Welcome To .: Planning For Process Sign-Off

Welcome to….
Planning for
Process
Sign-Off
Today’s Purpose:
To provide experience in
successfully planning
and evaluating major
Process Elements in
order to produce quality
products for the life of
the program.
Slide 2
What is PSO?
A systematic and sequential review of the
Supplier’s planned and actual manufacturing
process at the quoted peak daily line rate,
including:
Manpower Methods
Facilities Procedures
Equipment Software Level

Material Tooling
Slide 4
Today’s Agenda
1. PSO Strategy
2. Pre-PSO
Documentation Review
3. Pre-PSO Supplier
Readiness Evaluation
4. PSO on-site Visit
5. Post PSO visit
Slide 5
Process Sign-Off Strategy
Pre – PSO
 Review Requirements
 Documentation Review
 Supplier Readiness Evaluation
PSO On-Site Visit

 Witness Production Demonstration
Run
 PV & Packaging Shipping Testing
 Complete Sign-off
Post – PSO
 PPAP Warrant
 Continuous Conformance
Requirements
Slide 7
Scope of Process Sign Off
Why: Verify supplier quality planning
process & production processes
are capable of producing quality
parts in sufficient quantity
Who: Product Team Members &
Supplier
When: Starts early in CDS process, PSO
sign-off shall occur prior to S1,
CC throughout the life of
program
How: Pre-PSO Documentation Review,
PSO on-site visit and Post PSO
requirements
Slide 8
Risk Drivers
AQP Activity
Part Risk Level PAP PSO
Supplier Supplier
Low Self Directed
Led Led
Medium Collaborative Supplier DCX
High Directed DCX DCX
Slide 9
Where do PSO elements fit into CDS timeline?
Pre Specs Theme Final Specs S1 End S2 End Post
(Rahmenheft) Selection (Lastenheft PPDC S0 Start SO End S1 Start S2 Start & V1 V1
H G1 G2
) EF D1 D2 C B A Z
(165) Wks (143) Wks (121) Wks (104) Wks (78) Wks (35) Wks (22) Wks (10) Wks (0) Wks
#1 Part Number, Description CP25 – Disclose Parts in EBOM
#2 Design FMEA OD50 – Complete DFMEA
#3 Test Sample Sizes and Frequencies (DVP&R Plan & DV Testing) VF30 – Complete DV & PV Testing
#4 Process FMEA OD100 – Complete PFMEA

#9 Parts Handling Plan OD160 – Define Material Handling Plan
Initial Risk Evaluation (IRE) CP50 – Conduct Supplier Initial Risk Evaluation
#1.4 Engineering Standards
(CATIA Comments Page) OD210 – Production Release Design
#5 Process Flow Diagram/Floor Plan OD90 – Complete Process Design
#11 Tooling/Gages Identified OD140 – Complete Gage, Fixture, Test Equipment & Mistake Proofing Requirements & Test Plan
OD220 – Tooling/Equipment Design Complete
#14 Error/Mistake Proofing Plan OD140 – Mistake Proofing Requirements & Test Plan
#19 Parts Packaging/Shipping Plan OD160 – Define Material Handling Plan
#10 Operating Instructions VD150 – Verify Work Station Designs & Operation Descriptions
LEGEND #6 Control Plan VF116 – Complete Production Control Plan

#20 Gage & Test Equip. Evaluation
Yellow = PSO Element #16 Evidence of Product Specification
Requirement (SRE Run Results)
#15 LPA Plan

Red = Non-PSO #17 Line Speed Demonstration VF130 – Complete PSO
activity #22 Initial Process Study
Note: PSO Element #24 PV Testing Complete VF30 – Complete DV & PV

Requirement is PPAP
Testing
followed by
corresponding PAP
Task. Slide 10
Pre – PSO
PSO On-Site Visit

Run
Post – PSO
 PPAP Warrant
Requirements
Slide 11
Module 2: Pre-PSO
Documentation Review
Slide 12
DaimlerChrysler Process Sign-Off Summary
Report
DAIMLERCHRYSLER PROCESS SIGN-OFF SUMMARY REPORT
ALL PROCESS SIGN-OFF ELEMENTS APPROVED: X PSO EXTENDED RUN: X 4
SUPPLIER T. Automotive YE S NO YE S NO O P T IO N
MFG. LOCATION Somew here, MI SUPPLIER CODE 99999AF
PART NUMBER(S) 04885735AA PART NAME(S) Bushing- Sw age Toe Link Bush
CHANGE LEVEL(S) B PRE-PSO MEETING DATE 11/19/04
PROGRAM _LX_________________________________ PSO ON-SITE VISIT DATE / NUMBER__01/05/2005_____
* Docum ents w ith asterisk should be review ed during AQP m eetings and again during the Pre-PSO Docum entation Review
PSO PROCESS ELEMENTS
D O C UM E N T A T IO N P R OC ES S
1 PART NUMBER, DESCRIPTION AND Ac c e pt R e je c t Ac c e pt R e je c t
CHANGE LEVEL X X
*C ro s s re f e re n c e s h e e t Ye s No A c c e p t a b le S u p p lie r c h a n g e Ye s No
(IF AP P LIC AB LE) X n o t ic e p ro c e d u re X
1.4 Engineering Standards Identified E v id e n c e o f c u s t o m e r c h a n g e X
Ye s No n o t ic e p ro c e d u re
*C A T IA c o m m e n t s p a g e X P ro c e s s f o r o bt a in in g t h e Ye s No
wit h lis t o f a p p lic a b le s t a n d a rd s la t e s t s t a n d a rd re v is io n X
(e .g DC C , ENVIR ONM ENTAL,e tc ) Ac c e pt R e je c t Ac c e pt R e je c t
2 DESIGN FMEA X X
*D e s ig n F M E A c o m p le t e Ye s No D F M E A u p d a t e d t o in c lu d e Ye s No
& a c c e p t a b le X a p p lic a b le D V f a ilu re s X
Ac c e pt R e je c t
3 TEST SAMPLE SIZES AND FREQUENCIES X
Ye s No
*S ig n e d D V a n d P V p la n s X
*S ig n e d D VP &R ( D V c o m p le t e ) X
*S ig n e d wa iv e rs N/A
Slide 13
Some Changes from PSO 4
 Summary Report is now 3 pages
 PSO elements are in logical order
 Each element has checkbox to indicate
accept or reject
 Each sub-element has it’s own yes or
no checkbox
 Documents with * review during AQP &
again in Pre-PSO Document Review
Slide 14
PSO Process Elements Verified During On-Site Visit
Documentation Process
1. PART NUMBER, Accept Reject Accept Reject
DESCRIPTION &
CHANGE LEVEL
Yes No
* Cross-reference sheet Yes No
[if applicable]  Acceptable supplier
change notice
1.4 Engineering Standards procedure
Identified  Evidence of customer
* CATIA Comments Page
with list of applicable
change notice
standards  Process for obtaining
(e.g. DCC. Environmental, etc.) the latest revisions of
standards
Slide 16
Element 1 Differences
 Procedure to ensure Supplier has latest
Engineering Standard revision level
 A system in place to notify all applicable
departments of specification changes as they
occur
 Verify change notice procedure is cascaded
down through Extended Enterprise (2 down
through Extended Enterprise (2nd & 3rd Tier
Suppliers)
Slide 17
2. DESIGN FMEA Accept Reject Accept Reject
Yes No
Yes No  DFMEA updated
* Design FMEA to include
complete & applicable DV
acceptable failures
Slide 18
FMEA Driven Reaction Plan
High Severity Zone
RPN = Severity 10
x Occurrence 9
x Detection 8 High
Warranty
Severity Ranking
7 Zone
6
DCX Guidelines… 5
Use a Rolling Top 20 Pareto

4
Detection
methodology, give special
3
10 Ranking
attention to:
2
 Severity =8, 9, 10 1
 Severity =>5 with 1 2 3 4 5 6 7 8 9 10
Occurrence =>2 Occurrence Ranking

 Detection = 10
Slide 19
 FMEA done with latest AIAG guidelines
 FMEA “best practice” document and
communication process shall be
reviewed periodically
 Re-verify Design FMEA after any DV &
PV failures
 Reaction Plan
Slide 20
3. TEST SAMPLE Accept Reject
SIZES &
FREQUENCIES
Yes No
* Signed DV & PV plans
* Signed DVP&R
[DV complete]
* Signed Waivers
[if applicable]
Slide 21
 Both DV & PV and DVP&R have to be signed
by DaimlerChrysler engineering
 Must have signed waiver if DV has any
deviations
 Failures must be addressed with Daimler
Chrysler 8-Step Corrective Action form
 Supplier must have “Test to Failure” plan
Slide 22
Accept Reject
4. PROCESS Accept Reject
FMEA
Yes No
Yes No  Process correlates
* Process FMEA with occurrence
completed and detection
& acceptable numbers on PFMEA
Slide 23
 FMEA done with latest AIAG guidelines
 FMEA “best practice” document and
communication process shall be
reviewed periodically
 Re-verify Process FMEA after any DV &
PV failures
 Reaction Plan
Slide 24
Common FMEA Mistakes:
Some Rules to Follow
Common Mistakes… Some Rules…
 No clearly defined FMEA scope  State the failure effects in terms
 Process Causes or Controls Used of what the customer(might
notice or experience.
 Root Cause not Identified
 Potential cause is how the failure
 Forget to use Error/Mistake
could occur.
Proofing
 Elimination of specified “potential
 Setting Arbitrary Thresholds
causes” should result in a
 Too Vague / Not Detailed reduction in RPN – it is a check
 Too Late to ensure you found the
 Not Updated engineering root cause. The
severity will remain the same.
Slide 25
Basic FMEA Evaluation Questions
To prepare for Quality Gates ask these questions…
 Are all of major functions represented?
 Have you used historical data to identify all potential failure modes? Are they
detailed and specific?
 Are the effects to the customer described in detail? Is the severity rate
correctly evaluated?
 Are the potential causes detailed enough? Do they include how, when, where
and what failed?
 Does the current controls detect the cause?
 When was the FMEA last updated? Is it up to the latest design date?
 Are high RPN’s being addressed?
 What tests were used to validate corrective action?
 Are responsibilities and completion dates listed for recommended actions?
 Is there evidence of error/mistake proofing?
Slide 26
5. PROCESS FLOW Accept Reject Accept Reject
DIAGRAM &
MFG FLOOR PLAN
Yes No
Yes No
* Flow Diagram
 SPC operations
* Manufacturing Floor Plan identified on flow
diagram
* Work Station Layout  Unique equipment
numbers identified
on mfg floor plan,
flow diagram, or
workstation layout
Slide 27
 Identification of stations that measure
key characteristics shall be clearly
identified on flow diagram
 Unique identification machine numbers
shall be identified on the manufacturing
floor plan, flow diagram or work station
layout
Slide 28
6. CONTROL PLAN Accept Reject
Accept Reject
Yes No
Yes No
* Process characteristics
identified on the Control
 Proper adherence to
Plan Control Plan
* Verification of Mistake  Rework / Repair
Proofing on
Control Plan
stations have
acceptable controls
[if applicable]
Slide 29
Control Plan Evaluation Criteria
 Does it align with the process flow diagram?
 Does it reference DFMEA or PFMEA?
 Does it have Mistake Proofing or Error Proofing
methods?
 Does the reaction plan procedure have more than to
notify the supervisor?
 Does what they are controlling make sense for the
process? How was it determined?
 Willthe sample size and frequency be sufficient to
identify problems early enough?
 What continuous improvement plan do they have in
place?
Slide 30
 Include Mistake Proofing verification
 More attention on rework/repair operations–
they shall have controls equivalent to the
primary line
 A mechanism which links the Supplier’s
DFMEA & PFMEA to the Control Plan
 Supplier shall look at the “High Severity Zone” &
“Potential High Warranty Zone” to ensure that they
are addressed
Slide 31
7. QUALITY Accept Reject
PLANNING
Yes No
* Completed PAP/APQP
PSO Summary Matrix
7.2 Supply Base Management

* Easy Map, etc.
 Risk sub-components
 Level 3 PPAP data
7.3 Problem Solving Methods

* Example of a DOE, etc.
• 2 SID’s for DCC systems
* Example of a problem solving
technique
Slide 32
 Quality Planning now includes Supply Base
Management & Problem Solving Methods
 Supplier shall risk all components listed on
the Bill of Material
 PSO activities to be done for medium & high risk
sub-components.
 Sub-tiers to submit level 3 PPAP documentation
along with line speed demonstration results.
Slide 33
Element 7 Differences, con’t
 Communication Plan for lessons learned across
production lines within Supplier’s facility and
other Supplier facilities which ship product to
DaimlerChrysler
 DOE’s or other acceptable methods of process
optimization
 Problem solving methods should be verified by
specialist
 A minimum of two SID’s shall be obtained for the
DaimlerChrysler problem solving systems (e- CIMS)
Slide 34
Accept Reject
8. INCOMING MATERIAL Accept Reject
QUALIF / CERT
PLAN
Yes No Yes No
 Certificates of Analysis  Evidence of sub-tier
 Copies of sub-tier PSW’s monitoring
* Plan for lot control  Proof of lot control
* Plan for traceability
 Proof of traceability
Slide 35
 DaimlerChrysler requires use of the Lot
Sampling Table or Supplier can use 2 or
more inspection requirements in TS-16949
(section 7.4.3)
 Dock to Stock” (no incoming inspection) is
dependent on receiving 3 shipments without
defects or external complaints. Supplier shall
have documentation to support requirement
Slide 36
9. PARTS HANDLING Accept Reject
PLAN Accept Reject
Yes No
* Routing/Traveler Cards
Yes No
* Parts Handling Plan
 Evidence of acceptable
* Container Maintenance
parts handling
Plan
 Acceptable method of
inventory control
Slide 37
 Documented plan on how parts are managed
& tracked throughout entire manufacturing
process
 Should address segregation & identification of
scrap, rework/repair and WIP
 If Supplier’s traceability system depends on
their FIFO system, then all sub-tiers shall use
FIFO as well
 Document how containers are inspected &
repaired
Slide 38
 Acceptable method of inventory control
for Work In Process
 Acceptable method of inventory control
for returnable dunnage.
Slide 39
10. OPERATING Accept Reject
INSTRUCTIONS Accept Reject
Yes No
Yes
* Work Instructions No
 Visual displays clearly
* Inspection Instructions present at each station
 Operators follow
* Rework/Repair Instructions
work instructions
 Evidence of proper
operator training
Slide 40
 Operating Instructions shall be approved by
Supplier’s cross functional team, including
operators
 A robust process of training and qualifying
operators prior to operators performing
production processes shall exist
 List of Training requirements for each unique
workstation
 Visual inspection stations shall have methods
established to verify operator’s ability to find defects
(i.e. periodic testing, re-certification)
Slide 41
Documentation
Process
Accept Reject
11. TOOLING EQUIPMENT
Accept Reject
& GAGES IDENTIFIED
Yes No
Yes No
 STR in agreement with
* Tooling & Equipment List
Supplier’s manufacturing
facility
* Supplier Tool Record
 DCC ownership tags
present
Slide 42
 During on-site PSO visit, SQS verify all gages
/fixtures listed on STR (Supplier Tool Record) are
present on Supplier’s manufacturing floor
 When tooling is purchased for Tier 2’s/Tier 3’s, verify
the STR states the appropriate location
 All tooling, gages, fixtures and capital equipment
required to produce a product shall be identified
and appear on a tooling list
 All DaimlerChrysler owned tooling, gages and
fixtures shall be permanently tagged per AME 84-
206-0021 (GR/GR&R Tag)
Slide 43
12. SPECIAL PRODUCT Accept Reject
Accept Reject
& PROCESS
CHARACTERISTICS
IDENTIFIED
Yes No
* First Production Shipment Yes No
Certification (FPSC ) plan
acceptable &  SPC performed for
contains special identified
process & product
Special Characteristics
characteristics
Slide 44
 AllDaimlerChrysler directed sub-tiers
shall abide by the same FPSC quantity
requirements as DaimlerChrysler Tier 1
 Tier1-> 2 DCC Assembly plant = 2000
pieces; directed Tier 2 = 2000 pieces
 Completed FPSC shall be reviewed with
the DaimlerChrysler PSO team (Post
PSO activity)
Slide 45
13. PROCESS Accept Reject Accept Reject
MONITORING
Yes No Yes No
* Control charts  Acceptable 1st piece
approval process
* 1st piece approval  1st piece approval records
procedure
 Control &
Performance Charts
maintained appropriately
Slide 46
 Targets for FTC, Scrap and Rework to be
identified and documented
 Plans to improve FTC, scrap and rework shall be
documented
 PSO Team shall approve all Rework/Repair
operations, procedures and work instructions
 Must have acceptable First Piece Approval
process
 First piece retained until end of production run
 Documented evidence of its execution maintained
Slide 47
14. ERROR & Accept Reject Accept Reject
MISTAKE
PROOFING
Yes No
Yes No
* Error & Mistake
Proofing Plan
 Boundary samples
created & utilized
* List of Error &
Mistake Proofing  Mistake proofing
contingency plan
with visual/audible
alarm
Slide 48
 More detailed Element description.
 FMEA Severity >8 & all Special Product/ Process
Characteristics have Error/Mistake Proofing
 Error/Mistake Proofing with Line/Station Lock-out to ensure
defects don’t reach next operation.
 Audible and Visual indicators shall notify operator of the
failed operation
 Supplier create Boundary Samples for process
verification and agreed upon by PSO Team
 Boundary samples to include known conforming and non-
conforming; Appearance Master Samples, etc.
Slide 49
Accept Reject
15. LAYERED Accept Reject
PROCESS
AUDIT PLAN
Yes No
Yes No
* Acceptable LPA plan
 Acceptable LPA
* Frequency & structure performed
chart
Slide 50
Layered Process Audit (LPA)
LPA is an ongoing system of process checks, that verify
proper methods, settings, operator craftsmanship, error
proofing devices and other inputs are in place to ensure
a defect free product.
How does LPA work?

Process Audits are conduct by Encourages Management
looking at: Involvement:
1) Build Technique  Production Supervisor [1x shift]
2) Error Proofing  Area Management [2 x week]
3) Machining Attributes  Plant Manager [1 x week]
Slide 51
LPA Benefits
 Build variation based on work
standardization
Reduces
 End-of-line inspection
 Part defects
Improves First
time through capability
Morale
Facilitates Operator
training
Management / operator interface
Reinforces Safety regulations
Slide 52
LPA Compliance Verification
Documentation Review:
 LPA Roll-out Timing Plan
 LPA Procedures
 LPA Work Instructions
 LPA Structure & Frequency Chart
 LPA Process Control Audit Checklist
 LPA Error Proofing Verifications Checklist
 LPA Compliance Form: To be submitted
monthly to SQ Specialist
Slide 53
Accept Reject
16. EVIDENCE OF Accept Reject
PRODUCT
SPECIFICATIONS
Yes No Yes No
* Supplier Readiness  Completed & acceptable
Evaluation Completed Measurement System
and Acceptable Verification Report
Slide 54
 Supplier Readiness Evaluation form
 Supplier is required to perform Readiness Evaluation
run (SRE) at the production line speed
 Record First Time Capability, Gage R&R, etc.
 Recommendation for Suppliers to submit PSO
Summary Matrix (required for Body & White) with
SRE form for PSO review
 Compliance Report revised to Measurement
System Verification Report
 Approve Supplier’s process for measuring
product/process characteristics
Slide 55
Accept Reject
17. LINE SPEED Accept Reject
DEMONSTRATION
Yes No
 Contingency plan
for Bottlenecks
[if applicable]
Line Speed Observed:_______ FTC:_____
Slide 56
 PSOteam to compare Quoted Tooling
Capacity to the Daily Capacity Planning
Volume
 If there is a discrepancy between the two
numbers, the PSO team shall meet with
the DaimlerChrysler Buyer and the
Supplier to determine the required PSO
line speed
Slide 57
18. OUTGOING Accept Reject Accept Reject
QUALIFICATION
PLAN
Yes No Yes No
* Outgoing inspection  Evidence of
plan
non-conformance
* Part inspection
containment
standard
 Evidence of outgoing
audits [using part
inspection standard]
Slide 58
 Part Inspection Standards are required for all
“Key” parts (as identified by Engineering)
 Standard list all Product Characteristics inspected by
Supplier on finished product prior to shipment
 Outgoing Qualification Plan include “Forever”
Requirements
 Supplier Notification of Potential Non-Conformance
Process
 Documented evidence of outgoing audits (using
the Part Inspection Standard) and Containment
Records
Slide 59
19. PARTS PACKAGING Accept Reject Accept Reject
& SHIPPING
SPECIFICATIONS
Yes No Yes No
* Dunnage design  Acceptable container
sign-off from MHE management
[if applicable]
* Packaging & shipping
plan
plan
Slide 60
 MaterialHandling requirement shall
include a Unit Load Data (ULD) sheet
for Supplier designed dunnage approval
 DaimlerChrysler directed 3rd party
dunnage suppliers do not need MHE
design approval
Slide 61
20. GAGE & Accept Reject Accept Reject
TEST EQUIPMENT
EVALUATION
Yes No
Yes No
* Gage R&R studies
 Appropriate gages
* Calibration plan & used in the
schedule process
 Calibration performed
according to schedule
NOTE: The gage plan must explain how the

gage was determined.
Slide 62
 More detailed Element description
 Effective system to ensure calibration of
equipment done per schedule
 Reaction Plan for containment of
equipment that is out of calibration
 A Gage Plan that explains how
appropriate gage for process is
determined
Slide 63
 Allgages used in the process shall be
identified on Control Plan
 RPN’s reduced by measuring/gauging
shall have an acceptable gage
evaluation and calibration frequency
Slide 64
Repeatability & Reproducibility:
Some Rules
If repeatability is large compared to reproducibility the
reasons may be:
 Instrument needs maintenance
 Gage may need to be redesigned to be more rigid
 Clamping or location for gaging needs to be improved
 Excessive within part variation
If reproducibility is large compared to repeatability, the
reasons may be:
 Appraiser needs further training on how to use & read gage
 Calibrations on gage dial are not clear
 A fixture may be needed to help appraiser use the gage
more consistently
Slide 66
21. PREVENTIVE Accept Reject Accept Reject
MAINTENANCE
PLANS
Yes No
* PM Plan Yes No
 PM performed
* PM Schedule according to schedule
* PM Procedures/Work
Instructions
 Robust PM Process
 All tooling/equipment
on PM schedule
Slide 67
 PM plan to incorporate lessons learned from
prior production lines or Tooling/Equipment
related Quality concerns
 Addresses 3rd party (outsourced) PM
requirements
 Activities shall be identified on the schedule
 PM process equal to or better than that of the
Supplier
Slide 68
22. INITIAL Accept Reject Accept Reject
PROCESS
STUDY
Yes No
 Deviations [if applicable]
Yes No
 Acceptable First
Time Capability
 Acceptable Process
Sample size:_______ PpK requirement:_____
Capability
Slide 69
 Modified form
 Expanded to incorporate more information from
Production Demonstration Run (e.g. USL, LSL, UCL,
LCL)
 FTC requirement of 90% or greater
 < 90% needs approval of SQA Quality Manager
 Capability Matrix shall be used for those who
deviate from Initial Process Study sample size
requirements
 Ppk is based on sample size agreed upon by the PSO
team
Slide 70
“Z” Approval
 Elements 1– 22
“A” Approval
 Elements 1– 25
Slide 71
PSO Process Elements Required For Full Approval
23. PACKAGING Accept Reject Accept Reject
SHIPPING
TEST APPROVAL
Yes No
 Signed shipping / Yes No
simulation test  Shipping/simulation
approval testing completed
[MHE ULD sheet]
Slide 72
New Element
 Packaging shipping test results require
Corporate and Assembly Plant Material
Handling Engineering approval
 Simulation test results require Corporate
Material Handling Engineering approval
 DaimlerChrysler directed 3rd party dunnage
shall have shipping/simulation testing
performed
Slide 73
24. PRODUCTION Accept Reject Accept Reject
VALIDATION
TESTING COMPLETE
Yes No Yes No
 Signed DVP&R  BSR/NVH testing
[PV complete] complete
 Signed Waivers  PV test completed
[if applicable]  Repair/rework process
validation completed
[if applicable]
Slide 74
 Includes BSR/NVH
 Requires Engineering signature
approval of PV test plans
 Requires Engineering signature
approval of PV test results (DVP&R).
 PV testing must include parts from
rework/repair process (where
applicable)
Slide 75
25. CONTINUOUS Accept Reject Accept Reject
CONFORMANCE (CC)
Yes No Yes No
 Continuous
 CC team is sufficient
Conformance Team
identified & Trained to support Post-PSO
 Warranty process activities
flow diagram  Acceptable process
 Forever Requirements
for warranty analysis
submission procedure
 Family PV testing
agreed to by the
PSO team
Vehicle Families included in family

PV:______________________
Slide 76
 Service Requirements now identified for
Design & Serviceability
 Suppliers required to identify resources for Life
of Program
 Includes:
 Layered Process Audit uploads required quarterly
for life of program.
 3CPR (3rd Party Verification Audit) requirements
 Warranty requirements
 “Forever” Requirements
Slide 77
Pre – PSO
PSO On-Site Visit

Run
Post – PSO
 PPAP Warrant
Requirements
Slide 78
Module 3: Pre- PSO Supplier
Readiness Evaluation
Slide 79
Supplier Readiness
Evaluation purpose…
 Firstdocumented build attempt
 Provide pre-production data
(usually minimum of 30 pieces)
 Confirm process is:
 Set-up
 Debugged
 Readyfor Production
Demonstration Run
Slide 80
Supplier Readiness
Evaluation Data…
 Confirms proper setup, operation and
performance of installed production line
 This data is used to estimate:
 Production rates
 FTC
 Yields
 Pp and Ppk for special characteristics
Slide 81
Supplier Readiness Evaluation Form…
SUPPLIER T. Automotive PROGRAM LX
M FG. LOCATION Somew here, MI SUPPLIER CODE 99999AF
CHANGE LEVEL(S) B PRE-PSO M EETING DATE 11/19/04
PSO ON-SITE VISIT DATE / NUM BER 1/5/05
SUPPLIER READINESS EVALUATION
QUANTITY DETERMINED BY SUPPLIER A ND

DA IMLERCHRYSLER PSO TEAM: 300 pieces
SRE LINE RATE: 83 pcs/hr required by DCC; 250 pcs/hr demonstrated
SHIFT: 2nd shif t
PERFORMANCE RESULT S
Ite m P ro c e s s F e a t ure /P a rt P ro c e s s Meas . P a rt/P ro c Qua ntit y Qua ntity F TC P e r
US L UC L LC L LS L Pp P pk
# C ha ra c te ris tic / P a rt 1 F re q. A vg. A tte m pt e d A c c e pte d (witho ut re
1 Inner Metal I.D. Part 2/hr 12.30 12.25 12.23 12.15 12.10 4.89 3.65 300 300
2 Outer Metal O.D. Part 2/hr 40.40 40.35 40.26 40.25 40.20 4.63 2.95 300 292
3 End of Inner to Part 2/hr 5.30 4.90 4.50 4.40 3.70 2.94 2.93 300 288
4 End of Outer
5
6
7
8
9
10
11
12
13
14
15
16
1
No t es : M eas urement Taken During In-P ro ce s s / o r Final Ins p ect io n
Slide 82
Pre – PSO
PSO On-Site Visit

Run
Post – PSO
 PPAP Warrant
Requirements
Slide 83
Module 4: PSO on-site Visit
Slide 84
PSO on-site Visit purpose…
 Witness build using production tools
 Run must meet quality & production rate
requirements
 PSO Team observes first 22 elements
of the PSO Summary Report
 Success will result in parts for
Production Validation testing
Slide 85
PSO on-site Visit is
conducted …
 Kick-off
Meeting with appropriate plant
management to discuss:
 Purpose
 Agenda for Day
 Observing Production Demonstration
Run
 Closing Meeting to review results of
assessment
Slide 86
DaimlerChrysler Process Sign-Off Summary
Report
DAIMLERCHRYSLER PROCESS SIGN-OFF SUMMARY REPORT
ALL PROCESS SIGN-OFF ELEMENTS APPROVED: X PSO EXTENDED RUN: X 4
SUPPLIER T. Automotive YE S NO YE S NO O P T IO N
MFG. LOCATION Somew here, MI SUPPLIER CODE 99999AF
CHANGE LEVEL(S) B PRE-PSO MEETING DATE 11/19/04
PROGRAM _LX_________________________________ PSO ON-SITE VISIT DATE / NUMBER__01/05/2005_____
* Docum ents w ith asterisk should be review ed during AQP m eetings and again during the Pre-PSO Docum entation Review
PSO PROCESS ELEMENTS
D O C UM E N T A T IO N P R OC ES S
1 PART NUMBER, DESCRIPTION AND Ac c e pt R e je c t Ac c e pt R e je c t
CHANGE LEVEL X X
*C ro s s re f e re n c e s h e e t Ye s No A c c e p t a b le S u p p lie r c h a n g e Ye s No
(IF AP P LIC AB LE) X n o t ic e p ro c e d u re X
1.4 Engineering Standards Identified E v id e n c e o f c u s t o m e r c h a n g e X
Ye s No n o t ic e p ro c e d u re
*C A T IA c o m m e n t s p a g e X P ro c e s s f o r o bt a in in g t h e Ye s No
wit h lis t o f a p p lic a b le s t a n d a rd s la t e s t s t a n d a rd re v is io n X
(e .g DC C , ENVIR ONM ENTAL,e tc ) Ac c e pt R e je c t Ac c e pt R e je c t
2 DESIGN FMEA X X
*D e s ig n F M E A c o m p le t e Ye s No D F M E A u p d a t e d t o in c lu d e Ye s No
& a c c e p t a b le X a p p lic a b le D V f a ilu re s X
Ac c e pt R e je c t
3 TEST SAMPLE SIZES AND FREQUENCIES X
Ye s No
*S ig n e d D V a n d P V p la n s X
*S ig n e d D VP &R ( D V c o m p le t e ) X
*S ig n e d wa iv e rs N/A
Slide 87
PSO on-site Visit
Approvals…
 PSO “Z” Approval: 22 PSO elements
approved – partial tooling payment
 PSO “A” Approval: All PSO & PPAP
requirements meet – full tooling
payment
 Interim Approval Authorization: Z
approval some PSO deficiencies
Slide 88
Module 5:
Pre – PSO Post-PSO
PSO On-Site Visit

Run
Post – PSO
 PPAP Warrant
Requirements
Slide 89
Continuous Conformance…
 Support
 Layered Process Audit
 Problem Solving Methods
 Warranty
 Annual Validation
 Forever Requirements
Slide 90
PSO 5th Edition Layout…
 Introduction & Strategy
 PSO Element Description
 PSO Element Requirements
 PSO Forms
 Commodity Specific Requirements
 Guidelines for New Specialist /
Suppliers
 PSO Worksheets
 Appendix
Slide 91
Workshop Objectives
1. Explain and apply the PSO Strategy; including purpose, requirements and
procedure for each step.
2. Identify the required tasks and uses for each of the 25 Checklist Elements on
the PSO Sign-off Summary Report for both the Documentation and Process
side.
3. Demonstrate how to evaluate some of the major forms used to ensure a
quality product.
4. Describe the new guidelines for design and process FMEA.
5. Describe the requirements involved in a Layered Process Audit .

6. Develop a plan on how to accomplish all the elements on the PSO Summary
Report.
7. Determine if a supplier is ready for the PSO on-site visit based on evaluation
of the SRE documentation.
8. Identify observations that could be made during a Demonstration of a
Production Run.
9. Evaluate certain documentation requirements during the demonstration of the
supplier’s production run.
10. Plan how to ensure quality products throughout the life of the program.
Slide 92

Welcome To .: Planning For Process Sign-Off

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Equipment Software Level

PSO On-Site Visit

Medium Collaborative Supplier DCX

High Directed DCX DCX

#4 Process FMEA OD100 – Complete PFMEA

#5 Process Flow Diagram/Floor Plan OD90 – Complete Process Design

#19 Parts Packaging/Shipping Plan OD160 – Define Material Handling Plan

LEGEND #6 Control Plan VF116 – Complete Production Control Plan

#15 LPA Plan

Note: PSO Element #24 PV Testing Complete VF30 – Complete DV & PV

PSO On-Site Visit

Use a Rolling Top 20 Pareto

 Severity =>5 with 1 2 3 4 5 6 7 8 9 10

Occurrence =>2 Occurrence Ranking

7.2 Supply Base Management

7.3 Problem Solving Methods

How does LPA work?

Reinforces Safety regulations

Line Speed Observed:_______ FTC:_____

NOTE: The gage plan must explain how the

Vehicle Families included in family

PSO On-Site Visit

 Pp and Ppk for special characteristics

SUPPLIER READINESS EVALUATION

QUANTITY DETERMINED BY SUPPLIER A ND

SRE LINE RATE: 83 pcs/hr required by DCC; 250 pcs/hr demonstrated

SHIFT: 2nd shif t

PSO On-Site Visit

PSO On-Site Visit

5. Describe the requirements involved in a Layered Process Audit .

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Line Speed Observed:___ FTC:_