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Edition 5.5
PSO
PROCESS SIGN-OFF
(PSO)
Edition 5.5
December 2006
This manual shall define the requirements for Process Sign-Off (PSO) and detail the
documentation required to verify conformance to DaimlerChrysler's (DCC) Quality System
Standards. The PSO, ISO/TS-16949 and Chrysler Development System (CDS) will form
the foundation for Supplier readiness to assure proactive Advanced Product Quality
Planning. A Suppliers certification to ISO/TS-16949 alone is not sufficient for PSO
approval; all PSO requirements must be met in order to assure conformance to
dimensional, material, functional and (where necessary) appearance requirements. In
addition, it should be noted that every external Supplier of production parts to
DaimlerChrysler Corporation shall be ISO/TS-16949:2002 third party registered. Effective
01/01/2007, all requirements stated in this document apply to all DaimlerChrysler
Production Suppliers, including sub-tier Suppliers.
In order to achieve an appreciable improvement in part quality, this manual has been
modified to reflect DaimlerChrysler Corporations current PSO philosophy. Emphasis is
placed on the importance of adhering to our Product Creation Process, i.e. the Chrysler
Development System (CDS). This manual should be reviewed carefully and in its entirety
to assure that all PSO requirements are known and understood. The 25 PSO Process
Elements identified in the 5th Edition PSO Manual were re-evaluated and, in some cases,
modified or removed.
The name DaimlerChrysler and DCC, as used in this manual, refer to DaimlerChrysler
Corporation (i.e., DCC formerly known as Chrysler Corporation) and its subsidiaries,
which manufacture Chrysler, Dodge and Jeep brand vehicles. This manual does not
apply to other DaimlerChrysler AG subsidiaries or operations, which manufacture
Mercedes-Benz, Freightliner or other brand vehicles or products. Where the word
Supplier is used in this manual, it is intended to indicate both external and internal Tier
1 Suppliers. Where the term DCC PSO Team is utilized, it denotes DaimlerChrysler
Employee involvement only. The term PSO team indicates all individuals involved in the
PSO process (i.e., DCC and Supplier).
For questions or comments concerning the Process Sign-Off manual, please contact your
DaimlerChrysler Advance Supplier Quality Planning Specialist (ASQP Specialist).
ACKNOWLEDGMENTS
Bryan Book
Nance Taylor
Vic Randolph
Eric Helgeson
ASQP - BIW/Exterior
Larry D'Agostino
ASQP - Chassis
Simon Kissonergis
ASQP - Electrical/Electronics
Cris Miller
ASQP - Interior
Neil Murphy
ASQP - Powertrain
Ida Goodwill
CDS
Dennis Fett
Corporate Quality
Chris Cottam
Manufacturing Quality
Lynn Yang
Powertrain Quality
Mary Clor
Arno Reiter
Dave Koski
Hector Magaa
Page
Introduction ............................................................................................................ 1
Process Sign-Off Flow Chart & Responsibilities ......................................................... 6
Process Sign-Off Element Requirements.................................................................. 11
Appendix A Forms and Instructions ......................................................................... 45
Appendix B Tables and Examples ........................................................................... 61
Appendix C FTC Calculations .................................................................................. 67
Appendix D PSO Extended Run ............................................................................... 79
Appendix E Forever Requirements ........................................................................... 81
Appendix F Internal PSO Requirements .................................................................... 87
Frequently Asked Questions .................................................................................... 93
Reference Manuals................................................................................................. 98
Glossary ................................................................................................................ 99
Index................................................................................................................... 111
Process Sign-Off (PSO) shall be performed on all new or modified parts with
PPAP requirements or parts that have been out of production for 12 months
or longer. Additional conditions that may result in a PSO being required are:
Carry-over parts with historically high warranty and/or quality
problems;
Carry-over parts which have experienced a Supplier responsible yard
hold within the past calendar year;
New and/or additional production lines (e.g. capacity increases);
Production line moves, within a year of PSO approval;
Any product or process change that occurs during the lifecycle of a part
or system.
Full compliance with all PSO requirements and procedures ensures that
the Suppliers manufacturing process is stable, in control and capable of
producing parts that meet all requirements.
3. Validation Testing
Production Validation (PV) Testing, of the Production Demonstration parts,
will validate the Suppliers system and provide evidence that the parts
meet engineering, quality, durability, and reliability requirements
contained in the Performance, Process, and Material Specifications.
Packaging and shipping or simulation test approvals are required by
Material Handling Engineering if applicable.
The PSO date and an A disposition are required to be entered into Powerway.com prior
to the Supplier submitting the Warrant (PSW) and entering the PPAP date and PPAP A
disposition. This requirement is true for all parts, regardless of AQP Activity Level.
PSO N Approval: The N disposition is an internal code within Powerway.com. This
code indicates that the PSO On-Site Visit was unsuccessful and corrective action is
required by the Supplier. A new PSO planned visit date (or corrective action completion
date) is required to be entered into Powerway.com.
Interim Approval Authorization
All parts require full PSO and PPAP approval. PSO A approval is a prerequisite for PPAP
approval. PPAP approvals are submitted through Powerway.com by the Supplier. Failure
to submit PPAP before S1 Start will require an Interim Approval Authorization (IAA).
Reference the internal DCC procedure PSSP0108. Suppliers do not have access to this
procedure and should contact their DCC ASQP Specialist or Engineer for additional
information regarding IAAs.
NOTE 1: Even with Z Approval, an IAA is still required.
NOTE 2: Any deviations to the PSO requirements outlined in this manual must be
requested and approved in writing by the DCC ASQP Specialist and Product Engineer,
REGARDLESS OF AQP ACTIVITY LEVEL. Approval(s) must be obtained from DCC
before completion of the PSO process. Requested deviation(s) shall be formally outlined
in detail within the COMMENT SHEET of the completed PSO.
SUPPLIER PERFORMS
READINESS EVALUATION
RUN
CONDUCT PRE-PSO
MEETING (REVIEW
SUPPLIERS
DOCUMENTATION & SRE)
SUPPLIER CONDUCTS
PV TESTING
PSO TEAM
COMPLETES
PROCESS SIGN-OFF
2
INITIAL RISK
EVALUATION
& AQP LEVEL
Collaborative/Directed AQP
4
DAIMLERCHRYSLER
LED PSO
3
SUPPLIER LED PSO
5
PSO REQUIREMENTS
REVIEW WITH
PSO TEAM AND
SUPPLIER
3A
SUPPLIER
UPLOADS DOCUMENTS
INTO POWERWAY.COM
6
SUPPLIER PREPARES
DOCUMENTATION AND
CONDUCTS READINESS
EVALUATION RUN
8
SUPPLIER MODIFIES
AND SUBMITS
DOCUMENTATION
AND/OR CONDUCTS
READINESS
EVALUATION RUN
NO
7
PRE-PSO MEETING:
DOCUMENTATION/SRE
ACCEPTABLE?
YES
9
SCHEDULE
PSO ON SITE VISIT
10
SUPPLIER FINALIZES
LINE AND APPROVES
EVIDENCE OF PRODUCTION READINESS
Figure 2.1
PROCESS SIGN-OFF
RESPONSIBILITY
LEGEND
L = LEAD
RESPONSIBILITY
S = SUPPORT TO
P = PROVIDES
INFORMATION
P/S = DEPENDS ON
COMPOSITION OF
PSO TEAM
PROCESS NAME
Part enters
Powerway.com
Initial Risk
2
3&
Supplier led PSO
3(A)
DaimlerChrysler led
4
PSO
PSO Requirements
5
Review
Supplier prepares
6 documentation and
readiness evaluation
Pre-PSO
7 Documentation
Reviews
Supplier modifies and
8 submits
documentation
Schedule PSO On9
Site Visit
Supplier finalizes line
10 and approves
evidence production
DCC
PROCUREMENT
DCC
ENGINEERING
DCC
MANUFACTURING
DCC
ASQP
SUPPLIER
FLOWCHART RESPONSIBILITIES
P/
S
P/
S
REMARK
11
PSO ON-SITE VISIT or
SUPPLIER CONDUCTS
PRODUCTION
DEMONSTRATION RUN
YES
12A
PSO ON-SITE REVISIT
NECESSARY?
NO
12
ELEMENTS 1-20
ACCEPTABLE?
YES
NO
13
SUPPLIER CONDUCTS
CORRECTIVE ACTION
AND SUBMITS
DOCUMENTATION
14
Z DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
15
SUPPLIER CONDUCTS
ELEMENT 21
YES
18
REPETITION
OF ELEMENT 21
SUFFICIENT?
19A
SUPPLIER CONDUCTS
PSO IN ACCORDANCE
WITH PSO MANUAL
AND ENTERS PSO
DATE & DISPOSITION
INTO POWERWAY.COM
NO
17
INVESTIGATE REASON
FOR FAILURE AND ROOT
CAUSE ELIMINATION
16
ELEMENT 21
ACCEPTABLE?
NO
YES
20
SUPPLIER SUBMITS
PPAP WARRANT & ENTERS
PPAP DATE IN
POWERWAY.COM
19
PSO APPROVED,
A DISPOSITION AND
COMPLETION DATE
ENTERED IN
POWERWAY.COM
Figure 2.2
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
RESPONSIBILITY
LEGEND
PROCESS NAME
11
L = LEAD
12 Acceptance of Elements
RESPONSIBILITY
&12(A) 1-20
S = SUPPORT TO
P = PROVIDES
INFORMATION
Supplier conducts
corrective action and
P/S = DEPENDS
13
submits documentation.
ON
ASQP provides approval
COMPOSITION OF
PSO TEAM
"Z" code entered into
14 Powerway.com. Supplier
enters Dimensional PPAP
& date
Supplier conducts
15
Element 21
Acceptance of Element
16
21
Investigate reason for
17 failure and root cause
elimination
18
Repetition of Element 21
DCC
PROCUREMENT
DCC
ENGINEERING
DCC
MANUFACTURING
DCC
ASQP
SUPPLIER
PROCESS SIGN-OFF
FLOWCHART RESPONSIBILITIES
P/
S
S P/S L
P/
S
S P/S L
S P/S L
P/
S
S P/S S
P/
S
S P/S L
P/
S
S P/S S
P
P/
S
P
REMARK
Refer to
PPAP
Manual for
further
details
10
11
12
13
DESIGN FMEA
Element Requirements
2.1 Design FMEAs (DFMEAs) shall be created using the latest AIAG
and DCC guidelines. If AIAG and DCC guidelines disagree, DCC
guidelines take precedence.
Documentation
DFMEA (MANDATORY
ENGLISH)
Best Practice
procedure
2.2 The Supplier shall have an internal best practice procedure that
is utilized in the development of DFMEAs. The procedure shall include
documentation and data which explains how the DFMEA severity,
occurrence, and detection numbers were developed.
2.2.1 This procedure shall be reviewed periodically for effectiveness
and shall include lessons learned with inputs from past issues (e.g.
eCIMS, NCT, warranty, CSA, yard holds, etc.)
2.2.2 The procedure shall include use of the Rolling Top 20 rule
for continuous improvement. This requires the Supplier to Pareto
failure modes and address the top 20% using RPN values
(regardless of actual RPN value.)
2.3 Error proofing and controls shall be identified in the DFMEA.
2.4 The DFMEA is a living document and shall be traceable to all
design changes. It shall contain all special characteristics from
Element 12 Special Product/Process Characteristics Identified.
2.5 A DFMEA shall be completed for each unique Supplier-designed
product. The DCC Product Engineer has the lead responsibility for
ensuring that the DFMEA meets all requirements. Additionally, timely
completion and approval of all DFMEA activities shall be completed on
or before required quality gate timing. Reference the CDS Quality Gate
Book at http://roadmap.tcc.chrysler.com/cds/ for specific timing.
2.6 The DFMEA shall include all sub-components of the end-item
assembly.
2.7 The Supplier shall ensure all failures observed during Engineering
Development (ED) and Design Verification (DV) testing are captured
within the DFMEA.
2.8 The Supplier shall ensure the occurrence and detection ability of
failures observed during DV testing correlate with the occurrence and
detection numbers documented on the DFMEA.
2.9 Buzz-Squeak-Rattle (BSR) and Noise-Vibration-Harshness (NVH)
issues shall be addressed, if applicable.
NOTE: Special attention (as defined by DCC Engineering) shall be
given to failure modes with:
A Severity 8, regardless of Occurrence or Detection values.
A Severity 5 and Occurrence 2, regardless of Detection (this
equates to customer dissatisfaction and cs/1000 > 1.)
A Detection of 10.
See Appendix B FMEA Guidelines.
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
14
Documentation
DCC Engineering
signed DVP&R
(MANDATORY
ENGLISH)
Applicable Engineering
Standards
(MANDATORY
ENGLISH)
DCC Engineering
signed DV and PV test
plans (MANDATORY
ENGLISH)
Annual Validation
procedure
15
PROCESS FMEA
Element Requirements
4.1 Process FMEAs (PFMEAs) shall be created using the latest AIAG
and DCC guidelines. If AIAG and DCC guidelines disagree, DCC
guidelines take precedence.
4.2 The Supplier shall have an internal best practice procedure that
is utilized in the development of PFMEAs. The process shall include
documentation and data which explains how the PFMEA severity,
occurrence, and detection numbers were developed.
Documentation
PFMEA (MANDATORY
ENGLISH)
PFMEA Audit
Summary
(MANDATORY
ENGLISH)
Best Practice
procedure
16
17
Documentation
Control Plan
(MANDATORY
ENGLISH)
1st piece approval
procedure & records
Control Charts
Process Performance
Log Sheets
Defect Tracking Sheets
18
19
QUALITY PLANNING
Element Requirements
7.1 All Advance Product Quality Plans (APQPs) shall coordinate with
DCC Chrysler Development System (CDS) timing for each applicable
program. The plan shall identify major milestone events, required
product or process deliverables, responsible organizations, as well as
scheduled and actual timing dates. Reference the AIAG Advanced
Product Quality Planning and Control Plan (APQP) manual and CDS at
http://roadmap.tcc.chrysler.com/cds/.
Supply Base Management
7.2 The Supplier shall cascade quality planning throughout all subtiers (see cl.7.4.3 of ISO/TS-16949, Quality Management Systems).
7.2.1 The plan shall include an Easy Map diagram. This diagram
should outline the entire Supply Chain, beginning with raw
materials and ending with the DCC or the DCC-designated
manufacturing facility. All secondary processes and/or services
(e.g. plating, heat treating, etc.) shall be shown, including off-site
storage or shipping locations. Easy Map can be found on the
COVISINT website.
7.2.2 Each component listed on the Bill of Material corresponding
to the DCC part number shall have an Initial Risk Evaluation (or
equivalent) performed. The criteria for risking components shall
take into consideration the DCC risk drivers. DCC risk drivers are
found on the Initial Risk Evaluation document in Powerway.com.
Documentation
AQP or APQP
timeline/plan
List with PPAP status
of all sub-components.
Easy Map Supply
Chain diagram
Listed risk of all subcomponents and subtier processes.
Level 3 PPAP
documentation for all
sub-components and
sub-tier processes
risked medium or
high.
DOE (Design of
Experiments)
Copies of eCIMS or 8Step Corrective Actions
for issues encountered
in previous pilot
builds.
Lessons Learned
Communication
procedure
20
21
22
23
Documentation
Parts Handling Plan
Material handling
procedures
Containment Records
24
25
OPERATING INSTRUCTIONS
Element Requirements
10.1 Operator, set-up, changeover, 1st piece approval, mistake
proofing, rework/repair, gage operating, inspection and packaging
instructions shall be approved and signed by the appropriate Supplier
departments (e.g. Quality, Engineering, Manufacturing, etc.) They
shall be dated and traceable to the level of parts being produced, and
shall include sample sizes and frequencies.
10.1.1 Special characteristics shall be identified in the appropriate
instructions.
10.1.2 All instructions shall enable any adequately trained person
to perform the described operation.
Documentation
Operator instructions
Set up sheets
Inspection instructions
1st piece approval
instructions
Mistake proofing
instructions
Rework/repair
instructions
Operator Qualification
process
Gage instructions
10.2 The Supplier shall have a process for training and qualifying
operators prior to operators performing production processes (e.g.
classes, mentorship, temporary supervision, etc.). Operator training
shall be documented and maintained.
10.2.1 A list of training requirements for each unique workstation
shall be maintained.
10.2.2 Visual inspection stations shall have methods established
to verify the operators ability to find defects (e.g. periodic testing,
recertification, etc.)
10.2.3 Operations requiring special certification shall be identified
and operators certified to perform that operation shall be identified
(e.g. rework/repair.)
10.3 All instructions, control charts, defect tracking sheets, log
sheets, and reactions shall be located adjacent to the process, visible
to the operator and legible (reference TS-16949, cl. 7.5.1.2 Work
Instructions.) Visual management techniques (e.g. displays, pictures,
diagrams, etc.) shall be used whenever possible.
10.3.1 Sample parts used as visual displays shall be identified and
maintained to the correct revision level. The Supplier shall also
have a procedure which periodically verifies the condition of
designated conforming Boundary samples to ensure the samples
are still acceptable.
Rework and Repair Instructions and Procedures
10.4 The DCC PSO team shall approve all rework and repair
operations, procedures and work instructions.
10.4.1 All reworked/repaired products shall be clearly and
uniquely identified. See Element 9 Parts Handling Plan.
26
27
28
29
30
Documentation
Error and Mistake
Proofing Plan
List of error and
mistake proofing
implemented by
operation number
Error and Mistake
Proofing studies
Mistake Proofing
Contingency Plan
31
32
33
Documentation
LPA procedures
LPA work instructions
LPA Structure and
Frequency Chart
LPA Process Control
Audit Checklist
LPA Error Proofing
Verification Audit
Checklist
14.2 The LPA plan shall have procedures and work instructions for
each level of management which details their roles and
responsibilities. The plan shall also address handling of nonconformances discovered during the audit and include a detailed
schedule frequency and structure chart.
14.3 The LPA plan shall require top management reviews of LPA
results. It shall state the frequency of management reviews and
require documented meeting minutes and/or open issues.
14.4 The Supplier shall complete a Process Control Audit Checklist
and an Error and Mistake Proofing Verification Audit Checklist.
Examples of each can be found in the LPA course training manual.
14.4.1 The Process Control Audit shall be done once per shift (or
as agreed to by the PSO Team) by a group leader, supervisor, etc.
Management audits shall be done weekly. Manufacturing areas
shall be divided and auditors rotated so that all areas are included.
14.4.2 The Error and Mistake Proofing Verification Audit shall be
done once per shift or product change-over (whichever comes first)
and whenever an unscheduled disruption occurs in the production
line. The audit must be performed by qualified, trained personnel
only. Reference Element 13 Error and Mistake Proofing cl. 13.1.3.
14.4.3 After PSO approval, no item shall be removed from the LPA
checklists without the DCC ASQP Specialists approval regardless
of initial AQP Activity Level.
14.4.4 All non-conformances discovered at DCC manufacturing
facilities (at any program stage) shall be included in the LPA.
14.5 The Supplier shall demonstrate at least one level of an LPA
during the PSO On-Site Visit. The audit shall be on the process
undergoing the PSO; for PSO visits on multiple parts, the LPA review
shall include every process, not necessarily every part.
14.6 The Supplier shall maintain a list of trained LPA Team
members who shall be responsible for developing, implementing and
updating the LPA plan. The Team shall also be responsible for
uploading on-going LPA results into Powerway.com quarterly.
NOTE: On-going LPA results are NOT a requirement for PSO approval.
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
34
35
36
37
38
39
40
Documentation
Gage R&R results
Gage layout results
Gage and test
equipment validation
procedure
Gage and test
equipment calibration
records
Calibration schedule
41
Documentation
PM Plan (includes
schedules, frequencies,
instructions, etc.)
42
Documentation
Initial Process Study
Results
43
44
APPENDIX A
FORMS & INSTRUCTIONS
45
Header:
Document
Or Task:
46
PART NAME(S)
SUPPLIER
MFG. LOCATION
PART NUMBER(S)
SUPPLIER CODE
PRE-PSO MEETING DATE
CHANGE LEVEL(S)
PROGRAM
2. Design FMEA
2.1 D DFMEA
2.2 D Best Practice Procedure
Not Applicable
Missing/Reject
Corrections
Documentation / Task
Approved
Sec.
D/V/F*
All Documents
Approved
3.4
3.5
3.6
4. Process FMEA
4.1 D PFMEA
4.2 D Best Practice Procedure
4.5 D PFMEA Audit summary
5.2
5.4
5.6
D Cell Layout
V Process Flow or Cell layout Including # of Operators
D DFMA (Design for Manufacturing Assembly)
0
7. Quality Planning
7.1 D AQP or APQP timeline/plan
7.2 D List with PPAP status of all sub components
Indented list or Easy Map of Sub-Suppliers (Name,
Manufacturing location, Part name, Part Number,
7.2 D PPAP Status) To raw material supplier.
7.2
7.2
7.3
7.4
7.6
D
D
D
D
D
D
D
47
13.1
13.2
17. Parts
17.1 D
17.1 D
17.1 D
17.1 D
17.1 D
17.2 D
17.3 D
18. Gage
18.3 D
18.2 D
18.5 D
18.5 D
18.6 D
15.4
Key:
D
F
N
V
Document
Completed PSO form
Note
View
48
20
"N"
26
"Z"
PART NAME(S)
"A"
OPTION #
SUPPLIER
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROGRAM
MFG. LOCATION
SUPPLIER CODE
1/0/1900
DATE
PROCESS
Accept
Reject
N/A
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
20
Accept
20
Reject
N/A
Reject
24
Accept
Reject
N/A
PROCESS
N/A
15
Yes
No
Date
Yes
No
Date
Manufacturing Facility
ENGINEERING
SUPPLIER QUALITY
49
PART NAME(S)
SUPPLIER
0
PART NUMBER(S)
0
0
CHANGE LEVEL(S)
PROGRAM
0
0
MFG. LOCATION
SUPPLIER CODE
1/0/1900
PROCESS SIGN-OFF
COMMENTS SHEET
ITEM
ISSUE/ACTION
RESPONSIBILITY
TARGET
DATE
CLOSED
DATE
50
51
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Item
#
/Part1
Process
Meas.
Freq.
USL
UCL
Part/Proc
Avg.
LCL
LSL
Pp
Ppk
PERFORMANCE RESULTS
SHIFT:
Quantity
Attempted
1/0/1900
Quantity
Accepted
SUPPLIER CODE
MFG. LOCATION
SUPPLIER NAME
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
% GR&R
5th Edition
ACC/ REJ
52
PART NUMBER(S)
SUPPLIER
MANUFACTURING LOC
SUPPLIER CODE
CHANGE LEVEL(S)
PROGRAM
Calculation
Data input from production P.O.:
Input information
Part Number
Part Number
Part Number
Part Number
Part Number
Total (A1 + A5)
Pieces/day
Pieces/day
Pieces/day
Pieces/day
Pieces/day
Pieces/day
shifts
hours
days
hours/shift
hours/shift
hours/shift
hours/shift
Start:
hours/shift
Finish:
attempted parts
failed parts
hours
pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)]
I) Available production hours/day [B1*H]
J) DCC required parts per hour at the PDR [A/I]
K) Witnessed parts per hour at the PDR [G/F]
hours/shift
hours/day
parts/hour
parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100]
M) Difference between witnessed parts/hour and required parts/hour [K-J]
%
pieces
53
The combined DCC Daily Tooling Capacity should be obtained from the DCC Purchase Order - "TOOL CAP"
If shared line = N:
A1)
Input the Daily Tooling Capacity and part number from the DCC Purchase Order.
A2-A5)
Leave as the default 0.
If shared line = Y, shared with DCC parts only:
A1-A5)
Input the Daily Tooling Capacity and part number from the DCC Purchase Order for the various parts being
validated.
NOTE: The assumption for this calculation is that all of the part numbers have the same operating pattern and the same
takt time.
NOTE: If the components being validated have varying operating patterns or different takt times, then separate calculation
worksheets should be completed for each part.
If shared line = Y, shared with other customers:
A1-A5)
Input the Daily Tooling Capacity from the DCC Purchase Order for the various parts being validated.
C4)
In hours/shift, input the time dedicated per shift to other customers.
NOTE: The assumption for this calculation is that all of the part numbers have the same operating pattern and the same
takt time.
NOTE: If the components being validated have varying operating patterns or different takt times, then separate calculation
worksheets should be completed for each part.
B)
The shift pattern should be obtained from the DCC Purchase Order - "SH/HR/DY"
B1) Number of shifts per day - "SH" on Purchase Order
B2) Production hours per shift - "HR" on Purchase Order
B3) Number of production days per week - "DY" on Purchase Order
NOTE: Please input appropriate comments in the blanks provided.
C)
D) The parts attempted during the PDR are the total number of parts the supplier produced including rejects/scrap.
E) First time through fall out during the PDR is the number of parts that were rejected from the manufacturing process during
first evaluation. This is not the final number of unacceptable parts, but only those that failed first time through the
process. (This number will be used in the FTC calculation.)
F) Length of PDR in hours is the measured time it took to conduct the production demonstration run. Please input start and
finish time in cells provided.
G) Acceptable parts witnessed at the PDR are the total number of parts, minus any rejects, which were demonstrated during
the production run. (May differ from first time through fallout.)
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
54
Available production hours/day are the net hours per day the supplier has available to build product.
J) DCC required parts per hour at the PDR are the total number of acceptable parts the supplier must produce, in an hour's
time, necessary to satisfy DCC.
K) Witnessed parts per hour at the PDR are the number of acceptable parts witnessed by the PSO team, which the supplier
produced within an hour's time.
L) FTC (First Time Capability) is the percentage of acceptable parts witnessed at the production demonstration run out the
total number of parts attempted at the PDR.
If the DCC requirement of 90% or greater is met, the cell will turn green.
If the DCC requirement is not met (less than 90%), the cell will turn red.
NOTE: If the FTC is less than 90%, the PSO team shall take product and process technology, complexity, supplier
experience, and the effectiveness of defect containment actions into account when deciding whether the demonstrated lower
FTC values are acceptable with a documented deviation. A DCC Supplier Quality Manager's signed approval is required for
deviation from the PSO FTC requirement.
M) The difference between required parts/hour and witnessed parts/hour gives the total number of parts over or under the
DCC requirement.
If the part difference is greater than (the DCC required parts per hour + 10%), the cell will turn green indicating the
line speed is acceptable. i.e. (J + 10%) M, then cell = green (requirements met).
If the part difference is between 0 and (the DCC required parts per hour + 10%), the cell will turn yellow indicating the
line speed has met requirments, but the part difference is very close and may require additional attention.
i.e. 0 <= M < (J+10%) then cell = yellow.
If the part difference is less than 0, the cell will turn red indicating the requirement is not met. i.e. M < 0 the cell = red.
NOTE: In the event (M) is yellow, it is strongly advised to conduct an Extended Run PSO to stress the supplier's
production line and increase confidence in the supplier's ability to meet DCC requirements. PSO Extended Run
options are explained in the PSO manual. Continuous improvement actions should also be developed for bottleneck
operations or other operations which showed poor performance during the PSO run.
55
56
Item
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Item
#
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
Process /Part
Meas.
Freq.
2/Shift
Part
2/Shift
Meas.
Freq.
Part
Process /Part
USL
0.097
0.097
USL
UCL
0.00895
0.00895
UCL
Part/Proc Avg.
0.0874
0.0874
Part/Proc Avg.
LCL
0.0851
0.0851
LCL
LSL
0.077
0.077
LSL
Summary Example
Pp
2.54
2.5
Pp
Ppk
2.41
2.28
Ppk
Quantity Attempted
30
30
Quantity Attempted
SUPPLIER CODE
MFG. LOCATION
SUPPLIER
Quantity
Accepted
30
30
Quantity
Accepted
0
0
100%
100%
1/0/19005th Edition
ACC
ACC
ACC/ REJ
12.70%
9.37%
% GR&R
DaimlerChrysler
57
58
0
0
COMMENTS:
CHARACTERISTIC
SPECIFICATION
Length
Hole Size
SPECIFICATION
CHARACTERISTIC
DATA
METHOD OF MEASUREMENT
Witnessed By:
CALIPER
CMM MACHINE
METHOD OF MEASUREMENT
QUANTITY
ATTEMPTED
30
30
QUANTITY
ATTEMPTED
SUMMARY EXAMPLE
QUANTITY
ACCEPTED
30
28
QUANTITY
ACCEPTED
FTC PERCENTAGE
(without repair)
100%
93%
FTC PERCENTAGE
(without repair)
1/0/1900
SUPPLIER CODE
SUPPLIER NAME
MFG. LOCATION
As part of the PSO, the actual measurement process must be witnessed by the PSO Team.
- A minimum of 3 characteristics are to be checked. For any given part, assembly, or process,
the number of characteristics selected depends upon the complexity.
- A minimum of 30 randomly selected samples shall be checked during the PSO on-site visit.
- Variable data is preferred but attribute data is acceptable.
- Refer to the Ppk Capability Matrix (Appendix B of the PSO 5th Edition Manual) for Ppk requirements.
- For attribute data, a 30 piece sample with one or more non-conformances is unacceptable.
- All deviations shall be listed in the COMMENTS section of this document.
PROGRAM
CHANGE LEVEL(S)
PART NUMBER(S)
PART NAME(S)
PP / PPK
1.7/1.6
2.3/2.2
PP / PPK
PROCESS ACC/REJ
REJ
ACC
PROCESS ACC/REJ
DaimlerChryler
59
60
APPENDIX B
Tables and Examples
61
<S> / <E>
0-15
<D>
100% Inspection
16-25
26-50
51-75
50
76-125
75
65
126-225
90
75
226-425
100
85
426-1300
110
90
1301 and up
115
90
ACTIONS ON PROCESS
ACTIONS ON LOT
No Nonconforming units
Continue to operate
Accept
One or more
Nonconforming units
62
CAPABILITY MATRIX
There are two risks inherent in every decision, either (1) we have accepted bad parts (consumers risk), or
(2) we have rejected good parts (producers risk). Test plans seek to balance these risks by specifying
sample size and/or acceptance criteria so that neither the consumer nor the producer carries the higher
proportion of risk.
Sometimes, for business or other reasons, it may be important to hold one risk constant and allow the other
risk to float based on sample size. Such is the case for Pp and Ppk. DaimlerChrysler wants to minimize its
risk of accepting a population below 1.33Ppk.
The following table presents the sample size and acceptance criteria that keeps the risk of accepting a bad
population ( 1.33) at 6.4% (93.6% that population > 1.33 Ppk will be accepted). Depending upon sample
size, the risk of rejecting a good population ( 1.67) could be very high. The table allows for trade-offs
between sample size and producers risk to be identified.
Sample Size
Acceptance Ppk
Criteria
Risk of Accepting a
Population <= 1.33Ppk
Risk of Rejecting a
Population >= 1.67Ppk
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
150
200
250
300
2.94
2.10
1.89
1.78
1.71
1.67
1.64
1.61
1.59
1.58
1.56
1.55
1.54
1.53
1.52
1.52
1.51
1.50
1.50
1.49
1.46
1.44
1.43
1.42
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
6.4 %
86.3%
77.3%
68.7%
60.7%
53.3%
46.5%
40.4%
34.9%
30.1%
25.8%
22.0%
18.7%
15.9%
13.4%
11.3%
9.5%
8.0%
6.7%
5.6%
4.7%
1.9%
1.0%
0.6%
0.3%
63
1st Layer of
Management
Supervisors Supervisor 1
2nd Layer of
Management
Area
Managers
Supervisor 2
Own Department
Supervisor 3
Own Department
Plant Staff
and Plant
Manager
1 per 1 per
shift shift
2 per
week
Engrng Mgr
Rotate Depts.
1 per week
Quality Mgr
Rotate Depts.
1 per week
Tooling Mgr
Rotate Depts.
1 per week
H.R. Mgr
Rotate Depts.
1 per week
Training Coord.
Rotate Depts.
1 per week
Plant Manager
Rotate Depts.
1 per week
Department F
1 per 1 per
shift shift
Department E
1 per
shift
Department D
1 per
Own Department shift
Audit
Assignment
Department C
Assigned
Management
Personnel
(example)
Department B
Assigned
Management
Category
(example)
Department A
64
FMEA GUIDELINES
II. RPN's that have Severity 5 and an Occurrence 2 regardless of Detection and
RPN value. (This equates to customer dissatisfaction and C/1000 >1).
III. Detection = 10. (The potential defect is allowed to leave the plant and reach the
field).
65
66
APPENDIX C
FTC Calculations
67
PURPOSE
First Time Capability (FTC) is part of a process capability study that identifies how well it produces quality
parts. For multiple assembly lines or tools, FTC studies shall be conducted on each one. FTC can be an
important measure, because generally the lower the value, the greater the amount of rework required. As
defects and rework increase, there is a greater possibility that the Supplier will ship non-conforming parts.
DaimlerChryslers requirement for FTC is 90% or greater. Following the PDR, the PSO Team shall review the
FTC values for each operation and the overall process. If the FTC is less than 90%, the PSO team shall take
product and process technology, complexity, Supplier experience, and the effectiveness of defect
containment actions into account when deciding whether the demonstrated lower FTC values are acceptable
with a documented deviation. A Supplier Quality Managers signed approval is required for deviation from
the PSO FTC requirement.
FTC can be used to prioritize product and process improvement. If a Supplier encounters a situation where,
despite their best efforts, they cannot find a solution to an inherently low FTC, DaimlerChrysler can assist
in the improvement effort by supplementing the Supplier's team with experienced engineering and
manufacturing specialists from a wide variety of disciplines.
DESCRIPTION
FTC is measured as the number of items processed correctly divided by the total number of items
processed. Correctly processed means no repairs or rework are allowed. Therefore, in a multi-operation
process, a higher FTC is expected for an operation or zone than for an entire process.
2.
3.
Create a block diagram for the process showing each operation. The flow diagram or floor layout
provided by the plant can also be used.
Collect the following data from the PDR.
a. Quantity of assemblies attempted.
b. Quantity of rejected assemblies from each operation.
c. Quantity of acceptable assemblies from the end of the line. Do not include repaired or reworked parts.
Calculate the operation and process FTC using the examples as a guide.
68
Operation 1
Operation 2
Operation 3
270 Pcs
243 Pcs
Operation 4
226 Pcs
217 Pcs
300 Pcs
30 Pcs
Rejected
17 Pcs
Rejected
27 Pcs
Rejected
9 Pcs
Rejected
Figure 1
Example 1 - Series Process Flow Diagram With Demonstration Data
Begin by calculating the FTC for each operation. Operation 1 is shown here with its respective
PSO PDR data
Operation 1
270 Pcs
300 Pcs
FTCOp 1
30 Pcs
Rejected
Qty Completed
Qty Attempted
270
300
0.90 or 90%
Figure 1A
In a similar manner, calculate the FTC for each operation in the process using Equation 1. The
general operation model is shown in Figure 1B. Table 1 shows a summary of the quantities and
FTCs for the process in Example 1.
Quantity
Attempted
Operation
Number
Quantity
Completed
FTCOPERATION
Qty Completed
Qty Attempted
Equation 1
Quantity
Rejected
(1)
Figure 1B
69
Operation
Quantity
Attempted
Quantity
Completed
FTC
300
270
0.90
270
243
0.90
243
226
0.93
226
217
0.96
TABLE 1
Quantities and FTCs for Example 1
Enter the calculated operation FTCs in their respective operation blocks of the process diagram.
Calculate the process FTC by dividing the quantity completed for the process, 217 units, by the
quantity attempted 300 units.
Total Qty Completed 217
FTCPROCESS
0.723 or 72.3%
Total Qty Attempted 300
Enter the FTCPROCESS value on the process diagram. The completed Example 1 process diagram is
shown in Figure 2. The diagram can be included with the final PSO documents as a record of the
process starting capability.
Operation 1
FTC
90%
Operation 2
270 Pcs
FTC
90%
Operation 3
243 Pcs
FTC
93%
Operation 4
226 Pcs
FTC
96%
217 Pcs
FTC = 72.3%
300 Pcs
30 Pcs
Rejected
17 Pcs
Rejected
27 Pcs
Rejected
9 Pcs
Rejected
Figure 2
Example 1 - Series Process With Operation and Process FTC's Shown
94 Pcs
2 Pcs
Rejected
Operation 1
Operation 2
288 Pcs
Operation 4
Operation 6
242 Pcs
265 Pcs
218 Pcs
91 Pcs
81 Pcs
300 Pcs
12 Pcs
Rejected
10 Pcs
Rejected
23 Pcs
Rejected
24 Pcs
Rejected
Operation 5
78 Pcs
67 Pcs
11 Pcs
Rejected
Figure 3
Example 2 - Series / Parallel Process Flow Diagram With Demonstration Data
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
70
Calculate the FTC for each operation in the process using Equation 1 and the operation model
shown in Figure 1B on page 2. Table 2 shows a summary of the quantities and FTCs for the
operations in
Example 2.
Operation
Quantity
Attempted
Quantity
Completed
FTC
300
288
0.96
288
265
0.92
96
94
0.98
91
81
0.89
78
67
0.86
242
218
0.91
TABLE 2
Quantities and FTCs for Example 2
Enter the calculated operation FTCs in their respective blocks on the process diagram. Calculate
the process FTC by dividing the total quantity completed, 218 Units, by the quantity attempted,
300 units. The result is the FTC for the process.
FTCPROCESS
Qty Completed
Qty Attempted
218
300
0.726 or 73%
Add the process FTC to the process diagram. The completed diagram for Example 2 is shown in
Figure 4. The diagram can be included with the PDR report to document the initial process
performance.
96 Pcs
Operation 3
94 Pcs
FTC
98%
2 Pcs
Rejected
Operation 2
Operation 1
FTC
96%
288 Pcs
FTC
92%
Operation 6
Operation 4
265 Pcs
91 Pcs
FTC
89%
242 Pcs
81 Pcs
FTC
90%
218 Pcs
FTC = 72.6%
300 Pcs
12 Pcs
Rejected
10 Pcs
Rejected
23 Pcs
Rejected
78 Pcs
Operation 5
FTC
86%
24 Pcs
Rejected
67 Pcs
11 Pcs
Rejected
Figure 4
Example 2 Series / Parallel Process With Operation and Process FTCs Shown
71
CALCULATING FIRST TIME CAPABILITY (FTC) AND PROCESS YIELD WITH REPAIRS
DATA COLLECTION PROCEDURE
The recommended procedure for data collection for a process with repair is similar to the
procedure shown in Section I. Step #2 differs because of the need to record rework quantities
returned to the process stream. Step #3 differs because there are two values to calculate, FTC and
yield.
1.
Create a block diagram for the process showing each operation. The flow diagram or floor
layout provided by the plant can also be used.
2.
3.
Calculate the operation and process FTC and yield using the examples as a guide.
Operation 1
270 Pcs
Operation 2
268 Pcs
Operation 3
265 Pcs
Operation 4
264 Pcs
300 Pcs
30 Pcs
Rejected
19 Pcs
27 Pcs
25 Pcs
16 Pcs
10 Pcs
9 Pcs
Rework
Rework
Rework
2 Pcs
Scrap
3 Pcs
Scrap
1 Pc
Scrap
Figure 5
Example 3 Series Process Diagram With Demonstration Data Added
72
Calculate the FTC for each operation. Operation 1 is shown here with its respective production
demonstration data.
Operation 1
270 Pcs
300 Pcs
30 Pcs
Rejected
FTC OP 1
Figure 5A
Qty Completed
Qty Attempted
270
300
0.90 or 90%
The yield for Operation 1 is the same as the FTC because rework was not performed. Therefore,
YieldOP 1
Operation 2
270 Pcs
268 Pcs
270
300
0.90 or 90%
27 Pcs
25 Pcs
FTCOP 2
FTCOP 2
270 27
270
Rework
243
270
0.90 or 90%
2 Pcs
Scrap
Figure 5B
YieldOP 2 =
In a similar manner, calculate the FTC and Yield for the remaining operations using Equations 2
and 3. The general operation model is shown in Figure 5C. Table 3 shows the quantities, FTCs
and Yields for the operations in Example 3.
Operation
Number
Quantity
Attempted
Quantity
Reworked
Quantity
Completed
FTCOperation =
Quantity
Rejected
Rework
YieldOperation =
Qty Completed
Qty Attemp ted
Equation 3
Figure 5C
73
Operation
Quantity
Attempted
Quantity
Rejected
FTC
Quantity
Reworked
Quantity
Completed
Yield
300
30
0.90
N/A
270
0.90
270
27
0.90
25
268
0.99
268
19
0.93
16
265
0.99
265
10
0.96
264
0.996
TABLE 3
Quantities, FTCs, and Yields for Example 3
A simplified sketch of the series operations that will be used for the process FTC calculation is
shown in Figure 6. Enter the operation FTCs in their respective blocks on the sketch. Calculate
the process FTC by multiplying the individual operation FTCs together.
Operation 1
Operation 2
Operation 3
Operation 4
FTC=90%
FTC=90%
FTC=93%
FTC=96%
264 Pcs
300 Pcs
Figure 6
Simplified Process Sketch for Example 3
FTCPROCESS
FTCPROCESS
0.723 or 72.3
YieldPROCESS =
Qty Completed
Qty Attemp ted
YieldPROCESS =
264
= 0.880 or 88%
300
Add the operation and process FTCs and Yields to the process diagram. The completed process
diagram for example 3 is shown in Figure 7. The diagram can be included as part of production
demonstration report to document the starting process capability.
Operation 1
270 Pcs
FTC=90%
Yield=90%
Operation 2
268 Pcs
FTC=90%
Yield=99%
Operation 3
265 Pcs
Operation 4
FTC=96%
Yield=99.6%
FTC=93%
Yield=99%
264 Pcs
FTC = 72.3%
YIELD = 88.0%
300 Pcs
30 Pcs
Rejected
27 Pcs
19 Pcs
16 Pcs
25 Pcs
10 Pcs
9 Pcs
Rework
Rework
Rework
2 Pcs
Scrap
3 Pcs
Scrap
1 Pc
Scrap
Figure 7
Example 3 - Series Process With Operation, Process FTC's, and Yield Shown
74
Operation 3
107 Pcs
2 Pcs
to Rwk*
Operation 1
288 Pcs
Operation 2
283 Pcs
97 Pcs
Operation 4
276 Pcs
Operation 6
275 Pcs
92 Pcs
300 Pcs
12 Pcs
11 Pcs
to Rwk*
23 Pcs
18 Pcs
84 Pcs
27 Pcs
28 Pcs
Operation 5
Rework
Rework
77 Pcs
18 Pcs
12 Pcs
to Rwk*
5 Pcs
Scrap
Rework*
Op 3,4,& 5
1 Pc
Scrap
25 Pcs
Rework*
7 Pcs
Scrap
Figure 8
Example 4 - Series / Parallel Process With Demonstration Data Added
Calculate the FTC and yield for each operation using Equations 2 and 3. Notice that Operation 1
does not include any rework so FTC and Yield will be the same. This is not true for any other
operation in the Example 4 process. The general operation model is shown in Figure 5C. Table 4
shows a summary of the quantities, FTCs, and Yields for the operations in Example 4.
Operation
Quantity
Attempted
Quantity
Rejected
FTC
Quantity
Reworked
Quantity
Completed
Yield
300
12
0.96
N/A
288
0.96
288
23
0.92
18
283
0.98
102
0.98
107
1.05
97
11
0.89
92
0.95
84
12
0.86
77
0.92
276
28
0.90
27
275
0.99
TABLE 4
Example 4 Quantities, FTCs, and Yields
Enter the FTCs and yields that were calculated for Operations 1 through 6 in their respective
operation blocks of the process diagram. The entries for Example 4 are shown in Figure 9.
75
102 Pcs
Operation 3
FTC=98%
Yield=105%
107 Pcs
2 Pcs
to Rwk*
Operation 1
288 Pcs
FTC=96%
Yield=96%
Operation 2
283 Pcs
97 Pcs
Operation 4
FTC=92%
Yield=98%
FTC=89%
Yield=95%
23 Pcs
11 Pcs
to Rwk*
276 Pcs
Operation 6
FTC=90%
Yield=99%
92 Pcs
275 Pcs
300 Pcs
12 Pcs
18 Pcs
84 Pcs
28 Pcs
Operation 5
FTC=86%
Yield=92%
Rework
27 Pcs
Rework
77 Pcs
18 Pcs
12 Pcs
to Rwk*
5 Pcs
Scrap
Rework*
Op 3,4,& 5
1 Pc
Scrap
25 Pcs
Rework*
7 Pcs
Scrap
Figure 9
Example 4 - Process With Operation FTC's and Yields Shown
102 Pcs
Operation 3
107 Pcs
2 Pcs
to Rwk*
97 Pcs
Operation 4
92 Pcs
11 Pcs
to Rwk*
84 Pcs
Operation 5
Equivalent
Operation 3,
4, & 5
77 Pcs
18 Pcs
283 Pcs
12 Pcs
to Rwk*
Rework*
Op 3,4,& 5
25 Pcs
Rework*
7 Pcs
Scrap
25 Pcs
Rejected
Figure 9 A
Figure 9B
Calculate the equivalent operation FTCEq 3,4, 5. The equivalent single operation FTC calculation
using the total attempted quantity, 283 units, and the total rejected quantity, 25 units, is shown
below.
FTCEQ
FTCEQ =
76
A simplified sketch of the process that will be used for the FTC calculation is shown in Figure 9C.
Multiply the individual operation FTCs together to obtain the FTC for the process, FTCPROCESS.
Operation 1
Operation 2
Equivalent
Operation 3,
4, and 5
Operation 6
FTC=96%
FTC=92%
FTC=91%
FTC=90%
Figure 9C
Simplified Process Sketch for Example 4
YieldPROCESS
Qty Completed
Qty Attempted
YieldPROCESS
275
300
0.917 or 92%
Add FTCPROCESS and YieldPROCESS to the process diagram. The completed diagram for Example 4 is
shown in Figure 10. The diagram can be included with the final PSO documents as a record of the
starting performance.
102 Pcs
Operation 3
FTC=98%
Yield=105%
107 Pcs
2 Pcs
to Rwk*
Operation 1
288 Pcs
FTC=96%
Yield=96%
Operation 2
283 Pcs
97 Pcs
Operation 4
FTC=92%
Yield=98%
FTC=89%
Yield=95%
23 Pcs
11 Pcs
to Rwk*
276 Pcs
Operation 6
FTC=90%
Yield=99%
92 Pcs
275 Pcs
FTC = 72%
YIELD = 92%
300 Pcs
12 Pcs
18 Pcs
84 Pcs
FTC=86%
Yield=92%
Rework
27 Pcs
28 Pcs
Operation 5
77 Pcs
Rework
18 Pcs
12 Pcs
to Rwk*
5 Pcs
Scrap
Rework*
Op 3,4,& 5
1 Pc
Scrap
25 Pcs
Rework*
7 Pcs
Scrap
Figure 10
Example 4 - Series / Parallel Process With Operation and Process FTC's and Yields Shown
77
78
APPENDIX D
PSO Extended Run
79
Increased
confidence of
Supplier
readiness on
selected parts
Figure 1
It is important for the PSO Team to decide the type of PSO Extended Run that will be accomplished and the
timing, so it can be integrated into the PSO planning process. In some cases there will be additional pieces
built or multiple shifts exercised during the Production Demonstration Run and in other cases there will be
additional visits made at later dates to ensure readiness as launch approaches.
Due to the variety of manufacturing processes utilized at Suppliers, the final details of a PSO
Extended Run for a particular part are decided by the PSO Team. The following reference options (15) have historically been used but other, more applicable, options may be developed as indicated in
option number 6.
Option Number
1
2
Option Description
Option Benefit
Table 1
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
80
APPENDIX E
Forever Requirements
81
After approval by the Engineer, the Supplier Quality Specialist will fill out page two (2) Section 2.B. If approved by
the Supplier Quality Specialist, the Supplier will submit the form to the appropriate Buyer. If the change(s) was
rejected by the Supplier Quality Specialist, then the Supplier must correct the rejected item(s) and resubmit the
DCX Forever Requirements/ODD Box activity Form to the Supplier Quality Specialist. Failure to resubmit the
form to the Supplier Quality Specialist will end the Forever Requirements process for the proposed change(s).
8.
After approval by the Supplier Quality Specialist, the Buyer will fill out page two (2) Section 2.C. If approved by
the Buyer, the submitted change(s) are fully approved by DCX. If the change(s) was rejected by the Buyer, then the
Supplier must correct the rejected item(s) and resubmit the DCX Forever Requirements/ODD Box Activity Form to
the Buyer. Failure to resubmit the form to the Buyer will end the Forever Requirements process for the submitted
change(s).
9. The approval (or rejection) process should be concluded by all affected DCX personnel within 10
business days.
10. A fully signed electronic DCX Forever Requirements/ODD Box Activity indicates that DCX approves the
plan ONLY.
11. After the DCX Forever Requirements/ODD Box Activity Form is approved, the Supplier(s) will complete
all remaining tasks including the successful completion of all PER, PSO, PPAP, and other required
activities including and appropriate hard copy and/or electronic notification as necessary.
12. After approval by all affected DCX personnel, the Supplier will make copies of the DCX Forever
Requirements/ODD Box Activity Form and distribute it to all appropriate DCX personnel as indicated
by the Supplier Quality Specialist. In addition, the Supplier will retain the original copy of the fully
approved DCX Forever Requirements/ODD Box Activity Form.
13. Supplier will submit fully approved form(s) and/or information into Powerway.com as required.
Please be advised, the hard copy format is being replaced by an electronic Forever Requirement
(eFR CN System). Tentative date time frame is early 2007.
82
Yes
No
Need more
information
No
Yes
Need more
information
Yes
Need more
information
83
High
Low
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85
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APPENDIX F
DCC Internal PSO Requirements
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PV
Testing
Production
Demonstration Run
(PDR) & Analysis
Documentation
88
89
Tooling List
Tool Layouts
Assembly Graphics
Tool & Op Sheets
Spare Parts List
Error and mistake proofing plan. This includes a list of error and mistake proofing by operation
number
Line Speed Simulation
AME MQAS procedure for gauge identification
PM plan, schedule, procedure and work instructions
Plant Deliverables
Plants procedure for documentation revision changes due to part number changes
Plants procedure for obtaining and distributing CATIA revisions
Control Plan (MANDATORY ENGLISH DOCUMENT)
Best Practice document for developing Control plans (input from FMEA & Control plans for similar
products)
PPAP status list
Plant MQAS procedure for Problem Solving
Incoming inspection plan and procedures
Incoming sampling plans
Receiving reports
Material standards
Inspection/test reports
Parts Handling Plan
Material Handling procedures
Packaging Instructions
Maintenance plan for WIP (work in process) containers
Copy of Routing cards or travelers
Operator, 1st piece approval, mistake proofing, set-up, changeover, rework/repair, inspection and
packaging instructions
Record of operator training
Operator qualification process
Documentation control procedure
Visual management (displays & diagrams)
First Production Shipment Certification (FPSC) Plan (MANDATORY ENGLISH DOCUMENT)
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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PV Testing
Internal Powertrain Programs must adhere to the requirements outlined in element 21 of the PSO Manual.
All required forms and reference material can be found on the Internal Powertrain PSO website.
http://advmfg.appl.chrysler.com/mfg/stmpdash/pso/index.shtml
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1.
How far down do we go with the certification of the extended enterprise? 3rd tier? 4th tier?
Certification down to the production material Suppliers and if applicable any secondary
processes/services (e.g. plating, heat treating, etc) would be sufficient.
2.
What should our reaction plan be if Suppliers refuse to conduct PSO's on their sub-Suppliers?
PSO is part of DaimlerChrysler's Supplier evaluation and Production Part Approval Process.
According to TS-16949 and the DCC Customer-Specific Requirements for TS-16949,
Suppliers are responsible for evaluation and Production Part Approval of their sub-tiers. All
DCC Suppliers were required to be TS-16949 certified. Note that this does not require that
Suppliers perform a PSO specifically, it does require an evaluation and/or PSO-like activity.
Failure to conduct evaluations and Production Part Approval of sub-tiers is a failure to meet
TS-16949 requirements and may result in the loss of DCC business. Notify the Buyer and
P&S Management of any occurrence of this situation.
3.
Suppliers don't follow the Lot Acceptance Sampling Table. They always inspect about 5
parts/lot, lot size is 1,000 pcs. Should we force them to inspect as many as the table says?
For attribute sampling, two or more of the inspection criteria in TS-16949 shall be used,
otherwise the guidelines in the Lot Acceptance Sampling Table shall be followed. For variable
sampling, the Supplier shall be consistent with the Statistical Process Control manual
requirements.
4.
Collaborative AQP risked parts require a PSO if selected by the PSO Team. If the PSO Team
considers a product to be Self Directed, is PSO required?
Yes. All Self Directed products shall have a Supplier internally led PSO that documents and
establishes their production readiness. The Supplier's PSO documentation shall be uploaded
into Powerway.com.
All Directed AQP risked products will have both a DaimlerChrysler led AQP and PSO. All
Collaborative risked products will have a DaimlerChrysler led PSO and a Supplier led APQP.
5.
Since AAR is a requirement for PPAP, shouldnt AAR be required for PSO approval if the
process appreciably affects color?
AAR is not a requirement of PSO. Refer to the AIAG PPAP manual for an explanation of the
relationship between PSO and PPAP.
6.
If a Supplier changes a process, where does the Supplier go to start the PSO process, the
Responsible Design Engineer or the Supplier Quality Specialist? We've been told both.
Before a Supplier makes any changes to their assembly process they shall initiate a Forever
Requirements form and obtain approval from the DCC Release Engineer, ASQP Specialist,
and Buyer. The ASQP Specialist will determine the risk level of the change (if approved) and
corresponding PSO activity level.
7.
Most Suppliers use CMM printout for inspection documentation. Do we need to transfer this
data to the appropriate form?
No, a copy can be attached or a statement provided on the COMMENTS SHEET that the PSO
Team verified the measurement.
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8.
In a multi-cavity tool, should parts come from all cavities to calculate PP and PPK?
Parts should come from all cavities, however each cavity (process stream) should be
calculated individually as stated in the Statistical Process Control (SPC) manual published by
AIAG.
9.
Our forms do not have a control number or issue date. This is an ISO/TS-16949 requirement.
What should be done?
The forms are part of the manual, and they are identified in DaimlerChryslers Master Record
List.
10.
11.
Can the PSO Team accept a Production Demonstration Run which is less than 300 pieces/2
hours?
Yes. The PSO Team shall authorize any deviation from requirements (minimum of two hours
or 300 pieces, whichever is more stringent) and enter an explanation on the PSO
COMMENTS SHEET.
12.
13.
You don't have to have PSO approval prior to V1 if you have an IAA. Explain the system of
tool payment after PSO elements 1-20 without an approved PSW.
IAA is not an alternative to PSO. An IAA indicates failure to meet program requirements. It
enables shipments on an interim basis to support vehicle development timing until corrective
action (PSO approval) can be completed.
After a Supplier successfully completes the first 20 elements for both documentation and
process, the ASQP Specialist enters a Z disposition into Powerway.com which, following the
submission of a dimensional warrant, allows tool payment at the discretion of the Purchasing
Agent.
14.
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successful PDR can only be used for PV testing if the deficiencies are due to documentation
discrepancies or appearance (non-functional) issues not involving finish durability.
15.
16.
If the PSO is not approved does this imply that there is no FPSC?
No, FPSC is still required, but it will probably extend the time period and quantity of the
FPSC.
17.
Who gets the FPSC form in the plant? Is there an organization to handle this?
The Supplier shall review the completed form with the PSO team and upload it into
Powerway.com. The Supplier shall also retain the original form for up to one year following
the launch.
18.
Regarding FPSC, what if we take a truck frame with 400 dimensions, for example. How many
frames do we need to measure? All 2000?
The PSO Team, working with the Supplier, will determine what shall be an adequate plan to satisfy the
FPSC requirements.
19.
It's critical to know where parts are going - if there are 3 truck plants, it could mean 6000
parts for FPSC.
FPSC requires that the first 2000 parts shipped to each customer facility be certified. If there
are 3 truck plants, then 6000 parts will require FPSC.
20.
Expand the FPSC explanation. Add examples for attendees to follow. Include a slide that
explains a statistical analysis of the first 2,000 pieces is required which is different than the
300 piece PSO capability study.
The 300 piece Production Demonstration Run that is part of the PSO, satisfies the
component requirements for PV testing, other testing, S1 vehicles, and S2 vehicles. These
components are not intended to satisfy the FPSC requirements. However, under certain
circumstances, the PSO Team may allow the remainder of these PSO parts, if any, to be
included with production parts shipped to the Assembly Plant. Refer to the DaimlerChrysler
FPSC procedure PSSP0106.
21.
If an offshore DaimlerChrysler employee performs a PSO in his/her local country, this manual
requires them to use English for the master documentation. This should be a team decision.
DaimlerChrysler is a global company. As stated, English is the official language of DaimlerChrysler and
therefore an English translation has to be available. It does not preclude other language versions.
22.
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23.
24.
Is it acceptable for a Supplier to add or remove operators from a production line during the
line speed demonstration?
The number of operators required for the production line shall be identified on the Process
Flow Chart, Manufacturing Layout, and/or Workstation Layout. The Supplier may not
deviate from this number during the PDR; line-balancing and other ergonomic or efficiency
studies are expected to be completed prior to the PSO On-Site visit.
25.
26.
The Supplier has several required documents that they consider proprietary, and will not allow
us to review them. How do we handle this?
As stated in Element 7 (cl. 7.7): Note: For source packages that reflect proprietary document
exclusions, those documents sited for exclusion are not required to be uploaded into
Powerway.com. However, these documents shall be available for review at the request of the
DCC ASQP Specialist. A cover page with the documents title block, revision level and date is
required to be uploaded in place of the actual document. Review of the documents may take
place at the Suppliers location or at a DCC location, at the discretion of the team. In those
rare cases when a Supplier refuses to allow DCC personnel to review required documents at
all, the PSO should be rejected and the matter brought up to DCC management (ASQP,
Engineering, and/or Purchasing, as appropriate.)
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REFERENCE MANUALS
DaimlerChrysler Manuals:
Packaging and Shipping Instructions
Product Assurance Testing
Test Data Analysis manual
P&S 7-Step Corrective Action Process manual
Available From:
AME Standards:
AME Standards-Gage Standards
Available From: https://gsp.extra.daimlerchrysler.com/mfg/amedd/gages/index.htm
Other Manuals:
Production Part Approval Process (PPAP)
Measurement Systems Analysis (MSA) Manual
Statistical Process Control (SPC) Manual
Potential Failure Mode and Effects Analysis (FMEA)
Advanced Product Quality Planning and Control Plan (APQP) Manual
Quality Systems Requirements for Automotive Suppliers (ISO/TS 16949)
Quality Systems Requirements of VDA (VDA 6.3)
Available From:
NOTE:
DaimlerChrysler personnel can obtain copies of the manual through DaimlerChrysler's eCopier
on DashboardAnywhere.
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GLOSSARY
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100
requirements of the product. Each part shall have a Control Plan, but in many cases,
family Control Plans can cover a number of parts produced using a common process.
Customer approval of Control Plans may be required prior to production part submission.
COVISINT: A web based system that grants qualified Supplier users access to selected
portions of the DaimlerChrysler Network.
CP: capability index that compares the process capability to the maximum allowable
variation as indicated by the tolerance. This index provides a measure of how well the
process will satisfy the variability requirements. CP is not impacted by process location.
This index can be calculated only for two-sided (bilateral) tolerances. (Statistical Process
Control Manual, pg. 132)
CP=
USL - LSL
6 C
Where,
USL LSL
6 R
d2
R
d2
CPK: capability index that takes the process location as well as the capability into
account. (Statistical Process Control Manual, pg. 132)
C PK
CP
CPL =
Where,
USL - X
3 C
USL
LSL
3
3 R
3 R
and
d2
LSL
d2
X
C
R
d2
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CUSTOMER SATISFACTION AUDIT (CSA): a comprehensive review of a vehicles asshipped quality as it leaves an assembly plant. The CSA provides a reliable real-time
indicator of vehicle quality.
DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA): formalized method for
quantifying the risk associated with identified potential design failure modes. It is used to
identify corrective actions required to prevent failures from reaching the customer. The
DFMEA is a living document that is updated as the design changes and progresses
through design verification and production.
DESIGN OF EXPERIMENTS (DOE): a statistical approach to efficiently plan and structure
a series of controlled tests. In its broadest sense, it encompasses planning, setting up,
and running the tests, and analyzing the data. The goal is to identify the sources of
product variation that should be optimized or avoided for consistent product performance
with a minimum number of tests.
DESIGN VERIFICATION PLAN AND REPORT (DVP&R): formalized test planning and
reporting tool. It lists all testing necessary to assure that functional and reliability criteria
and target requirements are defined in specific measurable terms. It provides a
convenient reporting format for Engineering Development (ED), Design Verification (DV),
Production Validation (PV) and Continuing Conformance (CC) testing.
DESIGN VERIFICATION (DV) TESTING: testing phase that demonstrates the final
released component or assembly meets design intent. The tests, sample sizes, and
performance requirements are detailed in Engineering Performance Standards.
DRAWING CHANGE LEVEL (DCL): the latest design level of the released drawing. It is a
two digit alpha field that can be accessed on ODCICS2 through screen ENAA or ENJA.
ELECTRONIC CORPORATE ISSUE MANAGEMENT SYSTEM (e-CIMS): DCCs electronic
system for documenting serious issues that arise during vehicle prototype, launch, or
volume production phases.
ENGINEERING STANDARDS: are written requirements that describe materials,
processes, performance, reliability, quality and/or design requirements for a material,
process, or part or a family of materials, parts, or systems.
ENGINEERING STANDARDS SUPPLIER DISTRIBUTION (ESSD): the DCC computer
system that gives Suppliers access to DCC Engineering Standards. It is available on-line
at https://essd.extra.daimlerchrysler.com/ESSD/Login.jsp.
ERROR PROOFING: Error proofing is a method used to identify potential process errors
and either designs them out of the product or process, or eliminate the possibility that the
error could produce a defect. Examples of error proofing include:
A rod clip designed to work in left- and right-handed parts (as opposed to separate
clips for each;
A hole or slot designed so that mating parts can only fit in the proper orientation;
An operation that will not function until all components are present in the proper
orientation.
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103
LINE SPEED: the contracted maximum tool capacity rate determined by dividing the
Daily DaimlerChrysler Tooling Capacity (Pieces per Hour) by the Suppliers Net Operating
Time for DaimlerChrysler Parts (Hours/Day). The Line Speed shall be verified during the
Production Demonstration Run.
LOT: specific amount of material or group of components; not to exceed eight hours or
one days production, whichever is smaller.
MANUFACTURING FLOOR PLAN: a pictorial layout of the entire manufacturing facility
drawn to scale. It is to include all machinery, office space, lab space, shipping-receiving
areas, quarantine areas, hold areas, etc. The layout shall also indicate any proposed areas
for expansion and development.
MISTAKE PROOFING: Mistake proofing is an approach used to develop methods to
clearly identify errors that may occur and prevent them from becoming nonconformances. Examples of mistake proofing include:
Sensors, optics, and/or vision systems that detect missing or incorrectly-assembled
components;
End-of-line (EOL) testers that check functional requirements;
Pick lights or barcoding to assist in proper part selection;
Continuity testing for electrical components.
NET OPERATING TIME FOR DAIMLERCHRYSLER PARTS: equal to the number of hours
(normal work pattern), less scheduled down-time (e.g. breaks, start up, preventive
maintenance, shared production, tool changeovers, shut-down, etc.) and time scheduled
to run other customers parts and/or other DCC parts.
NON-CONFORMANCE TRACKING (NCT) SYSTEM: DCCs electronic system for
documenting and tracking part issues at the manufacturing plants. It also provides a
method for replacement of those parts and for Supplier dispute of the issue. Serious
quality issues are also documented in the e-CIMS system.
NVH: Noise Vibration Harshness are measurable perceptions of vehicle attributes.
These items are usually discovered and measured by DaimlerChryslers NVH laboratory
facilities. NVH attributes are typically tuned to a certain frequency and amplitude in order
to achieve an overall vehicle signature frequency. This signature is optimized by vehicle
development for the best customer responses.
OPERATOR INSTRUCTIONS: lists of steps in performing an operation that may contain
inspection requirements, required tools and gages, SPC applications, sample size and
frequency, and acceptance/rejection criteria. They shall communicate all requirements
involved in that particular operation. These shall be readily available to the operator.
PACKAGING: material that is used to store and ship parts. It provides protection and
containment of parts. It affects ease of handling by manual or mechanical means.
Packaging may consist of returnable or non-returnable items including dunnage.
PART CHANGE LEVEL (PCL): the latest design level of the part (not necessarily the
drawing). It is a two digit alpha field found on ODCICS2 through screens ECCE or ENCZ.
104
PP =
USL - LSL
6 P
Where,
USL LSL
6s
PPK: performance index that takes the process location as well as the performance into
account. (Statistical Process Control Manual, pg. 133)
PPK
PP
PPL =
Where,
USL - X
3 P
USL X
3s
LSL
3
and
LSL
3s
X
P
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107
screw, washer, and nut (in that order.) A sequential sensor would detect and flag
(through lights, station lock-out, etc.) if the nut was put on before the washer.
SPECIAL CHARACTERISTICS: product characteristics or manufacturing process
parameters which can affect safety or compliance with regulations, fit, function,
performance or subsequent processing of product. They include all governmental, Key
(diamond) <D>, emissions <E>, safety (shield) <S>, torque requirements, and
characteristics identified as SPC points on the design model. See PS-7300 - Key Product
Characteristics the Use of Diamonds for more information regarding Key characteristics
and PF-SAFETY for additional information regarding Safety characteristics.
STATISTICAL CONTROL: the condition describing a process from which special causes of
variation have been eliminated. Only common causes remain; e.g., observed variation
could be attributed to chance causes. On a control chart, statistical control is evident by
the absence of points beyond the control limits and by the absence of non-random
patterns or trends within the control limits.
STATISTICAL PROBLEM SOLVING (SPS): the organized use of special problem solving
tools (e.g. Fishbone Diagrams, Pareto Charts, ANOVA, etc.), to better understand
problems, their root causes and determine solutions.
STATISTICAL PROCESS CONTROL (SPC): the use of statistical techniques such as
control charts to analyze a process or its outputs to take appropriate actions to achieve
and maintain a state of statistical control and to improve the process capability.
SUB-COMPONENT: one or more parts that when assembled together results in the EndItem Assembly or module.
SUB-TIER SUPPLIER: see TIER 2 (& LOWER) SUPPLIER.
SUPPLIER READINESS EVALUATION (SRE) RUN: the first documented build attempt by
the Supplier following installation, setup, and tryout of the production equipment and
tools. The Supplier Readiness Evaluation Run shows that the process is set-up,
debugged, and ready for a Production Demonstration Run during the PSO On-Site Visit.
The Supplier Readiness Evaluation Run and analysis provides the Supplier with the
opportunity to optimize and refine the process. The Supplier, with the concurrence of the
DCC PSO Team, will determine the quantity of parts that are completed during this run.
The purpose of the SRE is to provide pre-production data that confirms the proper set-up,
operation, and performance of the installed production line. Data collected during this
run typically include measurement data, machine cycle times, operation times, quantity
attempted, quantity accepted, etc. From this data, estimated production rates, FTC,
yields, and PP and PPK for special characteristics are calculated. There are no minimum
requirements for process performance, FTC, yields, or other indicators at this time. The
DCC PSO Team will evaluate the data from this run when deciding whether to schedule
the PSO On-Site Visit.
SUPPLIER TOOL RECORD (STR): A form generated by the creation of a new TPO (Tool
Purchase Order) requiring the identification of Supplier, or DaimlerChrysler owned
tooling, affected by the TPO.
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SUPPLY CHAIN: includes all Suppliers used in producing a given part; from tier one to
the source of production materials.
SUPPLY CHAIN MAPPING: a method used to look at the complexity of the extended
enterprise value chain. Mapping details the manufacturing process, transportation and
other factors that go into component production.
TAKT TIME: The time in which one vehicle, assembly, or part (the item of interest) is to
be made.
TAKT Time
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INDEX
Page(s)
Advance Quality Planning (AQP) ........................................................... 2, 3
A Approval ..................................................................................................... 3, 4, 37, 43, 97
Bar Code Labeling.....................................................................................40
BSR/NVH ................................................................14, 16, 44, 89, 100, 104
Capability Matrix ......................................................................................63
Chrysler Development System (CDS) .............................14, 16, 20, 100, 107
Comments Sheet .................................................................................................................50
Control Plan .......................................... 12, 18-19, 22, 23, 29, 30, 35, 41, 44, 89, 90, 100-101
Daily Tooling Capacity ........................................................................37, 60
Design FMEA ........................................................................................14, 18, 29, 31, 89, 102
Documentation Checklist .....................................................................46-48
DVP&R ........................................................................................... 12, 15, 18, 29, 44, 89, 102
Electro-Static Discharge (ESD) Guidelines .................................................25
Element Requirements.....................................................................................................11-44
Error and Mistake Proofing .......................................................... 31-33, 90, 91, 102, 104, 108
Error and Mistake Proofing Requirements for Electrical Components .....................................33
Error and Mistake Proofing Requirements for Modules/Sequenced Part Delivery....................33
First Production Shipment Certification (FPSC) ................................................ 30, 90, 96, 103
First Time Capability (FTC) ..........................................................1, 19, 37, 38, 67-77, 95, 103
First Time Capability (FTC) Calculation Examples....................................67-77
Forever Requirements .....................................................................................................81-86
Frequently Asked Questions ................................................................93-98
Gage and Test Equipment Evaluation........................................................41
Gage R&R........................................................................... ..38, 41, 91, 103
Glossary .................................................................................................................99-109
IAA ........................................................ 3, 4, 95, 103
Incoming Material Certification Plan..........................................................22
Initial Process Study................................................................................ 29, 43, 56-57, 92, 97
Internal PSO Requirements ..................................................................88-92
Layered Process Audit .........................................................................34, 64
Lot Acceptance Sampling Table ............................................................................................62
Measurement System Report ............................................................................... 29, 35, 58-59
N Approval ...........................................................................................................................4
Net Operating Time for DCC Parts ................................................... ..37, 104
Operating Instructions .........................................................................26-27
Outgoing Material Inspection Plan.............................................................23
Packaging Approval...................................................................................39
Part Inspection Standard ................................................................................................ 22, 23
Part Number, Description, & Change Level.......................................................................12-13
Parts Handling Plan .............................................................................24-25
Parts Packaging and Shipping Specifications ........................................39-40
Powerway.com .......... ..3, 4, 7, 8, 9, 10, 20, 21, 34, 35, 46, 82, 94, 95, 96, 97
Process Performance Indices (PP, PPK) ........................................... 35, 38, 43, 63, 95, 105, 108
PPAP ................................................ 1, 2, 3, 4, 5, 8, 9, 20, 22, 38, 82, 90, 94, 98, 103, 16-107
Pre-PSO Documentation Review..................................1, 2, 3, 5, 7, 30, 35, 37, 41, 43, 105, 106
Preventive Maintenance ............................................................................42
Problem Solving ...................................................................................20-21
Process Flow Diagram and Manufacturing Flow Chart ...............................17
Process FMEA ........................................................................... 12, 16, 18, 29, 31, 44, 89, 106
Process Sign-Off Flowchart .....................................................6, 8
Process Sign-Off Responsibilities ...................................................7, 9
Process Sign-Off Strategy ............................................................5
Production Demonstration Run (PDR) ..............1, 3, 37, 38, 43, 53-55, 80, 92, 96, 97, 103, 106
COPYRIGHT 2007 DAIMLERCHRYSLER CORPORATION
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SECTION
Entire Document
DESCRIPTION OF CHANGE
Initial Revision
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PRINTED IN U.S.A.