FIAT Group Automobiles Supplier
IRE / QRA RESULTPROCESS PLANNING REVIEWSupplier QualityPerformed by:PROCESS VERIFICATION (VP)Material Reg. Date:Build Date:SQE:PRE-SERIES (PS)Material Reg. Date:Build Date:Project:Supplier:Supplier Code:Supplier Site:RELEASE TO PROD. (DaP)Material Reg. Date:Build Date:CURRENT PRODUCTIONMaterial Reg. Date:Build Date:PPR RESULT1 - QUALITY DOCUMENTATION2 - PROGRAM & TOOLINGTIMING3 - PROGRAM & PROCESSMANAGEMENT4 - OPERATIONS &ORGANIZATION5 - PRODUCT QUALIFICATIONS6 - IMPLEMENTATION OFQUALITYTechnical Documentation /Source PackageDesign Release /AcceptanceSub-tier ManagementWork InstructionsCapacity, Volumes, Rampup Curve, & Product MixPart & Process ApprovalDADARisk AssessmentDADesign Model StatusDASub-tier ComponentsDAMaintenanceBDADAProgram Lessons Learned &MPFMEADADASpecial Characteristics /GD&TDADesign FMEADASub-tier Raw Materials / ToolMakersDAProgram TimingGages & Measuring DevicesDADAProcess Flow Diagram & FloorPlanDADATooling Release & TimingDAProcess FMEADAPrototype PhasePackagingMaterial Handling &TraceabilityProject Development TeamDASpecial ProcessesTooling & EquipmentVerificationTrainingSelf-Qualification TestsDATesting Equipment &FacilitiesDADAError & Mistake ProofingDADADADENext Mtg.Date:SupplierOdMPart Description:CCustomerFIAT Group AutomobilesPart Number:APPR Date:Integrative TestsDAStatus of Last Process AuditReliability PlanDADAReadiness EvaluationBenestare / Part Qualif.Process (PQP)DADASafe-Launch ActivityMatchabilityFDADAControl PlanDADAPilot PhaseDAIMDSDAInterim ApprovalQuality PerceptionGDADANA - Not ApplicableNV - Not ValuatedResp.Supplier:1 - JOBSTOPPERSignature:DA2 - JOBSTOPPER Risk3 - ModerateIssueSQE:Name in block lettersBuyer:Stab.:Name in block lettersDADOCUMENTS ACCEPTABLE5 - Implem.ActivitySignature:Prod. Line:Name in block lettersSignature:Signature:Quality:Signature:Name in block lettersSignature:Name in block letters4 - NO RiskDAName in block letters
#SectionRequirementsDocuments* Scheda ProdottoVerify that the Supplier has the latest Technical Documentation, including the design model, GD&T, access to * Source Packagethe latest Customer Engineering Standards, access to color/gloss/graining masters, etc. Review the completed * Design Model / GD&TSource Package, Minimum Quality Requirements, and Statement of Requirements, noting key information and * MQR* SORprogram deliverables. Verify all issues raised by potential Suppliers during the sourcing phase have beendiscussed and adequately addressed. Ensure engineering specifications and Quality and Supply requirementsare understood by the Supplier.1ATechnical Documentation /Source Package1BRisk AssessmentReview the results of the Quality Risk Assessment (QRA) or Initial Risk Evaluation (IRE) with the team. Verifythe progress of any planned corrective actions from QRA or IRE open issues. Are they complete / on track?Program Lessons Learned &MPFMEAReview the Master PFMEA for this part/commodity and ensure all potential failure modes have beenaccounted for in the Supplier's PFMEA and process. Review quality spills and lessons learned from previousand similar products / processes. Verify that issues resulting in past quality spills, yardholds, or Field Actionsare adequately error-proofed or completely designed out of the part in the new process.1DDesign FMEAHas the DFMEA been reviewed with the Customer and Supplier? Verify it has been updated to the latestdesign release. Ensure it was developed taking into account lessons learned from previous programs andaction plans exist for items with the highest risk. Verify items with a Severity greater than or equal to 8 areadequately error-proofed or actions are taken to minimize the severity via design. Note: if the Customer isdesign responsible and no DFMEA exists, mark the item "N/A"1EProcess Flow Diagram & FloorPlan* Process Flow DiagramEnsure the Process Flow Diagram, floor plan, and workstation layout reflect the planned process. All processes* Work Station Layout /and sub-processes shall be included, from raw material receiving to final assembly shipping and includingManufacturing Floor Planrework/scrap areas. Verify that all are at the latest level of the process.1C1F1GProcess FMEAControl PlanReference* Engineering StandardsSupplier Distribution* FIAT Orange* QRA or IRE* MPFMEA* Corrective actions from pastprograms* Design FMEA* eCIMS/NCT* SQP* applicable warranty system* Potential Failure Mode &Effects Analysis manual (4thEdition)* FIAT Norm 0770 / 0771* ISO/TS-16949 7.3.3.2* Process FMEAEvaluate the Supplier's PFMEA using the Supplier PFMEA Audit Summary form. Ensure it was developed* Supplier PFMEA Audit Summarytaking into account lessons learned from previous programs and action plans exist for items with the highestrisk. Verify items with a Severity greater than or equal to 8 (or per Customer requirements, if more stringent)are adequately error-proofed or actions are taken to minimize the severity via design.* Potential Failure Mode &Effects Analysis manual (4thEdition) AIAG* FIAT Norm 00271* ISO/TS-16949 7.3.3.2* Control PlanRegularly review the status and content of the Supplier's Control Plan, both for Prototype (if applicable) and * Part I/SProduction processes. Verify the linkage between the Process Flow Diagram, PFMEA, and Control Plan. Ensurecontrols are adequate and match those described in the Design and Process FMEAs. Verify that the controlplan is updated to the latest design revision level. Review the Supplier's plan for certification of Incoming andOutgoing material. Review the Supplier's plan for monitoring the process, including SPC methods,performance data (scrap, efficiency, etc.), and Boundary Samples. When required, review the Part InspectionStandard (Part I/S) timing and status (including the manufacturing quality representative).* Advanced Product QualityPlanning & Control Planmanual (2nd Edition)* FIAT norm 9.01102* ISO/TS-16949 7.5.1.1* ISO/TS-16949 App. A* P&SQ Book of Knowledge(Part Inspection Standardprocess)Pagina 2 di 11
#SectionRequirementsDocumentsReference* Design modelDesign Release / AcceptanceReview the design release date. It is consistent with prototype availability and with the Program timing?Ensure the latest mathematics are available and are consistent with the latest release.Design Model StatusVerify the Supplier has the latest design model. Ensure that as changes occur, appropriate modifications aremade to program timing and other deliverables, as required. Also verify appropriate risk mitigation activitesare planned when deliverables become late to their required milestones. Review the Supplier's ChangeManagement process and ensure they have a method of communicating to sub-tier Suppliers.2CSpecial Characteristics / GD&TIs the design model complete with all Special / Critical Characteristics, other dimensional characteristics,functional characteristics, GD&T, and datums defined? Ensure that datums are consistent with vehicle/partmating points. Verify that engineering has agreed to all special / critical characteristics.2DProgram TimingReview the Supplier's plan for program timing. Ensure they are aware of all key milestones, and that keyprogram deliverables are scheduled according to the milestones they are due.2ETooling Release & Timing* Tool timing planReview the Tooling kick-off date. Is it consistent with the Program timing? Ensure the timing allows for parts* Tooling kick-offoff of production tooling by the required build / milestone. Note that the Tooling kick-off date is the date thattools actually begin construction (i.e., "cutting steel"). Once tools are kicked-off, follow their progress. Aretoolmakers aware of the latest design changes? If tool completion timing changes, ensure adequate riskmitigation plans are in place (as required). Note: for tooling followed by TAG, obtain status updates from theTAG representative.2FPrototype PhaseReview the Suppliers plan for delivery of prototypes. Are quantities and timing included? Does the planinclude evaluation of part quality (measurement of critical characteristics, etc.)?Pilot PhaseReview the Supplier's plan for delivery of parts for the applicable Pilot builds. Does it include quantities andtiming (for each phase)? What are the quality requirements for each pilot build, and is the Supplier aware ofthem? Ensure parts off of production tools will be available for the required milestone (e.g., VP).2A2B2GPagina 3 di 11* Design model* Change Management procedure* Design model / GD&T* Program timeline* Prototype delivery plan* Pilot build delivery plan* CPCP / PTCP* PSP
#3A3B3C3D3E3FSectionRequirementsDocumentsSub-tier ManagementReview the Supplier's management of existing sub-tier suppliers. Ensure they have a process for evaluatingsub-tier performance and a method of determining which ones are acceptable for new business. Does a subtier list exist and is it available for the applicable product?Sub-tier Components* Sub-tier component managementReview the Supplier's plan for management of the sub-tier components. Ensure all sub-tier suppliers haveplanbeen approved and the appropriate risk assessments have been done on the components. Review that theSupplier's timing for Process Audits / PDRs and PPAP of the sub-components supports overall program timing,and check the status of each component. Verify the Supplier has ensured sub-tier capacity. If potential supplyissues or risks (e.g., long distance) exist, ensure that appropriate risk mitigation activities are in place (e.g.,safety stock, expediting, etc.). For components that are not inspected (i.e., "dock-to-stock"), does the Supplierhave appropriate plans in place to begin inspection in the case of a defect?Sub-tier Raw Materials / ToolMakersReview the list of raw material suppliers and tool makers that the Supplier will be using. Are they all on theCustomer-approved lists for the job / material they will be supplying (as applicable)? Do they have theappropriate certifications or approvals (as applicable)? If potential supply issues or risks (e.g., long distance)exist, ensure that appropriate risk mitigation activities are in place (e.g., safety stock, expediting, etc.).Gages & Measuring Devices* MQRReview status of gages, fixtures, measurement devices, and testing equipment. Are they adequate for the job?* PFMEAHas the PFMEA been used to determine the appropriate measurement method? Ensure that each device is* List of planned gages & measuringappropriate for the measurement taken (e.g., not an attribute gage for characteristics where SPC is expected).devicesVerify that gages have been updated to the latest design level. Also verify that all gage requirements from theMQR have been addressed.Error & Mistake ProofingReview status of Error & Mistake Proofing plan. Ensure all items with a Severity of "8" or higher (or perCustomer requirements, if more stringent) on the Design and Process FMEAs have adequate Error andMistake Proofing. Ensure the Supplier has an adequate back-up plan in the event that applicable Error andMistake Proofing fails (e.g., sensors, End-of-Line Testers, etc.).Special ProcessesReview which special processes are required for the part (e.g., painting, plating, heat treat, surface treatments * Special processes planfor corrosion protection, etc.). What is the Supplier's plan for management and control of these processes?* Control PlanAre the specifications clearly defined? Review the Supplier's planned control methodology to determine* Engineering standardsadequacy. If Boundary Samples are needed, when will they be available, and are there plans for Customerapproval?Pagina 4 di 11Reference* Sub-tier management plan* List of approved sub-tier suppliers* List of raw material suppliers andtoolmakers* Error & Mistake Proofing plan* Engineering ApprovedSupplier List (EASL)
#4ASectionWork Material Handling & Traceability4EProject Development TeamReview the Supplier's team and resources devoted to the program. Are enough resources given? Is thecommitment of the members adequate? Are the obligations respected? Is the contact list complete?TrainingReview the Supplier's plan for hiring and training all personnel needed for the production process. Ensure theplan is adequate to provide fully-trained personnel to support each pilot build, launch ramp-up, and fullvolume production. Are special processes requiring training identified? Is there a skill or certification matrixshowing those operations requiring special training and identifying who has had that training (such as via aRASIC chart)? Review all plans for permanent rework and repair, and ensure responsibilities are clearlydefined.IMDSReview the Supplier's plan for management of IMDS submission. Ensure they are registered towww.mdssystem.com, and that they keep copies and records of their submissions. Verify they haveappropriate controls in place to manage sub-tier supplier IMDS submissions and are aware whenever a subtier supplier makes a change that could require a new submission.4GReferenceReview the Supplier's Maintenance Plan. Ensure all equipment, tooling, and gages used in the process are* Maintenance planincluded. Verify that the Supplier has a way to document both planned and unplanned maintenance, and thatresponsible personnel are identified. How does the Supplier develop their maintenance plan and requiredactivities?* Packaging planReview the Supplier's packaging plan and ensure it is not missing from the "scheda prodotto". Ensure they* Packaging specificationshave the latest shipping specifications and returnable containers for pilot builds (plus an expendable back-up).Verify that internal containers (i.e., for Work-in-Process) are adequate and prevent damage to parts storedwithin (and ensure that Customer-owned containers are not used for this purpose).Review the Supplier's FIFO plan and plan for traceability on components. Do they have adequate controls toassure FIFO is followed and that traceability is maintained (and not FIFO-dependant)? Are storage locationsadequately sized, positioned relative to the process, and protect stored materials?4FDocuments* Work Instructions: operator, setReview status of the Supplier's operating instructions, both prototype and production (as applicable). Are they up, changeover, 1st Piece Approval,updated to the current level of the part? Do they allow an adequately-trained operator to be able to perform Mistake proofing, rework/repair,the task? Work instructions include process set-up, gage operating, shipping & receiving, rework & repair,gage, inspection, packagingprocess work instructions, etc.Pagina 5 di 11* FIFO procedures* Material handling and re-stockprocedures* Traceability procedures* ISO/TS-16949 cl, 7.5.3 &7.5.3.1* FIAT norm 9.01102* FIAT standard 07611* FIAT standard 07170* Contact List* Training plan*Training records* List of operations and operatorsrequiring special certifications* IMDS Process* www.mdssystem.com* Fiat Cap. 9.01102 – Fiat Cap.9.01108
#5A5B5CSectionRequirementsDocumentsReference* Purchase OrderCapacity, Volumes, Ramp-upCurve, & Product MixVerify the Supplier has the latest information about the requested volumes, the sequence of the launchingversion, the ramp-up curve, and the product mix. Review the quoted Contract Capacity with the Supplier anddetermine the required line speed for the Readiness Evaluation and PDR. Review the shift pattern to ensurethat it supports production and allows enough time for PM activities.Tooling & Equipment VerificationVerify that Customer tooling & equipment (complete or under construction) is consistent with that which was * Tooling & equipment listdetermined needed during the sourcing phase. Any modifications (e.g., more tools required, some tools not * Supplier Tool Recordneeded/built, etc.) with respect to which was declared during sourcing shall be promptly reported to theBuyer. Review the Supplier's plan / procedure for release of tools and equipment to the production floor.Testing Equipment & FacilitiesReview the Supplier's testing facilities and equipment. Are they certified to perform the tests expected ofthem? Review all appropriate certifications and verify. If the Supplier does not have the appropriatecertifications, review their plan to use 3rd party ISO/IEC 17025 certified labs.Status of Last Process AuditWrite the result of the last Process Audit made on the same concerned process or a similar one. E.g., if the lastProcess Audit has been fully approved, enter "5"; if it has not, than enter the appropriate score. Verify if therequired corrective actions have been implemented. Review items that prevented approval to ensure they donot reoccur.Readiness EvaluationReview the planned date for the Readiness Evaluation and ensure it supports program timing (including thetest plan, as samples for testing come from this run). In order to be used for testing, parts must have a resultof 3 or better on the Process Audit form (no Job Stoppers or Job Stopper Risks). In addition, all parts shall bewithin specification (show capability or be 100% inspected), off of production tools (homeline), haveproduction-intent sub-components, and be inspected with measuring devices with acceptable R&R.* Supplier lab certification* 3rd Party labs & certification* ISO/IEC 17025* Previous Process Audit(s)5D5E5F5GSafe-Launch ActivityInterim Approval* Program timeline* FPSC Plan or Strengthened ControlReview the Supplier's plan for Safe-Launch (FPSC or Strengthened Control Plan). Have they included all critical Plan/ special characteristics? Is the duration acceptable (or will it need to be longer)? Will the PIC/PAC orProactive 3CPR processes be required for this product?If the component doesn't meet the quality requirements for the program milestones, what is the level of risk * Interim approvals (as applicable)for the issuing of an Interim Approval for the use of the part? Ensure adequate risk mitigation activities are inplace when an interim approval is required. Review the status of any existing interim approvals (andcorresponding engineering changes).Pagina 6 di 11* Process Audit* FPSC* PIC / PAC* FIAT norm 07171* Book of Knowledge(Proactive 3CPR)
#6ASectionRequirementsPart & Process ApprovalReview the Supplier's planned dates for the Process Audit, Stage 1 & Stage 2 Production Demonstration Run,and PPAP. Are they adequate to support program timing? If any of these will be late to the requiredmilestone, are acceptable Risk Mitigation activities in place? Ensure that if any of these deliverables are late,an appropriate interim approval is issued, as necessary.Self-Qualification TestsReview the Supplier's Self-Qualification plan. Is the forecasted closing date of Self Qualification Testsconsistent with the timing of Project? Has the plan been shared with Customer Engineering? Review thestatus of the testing (completed tests, on-going tests, approval status, etc.). For on-going tests, what is the riskof a negative result?Documents* Program timelineReference* Production DemonstrationRun* Process Audit* PPAP Manual (4th Edition)* Self-Qualification plan6B6CIntegrative TestsIs the forecasted delivery date of Integrative Tests samples consistent with the timing of Project (taking intoaccount also the lead time of Fiat Lab.'s)? What is the risk of a negative result of Integrative Tests?6DReliability PlanReview the Supplier's reliability plan. Has it been shared with Customer Engineering? Is it updated accordingto the development level of the Project?6EBenestare / Part Qualif. Processprogram timing (taking into account the lead time of the Plant Lab / Metrology Center)? Ensure appropriate(PQP)Risk Management activities and corrective actions are in place in the event of Yellow or Red result.6FMatchabilityReview the plan for obtaining Plant Approval. Is the forecasted delivery date of samples consistent with6GQuality PerceptionReview the plan for matchability submission. Is the availability of samples consistent with the timing of theProject? Ensure that there is a timing "safety factor" in the event of reoccurrence of the tests due to failures.Is there risk that the current part configuration will result in a high evaluation on internal indicators for qualityperception audits (e.g., CPA, TOC, ICP)? Ensure that issues resulting in high scores on previous programs forsimilar products have been evaluated and corrected in the design, DFMEA, and PFMEA, as appropriate.Pagina 7 di 11* Integrative Test samples deliveryplan* Reliability Plan* Benestare / PQP submission plan* Benestare process* PQP Process* Matchability plan* D/PFMEA* MPFMEA* Potential Failure Mode &Effects Analysis manual (4thEdition)* Customer Perception Audit* TOC/ICP
ScoringScore ClassificationAdvance Quality DefinitionJOB STOPPER Very late to required milestone and will cause other required deliverables to be late to their required milestone/vehicle launchRisk Mitigation Plan does not existCertain to cause delay in milestone/vehicle launchHas resulted in critical build/launch issues and certain to cause critical quality spills in production (yardholds, PRIs, field campaigns, etc.)Total lack of quality system or systemic controlJOB STOPPERRISK Late to required milestone and may cause other deliverables to be late to their required milestone/vehicle launchRisk Mitigation Plan exists but is not acceptable or requires unrealistic timing to meet milestoneMay cause delay in milestone/vehicle launchHas resulted in moderate build/launch issues or may cause critical quality spills in production (yardholds, PRIs, field campaigns, etc.)Chronic quality system or systemic control failures3MODERATEISSUE Potentially late to required milestoneRisk Mitigation Plan exists and is acceptableLow Risk to milestone/vehicle launchMay result in moderate quality spills in production not impacting critical / safety characteristicsNon-chronic quality system or systemic control failures4NO RISK5IMPLEMENTEDACTIVITYnaNOT APPLICABLEItem does not apply for this auditnvNOT EVALUATEDItem was not evaluated at this audit or not available; will be evaluated at a later date12 Progressing according to required milestone timing No Risk to milestone/vehicle launch Isolated documentation issueComplete and approved
OPEN ISSUES - PROCESS PLANNING REVIEW N AUDITOR REMARKS (SQE)QUESTIONRANKINGOBSERVATION / ISSUECORRECTIVE ACTIONRESPONSIBLEDATESTATUSStatus: 25% Identified problem; 50% Action Plan proposed; 75% Action Plan implemented; 100% Solved issueSupplier Responsible(Name and signature)SQE(Name and signature)
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ONE PAGE REPORT N Project:Part Description:Part Number:Family/MY:Date:Supplier QualityODM/Rev Lvl:Supplier Name:Supplier Code:Manufact. Plant:SQE:Abstract up to 3 arguments in order of severity:Argument:135(Process Planning Review 1, 2, 3, etc., Process Audit 1, 2, 3 etc., OK to samples orbatches for VP, Pre-series, etc.)Problem / Root cause:Containment / Corrective Actions: (Insert responsible and date)Timings:1st Try out:1st Part:Interim:Sampling for AQF:Sampling for Integr. Tests:Sampling for Match./Ben.:Batch VP, Pre-Serie:PROCESSVERIFICATION (VP)PRE-SERIES (PS)RELEASE TOPROD. (DaP)CURRENTPRODUCTIONDistribution:SQDQPLSQE Coord.BuyerE&DProject Coord.SviluppoSupplierSQMPiattaforma
2C Special Characteristics / GD&T Is the design model complete with all Special / Critical Characteristics, other dimensional characteristics, functional characteristics, GD&T, and datums defined? Ensure that datums are consistent with vehicle/part mating points. Verify that engineering has agreed to all special / critical characteristics.
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