mfg/stmpdash/pso/index.Calibration Schedule & reaction plan Initial Process Study results (on Production Demonstration Results form) – (MANDATORY ENGLISH DOCUMENT) Deviations to Initial Process Study requirements documented on the PSO COMMENTS SHEET (if applicable) – (MANDATORY ENGLISH DOCUMENT) Deviation from FTC requirement w/Commodity Supplier Quality Manager signature (if applicable) – (MANDATORY ENGLISH DOCUMENT) Simulation or shipping test results (Corp Mat Handling) Warranty process flow diagram – (MANDATORY ENGLISH DOCUMENT) Warranty procedures Annual Validation Schedule Production Demonstration Run & Analysis Internal Powertrain Programs must adhere to the requirements outlined in element 16 of the PSO Manual PV Testing Internal Powertrain Programs must adhere to the requirements outlined in element 21 of the PSO Manual.

extra.daimlerchrysler. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 93 .html for the most current version of the FAQ.FREQUENTLY ASKED QUESTIONS Please check https://gsp.com/qlty/pso/index.

For variable sampling. shouldn’t AAR be required for PSO approval if the process appreciably affects color? AAR is not a requirement of PSO. heat treating. Should we force them to inspect as many as the table says? For attribute sampling. Before a Supplier makes any changes to their assembly process they shall initiate a “Forever Requirements” form and obtain approval from the DCC Release Engineer. a copy can be attached or a statement provided on the COMMENTS SHEET that the PSO Team verified the measurement. All Self Directed products shall have a Supplier internally led PSO that documents and establishes their production readiness. 5. Suppliers don't follow the Lot Acceptance Sampling Table. and Buyer. If a Supplier changes a process. All Collaborative risked products will have a DaimlerChrysler led PSO and a Supplier led APQP. the Responsible Design Engineer or the Supplier Quality Specialist? We've been told both. Since AAR is a requirement for PPAP.g.1. otherwise the guidelines in the Lot Acceptance Sampling Table shall be followed. plating. 4.000 pcs. According to TS-16949 and the DCC Customer-Specific Requirements for TS-16949. The ASQP Specialist will determine the risk level of the change (if approved) and corresponding PSO activity level. is PSO required? Yes. 3. If the PSO Team considers a product to be Self Directed. where does the Supplier go to start the PSO process. the Supplier shall be consistent with the Statistical Process Control manual requirements. 7. lot size is 1. All DCC Suppliers were required to be TS-16949 certified. How far down do we go with the certification of the extended enterprise? 3rd tier? 4th tier? Certification down to the production material Suppliers and if applicable any secondary processes/services (e. Failure to conduct evaluations and Production Part Approval of sub-tiers is a failure to meet TS-16949 requirements and may result in the loss of DCC business. All Directed AQP risked products will have both a DaimlerChrysler led AQP and PSO. it does require an evaluation and/or PSO-like activity. Do we need to transfer this data to the appropriate form? No. two or more of the inspection criteria in TS-16949 shall be used. Suppliers are responsible for evaluation and Production Part Approval of their sub-tiers. 2. They always inspect about 5 parts/lot. Refer to the AIAG PPAP manual for an explanation of the relationship between PSO and PPAP. What should our reaction plan be if Suppliers refuse to conduct PSO's on their sub-Suppliers? PSO is part of DaimlerChrysler's Supplier evaluation and Production Part Approval Process. Collaborative AQP risked parts require a PSO if selected by the PSO Team. ASQP Specialist. The Supplier's PSO documentation shall be uploaded into Powerway. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 94 . Note that this does not require that Suppliers perform a PSO specifically.com. Most Suppliers use CMM printout for inspection documentation. etc) would be sufficient. 6. Notify the Buyer and P&S Management of any occurrence of this situation.

IAA is not an alternative to PSO. DaimlerChrysler PSO Teams will review FTC at each Supplier to confirm that defects have been minimized. An IAA indicates failure to meet program requirements. 11.com which. 13. and they are identified in DaimlerChrysler’s Master Record List. allows tool payment at the discretion of the Purchasing Agent. Appendix C. 10. there are exceptions. 14. You don't have to have PSO approval prior to V1 if you have an IAA. the ASQP Specialist enters a “Z” disposition into Powerway. following the submission of a dimensional warrant. After a Supplier successfully completes the first 20 elements for both documentation and process. should parts come from all cavities to calculate PP and PPK? Parts should come from all cavities. 12. It enables shipments on an interim basis to support vehicle development timing until corrective action (PSO approval) can be completed. it wouldn't be a measure of First Time Capability. 9. parts for PV testing shall be selected from a successful Production Demonstration Run.8. Release Engineer or Buyer for more information regarding IAAs. A non- COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 95 . Can the PSO Team accept a Production Demonstration Run which is less than 300 pieces/2 hours? Yes. While we recognize that rework of in-process rejects is common. Can parts used for PV testing be selected from a non-successful Production Demonstration Run? In general. Explain the system of tool payment after PSO elements 1-20 without an approved PSW. Information regarding current interim approval requirements is located in DCC internal procedure PSSP0108. This is an ISO/TS-16949 requirement. Suppliers do not have access to this procedure and should contact their DCC ASQP Specialist. Why don't we take rework into account when calculating FTC? Greater quantities of rejects increase the potential for greater quantities of non-conforming parts shipped. we want to measure the true First Time Capability of the process in order to quantify the quality potential. provides a standard method and examples for calculating FTC for a new process with no rework. The PSO Team shall authorize any deviation from requirements (minimum of two hours or 300 pieces. If rework were included in the FTC calculation. whichever is more stringent) and enter an explanation on the PSO COMMENTS SHEET. however each cavity (process stream) should be calculated individually as stated in the Statistical Process Control (SPC) manual published by AIAG. Clarify IAA requirements. What should be done? The forms are part of the manual. In a multi-cavity tool. however. The PSO Team will review any deficiencies. Our forms do not have a control number or issue date.

22. English is the official language of DaimlerChrysler and therefore an English translation has to be available. DaimlerChrysler is a global company. FPSC requires that the first 2000 parts shipped to each customer facility be certified. How many frames do we need to measure? All 2000? The PSO Team. Refer to the DaimlerChrysler FPSC procedure PSSP0106. Is the 2000 minimum quantity for FPSC a negotiable amount? Yes. 15. Expand the FPSC explanation. If an offshore DaimlerChrysler employee performs a PSO in his/her local country. however. 20. S1 vehicles. the PSO Team may allow the remainder of these PSO parts. it could mean 6000 parts for FPSC. but it will probably extend the time period and quantity of the FPSC. what if we take a truck frame with 400 dimensions.000 pieces is required which is different than the 300 piece PSO capability study. 21. under certain circumstances. 16. The 300 piece Production Demonstration Run that is part of the PSO. other testing. Regarding FPSC. If there are 3 truck plants. FPSC is still required. As stated. These components are not intended to satisfy the FPSC requirements. Who pays for additional manpower needed to support FPSC? FPSC is a PSO requirement and any additional manpower or tooling needed to fulfill this requirement is the sole responsibility of the Supplier. 19.if there are 3 truck plants. to be included with production parts shipped to the Assembly Plant. Who gets the FPSC form in the plant? Is there an organization to handle this? The Supplier shall review the completed form with the PSO team and upload it into Powerway. 17. This should be a team decision. this manual requires them to use English for the master documentation.successful PDR can only be used for PV testing if the deficiencies are due to documentation discrepancies or appearance (non-functional) issues not involving finish durability. The Supplier shall also retain the original form for up to one year following the launch. any deviation from the 2000 minimum shall be explained using the PSO COMMENTS SHEET. and S2 vehicles. 96 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION . if any. Add examples for attendees to follow. for example. If the PSO is not approved does this imply that there is no FPSC? No.com. working with the Supplier. It's critical to know where parts are going . satisfies the component requirements for PV testing. Include a slide that explains a statistical analysis of the first 2. will determine what shall be an adequate plan to satisfy the FPSC requirements. 18. However. then 6000 parts will require FPSC. It does not preclude other language versions.

In those rare cases when a Supplier refuses to allow DCC personnel to review required documents at all.” Review of the documents may take place at the Supplier’s location or at a DCC location. cannot be out-of-specification. as appropriate. at the discretion of the team. and will not allow us to review them. on the other hand. those documents sited for exclusion are not required to be uploaded into Powerway. line-balancing and other ergonomic or efficiency studies are expected to be completed prior to the PSO On-Site visit.23. Strictly speaking. Is it acceptable for a Supplier to add or remove operators from a production line during the line speed demonstration? The number of operators required for the production line shall be identified on the Process Flow Chart. if these are out-of-specification. 7. Any questions concerning approval of DCC designed packaging should be referred to the DCC Material Handling Group. 24. use general print tolerances. However. a reference dimension does not have a tolerance and. and/or Purchasing. the PSO should be rejected and the matter brought up to DCC management (ASQP. should I approve the PSO? This depends on what is meant by a “reference” characteristic. Engineering. therefore.com. If a reference characteristic is showing out-of-specification on the Initial Process Study. revision level and date is required to be uploaded in place of the actual document. All dimensions on the design model must meet and be capable to DCC specifications. 26. Basic dimensions.7): “Note: For source packages that reflect proprietary document exclusions. 25. At what level must packaging be signed off? Supplier designed packaging shall be signed off by DaimlerChrysler Corporate and the receiving Assembly Plant Material Handling Engineering prior to “Z” approval of the PSO using the Unit Load Data (ULD) sheet (available in the DCC Packaging and Shipping Instructions manual. The Supplier has several required documents that they consider proprietary. even those not regularly monitored. A cover page with the documents title block. and/or Workstation Layout.) COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 97 .) Actual packaging shipping test shall be signed off by DaimlerChrysler Assembly Plant Material Handling Engineering prior to PSO “A” approval. The Supplier may not deviate from this number during the PDR. How do we handle this? As stated in Element 7 (cl. For DCC designed packaging. Packaging shipping simulation testing shall be signed off by Corporate Material Handling Engineering prior to PSO “A” approval. Manufacturing Layout. these documents shall be available for review at the request of the DCC ASQP Specialist. then the PSO must be rejected. PSO approval must not be delayed due to a lack of approval(s).

4679 Corporate Engineering Publications: CEP-002 CATIA Standards Reference Manual CEP-010 Supplier Product Design Information Security Requirements Available From: https://essd.4748 Fax: 248.3) Available From: Automotive Industry Action Group (AIAG) Phone No: (248) 358-3003 NOTE: DaimlerChrysler personnel can obtain copies of the manual through DaimlerChrysler's eCopier on DashboardAnywhere.REFERENCE MANUALS DaimlerChrysler Manuals: Packaging and Shipping Instructions Product Assurance Testing Test Data Analysis manual P&S 7-Step Corrective Action Process manual Available From: Lanier Professional Services Detroit Production Center 2119 Austin Ave.htm Other Manuals: Production Part Approval Process (PPAP) Measurement Systems Analysis (MSA) Manual Statistical Process Control (SPC) Manual Potential Failure Mode and Effects Analysis (FMEA) Advanced Product Quality Planning and Control Plan (APQP) Manual Quality Systems Requirements for Automotive Suppliers (ISO/TS 16949) Quality Systems Requirements of VDA (VDA 6.com/ESSD/Login. MI 48309 Phone: 248. Rochester Hills.daimlerchrysler.com/mfg/amedd/gages/index.extra.564.jsp AME Standards: AME Standards-Gage Standards Available From: https://gsp.564. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 98 .daimlerchrysler.extra.

GLOSSARY COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 99 .

CONTROL PLANS: written descriptions of the systems for controlling parts and processes. “go” and “no-go”) or at the worst-possible acceptable condition (e.) Boundary samples must be clearly marked and/or identified to prevent shipment to the customer and properly controlled to prevent degradation and ensure relevance. The CDS process keeps the design window open for a longer period to ensure products meet or exceed external requirements. Manufacturing. AIAG's focus is to continuously improve business processes and practices involving trading partners throughout the supply chain.htm. It is known as a CAD/CAM system. The purpose of the AIAG is “to provide an open forum where members cooperate in developing and promoting solutions that enhance the prosperity of the automotive industry. They are written by Suppliers to address the important characteristics and engineering COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 100 .org/.tcc. BSR issues shall be eliminated in order to achieve customer satisfaction. or the Supplier. By completing design and feasibility prior to execution using virtual design tools. CHRYSLER DEVELOPMENT SYSTEM (CDS): CDS provides a framework for a total systems approach to Product Creation. BOUNDARY SAMPLES: part samples created as a visual inspection aid for operators. “no worse than”. All BSR issues are tracked by Vehicle Development and subsequently assigned to the most responsible party for resolution. costly changes are eliminated in the execution and launch phase. it ensures that the design and feasibility for both product and process is complete prior to execution.g. This is key to the CDS process.ADVANCED QUALITY PLANNING (AQP): a structured method of defining and establishing the required steps necessary to assure that a product satisfies the customer. CATIA: is a computer aided three dimensional interactive applications design and manufacturing system. be it Engineering. CONTINUING CONFORMANCE TESTING (CC): tests and evaluations performed after production launch to monitor the effects of processing and to assure continued conformance to engineering requirements. Samples are typically created at the specification limits (e. and General Motors.chrysler. AUTOMOTIVE INDUSTRY ACTION GROUP (AIAG): a group founded in 1982 by representatives from DaimlerChrysler. This analysis is especially important when a new product is introduced so product quality and variation reduction can be assessed.aiag. Consistency among product teams is achieved by using a standard process. The CDS website is at http://roadmap. Although somewhat subjective. At the same time. Ford. AQP embodies the concepts of defect prevention and continuous improvement as contrasted with defect detection.g. BUZZ – SQUEAK – RATTLE (BSR): objectionable vehicle noise attributes. This framework will shorten the overall time for the development and launch of a vehicle. while providing a forum for sharing.” The AIAG website is at http://www. This software was developed and is maintained by Dassault Systemes of France and is marketed in the United States by IBM. CAPABILITY STUDY: is a statistical analysis of the output from a machine or a process to determine its ability to produce product that meets specifications.com/cds/what_is_cds.

CPK is calculated as the minimum of CPU or CPL.LSL 6 C USL LSL 6 R d2 Where. 132) CP= USL . Customer approval of Control Plans may be required prior to production part submission. This index provides a measure of how well the process will satisfy the variability requirements.” (Statistical Process Control Manual. COVISINT: A web based system that grants qualified Supplier users access to selected portions of the DaimlerChrysler Network. … CP is not impacted by process location. USL = Upper Specification Limit LSL = Lower Specification Limit = Estimate of the standard deviation of a stable process using the average C range of subgrouped samples taken from the process R d2 = Average range of a series of subgroups of constant size = A divisor of R used to estimate the process standard deviation (see the Statistical Process Control Manual (AIAG) Appendix E. This index can be calculated only for two-sided (bilateral) tolerances. where: CPU = USL .” (Statistical Process Control Manual. CPK: capability index that “takes the process location as well as the capability into account. “family” Control Plans can cover a number of parts produced using a common process.requirements of the product. but in many cases. USL = Upper Specification Limit LSL = Lower Specification Limit X C = The average of subgroup averages (measured process average) = Estimate of the standard deviation of a stable process using the average range of subgrouped samples taken from the process = Average range of a series of subgroups of constant size = A divisor of R used to estimate the process standard deviation (see the Statistical Process Control Manual (AIAG) Appendix E. Each part shall have a Control Plan. pg. 132) C PK CP CP and CPK are equal only when the process is centered.X 3 C USL 3 R X d2 LSL d2 and CPL = X 3 LSL C X 3 R Where. CP: capability index that “compares the process capability to the maximum allowable variation as indicated by the tolerance. pg. 101 R d2 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION .

ENGINEERING STANDARDS: are written requirements that describe materials. launch. Production Validation (PV) and Continuing Conformance (CC) testing. Design Verification (DV).CUSTOMER SATISFACTION AUDIT (CSA): a comprehensive review of a vehicle’s asshipped quality as it leaves an assembly plant. It is used to identify corrective actions required to prevent failures from reaching the customer. It is a two digit alpha field that can be accessed on ODCICS2 through screen ENAA or ENJA. or volume production phases. and running the tests. or eliminate the possibility that the error could produce a defect. ENGINEERING STANDARDS SUPPLIER DISTRIBUTION (ESSD): the DCC computer system that gives Suppliers access to DCC Engineering Standards. reliability. and analyzing the data. ELECTRONIC CORPORATE ISSUE MANAGEMENT SYSTEM (e-CIMS): DCC’s electronic system for documenting serious issues that arise during vehicle prototype. or part or a family of materials. parts. DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA): formalized method for quantifying the risk associated with identified potential design failure modes. DESIGN VERIFICATION PLAN AND REPORT (DVP&R): formalized test planning and reporting tool. It provides a convenient reporting format for Engineering Development (ED). setting up. A hole or slot designed so that mating parts can only fit in the proper orientation. DESIGN OF EXPERIMENTS (DOE): a statistical approach to efficiently plan and structure a series of controlled tests.and right-handed parts (as opposed to separate clips for each. DESIGN VERIFICATION (DV) TESTING: testing phase that demonstrates the final released component or assembly meets design intent. it encompasses planning. The tests.jsp.daimlerchrysler. An operation that will not function until all components are present in the proper orientation. Examples of error proofing include: A rod clip designed to work in left. ERROR PROOFING: Error proofing is a method used to identify potential process errors and either designs them out of the product or process. The goal is to identify the sources of product variation that should be optimized or avoided for consistent product performance with a minimum number of tests. It lists all testing necessary to assure that functional and reliability criteria and target requirements are defined in specific measurable terms. and performance requirements are detailed in Engineering Performance Standards. The CSA provides a reliable real-time indicator of vehicle quality.com/ESSD/Login. DRAWING CHANGE LEVEL (DCL): the latest design level of the released drawing.extra. sample sizes. In its broadest sense. It is available on-line at https://essd. performance. or systems. The DFMEA is a living document that is updated as the design changes and progresses through design verification and production. processes. process. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 102 . quality and/or design requirements for a material.

torque etc. the Quality System Requirements for Automotive Suppliers. Certification is for a minimum of 2000 parts (per assembly plant) or for a specified period of time as identified by the PSO team. launch. Reproducibility is a measure of the ability of people to reproduce a series of measurements using the same gage. tolerances. in conjunction with ISO 9001:1994. FPSC is intended to identify part problems and contain the parts at the Supplier’s manufacturing facility during the launch phase. INTERIM APPROVAL AUTHORIZATION (IAA): documentation and approval to temporarily use a part that does not meet PPAP approval requirements for Pilot builds. and improve quality and customer acceptance. require special attention to ensure acceptable results. position.e. minimize total system costs. dimensions. and is evaluated by repeatedly measuring the same parts (equipment variation). COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 103 . FIRST PRODUCTION SHIPMENT CERTIFICATION (FPSC): the purpose of FPSC is to ensure that initial production shipments meet all DCC product specifications. GAGE DIMENSIONING & TOLERANCING (GD&T): a system of symbols used to define part and part feature shape. FPSC requires the Supplier to provide statistical evidence of conformance to special product and/or process characteristics prior to the shipment of components to the DCC (or DCC-designated) assembly plant. FIRST TIME CAPABILITY (FTC): FTC is equal to the number of acceptable parts produced divided by the number of parts rejected during the PDR. or production. and therefore. nor are parts initially rejected by the process but found to be acceptable after re-testing.EXTENDED ENTERPRISE : is a DaimlerChrysler coordinated process that unifies and extends the business relationships of Suppliers and Supplier tiers in order to maximize the effectiveness of vehicle development. KEY <D> CHARACTERISTICS: designated by the or <D> symbols on Engineering Source Documents. 100% of the FPSC parts are to be inspected for conformance to special product and/or process characteristics. GAGE REPEATABILITY & REPRODUCIBILITY (R&R): a method used to rate the appropriateness of a measurement system as a percentage of the product tolerance or process variation. size. Rework and repair are NOT counted in the number of acceptable parts. component or assembly that may cause failure to meet customer satisfaction specifications due to manufacturing and/or assembly. ISO/TS 16949: is a Technical Specification that describes. and is evaluated by two or more operators independently repeating the inspection of a set of parts (appraiser variation). Key Product Characteristics are toleranced and measurable characteristics (i. ISO/TS 16949 has been prepared by the International Automotive Task Force (IATF) for all participating worldwide OEM’s. Repeatability is a measure of the ability of the gage to repeat a given measurement. HOME LINE: Supplier’s assembly line located in the manufacturing facility where volume production of the part(s) takes place using production tooling and processes. See Appendix C for examples. etc.) of a part. Reference PS-7300 “Key Product Characteristics – the Use of Diamonds” for additional information.

The layout shall also indicate any proposed areas for expansion and development. MANUFACTURING FLOOR PLAN: a pictorial layout of the entire manufacturing facility drawn to scale. and acceptance/rejection criteria. It also provides a method for replacement of those parts and for Supplier dispute of the issue. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 104 . start up. whichever is smaller. etc. NET OPERATING TIME FOR DAIMLERCHRYSLER PARTS: equal to the number of hours (normal work pattern). and/or vision systems that detect missing or incorrectly-assembled components. PART CHANGE LEVEL (PCL): the latest design level of the part (not necessarily the drawing). breaks. MISTAKE PROOFING: Mistake proofing is an approach used to develop methods to clearly identify errors that may occur and prevent them from becoming nonconformances. hold areas.) and time scheduled to run other customers’ parts and/or other DCC parts. It affects ease of handling by manual or mechanical means. shipping-receiving areas. office space. not to exceed eight hours or one day’s production. It provides protection and containment of parts.g. required tools and gages. Examples of mistake proofing include: Sensors. shared production. SPC applications. tool changeovers. LOT: specific amount of material or group of components. lab space. It is to include all machinery. These items are usually discovered and measured by DaimlerChrysler’s NVH laboratory facilities. NON-CONFORMANCE TRACKING (NCT) SYSTEM: DCC’s electronic system for documenting and tracking part issues at the manufacturing plants. OPERATOR INSTRUCTIONS: lists of steps in performing an operation that may contain inspection requirements. shut-down. The Line Speed shall be verified during the Production Demonstration Run. sample size and frequency. End-of-line (“EOL”) testers that check functional requirements.LINE SPEED: the contracted maximum tool capacity rate determined by dividing the Daily DaimlerChrysler Tooling Capacity (Pieces per Hour) by the Supplier’s Net Operating Time for DaimlerChrysler Parts (Hours/Day). These shall be readily available to the operator. optics. quarantine areas. Packaging may consist of returnable or non-returnable items including dunnage. This signature is optimized by vehicle development for the best customer responses. It is a two digit alpha field found on ODCICS2 through screens ECCE or ENCZ. etc. Serious quality issues are also documented in the e-CIMS system. Continuity testing for electrical components. less scheduled “down-time” (e. They shall communicate all requirements involved in that particular operation. Pick lights or barcoding to assist in proper part selection. NVH attributes are typically tuned to a certain frequency and amplitude in order to achieve an overall vehicle signature frequency. preventive maintenance. NVH: Noise – Vibration – Harshness are measurable perceptions of vehicle attributes. PACKAGING: material that is used to store and ship parts.

PART SUBMISSION WARRANT (PSW): an industry-standard document required for all newly-tooled or revised products in which the Supplier confirms that inspections and tests on production parts show conformance to customer requirements. PERISHABLE TOOLS: tools which are consumed in the process of producing a product, and are usually a cost item, e.g., drill bits, cutters, sockets, driver tips, inserts, hobs, broaches, welding tips, etc. PP: performance index that “compares the process performance to the maximum allowable variation as indicated by the tolerance. This index provides a measure of how well the process will satisfy the variability requirements. … PP is not impacted by process location.” (Statistical Process Control Manual, pg. 133)

PP =

USL - LSL 6 P

USL LSL 6s

Where,

USL = Upper Specification Limit LSL = Lower Specification Limit = Estimate of the standard deviation of a stable process using the sample P standard deviation of a set of individuals about the average of the set. = Sample standard deviation for subgroups or processes; see the Statistical s Process Control manual, Chapter II, Section C or Chapter IV, Section A.

PPK: performance index that “takes the process location as well as the performance into account.” (Statistical Process Control Manual, pg. 133)
PPK PP

PP and PPK are equal only when the process is centered. PPK is calculated as the minimum of PPU or PPL, where:
PPU = USL - X 3 P X 3 LSL
P

USL X 3s X LSL 3s

and

PPL =
Where,

USL = Upper Specification Limit LSL = Lower Specification Limit

X
P

s

= The average of subgroup averages (measured process average) = Estimate of the standard deviation of a stable process using the sample standard deviation of a set of individuals about the average of the set. = Sample standard deviation for subgroups or processes; see the Statistical Process Control manual, Chapter II, Section C or Chapter IV, Section A.

PRE-PSO DOCUMENTATION REVIEW: a meeting conducted by the PSO Team, chaired and coordinated by the ASQP Specialist, with the Supplier. The meeting is conducted at a DCC selected location prior to the PSO On-Site visit. The purpose is to review all of the
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Supplier’s required documentation in a sequential way and determine the Supplier’s readiness for the Production Demonstration Run (300 pcs.) and PSO On-Site Visit. Generally, a Pre-PSO meeting is held for Directed and Collaborative AQP activity level programs; it is not a requirement for programs with a Self-Directed AQP activity level. PRE-PRODUCTION SAMPLE REPORT (PPSR): a dimensional and performance verification document, submitted with all part samples used prior to S1 Start. PREVENTIVE MAINTENANCE (PM): a planned system of actions performed to prevent breakdown of a machine or equipment as a result of normal use. PROCESS CAPABILITY: the 6 C range of inherent variation in a stable process. Reference the Statistical Process Control AIAG manual for more information. PROCESS PERFORMANCE: the 6 P range of total process variation. Reference the Statistical Process Control AIAG manual for more information. PROCESS FAILURE MODE & EFFECTS ANALYSIS (PFMEA): a structured method of documenting historical or potential process failure modes, their effects, and the controls taken to ensure their detection and/or prevention. The PFMEA rating system allows quantification of the risk presented by each failure mode with the Risk Prevention Number (RPN). The RPN is used to prioritize recommended actions. The PFMEA is developed by a cross-functional team and is uniquely developed for each process/product. PROCESS FLOW DIAGRAM: chart that illustrates the flow of materials through the process. The diagram generally starts at receiving, and includes work in process, production, shipping (including any special processing which may result from a nonconformance requiring disposition), and rework or repair operations. PROCESS SIGN-OFF (PSO) ON-SITE VISIT: a systematic and sequential review of the Supplier’s manufacturing process conducted by a PSO Team at the Supplier’s production facilities. The ASQP Specialist is responsible for leading the PSO On-Site Visit for Directed and Collaborative AQP activity level programs; the Supplier leads their own for SelfDirected AQP activity level programs. PRODUCTION DEMONSTRATION RUN (PDR): a production run conducted during the PSO On-Site Visit consisting of at least 300 parts or 2 hours of production (whichever is more stringent). The PDR is on the production line of record, with trained operators, PPAP (or equivalent) approved components and materials, and run at a rate equal to the daily maximum tooling capacity. The DCC PSO Team will be on the manufacturing floor during the PDR for all Directed and Collaborative AQP activity level programs. PV test parts are taken from the PDR to demonstrate that the production process has not degraded the design performance that was verified during DV testing. PRODUCTION PART APPROVAL PROCESS (PPAP): process for ensuring that production parts are manufactured that meet customer requirements. Parts PPAP shall be taken from a significant production run. DaimlerChrysler requires that this run is a minimum of two (2) hours or 300 pieces, whichever is more stringent, unless otherwise stated in writing by the customer. Parts from each position of a multiple cavity die, mold, tool or pattern are to be measured and representative parts tested. Reference the PPAP 4th Edition AIAG
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manual and the DaimlerChrysler (Chrysler Group) Customer-Specific Requirements for the PPAP 4th Edition for more information. PRODUCT SPECIFICATIONS: all engineering drawing requirements including standards referenced on those drawings and within the pre-source package. Some of these requirements are determined by team consensus during Advanced Quality Planning meetings and Design Reviews and can take the form of Safety Standards, Material Standards, SRPC’s, Temporary Standards, Process Standards, Laboratory Standards, Reliability Standards, or Performance Standards. PRODUCTION VALIDATION (PV) TESTING: tests performed to validate design conformance of initial production parts manufactured with production tools and processes. REPAIR: action taken on non-conforming product so that the product will fulfill its intended usage, although the product may or may not conform to specification. REWORK: action taken on non-conforming product so that it will meet specification. ROOT CAUSE: the assignable source of variation that affects all the individual values of the process output or phenomenon being studied. Root cause is the reason for the primary nonconformance, which has induced other failures and for which effective permanent corrective action can be implemented. S0 START – CDS Quality Gate D1. S0 is the first pilot build program based on product components and systems that meet design specification, produced off tools and equipment allowing build to production process intent. It includes vehicle and property builds that verify product and process design and train key plant personnel. Components may be built using hard or soft tools, as determined to be appropriate based on part or process knowledge required. Design verification (DV) testing shall be successfully completed before parts are submitted for S0. S1 START: CDS Quality Gate C. S1 is a home plant build to validate tooling, equipment and verify facilities. Vehicles are built for the certification test plan. Components for S1 are required to be PSO and PPAP approved. S2 START: CDS Quality Gate [no letter designation]. S2 is the home plant facility validation build. Vehicles are built for fast feedback and rental fleet feedback programs, and for dealers. SAFETY <S> CHARACTERISTICS: Designated by the or <S> symbols on Engineering Source Documents. They are product characteristics or manufacturing process parameters which can affect safety or compliance with government regulations. See PFSAFETY – “Product Safety – Use of Safety Shields <S>” for more information. SAMPLING PLAN: plan that defines the minimum number of parts that shall be inspected from a given population (see DaimlerChrysler’s Lot Acceptance Sampling Table Plan in this manual). SEQUENTIAL SENSING: type of sensor that detects if a series of operations are performed in the correct order. Example: A station requires that an assembly receives a
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Pareto Charts. STATISTICAL PROCESS CONTROL (SPC): the use of statistical techniques such as control charts to analyze a process or its outputs to take appropriate actions to achieve and maintain a state of statistical control and to improve the process capability. statistical control is evident by the absence of points beyond the control limits and by the absence of non-random patterns or trends within the control limits. SUB-TIER SUPPLIER: see TIER 2 (& LOWER) SUPPLIER. and nut (in that order. or DaimlerChrysler owned tooling. affected by the TPO. The DCC PSO Team will evaluate the data from this run when deciding whether to schedule the PSO On-Site Visit. performance or subsequent processing of product. fit. and PP and PPK for special characteristics are calculated. setup. washer. etc. The Supplier. STATISTICAL CONTROL: the condition describing a process from which special causes of variation have been eliminated. See PS-7300 . operation times. function. Key (diamond) <D>. SUPPLIER TOOL RECORD (STR): A form generated by the creation of a new TPO (Tool Purchase Order) requiring the identification of Supplier. will determine the quantity of parts that are completed during this run.“Key Product Characteristics – the Use of Diamonds” for more information regarding Key characteristics and PF-SAFETY for additional information regarding Safety characteristics. and tryout of the production equipment and tools.) A sequential sensor would detect and flag (through lights. machine cycle times. or other indicators at this time. They include all governmental. quantity accepted. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 108 . Data collected during this run typically include measurement data. STATISTICAL PROBLEM SOLVING (SPS): the organized use of special problem solving tools (e. operation. quantity attempted. Fishbone Diagrams. FTC. their root causes and determine solutions. observed variation could be attributed to chance causes. SUB-COMPONENT: one or more parts that when assembled together results in the EndItem Assembly or module. FTC. There are no minimum requirements for process performance. The Supplier Readiness Evaluation Run and analysis provides the Supplier with the opportunity to optimize and refine the process. safety (shield) <S>.g. SUPPLIER READINESS EVALUATION (SRE) RUN: the first documented build attempt by the Supplier following installation. The Supplier Readiness Evaluation Run shows that the process is set-up. emissions <E>. etc.) if the nut was put on before the washer. torque requirements. and ready for a Production Demonstration Run during the PSO On-Site Visit. From this data. ANOVA. On a control chart. etc. station lock-out.g.screw. and characteristics identified as SPC points on the design model. Only common causes remain.). SPECIAL CHARACTERISTICS: product characteristics or manufacturing process parameters which can affect safety or compliance with regulations. e. yields.. to better understand problems. with the concurrence of the DCC PSO Team. yields. and performance of the installed production line. estimated production rates. debugged. The purpose of the SRE is to provide pre-production data that confirms the proper set-up.

even though they do not ship directly to DCC. the Supplier of a module component may be treated as a Tier 1 Supplier. Note that in the case of some modules. COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 109 . unless otherwise specified. services. TAKT Time Net Operating Time Per Shift Customer Re quirements in Units of Pr oduction Per Shift TIER 1 SUPPLIER: a Supplier who is responsible for providing components. or raw material to another Supplier in the Supply Chain.SUPPLY CHAIN: includes all Suppliers used in producing a given part. VERIFICATION SAMPLES: samples created with known defects in order to verify the performance of Error and Mistake proofing. unless otherwise specified. a Tier 3 supplies a Tier 2. or raw material directly to DaimlerChrysler. WORK IN PROCESS (WIP): product that has not gone through the entire production process or is incomplete in some way. Mapping details the manufacturing process. services. transportation and other factors that go into component production. assembly. All references to “Supplier” in this manual refer to a Tier 1 Supplier. SUPPLY CHAIN MAPPING: a method used to look at the complexity of the extended enterprise value chain. TIER 2 (& LOWER) SUPPLIER: a Supplier who is responsible for providing components. from tier one to the source of production materials. TAKT TIME: The time in which one vehicle. All references to “sub-tier” or “sub-tier supplier” in this manual refer to a Tier 2 (or lower) Supplier. Verification samples must be clearly marked and/or identified to prevent shipment to the customer and properly controlled to prevent degradation and ensure relevance. or part (the item of interest) is to be made. A Tier 2 supplies a Tier 1. and so on.

INTENTIONALLY LEFT BLANK COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 110 .

....... 30..............................26-27 Outgoing Material Inspection Plan……………………..... ….......................... 44....................... 44..................................... 22..................... 106 Process Sign-Off Flowchart …………………………………… ... 94..3...14....... 53-55. 35........ 56-57............................. 96..............4 Net Operating Time for DCC Parts…………………… ...... …. 103 First Time Capability (FTC) Calculation Examples……………………....... 91............ 3........................ 9... 90.................................................. 4.......... 63........... 20................ 46..................... 104......................................38.............1.............................…............ 10.............. 3 “A” Approval .....11-44 Error and Mistake Proofing .. 30............ 103 Glossary ……............................. 108 Error and Mistake Proofing Requirements for Electrical Components ...99-109 IAA …………………………………………………… ..............14....... 29.... 90................ 5..88-92 Layered Process Audit…………………… ............. 23 Part Number..................... 43.... 105........ 16-107 Pre-PSO Documentation Review............ 43................... 20....................................................................... 106 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 111 .................... 30............................................... 105................... 16......................................................…......... 89.......... 37.............. 35..........33 Error and Mistake Proofing Requirements for Modules/Sequenced Part Delivery.... 100......................................................…............................................... 92. 8............................................. 44... 20.............. 38.......................................81-86 Frequently Asked Questions ……………………..... 7..…... 3....................... 9............. 29........ 104 Operating Instructions…………………… . 31-33............ 12.......................................................... & Change Level......... 41...... 96.....................................12-13 Parts Handling Plan…………………… ................. 9 Process Sign-Off Strategy ……………………………………...... 18-19............... 103 First Time Capability (FTC) ...... 1..….................................................... 2....... 64 Lot Acceptance Sampling Table .................... 2........ 82... Description.............…........23 Packaging Approval……………………... 35. 89........... 34... 89.........….......................22 Initial Process Study.......... 4...........39-40 Powerway...................................... 58-59 “N” Approval .................34......................... 37.............. 90............................ 16.............. 18... 89..... 104 Capability Matrix…………………… ........... 8.17 Process FMEA ..............................1................. 4.... 97 Process Performance Indices (PP.. 98................................................. 4................…... 22.... 41..............…........................................INDEX Page(s) Advance Quality Planning (AQP) …………………… ............................... 31............5 Production Demonstration Run (PDR) ..............................14................................... 12...... 82................... 7.......... 94....................................................24-25 Parts Packaging and Shipping Specifications…………………… .. 97 Internal PSO Requirements…………………… ............................... 97..6............................ 15.............................. 29... 89............................. 90.... 3.............................67-77 Forever Requirements .................................................... 102.................... 22..25 Element Requirements............................ 102 Documentation Checklist…………………… ..................…42 Problem Solving…………………… ..................................... 35....................................................................... 2..............….............. 44........ 5........ 80.39 Part Inspection Standard ...............20-21 Process Flow Diagram and Manufacturing Flow Chart…………………… .... 95.......... 95.... ….............. 29.. 96....................40 BSR/NVH…………………… ................................ 67-77.................. 38.. 107 Comments Sheet .....................….... PPK) ................................................................ 60 Design FMEA .................................................................................. 95........... 8 Process Sign-Off Responsibilities ……………………………................... 43.. 18...........41 Gage R&R……………………............. 21........................................50 Control Plan . 95...............37....... 16......63 Chrysler Development System (CDS) …………………… ...............com…………………… ............. 19.......... 43.. 100-101 Daily Tooling Capacity…………………… ..........................…7....….....…............ 37.............. 97 Bar Code Labeling……………………............. 29..... 108 PPAP ................................…................................93-98 Gage and Test Equipment Evaluation…………………….. 37.......................... 3.................... 3............................. 18......................... 102 Electro-Static Discharge (ESD) Guidelines…………………… ................................................................…..............37................. 103 Incoming Material Certification Plan…………………….…......... 38.............................................. 106 Preventive Maintenance…………………… ..33 First Production Shipment Certification (FPSC) ..1............................................. 41......................................….... 23........46-48 DVP&R .............. 92................... 31....................... 43................. 12..…...... 91.62 Measurement System Report .................. 103................ 29............…........ 38.................................. 103........ 100..….. 35.

............. 18.................. 44........................... 8........…......................... 26........................ 35..... Equipment.20-21 Reference Manuals ………………………………… ......... 5............................ 36......... 35.... & Gages Identified…………………… ............................ 7....... 37... 106. 24....... 95...........3....................... 96 PSO Checklist……………………..... 34.... 97 COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 112 ..................98 Rework and Repair Instructions and Procedures……………………............ 97.....................................14.......... 38.................................................................. 29-31.... 9. 4......29-30................................. 35.................. 36....41..................................... 41.2 Quality Planning…………………… .49 PSO Extended Run .................15 Third (3rd) Party Sources…………………… .......... …..................... 10......... 34................…................................................ 28.79-80 PSO On-Site Visit .................. 108 Supplier Readiness Evaluation (SRE) ……………………......28 “Z” Approval ……………………………………………….............. 92...... 3.... 16. 21..........................…................. ………….......................................…................ 1.......2............... 17....... 4.…............ 5.. 5...Production Validation (PV) Testing ... 107 Special Characteristics ...........26-27 Safety Characteristics…………………… .........................….............…..... 108 Supply Base Management…………………… ...... 42 Tooling.. 108 PSO Team Members............... 43........…. …....20 Test Sample Sizes & Frequencies……………………...................................................... 19.................................................................. 105....….....

5 EDITION CHANGE LOG REVISION DATE 12/2006 SECTION Entire Document Initial Revision DESCRIPTION OF CHANGE COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION 113 .PSO 5.

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

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