Daimler DPA - Questionnaire 4-0 Nov 2007

Daimler Process Audit
Questionnaire
For Processes with Material Products
Based on VDA 6.3
Version 4.0
As at: 11/2007

Evaluating Processes for Material Products
Based on VDA 6.3
DPA Questionnaire
Version: 4.0. As at: 11/07
File:DPA_Questionnaire4.0_301107
Changes/revisions in questionnaire version 4.0 (April 2007)

1) Inclusion of new questions, some questions have been combined or discarded, content-related
additions/revisions.
2) Daimler additions/differences vis--vis VDA 6.3 highlighted in bold.
Question numbers in italics are Daimler questions. Texts no longer highlighted in
different colors.
1) New, combined, and discarded questions:

Element M1:
The numbering has changed due to the fact that some questions have been discarded and others
combined.
M 1.5 Previously M1.9, text revised, focus on quality planning.
M1.6
M1.7
Will a fallback solution for product malfunctions or identified risks be elaborated during
development? (new text, previously M1.7 )
New question: Is the identification of special characteristics ensured on the basis
of the requirements and are the requirements regarding the traceability
of the products and characteristics safeguarded?
M 1.8 New question: Are external development partners integrated and are they
controlled?
- The old M1.8 rights of sale have been discarded.
The previous M1.3 and M1.6 covered the issue of capacities. These have now
been combined in M1.4.
- The previous M1.4 and M1.5 have now been combined in M1.3 (evaluating requirements regarding
feasibility)
M 1.9 New question: How are changes to the product or process handled, monitored,
documented during the product development phase?
and
Element M2
M 2.2 and M2.4: text has been changed slightly.
Element M 3
M 3.3 New text included, i.e. capacities for prototype construction, sample construction,
zero series, production test.
M 3.7 New question: Have the suppliers for procedures, tools, machines, services etc. been integrated
in process development?
Element M4
M 4.2 Text has been revised, focus on production control plan.
M 4.5 Text has been revised to focus on the fact that draft versions of the documents are available.
M 4.6 Text has been revised, i.e. capacities are available, suitable, and capable.
M 4.7 New question: Do the process-related obligations of the suppliers for procedures, tools,
Author: MBC/QKF U.Schmidt
Page: 2

Based on VDA 6.3
DPA Questionnaire
machines, and services that must be fulfilled at the relevant times comply with the process
development plan?
Element M5
(In future, M5 will be audited in part 2. If only one part 3 exists, then as before, i.e. M5 must be audited
in part 3)
M 5.1 Text revised: scheduling.
M 5.2 Text revised: planned and ensured.
M 5.5 Text revised, i.e. query releases for the relevant phase.
M 5.12 New question: Are the required suppliers integrated in the new product project
and are they familiar with the customer requirements?
M 5.13 New question: Have the risks in the supply chain been determined and
counteracted by means of suitable measures?
M 5.14 New question: Are process audits in accordance with VDA 6.3 planned and
performed during the development phase for suppliers commissioned for new
product projects?
Element M6
M 6.2.8 Text revised: prognostic and preventive maintenance.
M 6.2.9 New question: Do the records created during the processes ensure the required traceability?
(The difference here vis--vis M 6.3.4 is that this question concerns the process data)
M 6.2.10 + M 6.2.11 New environment questions that replace the previous M6.2.9 and all the green
text that relates to the environment.
- Are all the legal requirements regarding the handling of waste and hazardous substances fulfilled?
- Are all the requirements associated with the construction and operation of a plant fulfilled?
M 6.4.7 New question: Has a suitable procedure for re-qualifying products on a regular basis been
defined and implemented?
The question about re-qualification was previously just a bulleted point in 7.1.
M 6.4.8 New question: How are changes to the product or process handled, monitored, and
documented during series production?
The SPICE topic for software components has been updated in M1.3, M1.4 , M2.2, M2.3, and M5.1. The
process and evaluation are described at the beginning of the manual ("From Assignment to Realization").
Changes/revisions in questionnaire version 4.0 (11/ 2007)

1. Adjustment Daimler AG
Page: 3

Based on VDA 6.3
DPA Questionnaire
Contents
Processes with Material Products (Part 1 of VDA 6.3) ............................................................................... 5
Questionnaire for Process Audit of Material Products................................................................................ 5
1.1
2
Part A: Product Development Process .............................................................................................. 7

2.1
2.2.
Structure of the Questionnaire................................................................................................ 6

Product Development (Design) ............................................................................................... 8
2.1.1
M1: Planning Product Development.......................................................................... 8
2.1.2
M2: Implementing Product Development ............................................................... 17
Process Development ............................................................................................................ 22

2.2.1
M3: Planning Process Development........................................................................ 22
2.2.2
M4: Implementing Process Development ............................................................... 29
Part B: Series Production ................................................................................................................. 36

3.1
M5: Suppliers / Input Material.............................................................................................. 37
3.2
M6: Production....................................................................................................................... 46
3.3
3.2.1
M6.1: Personnel / Qualification .............................................................................. 47
3.2.2
M6.2: Production Material / Equipment................................................................. 51
3.2.3
M6.3: Transportation / Parts Handling / Storage / Packaging............................ 60
3.2.4
M6.4: Non-Conformity Analysis / Corrective Measures / Continuous Improvement

65
M7: Customer Support / Customer Satisfaction / Service................................................ 71

Appendix
- Definition/content of a production control plan
- Example of a production control plan
- Overview of the MBST
- Initial screen for the DPA database
Page: 4

Based on VDA 6.3
DPA Questionnaire
Processes with Material Products (Part 1 of VDA 6.3)

The Daimler process audit (DPA) questionnaire was drawn up by Daimler AG experts and is
based on the VDA 6.3 questionnaire. It is updated and published by MBC/QKF (Quality
Management for the Mercedes-Benz Car Group, purchased parts).
The current version of the DPA questionnaire is available for all Daimler employees on the
intranet at the following address:
Supplier management manual / link under quality/logistics processes:

DPA Home
Questionnaire for Process Audit of Material Products

The questionnaire for material processes is divided into two categories:
Part A: Product development process
Part B: Series production
This questionnaire provides a basis for the work carried out by the auditor. The different
elements can be combined and executed depending on the A/B/C classification.
He can adapt the questionnaire in line with the particular audit by adding or removing sections
where required.
Part A
Product development process

M1
M2
M3
M4
Part B
Planning product development

Implementing product development
Planning process development
Implementing process development
Series production
M5
M6
M 6.1
M 6.2
M 6.3
M 6.4
M7
Suppliers / input material

Production
Personnel / qualification
Production material / equipment
Transportation / parts handling / storage / packaging
Non-conformity analysis / corrective measures / continuous
improvement
Customer support / customer satisfaction / service
Page: 5

Based on VDA 6.3
1.1
DPA Questionnaire
Structure of the Questionnaire

The questionnaire is divided into the following sections for each element:
-
Introduction
Questions
Requirements / explanations
Lists (i.e. what needs to be taken into account)
The lists indicate which aspects, among others, are of particular importance with respect to the
product or process. In each case, the relevant points must be selected, supplemented, and
assessed on a product or process-specific basis.
When the various process levels are evaluated with respect to part B (series production), each
process level must be specified.
In this questionnaire, questions or comments specific to Daimler AG are indicated accordingly.
Key:
- Additional Daimler requirements vis--vis VDA 6.3 question: CorpoS bold
- Special Daimler question: question no. is CorpoS bold italics (e.g.
6.2.8)
- Question with logistical aspects: (L)
i.e. must be answered in conjunction with a logistics expert.
Page: 6

Based on VDA 6.3
Part A:
DPA Questionnaire
Product Development Process
Product/process development in the product creation process is based on the four phases of
the product quality planning cycle (plan/implement/analyze/improve). Interdisciplinary
collaboration and systematic procedures at all stages of product development are essential for
fulfilling all the requirements regarding production start-up for a product.
At the start of the product development process, all those involved must be aware of the
customer requirements, market trends, standards, and laws, which must be systematically
integrated in the core and supporting processes, taking into account any changes made during
product development.
Reviews must be conducted at regular intervals to monitor compliance with the defined
processes and targets since any non-conformities or change requirements can affect the
targets.
Correct and systematic risk analysis and evaluation methods in the product development
process ensure that non-conformities and required corrective measures can be identified in
good time. These are a key factor in optimizing and limiting costs.
All employees involved in a project are subject to stringent requirements regarding
qualifications and performance. They must work in a systematic manner at all stages of product
development to ensure that all customer requirements are fulfilled and series production can
begin with the required high level of quality.
Note:
The VDA publication volumes 1, 2, 3, 4.1, 4.2, 4.3, 6.1, 6.2, 6.4, and 7 are also
valid and must be taken into account.
Page: 7

Based on VDA 6.3
2.1
Product Development (Design)
2.1.1
M1:
DPA Questionnaire
Planning Product Development
The internal planning objectives for a new product, which are based on customer requirements
and the relevant legislation, must be defined during the quotation phase. Once the order has
been received, these are then specified in greater detail and included in a product development
plan.
In the product development plan, all the required tasks must be specified and assigned
achievable goals and deadlines.
The requirements for a product are often more stringent than the customer requirements and
must be analyzed and specified in detail by the organizational/functional units. The
requirements are subject to constant review and, in the light of the results of these reviews,
changes may need to be made during the planning phase.
Questions
M1.1
Are the customer requirements known and have they been evaluated?
M1.2
Is a product development plan available and does it comply with the

Daimler project schedules (MDS schedule/CV-DS schedule)?
M1.3
Have the requirements for the product been determined and their feasibility
evaluated at a cross-functional level?
M1.4
Have the required personnel and technical requirements for product development
and handling the project been planned / are they fulfilled?
M1.5
Has quality planning for controlling the system FMEA for the product and the process
been integrated in the project?
M1.6
New
Will a fallback solution for product malfunctions or identified risks

be elaborated during development?
M1.7
New
Is the identification of special characteristics ensured on the basis

of the requirements and are the requirements regarding the
traceability of the products and characteristics safeguarded?
M 1.8
New
Are external development partners integrated and are they

controlled?
M 1.9
New
How are changes to the product or process handled, monitored

and documented during the product development phase?
Page: 8

Based on VDA 6.3
M1.1
DPA Questionnaire
Are the customer requirements known and have they been
evaluated?
All customer requirements regarding the product to be developed must be known
and integrated in the development process.
The following must be taken into account:
-
Drawings, standards, specifications, performance specification

Logistics concepts
Technical terms of delivery, test specifications
Quality agreements, target agreements
Key product/process characteristics
Purchase order documents with BOMs and dates
Legislation/directives
Waste management plans, environmental aspects, recycling
Daimler: MBST, DBL, functional specifications, ppm objectives
Information flow, organizational implementation
Management of change years and technical changes
What provisions are in place regarding the responsibilities, assignment,
and documentation of Daimler-specific requirements?
Are there any special requirements regarding specific input materials or
sub-suppliers?
MDS /CV-DS schedule
Note:
Customer requirements regarding input materials or sub-suppliers and who is
responsible for qualification in these cases must be clearly documented.
Page: 9

Based on VDA 6.3
M1.2
DPA Questionnaire
Is a product development plan available and does it comply with Daimler

project schedules?
(MDS schedule/CV-DS: Mercedes, Commercial Vehicle Development System)
The product development plan is part of the project plan and correlates with the
process development plan. All activities, including those carried out by suppliers,
must be defined prior to production start-up. The target objectives must be derived
from the requirements and observed at the defined project stages.
-
Customer requirements
Costs
Deadlines: Planning/procurement release, change stop
Date of production start-up
Date of initial sample
MDS deadlines (e.g. PRO 1, PRO 2, PRO 3, or CV-DS deadlines)
Tool deadlines and lead times
Quality planning (e.g. reliability tests, function tests, test plan)
Prototypes/pilot production series, start of series production
Capacity analysis
Definition and monitoring of targets
Regular reports to company management
Simultaneous Engineering Teams (SET)
Procedure for changes to deadlines and
quantities made by the customer
Logistical planning model including milestones
Note:
The product development plan must contain clear specifications regarding
the date by which individual product characteristics must be defined so
that logistical processes can be planned (e.g. parts size and geometry as a
basis for load container planning). The product development plan must
also use suitable controlling instruments that highlight the effects of
individual product characteristics on the costs of logistical processes.
Page: 10

Based on VDA 6.3
M1.3
DPA Questionnaire
Have the requirements for the product been determined and their feasibility
evaluated at a cross-functional level?
Requirements regarding the product must be determined and their feasibility
evaluated by means of interdisciplinary collaboration and benchmarking. QFD and
DOE are methods that can be implemented here. Previous experience and future
expectations must be taken into account in the analysis. Requirements regarding the
product must be in line with market requirements as well as the requirements and
expectations of the customer. The product must also be competitive.
QFD = Quality Function Deployment
DOE = Design of Experiments
-
Customer requirements (performance specification, functional specifications,

DBL, etc.)
Corporate objectives
Simultaneous engineering
Robust design / reliable process
Regular meetings with customer/supplier
Special characteristics, legal requirements
Functional dimensions
Installation dimensions
Materials
Design
Process setup, capacity
Special characteristics
Regulations, standards, legislation, environmental compatibility
Procedure for changes to deadlines and quantities made by the customer
Logistical requirements (e.g. regarding transportation and storage) must
also be taken into account here. [L]
SPICE (requirements regarding AutomotiveSPICE PAM as of MBST 2007)
System requirements analysis
ENG 2 process, AutomotiveSPICE PAM
System architecture design
Software requirements analysis
Software design
MPS examples:
3.3.3
Customer quality sensor
3.3.4
Higher-level quality control loop experience with previous
products
5.1.9
Practice sharing, benchmark
Page: 11

Based on VDA 6.3
M1.4
DPA Questionnaire
Have the required personnel and technical requirements for product

development and handling the project been planned / are they fulfilled?
Requirements regarding personnel qualification and the resources to be provided
must be determined before the project begins and specified in the project plan.
-
M1.5
Project management, project planning team / responsibilities

Communication options (remote data transfer)
Flow of information from and to customer during planning (regular meetings,
conferences)
Tools / equipment
Internal and external testing/laboratory equipment
CAD, CAM, CAE
Deadline controlling
Project management
MAN 3 process, AutomotiveSPICE PAM
Quality assurance
SUP 1 process, AutomotiveSPICE PAM
Configuration management
Troubleshooting management
Change management
MPS examples:
1.1.6
Use checklists to check resource planning requirements
1.1.8
Regular communication internally and with customer
1.2.1
Describe roles define TCR (tasks/competencies/
responsibilities)
Has quality planning for controlling the system FMEA for the product and the
process been integrated in the project?
Product risks must be clarified and minimized on a continuous basis with suitable
measures by means of interdisciplinary collaboration, with customers and suppliers.
The system FMEA is recommended for complex parts or complete functional
Page: 12

Based on VDA 6.3
DPA Questionnaire
systems (see VDA publication 4, parts 1 and 2). Other similar analysis methods must
be agreed upon with the customer.
The focus here is on verifying that a design FMEA is carried out.
Customer requirements / performance specification
Function, security, reliability, service friendliness, key characteristics
Environmental aspects
Integration of all the affected areas
Test results
Product-specific measures from the process FMEA
-
MPS examples:
3.2.10 Supplier quality management FMEA
3.2.9 Process FMEA (e.g. when new technology is implemented)
Page: 13

Based on VDA 6.3
M1.6
New
DPA Questionnaire
Will a fallback solution for product malfunctions or identified risks be

elaborated?
A risk analysis is to be used to highlight what would happen if a product or
component malfunctions. Measures must be planned to ensure that the customer
always receives products that are free of defects, that is, even if problems with input
materials or sub-suppliers occur at short notice.
- Single sourcing
(Alternatives for technical or business single sourcing)
Note:
With single sourcing, suitable measures (e.g. technical alternatives) to
minimize associated delivery risks must be planned and taken into account
during product development.
Customer requirements (planned no. of units)
Note:
The measures derived from the risk analysis must be suitable for fulfilling the
planned customer requirements (no. of units and functions).
MPS examples:
3.2.1 0 Supplier quality management - FMEA
4.1.1 Benchmark figures for production program planning
M 1.7
New
Is the identification of special characteristics ensured on the basis of the

requirements and are the requirements regarding the traceability of the
products and characteristics safeguarded?
When special characteristics are identified, company requirements and customer
requirements regarding how these are identified must be taken into account and
included in the relevant documents (drawing, specifications, production control plan,
work and inspection instructions).
- Safety-relevant characteristics
- Functional characteristics
- Legal requirements
- Consistency of identification in the supply chain
- Note: Mercedes uses DS, DZ, and DS for safety-relevant characteristics and DZ for
certification-relevant characteristics.
The outlay involved with documentation required must be planned and coordinated
with the customer on the basis of the risks associated with the customer and in the
field taking into account safety aspects and warranty costs.
Page: 14

Based on VDA 6.3
DPA Questionnaire

-
M 1.8
New
Traceability: part no., production data, branding etc.

Consistency of traceability in the supply chain
Are external development partners integrated and are they

controlled?
The commissioning and performance of external development partners (design
engineers, calculation specialists, software developers, laboratories, institutes, test
benches, tool manufacturers etc.) must be controlled.
In the process, the interfaces with external partners must be identified and
safeguarded. Communication with these partners must be controlled with respect to
the fulfillment of customer requirements.
Controlling of responsibilities between Daimler, 1st level supplier, and subsuppliers.
Personnel and technical resources (see question 1.4)
Deadlines, milestones, reviews
Costs
Quality of work carried out
Order documentation/evaluation
Confidential documentation
How are the sub-suppliers informed of Daimler-specific requirements?
Page: 15

Based on VDA 6.3
M 1.9
New
DPA Questionnaire
How are changes to the product or process handled, monitored, and

documented during the product development phase?
Requirements / explanations:
The change procedure (i.e. from the change request to implementation) must be
clearly described, the responsibilities clearly defined, and the change statuses
documented systematically and transparently.
A suitable system must be in place to support this.
- Change released by the organization and customer
(e.g. feasibility, interfaces with components, effect on costs/deadlines, etc.)
- Circulating changes (e.g. process development or to upstream
supplier)
- Tracking the degree to which the change has been implemented
- Documenting change histories
- Updating the relevant documents (drawings, instructions, etc.)
Page: 16

Based on VDA 6.3
2.1.2
M2:
DPA Questionnaire
Implementing Product Development
All the tasks defined during product planning must be carried out during the implementation
phase of product development. Potential changes must also be identified and taken into
account. The project manager or project management team have the crucial task of integrating
all the interfaces in all tasks in good time and informing management and, if necessary, the
customer of any problems as quickly as possible.
Reviews must be conducted at defined intervals during the implementation phase. If any targets
are not achieved, corrective measures must be defined and implemented, and their
effectiveness monitored.
Questions
M2.1
Is the system FMEA for the product updated during the course of the project and are
the defined measures implemented?
M2.2
Is a quality planning procedure that covers all the risk analyses as well as product
verification and validation tasks integrated in the product development process?
M2.3
Are the required releases/qualification records available at the respective times?
M2.4
Are the planned resources available, suitable, and capable?
Page: 17

Based on VDA 6.3
M2.1
DPA Questionnaire
Is the system FMEA for the product updated during the course of the project
and are the defined measures implemented?
Changes to the product and process must be evaluated by the project manager. A
new analysis may have to be carried out after consultation with the FMEA team.
Updates are also necessary after the measures have been implemented (design
review).
The focus here is on verifying/validating the design FMEA process in the project.
Key parameters/characteristics, legal requirements
Function, installation dimensions
Materials
Environmental aspects
Transportation (internal/external)
Product-specific measures from the process FMEA
-
M2.2
MPS examples:
3.2.9
Process FMEA (e.g. when new technology is implemented)
3.2.10
Supplier quality management - FMEA
Is a quality planning procedure that covers all the risk analyses as well as
product verification and validation tasks integrated in the product
development process?
Quality planning must include a test plan for the components, assemblies, subassemblies, parts, and materials belonging to the product, including the
manufacturing processes in the prototype and pilot production phase. The test plan
is a living document and must be created/updated for new products or when
changes are made. The QM plan (to DIN EN ISO 9000:2000/3.7.5) must normally be
drawn up for the following phases:
It is recommended that a QM plan covering product development, process
development, and production be created (see also question M4.2).
Prototype phase
A description of the dimensional as well as the material and functional inspections
that must be carried out during prototype construction (if required by the customer).
Pilot production phase / interface with process development

Page: 18

Based on VDA 6.3
DPA Questionnaire

that must be carried out after prototype construction and prior to series production.
The plan must contain details of the following (among other things):
-
Definition and identification of significant characteristics

Creation of the test and inspection plan
Provision of equipment and fittings
Timely, planned provision of measuring equipment
Tests carried out at the appropriate product implementation milestones
Clarification of acceptance criteria
Note: For more information, see also VDA publication 4.3

-
Is the initial sample deadline included in the QM plan?

Were the planned deadlines observed?
Were measures elaborated in the event of non-conformities?
Has the QM plan been updated?
MPS examples:
1.2.2
Process description
3.1.4
Section inspection / section audit
3.1.7
Production test 1, 2, 3
3.1.8
Release for series production
3.2.6
Establish process audits for QGs
3.2.10
Supplier quality management (external/internal)
Q-LIMA
3.2.11
Process safeguarding plan
3.3.2
Quality gates in vehicle assembly
3.3.4
Higher-level quality control loop
SPICE measures status

Have all SPICE measures been scheduled? Who is/are
for these? Is work progress monitored by quality assurance?
responsible
Page: 19

Based on VDA 6.3
M2.3
DPA Questionnaire
Are the required releases/qualification records available at the respective

times?
The releases/qualification records must be verified for all individual parts,
assemblies, and purchased parts.
-
Product testing including installation test, functional test, service life test,
environmental simulation (these are carried out on the product or with the
product) test reports/logs
Status of prototype parts
Pilot production sample
Manufacturing and test equipment/devices in trial construction.
Legal approvals
Has Daimler AG submitted a development release? [P]
Prototype/pilot production sample:
Is a
parts description available in which the series deviations from Daimler AG
requirements can be identified? [P]
Results of 2.2 are requested here.
SPICE (requirements regarding AutomotiveSPICE PAM as of

MBST 2007)
Software implementation
Software integration test
Software test
System integration test
System test
Page: 20

Based on VDA 6.3
M2.4
DPA Questionnaire
Are the planned resources available, suitable, and capable?

The required capacities are defined in quotation costing and advance planning. They
must be available or planned and made available by the relevant deadline, which
must be defined. The resources required for this must be made available in the
project.
Qualified personnel
Lost time through absenteeism
Throughput times
Buildings, premises
Trial construction
Prototype construction
Tools / equipment
Test / inspection / laboratory equipment
Avoiding surpluses [P]
Material availability (see question M5.11) [L]
-
Page: 21

Based on VDA 6.3
2.2.
Process Development
2.2.1
M3:
DPA Questionnaire
Planning Process Development
Basic plans for manufacturing a product in accordance with customer requirements must be
elaborated during the quotation phase. Once the order has been received, these are then
specified in greater detail and included in a product development plan. Existing technical and
personnel resources must be taken into account and any necessary extensions planned in
advance.
When the tasks, objectives, and deadlines are defined, all interfacing areas must be integrated
by means of interdisciplinary collaboration. All tasks and responsibilities must be clearly
defined.
When process are planned and implemented, changes may need to be carried out as a result of
new customer requirements or special legislative requirements, which also means that the
planning approaches may have to be reexamined.
Note: These questions are aimed at the process developer/planner.
Questions
M3.1
Are the product requirements available?
M3.2
Is a process development plan available? Is it aligned with the project schedule of

the customer? Are the targets observed?
M3.3
Have the capacities required for implementing the prototype construction, sample
construction, zero series, production test, and series production been planned?
M3.4
Have the requirements regarding the process been determined and taken into
account?
M3.5
Have the personnel and technical prerequisites for carrying out the project been
planned/fulfilled?
M3.6
Has the system FMEA process been created and have the improvement measures
been defined?
M3.7
New
Have the suppliers for procedures, tools, machines, services etc.

been integrated in process development?
Page: 22

Based on VDA 6.3
M3.1
DPA Questionnaire
Are the product requirements available?

All requirements regarding the product to be manufactured must be known and
integrated in planning.
-
Legislation, standards, directives
Logistics concepts
Technical terms of delivery
Quality/target agreements
Special characteristics
Materials
Waste disposal, environmental protection,
recycling (see also MBST)
Note: This process is identical to 1.1 and 1.3 with the exception that, in this case,
the requirements must be submitted to the process planner.
M3.2
Is a process development plan available? Is it aligned with the project

schedule of the customer? Are the targets observed?
The process development plan is part of the project plan and correlates with the
product development plan. All activities must be defined up to production start-up (in
addition, all suppliers must be defined, qualified accordingly, and listed with status).
The target objectives must be derived from the requirements and observed at the
defined project stages.
-
Milestones for cost aspects/controlling
Deadlines: Planning/procurement release, prototype/pilot production, start of
series production
Project plans for investment projects (building and facilities)
Capacity study
Process/equipment/documentation for ensuring traceability
Provision of production/test equipment, software, packaging (availability)
Concept for safeguarding changes (start-up problems etc.)
Logistics/delivery concept
Definition and monitoring of targets
Regular reports to company management
Page: 23

Based on VDA 6.3
DPA Questionnaire
Deadlines for production tests:

Steps must be taken to ensure that production tests carried out by the
suppliers are synchronized with those carried out by the customer (Daimler
AG, MBC) and agreed upon.
Change management:
Update process development plan
More stringent requirements of Daimler AG, MBC during the course of
changes in series production (e.g. safeguarding parts supply),
change years, and technical changes.
MPS examples:
3.1.8 Approval for series production
3.2.6 Process audits for verifying/validating quality gates
3.2.10 Supplier quality management specification of deadlines for
procurement approval, supplier approval, and change stop
3.2.12 Test equipment monitoring / analyses to assess suitability of
measuring equipment
Page: 24

Based on VDA 6.3
M3.3
DPA Questionnaire
Have the capacities required for implementing the prototype construction,

sample construction, zero series, production test, and series production been
planned?
The required capacities must be determined and taken into account in the quotation
phase. The data must be specified in greater detail once the order has been placed.
If any requirements change, the capacity study may have to be updated. The
required resources must be planned and made available.
-
Availability of input material
Qualified personnel
Lost time through absenteeism / downtime
Throughput times/no. of units for each plant/item of equipment
Expected process capability
Balancing capacity fluctuations
Buildings, premises
Plants, tools, production/test equipment, auxiliary tools, laboratory equipment
Means of transportation, containers, warehouse
CAM, CAQ
MPS examples:
1.3.2
1.3.4
1.3.5
1.4.4
1.4.8
3.1.4
3.3.2
Performance standards
Employee selection process
Learning isles
Plan integration of employees with restrictions on
deployment
Qualification matrix
Page: 25

Based on VDA 6.3
M3.4
DPA Questionnaire
Have the requirements regarding the process been determined and

taken into account?
The requirements regarding the process must be determined by means of
interdisciplinary collaboration. QFD and DOE are methods that can be implemented
here. Previous experience and future expectations must be taken into account in the
analysis.
-
Legal requirements
Proof of functionality
Suitability of plants, tools, and test equipment
Design of workplace and test bay
Handling, packaging, storage, branding
Documentation requirements
Logistical requirements must also be taken into account (e.g. standard
delivery form (Just in Sequence (JiS), Just in Time (JiT), or plant logistics
performance center (LLZ), delivery, delivery request type (VDA 4905, 4915,
4916), delivery note remote data transfer (VDA 4913), alternative webbased interface (WebEDI), transportation agreement (regional forwarding
agent, direct relation), INCOTERMS (carriage paid, ex works), delivery
frequency and times, etc. [This should be covered with a logistician.]
MPS examples - methods:

1.2.2
Process description
1.5.1
Work safety and occupational health guidelines
1.5.3
Ergonomic evaluation of work processes
2.2.2
Marking, identification, labeling
3.1.4
3.2.1
Total Productive Maintenance (TPM)
3.2.4
SPC (Statistical Process Control)
3.2.12
Test equipment monitoring / analyses to assess suitability of
measuring equipment
3.3.4
Experience with previous products
5.1.9
Practice sharing, benchmark
5.1.10
Simultaneous engineering expectations of system partner
Page: 26

Based on VDA 6.3
M3.5
DPA Questionnaire
Have the personnel and technical prerequisites for carrying out the project
been planned / fulfilled?
Requirements regarding personnel qualification and the resources to be provided
must be determined before the project begins and specified in the project plan.
-
M3.6
Project management, project planning team/responsibilities, incl. stand-in

regulations
Qualified personnel
Plants, tools, production/test equipment, auxiliary tools, laboratory equipment
Communication options (e.g. remote data transfer)
Flow of information from and to customer during planning (regular meetings,
conferences)
CAM, CAQ
Environmental relevance (e.g. hazardous materials)
Is a logistics plan that includes the customer and/or the supplier
available?
Note:
A logistics plan is required that coordinates and plans the logistics
processes at the interfaces together with the customers and suppliers.
Responsibility for logistics must be clarified beforehand (e.g. INCOTERMS).
[L]
Has the system FMEA process been created and have the improvement
measures been defined?
Process risks must be clarified and minimized with suitable measures by means of
interdisciplinary collaboration (this includes customers and suppliers). The FMEA
system is recommended for complex parts or complete functional systems (see VDA
publication 4, parts 1 and 2).
- MBST
- All manufacturing stages (of suppliers too)
- Customer requirements, function
- Key parameters / special characteristics
- Traceability, environmental aspects
- Transportation (internal/external) and handling
- Integration of all the affected areas
- Process-specific measures from the design FMEA
Logistics
Page: 27

Based on VDA 6.3
M3.7
New
DPA Questionnaire
Capacity and failure analysis

Logistics processes
Note:
As part of the process FMEA, all logistics processes from the upstream
supplier to the customer must be analyzed. This also includes all
information-related processes carried out by the logistics department
(delivery request receipt and processing, production planning and control,
order processing, upstream supplier management (i.e. sub-supplier
structure and processes, including emergency cover in input material
procurement)).
Have the suppliers for procedures, tools, machines, services etc. been
integrated in process development?
All partners who are heavily involved must be integrated in process development.
Dates for commissioning, review and acceptance inspections must be defined in
order to indicate that suppliers are integrated in the process development plan.
Commissioning of these suppliers must be verified by means of suitable
documentation. Service suppliers include:
- Logistics
- Maintenance
- Calculation/CAD
- Laboratories
- Construction services
The dates must be coordinated with the part-specific project plan.
Page: 28

Based on VDA 6.3
2.2.2
M4:
DPA Questionnaire
Implementing Process Development
In the implementation phase of process development, all the tasks defined during process
planning (process development plans) must be carried out. In addition, potential changes must
be identified and taken into account. For project management/monitoring purposes, a project
manager must integrate all the interfaces in all tasks in good time and inform management and,
if necessary, the customer of any problems as quickly as possible.
Reviews must be conducted at defined intervals during the implementation phase. If any targets
are not achieved, corrective measures must be defined and implemented, and their
effectiveness monitored.
Questions
M4.1
Is the system FMEA process updated during the course of the project if changes are
made and are the defined measures implemented?
M4.2
Are the production control plans for the different product development phases
available?
M4.3
Are the required releases/qualification records available at the respective times?
M4.4
Has pre-production under series conditions been planned or carried out for the
approval for series production?
M4.5
Are the production and inspection documents available and complete?
M4.6
Are the required capacities available, suitable, and capable (part 3)?
M 4.7
New
Do the process-related obligations of the suppliers for

procedures, tools, machines, and services that must be fulfilled at the
relevant times comply with the process development plan?
Page: 29

Based on VDA 6.3
M4.1
DPA Questionnaire
Is the system FMEA process updated during the course of the project if
changes are made and are the defined measures implemented?
Changes to the product and process must be evaluated by the project manager. A
new analysis may have to be carried out after consultation with the FMEA team.
Updates are also required once the measures have been implemented.
- MBST
- Customer requirements
- All manufacturing stages (of suppliers too)
- Key parameters/characteristics, legal requirements
- Installation dimensions
- Materials
- Traceability, environmental aspects
- Transportation (internal/external)
- Process-specific measures from the design FMEA
- Change history
M4.2
Are the production control plans for the different product development
phases available?
The production control plan must contain the components, assemblies, subassemblies, parts, and materials belonging to the product, including the production
processes.
The production control plan must normally be drawn up for the following phases:
Prototype phase (if required by the customer)
Description of the dimensional check as well as the material inspections and
performance tests carried out when the prototype is constructed.
Pilot production phase
that must be carried out prior to series production.
Series production phase
Comprehensive documentation of the process steps with the relevant product and
process characteristics, the process control measures, the inspections, and the
measurement systems that are to be taken into account during series production.
The plan must contain details of the following (among other things):
- Definition and identification of significant characteristics
Page: 30

Based on VDA 6.3
DPA Questionnaire
Creation of the test and inspection plan

Provision of equipment and fittings
- Timely, planned provision of measuring equipment
- Tests carried out at the appropriate product implementation milestones
- Clarification of acceptance criteria
Note: For more information, see also VDA publication 4.2
-
M4.3
MPS examples:
3.1.4
3.1.7
Production test 1, 2, 3
3.1.8
Approval for series production
3.2.6
Establish process audits for QGs
3.2.10
Supplier quality management (external/internal)
Q-LiMa
3.3.2
Are the required releases/qualification records available at the respective

times? Are the qualification records for internal company processes available?
The releases/qualification records must be verified for all individual parts,
assemblies, purchased parts, as well as production and test equipment.
-
Product testing (e.g. installation test, functional test, service life test,
environmental simulation)
Pilot production parts
Prototype sample
Commissioning
Logistics concept (e.g. suitability of packaging tested with trial shipment)
Tools, machines, equipment, test equipment
Proof of functionality of key product/process characteristics
Is initial sampling carried out internally here?
(irrespective of the sampling method requested by the customer)
Production tests
Page: 31

Based on VDA 6.3
M4.4
DPA Questionnaire
Has pre-production under series conditions been planned or carried out

for the approval for series production?
Pre-production must be carried out to evaluate and, if necessary, correct all
production factors and influences at an early stage, thereby helping to avoid
bottlenecks and deterioration in quality during series production.
The process of planning and performing pre-production along with the
appropriate agreements are verified/validated in questions M3.2 and M3.4.
-
Establishing the minimum number of pieces
Process capability analysis
Measuring equipment capability
Readiness of the production materials and equipment for series production
(measurement reports)
Handling, packaging, identification, storage
Personnel qualification
Work and inspection instructions
Design of workplace and test bay
Initial sample testing
Planning the initial sampling process and content:
Are measures in place to ensure that the initial sample is introduced in
good time prior to the launch of series production?
Is the procedure used at Daimler AG, MBC, and TG (guidelines,
special terms no. 13) known and implemented?
Are all specifications taken into account for initial sample testing?
Production tests carried out in the same manner at Daimler AG, MBC, and
TG [L]
Identification of BOM and materials planning errors [L]
Note:
The production tests are also to be carried out to verify that the
information-related processes function properly (BOM explosion,
requirements determination, purchase order quantity calculation,
triggering of requirements, etc.) so that BOM and materials planning
errors can be identified and avoided at an early stage. [L]
MPS examples:
1.4.8
2.1.5
On-site measurement
3.1
Rapid problem detection and troubleshooting
3.2.3
Error prevention
3.2.6
Process audit
3.2.10
Supplier quality management
3.2.12
Analyses to assess suitability of measuring equipment
3.3.2
4.1.1
Production program planning
Page: 32

Based on VDA 6.3
M4.5
DPA Questionnaire
Are the production and inspection documents available and complete?

Process parameters/inspection characteristics must always be specified with
tolerances. The manufacturing and inspection documents must be available at the
work/inspection station. In the event of non-conformities, the measures
implemented must be documented.
A draft is acceptable depending on the time of the audit.
Specifications include:
-
Process parameters (e.g. pressures, temperatures, times, speeds)

Machine/tool/auxiliary equipment data
Inspection requirements (key characteristics, test equipment, methods,
frequency of tests)
Intervention limits in process control cards
Machine and process capability records
Operating instructions
Work instructions
Inspection instructions
Information about current non-conformities
Rework documentation
MPS examples:
1.2.2
Process description
2.1.1
Standard work sheets
2.1.2
Standardized workstation documentation
3.1.3
Reference samples
3.2.4
3.2.10
Supplier quality management
Page: 33

Based on VDA 6.3
M4.6
DPA Questionnaire
Are the required capacities available, suitable, and capable?

The required capacities are defined in quotation costing and current process
development.
-
Availability of input material
Qualified personnel
Lost time through absenteeism / downtime
Throughput times/no. of units for each plant/item of equipment
Buildings, premises
Plants, tools, production/test equipment, auxiliary tools, laboratory equipment,
means of transportation, containers, warehouse
Capacity prior to launch of series production (initial supply of parts) [L]
Note:
The capacities must be available in good time prior to the launch of series
production at the customer. It is important to determine whether all users
(all plants, ET, CKD) are taken into account when capacities are calculated.
Have the maximum volumes for the process steps been determined? [L]
Note:
The process steps prone to bottlenecks must be known; it must be
remembered that the processes that can result in bottlenecks can change
as a result of shifts in the variant structure.
Have plans been drawn up to increase capacity for the bottleneck
processes? [L]
Page: 34

Based on VDA 6.3
M 4.7
New
DPA Questionnaire
Do the process-related obligations of the suppliers for procedures, tools,

machines, and services that must be fulfilled at the relevant times comply
with the process development plan?
At each stage, process development must define and verify the status of the
products and processes to be used.
Examples: Test reports, audit results, development approval, reference sample, etc.
- Approvals
- Identification of tools
- Design of tools / no. of pieces
- Proof of functionality
- Tolerance analyses
- Load tests
Page: 35

Based on VDA 6.3
Part B:
DPA Questionnaire
Series Production
To ensure that series production is carried out in line with the defined process, all the required
measures from the product development process must be implemented systematically.
Taking customer requirements into account, the supplier's own processes regarding production,
product delivery, and usage must be continuously evaluated and optimized.
To ensure that the customer is satisfied with quality, prices, and service, a customer-orientated
approach in all processes is essential.
Quality performance is determined by man, machine, material, and means/environment with
lean production processes, low stock levels, and a high level of employee expertise.
Responsibility on the part of the employees involves not only the ability to identify nonconformities with respect to products and processes, but also to implement and initiate
improvement measures at their own initiative.
Suitable methods must be used to continuously evaluate processes and procedures, analyze
non-conformities, and implement suitable corrective measures in order to maintain, improve,
and fulfill all requirements regarding process capability.
To maintain and improve customer satisfaction, the organizational/functional unit is obliged to
monitor its products after production. Active collaboration with the customer and the early
identification of faults and non-conformities form the basis for long-term, trusting cooperation.
Page: 36

Based on VDA 6.3
3.1
M5:
DPA Questionnaire
Suppliers / Input Material
Shorter delivery times to the customer (e.g. just in time) and a reduction in throughput times
affect procurement times and require special activities in the individual processes.
This requires a highly reliable system because errors or defects with the delivery cannot
normally be corrected by means of alternative parts or materials.
If intermediate stock levels are low or do not exist, quantitative or logistical problems can lead
directly to interruptions in production.
In conjunction with its suppliers, the company that is being audited is obliged to safeguard the
processes and procedures for the respective products/materials and ensure process capability
with respect to all key, customer-relevant characteristics. The effectiveness of defined quality
assurance and continuous improvement measures must be verified.
Questions
M5.1
Are only approved quality-capable suppliers used and defined in accordance with the
schedule?
M5.2
Has the agreed quality of the purchased parts been planned and ensured?
M5.3
Has quality performance been evaluated and are suitable measures implemented in
the event of non-conformities with respect to the requirements?
M5.4
Have target agreements for continuously improving products and processes been
coordinated with the suppliers and have they been implemented?
M5.5
Are the required approvals for the products delivered available in the various phases
and have the required improvement measures been implemented?
M5.6
Have the procedures agreed upon with the customer with respect to products
supplied by the customer been observed?
M5.7
Are the stock levels of the input material adjusted in the various phases in line with
product requirements?
M5.8
Are the input materials/internal remaining quantities delivered

and stored according to their purpose?
M5.9
Do the employees possess the expertise required to perform their tasks?
M5.10
Is a process for monitoring the procurement market in place and are

measures derived from market observations and requirements forecasts?
M 5.11
Is the availability of input materials (components) ensured in the event of

increased demand when series production is launched and after it is
complete? [L]
Page: 37

Based on VDA 6.3
DPA Questionnaire
M 5.12
New
Are the required suppliers integrated in the new product project

and are they familiar with the customer requirements?
M 5.13
New
Have the risks in the supply chain been determined and

counteracted by means of suitable measures?
M 5.14
Are process audits in accordance with VDA 6.3 or similar methods planned
and performed during the development phase
for suppliers commissioned for new product projects?
New
Page: 38

Based on VDA 6.3
M5.1
DPA Questionnaire
Are only approved quality-capable suppliers used and defined in accordance

with the schedule?
Before the suppliers are determined, an evaluation of the QM system
(certification/auditing) must be available. At production breakpoint, it must be
ensured that only suitable suppliers are used. Experience gained from quality
performance assessments must be taken into account.
- For new product projects, the timely selection and evaluation
of new suppliers (i.e. focusing on the MDS schedule / CV-DS
of Daimler) must be taken into account.
Meetings with suppliers / regular support
Evaluation of quality capability (e.g. audit results / certificates)
Daimler AG, MBC, and TG expect verification of VDA 6.1, QS9000, or
ISO/TS 16949 and/or technical quality capability assessment (e.g.
determined via process audit)
Evaluation of quality performance (quality/costs/service)
Evaluation of logistics performance (delivery reliability, service levels,
customer satisfaction) (L)
M5.2

Supplier monitoring
ACQ 4 process, AutomotiveSPICE PAM
Has the agreed quality of the purchased parts been planned and ensured?
-
Sufficient inspection options (laboratory and measuring equipment)

Internal/external inspections
Supplied gages/surveys
Drawings / order details / specifications
QA agreements (additional agreed ppm targets)
Coordination of inspection and testing procedures and frequency of inspections
Analysis of key non-conformities
Proof of functionality
Page: 39

Based on VDA 6.3
M5.3
DPA Questionnaire
Has quality performance been evaluated and are suitable measures

implemented in the event of non-conformities with respect to the
requirements?
The capabilities and performance of a supplier are to be reviewed at defined intervals
and then recorded and evaluated in a part-specific list (supplier catalog).
Qualification programs must be established in the event of negative results.
Implementation must be verified.
-
M5.4
Minutes of quality meetings

Agreement and monitoring of improvement programs
Inspection/measurement reports for improved components
Analysis of key non-conformities/problematic suppliers
e.g. evaluation of purchased parts
e.g. logistical supplier evaluation (delivery reliability: quality reliability and
on-time delivery, service levels) (L)
Have target agreements for continuously improving products and processes

been coordinated with the suppliers and have they been implemented?
-
Workshops (interdisciplinary work groups)

Define measurable target variables for quality, price, service, e.g.:
Reducing time and effort involved in inspection activities while increasing
process reliability
Reducing rejects (internal/external)
Reducing stock in circulation
Increasing customer satisfaction
Reducing the ppm rates as part of a zero-error strategy (at least once a
year)
Avoiding special transportation (L)
Page: 40

Based on VDA 6.3
M5.5
DPA Questionnaire
Are the required approvals for the products delivered available in the various
phases and have the required improvement measures been implemented?
For all supplier products, new/amended products/processes must be approved
prior to the production breakpoint.
This must be integrated in an end-to-end change management system covering
everyone from the customer to the sub-supplier.
-
M5.6
Construction model trial releases

Initial sample reports (to VDA)
Has an initial sample of all the purchased parts been provided and
released? Have the criteria in accordance with VDA 2 been taken into
account?
Proof of functionality for key characteristics
Observance of safety data sheets, EU guidelines
Evaluation of reliability
Re-qualification inspection reports and the resulting improvement measures
Have the procedures agreed upon with the customer with respect to products
supplied by the customer been observed?
The requirements regarding the products supplied must be taken from the quality
agreements and systematically implemented.
Products supplied include:
Services
Sub-suppliers named and commissioned by Daimler AG, MBC, and TG
Tools, test equipment
Packaging
Products
-
Control, verification, storage, transportation, maintenance of quality and

properties
Information flow in the event of non-conformities or loss
Quality documentation (quality status, quality history)
Supplier evaluation / observation
Page: 41

Based on VDA 6.3
M5.7
DPA Questionnaire
Are the stock levels of the input material adjusted in the various phases in
line with product requirements?
The required stock levels must be determined and taken into account as early as the
process planning phase. If requirements change, the requirements analysis may have
to be updated.
-
M5.8
KANBAN / just-in-time
Storage costs
Emergency strategy and input material bottlenecks
FIFO (first in/first out)
(Transparency across available stock and/or stock in
circulation, storage area etc.) (L)
Are the input materials/internal remaining quantities delivered and stored

according to their purpose?
-
Packaging
Warehouse management system
FIFO (first in/first out)
Tidiness and cleanliness
Climatic conditions
Protection against damage/contamination
Identification
(traceability / inspection status / sequence of operations / application status)
Measures to avoid mix-ups
Secure storage (set up and used)
Page: 42

Based on VDA 6.3
M5.9
DPA Questionnaire
Do the employees possess the expertise required to perform their

tasks?
Employees must be appointed to assume the following responsibilities:
-
Selecting, evaluating, and qualifying suppliers

Product inspection
Storage/transportation
Logistics
They must be aware of/have expertise in the following areas, for example:
-
M5.10
Product / specifications / special customer requirements

Standards / laws
Packaging
Processing
Evaluation methods (e.g. audits, statistics)
Quality methods (e.g. 8-D method, cause/effect diagrams)
Foreign languages
Is a process for monitoring the procurement market in place and are

measures derived from market observations and requirements forecasts? [L]
-
Observing the procurement market helps to identify trends in the procurements

markets for input materials and to implement measures in sufficient time to
meet the demand for input materials resulting from the customer demand for the
product.
Industry-specific market behavior

Global trends
Customer demand (forecast)
Page: 43

Based on VDA 6.3
M5.11
DPA Questionnaire
Is the availability of input materials (components) ensured in the event of

increased demand when series production is launched and after it is
complete? [L]
When the input materials are defined during product development, steps must be
taken to ensure that the sub-suppliers have sufficient capacity throughout the entire
period of demand in order to meet increased demand with respect to the current
planning status and to ensure that spare parts can be supplied (if this is in the
contract).
-
Risks with respect to the provision of input materials

Capacities of upstream suppliers, alternatives
Spare parts supply up to 15 years after series production has finished
Note:
Final stock (i.e. defining overall demand) cannot be created. The extent to which
input materials can be processed must also be taken into account throughout the
entire period.
M 5.12
New
Are the required suppliers integrated in the new product project and are they
familiar with the customer requirements?
All suppliers must be controlled with respect to their assignment and performance.
The interfaces with them must be known and safeguarded within the process.
Communication with these partners must take place with a customer-oriented
approach.
- A list of suppliers must be submitted.
- 1st tier in-house responsibilities must be defined
(communication of requirements, tolerances, schedules, changes,
change management, process acceptance inspections, approvals, complaints, etc.)
- The communication of customer requirements must be transparent.
- The order documentation must contain:
Requirements as defined in the component performance
specification, from DBL, MBST, guides, etc.
- Standard reporting procedure
Page: 44

Based on VDA 6.3
M 5.13
New
DPA Questionnaire
Have the risks in the supply chain been determined and counteracted by
means of suitable measures?
Daimler expects that the appropriate methods are used to analyze the risks in the
supply chain. Daimler method, e.g. SRA (structure/risk analysis).
Risks associated with development, production, upstream suppliers, logistics,
resources, and capacities must be analyzed. Steps must be taken to ensure that the
associated responsibilities are assigned and that measures are evaluated and
implemented transparently.
M 5.14
New
Are process audits in accordance with VDA 6.3 or similar methods planned
and performed during the development phase
for suppliers commissioned for new product projects?
It is expected that the supplier carries out audits for classified parts in the
development phase and to safeguard the startup phase.
- An ABC analysis or similar prioritization scheme must be available
- An audit plan must be available
- Qualified auditors
- Qualified reporting
Page: 45

Based on VDA 6.3
3.2
M6:
DPA Questionnaire
Production
All the following questions must be asked at each process stage.

During the individual process stages involved in manufacturing a product, the
planned/implemented technical and personnel processes and procedures must be maintained,
monitored and, taking into account economic aspects, subject to continuous improvement.
Employee qualifications, suitability and improvement of process and inspection equipment, as
well as transportation methods specially adjusted in line with the parts to be produced and
storage facilities for the products are focal points here.
All the activities are based on the customer requirements for each product and the associated
processes, which can change at any time up to the point a product is modified or discontinued.
All changes must be identified early on and integrated in the individual processes.
Employees must focus on the customer's entitlement to zero defects at all stages of the
process. Company management must ensure that the conditions required to achieve this are in
place.
The "customer/supplier" relationship is also of special significance with respect to the internal
processes. It is characterized by quality circles and teamwork; personnel at each process stage
must be assigned a high level of responsibility.
All changes in the process for manufacturing a product must be reported to the customer who
plays a key role in deciding what additional qualification measures or new releases are required
(see also VDA publication, part 2).
Page: 46

Based on VDA 6.3
3.2.1
M6.1:
DPA Questionnaire
Personnel / Qualification
Management tasks involve selecting employees who are qualified to perform their activities,
maintaining their qualification, and qualifying them for additional activities. The qualification of
employees for the product or process task they perform must be verified.
The employees must be aware of the customer requirements and quality objectives. The duties
assigned to them must display a commitment to quality.
Capacity analyses must be carried out for all processes to determine and deploy sufficiently
qualified personnel. Required substitutes in the individual processes must be determined.
Qualified personnel must also be available for this.
Questions
M6.1.1
Have employees been assigned the relevant responsibilities and authorities for
monitoring product/process quality?
M6.1.2
Have employees been assigned the relevant responsibilities and authorities

regarding the production equipment/environment?
M6.1.3
Are employees capable of fulfilling the tasks they have been assigned and is their
qualification maintained?
M6.1.4
Has a personnel deployment plan been drawn up with a stand-in regulation?
M6.1.5
Have measures to boost the motivation of employees been implemented effectively?
Page: 47

Based on VDA 6.3
M6.1.1
DPA Questionnaire

for monitoring product/process quality?
-
M6.1.2
Involvement in improvement programs

Self assessments
Process approval
(setup approval / first production piece testing / last production piece testing)
Process control (interpreting control charts)
Authority to stop production
MPS methods:
1.2.1
Job descriptions
1.4.1
Group task
1.4.2
Group spokesperson

regarding the production equipment/environment?
-
M6.1.3

Carrying out/initiating repairs and servicing
Parts provision/storage
Carrying out/initiating the installation and calibration of measuring and test
equipment
MPS methods:
1.2.1
Job descriptions
1.4.1
Group task
2.1.5
On-site measurement
Are employees capable of fulfilling the tasks they have been assigned and is
their qualification maintained?
Briefing/training/qualification records regarding the process
Knowledge about the product and non-conformities that have occurred
Instruction in occupational health and environmental aspects
Instruction in handling "components with special verification requirements"
-
Page: 48

Based on VDA 6.3
M6.1.4
DPA Questionnaire
Qualification records (e.g. welder certificates, sight tests, driving license for
industrial trucks)
Do they receive the required information?
Is this forwarded clearly and understandably?
Organizational competence
MPS methods:
1.2.3
Initial training for employees
1.3.1
Qualification
1.3.4
1.3.5
Learning isles
1.3.6
CIP workshop
1.4.2
Group spokesperson
Has a personnel deployment plan been drawn up with a stand-in regulation?

When the deployment of personnel is planned, the absentee figures
(illness/holidays/training) must be taken into account. The required qualifications of
substitute personnel must also be ensured.

-
Shift plan (contract related)

Qualification record (qualification matrix)
Work analyses / time studies (e.g. MTM, REFA)
Information flow, organizational implementation [P]
MPS methods:
1.4.2
Group spokesperson
1.4.6
Group boards
1.4.7
Rotation
1.4.8
Page: 49

Based on VDA 6.3
M6.1.5
DPA Questionnaire
Have measures to boost the motivation of employees been implemented

effectively?
The willingness to work must be promoted by means of targeted information which,
in turn, increases awareness of quality.
-
Quality information (planned/actual values)

Suggestions for improvement
Voluntary activities (training, quality circle)
Low illness frequency rate
Contribution to boosting quality
Self assessment
Note:
This question is also related to question M7.5.
-
MPS methods:
1.1.2
Employee feedback
1.1.3
Employee surveys
1.1.4
Employee recognition
1.1.5
Appraisal system
1.1.9
Team development activities
1.1.12
Program to improve attendance
1.4.3
Group meetings
1.4.6
Group boards
2.1.4
Scoreboards
5.1.5
Employee-driven CIP
5.1.6
Expert-driven CIP
5.1.7
CIP workshop
Page: 50

Based on VDA 6.3
3.2.2
M6.2:
DPA Questionnaire
Production Material / Equipment
The production equipment used must allow the product quality requirements to be fulfilled. The
required process capability and efficiency must be achieved and continuously improved.
Measuring and test equipment must also fulfill these requirements. When production is
restarted, special conditions must be observed. In addition, suitable work and inspection
stations must be set up for the product. Quality and process data from previous production
processes must be known and all the defined improvement measures must be implemented.
Questions
M6.2.1
Do the production equipment/tools fulfill the product-specific quality requirements?
M6.2.2
Can the quality requirements be monitored effectively during series production using
the measuring and test equipment available?
M6.2.3
Do the work and inspection stations fulfill requirements?
M6.2.4
Have the relevant specifications in the production and inspection documents been
defined in full and are they observed?
M6.2.5
Is the required auxiliary equipment available for adjustments?
M6.2.6
Is an approval for production start-ups issued and are adjustment details as well as
non-conformities recorded?
M6.2.7
Are the required correction measures implemented in good time and checked to
ensure that they are effective?
M 6.2.8
Are the machines and equipment serviced and maintained on a preventive

basis (e.g. by means of runtimes) as well as on an anticipatory basis (by
means of maintenance schedules) and, in turn, is the availability of the
machines improved?
M 6.2.9
New
Do the recordings made during the processes ensure the required

level of traceability?
M 6.2.10 Are legal requirements regarding the handling of waste and hazardous
substances fulfilled? (environment)
M 6.2.11 Are the requirements associated with the construction and
New
operation of a plant fulfilled? (environment)
Page: 51

Based on VDA 6.3
M6.2.1
DPA Questionnaire
Do the production equipment/tools fulfill the product-specific quality

requirements?
-
M6.2.2
Machine/process capability verification for key characteristics/process

parameters
Compulsory control/regulation of key parameters
Warning in the event of deviations from target specifications (e.g. lamps, sirens,
shutdown)
Feed and delivery equipment
Servicing/maintenance status of tools/plants/machines (incl. planned
maintenance)
MPS methods:
3.1.5
Quality alert / quality stop / machine stop
3.2.1
Total Productive Maintenance (TPM)
3.2.2
Error proofing
3.2.3
Mistake proofing
3.2.4
Can the quality requirements be monitored effectively during series

production using the measuring and test equipment available?
-
Reliability, functional, and corrosion resistance tests

Measuring accuracy / measuring and test equipment capability
Data acquisition and analysis
Calibration records
Coordination of measuring facilities/tools with the customer
MPS methods:
3.2.4
3.2.12
measuring equipment
Page: 52

Based on VDA 6.3
M6.2.3
DPA Questionnaire
Do the work and inspection stations fulfill requirements?

The environmental conditions (for repairs/rework too) must be coordinated with the
work content and the products in order to avoid contamination, damage, and mix
up/misinterpretation.
-
Ergonomics
Lighting
Environment/handling of components
Occupational safety (German accident prevention regulations (UVV))
MPS methods:
1.5
Occupational safety and environmental awareness
2.1.3
Standard work in process
2.2
Visual Management 5A
5.1.2
7 types of waste
5.1.3
5 W questions
Page: 53

Based on VDA 6.3
M6.2.4
DPA Questionnaire
Have the relevant specifications in the production and inspection documents

been defined in full and are they observed?
Process parameters as well as inspection and test characteristics must always be
specified with tolerances. The manufacturing and inspection documents must be
available at the work/inspection station. Non-conformities and measures
implemented must be documented.
-
M6.2.5
Process parameters (e.g. pressures, temperatures, times, speeds)

Machine/tool/auxiliary equipment data (tool and machine numbers)
Inspection requirements (key characteristics, test equipment, methods,
frequency of tests)
Intervention limits in process control cards
Machine and process capability records
Operating instructions
Work instructions
Inspection instructions
Information about current non-conformities
MPS methods:
2.1.1
Standard worksheets, station worksheets
2.1.2
2.1.4
Scoreboards
3.1.4
3.1.5
Quality alert / quality stop / machine stop
3.1.6
Quality and production status information
3.2.11
3.2.12
measuring equipment
3.3.2
Is the required auxiliary equipment available for adjustments?

-
Tooling plans
Tool setting equipment / comparison equipment
Flexible tool changeover equipment
Reference samples
Page: 54

Based on VDA 6.3
MPS methods:
2.1.1
Standard worksheets, station worksheets
2.1.2
3.1.3
Reference samples
3.2.11
4.3.2
Rapid changeover
M6.2.6
DPA Questionnaire
Is an approval for production start-ups issued and are adjustment details as

well as non-conformities recorded?
"Approval for series production" is the contract-related initial and re-release for the
start of production. The approval is required for the product and process and must
be issued in writing by authorized employees on the basis of acceptance criteria. At
this point, any problems that have been identified during product/process planning
and/or previous series production processes must be rectified.
The release inspections must be carried out in accordance with clearly-defined
inspection instructions to ensure that they can be reproduced. The use of a checklist
is recommended here.
If production is continued after the test pieces have been extracted, the products
must be placed on hold until the test pieces have been released. Reworked products
must be included in the release processes.
-
New, modified product

Standstill of the equipment/process interruption
Repairs, tool changeover
Material change (e.g. batch change)
Modified production parameters
First production piece testing with documentation
Up-to-dateness of the parameters
Tidiness and cleanliness at the workstation
Packaging
Release/change status of tools and measuring/test equipment.
MPS methods:
1.1.6
Checklists
1.2.2
Process description
1.3.1
Qualification, qualification matrix
2.1.5
On-site measurement
3.1.8
Approval for series production
3.2.11
Page: 55

Based on VDA 6.3
M6.2.7
DPA Questionnaire
Are the required correction measures implemented in good time and checked
to ensure that they are effective?
Correction measures relate to the entire process chain from the input material to use
by the customer. The effectiveness of correction measures implemented must be
assessed and verified.
-
M 6.2.8
Risk analysis (process FMEA), fault analyses

Improvement programs from audits
Information to the party responsible
Interface discussions (internal/external)
Internal complaints
Customer complaints
Customer surveys
Measures and deadline controlling
MPS methods:
3.1.1
Quality control loops in production
3.1.2
Cause analysis
3.1.4
3.2.5
System audit / certification
3.2.6
Process audit
3.2.8
Troubleshooting process
3.2.9
Process FMEA
3.3
Customer focus (internal and external)
5.1.1
PTCA
5.1.3
5 W questions
Are the machines and equipment serviced and maintained on a preventive

basis (e.g. by means of runtimes) as well as on an anticipatory basis (by
means of maintenance schedules) and, in turn, is the availability of the
machines improved?
Number and qualification of the employees deployed for this purpose

Observance of defined maintenance intervals
Coordination of planned and actual outlay
Documentation of the maintenance activities performed
Archiving of proof of work
Regular plausibility check of the planned
maintenance intervals
Planning/availability of spare parts
Page: 56

Based on VDA 6.3
M 6.2.9
New DC
DPA Questionnaire
Commissioning of external service providers for maintenance work

Availability/use of the associated technical documentation
Provision of equipment for area responsible for performing maintenance work
Quality of the maintenance work
MPS methods:
1.1.6 Checklists and check
1.3.1 Qualification
1.4.8 Qualification matrix
3.2.1 Total Productive Maintenance (TPM)
Do the recordings made during the processes ensure the required

level of traceability?
DAIMLER expects to be able to trace parts with the special characteristics DS and
DZ.
- Fulfillment of the machine parameters
- OK / not OK statement and check value.
- Machine and tool ID no.
- Batch/lot
- Personnel involved in the process
- Permanent marking on the part (part no./production date at least)
- Implemented internal/external correction measures (to the customer)
Page: 57

Based on VDA 6.3
DPA Questionnaire
M 6.2.10 Are legal requirements regarding the handling of waste and hazardous
substances fulfilled? (environment)
From a legal point of view, waste refers to all movable items that the owner disposes
of, intends to dispose, or must dispose of. The type and volume of waste as well as
its disposal must be documented for this process.
Hazardous substances are materials, preparations, or products that pose a risk to
human health, nature, and material objects.

-
What waste types are there and how much waste exists?
This data must be recorded (waste lifecycle analysis, IT tool, written)
Verbal statement if there is a low quantity of waste or few waste
types
How is the disposal documented?
Proof of disposal (approved or simplified proof of disposal)
Waste indicated with key numbers
Documentation of general disposal data (e.g. specifications
regarding the person(s) responsible for disposal, waste quantity,
type of waste, collection/disposal date, or disposal channel)
Have hazardous substances been determined and identified?
Check whether the substance used is hazardous
Categorization according to level of hazard posed
Research is carried out to investigate whether the hazardous
substance in question can be replaced with a substance that is less
hazardous or not hazardous at all.
Is an up-to-date list of hazardous substances available?
Are employees instructed how to handle hazardous substances?
Documented briefing takes place on the basis of the
operational/work instructions.
Are hazardous substances stored properly?
Ban on joint storage of materials is observed
Regular maintenance of areas used to store hazardous substances
and safety cupboards
Note on awarding points:

0 points: no criteria (dash bulleted points) fulfilled
4 points: 2 criteria (dash bulleted points) fulfilled
6 points: 4 criteria (dash bulleted points) fulfilled
Page: 58

Based on VDA 6.3
DPA Questionnaire
M 6.2.11 Are the requirements associated with the construction and operation of a
plant fulfilled? (environment)
Externally, process-related emissions (e.g. pollutants and noise) pose a hazard to the
environment and, internally, a hazard to occupational health and safety. For this
reason, preventive measures must be implemented for plants that, due to their
nature or operation, are likely to produce such emissions. Protective measures are
an integral part of construction and operating permits issued for these plants.
-
Construction and/or operating permits are available

Documents (e.g. standard operating procedures, work instructions etc.) are
available in which the obligations and duties of the operator are defined
Have the conditions defined in the license provisions been fulfilled?
The relevant employees are aware of the conditions and possess the
knowledge (training) necessary to implement them.
Data about emissions (e.g. effluent, exhaust air, waste, soil contamination,
or noise) is available.
Note on awarding points:

0 points: if the first criterion (dash bulleted point) is not fulfilled, no points are
awarded at all for this question.
Page: 59

Based on VDA 6.3
3.2.3
M6.3:
DPA Questionnaire
Transportation / Parts Handling / Storage / Packaging
Production processes are to be continuously adjusted in line with each other; only the volume
agreed upon with the customer is produced. Incomplete products must not be stored
temporarily. The manufacturing and test status of parts must be clearly indicated. Special
processes must be in place for handling and identifying parts that are to be rejected or
reworked.
Methods for storing and transporting the products throughout the process chain must be
agreed upon with the customer. Such methods must ensure that no products are damaged.
Tools, production and inspection equipment must be adequately preserved and stored without
risk of damage during periods when production is interrupted. Measures must be taken to
ensure that such equipment can be redeployed with the minimum of preparation.
Questions
M6.3.1
Are the quantities/production lot sizes coordinated with requirements and are they
transferred systematically to the next workstation?
M6.3.2
Are products/components properly stored and are the means of transportation and
packaging equipment suitable for the special properties of the
product/components?
M6.3.3
Are rejects, rework and adjustment parts, as well as internal remaining quantities
systematically separated and identified?
M6.3.4
Are measures in place to avoid mix-ups and accidental exchanges in the material and
parts flow and to ensure traceability?
M6.3.5
Are tools as well as measuring and test equipment stored correctly and are the
owners of the tools/equipment clearly indicated?
M 6.3.6
Are capacity fluctuations controlled effectively? [L]
Page: 60

Based on VDA 6.3
M6.3.1
DPA Questionnaire
Are the quantities/production lot sizes coordinated with requirements and are
they transferred systematically to the next workstation?
-
Suitable means of transportation

Defined storage areas
Minimum/no intermediate storage
KANBAN
Just in time
Warehouse management
Change status
Only OK parts are transferred
Recording number of pieces/evaluation
Information flow
Stock levels
Note:
Stock levels (goods receipt storage, intermediate storage, goods issue
storage) can, among other things, be used to deal with short-term changes
in customer requirements and, as such, must be coordinated with the
customer.[L]
Production volume adjusted in line with customer demand [P]
Note:
When material/purchased parts are delivered directly to the

respective production plants, the requirements defined in question
M5.7 must also be taken into account.
MPS methods:
2.1.3 Standard work in process
2.2.2 Marking, identification, labeling
4.1
Production smoothing
4.2
Pull production
4.3
Assembly line production
5.1.2 Types of waste
Page: 61

Based on VDA 6.3
M6.3.2
DPA Questionnaire
Are products/components properly stored and are the means of

transportation and packaging equipment suitable for the special properties of
the product/components?
-
Stock levels
Protection against damage
Parts positioning
Tidiness, cleanliness, overstocking (storage areas, containers)
Monitoring of the storage time
Environmental influences, air conditioning
Packaging guidelines of Daimler AG, MBC
Note:
Are the packaging guidelines defined by Daimler AG, MBC
available in the shipping department and are they taken into account? [L]
Note:
M6.3.3
When material/purchased parts are delivered directly to the

respective production plants, the requirements defined in question
M5.7 and M5.8 must also be taken into account.
MPS methods:
1.5.2 Visual safety signs
2.1.3 Work in process
2.2.1 "5A method"
2.2.2 Marking, identification, labeling
4.3.1 Kitting
Are rejects, rework and adjustment parts, as well as internal remaining

quantities systematically separated and identified?
Secure storage, secure areas
Labeled containers for rejects, rework parts and adjustment parts
Non-conforming products and non-conformity characteristics
Identification
Defined transfer/rework stations in the production department
-
MPS methods:
1.5.4
Scrap / separation of waste
2.1.7
Standardized equipment
3.2.11
Page: 62

Based on VDA 6.3
M6.3.4
DPA Questionnaire
Are measures in place to avoid mix-ups and accidental exchanges in the

material and parts flow and to ensure traceability?
Depending on the product risk, traceability must be ensured along the entire process
chain from the supplier to the customer.
-
M6.3.5
Identification of parts
Identification of work, inspection, and usage status
Indication of batch
Expiry date
Removal of all invalid identification/markings
Work papers with part/production master data.
Design status, input material, and finished products
Note:
Suitable procedures must be implemented to ensure that the correct
design status of the input material is always used and that the correct
design status of the finished products is always produced and delivered to
the customer. [L]
MPS methods:
2.2.2
Marking, identification, labeling
3.2.11
4.3.5
First in/first out (FIFO)
Are tools as well as measuring and test equipment stored correctly and are
the owners of the tools/equipment clearly indicated?
Tools, equipment, and inspection equipment that is not in use and has not been
released must also be stored and managed properly.
-
Storage without risk of damage

Defined storage location
Administered issue
Environmental influences
Identification
Defined release and change status.
MPS methods:
2.1. 7
Standardized equipment
Page: 63

Based on VDA 6.3
M6.3.6
DPA Questionnaire
Are capacity fluctuations controlled effectively? [L]

Identification/procedure in the event of capacity fluctuations
(overshot/undershot)
Note:
Suitable procedures must be in place to ensure that capacity
fluctuations resulting from varying customer demand can be
identified immediately.
Flexibility
Note:
The extent to which capacities can be flexibly adjusted in line with
customer demand and the lead times required for this must be
clarified. The measures implemented in such cases to fulfill
customer demand must be defined.
Identification of production backlogs
Note:
Suitable procedures must be defined to ensure that production
backlogs can be identified in good time and, if necessary, predicted.
-
MPS methods:
4.1 Production smoothing
4.1.1 Production program planning
4.1.2 In-line sequencing in vehicle plant
Page: 64

Based on VDA 6.3
3.2.4
M6.4:
DPA Questionnaire
Non-Conformity Analysis / Corrective Measures / Continuous

Improvement
Each company is obliged to monitor products and processes continuously to identify nonconformities vis--vis customer requirements and expectations and to eliminate these by means
of appropriate measures. Preventive action taking into account statistical methods must be
implemented in all processes to fulfill the customer demand for zero defects.
Detailed analyses to identify the root cause of non-conformities and to initiate suitable
corrective measures are the basis for all improvements. In all cases, the effectiveness of
implemented corrective actions must be verified.
The persons and departments responsible in the process must be involved in implementing
continuous improvement measures and eliminating non-conformities. They themselves are
responsible for ensuring that the customer is satisfied.
Questions
M6.4.1
Is quality and process data recorded in full so that it is ready to be evaluated?
M6.4.2
Is the quality and process data analyzed statistically and are improvement programs
derived from this?
M6.4.3
If non-conformities are identified vis--vis product and process requirements, are the
causes analyzed and are the correction measures checked to ensure that they are
effective?
M6.4.4
Are processes and products subject to regular auditing?
M6.4.5
Are products and processes subject to continuous improvement?
M6.4.6
Are target parameters defined for the product and process and is their
compliance monitored?
M 6.4.7
New
Has a suitable procedure for re-qualifying products on a regular

basis been defined and implemented?
M 6.4.8
New
How are changes to the product or process handled, monitored,

and documented during series production?
Page: 65

Based on VDA 6.3
M6.4.1
DPA Questionnaire
Is quality and process data recorded in full so that it is ready to be evaluated?

Quality and process data must be available in full to verify that it complies with
requirements. Steps must also be taken to ensure that it can be evaluated. Special
events must be documented (logbook).
-
M6.4.2
General charts
Non-conformity lists
Control charts
Data acquisition
Recorders for process parameters (e.g. temperature, time, pressure)
Production data acquisition (e.g. plant downtime, power failures, program
error messages) [W]
Parameter changes
MPS methods:
1.2.2
Process description
2.1.2
2.1.5
On-site measurements
3.2.4
3.2.11
Is the quality and process data analyzed statistically and are improvement
measures derived from this?
Findings and problems must be assigned to the departments responsible who must
then elaborate and implement improvements.
-
Process capabilities
Type/frequency of non-conformities
Non-conformity costs
Process parameters
Rejects/rework
On-hold notifications / sorting actions
Cycle and throughput times
Reliability/response in the event of failure
Page: 66

Based on VDA 6.3
DPA Questionnaire
The following can be used:

-
M6.4.3
SPC
Pareto analyses
Cause-and-effect diagram
MPS methods:
3.1.1
3.1.2
Cause analysis
3.2.4
3.2.8
Troubleshooting processes
5.1.1
PTCA
5.1.3
5 W questions
If non-conformities are identified vis--vis product and process requirements,

are the causes analyzed and are the correction measures checked to ensure
that they are effective?
If product/process failures occur, suitable immediate measures (e.g. placing on hold,
sorting, informing) must be implemented to ensure compliance with the
requirements until the cause of the failure has been removed and the measures have
been checked to ensure that they are effective.
-
Additional dimensional, material, functional, endurance tests

Cause-and-effect diagram
Taguchi, Shainin
FMEA/fault analysis
Process capability analysis
Quality circle
Analytical evaluation methods (e.g. 8D method)
Flow of information to customer
MPS methods:
3.1.1
3.2.9
Process FMEA
5.1.1
PTCA
Page: 67

Based on VDA 6.3
M6.4.4
DPA Questionnaire
Are processes and products subject to regular auditing?

Audit plans must be drawn up for the product and its manufacturing process.
Reasons for audits include:
-
New projects/processes/products
Non-fulfillment of quality requirements (internal/external)
Maintenance of records of compliance with quality requirements
Highlighting potential for improvement
Non-conformity reports must be distributed to those responsible and the

improvement measures must be monitored.
-
M6.4.5
Key characteristics
Function
Process parameters/capabilities
Identification, packaging
Defined processes/procedures
Measures and deadline controlling
MPS methods:
3.1.4
3.2.5
System audit / certification
3.2.6
Process audit
3.3.3
Customer quality sensor
3.3.4
Higher-level quality control loop
5.1.1
PTCA
Are products and processes subject to continuous improvement?

Potential for improvement must be determined from previous findings regarding
quality, costs, and service.
-
Cost optimization
Reduction of waste (e.g. rejects and rework, energy and process materials)
Improvement of process reliability (e.g. process analysis)
Optimization of set-up times, increase in plant availability
Page: 68

Based on VDA 6.3
M6.4.6
DPA Questionnaire
Reduction of throughput times

Reduction of stocks
MPS methods:
1.3.6 CIP workshop
2.2.1 "5A method"
4.3.2 Rapid changeover
5.1. Elimination of waste (without 5.1.8 or 5.1.10)
Are target parameters defined for the product and process and is their compliance
monitored?
The target objectives must be coordinated and feasible. Steps must also be taken to
ensure that they are up to date. Any required special measures must be defined and
implemented.
-
M 6.4.7
New DC
Presence and absence of employees

Series quantities are able to produce in series cylce time.
Scrap trend in planned range
Plant and machine availability
No. of items produced
Quality scores (e.g. failure rates, audit results)
Throughput times
Non-conformity costs
Process key figures (e.g. process capability).
MPS methods:
1.1.1
Target agreements
2.1.4
Scoreboards
3.3.1
Quality agreements (in certain cases with escalation levels)
Has a suitable procedure for re-qualifying products on a regular basis been

defined and implemented?
Regular product re-qualification covers all the annual dimensional and functional
checks for materials and functions to verify and validate them vis--vis customer
requirements.
Suitable inspection and testing equipment must be available for the regular product
re-qualification process. The intervals (at least once a year) and the responsibilities
for this must be defined in the production control plan. Departures from the
specifications for regular product re-qualification must be agreed upon in writing with
Daimler. For more information, see MBST.
Page: 69

Based on VDA 6.3
DPA Questionnaire
Examples:
Capacities in the plants/departments that perform the inspections, applicable
inspection instructions, documentation for traceability and responsibilities must be
clearly defined here.
6.4.8
New DC
How are changes to the product or process handled, monitored,

and documented during series production?
The change procedure (i.e. from the change request to implementation) must be
clearly described, the responsibilities clearly defined, and the change statuses
documented systematically and transparently.
A suitable system must be in place to support this.
- Change released by the organization and customer
(e.g. feasibility, interfaces with components, effect on costs/deadlines, etc.)
- Circulating changes (e.g. to process development, production areas, warehouse, or
upstream suppliers)
- Tracking the degree to which the change has been implemented
- Documenting change histories
- Updating the relevant documents (drawings, instructions, etc.)
Page: 70

Based on VDA 6.3
3.3
M7:
DPA Questionnaire
Customer Support / Customer Satisfaction / Service
The customer is entitled to be provided with products that are free from defects and expect that
all requirements are fulfilled when the product is processed further or implemented. This
includes a support service provided by the supplier once the product has been delivered to
ensure that any non-conformities vis--vis the customer requirements and expectations are
identified early on and to maintain or restore customer satisfaction by implementing the
appropriate improvement measures. For this reason, customer service plays a key role in
gauging customer satisfaction. The customer service team must be staffed with qualified
personnel who are able to initiate improvements at all levels and departments of the supplier.
Measures must be taken to ensure that quality problems are responded to immediately and that
parts are supplied in accordance with the quality requirements of the customer.
This applies both within Daimler AG, MBC, and TG as well as for internal
customer/supplier relationships.
Questions
M7.1
Are customer requirements fulfilled when the product is delivered?
M7.2
Have suitable and effective contacts been appointed for the product
implementation phase and the order process?
M7.3
Does the customer service team respond to complaints quickly and ensure that
parts are delivered?
M7.4
In the event of non-conformities vis--vis quality requirements, are non-conformity

analyses performed and improvement measures implemented within the customer
response times?
M7.5
Do employees possess the expertise required to perform their tasks?
M7.6
Are steps taken to ensure that spare parts can be supplied prior to, during,
and after the series production phase and to allow parts to be returned and
recycled?
Page: 71

Based on VDA 6.3
M7.1
DPA Questionnaire
Are customer requirements fulfilled when the product is delivered?

All requirements, in particular those which are included in the supplier evaluation by
the customer, are taken into account.
-
M7.2
Quality agreements
Shipping audits
Endurance testing (determination of response in the event of a failure)
Storage / request processing / parts provision / shipping
Functional tests
Suitability of testing and measuring equipment
Agreed inspection and testing procedures
Up-to-dateness of the specifications
Procedure for deployment and deadline coordination with the customer
plant [P]
MPS methods:
3.3.1 Quality agreements (in certain cases with escalation levels)
3.3.3 Customer quality sensor
3.3. Quality control loop
4.1.1 Production program planning
Have suitable and effective contacts been appointed for the product
implementation phase and the order process?
Steps must be taken to ensure that competent contacts for the different
organizational departments of the customer are available. Customer support is also a
measure of active collaboration. Sub-suppliers are obliged to observe and, if
necessary, improve their products across all development and application phases.
-
Records of customer visits, if necessary, derivation of measures

Knowledge of product application
Knowledge of product problems
Implementation of new requirements
Notification of improvement measures
Notification of product and process changes/redeployment (also of suppliers)
Initial/repeat sampling (trial/series)
Notification of non-conformities vis--vis requirements
Customer support in the event of a purchase from a foreign country
(competent and fast support via domestic organization)
Page: 72

Based on VDA 6.3
M7.3
DPA Questionnaire
MPS methods:
5.1.8
Change management
Does the customer service team respond to complaints quickly and ensure
that parts are delivered?
Concepts to ensure that parts are supplied as well as for handling unscheduled
problems must be elaborated during process planning. In the series production
phase, steps must be taken to ensure that they are up to date.
Internal company processes as well as those of the sub-suppliers must be
taken into account here.
-
Emergency plans
Capacities and response time for sorting
Options for modifying plants, special production material, tools, product
specifications and procurement types
Deployment of external capacities
Communication in the event of delivery bottlenecks
Note:
Procedures must be in place to ensure that the supplier informs the
Logistics department of the Daimler-Benz customer plant as soon as any
delivery bottlenecks are identified (or, if necessary, before they actually
occur). The supplier must inform Logistics of the expected duration and
extent of the delivery bottleneck, why it has occurred, and the measures
that have been introduced to counteract it.
Decision-making authority when special measures are implemented
Note:
Details must be provided of how the decision-making authority is defined
so that special measures to avoid or rectify delivery bottlenecks can be
implemented (e.g. additional shifts, external support, special
transportation, redundant supply, etc.).
MPS methods:
3.3.1Qualiy agreements (in certain cases with escalation levels)
Page: 73

Based on VDA 6.3
M7.4
DPA Questionnaire
In the event of non-conformities vis--vis quality requirements, are nonconformity analyses performed and improvement measures implemented
within the customer response times?
-
M7.5
Analysis options (laboratory, inspection/test equipment, personnel)

Pareto analyses of failure characteristics (internal/external)
Use of troubleshooting methods (e.g. 8D report)
Correction of sampling deviations
Revision of the specifications
Effectiveness check
Product monitoring and improvement
Flow of information to customer in the event of non-conformities
MPS methods:
3.1.2
Cause analysis
3.2.8
Troubleshooting processes
5.1.1
PTCA
5.1.3
5 W questions
Do employees possess the expertise required to perform their
tasks?
Employees must be appointed to assume the following responsibilities:
Customer support
Product inspection
Storage/transportation
Logistics
Non-conformity analysis
-
They must be aware of/have expertise in the following areas, for example:
Product / specifications / special customer requirements
Standards / laws
Processing / use
Evaluation methods (e.g. audits, statistics)
Quality methods (e.g. 8D method, cause/effect diagram)
Foreign languages
-
MPS methods:
1.2.3
Initial training for employees
1.3.4
1.4.8
Page: 74

Based on VDA 6.3
M7.6
DPA Questionnaire
Are steps taken to ensure that spare parts are supplied prior to, during, and
after the series production phase and to allow parts to be returned and
recycled?
In addition to series production, spare parts supply must be planned with required
variants and changes and must be taken into account with respect to the required
resources.
-
Creation of an initial stock of spare parts three months prior to series production
start-up
Additional demand of the Daimler AG parts center during series production
taking into account product application and problems
Obligation to supply spare parts up to 15 years after series production has
finished (see special terms no. 13)
Spare parts supply with previous parts following modifications
(tool management, production capabilities)
Supply concepts for small numbers of spare parts following modifications
and/or after production has finished
Page: 75

Based on VDA 6.3
DPA Questionnaire
1. Production Control Plan
The production control plan describes the system and processes involved in controlling a product. Among
other things, it contains all the special characteristics (critical and significant) that appear in the drawings
and
specifications and that were derived from the FMEAs.
A production control plan can refer to a single product group or
product family. Instructions on monitoring processes are to be defined and applied at all times. A production
control plan is required throughout the entire service life of a product, that is, in the pilot production and
series production phase and, if required, for the prototype phase.
Elements of the production control plan
The organization must create a production control plan that
covers at least the following areas:
a) General data
- Number of the production control plan
- Publication and change date (if available)
- Customer information (see customer requirements)
- Name of the organization / location
- Part number(s)
- Parts designation/description
- Design change status
- Phase to be applied (prototype, pilot production, series production),
- Main contact
- Construction level or operation no.
- Process designation / description of the task
b) Product control
- Special, product-related characteristics
- Other control characteristics (number, product, or process)
- Specifications/tolerance
c) Production process control
- Process parameters
- Special, process-related characteristics
- Machines, equipment, tool holders, tools for
production
ISO/TS 16949:2002(D)
The production control plan (ISO/TS 16949:2000, 7.5.1.1) is a living document and must be
created/updated for new products or when changes are made.
For the content of the control plan, see also appendix A of ISO TS 16949: 2002.
Page: 76

Based on VDA 6.3
DPA Questionnaire
Example of a production control plan
Page: 77

Based on VDA 6.3
DPA Questionnaire
Overview of the MBST excerpt from Sept. 2006
The current version is available on the intranet
Page: 78

Based on VDA 6.3
DPA Questionnaire
Initial screen for the DPA database
Page: 79

Based on VDA 6.3
DPA Questionnaire
Link: http://intra.corpintra.net/hlm/lieferantenhandbuch
Page: 80

Daimler DPA - Questionnaire 4-0 Nov 2007

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Daimler Process Audit

Daimler Process Audit

Changes/revisions in questionnaire version 4.0 (April 2007)

1) New, combined, and discarded questions:

Daimler Process Audit

Changes/revisions in questionnaire version 4.0 (11/ 2007)

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Part A: Product Development Process .............................................................................................. 7

Structure of the Questionnaire................................................................................................ 6

M1: Planning Product Development.......................................................................... 8

M2: Implementing Product Development ............................................................... 17

Process Development ............................................................................................................ 22

M3: Planning Process Development........................................................................ 22

M4: Implementing Process Development ............................................................... 29

Part B: Series Production ................................................................................................................. 36

M5: Suppliers / Input Material.............................................................................................. 37

M6.1: Personnel / Qualification .............................................................................. 47

M6.2: Production Material / Equipment................................................................. 51

M6.3: Transportation / Parts Handling / Storage / Packaging............................ 60

M6.4: Non-Conformity Analysis / Corrective Measures / Continuous Improvement

M7: Customer Support / Customer Satisfaction / Service................................................ 71

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Processes with Material Products (Part 1 of VDA 6.3)

Supplier management manual / link under quality/logistics processes:

Questionnaire for Process Audit of Material Products

Product development process

Planning product development

Suppliers / input material

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Structure of the Questionnaire

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Product Development Process

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Product Development (Design)

Planning Product Development

Is a product development plan available and does it comply with the

Will a fallback solution for product malfunctions or identified risks

Is the identification of special characteristics ensured on the basis

Are external development partners integrated and are they

How are changes to the product or process handled, monitored

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Are the customer requirements known and have they been

Drawings, standards, specifications, performance specification

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Is a product development plan available and does it comply with Daimler

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Customer requirements (performance specification, functional specifications,

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Have the required personnel and technical requirements for product

Project management, project planning team / responsibilities

Author: MBC/QKF U.Schmidt

Daimler Process Audit

Author: MBC/QKF U.Schmidt

Daimler Process Audit