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John Deere Standard

APPROVED FOR SUPPLIER DISTRIBUTION

JDS-G223

Supplier Quality Manual
TABLE OF CONTENTS Section/Title 1 2 3 4 Page Vision .....................................................................................................................................................3 Goal........................................................................................................................................................3 Purpose..................................................................................................................................................3 Quality Management System.................................................................................................................3

4.1 General Requirements...........................................................................................................................4 4.2 Documentation Requirements ...............................................................................................................4 5 Management Responsibility...................................................................................................................6 5.1 Management Commitment ....................................................................................................................6 5.2 Customer Focus.....................................................................................................................................6 5.3 Quality Policy .........................................................................................................................................7 5.4 Planning .................................................................................................................................................7 5.5 Responsibility, Authority and Communication .......................................................................................7 5.6 Management Review .............................................................................................................................8 6 Resource Management..........................................................................................................................8 6.1 Provision of Resources ..........................................................................................................................8 6.2 Human Resources .................................................................................................................................9 6.3 Infrastructure..........................................................................................................................................9 6.4 Work Environment .................................................................................................................................9 7 Product Realization - Enterprise Product Delivery Process ..................................................................9 7.1 Planning of Product Realization.............................................................................................................9 7.2 Customer-Related Processes..............................................................................................................11 7.3 Design and Development ....................................................................................................................16 7.4 Purchasing ...........................................................................................................................................18 7.5 Production and Service Provision........................................................................................................19 7.6 Control of Monitoring and Measuring Devices.....................................................................................20 8 Measurement, Analysis and Improvement ..........................................................................................21 8.1 General ................................................................................................................................................21 8.2 Monitoring and Measurement ..............................................................................................................21
Issued: June 1998 Revised: 2009-03-12 Term Code: Supersedes: 2009-02-16 Design Control: DT Page 1 of 88

John Deere Standards are intended for use by Deere & Company, its divisions and subsidiaries. Suppliers who rely on them in furnishing products to or for the benefit of the Company must determine that they are in possession of the latest version. Distribution of the standards to parties other than John Deere Suppliers, whether with or without charge, are for information only and Deere & Company disclaims all responsibility for results attributable to the application of or compliance with such standards. The Company makes no representation, express or implied, that conformity ensures compliance with applicable law or other rules or regulations. Further, those who are in receipt of and elect to use the standards, agree to assume the responsibility for compliance with patents, as well as potential patent infringement. Deere & Company Engineering Standards Department, One John Deere Place, Moline, Illinois 61265-8098, U.S.A. Unpublished — All rights reserved under the copyright laws.

JDS-G223

APPROVED FOR SUPPLIER DISTRIBUTION

8.3 Control of Nonconforming Product ......................................................................................................27 8.4 Analysis of Data ...................................................................................................................................28 8.5 Improvement ........................................................................................................................................28 9 Process Control Flow Chart – PDP and Initial Production...................................................................31 10 Production Part Approval Process (PPAP) Requirements ..................................................................32 11 Change Request and Verification Warrant Form.................................................................................33 12 Major Component Reliability Assessment Process and Form.............................................................35 13 Product Verification & Validation Plan – V2 Net Data .........................................................................37 14 Design, Process, and Assembly Review Form....................................................................................40 15 Initial Sample Inspection Report (ISIR) – Dimensional and Material Results......................................43 16 Capability Study Form..........................................................................................................................44 17 Control Plan Checklist and Form .........................................................................................................45 18 Appearance Approval Report ..............................................................................................................48 19 Performance Test Results ...................................................................................................................49 20 Corrective Action Request Form..........................................................................................................50 21 Engineering Deviation Authorization Checklist and Form ...................................................................51 22 Process Evaluation - Continuous Process Monitoring Matrix.............................................................53 23 Six Sigma Conversion Table for Variable Data ...................................................................................57 24 Process Control Methods.....................................................................................................................58 25 Suggested Quality Tools......................................................................................................................59 26 Glossary...............................................................................................................................................61 27 Engineering Standards ........................................................................................................................63 28 Supplier Information Survey ................................................................................................................64 29 Red Flags Supplier Quality System Survey.........................................................................................71 30 Supplier Quality System Audit Questionnaire......................................................................................73 31 Product Engineering Audit Flowchart and Questionnaire....................................................................81 32 Process Verification Audit Questionnaire ............................................................................................85 33 Contact Information..............................................................................................................................87 34 References...........................................................................................................................................87 Summary of Changes from Previous Edition (For Information Only — Not Part of the Standard) ....................................................................................88

2

APPROVED FOR SUPPLIER DISTRIBUTION

JDS-G223

The adoption of a Quality Management system should be a strategic decision of an organization. The design and implementation of an organization’s quality management system is influenced by varying needs, objectives, products, and processes as well as the size of the organization. It is understood that each supplier is on their own continuous improvement path, however, there are certain requirements in this standard that require compliance regardless of the state of the Supplier’s quality system. The requirements identified with a key are very critical. Noncompliance with these requirements put the supplier at the highest risk of violating the Purchase Order Terms and Conditions. The word “shall” when used in this document indicates a mandatory requirement.

1

Vision

Our vision is for all John Deere Suppliers to implement and maintain a quality system that allows them to produce and deliver to John Deere globally competitive products and services clearly seen by our customers as superior in performance and value. Our suppliers shall conduct business with a high degree of integrity and in a socially and environmentally responsible manner in accordance with the John Deere Supplier Code of Conduct, which can be viewed at http://www.deere.com/suppliercode/.

2

Goal

The goal of the John Deere Supplier Quality Manual is to provide a uniform method for all John Deere units to communicate general requirements, expectations, and guidelines to the supply chain. This supports the John Deere Achieving Excellence purposes: continuously measuring supplier performance, rewarding improvements, and recognizing suppliers' outstanding efforts; embracing proactive quality planning as a routine part of doing business; and helping suppliers' continuous improvement efforts.

3

Purpose

The John Deere Supplier Quality Manual has two purposes. First, this manual defines the fundamental quality system activities that John Deere units expect from suppliers and their supply chain to ensure ongoing quality planning, control, and improvement. Secondly, suppliers can use the manual as an aide in further developing their own quality systems. In many sections throughout the manual, instructions can be found not only on what the requirements are, but how to meet the requirements. John Deere’s commitment to integrating suppliers as team members “creates the distinctive John Deere Experience that ultimately propels a great business and, for all with a stake in our success, delivers … PERFORMANCE THAT ENDURES.” This manual is part of that commitment.

4

Quality Management System

John Deere realizes that many suppliers are registered or are currently pursuing registration/compliance to standards audited by third party registrars (such as ISO/TS 16949, Malcolm Baldrige (not a standard), ISO 9001, or one of the various equivalents from other industries, states, or countries). This revision and format of the manual is based on the Quality Systems of ISO/TS 16949:2002 version. John Deere encourages our supply chain to become compliant to the International Automotive Management Standard, ISO/TS 16949. This manual represents the minimum requirement for John Deere. John Deere units may require registration to more stringent standards. Many of the activities referenced in this manual are further explained in the AIAG (Automotive Industry Action Group) manuals, such as Measurement System Analysis (MSA) and Failure Mode and Effects Analysis (FMEA). It is recommended that suppliers obtain copies of the AIAG manuals. John Deere units will continue to move towards the requirements of ISO/TS 16949 and further embrace the philosophies of continuous improvement. Through executing the proper quality planning activities, John Deere and our supply base will be able to install control measures to eliminate the issues that lead to customer dissatisfaction. 3

JDS-G223

APPROVED FOR SUPPLIER DISTRIBUTION

To achieve continuous improvement, John Deere expects our suppliers to embrace a sound quality system and to work with us in a spirit of trust, cooperation, and teamwork. JDS-G223 establishes expectations for quality activities, while recognizing that each John Deere unit has unique customer needs. This manual is not intended to replace a supplier’s existing quality system. Suppliers should perform a self-evaluation to determine where their quality system aligns with this manual, and should also perform an evaluation of their supply chain. As included in the terms and conditions, acceptance of a John Deere purchase order constitutes acceptance of the requirements of this manual. Suppliers should require similar terms and conditions with their supply chain. Suppliers are expected to discuss and understand the specific applicability of these requirements with their John Deere representatives and their applicable supply chain in order to make effective business decisions.

4.1

General Requirements

The supplier shall establish, document, implement, and maintain a quality management system and continually improve its effectiveness in accordance with the requirement of this John Deere Supplier Quality Manual. The supplier shall: Identify the processes needed for the quality management system and its application throughout the organization • Determine the sequence and interaction of these processes • Determine criteria and methods needed to ensure that both the operation and control of these processes are effective • Ensure the availability of resources and information necessary to support the operation and monitoring of these processes • Monitor, measure, and analyze these processes • Implement actions necessary to achieve planned results and continual improvement of these processes. These processes shall be managed by the organization in accordance with the requirements of this John Deere Supplier Quality Manual. • Adhere to the John Deere Supplier Code of Conduct Where an organization chooses to outsource any process that affects product conformity with requirements, the organization shall ensure control over such processes, including control of raw material. Control of such outsourced processes shall be identified within the quality management system. Processes needed for the quality management system referred to should include processes for management activities, provision of resources, product realization, and measurement. •

4.2
4.2.1

Documentation Requirements
General • • • • • Documented statements of a quality policy and quality objectives A Quality Manual Documented procedures as required by this John Deere Standard Documents needed by the organization to ensure the effective planning, operation and control of its processes, and Records required by this John Deere Standard.

The quality management system documentation shall include:

4.2.2

Quality Manual • • • The scope of the quality management system Documented procedures or reference to them A description of the interaction between the processes of the quality management system, such as with a flowchart. 4

The supplier shall have a Quality Manual that is a controlled document and includes the following:

Suppliers can review changes to standards by selecting “What’s New” on the John Deere Standards site listed above or via this URL: https://jdsupply.deere. A supplier shall have a documented procedure for control and distribution of drawings and/or standards. Examples of such records may include. Obsolete drawings shall be destroyed or appropriately identified as such. and to review changes to standards.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 4. but are not limited to: • • • • • • • • • • • • • • • • • • • • • • • • • Measurement Data Design and Process Failure Modes and Effects Analysis Measurement Systems Analysis Data Capability and Statistical Process Control Data Major Process Change Data Production Lot Control Data Verification Warrant and Documents Corrective Action Requests and Responses Gage Calibration and Maintenance Records Gage Repeatability & Reproducibility Analysis Heat Treatment . For specifications referenced within a document.htm 4. Process Audits. These records shall be stored in an environment that protects documents from deterioration and are readily accessible upon request by a John Deere representative.com/business_processes/product_delivery_process/jd_eng_standards/jd_eng_stan dards_index.4 Control of Records All quality records shall be kept for at least three years unless otherwise specified in the supplier’s quality manual and agreed to by John Deere.2.Metalurgical Examination Results and Material Composition Data Initial Sample Inspection Report Quality System Internal Assessments Employee Training Records (kept for term of employment) Destructive and Non-Destructive Testing Data Scrap. and Deviation Records Product Verification & Validation Activity Template . Suppliers shall use the most current standards.htm.com/business_processes/product_delivery_process/jd_eng_standards/whats_new/ whats_new. the supplier shall notify John Deere by furnishing a Change Request and gain approval via a Verification Warrant.2.3 Control of Documents A supplier shall establish and maintain documented procedures to control all documents and data of external origin such as standards and customer drawings. It is also expected that the supply chain’s records pertaining to John Deere product shall be retained in the same manner. (See Section 7. a supplier shall have currently released editions of these documents available at all appropriate manufacturing locations. and Corrective Actions Appearance Approval Report – (See Section 18) Production Part Approval Documents Design Review and Design Analysis documents Risk Assessments 5 .deere.3) John Deere Standards are available through JD Supply Network at: https://jdsupply. Reclaim. to understand them.(See Template in Section 13) Functional and Performance (Laboratory and Field) Test Data Quality Plans or Control Plans for Parts and Assemblies (most recent plan only) Quality Rejections and Disposition Records Quality System Audits.2. When John Deere is using a supplier-controlled drawing and this drawing is changed.

and long-range goals/metrics. Quality Improvement • Formulate continuous improvement policy. Needs and expectations of John Deere include conformance to design and performance specifications.JDS-G223 5 Management Responsibility APPROVED FOR SUPPLIER DISTRIBUTION Top management is required to take an active role in the quality management system. and fulfilled with the aim of achieving customer satisfaction. 6 . Quality Planning • Develop and maintain quality policies. • Monitor cost of quality. Top management shall provide documented evidence of its commitment to the development and improvement of the quality management system by: • • • • Communicating to the organization the importance of meeting customer as well as regulatory and legal requirements Establishing the quality policy and objectives Conducting regularly scheduled management reviews of the quality system and execution Ensuring the availability of necessary resources. A sound quality system shall be structured after a proven methodology such as ISO 9001.1 Management Commitment A supplier to John Deere shall demonstrate a top management commitment to continuous improvement. cost management. • Support product-feature and manufacturing-process development. and technical support. Each business process should detail the roles of management. converted into requirements. 5. or the European Foundation for Quality Management. Quality Control • Assure systems adequacy . 5. and quality improvement. • Implement mistake-proofing techniques. • Develop and maintain training procedures. • Support supplier development strategies. quality control. • Develop and maintain change notification procedures. • Communicate corrective action to customers. • Create an environment for quality and process control by individual workers through procedures and job instructions documentation. • Create information feedback loops. wavelength. delivery. • Provide recognition. This commitment shall address the managerial processes of quality planning. reliability. • Develop and maintain short. the Deming award.develop a Quality Control Manual. • Adhere to problem containment and traceability procedures. • Develop and maintain Quality Plans and Control Plans. • Provide resources and training. • Create continuous improvement teams to complete projects and solve problems using structured problem-solving processes. • Identify projects to resolve current problems. • Determine customers and their needs. • Develop and maintain gage calibration system. • Integrate controls in problem solutions.2 Customer Focus Top management shall ensure that customer needs and expectations are determined. the Malcolm Baldrige Criteria for Performance Excellence. ISO/TS 16949.

Authority and Communication Responsibility and Authority A quality management system shall be implemented in order to provide confidence that the organization can satisfy the needs of its customers. Includes a commitment to meeting customer requirements and to continuous improvement. culture. to assist corrective action activities. and other continuous improvement methods and activities. equipment. The system should be consistent with the size. • Basic statistical concepts identifying and improving variation and control. • Inspector and operator training programs in the use of control plans and care of measurement and test equipment. 5. This long-term quality plan shall include. PPAP (Production Part Approval Process). and to provide timely reporting to John Deere. Quality Training • Quality planning processes and tools • Root cause determination. Quality Information Systems • Integration of computers to statistically analyze data. and.3 Quality Policy • • • • • Is appropriate to the purpose of the organization. and team involvement. 2. such as: APQP (Advanced Product Quality Planning). and for approval of new tooling.5. • Installation of inspection equipment and gaging to provide improved monitoring of manufacturing processes and quality data collection 4.4 Planning Top management shall ensure that quality objectives are established for the appropriate functions and levels. A copy of a long-term quality improvement program shall be available for review by John Deere personnel. Top management shall endorse a written quality policy that: 5. Control Plan Checklist and Form (See Section 11). A supplier shall show evidence of a quality policy emphasizing continuous quality improvement driven by top management through preventive and corrective action. Is reviewed for continued appropriateness. Provides a framework for establishing and reviewing quality objectives. and program development.1 Responsibility. Improvement activities should be based around these trends. • Assembly team or cell-unit manufacturing concepts • Training aids for set-up and operation of equipment • Preventive maintenance programs 3. mistake proofing. Is communicated and understood at appropriate levels in the organization. The quality objectives shall be measurable and consistent with the supplier’s quality policy. Quality Budgeting • Budget planning for quality and plant improvements such as training. but is not limited to: 1. 7 .5 5.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 5. and products of the organization. John Deere expects the supplier to have a structured quality planning process. Management shall define specific quality indicators (metrics) and have a system in place to track them and monitor for trends. Manufacturing and Tooling Improvements • Capability studies and capability objectives for current and new processes. • A quality plan to shift resources spent on appraisal and correcting internal and external failures to defect prevention.

Follow-up actions from earlier management reviews. The results of the audits shall be documented and retained for at least three years.6. Changes that could affect the quality management system. Process performance and product conformance. Subsequent audits shall include verification of corrective actions.1 Management Review Management Review .3 Internal Communication The organization shall ensure that communication takes place between its various levels and functions regarding the processes of the quality management system and their effectiveness. control. employees shall be provided with the equipment. This communication may take the form of team meetings. 8 . Customer feedback (such as Achieving Excellence and warranty). 5.General The supplier’s management shall use internal audits to evaluate the degree of compliance and effectiveness of the quality system. Status of preventive and corrective actions. or other techniques.3 Audit results and schedule. publications. or work experience and be knowledgeable of appropriate quality tools and processes that affect the quality of products and services provided to John Deere. Review Output The outputs from a management review shall include supporting and leading actions addressing deficiencies relating to: • • • Improvement of the system and its processes.6. facilities and a work environment conducive to producing high quality products and services that consistently meet functional requirements and product specifications and provide genuine value to John Deere and our customers. electronic media. Improvement of product related to customer satisfaction. The supplier shall have internal auditors who are qualified to audit the requirements of this John Deere Supplier Quality Manual.2 Review Input Inputs to management review shall include current performance and improvement opportunities related to: • • • • • • 5. bulletin boards.5. Resource needs. A formal corrective action process (See Section 8. 5.2 Management Representative APPROVED FOR SUPPLIER DISTRIBUTION Top management shall appoint member(s) of management who shall have responsibility and authority for planning. training. Further. 5. execution.JDS-G223 5. The supplier shall have a documented program to perform internal audits. 6 6.2) that includes root cause determination shall be used to correct deficiencies.1 Resource Management Provision of Resources Employees shall be qualified for the job they perform through education. These audit records shall be made available to John Deere personnel for review upon request. and improvement of quality-related activities.5. Trained personnel that are independent of the area being audited shall perform the audits.6 5.6.5.

1 Product Realization . resources. The resource management plan shall also include the evaluation of the skill level of employees to determine their understanding of quality tools and processes and their ability to apply these tools relevant to their job. and documentation. software.Enterprise Product Delivery Process Planning of Product Realization • • • The quality objectives for the product or service. workspace. An effective and structured product realization planning process shall result in the determination of: John Deere’s product realization process is called the Enterprise Product Delivery Process or EPDP.3 Infrastructure A supplier shall provide and maintain facilities. 6. including Portfolio Management Process (PMP) Gates and EPDP Leadership Gates. The need to develop specific processes. and support services to achieve conformity to product specifications and functional requirements. 7 7.com/supplier_training/supplier_training. facilities. The resource management plan shall provide for the evaluation of the resources needed to implement and improve the processes of the quality management system and customer satisfaction. (See Section 25). The EPDP consists of six phases containing twentyone milestones. It is the sequence of processes required to successfully produce a product or service that meets or exceeds the expectations of John Deere and our customers.4 Work Environment A supplier shall provide a work environment that supports quality objectives by identifying and managing human and physical factors that affect the quality of products and services provided to John Deere. (Contact your John Deere Supply Management representative for availability of classes. and Verification and validation activities and the criteria for acceptability. John Deere classes for Supplier Quality Manual.2 Human Resources A supplier shall provide a system of ongoing monitoring of each employee’s education. equipment.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 A Supplier shall develop a quality management system and resource management plan that demonstrates a commitment to continuous improvement as described in Section 4 of this manual. John Deere Standards. 9 . training and work experience and provide opportunities for training and continuing education to improve employee’s skill level. Authority For Expenditure (AFE) approval is granted in EPDP Gate 6.htm 6. 6.) The training shall provide employees with an awareness of the relevance and importance of their activities and how they contribute to the achievement of quality objectives in the business plan. hardware. The following chart identifies the milestones.deere. and Enterprise Product Delivery Process Supply Chain Integration are available at this URL: https://jdsupply.

10 . If there is a tooling or process difference between the actual parts used on the pre-production build versus the tooling or process for the production build.1.2. Parts shall be production intent for physical builds (including those in EPDP Phase 4). and should be produced using production tooling in a production process. and electronic build events for the purpose of collaboratively planning for product realization and preventing problems during physical builds. Suppliers shall participate in Advanced Product Quality Planning activities. Key characteristics (See Section 7. FMEAs. such as Design Reviews. After successful completion of the final phase of EPDP (Phase 6). Quality planning activities shall be completed for first physical builds. and updated for subsequent physical builds.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION 7.1 Advanced Product Quality Planning EPDP includes Advanced Product Quality Planning.3 Confidentiality The organization shall ensure the confidentiality of customer-contracted products and projects under development. the Order Fulfillment Process will be followed. unless approved by the John Deere representative. 7.2 Acceptance Criteria Acceptance criteria is approved by John Deere. 7. The Order Fulfillment Process (OFP) at John Deere is a global process that is designed to deliver the right product at the right place at the right time.1) are identified and recorded during the early stages of design and communicated to suppliers. there shall be evidence of conformance to the specification and risk mitigation.1.1. Quality planning steps shall be repeated for parts that are supplied not using production tooling and processes.1. and related product information. It begins with an estimate of retail sales and ends with the retail delivery and payment. where required.

5.2 7. 11 . product specification and/or assembly specification.Product and Process. Action items shall be documented and tracked. control plans. Product Key Characteristics shall be documented on the Control Plan. quality engineering. Process key characteristics are those characteristics of a process that significantly impact customer satisfaction and that require extra control. and complexity. Process. 7. supplier representatives. changes to suppliers and processes. or with the use of telephone and electronic communication. Each category affects a part or component's overall risk to John Deere. Product key characteristics are those characteristics of a part whose variation within the design tolerance and/or specification can affect customer satisfaction. DPARs may be conducted in person. assemblies. and capability studies to manage variation and targeting to ensure that the product is within tolerance and/or specification. Documentation of DPAR events shall be maintained. Quality Plan Levels range from 0 to 4. Gage R&R. and any other personnel necessary to evaluate a supplier’s capability to meet product or service requirements. and preventive process for managing risks associated with new or revised parts.2. see (See Section 7. the drawing/model. Multiple DPARs may be required for multiple physical builds. depending on the magnitude of change from one build to the next. and Assembly Review (DPAR). the supplier shall form a team to conduct these reviews with their supply chain. PLQP provides a consistent. fulfill their intended purposes. Examples of the items covered during this meeting are shown in the Design. There are two types of Key Characteristics . The selected measurable characteristics require extra control. Product key characteristics on older prints may have been depicted through the use of a special symbol such as ) or . or manufacturability and ability to assemble.2. Parts or subsystems may be grouped together in a DPAR. Process Key Characteristics can exist without corresponding Product Key Characteristics. One of the activities that can be required is the Design. and Assembly Review Checklist (See Section 14).1). such as Process FMEA. and/or assembly specifications. and changes to existing products or processes. Process. ability to perform its intended design requirements (form. Production Part Approval Process (PPAP) requirements shall be clearly understood as an output of the DPAR. function. Based on the Quality Plan Level. A structured process shall be used to identify Key Characteristics and corresponding controls. The Quality Plan Level (QPL) is a measure of part risk based on three categories: cost. Process Key Characteristics shall be documented on the Control Plan.1 Customer-Designated Special Requirements A Key Characteristic is a product or process characteristic whose variation or targeting control is necessary to meet customer requirements and that directly or significantly impact customer satisfaction through compliance with government. the required quality activities are identified. model. and are not designated by a special symbol. At John Deere the Part Level Quality Planning (PLQP) activities help ensure that new products or processes. appearance). The teams should include supply management. statistical process monitoring. severity. The PPAP requirements shall be documented on a Verification Warrant Form (See Section 11). with 4 representing the greatest risk.1. No deviations are allowed for out-of-tolerance and/or out-of-specification product key characteristics. A DPAR is a meeting which confirms all expectations of the products or services prior to a physical build. John Deere teams initiate this review as early as possible before tooling release. Where the supplier maintains design control of the product. Product key characteristics shall be identified by the symbol <KC> on a drawing. reliability. Documentation of DPAR events shall be maintained by the design control entity.1 Customer-Related Processes Determination of Requirements Related to the Product Specific quality planning activities are required for every new or revised part or process. country or industry standards and/or regulations. design engineering. The PPAP requirements correlated to the QPL are in Section 10.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 7. structured. fit. For minimum process capability on key characteristics.

2..3). contract amendments. From this meeting the supplier should acquire all of the information required to clearly understand John Deere requirements. (See Section 8. and their supply chain capabilities and requirements should be reviewed during the DPAR. The supplier should be prepared to address questions in this meeting and respond back to any unanswered questions on the date specified during the meeting. and customer feedback.2.1. and historical information. Refer to Preventive Action. handling. and PFMEA Review the supplier’s supply chain capabilities and requirements Clarify requirements for capability assessment and gage studies on key characteristics. Where product requirements are changed.5. The supplier shall provide John Deere a Process Failure Modes and Effects Analysis (PFMEA) for each component with one or more key characteristics prior to the end of Phase 3 of the Enterprise Product Delivery Process shown in Section 7.JDS-G223 7. If key characteristics are not identified directly on the drawing. delivery schedules. contracts or order handling. process capabilities. the supplier shall ensure that relevant documentation is revised appropriately. The supplier shall communicate to John Deere any changes that may affect the data documented in this review. packaging. FMEAs.2 APPROVED FOR SUPPLIER DISTRIBUTION Review of Requirements Related to the Product Key characteristics for the product and processes are confirmed in the DPAR using information from Design Reviews.g. PFMEA. Identify and assign preventive action for potential problems in manufacturing or procurement Discuss product or service order quantities. It is during this review that the supplier should ask for clarification on any unclear issue. The supplier’s processes.1). (See Customer Notification and Submission Requirements Table 1 and Table 2. and product or service cost Mistake-proof the design and manufacturing processes.3 Customer Communication The supplier shall identify and implement a communication plan with John Deere and with their supply chain relating to product or service information. asbestos or lead in paint) and/or other substances restricted by applicable laws (See Section 7. to ensure a low probability of error Identify or evaluate potential cost reduction or value improvement opportunities Review obligations related to product. product preservation. 7. The supplier shall also ensure that personnel involved in the realization of the product or service are made aware of the changed requirements. plus other characteristics that are identified by John Deere Clarify supplier responsibility for PPAP requirements (communicate formally via Verification Warrant Form (See Section 11).) 12 .4. including environmental. process capabilities. Effective reviews require supplier participation. regulatory and legal requirements Review dimensional featuring according to functional requirements Review the Bill of Materials (BOM) for accuracy Review service requirements Determine material products shall not contain any substances in excess of the amounts set forth on John Deere’s Restricted Materials List (e. Purposes of the DPAR are: • • • • • • • • • • • • • • • • • • Confirm the product and process Key Characteristics Discuss applicable John Deere requirements and John Deere Standards Identify revisions to the print or process necessary to manufacture or procure the product or service to specifications Review the quality plan level Ensure understanding of the part function and the manufacturing process Review the supplier’s processes. they may be documented in the DPAR Checklist (See Section 14). including assembly. product or process changes.1.

or appearance per the following requirements listed in Table 1. may make that decision. Alternate materials shall appear on the drawing. and fully conversant with the relevant John Deere specifications. mill certifications). steel mill. other construction as documented on a deviation (permit) or included as a note on the design record and not covered by an engineering change. but have been verified as fully meeting the design intent and can be used interchangeably. 2. The purpose of the next three paragraphs is to clarify the determination of an equivalent or alternate material and the process for notification and approval. Production from new or modified tools (except perishable tools). Refurbishment means the reconstruction and/or modification of a tool or machine or to increase the capacity.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Material Control and Communication The manufacture of equipment and components. fit. based on a worldwide design. in their full range of variation. has significant material specification challenges. foundry. Processing areas like heat treatment. Refer to Engineering Deviation Authorization Checklist and Form (See Section 18). and are taken from AIAG Production Part Approval Process Manual (See Section 34. Use of other construction or material than was used in the previously approved part or product. This requirement only applies to tools. An equivalent material is one whose specifications. Incorrect material substitutions can result in product failures. molds. such as standard measuring devices. etc. able to provide supporting documentation (e. Table 1 — Planned Changes Requiring Notification Prior to Implementation Requirement 1. the manufacturing process should not require revision. or change its existing function. Clarification or examples For example. Any questions relating to the equivalence of two materials should be directed to a qualified John Deere materials engineer. Production following refurbishment or rearrangement of existing tooling or equipment. form. forming. dies. function. etc.deere. An alternate material is one whose specifications do not fully meet those of the drawing-specified material. John Deere may subsequently elect to require a submission for PPAP approval. 3. meet those of the drawing-specified material. 13 . Materials that are commonly available in one geographical region may be difficult or excessively costly to obtain in another.g. in writing. Ford. Determination that a material is equivalent requires a careful evaluation of all related specifications and characteristics. drivers (manual or power). This review shall only be performed by individuals who are well versed in those particular materials. CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS Customer Notification A supplier shall request approval from John Deere before making changes to a specification or process for supplied products or services for any change that may impact safety. performance. and welding will likely show the greatest differences when utilizing alternate materials. including additional or replacement tooling. only the primary material producer (e. which due to their unique form or function can be expected to influence the integrity of the final product. They are reprinted from the PPAP Manual with permission of Chrysler LLC.com/sc) by selecting Change Request from the Quality Menu for JDSN Collaboration. qualified to make that evaluation.. It is not meant to describe standard tools (new or repaired). Alternate materials will likely require changes to the manufacturing processes utilized to make or process parts. Unless specifically authorized by the appropriate John Deere representative. bending. Reference 12). warehouse). Either a print change or a temporary deviation to allow the alternate material is required.g. patterns. durability. If material is equivalent. The subtleties of detail within the John Deere Material (JDM) specifications requires specialist training to interpret. performance. The following tables specify when notification is required. The supplier shall notify the responsible John Deere design unit of any design or process changes as indicated in the table below via Change Request on JD Supply Network (https://jdsn-collab. and GM Supplier Quality Requirements Task Force.

durability. ingredient levels) of the 14 . performance. e. a customer may specify certain PPAP requirements for service parts. The only exception is when the part has low volume.: heat-treating. Product and process changes related to components of the production product manufactured internally or manufactured by suppliers that impact safety. or services (e. durability. function. Any change that affects customer requirements for safety.g. 5. Change in product appearance attributes where there is not appearance specification. plating) that affect customer fit. form. durability. performance. 8. performance. These changes would normally be expected to have an effect on the performance of the product. 6. includes packaging). Production process tooling and/or equipment transferred between buildings or facilities in one or more locations. fit. These changes can be made without customer approval unless the process flow is changed as a result of this adjustment. function. durability. Product produced after the tooling has been inactive for volume production for twelve months or more. Change of supplier for parts. For product that has been produced after tooling has been inactive for twelve months or more: Notification is required when the part has had no active purchase order and the existing tooling has been inactive for volume production for twelve months or more. form. or performance requirements. fit. service or specialty vehicles. or performance requirements. Rearrangement is defined as activity which changes the sequence of product/process flow from that documented in the process flow diagram (including the addition of a new process). 4. Minor adjustments of production equipment may be required to meet safety requirements such as. function. For bulk materials only: New source of raw material with special characteristics from new or existing subcontractor. form. etc. and/or appearance requirements should be part of John Deere specifications as agreed on during reviews. etc. repair or replacement of parts. form. Change outside of DFMEA (product composition. Revised parameters in the same process (outside PFMEA parameters of the approved product.g. Suppliers are responsible for approval of subcontracted material and services that do not affect customer fit. function.. and/or appearance of the salable product. durability. the supplier shall concur with any requests by a subcontractor before submission to the customer. nonequivalent materials. fit. form. elimination of potential Electro Static Discharge risks. However.JDS-G223 Requirement APPROVED FOR SUPPLIER DISTRIBUTION Clarification or examples This is not meant to be confused with normal maintenance. and/or appearance requires notification to the customer. Additionally. Note: The safety. painting. function. 7. installation of protective covers. Production from tooling and equipment transferred to a different plant location or from an additional plant location. for which no change in performance is to be expected and post repair verification methods have been established.

Engineering change to design records.5. performance. For Bulk Materials only: Process technology new to the supplier. or materials for production product/part number(s). material. 2. not previously used for this product. supplier should have evidence that the new method provides results equivalent to the old method. Changes in any of the above situations (Table 1 and Table 2) require appropriate quality planning and written request (using JDSN Collaboration or Change Request Form) with acceptance to proceed from John Deere prior to implementation.g. specifications or materials. Correction of a discrepancy on a previously submitted part.2) The supplier shall ensure that proper notifications of changes by their supply chain are communicated as well. 4. Submission to Customer For change in test method. suffix) product/part number assigned to it. including material. Submission is required to correct any discrepancies on a previously submitted part. Table 2 — Changes Requiring PPAP Approval Prior to First Production Shipment Requirement 1. Conditional Approval may be granted to authorize limited production shipments when there are outstanding PPAP requirements. specifications. as necessary. See Change Request and Verification Warrant (See Section 11) for additional change request information. PPAP approval is required prior to shipping parts. engineering validation issues Submission is required on any engineering change to production product/part design records.e. Change in test/inspection method – new technique (no effect on acceptance criteria). or color not previously supplied to the specific customer). 3. Clarification or examples Submission is required for a new product (initial release) or a previously approved product which has a new or revised (e. A new part of product (i. The supplier shall obtain PPAP approval prior to the first production shipment in the following situations unless the responsible product approval activity has waived this requirement (see Table 2). 9. all applicable items in the PPAP file to reflect the production process. The PPAP file shall contain the name of the responsible customer product approval activity person granting the waiver and the date. a specific part. 15 .APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Clarification or examples Requirement approved product. A new part/product or material added to a family may use appropriate PPAP documentation from a previously fully approved part within the same product family. The supplier shall review and update. (See Section 7. regardless of whether or not the customer requests a formal submission. A “discrepancy” can be related to: • The product performance against the customer requirement • Dimensional or capability issues • Subcontractor issues • Full approval of a part replacing an interim approval • Testing.

Design Reviews take place earlier than the DPAR in the Enterprise Product Delivery Process. When design control of the product resides with the supplier. anticipated applications. and key performance characteristics. existing and potential failure modes. or supplier testing may be used to validate designs.1 APPROVED FOR SUPPLIER DISTRIBUTION Design and Development Design and Development Planning Design Reviews shall be conducted periodically as the product or process is designed. Design reviews may be conducted at various stages of the design and development process to accomplish the outputs listed below and to periodically review the ability of the supply chain to fulfill requirements. field. regulations.3. standards. then later when more detail is available. and methods of. and work with John Deere in correcting these problems. The review is documented and corrective action plans are developed and validated for any problems identified. the supplier shall participate in design reviews. and materials engineering. including key characteristics plus other characteristics that are identified by John Deere Determination of applicable regulatory and legal requirements Identification of applicable information derived from previous similar designs Identification of product or service acceptance criteria Definition of the characteristics of the product that are essential for safe and proper use Special packaging requirements for proper delivery to the customer Design and Development Inputs Design verification and validation plans are developed to ensure that the product design shall meet the objectives for performance and reliability that have been established resulting in a product that meets or exceeds defined customer needs. reliability engineering. Tools.3 7. product support. assist in the identification of potential problems. quality engineering. product verification and validation. environmental conditions. Typical areas for discussion are designs. Laboratory. supply management. communication at each stage in the design and development process Functional and performance requirements of the product or service Identification of criteria for acceptability. assembly techniques. 16 . Important outputs of the design review process are: • • • • • • • • • • • 7. The PV&V plan should consider component functionality and durability. customer. first to identify how the design will work and how the various subsystems will work together. as appropriate. and personal hazards. the supplier shall conduct such reviews and include representation from their supply chain and John Deere. When requested. The completed form shall be returned to John Deere so the data can be imported into the John Deere V2 Net System for documentation and tracking purposes. Design reviews are typically conducted with John Deere and supplier team members from areas such as: product engineering. Product verification and validation plans and results shall be documented using a spreadsheet template provided by the John Deere representative from the John Deere V2 Net System. customer expectations. manufacturing processes. software function. marketing.JDS-G223 7. John Deere and the supplier jointly develop the Product Verification and Validation (PV&V) plan. Refer to Product Verification & Validation Plan – V2 Net Data (See Section 13). are used to identify problems and are used in an iterative fashion with Design Reviews. interfaces with other system components and controls.3. such as Failure Mode and Effects Analysis.2 Identification of the design and development processes Identification of the verification and validation activities appropriate for each design and development stage Identification of responsibilities and authorities for each of the design and development stages Determination of the requirements for. Suppliers shall provide technical leadership for their product.

the supplier shall complete and submit the Component Performance & Reliability Assurance Form to John Deere.4 Design and Development Review At suitable stages. or others that are routinely conducted for the supplied product. 17 . If requested. b) provide appropriate information for purchasing. the supplier shall provide statistical evidence that the component goal is met. a) to evaluate the ability of the results of design and development to meet requirements. Records of the reviews and any necessary actions shall be maintained. In this case.5 Design and Development Verification Verification shall be performed in accordance with planned arrangements (See Section 7. To achieve component reliability.3. Records of the results of the verification and any necessary actions shall be maintained (See Section 4. 7.3. This assessment is normally done as part of a Supplier Quality System Audit (See Section 30). John Deere may provide suppliers a component reliability goal. 7. the supplier shall assist in conducting the PV&V activities either at John Deere or the supplier’s facility.4).3 Design and Development Outputs The output of design and development shall be provided in a form that enables verification against the design and development input and shall be approved prior to release. 7.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 If requested. Higher component reliability is vital to improved profitability and customer satisfaction. Whenever practical. Design and development outputs shall. DIN. ISO. where known. validation shall be completed prior to the delivery or implementation of the product.3.3. a) meet the input requirements for design and development.2. The Major Component Reliability Assessment Process (See Section 12) shall be used when directed by John Deere. including reliability. The Major Component Reliability Assessment Process assures component reliability goals are set and plans are created and executed to validate and demonstrate the ability to meet the goals. production and for service provision. Participants in such reviews shall include representatives of functions concerned with the design and development stage(s) being reviewed. A reliable machine starts with reliable components. (See Section 12) The supplier and John Deere shall sign this form when the component meets or exceeds its requirement(s).1) to ensure that the resulting product is capable of meeting the requirements for the specified application or intended use.4).3. and d) specify the characteristics of the product that are essential for its safe and proper use. c) contain or reference product acceptance criteria.2.1) to ensure that the design and development outputs have met the design and development input requirements.1) when the supplier has design control of a new component or when there are plans to use an existing component in a more severe application. 7. Typically. systematic reviews of design and development shall be performed in accordance with planned arrangement.2. Also. This form should be signed before any components are provided for a John Deere physical build of machines for field durability testing. Records of the results of validation and any necessary actions shall be maintained (See Section 4.6 Design and Development Validation Design and development validation shall be performed in accordance with planned arrangements (See Section 7. The supplier shall understand appropriate engineering standards (See Section 27). and b) to identify any problems and purpose necessary actions. ASTM.3. John Deere may conduct a Product Engineering Assessment (See Section 31) for components with Quality Plan Levels ≥ 3 when the supplier has component or subsystem design control. the process will be used for components with a Quality Plan Level ≥ 3 (See Section 7. The supplier shall provide information about standardized tests such as SAE.

18 .. or utilize the manufacturing process. asbestos or lead in paint) and/or other substances restricted by applicable laws. A supplier shall have a documented system to properly select suppliers with the capability to meet this standard and other applicable John Deere Standards. The initial supplier selection process for providers of products or services for John Deere shall include an on-site assessment.3). communicated and controlled. Assessments shall determine the supply chain’s capability to meet the requirements of this standard (JDS-G223).3. and John Deere notification prior to implementation. 7. Through discussion and physical testing verify that supplied products do not contain substances in excess of the amounts set forth on John Deere’s Restricted Materials List (e. The supplier shall be properly licensed by the holder of the patent or copyright to produce or utilize the manufacturing process. or other means. Suppliers shall monitor their supply chain’s performance. or that it is properly licensed to use the requisite Intellectual Property Rights. the supplier shall take appropriate measures to communicate all their proposed changes and their supply chain proposed changes. see Customer Communication (See Section 7. or any process change by the supply chain that produces the John Deere product.g. A change in the supply chain. The supplier shall evaluate the effect of any proposed changes to all constituent parts and completed products. The Restricted Materials List ia located on the John Deere Supply Network. 7.2. the Company desires to purchase. Process. A supplier shall have a communication plan to notify their supply chain of the latest specifications and to verify the product on an ongoing basis.1 Purchasing Purchasing Process As a primary supplier to John Deere. The duration of the requisite Intellectual Property shall be sufficient to cover the term of the proposed supply agreement. as determined jointly by John Deere and the supplier.4. it may be appropriate for the supplier to have their supplier(s) participate in John Deere initiated Design. and Assembly Reviews and other quality activities. lab or field-testing. John Deere units require documented approval before implementation (See Section 7. The Intellectual Property rights are effective and legally enforceable in the country where the supplier will produce the product or utilize the manufacturing process.JDS-G223 7.1 Regulatory Conformity The supplier shall own the patent or copyright that allows it to lawfully manufacture the product. documented. and the documentation to substantiate that its Intellectual Property Rights are effective in the country where it will produce or utilize the manufacturing process. The results of the review of changes and subsequent follow-up actions shall be documented.4. At times. failure modes and effects analysis. In cases where design control resides with the supplier. requires appropriate quality planning. The supplier shall identify any third party Intellectual Property Rights that could interfere with the proposed supply agreement.3). This may be accomplished through a design review. the supplier is responsible for the quality of the products and services provided by their supply chain.1. The changes shall be approved by John Deere prior to implementation.2. The supplier shall have documentation to substantiate that it owns the requisite Intellectual Property rights.7 APPROVED FOR SUPPLIER DISTRIBUTION Control of Design and Development Changes Changes to the design of a product or service shall be identified. via the Change Request and Verification Warrant to John Deere. The requirements of this document should be extended to the supplier’s supply chain.4 7.

2 Purchasing Information Purchasing documents of John Deere suppliers shall contain information describing the requirements for approval of the product and the qualification of the procedures. heat treatment. Minimum process capability for a key characteristic is a Ppk >1.4. processes. Approval is required prior to shipping production parts. Higher process capability requirements may be specified by the John Deere representative. specifications. Production Part Approval Process) • • • • • Qualification of processes Qualification of equipment and personnel Use of defined methodologies and procedures Requirements for records Re-validation After PPAP documents have been submitted. inspection and test instructions. Examples of process control documents are process sheets. Documentation shall be provided to assure quality of products at initial production and is used to maintain ongoing acceptable quality levels. Conditional Approval may be granted to authorize limited production shipments when there are outstanding PPAP requirements. including a control plan. test procedures. process and product key characteristics identified during Design Reviews. The primary supplier to John Deere is fully responsible for the quality of the products and services they provide. unless otherwise agreed to by John Deere. Validation shall demonstrate the ability of the processes to achieve planned results.1 Production and Service Provision Control of Production and Service Provision Process control is needed to ensure that the manufacturing process is performed under stable conditions.2 Validation of Processes for Production and Service Provision The Supplier shall validate any special process for production and service where the resulting output cannot be verified by subsequent monitoring or measurement. Process control documentation or control plans shall be available for review by John Deere. including that of the supplier’s supply chain. The key processing parameters.5 7. 19 . Process control documents shall be in place prior to initial production and be readily available to the employees responsible for the operation of the process. 7. and coating. 7.33 or Cpk >1. standard operating procedures. The supplier shall define arrangements for validation that shall include the following. and DPARs shall be addressed in the process control documents. refer to Process Evaluation (See Section 22).33. FMEA’s.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 7. as applicable: (See Section 20). EPDP Phase 5. plating. John Deere reviews the submissions and approves or rejects the Verification Warrant (See Section 11).5. PPAP requirements shall be completed prior to full production. This includes any processes where deficiencies may become apparent only after the product is in use or the service has been delivered.4. 7. and specific part control plans. If minimum process capability for a key characteristic has not been demonstrated the Continuous Process Monitoring Matrix shall be used to determine required activities.3 Verification of Purchased Product Verification of purchased product shall be conducted using a documented quality assessment methodology.5. equipment and personnel necessary to produce the product. Examples of special processes are welding. preventive maintenance instructions.

20 . who shall provide a gage drawing with the gage for the supplier’s records. and maintenance of measuring. and measuring equipment / fixtures owned by John Deere are covered under this section. and replacement of nonconforming gages. tooling. test fixtures. and specific lots of material. packaging. repair. Traceability allows for parts to be matched to a certain time frame. Should a problem arise. with three or more operators. This shall include identification. inspection. damaged or otherwise found to be unsuitable for use shall be recorded and reported to John Deere. Occurrence of any John Deere property that is lost. 7.6 Control of Monitoring and Measuring Devices Gaging Selection In selecting measuring equipment. the supplier shall notify John Deere of the suspect parts. The personnel who will be using the measuring instrument in production should always conduct the Gage R&R study. while it is under the supplier's control or being used by the supplier. and test machines to a supplier. (See Section 27). After the receipt of John Deere gages. The measuring equipment selected should have a discrimination of less than one-tenth of the total product tolerance being measured. Whenever a gage is found out of calibration and it has been used to verify parts for John Deere.5. John Deere is concerned with the capability of the measurement system to detect and indicate even small changes of the measured characteristic. and safeguard them against adjustments that would invalidate the calibration. a supplier shall calibrate. including intellectual property. 7.5. This also applies to the constituent parts of a product. 7. A supplier shall calibrate these devices at consistent periodic intervals against applicable standards with known traceability. product can be contained and corrective action initiated. storage. handling. processes.5. Processing equipment.3 Identification and Traceability APPROVED FOR SUPPLIER DISTRIBUTION A supplier shall establish and maintain documented procedures for product identification. Refer to Engineering Standards.JDS-G223 7. For certain applications John Deere will send gages. and protection. control. Preparation and Packaging of Service Parts. The supplier shall identify. Service parts shall be prepared in accordance with John Deere Standard JDV-9. Gage Repeatability and Reproducibility A gage repeatability and reproducibility (R&R) study measures the total repeatability and reproducibility of a gage system as a percentage of the total specification. and test equipment used to assure that products and processes conform to applicable requirements.4 Customer Property The supplier shall exercise care with all John Deere property. John Deere recommends that Gage R&R studies be performed whenever production personnel using the measuring instrument are changed. A supplier shall review gages to assure proper function and application. protect and maintain John Deere property provided for use or incorporation into product. The method for performing the Gage R&R study is either the Range Method or the ANOVA method. The supplier shall have product traceability to the extent required so that if a discrepancy is found. John Deere and the suppliers shall identify suspect parts. verify. Calibration A supplier shall establish and maintain documented procedures for the calibration. They remain the property of John Deere. Identification is a process to identify product during all stages of production.5 Preservation of Product The supplier shall preserve conformity of product with customer requirements during internal processing and delivery to the intended destination.

If the supplier uses a gage with a total variation greater than 30 percent.2 Internal Audit Suppliers shall conduct their own internal audits per Section 5. This type of equipment shall be identified in the calibration program and verified at a specified frequency using traceable standards. Trends in customer satisfaction performance should be reviewed and improvement activities developed around the data.2. 8 8. a repeatability and reproducibility analysis shall be conducted utilizing specific part programs on all key characteristics plus other characteristics that are identified by John Deere. and implement measurements where processes affect the quality of products or services John Deere receives. unless the study uses an industry-approved methodology such as found in Concepts for R&R Studies (See Section 34. This metric shall be included in the management review process. the supplier shall take corrective action to make the gage measurements repeatable and reproducible. 21 . John Deere shall be contacted for approval. Management Review – General. plan. These statistical tools are not only used on processes and products. Gage R&R studies are required for each unique variable gage used to monitor key product or process characteristics. Analysis and Improvement General Measurement. A supplier shall define. Some types of equipment. the gaging system is acceptable for use. Studies on families of gages or equipment are not acceptable.2. Reference 4). 8. and monitor longterm performance levels. and using performance metrics in processes and products critical to John Deere.1 Measurement. defining.6.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Gage R&R studies apply to variable gages. drive continuous improvement activities. such as flow meters and hardness testers do not lend themselves to Measuring System Analysis. If the total variation of the repeatability and reproducibility of the gage system (gage and operator) is less than 30 percent of the total tolerance range. Attribute gages (such as ring or plug gages) do not require gage R&R studies unless otherwise specified by John Deere. Total variation is the ratio of the uncertainty of the repeatability and reproducibility of the gaging system to the tolerance range of the characteristic to be measured. but also measure customer satisfaction and supply chain performance.2 8. If the gage system fails. Customer satisfaction improvement activities should utilize a structured process improvement technique. These performance metrics are used to determine the current level of performance. Critical to the use of these performance metrics are statistical tools. For non-dedicated gages such as coordinate measuring machines. Suppliers shall use this data to drive improvements in John Deere’s satisfaction metrics. John Deere will use the Achieving Excellence process (and its associated metrics) and warranty data to measure our satisfaction with the supplier’s performance. 8. analysis and improvement is the process of planning. Attribute gages shall be checked periodically for accuracy.1 Monitoring and Measurement Customer Satisfaction A supplier shall include a customer satisfaction metric in the review of its quality management system. A gage shall be proven repeatable and reproducible before it can be used in a capability study or is used to accept or reject parts.1.

John Deere will use the Red Flag Supplier Quality System Survey (See Section 29) or Supplier Quality System Audit (See Section 30) to complete the supplier quality system assessment. John Deere may ask the supplier to complete a Supplier Information Survey (See Section 28) prior to the on-site quality system assessment.2. The charting of the monitored variables should be completed by the person(s) able to take action on the process. 8. John Deere may perform Process Verification Audits on selected components using the Process Verification Audit Questionnaire (See Section 32). Review of process monitoring techniques shall be made available to John Deere personnel upon request. and the supplier shall submit a corrective action plan to address these issues within the agreed upon target date. Process. functionality. 8.2. or when preparing for full production. and Assembly Reviews. John Deere will share findings in a debriefing meeting and issue a report to the supplier summarizing the results. If mistake proofing is not feasible. Documentation shall exist showing evidence that proper techniques were followed by the owner(s) of the process(es).JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION John Deere reserves the right to conduct a quality system assessment at the supplier’s facility.3 Monitoring and Measurement of Processes A supplier shall determine and implement measurements necessary to monitor processes critical to customer satisfaction.2.3 Product Audit The organization shall audit products at appropriate stages of production and delivery to verify conformity to all specified requirements. 8.2. Any items requiring corrective action shall be clearly noted. Special Process Audit Questionnaires may be found on JD Supply Network. At the close of the assessment. during Design Reviews.1 Quality Management System Audit The supplier shall audit its quality management system to verify compliance with this standard (JDSG223) and any additional quality management system requirements. 8. Statistical Process Control charting should be used on key process control variables in order to eliminate the possibility of producing deficiencies.5. When performing this assessment. documentation.) 22 . at a defined frequency.2. gaging.2.4 Monitoring and Measurement of Product Product measurements and monitors are required to confirm the products are being produced properly and remain stable over time. Failure Modes and Effects Analysis. such as product dimensions. This section not only applies to manufacturing processes. Mistake proofing activities should be the first method of control considered. and/or Design.2. This on-site supplier quality audit is intended for parts with a high level of criticality to determine the effectiveness and conformance of process controls when performing work for John Deere.2.2 Manufacturing Process Audit The organization shall audit each manufacturing process to determine its effectiveness. Where indicated by the Continuous Process Monitoring Matrix in Section 22. John Deere would expect access to a supplier’s personnel. but also to business processes that are critical to customer satisfaction. packaging and labeling.2. A written procedure describing actions to take when out-of-control conditions exist shall be present. and test facilities. John Deere may perform Special Process Audits for special processes as defined in Section 7. Included in product measurement and monitoring are capability studies. statistical techniques shall be used to monitor the process. Capability / variability studies shall be conducted on all key characteristics plus other characteristics that are identified by John Deere and the supplier in the quality planning process (for example. John Deere may conduct a Product Engineering Assessment (See Section 31) for components with Quality Plan Levels ≥ 3 when the supplier has component or subsystem design control. This audit may also be performed on similar parts when the work has not yet been sourced. 8. The work performed can include manufacturing operations at the supplier’s facility or operations sub-contracted to the supplier’s supply chain.

However. When calculating a capability index. If the stability and normality assumptions must be rejected. In EPDP (See Section 7). Reference 16) states on page 132: “Cpk and Cp should always be evaluated together. For a more complete understanding of process terms it is recommended that Statistical Process Control. sample sizes of 50 to 75 be used for better estimates of stability and normality assumptions. A Cp value significantly greater than the corresponding Cpk indicates an opportunity for improvement by simply centering the process. Table 3 — Indices Matrix Indices Capability Indices estimated during Order Fulfillment Process Performance Indices estimated during Enterprise Product Delivery Process Concerned with Only Process Spread (Process Potential) Cp Pp Concerned with Process Spread and Centering (Process Performance) Cpk Ppk 23 . This is a useful technique to show how sample size and other constraints affect the point estimate. by AIAG (See Section 34. then the typical capability index calculations may be used to measure conformance to specifications. In the Order Fulfillment Process your data should come from control charts and sigma is estimated by R / d 2 . where the Cpk considers both the variability and the centering of the process. In variable data studies the results should be tested to see if the normal (bell-shaped) distribution adequately describes the characteristic. If the process is statistically stable and normally distributed. This can be done using a histogram and/or a normal probability plot. and these “one number summaries” leave much unsaid about a process’s performance over time. AIAG (See Section 34. If these assumptions are violated the capability index is of little value. and the matrix shows that the choice of ˆ index depends on (1) where the estimate of sigma comes from ( R / d 2 or σ ) and (2) if the index considers spread or spread combined with process centering. (The formula for Cp only considers variability. Reference 16) be studied. Refer to AIAG SPC Manual (See Section 34. In particular. Selecting the appropriate index depends on the source of data.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Process capability studies are conducted to provide insight into how well a process performs in regard to a customer specification. The data for these studies should be obtained using variable gaging meeting Gage R&R requirements. Practitioners need to remember that process capability indices are simply time sensitive point estimates. A good way of estimating the uncertainty in the point estimate is by calculating a Lower Confidence Limit for the point estimate. it is imperative that (1) process stability is demonstrated by a statistical control chart.) The following matrix summarizes indices required by John Deere. The understanding and quantification of process centering and variation is necessary to understand product quality. topics covered on pages 21. because of sampling variation in the standard deviation it is recommended that when possible. and (2) the confidence interval methodology presented below is completely unreliable. reference AIAG Statistical Process Control manual (See Section 34. (1) the capability ratios have little relevance for describing the process. 132. your data will be coming from smaller sample sizes (minimum of 30) and sigma is estimated by σ . John Deere approval is needed for the use of attribute gaging on key characteristics. Two popular measures titled “capability index” are Cp and Cpk. 185 and 203 are very important. Numerous software packages prepare both histograms and probability plots. in control process unless John Deere specifies otherwise. Reference 16). Reference 16) refers ˆ ˆ to both capability indices (Cp and Cpk) using R / d 2 and performance indices (Pp and Ppk) using σ . and (2) the normal distribution model adequately describes the measured characteristic. There are many different process indices in the quality literature.” It is recommended that capability studies use a minimum of 30 pieces taken from a stable. Key characteristics measured with attribute gages are not required to have Attribute Gage Studies performed unless required by the John Deere representative. If an Attribute Gage Study is required.

In particular before production. verifying all features of the part. Cp. 24 . They will be equal only if the process is centered. Reference 16). are valid only when the process is (1) stable and in a state of “statistical control. Cp and Cpk are usually calculated using only the within-subgroup variation calculated by R / d 2 . plus other characteristics that are identified by John Deere.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION The following diagram illustrates process measures before and after full production at John Deere. The verification process prior to shipping products is documented in the quality plan. The two calculated performance indices are Pp and Ppk. When calculating the Performance Indices before large scale production. usually n ≤ 30 pieces. The usual computing formulas are found on page 132 of AIAG Statistical Process Control (See Section 34. there are limited builds of products that usually contain small sample sizes. Reference 16). σ . USL − LSL Cp = 6⎛ R ⎞ ⎜ ⎟ ⎝ d2⎠ X − closest spec C pk = 3⎛ R ⎞ ⎜ ⎟ ⎝ d2⎠ All four process measures. The supplier shall perform the following activities to assure John Deere that the product being supplied is to specification: • • A supplier shall submit an Initial Sample Inspection Report (See Section 15). This statistic. and that parts are produced from production tooling and processes. Documentation requirements are listed in Section 10. USL − LSL Pp = ˆ 6σ X − closest spec Ppk = ˆ 3σ ˆ σ= ∑ (x − x ) n −1 2 Once production has begun and larger samples are collected then the Capability Indices. Ppk. all the ˆ ˆ data is used to calculate the long term capability using sample standard deviation. If either of these requirements are not met these indices can be very misleading. whether produced internally or by the supply chain.” and (2) the process output is approximately normally distributed. See page 136 of AIAG Statistical Process Control (See Section 34. is called the Total Process Variation and includes both within-subgroup and between-subgroup variation and uses all of the readings obtained from either a detailed control chart or a process study. and Cpk. σ . Pp. A supplier shall provide capabilities on all key product and process characteristics. Cpk will always be less than or equal to Cp.

37 1.64 2.33 Table 5 — Lower & upper confidence limits on Ppk or Cpk at two levels for various sample sizes. Control plans shall be available for all John Deere components with product and process key characteristics. Use the (Average MR)/d2 as an estimate of sigma and plot the Individuals chart. by Vardeman and Jobe.52 2. Sample Size (n) 5 10 20 30 50 Ppk or Cpk = 1.42 0.87 0. 1.95 1.14 0. plating. A state of statistical control exists when a process is performing as consistently as it can perform. if appropriate.71 1. The circumflex (^) over a value indicates a sample ˆ statistic. ˆ An approximate 100(1-α) confidence limit for Ppk or C pk is: ˆ C pk − Z ∝ 1 9n + ˆ 2 Cpk 2n − 2 ∧ Table 4 — Confidence Limit Z α Values Percent of Confidence 90% 95% 99% Z α Value 1.79 1.28 1. Perform a Gage R&R study. 213 (See Section 34.58 1.33 -95% Confidence +95% Confidence 0. Reference 16). 2. (See AIAG SPC-3: Statistical Process Control (See Section 34.00 -95% Confidence +95% Confidence 0.63 0. John Deere requires release inspection anytime the capability of the supplier’s processes is in question.18 25 Ppk or Cpk = 1. including: chemical and mechanical properties. such as C pk or Ppk . Reference 17). For Process Control Methods (See Section 24).71 1. Draw a histogram and estimate the fraction nonconforming from the 30-piece study. The control method called out in the Control Plan shall be determined from the capability of the process as specified in the Continuous Process Monitoring Matrix (See Section 22). heat number and source mill. Calculate an appropriate one-sided 90% lower confidence limit for the Ppk . Documentation of conformance to this section shall be made available to John Deere personnel upon request. ∧ ˆ 5.24 0.76 1.63 1.56 . ˆ 6. Check to see if the process is in a “state of statistical control” by using the chart for Individuals and Moving Ranges (X-MR). If the data passes steps 2 and 4 then calculate a Ppk . A supplier shall track the material certification for John Deere part numbers.10 1.82 1. The following steps are recommended for a minimum sample size of 30 continuous-piece study Refer to the Process Control Flowchart (See Section 9).APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 • • • A supplier shall verify products according to the Control Plan (See Section 17) unless the John Deere unit does not require it. Graphically represent the 30 data points with a normal probability plot to see if the bell curve adequately describes the data. 4. See Statistical Quality Assurance Methods for Engineers. hardness.29 0. p.03 1. 3.

the John Deere Quality Services group can be used as a resource. John Deere is moving toward six ˆ sigma processes. Some characteristics specified with geometric dimensioning and tolerancing (GD&T) do not lend themselves to standard methods of calculating capability. For the Ppk calculation d2 use at least 30 pieces and find an overall standard deviation. ( ∧ C pk is calculated by taking the Average Range and dividing by a constant d2 R ˆ ). and the information listed in Section 16 Capability Study Checklist and Form should be included. If this is the case and assistance is needed. casting hardness. The difference between ∧ ˆ C pk and Ppk is the calculation of the sample ∧ ˆ standard deviation ( σ ). the smaller the uncertainty in that estimate. The larger the sample used to estimate them. Reference 11). Reference 16) and page 260 of Process Quality Control by Ott (See Section 34. ⎧USL − X X − LSL ⎫ ˆ Ppk = Min ⎨ . If the process does not follow a normal distribution. Reference page 144 of AIAG Statistical Process Control Manual (Reference 16).5 being the ultimate goal. You can convert the Ppk into the approximate six sigma scale ˆ ˆ ˆ by multiplying Ppk by 3 and adding 1. Of the four indices described above. reference Section 23. The Preliminary Process Capability uses a process standard deviation ( σ or R ).33 is minimal. (2) graphically check for ˆ the normal distribution. which will be larger than the one using the Average Range. not the finish line. which gives only a “within subgroup” estimate of the standard deviation. C pk = Min⎨ ⎬ 3s ⎪ ⎪ 3s ⎩ ⎭ R s= d2 At John Deere. concentricity. The following formulas are commonly used for performance and capability indices. only Cp and Pp are robust with respect to non-normality.5. These point estimates are subject to variation over time. Examples of inherently non-normal process measures include flatness. The capability study shall be documented. d2 ˆ Both C pk and P pk estimates of population capability and process performance assume the data come from a normal (bell-shaped) distribution with specification limit(s) about the target. and (3) use a lower confidence limit for the Ppk . 26 .JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION The only way to know if a capability target is met is to (1) make an X-MR chart.” Conformance to specifications is merely the starting point. ˆ Preliminary process performance Ppk should be conducted in the early stages of the Product ˆ Development Process. A Ppk of 1. tensile strength. ⎬ ˆ ˆ 3σ ⎭ ⎩ 3σ ˆ σ= ( X i − X )2 ∑ n −1 ⎧USL − X X − LSL ⎫ ⎪ ⎪ ˆ . a John Deere quality representative should be contacted. and parallelism. For non-normal process analysis refer to page 140 of the AIAG Statistical Process Control Manual (See Section 34. with a desired Ppk of 1. for John Deere suppliers to assure a high level of defect free product. world-class capability is defined as “on target with minimum variance.

Therefore. John Deere shall be entitled to recover from the supplier all costs and expenses reasonably incurred in taking corrective action per the terms and conditions. shall be accessible to and utilized by appropriate personnel. isolation. Miskulin & Runger.33. The Average Production Length to detection would be less than or equal to one day’s consumption at John Deere. and for notification to the departments concerned (both internal and external). The supplier shall inspect.. When nonconforming product is corrected it shall be subject to re-verification to demonstrate conformity to the requirements. assume it is economical for a supplier to check no more than 2% of production for control purposes. 8. If the process sigma changes by one unit. Journal of Quality Technology. If parts are found to be nonconforming at John Deere. contain. we want to detect a one sigma process shift before producing 250 pieces. The supplier shall have a representative establish containment at the John Deere factory.2 Control of Reworked Product Instructions for rework. See “Statistical Process Control Scheme Design”. 27. reclaim. test. by Keats.1 mm. Use the spreadsheet titled “Sample Size & Control Limit Design” on JD Supply Network. and enter 2% in B4 which is the sampling rate. the control chart will indicate a significant change before 239 parts are produced for John Deere.Supplemental Product with unidentified or suspect status shall be classified as nonconforming product. July 1995.” It is never appropriate to average capability or performance indices for several processes into one index.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Process measures should be used to align the “voice of the process” with the demands from the “voice of the customer.com/business_processes/strategic_sourcing_process/strategic_sourcing_process_in dex.g.deere.1 Control of Nonconforming Product . 8. enter in cell B3 the value of “1” for the sigma shift. Since 239 are fewer than 250 the plan provides the protection that John Deere requires. 8. and set the control chart limits at: 100 ± (1. 3. 27 . including re-inspection requirements.667)(0. To use the Sample Size & Control Limit Design spreadsheet for control limits and sampling frequency.07mm.1)/ √6 = 100± 0. No. The list is located at: http://jdsupply. it shall be the supplier’s responsibility to aid John Deere in evaluating and correcting the problem.3. documentation.3 Control of Nonconforming Product The supplier shall establish and maintain documented procedures to ensure that proven or suspected nonconforming products are prevented from unintended use or installation. The spreadsheet tells us to measure 6 pieces every 294 pieces. This control shall provide for identification.667)( σ)/(√6) = 100±(1. disposition of nonconforming products. evaluation. If nonconforming products get into John Deere products or become a warranty problem. Quicker response may be required based on the severity of the situation.3. material in transit. asbestos or lead in paint) and/or other substances restricted by applicable laws. Production Sample Size Considerations John Deere requests that the supplier use a sampling plan for measurement data that insures no more than one day’s production would go undetected. The process is known to have a mean of 100 mm with a standard deviation of 0. sort. For example. and at the supplier within 24 hours. the supplier shall provide the resources necessary to evaluate. Vol.htm. and/or obtain other verification to ensure that the products do not contain substances in excess of the amounts set forth on John Deere’s Restricted Materials Lis (e. John Deere consumes 250 pieces per day. and a Cpk equal to 1. and/or scrap the nonconforming product.

At a minimum.5.5 8. past experience. The supplier shall maintain a record of the expiration date and quantity authorized.JDS-G223 8. or is not performing adequately. the supplier shall analyze the following. When a product or process does not meet customer specifications.1 Improvement Continual Improvement Evidence shall demonstrate the use of data. and lessons learned to show continuous improvement of the quality management system.3 Customer Information APPROVED FOR SUPPLIER DISTRIBUTION John Deere shall be informed promptly in the event that nonconforming product has been shipped. • • • • Achieving Excellence results Internal and external product failures (including warranty) Process or product quality trends Supply chain (including the supplier’s supply chain) quality performance Summarized quality performance should be made available to all of the supplier’s employees.3. A partial list of these statistical and problem-solving techniques can be found in Section 25. Quality performance data shall be made available at the request of John Deere personnel. Each shipping container of deviated product shall be properly identified with the deviation number. This applies equally to products or services purchased from the supply chain.4 Customer Waiver If a supplier wants to ship a product not meeting the specified requirements. 28 . written approval shall be obtained from John Deere prior to shipment of the product.4 Analysis of Data John Deere expects our suppliers to obtain appropriate data and apply statistical and problem solving techniques to solve specific problems and to drive continuous improvement activities in a timely manner. 8. 8. one suggested methodology is DMAIC.3. This request can be made using the Engineering Deviation Authorization Checklist and Form in Section 21. The supplier shall concur with any requests from their supply chain before submission to John Deere. Define: Define the project goals and customer (internal and external) deliverables Measure: Measure the process to determine current performance Analyze: Analyze and determine the root cause(s) of the defects Improve: Improve the process by eliminating defects Control: Control future process performance 8. The supplier shall also ensure compliance with the original or superseding specifications and requirements when the authorization expires.

D1 Establish the Corrective Action Team Purpose: To define the members of the team that can successfully resolve the problem. D7 Prevent Recurrence Purpose: Modifications to Management Systems. in-transit material. re-inspection. Quantitative results confirming that the selected corrective actions will resolve the issue for the customer. Work Instructions. The Eight Corrective Action Disciplines (8D) or Resolution Phases required: 1. A sample form is shown in Section 20 if NCCA is not available. 3. The supplier shall document Corrective Action in each Resolution Phase. Training Performed. Customer / Warranty Problems: Interim customer solution used to quickly restore customer acceptance.. Training Plans. 2. Engineering Documentation to prevent recurrence of this and all similar problems. D3 Containment Action & Short Term Corrective Action Purpose: Actions to isolate the effect of the problem from any customer until corrective action is implemented. This action shall be completed by the target date as specified by John Deere. Suppliers shall investigate resolution to nonconformities using eight Corrective Action steps or Resolution Phases. D4 Define and Verify Root Cause Purpose: Scientific. 4. 5. The responsible person or 8D team reviews all activity performed through resolution phases and confirms that all steps have been completed. in-house at supplier facility. Operating Systems. A status report shall be submitted to the originator of a John Deere initiated corrective action request (preferred via the Nonconformance Corrective Action (NCCA) system) within five days from the date of receipt. Each corrective action D-step shall be completed by the target date. practices. but not limited to. D8 Team Recognition Purpose: Acknowledgement from management of the good work done by the 8D team. Containment shall be completed within 24 hours of problem notification. 8. 6.2 Corrective Action Corrective action eliminates the cause(s) of nonconformities in order to prevent recurrence. D6 Implement Permanent Corrective Action Purpose: Action taken in this phase will correct the root cause of the problem and prevent its recurrence. research and field information that would quantify or describe the problem in detail. complete breakdown of the Direct Cause. rework. Identify and contain nonconforming product at all locations including. 29 . dealers and end-use customer. Production & Experimental/Pilot Build Problems: What you did to stop the problem today. 7. To minimize the effect of any nonconforming product by containment. unless otherwise specified by the John Deere investigator. identifying responsible people and target dates for each action. Implementation includes listing action steps. This set is to recognize extra effort and reinforce successful behavior. material located at various John Deere sites (including Parts Depots). DFMEAs. It is recommended that the improvements resulting from the Eight Step Problem Resolution Process be replicated to like processes or products to assure the problem has been solved. and procedures such as Process Control Plans. etc.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 8. D5 Choose and Verify Solution Purpose: Identification of solutions or actions that will eliminate the Root Causes as well as the Contributing Causes. Contributing Causes and Root Causes of the problem. to verify conformance of current product. PFMEAs. D2 Problem Identification Purpose: To document all facts.5.

5.3 Preventive Action APPROVED FOR SUPPLIER DISTRIBUTION Preventive action eliminates the cause(s) of potential nonconformities in order to prevent their occurrence. Copies of these forms are available through the John Deere Supply Network website: http://jdsupply. 30 . Preventive action focuses on building good quality into the product and processes to ensure that nonconforming products never reach the customer. design FMEAs. A supplier shall take a systematic approach to defining and implementing preventive action activities. or the severity is ≥ 9. as long as all identified John Deere requirements and information are addressed. Processes should be developed so employees can do the job right every time. See AIAG FMEA Manual (See Section 34. and process FMEAs. require follow-up actions.deere. except for the Change Notification and Verification Warrant. mistake proofing techniques. Preventive action activities shall be a part of the management review process.JDS-G223 8. but are not limited to: data collection systems. The processes include. At a minimum. The systematic process improvement approach should include five basic steps: Define: Define the project goals and customer (internal and external) deliverables Measure: Measure and determine customer needs and specifications Analyze: Analyze the process or product options to meet customer needs Design: Design the process or product to meet customer needs Verify: Verify the design performance and ability to meet customer needs NOTE: The following sections provide sample forms. training. FMEA items with Risk Priority Number value > 100. A supplier may use their own form(s). continuous improvement actions. Reference 10).com. process control plans.

Any fundamental change to the process (moving location. Perform statistical test for normality using Statistica or equivalent software. or institute stringent control method Unstable Evaluate for Stability and Control 5 Take measurements Stable Fill out John Deere approved form with key feature. When sufficient quantities are ordered. Standard Procedures) Perform steps to reduce spread. For non-normal distributions.e. a non-normal analysis must be performed to calculate the appropriate Ppk value. Process and Assembly Review 2. P 45) to verify stability and control 6. or substituting machines) may require a new capability analysis as part of the PPAP submission. Section 11) Yes Perform analysis using alternate technique or contact John Deere Quality Representative 7 No Normally Distributed? 6 Yes 8 Perform steps to reduce spread. 7. DPAR means Design. capability on the new part key characteristics shall be demonstrated. existing SPC or recent capability studies on parts with similar key characteristics may be used to demonstrate capability for a new part if there is not sufficient quantity of the new part ordered to complete the capability study. or institute stringent control method Submit with completed Verification Warrant Yes 31 .APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 9 Process Control Flow Chart – PDP and Initial Production Drawing (includes Key Characteristics) Can Key Characteristics be measured using Variable Gaging? Yes Identify Processes / Machines to be Used 1 DFMEA & PFMEA 2 Identify by number each key feature to be investigated (on John Deere supplied Print) No Perform Attribute Gage R&R and refer to Continuous Process Monitoring Matrix (Section 24) Perform Gage R&R for all instruments used to assess product No 4 Complete all requirements confirmed during DPAR Gage R&R and Capability Study Data available on state of current process for similar parts? 3 Yes NOTES 1. Process Index targets must be agreed to between supplier and John Deere prior to undergoing test. description and method of measuring (John Deere Control Plan. 8. 3. Some software tools are available to perform analysis if supplier doesn't currently perform R&R 5. Calculate Process Indices Ppk Statistical Analysis exceeds target No Correct measuring process R&R<30% of Tolerance? Yes Sufficient Detail and Acceptable? No No Produce Parts on Production Machines / Tooling at Production Rates (i. Use Individual & Moving Range with mathematical test (available in Memory Jogger II. 4. In some cases. Approval of the capability analysis is specific to a certain part number on a certain process or machine.

Supplier Functional Verification Testing S S Prior to production Results 20. 18) (See Section 34. Engineering Change Documents. Design.2. The requirements are determined by the Quality Plan Level (See Section 7. Initial Sample Inspection Report . Appearance Approval Report. Table 10. Reference 12) to include the requirements listed in the table below.2 Level 2 of the AIAG PPAP (p. Process. * If requested by John Deere. Design Review S design 6. Design Record S . Experimental Part Inspection S S S Prior to production (Engineering) 19. if any S First production 3. Conditional Approval may be granted to authorize limited production shipments when there are outstanding PPAP requirements. John Deere requires Section 4. R S S S Prior to control plan Studies 15. * Records of Compliance With R Customer-Specific Requirements S = The supplier shall submit to John Deere and retain a copy of records or documentation items at appropriate locations.1). R = The supplier shall retain at appropriate locations and make available to John Deere upon request. 32 . John Deere reviews the data and either Approves or Rejects the Verification Warrant. * Master Sample R 22. Control Plan (including Checking Aids) R S S S Prior to production 11. Measurement System Analysis Studies R S S S Prior to use – Gage R & R Studies for Key Characteristics 12. if R Prior to production required Design FMEA (Failure Modes and Prior to complete 4.1 lists submission and retention requirements.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION 10 Production Part Approval Process (PPAP) Requirements The required Production Part Approval activities and documents will be specified by the John Deere representative.ISIR S S S S S Prior to production (Dimensional Results) Material / Metallurgical / Functional / 13. S S S S S Prior to production Performance Results (as appropriate) Initial Process Studies – Capability 14. After the PPAP documents have been submitted. Customer Engineering approval.for all other components / details S Prior to production 2. Unless otherwise specified. Approval is required prior to shipping production parts including all builds. provide documentation. Process FMEA R S S Prior to control plan 10. & Assembly Review S S S Prior to production (DPAR) – Initiated by John Deere 7. R S Effects Analysis) design Prior to complete 5. if S S S Prior to production applicable (for JD Class A parts) 17.for proprietary components / details R Prior to production . * Qualified Laboratory Documentation S Prior to production 16. Production Part Approval Requirements by Quality Plan Level AIAG John Deere Quality Requirement Complete By Level Plan Level 2 0 1 2 3 4 1. Functional Geometry Review S S Prior to production 8. * Sample Product S 21. Verification Warrant S S S S S Prior to production 18. Process Flow Diagrams / Process Map R S S Prior to production 9.

com/sc. Supplier shall be expected to fully reimburse John Deere for all expenses incurred to correct the deficiency. Changes that deviate from drawings or specifications Explanation Supplier Signature and Title Date Supplier not to proceed until it receives authorization from John Deere. This authorization to proceed is granted upon the understanding that it is advisory in nature and in no manner changes the Supplier’s original responsibility for ensuring that all characteristics.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 11 Change Request and Verification Warrant Form John Deere requires Suppliers to electronically submit Change Requests on via JDSN Collaboration https://jdsn-collab. 33 . The required information is listed below. and/or inherent in the samples as originally tested and approved.com/sc.deere.deere. John Deere is responsible for providing a follow up date for any conditional approvals. Part and Supplier information • • • • • • • Part Number or Numbers Part Name Decision Number Revision Level Supplier Name Supplier Number Address Reason for submitting request for manufacturing process and product change authorization • • • • • • Design/Material Change Process Change Location Change Tooling Change Supplier Change Other Reason for proposed change • • • • • • • • • • Improve Product Quality Increase Manufacturing Efficiency Reduce Lead Time Other Describe proposed change and the quality plan to ensure the quality of product will not be adversely affected. Proposed implementation date. If electronic submission is not possible. designated in the applicable engineering specifications. and should such changes result in failure to meet customer requirements. Supplier accepts full responsibility for the changes of types of changes listed above. Attach all supporting information. Submission of Change Request should be submitted electronically via JDSN Collaboration https://jdsncollab. are maintained. the following form shall be used.

JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form. The Supplier is still responsible for the changes.com/. tooling. and processes used? Name (printed): Supplier Authorized Signature: Yes No (Explanation Required ) Title: Phone: Date: FOR JOHN DEERE USE ONLY Accept Change Request Reject Change Request Signatures: Approve Verification Warrant Conditionally Approve Verification Warrant Reject Verification Warrant (For Conditional Approval only) Conditions: Quality Engineer: Supply Management: Design Engineer (for supplier initiated design changes only) Materials Engineer (for supplier initiated material and/or special process changes) Other: Date: Date: Date: Date: Date: This approval is advisory and does not change the Supplier's responsibility for ensuring that all characteristics meet their specifications. I have noted any deviations below: Production material. source manufacturing change. please refer to https://jdsupply. 34 .) Please specify. Efficiency Other Submission Information: Control Plan Capability Study (Cpk) Material Certification Material Test Results Part Design FMEA Special Notes: Due dates in (DD MMM YY) Gage R&R Sample Parts Verification Test Process flow diagram Process FMEA ISIR (Initial Sample Inspection Report) Master Sample Appearance Approval Report Component Performance & Reliability Assurance Performance Test Results Submission Results (for Verification Warrant use only): These results meet all drawing and specification requirements: Yes No (Explanation Required) I affirm that the samples. data and information represented by this submission are representative of our parts and have been made to the applicable John Deere Drawings and specifications and are made from specified materials on regular production tooling with no operations other that the regular production process. process. etc. etc.deere. the Supplier will reimburse Deere for the expenses needed to correct the deficiencies. This reimbursement for deficiencies may be defined in Warrant Agreements or specific contracts. Change Request -orVerification Warrant (Part Submission Warrant) Part Number Part Name / Description: Originator: Supplier Name: Supplier Contact: Decision No Phone Phone: Revision Level Product Application: Fax: Supplier ID Code: Fax: * Attach documentation as needed Design/Material Change(s) *Supplier Change (new source. For the latest version of this document. *Other . tooling.Please Specify Reason For Submission: Initial Submission *Manufacturing Change (location. If the changes result in deficiencies not found in these approved items.) Please Specify Correction of Discrepancy (Resubmission) Impact of Change: Quality Improvement Proposed Implementation Date: Reduced Lead Time Increased Mfg.

in Section 12) (end EPDP Phase 3 – Milestone 11) Integrate Component into the Product (end EPDP Phase 4 – Milestone 14) 35 . Develop Goals (end EPDP Phase 2 – Milestone 5) Develop Component Specifications (end EPDP Phase 2 – Milestone 5) Select Critical Component Supplier(s) (end EPDP Phase 2 – Milestone 5) Understand Critical Component Supplier(s) Performance (end EPDP Phase 3 – Milestone 7) Establish Component PV&V Plan with Supplier (Reference PV&V Plan – Activity Template. Refer to Section 7.2. Section 18) (end EPDP Phase 3 – Milestone 8) Verify Component Meets the Specification (Reference Component Performance & Reliability Assurance Form.3.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 12 Major Component Reliability Assessment Process and Form The Major Component Reliability Assessment Process steps are shown below.1 and Section 7.

prediction or other analytical technique. Include statistical confidence level. including reliability. Can be historical data. including reliability.Due Date: Production Intent Prototype Due Date: Other Information: Supplier Number: Zip Code: Are PV&V Plan Results Acceptable? Attach appropriate documentation. please refer to https://jdsupply. document the method and results of analytically verifying the component meets or exceeds its requirement(s). Attach supporting documentation. Supplier Name: Supplier Address: City: State: Component Name: Component Part Number: Requirement Verification (Analytical) . YES _____ NO ______ John Deere PV&V Representative: Date: Does Component Meet Specification Requirements? YES ___ NO ____ Supplier Representative: Date: Supplier Requirement Verification – Analytical (Filled in by Supplier) Instructions: If required by John Deere. Attach supporting documentation.deere. Supplier Representative Comments: Date: Signatures: John Deere Representative: Supplier Representative: Date: Date: 36 .com/. Can be lab or mule vehicle testing.Due Date (Optional): Requirement Verification (Prototype) . For the latest version of this document. Supplier Representative: Date: Supplier Requirement Verification – Prototype (Filled in by Supplier) Instructions: Document the method and results of physically verifying the component meets or exceeds its requirement(s).JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form. Component Performance & Reliability Assurance Form Signoff to occur by PDP Leadership approval to start physical builds (Phase 3 Milestone 11).

APPROVED FOR SUPPLIER DISTRIBUTION

JDS-G223

13 Product Verification & Validation Plan – V2 Net Data
# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Verification and Validation (V2) Net Data Template Elements Description This field is for John Deere use only, suppliers leave blank. This number is provided automatically by the V2Net System. Activity Title Short description of the validation and verification activity. Limit to 100 characters. This is a required field. Category Select appropriate category description from the “Category Type Matrix”. This is a required field. Type Select appropriate activity type that corresponds to the selected category from the “Category Type Matrix”. This is a required field. Description Provide a detailed description of the activity. This is a required field. Machine / Component If appropriate, enter the serial number of the machine or component. Limit Serial Number to 50 characters. Actual % Complete Enter a number between 0 and 100 to reflect the percent of activity completion. Planned Activity Enter the number of days (between 1 and 200) the activity will take to Duration complete. Planned Start Date Enter the planned start date of the activity. Use dd-mmm-yy format. Planned End Date Enter the planned end date of the activity. Use dd-mmm-yy format. Resource Name This field is for John Deere use only, suppliers leave blank. If a John Deere resource is required, make the appropriate selection from the pulldown list. Actual Start Date Date activity started. Use dd-mmm-yy format. Activity Complete Date Date activity complete. Use dd-mmm-yy format. Date Parts Available Date when the parts to complete the activity available. Use dd-mmm-yy format. Acceptance Criteria Detailed description of the acceptance criteria for the activity. Item Activity Number

37

JDS-G223

APPROVED FOR SUPPLIER DISTRIBUTION

This is a sample form. The published form has three worksheets – V2Net Data Header, V2Net Data Template, and the Category Type Matrix. For the latest version of this document, please refer to https://jdsupply.deere.com/.

38

APPROVED FOR SUPPLIER DISTRIBUTION

JDS-G223
Field Performance Test Field Durability Test Competitive Assessment Competitive (Best in Class) Assessment (Best in Class) Customer Validation Customer Validation (Customer Focus (Customer Focus Groups, etc.) Groups, etc.)

John Deere Category Type Matrix For V2Net
CATEGORY TYPE Review Customer Validation (Customer Focus Groups, etc.) Design FMEA (Failure Modes & Effects Analysis - System, subsystem, assembly, or component level) Design Review Design Analysis Lab Test Casting Solidification ADV (Accelerated Design Verification)

CFD (Computational Fluid Dynamics)

Chassis Dyno

Drivetrain Engineering DPAR (Design, Process, Electrical / and Assembly Review) Electronics E-build Fastener Application General Review HDRS (Hazard Discovery and Rating System) Industrial Design Review

Print Review Process FMEA (Failure Modes and Effects Analysis) Reliability Planning Risk Assessment Serviceability Review Software Reviews Standards Compliance (Standards Regulations & Conformity Assessment SRC) Styling/Appearance Supplier Review System FMEA (Failure Modes and Effects Analysis)

General Field Durability Test Component (Durability, Life, General Field Implement or etc.) Performance Test Component Compatibility Fuel System Cooling System Implement or Component Load Measurement Compatibility Activities Gear Design Data Acquisition (Lab & Field, Load Measurement Performance load measurement, etc.) activities General Analysis Drivetrain Test NVH (Noise, Vibration, Standards Compliance Harshness) (Standards Regulations & Conformity Assessment - SRC) Human Factors Dynamic Response (Shaker, Performance Supplier Durability Test Modal Analysis, etc.) Hydraulics and Electrical (JDQ 53.2, Standards Compliance Control Systems Electromagnetic Interference, (Standards Regulations & Analysis HALT) Conformity Assessment SRC) Implement Energy Management Supplier Performance Compatibility Test Lighting Engine Dyno Lubrication Environmental (Salt Spray, Scab Test, Dust Box, Mud Box, QUV, Weatherability) NVH (Noise, Fatigue (MTS, Field Stress, Vibration, Harshness) etc.) Other (Spring General Lab Test Calculations, Bearing & Belt Drive Life & Loads) Plastic Molding Heat Sealing HVAC (Heating Ventilation and Air Conditioning) Simulation Hydraulics and Control (Dynamics/Kinematic Systems s, Hydraulics, etc.) Soil Dynamics Load Measurement Activities Structural Analysis Maintenance and Renovation (Fatigue, FEA, Hand Calc., Optimization, etc.) Supplier Design Material Properties Analysis Thermal (Cooling, Noise Vibration and etc.) Harshness (NVH) Tolerance Stack Ups Other Valve Train Performance (Stability, Function, soil Bin, etc.) Virtual Reality Standards Compliance (customer validation, (Standards Regulations and visibility, etc.) Conformity Assessment SRC) Supplier Test Valve Train Wind Tunnel

Cold Function (Starting, Performance, etc.) Component

Durability Field Stress

Durability

39

JDS-G223

APPROVED FOR SUPPLIER DISTRIBUTION

14 Design, Process, and Assembly Review Form
This is a sample form. For the latest version of this document, please refer to https://jdsupply.deere.com/.

The list of items below should be considered when conducting a DPAR. Documentation of the DPAR results shall be recorded. C = Complete; I = In Process; N = Not Applicable Design, Process and Assembly Review Checklist C/I/N # DESCRIPTION COMMENT 1. DESIGN REVIEW (Print or Model) 1.1 Review material requirements 1.2 Review geometric dimensioning and tolerancing 40

16 Review Appearance / Paint requirements 1.14 Review machining instruction requirements 2.10 1.11 Review requirements for cleanliness. 2.2 Determine availability of measuring equipment gages.4 1.19 Determine potential cost impacts of any changes identified 3.5 1.15 Review procedure and requirements for initial sample inspection 1.5 Determine how many gages and test fixtures are required 3.1 Review all processes required to produce the part/assembly.14 Review guidelines for control methods after capability assessment 1.17 Review requirements for cleanliness and deburring 1. plating. heat treatment.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Review drawing/model format for clarity and completeness Review design and functional requirements Review John Deere / Supplier test plan and test results Review tolerances for manufacturability Review all applicable specifications & standards Identify key design characteristics from Design Reviews & other sources Determine requirements for Gage R & R studies on measuring equipment Determine method to measure key design characteristics Determine capability study or control plan requirements on key characteristics plus other characteristics defined by John Deere or the supplier.2 Review manufacturing process for completeness 2. processes. painting 2.11 . Process Failure Modes & Effects Analysis (PFMEA’s) & other sources 2.13 Determine method for capability studies on key characteristics plus other characteristics defined by John Deere 1. test fixtures etc.18 Identify cost reduction opportunities 2.8 Review preferred methods for capability assessment 2.18 Identify cost reduction opportunities 1.19 Determine potential cost impacts of any changes identified 2. 3. etc.6 1.g. 1. PROCESS REVIEW 2.6 Determine requirements for Gage R & R studies on measuring equipment 2.4 Review procedures for drawings and inventory of gages and test fixtures 3. tools. 2.6 Determine who will design and build gages and test fixtures 3.7 1. machining.5 Determine method to measure key process characteristics 2. assembly. welding. bonding.10 Review guidelines for control methods after capability assessment 2.9 Determine potential cost impacts of any changes identified 41 1. e. etc.15 Review training needs 2. debarring.8 Identify cost reduction opportunities 3.17 Review ergonomics for material handling.3 Determine quality or control plan requirements 3.13 Review Sequence of Events (SOE) 2. test fixtures. GAGING REVIEW 3. rust preventives etc. grinding.7 Determine capability study or control plan requirements on key characteristics plus other characteristics defined by John Deere 2.9 Determine method for capability studies on key characteristics plus other characteristics defined by John Deere 2.7 Review policy for ongoing gage maintenance and calibration 3.8 1. stamping.12 Review Operator Method Sheets (OMS) 2.4 Review key process characteristics from Design Reviews.1 Determine what measuring equipment gages.9 1.3 1. packaging.3 Review specifications related to these processes 2. are required 3.16 Review Mistake Proofing opportunities 2.12 Review preferred methods for capability assessment 1.

FMEA results 6.1 Review requirements for component packaging/returnable containers 5.16 Review material handling systems that prevent part damage 4. 4.28 Determine potential cost impacts of any changes identified 5.18 Review ease of access for assembly 4.12 Completion of Verification Warrant 6. Roll Over Protection System (ROPS).6 Review Design Review.13 Review needs for assembly gages and aids 4.24 Review performance testing requirements in assembly 4.5 Determine potential cost impacts of any changes identified 6.9 Review fit & finish requirements 4. hydraulics.1 Review systems listed for Design Reviews in PDP Phase 2 & 3 4.23 Review special process requirements (bonding.4 Identify cost reduction opportunities 5.20 Review plans for assembly tools 4.12 Review assembly instruction requirements 4.26 Review ergonomics for material handling.2 Review cleanliness requirements & possible contamination problems 4. including the need for rust protection 5. etc.27 Identify cost reduction opportunities 4.g.2 Verify service requirements complete 6.11 Review Sequence of Events (SOE) 4.7 Print release date 6.10 Review Operator Method Sheets (OMS) 4.7 Review fasteners 4.g.15 Review process for Mistake Proofing opportunities 4.5 Review appearance.14 Review training needs for key assembly characteristic 4. line.2 Review the need for temporary sealing for the wash or paint process 5. processes.10 Production Part Approval Process (PPAP) requirements 6. MISCELLANEOUS ITEMS REVIEW 6. and finish process requirements 4.3 Review critical product systems . etc. and noise problems 4.8 Production tooling Purchase Order ready date 6. PACKAGING REVIEW 5.6 Review linkage adjustment capabilities 4.5 Review all software requirement specifications 6. and wiring routing 4. fit. asbestos or lead in paint) and/or other substances restricted by applicable laws 6. ASSEMBLY REVIEW 4.3 Review packaging & shipping requirements for finished goods.e.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION 4. painting.11 Supplier audit / visit 6.3 Review engineering Bill of Material (BOM) 6.4 Review to ensure the part or assembly does NOT contain substances in excess of the amounts set forth on John Deere’s Restricted Materials List (e.25 Review and verify specification 4. vibration.8 Review potential leak.22 Review trial installation requirements 4. tools.9 Lead times for tooling 6..13 Sign off of attendees 42 .4 Review hose.21 Review ability for fluid systems to reach steady state levels 4.19 Review need for assembly fixtures 4.) 4.17 Review torque requirements for key joints 4. electrical 4. brakes.1 Review cost targets 6. steering. drive train.

please refer to https://jdsupply.deere. 26 27 28 29 30 Yes No Five Unit of Measure Tolerance (+) / (-) Piece 1 Measurement Results Piece 2 Piece 3 Piece 4 Piece 5 OK / John Deere Not OK Verification Supplier Representative Signature: John Deere Quality Representative: Disposition: Title: Title: E-Mail: E-Mail: Date: Date: Approve Fail Deviate Resubmit 43 . for the latest version of this document. Initial Sample Inspection Report – Dimensional and Material Results Part Number Design / Revision Level Part Name / Description Decision Number Report Type Dimensional Material Production Tooling & Processes Utilized Supplier Name Supplier Number Name of Inspection facility Yes No Lab Report Attached How many pieces measured? One Two Three Four Item Nominal Dimension / Specification or Material Specifications 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Items 26 – 30 are text applicable.com/.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 15 Initial Sample Inspection Report (ISIR) – Dimensional and Material Results This a sample form.

deere. unless otherwise noted herein.JDS-G223 16 Capability Study Form APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form. Part Name/ Description New Part Date: Desk No.Fill In All Data Below Is the process for each feature in control. for the latest version of this document. Change New Source Design Level Decision Number Comments: Supplier . please refer to https://jdsupply. otherwise calculate C pk Dimensional Requirements (Key Characteristic) Results Actual Measurements Minimum 0f 30 Measurements Required Feature No. X X ˆ σ ˆ ˆ Pp Ppk ∧ ∧ R/d2 C p C pk Approve / Reject Inspection Results Prepared By: We hereby certify the reported results are correct and that our sample meets John Deere specifications. Supplier Quality Representative: __________________________ Date: ________________ E-mail: _______________________ John Deere Approval: John Deere Quality Representative: Date: Disposition: Accept Reject Conditional Acceptance Resubmit Sample E-mail: __________________________ John Deere Supply Management Activities: Date: Original Documentation Sent to File Send Notification to Supplier 44 . Capability Study Part No.com/. Resubmission Page of Other Decision Eng. stable and normally distributed? Yes No ˆ ˆ If samples are sequential then report Ppk .

6 Supplier ID / Code Enter the identification number as requested by the procuring organization (e. 20 Process Name / Description of the generating process/operation which produces the characteristic. 7 Core Team Members Enter the name(s) and telephone number(s) of the individual(s) responsible for preparing the Control Plan to the latest revision. Use visual aids where applicable. # 1 45 . numbered print. if Part Number applicable. 14 Revision Date Date the latest Control Plan was updated.) 4 Name and description of the part and/or process being controlled. 19 Part / Process Number Enter the part number. Pre-Launch. If multiple part numbers exist (assembly). 8 Name(s) of the individual(s) responsible for preparing the Control Plan or Preparer the primary contact responsible for the Control Plan. Approval / Date 18 Other Approval / Date Obtain any other agreed upon approval (if required). Operation Description 21 Machine. but not limited to. 22 No. / Date 11 Engineering Change Latest engineering design level and/or issue date from the drawing specification. dimension or property of a process or its output (product) on which variable or attribute data can be collected. Number: Enter a cross reference number from all applicable documents such as. Level / Revision Level 12 Decision / Engineering John Deere number assigned to the engineering change. Prototype. if applicable. identify the processing equipment.) Item Description Control Plan Category: Indicate the appropriate category.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 17 Control Plan Checklist and Form Control Plan Elements (BOLD items are required. if required. Jig. indicate the page numbers (page _ of _). FMEAs. Tools for Manufacturing CHARACTERISTIC A distinguishing feature. 9 Responsible Person Indicates who is responsible for completing the control method. 15 Page For multiple Control Plan pages. For each operation that is described. as appropriate. Change Number 13 Date Date the original Control Plan was compiled. list the individual part numbers and their processes accordingly. Approval / Date 17 Customer Quality Obtain the responsible quality representative (if required). process flow diagram. 10 Supplier / Plant Approval Obtain the responsible manufacturing plant approval (if required). 3 Enter the John Deere part number (and supplier part number. and sketches. Device. g. 16 Customer Engineering Obtain the responsible engineering approval (if required). Corporate Supplier ID or factory department). Part Name / Description 5 Enter the name of the company (supplier) and the appropriate division or Supplier / Plant manufacturing plant preparing the Control Plan. Prototype: Build for verification of design Pre-launch: Build prior to normal production for verification of processes or Production Production: Build or product that John Deere will offer for sale to customers 2 Control Plan Number Enter the control plan document number used for tracking.

and disposition made by the responsible person designated in the reaction plan. Process Characteristics for which variation must be controlled to minimize product variation must be identified. computer aided design data. but are not limited to. fixtures. (See Section 7.1. There could be one or more Process Characteristics listed for each Product Characteristic. When sampling is required. component.JDS-G223 23 Product APPROVED FOR SUPPLIER DISTRIBUTION Enter the applicable Product Characteristic. An analysis of the reproducibility. Statistical Process Control. Enter the applicable Process Characteristic. This could include gages. 24 Process 25 Key Characteristic METHODS 26 Product / Process Specification / Tolerance 27 Evaluation / Measurement Technique 28 29 Sample Size / Frequency Control Method 30 Reaction Plan 46 . inspection. Enter a brief description of how the operation will be controlled. such as. In addition. quarantined. stability. function. The method of control should be continually evaluated for effectiveness. mistake-proofing. enter the sample size and frequency. and sampling plans. A Key Characteristic is a product or process characteristic whose variation or targeting control is necessary to meet customer requirements and that directly or significantly impact customer satisfaction through compliance with government. In all cases. tools. Indicate if the characteristic is designated as a Key Characteristic. repeatability. material standard. A Process Characteristic can only be measured at the time it occurs. Key Characteristics may be the Product or Process type.1) A systemic plan using procedures and other tools to control a process.2. Enter the corrective actions necessary to avoid producing nonconforming products or operating out of control. design reviews. This column may also refer to a specific reaction plan number and identify the person responsible for the reaction plan. the manufacturer my list other Product Characteristics for which process controls are routinely tracked during normal operations. appearance). and / or test equipment required to measure the part / process / manufacturing equipment. but not limited to. suspect and nonconforming products must be clearing identified. Specifications / tolerances may be obtained from various engineering documents. drawings. ability to perform its intended design requirements (form. or assembly that are described on drawings or other primary engineering information. set up person. manufacturing and / or assembly requirements. or manufacturability and ability to assemble. Operations may be controlled by. include procedure numbers. country or industry standards and/or regulations. attribute data. supervisor) and should be clearly designated in the plan. Identify the measurement system being used. Provisions should be made for documenting. In some processes one Process Characteristic may affect several Product Characteristics. where applicable. Product Characteristics are the features or properties of a part. The actions should normally be the responsibility of the people closest to the process (operator. Process Characteristics are the process variables (input variables) that have a cause and effect relationship with the identified Product Characteristic. All Key Product Characteristics must be listed on the Control Plan. and accuracy of the measurement system should be done prior to relying on a measurement system and improvements made accordingly. fit. reliability.

47 . please refer to https://jdsupply. For the latest version of this document.com/.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 This is a sample form.deere.

JDS-G223 18 Appearance Approval Report APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form. please refer to https://jdsupply. 48 . For the latest version of this document.com/.deere.

deere. For the latest version of this document.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 19 Performance Test Results This is a sample form. John Deere Production Part Approval Performance Test Results Supplier Name: Supplier Code: Name of Laboratory: Test Specification / Rev / Date Specification / Limits Test Date Quantity Tested Part Number: Part Name: Revision Level: Test Results (Data) / Test Conditions OK Not OK NOTE: Blanket statements of conformance are unacceptable for any test results. please refer to https://jdsupply. Comments: Submitted By: E-Mail: Date: 49 .com/.

deere. A status report shall be submitted to the originator of a John Deere initiated corrective action request (preferred via the Nonconformance Corrective Action (NCCA) system) within five days from the date of receipt.com.JDS-G223 20 Corrective Action Request Form APPROVED FOR SUPPLIER DISTRIBUTION Seven of the Eight Corrective Action Disciplines (8D) or Resolution Phases are required.deere. John Deere Corrective Action Request 8D Report Creation Date: Report Number (NCCA / Q-note): John Deere Unit: Supplier Signature: Severity: John Deere Location: Supplier ID: Incidental Minor Major Critical Supplier Name: Supplier Location: John Deere Part Part Name: Number: Supplier Part Quantity Affected: Number: STEP DESCRIPTION D1 Establish the Team / Responsibility John Deere Name: Telephone: Supplier Name: Telephone: D2 Nonconformity (NC) Problem Identification / Cause of Reject Enter comments: E-Mail: FAX: E-Mail: FAX: Responsible Implementation Actual Completion Person’s Name Target Date Date Responsible Implementation Actual Completion Person’s Name Target Date Date D3 Enter comments: Containment Action and Short Term Corrective Action / Immediate Actions(s) Define and Verify Root Cause / Cause of Nonconformity Choose and Verify Solution Implement Permanent Corrective Action / Long-Term Corrective Action(s) Prevent Recurrence Team Recognition / Management Feedback (Optional) D4 Enter comments: Responsible Implementation Actual Completion Person’s Name Target Date Date D5 Enter comments: Responsible Implementation Actual Completion Person’s Name Target Date Date Responsible Implementation Actual Completion Person’s Name Target Date Date D6 Enter comments: D7 Enter comments: Responsible Implementation Actual Completion Person’s Name Target Date Date Responsible Implementation Actual Completion Person’s Name Target Date Date D8 Enter comments: NOTE: Containment of nonconforming material is required within 24 hours of problem notification. For the latest version of this document. It is preferred that Correction Action Documentation is done via the Nonconformance Corrective Action (NCCA) System: https://ncca. 50 .com/. unless otherwise specified by the John Deere investigator. This is a sample form. D1 through D7. please refer to https://jdsupply.

other than specified in the assigned deviation.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 21 Engineering Deviation Authorization Checklist and Form John Deere will accept supplier’s deviation forms containing. at a minimum. This deviation does not allow for any additional print changes. The supplier shall produce parts to John Deere print specifications. 51 . • • • • • • • • • • • • • Date John Deere Part Number and Description Quantity Affected Proposed Deviation (Use As Is or Reclaim) Description of Proposed Deviation Reason for Deviation Supplier Name and ID Number Supplier Contact Telephone Number FAX Number E-mail address Long Term Corrective Action Target Date for Corrective Action (1 year maximum) REPLY from JOHN DEERE • • • • • • Accept Reject Deviation Number Corrective Action Verification Required (Yes or No) Use for Service (Yes or No) Approval Signatures The assigned deviation number shall accompany all parts shipped to John Deere covered by this deviation. the following information. The assigned deviation shall be referenced in any future correspondence concerning these parts.

: Part Description: Models Used On: Requested By: Quantity Affected: Proposed Deviation: APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form.JDS-G223 ENGINEERING DEVIATION AUTHORIZATION Part No. (if applicable) Department or Supplier Name and ID Number: Telephone Number: FAX Number: Date: Target Date: Verification Required? Yes No Assigned To: For John Deere Use Only APPROVED Comments: Authorized Piece(s) / For: Prod. Decision or ECN: Date: Date: APPROVED with Limitations (see Comments) REJECTED No (If No. John Deere EDA NUMBER: Dept Charged: Use As Is: Date: Reclaim (describe below): Description of Proposed Deviation: Reason for Deviation: Reclaim Method: Personnel Contacted: Supplier Contact Name: E-Mail Address: Reviewed by Quality Engineer: Long Term Corrective Action: ECN No. 3) May02 .com/. parts shall be identified as “Not for Service”) 52 Reference: CED-101 (Rev. For the latest version of this document please refer to https://jdsupply. Project Doc Number Ref.deere. Days APPROVALS: Product Engineering (Required): Quality Engineering (Required) Add to Distribution List: Use for Service: Yes Ref.

Conduct routine audits and infrequent capability studies (using R / d 2 from traditional SPC methods). Variability reduction is the second priority when Process Potential nears Process Capability. and then reduce the overall process variation to improve the process capability. The goal is to get to Case 5. 4 5 6 53 . Audit frequency is determined based on the ability to recall nonconforming material if audits result in finding such material. and in control.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 22 Process Evaluation . Case 2 – The first priority is targeting the mean.0 ≤ Cp < 1. See Case 5 Control charting required Cpk ≥ 1. First. target the process using EWMA and/or CuSum – Means Testing.3 Action Plans Nonconforming product is known to occur. and/or has excessive variation.0 or Unknown Mean and Variability. Variability reduction is unnecessary if properly targeted. The first attempt should be to target the process on the nominal specification. See Case 3 100% inspection and corrective action required 1. Case 3 – The first priority is targeting the mean. Reduce the variability until the process potential is approximately one. See Case 2 100% inspection and corrective action required Cp ≥ 1. Once Process Potential equals Process Capability.33 Mean and/or Variability. Improvement of targeting and reduction of variability is required. The process is targeted. these cases imply rework or scrap conditions. quality tools and techniques should be used to determine the cause(s). See Case 6 Routine audits required The goal for each process is to produce parts at the nominal specification value. Improvement of targeting is required.33 Mean Only. Once Process Potential equals Process Capability.33 Not Possible Mean and/or Variability. Case 6 is achieved.2.33 Not Possible Not Possible Auditing of Both. target the process using EMWA and/or CuSum. See Case 1 100% inspection and corrective action required 1.0 ≤ Cpk < 1. capable. 100% inspection and a corrective action plan are required.) Case 1 – The first priority is reduction of variability.Continuous Process Monitoring Matrix CONTINUOUS PROCESS MONITORING MATRIX Process Potential – Pp or Cp Cp < 1. Case 1. First.0 or Unknown Process Capability – Ppk or Cpk Cpk < 1. Reduce the tolerance by half of the Gage R&R (expressed as a percent of the tolerance applied. Targeting the mean is the second priority. If a process is not targeted. See Case 4 Control charting and sampling required Mean Only. switch the priority to using traditional SPC for variability audits and variability reduction.

Mean control is the primary goal. Variance shall be monitored and reduced.33 Cpk < 1.33 Cpk < 1. The primary issue is targeting.33 CASE 5 Cp ≥ 1. At a minimum. This process is capable of producing parts that conform to specifications.0 DESCRIPTION REQUIREMENTS This process is not able to continuously produce parts conforming to specifications.0 CASE 4 1. CASE 3 Cp ≥ 1.JDS-G223 CASE CASE 1 Cp < 1. There is little concern of nonconforming product. The primary issue is targeting. This process is capable of producing parts that conform to specifications. Pre-Control. Pre-Control. John Deere written approval is needed prior to shipping parts. or run charting) to verify the parts being produced conform to design specifications. Charting (SPC.0 Cpk < 1. or run charting) shall be used to verify the parts being produced conform to design specifications. Charting (SPC.0 ≤ Cpk < 1. 75%. 25%. This condition requires 100% inspection and a corrective action plan to improve the process.33 1. The primary issue is targeting. 54 . such as during the quartile marks for each run (first.0 ≤ Cp < 1. These conditions require 100% inspection and a corrective action plan to improve the process. If the process capability is unknown. Evidence of less than .0 ≤ Cpk < 1. The interval is determined by the Cp value – the greater the Cp value. Audit variance using SPC. Typical SPC won’t help until the process is fixed for both the mean and the variability. such a process should be verified as appropriate by inspecting the parts being produced. well centered. This process is not able to continuously produce parts conforming to specifications. 50%. This condition requires 100% inspection and a corrective action plan to improve the process. data collection is required to determine the capability of the process. An attempt should be made to determine the special cause(s) that are prohibiting the process from being centered or are creating excess variation. and in control. Variance shall be monitored. Parts produced are conforming.33 Cpk ≥ 1.0027% defective is required. John Deere written approval is needed prior to shipping parts.33 CASE 6 Cp ≥ 1. the less frequent the parts have to be checked. Mean control is the primary goal. An attempt should be made to determine the special cause(s) that are prohibiting the process from being centered or are creating excess variation. John Deere written approval is needed prior to shipping parts.0 or Unknown GRAPHICAL REPRESENTATION APPROVED FOR SUPPLIER DISTRIBUTION CASE 2 1. and last piece). but may or may not be targeted at the nominal specification value.0 ≤ Cp < 1. but may or may not be targeted at the nominal specification value.33 1.33 This process is capable. The primary issue is targeting. John Deere written approval is needed prior to shipping parts. Evidence of < . and a sampling plan to inspect parts per a frequency interval shall be executed. This process is not able to continuously produce parts conforming to specifications.0027% defective is required.

75σ 2.02 3.25σ 0.6 from The Management and Control of Quality. it may not be detected.5σ 0.DEFECTIVE PPM DUE TO PROCESS SHIFTING Process Shift 0 0.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 A shift or drift in the process can happen.8 12.1 0.57 1.5 233 577 1300 5.0063 0. by Evans and Lindsay.50σ 0.00σ 1.1056 0.002 0.5σ 6.019 0. The column at the far right shows the corresponding defective PPM if the process average moves 1. and depending on the process control technique being used.5 233 577 1350 3000 6200 5σ 0.5σ from the target (also known as the quality or six sigma level).4 233 6σ 0. QUALITY LEVEL .034 0.8 32 88.00σ 3σ 2700 3577 6440 12288 22832 40111 66803 105601 158700 3.50σ 1. Reference 18: Table 14. Suppliers need to be aware of this and shall measure their process capability at least annually. The matrix below further shows the effect off-centering due to a process shifting has on the defective PPM.4 10. West Publishing Company) 55 .25σ 1. 3rd Edition.02 3. When this has been exhausted.5σ 465 666 1382 3011 6433 12201 22800 40100 66800 4σ 63 99 236 665 1350 3000 6200 12200 22800 4.4 11 32 (See Section 34.75σ 1. Any action other than that listed in the Continuous Process Monitoring Matrix shall be approved by John Deere.4 11 32 88.39 1 3.7 32 88.71 1. a review of the product design should be done to determine if the drawing requirements could be changed.

‘Measuring Process Capability’.21 – Flowchart for process capability studies. Copyright 2001 56 .R. D.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION START PROCESS VERIFY MEASUREMENT SYSTEM ESTABLISH CAPABILITY GOAL SELECT CHARACTERISTIC BEGIN APPROPRIATE CONTROL CHARTING CALCULATE CONTROL LIMITS BASED ON DATA IS PROCESS IN CONTROL? YES NO IMPLEMENT CORRECTIVE ACTION FOR SPECIAL CAUSE VARIABILITY NO DATA TRANSFORM POSSIBLE ADJUST PROCESS AVERAGE TO TARGET IS DATA NORMAL? YES ESTIMATE PROCESS PARAMETERS AND MEASURE CAPABILITY NO YES YES REDUCE SOURCES OF COMMON CAUSE VARIABILITY YES NO IS CAPABILITY > GOAL? NO YES IS FURTHER IMPROVEMENT NEEDED? YES IS THE PROCESS TARGETED? NO CAN AVERAGE BE MOVED? NO DETERMINE REQUIRED FREQUENCY OF ASSESSMENT MAINTAIN PROCESS AT CURRENT LEVEL REPORT AS REQUIRED STOP Figure 4. Bothe.

50 -0.00 1.50 0.6843 2979.75 2.00 1.50 1.0000 1.50 3.00 3.0000 0.0889 501349.0000 1.00 6.1678 226715.6017 0.6994 308770.5981 0.1739 22750.3983 0.17 -0.8943 0. Cpk -0.8413 0.0000 Probability of a Defect 1.9999 1.75 6.42 1.42 -0.6885 3.50 0.83 0.9970 0.0401 0.75 4.0668 0.0030 0.1203 697672.25 1.0000 0.00 Sigma Level 0.3023 0.0006 0.58 1.3832 864094.25 2.25 6.0000 0.9987 0.3088 0.0001 0.1057 0.67 1.0002 0.5487 6209.0000 1.7733 0.25 4.0062 0.75 5.0190 0.33 0.50 Probability Good 0.75 3.25 3.4186 12224.8780 785597.0000 934409.5013 0.08 1.25 0.00 0.50 4.4622 66810.67 0.2144 0.25 0.9332 0.9938 0.0656 0.2867 0.33 -0.17 1.58 0.00 7.0000 0.0228 0.6912 0.5989 40060.0122 0.4173 31.9599 0.25 5.0000 0.50 2.0171 0.0000 Defects Per Million Opportunities 1000000.08 0.4019 0.0000 1.0013 0.6291 88.75 0.1359 0.00 4.50 5.00 5.9998 0.0252 232.6712 10.00 2.75 1.9772 0.9252 105660.8641 0.6977 0.75 7.8980 401870.0010 57 .0000 1.83 2.7677 1349.2267 0.0760 0.00 0.4987 0.0000 0.9994 0.9344 0.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 23 Six Sigma Conversion Table for Variable Data This chart is used to determine Six Sigma equivalents for variable data based on the process being in statistical control and normally distributed.0000 1.8990 577.50 1.25 -0.75 1.0000 1.92 1.50 6.7697 158686.7856 0.0000 0.42 0.1266 601686.3977 1.0000 0.9878 0.0000 0.08 0.33 1.1587 0.25 1.17 0.

the process is run for the expected life of the tool. Modified control charts have control limits that are not established by conventional. The Acceptance information from these samples is used as a basis for making acceptance decisions Sampling concerning parts or processes. Control determinations are made by comparing the values of statistical measures of an ordered series of samples. These continuous control methods are appropriate for mistake-proofing when abnormal process variations are not present. They can establish whether. u. with control limits. np. heat-treat furnace data) or a discrete output (e.) Pre-Control is effective for any process where the quality characteristic of interest can be adjusted. and machining. SPC Control Charts can be used in an acceptance sense. in relation to tolerance requirements. This method can be used when the product stream is continuous such as painting.) SPC Control Charts are used as a basis to make decisions about a process. c. Inc. The last part produced with the old tool is then checked. 58 Modified SPC Pre-Control Restudy Setup Check Short-Run SPC SPC Control Charts Tool Control . as a precursor to a conventional SPC chart. There are no additional requirements and no underlying assumptions concerning capability.g. (See Section 34. to be considered uneconomical to control with conventional SPC Charts. Short Run SPC is used for small lot sizes of parts with characteristics common to a process. calling for action or investigation when a process shifts from its standard level. then all the parts are OK. SPC Control Charts demonstrate whether. Xbar & R.) Measurement data is used to verify process capability and Cpk on a periodic basis. (e. Eleventh Edition. This method can be used temporarily. These shifts should be small enough. (See Section 34. ASTM Manual on Presentation of Data and Control Chart Analysis.. or normality of the quality characteristic. assembly.) A control method where the first part is checked after a new tool is installed. They are sometimes referred to as Acceptance Control Charts. Reference 2: ASQ Glossary and Tables for Statistical Quality Control. a process can satisfy product or service tolerances. or not. SPC for Short Runs Curriculum. SPC Control Charts can be used with variable or attribute data. Each characteristic is transformed and plotted with other characteristics on the same chart. If the part checks OK. Examples are: CMM checks.JDS-G223 24 Process Control Methods APPROVED FOR SUPPLIER DISTRIBUTION Process control methods may include. but are not limited to. The process can have either a continuous output.g. control limit-setting techniques. (See Section 34. machine parts). Reference 8: Juran’s Quality Control Handbook. 5th Edition.. Reference 2: ASQ Glossary and Tables for Statistical Quality Control. or subgroups. the following methods.. Reference 3: AT&T Statistical Quality Control Handbook. Xbar & s. Examples are: (p. 1 January 1990.” It is generally assumed that assignable causes will create shifts in the process level.) Continuous Sampling This method requires that a consecutive number of pieces pass inspection before starting normal sampling cycles. (See Section 34. or not. and is “in a state of statistical control. welding. If it is OK. and gear geometry checks. This could be applicable for large numbers of parts from discreet batches. Reference 5: International Quality Institute. or as a permanent control method. Part characteristics are checked whenever the process is set-up and at periodic intervals. and IXMR). roundness checks. (See Section 34. CONTROL DEFINITION METHOD A sampling technique where units of product are drawn from a specific lot. 125 pages. the process is "in control".

C A. Juran Quality Improvement Pocket Guide C.E A.B.1 7. Memory Jogger II™ Pocket Guide of tools for Continuous Improvement D.C.1 6.E.C.D B.E.E F A.4 8.2 Manual Sections 7.1 Affinity Diagram Box Plot Brainstorming Capability Studies Cause & Effect Diagram Control Chart Control Plan Data Collection Design of Experiments Flow Chart FMEA – design FMEA – process Force Field Analysis Gage R & R Histogram Mistake – Proofing Pareto Chart PPAP (1st piece/lot certification) Problem Solving Process Mapping QFD Run Chart Scatter Diagram Tree Diagram Root Cause Analysis X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 5.C.1 8.6 6.C B A.2 5. John Deere Support – contact your John Deere representative.D B.E A.C E A.3 5.B.E.D C.C.2 8. Juran’s Quality Control Handbook F.E A.B.B.5 X X X Ref.B F REFERENCE (SEE SECTION 34) A.C.6 8.3 7.E.E D X X X C F F C B.C. AIAG manuals E. 59 .D B.E.2 7.5 7.4 7.4 5.3 8. A.D A. Juran Quality Planning Ready Reference B.D D E.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 25 Suggested Quality Tools Quality Tools 5.

Charts to monitor control and improve process performance. A graphical representation of the process data. Graphically display.shows variation in data for easier analysis. and determining if there is interaction between any of the variables. Documents significant process or part characteristics that require monitoring for capability levels. Gage Repeatability and Reproducibility measures the repeatability and reproducibility of gages to ensure that the gage meets the design intent. Pictorially shows where to focus effort for greatest improvement potential. Systematic approach to ensure the data/information gathered is accurate and meaningful. Failure Modes and Effects Analysis is an analytical method for determining the risk level of designs. graphically. Statistical measurement of the ability of manufacturing process(es) to consistently meet specifications/tolerances. Method to study data for trends or patterns over time.process Force Field Analysis Gage R & R Histogram Mistake . Failure Modes and Effects Analysis is an analytical method for determining the risk level of processes. 60 . Identifies the forces and factors in place that support or work against the solution. A method for analyzing multiple variables at one time. Production Part Approval Process that is used to assure that a new or changed product or process meets specifications.JDS-G223 DESCRIPTION OF QUALITY TOOLS Affinity Diagram Box Plot Brainstorming Capability Studies Cause & Effect Diagram Control Chart Control Plan Data Collection Design of Experiments Flow Chart FMEA . Visual analysis to determine if relationships between two sets of variables. Pictorial display of data distribution . A method to eliminate potential operator error from the process.Proofing Pareto Chart PPAP (1st piece / lot certification) Problem Solving Process Mapping QFD APPROVED FOR SUPPLIER DISTRIBUTION Run Chart Scatter Diagram Tree Diagram Root Cause Analysis Method for generating large numbers of ideas and then organizing and summarizing into groups. Quality Function Deployment is a structured approach for determining customer needs and translating those needs into the organization's language. A group of activities that together define what is being done to provide a service of product for the customer. into increasing levels of detailed actions that could be done to achieve the stated goals. possible causes related to a problem. Breaks any broad goal.design FMEA . This tool enables more thorough corrective actions. Identifies the flow or sequence of events in a process (also called Process Mapping). For creatively generating a high volume of ideas. An effective process for finding the cause(s) of an event. in detail. A common model that creates a common language for continuous improvement.

and to provide a means to document corrective action. while measuring the identical characteristic on the same part. process. is proven to meet its specification. while measuring the identical characteristic on the same part. Action taken to eliminate the cause of nonconformities in order to prevent recurrence. function. using the same measurement instrument. The standard deviation is calculated as R / d 2 . to record and control the use of the product. The goal for Cpk is to achieve a value of 1. prior to shipment. The process must be normally distributed and in control when calculating this index. The EPDP consists of six phases containing twenty-one milestones. The standard deviation is calculated as R / d 2 . This may also be referred to as Design for Manufacturability and Assembly. to assure that all process outputs remain in a state of control. when used several times by one appraiser. Constant used to estimate the sample standard deviation based on the sample size and average range value. The one-tenth of total variation allows the gage or measuring system to group measurements into 10 data categories. location. The process by which a product. The Control Plan reflects a strategy that is responsive to changing process conditions. and ease of assembly. Cpk The capability index is similar to Cp. through objective evidence.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 26 Glossary Cp The capability index defined as the ratio of the specification width to the natural variation of the process. supply base. manufacturability. is the ability of the gage or measuring equipment to detect and indicate small changes in the measured characteristic. It does this by taking the ratio of the difference between the process average and the lower specification (or higher specification. A simultaneous engineering process designed to optimize the relationship between design function. Repeatability is the variation in measurements obtained with one measurement instrument. Records of the results of the procedures and job instructions that show the system is operating. or any change that may impact fit. The Control Plan describes the actions that are required at each phase of the process. an Engineering Deviation Authorization (EDA) is required. Chart showing the recommended steps needed for controlling a process. Sometimes referred to resolution.33 or greater. When part characteristics do not comply with engineering specifications. but it takes into account the centering of the process. The process must be normally distributed and in control when calculating this index. form. A Control Plan is a written description of the system for controlling parts and processes. Change Request Request for acceptance from John Deere prior to making changes to a specification. Cp indicates if the process is capable of producing parts within specification. Reproducibility is the variation in the average of the measurements made by different appraisers. 61 Control Plan Corrective Action d2 Design Process and Assembly Review (DPAR) Design Verification Deviation Discrimination Documents Enterprise Product Delivery Process (EPDP) Flow chart Gage Repeatability Gage Reproducibility . John Deere’s product realization process is called the Enterprise Product Delivery Process or EPDP. An approved Verification Warrant is required prior to shipment of production parts. whichever is less) to one-half of the natural variation limit. from receiving to shipping. performance or durability. and is maintained and used throughout the product life cycle. It is the sequence of processes required to successfully produce a product or service that meets or exceeds the expectations of John Deere and our customers. used several times by each appraiser.

but. An alternate material is one whose specifications do not fully meet those of the drawingspecified material. and trademarks. A global process at John Deere that is designed to deliver the right product at the right place at the right time. defining what management has committed to address and achieve with their quality system. The sample standard deviation is calculated by using all the data points. Alternate materials shall appear on the drawing. The most common of these are Cp and Cpk. warehouse). and specific part control plans. fit. This relationship is often quantified by measures known as process capability indices. only the primary material producer (e. features and performance meet customer needs and expectations. A Key Characteristic is a product or process characteristic whose variation or targeting control is necessary to meet customer requirements and that directly or significantly impact customer satisfaction through compliance with government. Determination that a material is equivalent requires a careful evaluation of all related specifications and characteristics. reliability. it is a term used to predict the process capability of a new process.g. This review shall only be performed by individuals who are well versed in those particular materials. equivalent Order Fulfillment Process (OFP) Physical Build Ppk Preventive Action Procedures Process Capability Process Control Product Validation Creative ideas and expressions of the human mind that have commercial value and receive the legal protection of a property right. Ppk is based off of the total variation and uses the sample standard deviation value in its calculation. Referred to as a performance index. able to provide supporting documentation (e. function.JDS-G223 Intellectual Property APPROVED FOR SUPPLIER DISTRIBUTION Job instructions Key Characteristic Manuals Material. Process capability is the range over which the natural variation of a process occurs as determined by the system of common causes. or manufacturability and ability to assemble. It begins with an estimate of retail sales and ends with the retail delivery and payment. Typically. The process must be normally distributed and in control when making this calculation. Documentation of the who. appearance). Often thought of as the top level documentation. and when of the manual’s requirements. Define how the employees accomplish the procedures. and the range or spread of the variation. ability to perform its intended design requirements (form. JDM 4120. Term used in the Enterprise Product Delivery Process to indicate a physical model which is used to evaluate the complete product. Unless specifically authorized by the appropriate Deere representative. inventions. It is recommended that both of these be used when determining what corrective action is needed to make a process capable. the centering of the natural variation. A particular method for performing a task.e. test procedures. what. and fully conversant with the relevant Deere specifications. have been verified as fully meeting the design intent and can be used interchangeably. a much higher value is required for Ppk as opposed to the Cpk due to the amount of uncertainty in the process. country or industry standards and/or regulations. standard operating procedures. alternate Material. An example of alternate materials is the material specification of the R200571 Gear which has JDM 8620. Monitoring of characteristics for capability to produce a feature under stable conditions to maintain ongoing acceptable quality levels. in writing. steel mill. mill certifications). patents. The importance of process capability is in assessing the relationship between the natural variation of a process and the design specifications. processes and tooling. may make that decision. Process capability has three important components: the design specification. inspection and test instructions. preventive maintenance instructions. Examples of process control documents are process sheets. The major legal mechanisms for protecting intellectual property rights are copyrights.) 62 . business methods and manufacturing processes. Action to eliminate the causes of potential nonconformities in order to prevent their occurrence. The process by which a product is confirmed by objective evidence to function properly in the total environment (i. or DIN 20NiCrMo2.g. qualified to make that evaluation. It includes ideas. foundry.

Providers of production and service parts. (e. finishing services (plating. etc) both inter-unit and external to John Deere. attention to detail. It’s often too late because deficiencies may not be obvious until after the resulting products have been used or services have been delivered. painting. monitored. communications. and complexity. Indicates mandatory requirements.5M.ihs.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Product Verification PV&V Risk Priority Number Shall Should Special Process R R Supplier Ensures the adequacy of design per the product performance and functionality specification (i. In order to prevent output deficiencies. and is operating at its current level of effectiveness. these special processes shall be validated in order to prove that they can generate planned results. In some cases this may include providers of engineering and production services. sub tier suppliers. Each category affects a part or component's overall risk to John Deere. A special process is any production or service delivery process that can generate outputs that cannot be measured. or the supplier’s supply chain. attitude. The product of Severity. Location of Standards John Deere Standards can be obtained on the web by going to John Deere Supply Network at the following URL: http://jdsupply. responsiveness. Detection. heat treating. A John Deere measure of part risk based on three categories: cost. Quality Plan Levels range from 0 to 4. All activities relative to procuring products needed to build the finished product.e. Average Range which is defined as the sum of all ranges divided by the number of ranges. A Verification Warrant (part submission warrant) is the cover page for the PPAP documents and requires John Deere approval prior to shipping production parts. the product will properly function in its intended application over its design life). plating) Range which is defined as the difference between the high and low values. painting. Achieving Excellence evaluation criteria for relationships. welding. heat treat. and provide drawings incorporating GD&T principles for John Deere Worldwide factories to the latest ASME Standard Y14. or verified until it’s too late.htm Industry standards can be obtained through other means such as Global Engineering Documents.com/business_processes/product_delivery_process/jd_eng_standards/jd_eng_stand ards_index. A composite analysis of the supplier’s initiative. Suppliers that supply our primary suppliers. with 4 representing the greatest risk.com/ 63 . Product Verification and Validation. Supply Management Sub contractor Quality Plan Level (QPL) Quality Record Warrant Wavelength 27 Engineering Standards Understanding Drawings John Deere expects suppliers to understand Geometric Dimensioning and Tolerancing (GD&T). http://global. Historical evidence that the quality system is functioning. severity.deere.g. and Occurrence in a Failure Modes and Effects Analysis. and performance. Indicates a mandatory requirement with some flexibility allowed in compliance methodology. Also referred to as Design Verification and Validation (AIAG) and Design and Development Verification and Validation (ISO). The required quality activities are identified based on the Quality Plan Level. also referred to as second and third tier suppliers.

capacity): Company Profile: B. and expansion issues. Financial planning. Cost objectives.deere. Operating Philosophies. & Continuous Quality Improvement? 64 E-Mail Internet EDI Web-based EDI Other: Yes Yes Yes No No No Yes No 7 Yes No . Plant. facilities. would you be able to discuss these areas with John Deere? Is the business plan a formal document that includes: Market related issues. If you responded "Yes" to any of the above questions and are unable to provide requested documents. please provide. R & D projections. please provide. Competitive assessment. Do you have a long-term business plan? If yes. For the latest version of this document please refer to https://jdsupply. JOHN DEERE SUPPLIER INFORMATION SURVEY John Deere Survey Lead: JD Survey Team Members: Lead John Deere Unit: Location: A.JDS-G223 28 Supplier Information Survey APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form. Supplier Information Company (Supplier) Name: Survey Date(s): DUNS #: Supplier Contact Name: Company Web Site url: Title or Position: John Deere Supplier ID (if Department: any): Supplier Address Supplier E-Mail: City / Zip Code: Supplier Phone Number: Country: Supplier Fax Number: Nearest Large City: Language Capabilities: Nearest Export Shipping Port: Date of Last John Deere Assessment or Survey (if any): State Owned Enterprise Private Public Wholly Owned Other: Legal Form / Ownership: Joint Venture Subsidiaries (with location. Plant Space Employment Capacity / Current Utilization space. Growth projections. Do you have a mid-term business plan? If yes.com/. Formal methods of update. Sales projections (realistic and adequate?). Performance tracked and measured. 1 2 C. Sales projections (realistic and adequate?). please provide. 3 4 5 6 Communication Which system(s) can you access? How many people communicate in English? Management Information Do you have a documented organization structure? If yes. Human resource development. employment.

Coordinate Measuring Machine)? Are Process Capability Study Indices (Cpk) available for Critical-To-Quality parameters? Reject Rate Does your company warranty products? Will you accept costs in field modification programs related to the failure of your product? Personnel Do you provide training programs? Do you provide training specific to product and process understanding for employees? Do you review job descriptions and individual performance reviews with employees? Does your organization demonstrate management and labor commitment to company goals? Do you set individual performance goals? Do you have organized programs to promote employee participation (i. please provide union affiliation(s). please specify any conditions and your policy on low volume service parts.g. Which industry do you supply (e. indirect. Yes No Is your company a manufacturing facility? If yes. employee suggestions programs)? What are employee absenteeism and turnover rates? Number of employees (direct. 9 Who are your suppliers (multiple tier) and competitors? What are their relative strengths and weaknesses? Quality Systems Quality System Certifications If yes. 15 16 17 18 19 20 Yes No Internal External Yes No Yes No Yes Yes Yes Yes Yes Yes No No No No No No 21 22 23 24 F.) Yes No Do you supply service parts? If yes.. problem solving teams. Commercial Situation * * Current John Deere suppliers do NOT need to complete this section. healthcare.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 8 D. Expiration date(s) of certification What are your measurement and testing capabilities (e.e. 25 26 27 28 Do you have a union affiliation? If yes. unemployment rate. availability of skilled and unskilled labor) and the company's relative standing in size and stability. what are your major manufacturing processes? (Please indicate details on following worksheets.g. history and length of any strikes.e.1/6 Other: 10 11 12 13 14 E. off-highway)? Major Who are your main customers? Name % of Sales Employees Direct Indirect Salaried Yes No First Shift Second Shift Third Shift Products Volume PPM 29 How much business do you already have with John 65 Business John Deere Division . please provide accreditation body / bodies. Please describe area labor availability (i. business team concepts. contract expiration date(s).. salaried): ISO-9001 ISO-9002 ISO-9000:2000 ISO/TS 16949 QS-9000 VDA 6. automotive.

export. and repair services do you use (list sources. Yes No Year Period Current Assets Current Liabilities Total Liabilities Retained Earnings Total Equity Sales Interest Expense Pre-Tax Income Cash & Securities Inventories Accounts Receivable Accounts Payable Long Term Debt EBITDA Net Income (After Tax) Export (% of sales) Export to Europe (% of sales) Export to USA (% of sales) Number of Employees Facility Size (square feet) Yes Yes No No Land Age G. restricting increased capacity or production rates? What other facilities does your company operate? What internal tooling / die design. Z . shifts. and age. Are buildings. land. and utilities adequate for the commodity being considered? Is the facility laid out for efficient material flow and manufacturing? What is the installed production capacity for each major product? (Define by quantity and time required to produce the material in days. current or pending? Please provide the financial.JDS-G223 30 31 APPROVED FOR SUPPLIER DISTRIBUTION Deere. cooperative associations. facilities. maximum. business agreements. 41 . manufacturing. if any? Are there any joint ventures.) What are the constraining factors. and repair capability for tooling exists? Describe any tooling / gaging programs geared toward improved efficiency such as tooling standardization and quick change tooling. 32 33 34 35 Facilities / Production Please indicate the size of facility. if any. average)? 66 36 37 38 39 40 H. What external tool / die design manufacturing.SCORE and employee data listed for the last four years. or significant sales agreements. and hours per shift. if any? Cost System What is your pay scale range (minimum.

e. 50 51 K. please specify the location(s)? Do you have warehouse overseas? If yes. stored. 48 49 J. labor incentives. and shipped in a manner that prevents damage? Do you utilize bar coding? Describe the level of product traceability that exists within the manufacturing facility. please specify the location(s)? What is your current logistics system? 67 Yes No Yes No Yes No Yes Yes Yes No No No FIFO LIFO Random Other. and what actions are taken as a result of that comparison? Provide a breakdown of full cost disclosure (material. How do you calculate your quoted prices? Can Product Engineering costs be tracked by project and invoiced separately if so requested? Continuous Cost Improvement Programs Do you have a Continuous Cost Improvement Program which covers both internal and external costs? Do you share cost improvement results with your customers? Print / Specification Control How are prints and / or specifications changes controlled? How do you ensure that current active files contain only up-to-date drawings? Material Handling / Packaging Is material identified clearly during and between operations? Is material handled. 65 66 67 Do you have incentive programs (e. (i. Please Specify: . How are they applied? How is planned cost performance compared to actual cost performance. lead times and run sizes)? Logistics Do you have distribution system overseas? If yes. overhead) by part number / product. labor.. 60 61 62 63 64 N. gain sharing.. Please Specify: Yes No Current Goal Yes No Yes Yes No No Yes Yes ERP No No MRP Location(s): Location(s): Other.g. bonus programs)? Provide a copy of your study or other methods used to determine overhead application rates. Inventory What type(s) of inventory control are used? Do you have a method for controlling material with a limited shelf life? Describe how inventory accuracy is monitored. 56 57 58 59 M. 52 53 54 55 L.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Yes No 42 43 44 45 46 47 I. (Note trends) What is current inventory turnover and what is goal? Scheduling How are production schedules driven? Do you have a procedure for reconciliation between customer schedules / orders and production records? What are your normal lead times? Do you have plans for lead time reduction? Do you have flexibility in manufacturing schedule.

JDS-G223 68 69 O.. which disciplines are included on the teams? Do you have multi-function project management Yes No techniques in place to effectively track and meet all key event dates (e. Quality Function Deployment (QFD))? Disciplines: Are simultaneous engineered teams used when Yes No new products are developed? If yes. Failure Modes and Effects Analysis (FMEA). problem resolution and testing? List both local and corporate. what R & D programs have you successfully implemented in recent years? Product Testing ** ** Please complete if you own the design for the product that John Deere wishes to purchase. quality and cost against competitors? Do you provide prototype parts? If yes. Are direct customer / supplier engineering Yes No communications encouraged? What design processes are utilizing up-front design analysis techniques (e. report 68 Yes No Yes Yes Yes No No No Yes Yes Yes No No No Lead TIme: . performance.. Describe your capability to conduct analysis.g. etc) considered in developing the Product Verification and Validation (PV&V) plan? Do you incorporate customer requirements and customer duty cycle information into PV&V activity? Do you have application data for your products? Are you able to demonstrate reliability. Please Specify: existing customers? What kind of Computer Aided Design (CAD) AutoCAD Catia IGES/STE None Pro/E Unigraphics Other. prototype material.g. sample submission dates. 80 81 Do you have a procedure to track actual delivery Yes No performance on order quantities and customer due dates against desired customer performance? Do you have any Just-In-Time and / or point of use Yes No delivery systems? Engineering and Technical Support What kind of data interchange tools do you use with VDA EDIFAC ODETTE Other. quote / estimate programs. Reliability and Performance Risk Assessment. tooling programs. Customer Satisfaction Information. application. please indicate lead time. 70 71 72 73 74 75 APPROVED FOR SUPPLIER DISTRIBUTION 76 77 78 79 P. new product launch programs)? Description: Do you have an in-house Research and Yes No Development (R&D) department? R&D Programs: Do you have R & D activities for development of Yes No new technologies? If yes.e. and design life requirements of your components? Do you update PV&V procedure based on failures discovered during customer use? Do you benchmark your performance. Complete System Testing Do you have test facilities in-house to complete Yes No System Testing in a Vehicle component testing? Other: 82 83 84 85 86 87 88 Are multiple input sources (i. reliability. Please Specify: Systems do you use? How many terminals do you have? Do you have an in-house tool shop? Yes No What engineering / technical support can be provided for design.

that John Deere desires to purchase? Do you have documentation to substantiate that you own.)? Have you obtained and maintained all environmental permits and registrations that apply to their facilities.g. or chemical spills and implement emergency 69 Yes Yes No No How Monitored: Yes Yes No No Product Liability Claim(s): Yes No Yes No ISO-14001 ISO 18001 Other: Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No . Describe your policies concerning defense of product liability claims? Describe your policies concerning defense of product liability claims? Do you have any pending product liability claims involving product(s) we are considering? If yes. 95 96 R. health and safety legislation (through government certificate or registration. subject to any enforcement action by any governmental authority for non-compliance with environmental. and accurately predict product life in the user's environment (e. accelerated. 97 98 99 100 101 102 103 104 105 all applicable product performance tests. or proper license that allows you to lawfully manufacture the product. or at any time during the past calendar year. please provide accreditation body / bodies. or disposed of on-site managed in properly designed facilities that will prevent future environmental impacts? Do you have a program to identify and assess potential emergency situations such as weather. fire. or are licensed to use. how are they monitored? Have lab test acceleration factors been determined by correlation of lab and field test data? Describe your procedure for analysis of field return failures. Expiration date(s) of certification Do you have a system to ensure compliance with the minimum working age prevailing standard? What is the age of your youngest employee? Do you have an accurate system to measure hours worked to ensure conformance with applicable wage and hour labor laws? Do you have a process to ensure compliance with applicable laws concerning discrimination in hiring and employment practices? Are you currently. and products.. life. safety)? Are outside performance testing sources are used? If yes. including reporting obligations in accordance with applicable laws and regulations? Are wastes that are stored. safety. or labor requirements? Can you demonstrate legal compliance with government environmental. please describe. treated. third-party audit. field. operations. or utilize the manufacturing process. the requisite Intellectual Property Rights? Supplier Code of Conduct Environmental and /or Health & Safety System Certifications If yes.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 89 90 91 92 93 94 Q. Regulatory Conformity Do you own the patent / copyright. etc.

brand. electrical. illness frequency.g. chemical fumes. slips. / Size Quantity Age T.g. mechanical. evaluate and control safety hazards (e. Pulleys & Sheaves Rubber Parts Survey Summary (to be completed by John Deere Lead) 70 . Process Technologies *** *** If applicable. and pneumatic) of workplace equipment and machinery and conditions (e. mold) at or below levels established as safe by applicable laws and regulations? Do you have a program to identify. confidential.g. evaluate and control workplace exposures to chemical. hydraulic. biological and physical agents (e. and severity incidence rates? Do you have a program to ensure compliance with applicable laws concerning proprietary.JDS-G223 106 APPROVED FOR SUPPLIER DISTRIBUTION 107 108 109 110 S. Yes No Yes No Yes No Yes Yes No No Machine Description Machine Manufacturer Ton. Please include major manufacturing and testing equipment indicating size. 111 plans and procedures? Do you have a program to identify. Aluminum Fittings Hydraulic Plumbing Belts Flangets Plastic Castings Forgings Sheet Metal Electric Assembly Gears & Shafts Spring Electronics Hubs. dust. and personal information? Equipment Provide a list of equipment. please complete the appropriate worksheet. noise. fall hazards. and condition. trips. physically demanding work) to prevent injury to workers? Do you have a program to provide and require the use of personal protective equipment when safety hazards and workplace exposures cannot be controlled by other means? Can you provide list time injury. age.

if not provided in advance. and Date of Certification Expiration (ISO.com/.deere. Registrar. JOHN DEERE RED FLAGS SUPPLIER QUALITY SYSTEM SURVEY Supplier Name: Supplier Number: Supplier Address: Supplier E-Mail: John Deere Survey Lead: Principle Products: Audit Date(s): Supplier Representative(s): Supplier Phone Number: Supplier Fax Number: Survey Team Members: Date of Last John Deere Assessment or Survey (if any): Process(es) / Product(s) Audited: Supplier Contact(s): Position: Phone: Note: Secure copy of certification(s). For the latest version of this document please refer to https://jdsupply. and Date of Expiration (ISO 18001): Overall Survey Results and Recommendations Supplier Quality System Level: Sourcing Recommendation:: Survey Observation Summary: Red Flag Quality System Survey Scorecard # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Quality Tool & Process Dimensions Not Used or NO Primitive or YES Partial Use Fully Utilized Points Notes / Comments Are there any restricted materials or other banned substances in the product to be purchased by John Deere? Y/N Is there child (under 14 years) or forced labor present? Y/N Use of PPM Metrics to track quality Y/N Quality PPM improvement trend over time Y/N Nonconformities “prevented” not “caught” Y/N Dependent on Inspection Y/N Operator Dependent Y/N Track Rework leading to Corrective Actions Y/N In-process Gaging Data Generation Gage R & R’s SPC Application Process Controls Written Procedures Control Plans Corrective Action Programs Clear Misson Statement and Quality Policy Y/N If yes.): Environmental System Certification.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 29 Red Flags Supplier Quality System Survey This is a sample form. supplier fails the survey If yes. ISO/TS. Registrar. and Date of Expiration (ISO 14001): Health and Safety System Certification. supplier fails the survey 71 . Registrar. Quality System Certification. etc.

PV&V capabilities align with design control responsibilities Training program for design and PV&V staff Metrics used to measure if design requirements are met Understand application of their product Update design guidelines and PV&V procedures based upon customer failure modes Total Survey Points: Level I: Level II: Level III: Level IV: Start Up Quality System Beginning Quality System Mature Quality System Highly Developed Quality System 72 .JDS-G223 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Posted and Understandable Metrics Training Program Functional Process / Design FMEA Documentation Control Plans developed by Failure Modes & Effects Analysis (FMEA’s) ISIR Utilization Document Control ISO Registration Y/N Cost of Quality (COQ) Root Cause Analysis (RCA) Problem Solving Tools Advanced Quality Planning (AQP) Focused Six Sigma Initiatives Living Failure Modes & Effects Analysis (FMEA’s) Control Plan illustration of Cpk for Key Characteristics Production Part Approval Process Quality Function Deployment (QFD) Utilized Mistake Proofing QS 9000 or TS 16949 Registered Y/N APPROVED FOR SUPPLIER DISTRIBUTION Red Flag Product Engineering Survey Addendum (Only for Supplier Design Control Components with Quality Plan Level ≥ 3. lab test and field test correlated with customer use Procedure and acceptance criteria for each PV&V activity Design.) # 35 36 37 38 39 40 41 42 Product Engineering Dimensions Not Used or NO Primitive or YES Partial Use Fully Utilized Points Notes / Comments Generate and track execution of Product Verification and Validation (PV&V) Plans Design analysis.

There is no evidence of implementation or documentation (major nonconformance).): Environmental System Certification. 4 Requirement is "world class" in terms of scope and implementation or it shows major signs of significant improvement over the last 12 months which is meaningful to the Customer. 3 Requirement is met and effectively implemented and fully documented. Document in NCCA Does Not Comply Does Not Comply Complies Complies No action required No action required Complies ** A supplier must have a score of 2 or greater on each of the questions to be acceptable.com/. Registrar. etc. Registrar. Registrar. 2 Requirement is met but there are minor inconsistencies in implementation or documentation. For the latest version of this document please refer to https://jdsupply. and Date of Expiration (ISO 14001): Health and Safety System Certification. Document in NCCA Requires Corrective Action Request (CAR). 1 Requirement is partially met but there are major inconsistencies in implementation or documentation (major nonconformance).deere. Quality System Certification. Document in NCCA Requires Corrective Action Request (CAR). and Date of Expiration (ISO 18001): GENERAL SUPPLIER RATING CRITERIA Score Ability to meet requirement in ** question: 0 Requirement is not met. if not provided in advance. 73 Rating Corrective Action Requires Corrective Action Request (CAR). and Date of Certification Expiration (ISO. ISO/TS.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 30 Supplier Quality System Audit Questionnaire This is a sample form. or is in the early phases and only preliminary evidence of implementation effectiveness exists (minor nonconformance). JOHN DEERE JDS-G223 SUPPLIER QUALITY SYSTEM QUESTIONNAIRE Supplier Name: Supplier Number: Supplier Address: Supplier E-Mail: Audit Team Leader: Principle Products: Supplier Phone Number: Supplier Fax Number: Audit Team Members: Audit Date(s): Supplier Representative(s): Date of Last John Deere Assessment or Survey (if any): Process(es) / Product(s) Audited: Supplier Contact(s): Position: Phone: Note: Secure copy of certification(s). .

including operator training.5 Is required product identification (including material certification and heat number. with executive responsibility. Question Supplier has procedures in place designed to ensure that the requirements set out in John Deere’s Supplier Code of Conduct are met? Y/N There are no products containing substances in excess of the amounts set forth on John Deere’s Restricted Materials List and/or other substances restricted by applicable laws? Y/N Score Audit Status: Answers for the above two questios. tooling. etc) where conformance to specification cannot be verified in subsequent operations? Section Score: Section Compliance: (Complies = no question scored less than 2) D. and approved by authorized internal personnel before implementation? 8 7. Supplier is responsible to insure all tiers of the supply base comply to these requirements. Q1 and Q2. and delivery? Section Score: Section Compliance: (Complies = no question scored less than 2) 74 . 4 8.2 Is a structured process used to identify Key Characteristics and control methods? Please list methods and tools. APPROVED FOR SUPPLIER DISTRIBUTION Score each question using a 0 to 4 point scale.2 Is there timely review. Management Review 1 5. and implementation of customer engineering standards and specifications and changes? Verify revision levels of drawings or models in use at the supplier? 11 7.2 Has written customer approval or waiver been obtained and documented prior to a design or process change being implemented into production? Section Score: Section Compliance: (Complies = no questions scored less than 2) C. review all quality system elements at defined intervals to ensure its continuing suitability and effectiveness? 2 5. in particular on Key Control Characteristic (including facilities. is revised? 7 7. A. frequency.2 Are mistake proofing techniques used where appropriate. Score non-applicable questions as 3. etc. plating. monitored for special processes (heat treat.5 Are control plans reviewed and updated as appropriate when any of the following occurs: Product or process changes? Processes are found to be unstable or non-capable? Inspection method. if applicable) maintained through all stages of production.JDS-G223 I.6 Does the supplier's Management. welding.6 Are the following metrics posted and are improvement goals established? Internal quality reject Part Per Million (PPM) External quality reject PPM On-time delivery Section Score: Section Compliance: (Complies = no questions scored less than 2) B. # Q1 Q2 Quality Ref. Product Identification and Traceability 12 7. equipment.5 Compare control plan items against part print and determine control plan adequacy.5 Are appropriate process parameters. Document Control 9 4.3 Are supplier-initiated design or process changes documented. 6 7.2 Has the supplier established a process to ensure that invalid and / or obsolete documents are promptly removed from all points of use or otherwise assured against unintended use? 10 4. must be yes for the audit to continue. assembly. and for problem resolution)? 5 7. Quality Planning 3 7. distribution. where 4 is the best possible score. reviewed.

2 Does supplier maintain or exceed the process capability requirements of JDSG223 on key control characteristics? Are monitoring and improvement plans in place for those processes that do not meet the process capability requirements? 21 8. plating.2 Does the supplier carry out final inspection and testing in accordance with the Control Plan and/or documented procedures? 25 8.2 Does the supplier assure that no product is released until all activities specified in the documented procedures have been satisfactorily completed and that the associated data and documentation is available and authorized? 26 8. and / or source mill? 15 7.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Process Control 7. gages and other equipment? Customer designated Key Control Characteristics? Supplier designated Key Control Characteristics? Statistical Process Control (SPC) requirements as appropriate? Relevant engineering and manufacturing standards? Inspection and test instructions. including frequency? Reaction plan as appropriate? Revision date and approvals of Work Instructions? Visual aids as appropriate? Tool change intervals and set-up instructions? Material certification. Inspection and Testing 22 8. such as: chemical and mechanical properties. heat number.3 Is production equipment and working environment suitable for manufacturing of specified characteristics? Are production machines and equipment appropriate for the product being produced? Is there documented evidence of process capability? Are production machines and equipment clean and adequately maintained? 18 7.2 Does the supplier inspect and test in-process product as required by the Control Plan and / or the documented procedures? 24 8. hardness.2 Does supplier retain and use appropriate data on key control characteristics for continuous process improvement? 20 8.5 Is there evidence of a preventive maintenance program? 19 7.2 Does the supplier conduct scheduled audits of the final product in accordance with 75 E.5 Does the reaction plan for internal out-of-control conditions include as appropriate: Containment and 100 percent inspection? Specific corrective action timing? Responsibility assignment? Documented customer approval? 16 7.2 Does supplier verify that characteristics are to specification after a setup has been completed? Section Score: Section Compliance: (Complies = no question scored less than 2) F.5 Do operators clearly understand their responsibilities when loss of process control or out of specification conditions exist? 17 6.5 Do process monitoring and other operator instructions include or reference: Operation name and number? Part name and part number? Current engineering level / date or decision number? Required tools. 13 .5 Have documented process monitoring and other operator instructions been prepared for all employees? Are they accessible at the workstation? Is there evidence of use? 14 7.2 Does the supplier ensure that incoming product is not used or processed until it has been inspected or otherwise verified as conforming to specified requirements in accordance with the quality plan and/or documented procedures? 23 8.

whenever the 76 31 7. and Test Equipment 29 7.g.4 Does the supplier quantify and analyze nonconforming product..3 Does the control of nonconforming or suspect material provide for material identification / segregation / evaluation and notification of all appropriate functions? 38 8.4 Does the supplier inspect.6 Does the measurement system provide appropriate discrimination of the total product tolerance being measured? 30 7. establish a 8.)? Is each piece of inspection equipment calibrated: At prescribed intervals? On certified master equipment (traceable to standards)? In a controlled environment? 32 7.5 Is the inspection and test status of product identified such that the conformance 8. and track progress to the plan? 42 7.6 Does the supplier maintain calibration records for inspection measuring and test equipment? 35 7. asbestos or lead in paint) and/or other substances restricted by applicable laws? Section Score: Section Compliance: (Complies = no question scored less than 2) G.2 Does the supplier maintain records which provide evidence that the product has been inspected and / or tested and approved prior to release? 28 7.3 status is recognizable and understood? Section Score: Section Compliance: (Complies = no question scored less than 2) I.3 Does the supplier clearly identify nonconforming and suspect product and the quarantine areas? 39 8.3 Are repaired and/or reworked products re-inspected and / or tested according to the Control Plan and/or documented procedures? 41 8.6 . defined? 40 8.3 in excess of the amounts set forth on John Deere’s Restricted Materials List (e.3 Is the responsibility for review. Control of Nonconforming Product 37 8. and authority for the disposition of nonconforming product.6 Has the supplier identified inspection measuring and test equipment with a suitable indicator or approved identification record to show the calibration status? 34 7.2 Does the supplier obtain customer authorization prior to shipment. lobbing. Inspection. Measuring. surface finish.6 Does the procedure for calibration of inspection measuring and test equipment include the following: Unique identification? Part name and part number? Location? Frequency of checks? Check method? Acceptance criteria? Corrective actions when inspection equipment is found out of calibration? Review process for product inspected with "out of calibration" measuring equipment? 33 7. test. etc.5 prioritized reduction plan.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION the Control Plan to verify conformance to all specified requirements including packaging? 27 8. and verify that products do not contain substances 8.6 Has the supplier performed Gage Repeatability and Reproducibility studies on key control characteristics and do they meet the established criteria in JDS-G223? Section Score: Section Compliance: (Complies = no question scored less than 2) H. Inspection and Test Status 36 7.6 Has the supplier identified all inspection measuring and test equipment that can affect product quality? Are appropriate measurement systems used for required characteristics (roundness.

5 Have methods to prevent damage or deterioration been provided for the handling of production material and are they being followed? 48 7. Statistical Techniques 56 8.4 What appropriate statistical tools are being used during: (Reference JDS-G223 25 Suggested Quality Tools) Quality planning? 77 .5 Are returned parts analyzed and are records of this analysis kept and made available upon request? Section Score: Section Compliance: (Complies = no question scored less than 2) K. Storage.5 Do procedures for corrective action include effective handling of customer complaints and reports of non-conformances? Do these procedures: Verify corrective action from past Corrective Action Requests? Consider implementation of corrective action on similar products / processes? Consider impact of corrective action on other products / processes? 45 8. Quality Audits 49 5.2 Does the supplier use the appropriate statistical tools required to establish.5 Does the supplier use a disciplined problem solving method to address internal and external non-conformances? 44 8. Packaging. Training 54 6.1 Is a documented training plan established that identifies operator basic training needs? 55 6. for any deficiencies identified in an audit.6 Does the supplier have a documented program to perform internal audits of the 8. control.6 Are corrective actions. Corrective and Preventive Action 43 8.5 Do procedures for corrective action include mistake proofing or other preventive action to avoid root cause re-occurrence and verification to ensure effectiveness? 46 8.6 Are personnel conducting the audit trained and independent of the function being audited? 51 5. carried out on a timely basis? 53 7. and verify product quality? 57 8.2 quality system? 50 5.5 Are methods to prevent damage or deterioration been provided for the shipment of production and service material and are they being followed? Section Score: Section Compliance: (Complies = no question scored less than 2) L.4 Is there a documented procedure for auditing of the supplier's supply chain? Is there evidence that it is being followed? Dimensional Specifications Mechanical Properties Hardness Plating Traceability of heat number to the mill shipment Evidence of auditing traceable to the mill Section Score: Section Compliance: (Complies = no question scored less than 2) M. and Preservation 47 7.6 Are the audit results recorded and brought to the attention of the responsible personnel? 52 5.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 product or process is different from the current Production Part Approval Process (PPAP) approval? Section Score: Section Compliance: (Complies = no question scored less than 2) J.1 Have operator's basic training needs been fulfilled for the job being performed? Section Score: Section Compliance: (Complies = no question scored less than 2) N.

) If answer is “no”. the Company desires to purchase? 59 7. subject to any enforcement action by any governmental authority for non-compliance with environmental. Discrimination 67 1 Does the supplier have a process to ensure compliance with applicable laws concerning discrimination in hiring and employment practices? Section Score: Section Compliance: (Complies = no question scored less than 2) T. Supply Chain Value Assurance at 90smcompliance@johndeere. or labor requirements at any facility at which products supplied to John Deere are manufactured? 69 1 Can the supplier demonstrate legal compliance with government environmental.4 If the supplier possesses the requisite Intellectual Property Rights. safety.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION Quality control? Quality improvement? Section Score: Section Compliance: (Complies = no question scored less than 2) O. Child Labor 65 1 Does the supplier have a system to ensure compliance with the minimum working age prevailing standard? (Minimum working age for John Deere suppliers is 14 years. General Information 64 1 Does the supplier have procedures in place designed to ensure that the requirements set out in John Deere’s Supplier Code of Conduct are met? Section Score: Section Compliance: (Complies = no question scored less than 2) Q. Environment. Health. Section Score: Section Compliance: (Complies = no question scored less than 2) R.com. Regulatory Conformity 58 7.4 Does the supplier have documentation to substantiate that it owns the requisite Intellectual Property rights. and Safety 68 1 Is the supplier currently.4 Are the Intellectual Property rights effective and legally enforceable in the country where the supplier will produce the product or utilize the manufacturing process? 61 7. etc.)? 78 .4 Is the supplier aware of any 3rd party Intellectual Property Rights which could interfere with the proposed supply agreement? If yes. or that it is properly licensed to use the requisite Intellectual Property Rights? 60 7. or at any time during the past calendar year. notify Manager. identify the 3rd party and the Intellectual Property Rights involved.4 Does the supplier have documentation to substantiate that its Intellectual Property Rights are effective in the country where it will produce the product or utilize the manufacturing process? 62 7. or utilize the manufacturing process. Supplier Code of Conduct P. Compensation and Working Hours 66 1 Does the facility have an accurate system to measure hours worked to ensure conformance with applicable wage and hour labor laws? Section Score: Section Compliance: (Complies = no question scored less than 2) S.4 Does the supplier own the patent or copyright that allows it to lawfully manufacture the product. health and safety legislation (through government certificate or registration. Section Score: Section Compliance: (Complies = no question scored less than 2) Category Score: Category Compliance: (Complies = no questions scored less than 2) II. thirdparty audit. is the duration of such rights sufficient to cover the term of the proposed supply agreement? 63 7.

treated.g. including reporting obligations in accordance with applicable laws and regulations? 71 1 Are wastes that are stored. physically demanding work) to prevent injury to workers? 75 1 Does the supplier have a program to provide and require the use of personal protective equipment when safety hazards and workplace exposures cannot be controlled by other means? Section Score: Section Compliance: (Complies = no question scored less than 2) U. biological and physical agents (e.g.g. trips. evaluate and control workplace exposures to chemical. and personal information? Section Score: Section Compliance: (Complies = no question scored less than 2) Category Score: Category Compliance: (Complies = no questions scored less than 2) 70 1 79 .APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Has the supplier obtained and maintained all environmental permits and registrations that apply to their facilities. slips. mold) at or below levels established as safe by applicable laws and regulations? 74 1 Does the supplier have a program to identify. electrical. or disposed of on-site managed in properly designed facilities that will prevent future environmental impacts? 72 1 Does the supplier have a program to identify and assess potential emergency situations such as weather. noise. Confidential Information 76 1 Does the supplier have a program to ensure compliance with applicable laws concerning proprietary. evaluate and control safety hazards (e. chemical fumes. hydraulic. fire. mechanical. confidential. and pneumatic) of workplace equipment and machinery and conditions (e. dust. fall hazards. and products. or chemical spills and implement emergency plans and procedures? 73 1 Does the supplier have a program to identify. operations.

5 Hour 2. Packaging and Preservation • Statistical Techniques Brief review of findings. mission. • Quality planning • Communication with their supply chain • Document Control • Product Identification and Traceability • Process Control • Control of Nonconforming Product • Corrective and Preventive Action • Storage. if available: .5 Hours 2. Registrar.0 Hours 0.Quality System Certification. Training Records Regulatory Conformity and Supplier Code of Conduct questions (Environment. Non-conformances. review plan for Day 2 Brief review of findings.25 Hours 1.5 Hours Audit team meeting Briefing Complete assessment Element review Working lunch (on-site) Continue element review John Deere meeting Closing Session plant 1. Review business competencies.) . and follow-up schedule for corrective action activities. Communication of final report schedule. Human Resources) John Deere Team presents Strengths. and Date of Certificate Expiration (ISO 18001) Current Quality Manual Quality Procedure Manual(s) Completed self-assessment of the JDS-G223 audit Corrective Action files for the last six months Internal Audit reports for the last twelve months External Quality System Audit reports for the last twelve months Minutes and Quality metrics used for management reviews from the last six months Training Records • • • • • • • • JDS-G223 QUALITY SYSTEM AUDIT SCHEDULE TEMPLATE: Topic Opening Session Begin assessment in plant Time 1. Safety. and assessment plan.5 Hours 1.Environmental System Certification. Management Review Minutes and Quality Metrics. QS.0 Hours 0. quality policy. Opportunities for Improvement. and Date of Certificate Expiration (IS). etc.Health & Safety System Certification.from incoming material to shipping. Working lunch (on-site) Continue plant assessment 0.5 Hours 2.5 Hours Description DAY 1 Define scope of assessment. and vision.5 Hours 80 .JDS-G223 • APPROVED FOR SUPPLIER DISTRIBUTION ASSESSMENT MATERIAL (to be available for an audit): John Deere requires copies of the following certifications. Registrar. Registrar & Date of Expiration (ISO 14001) . Process flow will be followed .0 Hour 1. resources. Internal Audit Reports. Focus will be on control and verification procedures. review plan for Day 2 DAY 2 • Inspection and Test • Inspection and Measuring Equipment • Inspection and Test Status Corrective Actions.5 Hour 1.

APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 31 Product Engineering Audit Flowchart and Questionnaire 81 .

** This Product Engineering Audit is only for suppliers which produce components with a Quality Plan Level (QPL) ≥ 3 and in which the supplier has design control. Quality Function Deployment (QFD). Score non-applicable questions as 3. Product Verification & Validation Plan 1 What input sources are used to develop the Product Verification and Validation (PV&V) plan for the supplier's products? (e. * John Deere employees reference Product Engineering Likert Scale for additional information on scoring.. JOHN DEERE SUPPLIER PRODUCT ENGINEERING QUESTIONNAIRE Supplier Name: Supplier Number: Supplier Address: Supplier E-Mail: Audit Team Leader: Principle Products: Audit Date(s): Supplier Representative(s): Supplier Fax Number: Audit Team Members: Date of Last John Deere Assessment or Survey (if any): Process(es) / Product(s) Audited: Supplier Contact(s): Position: Phone: Rating Does Not Comply Does Not Comply Complies Complies Complies GENERAL SUPPLIER RATING CRITERIA * Score ** Ability to meet requirement in question: 0 Requirement is not met. Product Engineering # Question A. humidity. or is in the early phases and only preliminary evidence of implementation effectiveness exists (minor nonconformance).com/. etc. There is no evidence of implementation or documentation (major non-conformance).g. Does the supplier understand the corner conditions? Describe methodology. 2 Requirement is met but there are minor inconsistencies in implementation or documentation. General Component Specifications) 2 How are customer requirements and customer duty cycle information incorporated into PV&V activity acceptance criteria (targets or success criteria)? What (if any) tools are used for this linkage (e. Critical to Quality)? Does the supplier work with their customers to determine the PV&V plan and acceptance criteria? (Their customer = John Deere) 3 Does the supplier understand the application (loads. Customer Satisfaction information. 4 Requirement is "world class" in terms of scope and implementation or it shows major signs of significant improvement over the last 12 months which is meaningful to the Customer. temperature ranges. 82 Score . For the latest version of this document please refer to https://jdsupply.g.JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION This is a sample form. A supplier must have a rating of 2 or greater for each of the questions to be acceptable. I.) for their components? Describe methodology. customer usage. environment. Reliability and Performance Risk Assessment.. where 4 is the best possible score. 3 Requirement is met and effectively implemented and fully documented. Score each question using a 0 to 4 point scale.deere. 1 Requirement is partially met but there are major inconsistencies in implementation or documentation (major nonconformance). dust conditions.

)? What CAD system is utilized and how many terminals do you have? 9 What are the defined skill sets for each design and PV&V position? What is the training program for each design and PV&V position? 10 What are your Research & Development activities for new technologies? What. R&D programs have you successfully implemented in recent years? Section Score: Section Compliance: (Complies = no elements scored less than 2) C. Optimized Design 11 How are the supplier's PV&V procedures and design guidelines updated based upon major failure modes discovered on their components during customer use (production)? During field test? 12 What types of reviews are included in the PV&V plan? What design reviews are conducted if a PV&V plan is not used? For each type of review.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 Does the supplier have a method of documenting and retaining this data? Describe methodology. technology and customer duty cycle)? 8 Do you have computer aided design and analysis resources? How is it used (i. prototype material. etc. what is the lead time for prototype parts? How is conformity to design specifications (made to print) verified? What cost structure is used for prototype parts? Section Score: Section Compliance: (Complies = no elements scored less than 2) 83 4 5 .g. safety)? How is the design analysis correlated with customer use? What component design areas does the supplier have where analytical results are as good as test results . sample submission dates. How is execution of the PV&V plan tracked? How does the supplier demonstrate their components meet reliability. how are issues and problems identified? How are corrective actions verified and validated? 13 Is there capability to conduct analysis (e. performance.. modeling..e.where no correlation hardware tests are required? 14 How does the supplier know what they are offering is the best design from their product line for our application? Does the supplier benchmark their performance / reliability / quality / cost against their competitors? Section Score: Section Compliance: (Complies = no elements scored less than 2) D. hand calculation. Product Development Process 15 Are simultaneous engineering teams used when new products are developed? What disciplines are included? 16 Are multi-function project management techniques in place to effectively track and meet all key event dates (e. life. accelerated. and new product launch programs)? 17 Are prototype parts furnished to customers? If so. and design life requirements? What metrics are used to measure if design requirements are met? Section Score: Section Compliance: (Complies = no elements scored less than 2) B. finite element analysis. quote / estimate programs. field. part design. tooling programs. if any. Product Engineering Strategic Planning 6 What responsibilities are included within the PV&V organization? Who is responsible for the PV&V effort? Who do they report to? What is the PV&V staffing ratio of PV&V engineers to design engineers? 7 What plans or processes does the supplier use that demonstrate they are capable of verifying and validating the components under their design control by adapting their design and PV&V capabilities to the changing product environment (application. tool design. simulations.g.

. design analyses. Supplier Verification -Tier I & Tier II 20 How are supplier lab tests correlated with customer use? What component design areas does the supplier have where lab results are as good as field test results . ASTM. SAE) and/or by using John Deere component specifications? Section Score: Section Compliance: (Complies = no elements scored less than 2) F.g.JDS-G223 E. lab tests) documented. Section Score: Section Compliance: (Complies = no elements scored less than 2) Category Score: Category Compliance: (Complies = no elements scored less than 2) 84 .where no correlation field tests are required? How is product life accurately predicted in the users' environment? 21 How are Tier II supplier lab tests correlated with customer field use? Section Score: Section Compliance: (Complies = no elements scored less than 2) G. ASAE. 18 APPROVED FOR SUPPLIER DISTRIBUTION Product Verification & Validation Activities How are established procedures for PV&V activities (reviews. reported and used? How does the supplier communicate PV&V results to their customers? What is the documentation process for reporting results and the document retention policy of these results? 19 Does the supply base conduct their testing activities using accredited test standards (e. Continuous Improvement Projects 22 How is the PV&V process applied to continuous improvement (running changes) projects? What percent of the PV&V plan is completed prior to release? 23 Describe your procedure for analysis of field return failures.

deere. ISO/TS. Registrar. and Date of Expiration (ISO 14001): Health and Safety System Certification. For the latest version of this document please refer to https://jdsupply. Recommend CAR. and is there a documented control plan in place to continuously monitor the process control and capability? If the part has Key Characteristics. effectively implemented. if not provided in advance.com/. visible. Registrar. Document in NCCA Opportunity for Improvement. 1 Does Not Comply Requirement is not met or partially met. Requirement is met but there are minor inconsistencies in implementation or documentation. where 3 is the best possible score. was the change process followed per JDS-G223? Do the process control documents adequately address all process parameters and product characteristics? Are the Product and Process Key Characteristics known.): Environmental System Certification. JOHN DEERE PROCESS VERIFICATION AUDIT QUESTIONNAIRE Supplier Name: Supplier Number: Supplier Address: Supplier E-Mail: Audit Team Leader: Reason for Audit: Audit Date(s): Supplier Contact(s): Supplier Phone Number: Supplier Fax Number: Audit Team Members: Date of Last John Deere Assessment or Survey (if any): Process(es) / Product(s) Audited: Note: Secure copy of certification(s). but not required No action required 2 Needs Improvement 3 Complies ** A supplier must have a score of 2 or greater on each of the questions to be acceptable. Part Number(s) or Families: # A. and Date of Expiration (ISO 18001): GENERAL SUPPLIER RATING CRITERIA * Score ** Ability to meet requirement in question: NA Requirement is not applicable. Requirement is met. There is no evidence of implementation or documentation. or major inconsistencies in implementation or documentation (major nonconformance). etc. Quality System Certification. Registrar. 1 2 3 4 a b c n Question Document Control Is the part print to the current Revision Level? Are the Control Plan documents being used up-to-date? If the Control Plan at the supplier is not the same version as the one at John Deere. have a Gage R&R and capability study been 85 Score . and Date of Certification Expiration (ISO. Rating Does Not Apply Corrective Action No action required Requires Corrective Action Request (CAR). Score each question using a 1 to 3 point scale. Input NA for non-applicable questions. and fully documented.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 32 Process Verification Audit Questionnaire This is a sample form. or is in the early phases and only preliminary evidence of implementation effectiveness exists.

frequency and sampling method take into account the sources of variation? (Examples: multiple machines or fixtures for same characteristic. properly maintained? Are all the gages calibrated and records retained? Do Gage R&R studies have acceptable results? Corrective Action Is the Reaction Plan listed on the Control Plan effective & being followed? Is there an adequate process for isolation & control of non-conforming material (inc. does the Control Plan follow the requirements of the Continuous Process Monitoring Matrix? Are cleanliness requirements documented on the Control Plan? Are the Process flow diagrams.) 86 . Customer Notification) & is it being followed? Is an effective closed-loop corrective action process. Capability Studies. multicavity molds for the same part. like tool wear and environment) Are other pertinent process control documents in place and being followed? (Examples: process sheets. inspection and test instructions.JDS-G223 d e 5 6 7 8 B. as appropriate? Change Control What is the change control process. including Control Plans. performed? If the key characteristic has a Cpk < 1. & are they followed? Are operators properly trained to perform their operations? Are appropriate personnel properly trained for performing work involving key product and process characteristics (especially for special processes)? Tools / Gages Is there an understanding of which tools/gages are needed for each operation. controlled and backed up? (Examples: CNC & PLC programs). 9 a b c d 10 APPROVED FOR SUPPLIER DISTRIBUTION 11 12 13 14 C. preventive maintenance instructions) Are Suppliers' (sub-tier) documentation of the above (questions 1-6) for key characteristics controlled and up-to-date? Are computer programs used in the manufacturing process secure. including identification of root causes. preventive maintenance instructions) Is inspection data retained and stored appropriately? Are instructions included for packaging to protect the parts (both in-process & final) from damage & contamination.) Are Change Control Procedures followed in accordance with JDS-G223 (Supplier Change Request)? Does this include applicable sub-tier suppliers? Scoring Summary Total Points Percent of Total Points Available (NA questions are excluded. and are the needed tools/gages at the work station? Are any tools/gages being used or needed but not called out? Does the operator understand the proper use of the tools/gages and is he/she using them properly? Is equipment. standard operating procedures. fully implemented? Does the supplier use NCCA. PFMEAs.33. 24 25 F. and changes over time. Material and Process Control Is the Control Plan applied at each operation and being followed. 15 16 17 18 19 20 D. must be updated. and is it effective? (All part and process documentation. 21 22 23 E. including tooling. and Gage R&Rs controlled and up-to-date? Are other pertinent process control documents up-to-date? (Examples: process sheets. inspection & test instructions. from incoming material to shipping? Is the frequency of inspection being performed as described in the Control Plan? Are the inspection method and equipment being used as described in the Control Plan? Do the operator instructions reflect the requirements of the Control Plan? Do the sample size. standard operating procedures.

asme. Neubaurer. Web site: http://www. The Memory Jogger II.org 3. Inc. Automotive Industry Action Group. 26200 Lahser Rd Suite 200. Edward G. ASTM Manual on Presentation of Data and Control Chart Analysis. http://www.goalqpc. Connecticut.com 6.htm.astm.aiag. Evans & Lindsay. Southfield. Administration and maintenance of John Deere standards is available through JD Supply Network: http://jdsupply. Third Edition. McGraw Hill 9. Wisconsin. 1-248-358-3003. American Society fro Quality.org 13. Automotive Industry Action Group. ISO/TS 16949. Fourth Edition. Quality Press. John Wiley 18. Automotive Industry Action Group. Juran’s Quality Control Handbook. Southfield. 1-248-358-3003.org 7. 34 References The following books.org 4.org 5. Barrentine.aiag. International Quality Institute. Vardeman and Jobe. Southfield. SPC for Short Runs curriculum.deere. Potential Failure Modes and Effects Analysis. Automotive Industry Action Group. http://qualitypress. GOAL/QPC. Statistical Process Control Second Edition ©. http://www. Quality Improvement Pocket Guide. http://www. MI 48034 (248)-358-3003. Wilton. http://www.aiag. Quality Planning Pocket Reference.com 87 . 26200 Lahser Rd Suite 200. MI 48034.deere. West Publishing Company 19. 3rd Edition ©.goalqpc. MA 01844. http://www. and web sites are referenced in this manual: 1. ASME B89. Methuen. The Management and Control of Quality. 1-800-643-4316. Southfield. Web site: http://www.org 17.aiag. http://www. 26200 Lahser Rd Suite 200.org 11. 1-248-358-3003. American Society for Quality. 13 Branch Street. 1-800-248-1946. Southfield. MI 48034. Automotive Industry Action Group.. Statistical Quality Assurance Methods for Engineers ©. Milwaukee 12. Ott.aiag. Wheeler. Production Part Approval Process. Ellis R. 7th Edition ©. Connecticut. Measurement Systems Analysis. Methuen. MA 01844. 1-800-545-8620. Advanced Topics in Statistical Process Control ©. Juran Institute. publications. Wilton. 1-248-358-3003. 26200 Lahser Rd Suite 200. 13 Branch Street. http://www.APPROVED FOR SUPPLIER DISTRIBUTION JDS-G223 33 Contact Information If you have suggestions for improvements to the John Deere Supplier Quality Manual please contact your John Deere Supply Management or Quality Representative.com/business_processes/product_delivery_process/jd_eng_standards/jd_eng_stand ards_index. Milwaukee. John Deere Supply Network: http://jdsupply. 1-800-338-7726 14. Juran Institute.org/ 16. ASQ Glossary and Tables for Statistical Quality. http://www. Process Quality Control. Schilling and Dean V.asq. 5th Edition. 1-800-338-7726 15. ASQ Quality Press. 1-800-643-4316.com/ 8. Concepts for R&R Studies. Donald J. MI 48034. Implementation Guide. American Society of Mechanical Engineers. SPC Press. 26200 Lahser Rd Suite 200. 4th Edition ©. MI 48034. http://www.asq.com 2.org 10. Second Edition ©. Larry B.spcpress. GOAL/QPC.

1 Quality Management System Audit 8.DMAIC replaced with DMADV Additional Audit Types (Forms.2.1 Key Characteristics Product and Process 7. starting in Section 9) .JDS-G223 APPROVED FOR SUPPLIER DISTRIBUTION A Summary of Changes from Previous Edition (For Information Only — Not Part of the Standard) 7.2. and QS9000.Additional Sections 8.1 Quality Plan Levels 7. or severity > 9 require follow-up" .(starting in Section 9) Additions / Revisions Form 10 PPAP requirements based on PLQP Form 12 Component Performance & Reliability Assurance Form 22 Updated Continuous Process Monitoring Matrix Form 31 Supplier Product Engineering Audit Flowchart Forms .2.4 Monitoring and Measuring of Product .Added "FMEA items with RPN > 100.2.1.2.(starting in Section 9) Deletion: Comparison Matrix for JDS-G223.2 Component Reliability Assessment Process and V2 Net Process 8.2 Manufacturing Process Audit Process Verification Audit (Form 32 Page 85) Special Process Audit (not in manual but will be linked to forms) Forms .3.2. ISO 9001:2000.5. Third Edition 88 .Ppk and Cpk clarification 8. TS 16949.3 Preventive Action .2.